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SECTION 00 – GENERAL INFORMATION
Section
CONTENTS
Description Page
Reattaching Cylinders After Repair with Boom Resting on Boom Lock Pins . . . . . . . . 00-17
00-1
INTRODUCTION
This service manual provides the technical information needed to properly service and maintain the Models LS160 and LS170 skid steers. Use it in conjunction with the operator’s manual which is supplied with the skid steer. Keep both manuals available for ready reference.
The L160 and L170 have many similarities with the major differences being engine horsepower and lifting capacity.
SECTION 00 - GENERAL INFORMATION
Whenever working on New Holland equipment, left and right sides of the machine are determined by standing behind the unit, looking in the direction of travel.
The easiest and least time-consuming removal, disassembly, and reassembly procedures are detailed in the manual. Modifying these procedures is not recommended.
New Holland skid steers are designed with emphasis on safety for operator protection. However, careless and negligent operation can still result in serious injury to persons or damage to property. Be sure to read and follow all safety instructions in this manual.
Your New Holland dealer is interested in your obtaining the most from your investment and will be glad to answer any questions you may have about your skid steer. When major service is required, your dealer’s staff of trained service technicians is ready to serve you.
When in need of parts, always order genuine New
Holland service parts from your New Holland dealer.
Be prepared to give your dealer the model and serial number of the engine and skid steer (the location of these numbers is described later in this section).
Record the serial numbers here.
Skid Steer Model
Skid Steer Serial Number
Engine Model
Engine Serial Number
CAUTION
This symbol is used throughout this book whenever your own personal safety is involved.
Take time to be careful!
ABOUT IMPROVEMENTS
New Holland is continually striving to improve its products. We must, therefore, reserve the right to make improvements or changes when it becomes practical and possible to do so, without incurring any obligation to make changes or additions to the equipment sold previously.
ALL SPECIFICATIONS ARE SUBJECT TO
CHANGE WITHOUT NOTICE.
00-2
SECTION 00 - GENERAL INFORMATION
COMPANY POLICY
Company policy, which is one of continuous improvement, reserves the right to make changes in design and specifications at any time without notice and without obligation to modify units previously built.
All data given in this book is subject to production variations. Dimensions and weights are approximate only and the illustrations do not necessarily show skid steers in standard condition.
PARTS AND ACCESSORIES
Genuine NEW HOLLAND parts and accessories have been specifically designed for HEW HOLLAND
MACHINES.
We would like to point out that “NON-GENUINE” parts and accessories have not been examined and released by NEW HOLLAND. The installation and or use of such products could have negative effects upon the design characteristics of your machine and thereby affect its safety. NEW HOLLAND is not liable for any damage caused by the use of “NON-GENUINE” NEW HOLLAND parts and accessories.
MODEL CODES
The range of Skid Steers described in this manual is identified in the text by the engine horsepower Pferdestarke.
(PS). The skid steers listed below may not be available in all countries or markets.
ENGINE PS
N844 40
N844T 50
MODEL
LS160
LS170
00-3
SECTION 00 - GENERAL INFORMATION
PRECAUTIONARY STATEMENTS DANGER
The word “DANGER” denotes a forbidden practice in connection with a serious hazard.
PERSONAL SAFETY
Throughout this manual and on machine decals, you will find precautionary statements (“CAUTION”,
“WARNING”, and “DANGER”) followed by specific instructions. These precautions are intended for the personal safety of you and those working with you.
Please take the time to read them.
Failure to follow the “CAUTION”, “WARNING”, and
“DANGER” instructions may result in serious bodily injury or death.
CAUTION
The word “CAUTION” is used where a safe behavioral practice according to operating and maintenance instructions and common safety practices will protect the operator and others from accident involvement.
MACHINE SAFETY
Additional precautionary statement (“IMPORTANT”) is followed by specific instructions. This statement is intended for machine safety.
IMPORTANT: The word “IMPORTANT” is used to inform the reader of something he needs to know to prevent minor machine damage if a certain procedure is not followed.
WARNING
The word “WARNING” denotes a potential or hidden hazard which has a potential for serious injury. It is used to warn operators and others to exercise every appropriate means to avoid a surprise involvement with machinery.
00-4
SAFETY PRECAUTIONS
CAUTION
Unsafe operating practices and improper use of the skid steer and its attachments on the part of the operator can result in injuries. Observe the following safety precautions at all times:
1. For servicing, the skid steer should be on level terrain, engine stopped with the wheels blocked or the entire skid steer solidly supported with the wheels off the ground before servicing any component of the drivetrain.
2. For servicing under the operator’s seat, raise the seat and pan assembly up to the raised latched position and securely latch.
3. Do not operate the skid steer unless the seat is latched in the operate position.
4. Do not service the skid steer with a raised boom unless the boom is resting on the boom lock pins.
5. Do not service the skid steer with the engine running unless the skid steer is properly and securely supported with all four wheels off the ground.
6. Use caution when servicing the unit around moving parts.
7. Do not tilt the boom and cab without proper instruction.
8. Do not tilt the boom and cab without using the proper cab tilting tool.
9. Reinstall all shields removed for service.
10. Never loosen any hydraulic connections before relieving the pressure in the hydraulic system.
11. Wear eye protection such as goggles, etc.
12. Wear ear protection such as ear plugs, etc.
When you feel the noise level is uncomfortable.
13. If any servicing or adjustments require the battery to be disconnected, disconnect the
(–) negative ground cable.
14. When servicing electrical components, disconnect the (–) negative ground cable.
15. If the electronic instrument cluster (eic) requires removal from the dash area or the skid steer, disconnect the (–) negative
SECTION 00 - GENERAL INFORMATION ground battery cable. This will shut off power to the eic and prevent damage to the eic board or blowing the 5-amp fuses if the board is accidentally grounded.
16. If welding is required on the skid steer, disconnect the (–) negative ground cable.
failure to disconnect the battery may result in damage to the EIC (Electronic Instrument
Cluster) monitoring system and other electrical components.
17. If welding is required on an attachment, remove the attachment from the skid steer.
18. Give complete and undivided attention to the job at hand so that complete control of the skid steer is maintained at all times.
19. Drive slowly over rough ground and on slopes; keep alert for holes, ditches and other irregularities that may cause the skid steer to overturn.
20. Avoid steep hillside operation which could cause the skid steer to overturn.
21. Never transport a loaded bucket at full height.
Operate the skid steer with the load as low as possible until it becomes necessary to raise the boom to discharge the load into a truck, container, etc.
22. Reduce speed when turning so there is no danger of the skid steer overturning.
23. Never drive up or back up a hill or incline with a raised boom or the skid steer could over turn.
24. Always look behind you before backing the skid steer.
25. Maintain proper transmission oil level to prevent loss of hydrostatic braking.
26. Do not allow passengers to ride on the skid steer at any time.
27. Do not allow children to operate the skid steer or ride on the skid steer at any time.
28. Do not allow anyone to operate the skid steer without proper instruction. OSHA requires that all operators be instructed on the proper operation of the machine before they operate the unit.
29. Do not operate the skid steer in any position other than while in the operator’s seat with the seat belt securely fastened.
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30. Before starting the engine, be sure that all operating controls are in neutral and the parking brake is engaged.
31. Never operate the skid steer engine in a closed building without adequate ventilation.
32. Refuel the skid steer outdoors with the engine shut off. Replace the fuel cap securely. Use an approved fuel container. Do not smoke when handling fuel. Avoid spilling fuel.
33. After operating the engine, never touch the muffler, exhaust pipe, engine or radiator until they have had time to cool.
34. Dress appropriately - wear relatively tight-fitting clothing when operating the skid steer. Loose or torn clothing can catch in moving parts or controls.
35. Before servicing the skid steer or any of its attached equipment, be sure that the attachments are lowered to the ground or that the boom arms are supported by the boom lock pins.
36. Do not work under overhangs, electric wires, or where there is danger of a slide.
37. Wear an approved safety hat when operating the machine and while in any work area.
38. When driving the skid steer on a road or highway, use warning lights or warning devices as may be required by local or state government regulations. Headlights, warning lights and smv signs are available through your new holland dealer.
39. Keep the skid steer clean. Do not allow trash, debris or other articles to accumulate in the cab, floor or foot control pedal area that may hinder safe machine operation.
40. Never operate the skid steer with any of the shielding removed.
41. Never operate the skid steer without windows and/or screens in place.
42. Never extend any part of the body outside of the operator’s area.
SECTION 00 - GENERAL INFORMATION
43. Always properly tie down the skid steer to a truck or trailer before transport.
44. Make sure all bystanders are at a safe distance away from the skid steer before starting the engine.
45. Do not allow anyone near the skid steer while the engine is running and the skid steer is operational.
46. When using the skid steer to crane objects, do not allow any person to ride on objects being craned.
47. Do not use the skid steer as a work platform for supporting materials.
48. Do not lift personnel or allow personnel to work while standing in the bucket or on other attachments. This is not a man-lift.
OSHA requirements now make it the employer’s responsibility to fully instruct each operator in the proper and safe operation of all operative equipment. Both employer and employee should thoroughly familiarize themselves with the following sections.
CAUTION
Some pictures in this manual show safety shields removed or open to show parts being serviced or for clarity. All shields should be closed or replaced prior to operating the machine.
DANGER
Fasten seat belt before starting engine!
This skid steer is a very stable unit but it can be upset if stopped suddenly when the bucket is raised and loaded.
Therefore, do not start the engine before securely fastening the seat belt, and carry the load low.
00-6
GENERAL SAFETY INFORMATION
HANDLE FLUIDS SAFELY fire hazards.
SECTION 00 - GENERAL INFORMATION
When you work around fuel or other flammable material, do not smoke, work near heaters or other
Do not store flammable material in open containers.
Store flammable fluids away from fire hazards.
Do not incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, oil, and debris.
Do not store oily rags; they can ignite and burn spontaneously.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source.
AVOID HEATING NEAR PRESSURIZED FLUID
LINES
Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders.
Do not heat by welding, soldering, or using a torch near pressurized fluid lines.
Pressurized lines can be accidentally cut or damaged when heat goes beyond the immediate flame area.
USE CARE IN HANDLING AND SERVICING
BATTERIES
USE CARE AROUND HIGH-PRESSURE FLUID
LINES
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Tighten all line connections before applying pressure.
Check for leaks with a piece of cardboard.
Protect hands and body from high-pressure fluids.
Prevent Battery Explosions
Keep sparks, lighted matches, and open flame away from the top of the battery. Battery gas can explode.
Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode. Warm the battery to 60 ° F (16 ° C).
WARNING
If any servicing or adjustments require the battery to be disconnected, or welding is required on the skid steer, disconnect the (–) negative ground cable. Failure to disconnect the battery may result in damage to the eic
(electronic instrument cluster) monitoring system and other electrical components.
WARNING
If welding on an attachment is required, first remove the attachment from the skid steer boom attaching plate.
00-7
WARNING
SECTION 00 - GENERAL INFORMATION
Engine starting with a booster battery requires extreme care as batteries produce explosive gases. The slightest spark can cause an explosion.
Follow these safety tips:
1. Always shield your eyes when charging or working near a battery. Always provide good ventilation.
2. Cover the battery with a piece of carpet or other heavy material. Do not remove the battery vent caps.
3. Connect one cable to the (+) positive terminal of the weak battery. Connect the other end of the cable to the (+) positive terminal of the stronger battery.
4. Connect the second cable to the (–) negative terminal of the stronger battery.
5. Connect the remaining (–) negative cable end to the engine block or starter ground terminal.
6. Reverse this procedure when disconnecting the booster.
USE SAFE SERVICE PROCEDURES plate. If servicing requires the complete skid steer to be in the supported position, support all four wheels off the ground using adequate jack stands or blocks.
If servicing requires the engine to be operated, raise the machine and properly support the unit with adequate jack stands or blocking with all four wheels off the ground.
CAUTION
Before servicing the skid steer or any of its attached equipment, be sure that the attachments are lowered to the ground or the boom arms are supported by the boom lock pins.
USE PROPER TOOLS
Use tools appropriate for the job.
If tilting of the cab is required, use the proper tools and follow the procedure for tilting the cab in Section
1 of this manual.
REVIEW SAFETY EQUIPMENT, SIGNS AND
SHIELDS
Replace missing or damaged safety decals.
Reinstall all shielding removed for servicing.
Replace any damaged or missing shielding.
Wear Protective Clothing
Do not wear loose clothing.
Wear close-fitting clothing.
Wear safety glasses or face shield as required.
Wear other safety equipment appropriate to the job.
Wear earplugs or earmuffs as required.
SERVICE MACHINES SAFELY
Use caution when working around moving parts.
If servicing requires the boom to be in the raised position, support the boom on the boom locks and remove any attachment from the boom mounting
CONTROLS
Operate unit and check machine functions for proper operation.
Check seat belt for proper operation, wear, and damage - Replace as needed.
Check operator restraint system - EIC for proper operation.
Check boom and bucket spool locks for proper operation.
Check mechanical boom locks for proper operation.
Check parking brake for proper operation and adjustment.
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SECTION 00 - GENERAL INFORMATION
MACHINE MODEL AND SERIAL NUMBER
LOCATION
The skid steer model and serial number tag is located on the right front interior of the operator’s cab at 1.
ENGINE MODEL AND SERIAL NUMBER
LOCATION
The engine model and serial number is located on the left side of the block at 1.
2534-05
For the tightening torques for reassembly, use the following hardware torque chart unless the torque is specified in the instructions.
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1
1
2
00-9
SECTION 00 - GENERAL INFORMATION
MINIMUM HARDWARE TIGHTENING TORQUES
IN FOOT POUNDS (NEWTON-METERS) FOR NORMAL ASSEMBLY APPLICATIONS
INCH HARDWARE AND LOCKNUTS
SAE GRADE 2 SAE GRADE 5 SAE GRADE 8
NOMINAL UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED
SIZE or W/ZnCr or W/ZnCr or W/ZnCr
PLATED
SILVER GOLD
PLATED
SILVER GOLD
PLATED
SILVER GOLD
LOCKNUTS
GR.B
w/GR5
BOLT
GR.C
w/GR8
BOLT
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
55* (6.2) 72* (8.1)
115* (13) 149* (17)
17 (23) 22 (30)
86* (9.7)
178* (20)
26 (35)
27 (37)
42 (57)
60 (81)
35 (47)
54 (73)
77 (104)
42 (57)
64 (87)
92 (125)
83 (112) 107 (145) 128 (174)
146 (198) 189 (256) 226 (306)
142 (193) 183 (248) 365 (495)
213 (289) 275 (373) 547 (742)
112* (13) 121* (14)
229* (26) 250* (28)
34 (46) 37 (50)
157* (18)
324* (37)
48 (65)
61* (6.9)
125* (14)
19 (26)
86* (9.8)
176* (20)
26 (35)
54 (73)
83 (113)
59 (80)
91 (123)
77 (104)
117 (159)
120 (163) 130 (176) 169 (229)
30 (41)
45 (61)
65 (88)
42 (57)
64 (88)
92 (125)
165 (224) 180 (244) 233 (316) 90 (122) 127 (172)
293 (397) 319 (432) 413 (560) 160 (217) 226 (306)
473 (641) 515 (698) 667 (904) 258 (350) 364 (494)
708 (960) 773 (1048) 1000 (1356) 386 (523) 545 (739)
NOTE: Torque values shown with * are inch pounds.
IDENTIFICATION
CAP SCREWS AND CARRIAGE BOLTS
NOMINAL
SIZE
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
SAE GRADE 2 SAE GRADE 5 SAE GRADE 8
REGULAR NUTS SAE GRADE 5
HEX NUTS
SAE GRADE 8
HEX NUTS
LOCKNUTS
GRADE IDENTIFICATION
GRADE A NO NOTCHES
GRADE B ONE CIRCUMFERENTIAL NOTCH
GRADE C TWO CIRCUMFERENTIAL NOTCHES
GRADE IDENTIFICATION
GRADE A NO MARKS
GRADE B THREE MARKS
GRADE C SIX MARKS
MARKS NEED NOT BE LOCATED
AT CORNERS
GRADE A NO MARKS
GRADE B LETTER B
GRADE C LETTER C
GRADE IDENTIFICATION
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SECTION 00 - GENERAL INFORMATION
MINIMUM HARDWARE TIGHTENING TORQUES
IN FOOT POUNDS (NEWTON-METERS) FOR NORMAL ASSEMBLY APPLICATIONS
METRIC HARDWARE AND LOCKNUTS
NOMINAL
SIZE
CLASS 5.8
UNPLATED PLATED
W/ZnCr
CLASS 8.8
UNPLATED PLATED
W/ZnCr
CLASS 10.9
UNPLATED PLATED
W/ZnCr
LOCKNUT
CL.8
W/CL8.8
BOLT
M4
M6
M8
M10
M12
M16
M20
M24
15* (1.7) 19* (2.2)
51* (5.8) 67* (7.6)
23* (2.6)
79* (8.9)
30* (3.4)
102* (12)
33* (3.7)
115* (13)
42* (4.8)
150* (17)
16* (1.8)
56* (6.3)
124* (14) 159* (18) 195* (22) 248* (28) 274* (31) 354* (40) 133* (15)
21 (28)
36 (49)
27 (36)
46 (63)
32 (43)
55 (75)
41 (56)
72 (97)
45 (61)
79 (107)
58 (79)
102 (138)
22 (30)
39 (53)
89 (121) 117 (158) 137 (186) 177 (240) 196 (266) 254 (344) 97 (131)
175 (237) 226 (307) 277 (375) 358 (485) 383 (519) 495 (671) 195 (265)
303 (411) 392 (531) 478 (648) 619 (839) 662 (897) 855 (1160) 338 (458)
NOTE: Torque values shown with * are inch pounds.
IDENTIFICATION
HEX CAP SCREW AND CARRIAGE BOLTS
CLASSES 5.6 AND UP
MANUFACTURER’S IDENTIFICATION
PROPERTY CLASS
HEX NUTS AND LOCKNUTS
CLASSES 05 AND UP
MANUFACTURER’S IDENTIFICATION
PROPERTY CLASS CLOCK MARKING
00-11
SECTION 00 - GENERAL INFORMATION
INSTALLATION OF ADJUSTABLE
FITTINGS IN STRAIGHT THREAD O RING
BOSSES
1. Lubricate the O ring by coating it with a light oil or petroleum. Install the O ring in the groove adjacent to the metal backup washer which is assembled at the extreme end of the groove, 4.
2. Install the fitting into the SAE straight thread boss until the metal backup washer contacts the face of the boss, 5.
NOTE: Do not over tighten and distort the metal backup washer.
3. Position the fitting by turning out
(counterclockwise) up to a maximum of one turn.
Holding the pad of the fitting with a wrench, tighten the locknut and washer against the face of the boss, 6.
STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS
SIZE
8
10
12
14
4
5
6
16
20
24
32
TUBING
OD mm In.
6.4
7.9
9.5
1/4
5/16
3/8
12.7
15.9
19.1
22.2
1/2
5/8
3/4
7/8
25.4
31.8
38.1
50.8
1
1-1/4
1-1/2
2
TUBE NUTS
FOR 37
°
FLARED FITTINGS
THREAD
SIZE
7/16-20
1/2-20
9/16-18
3/4-18
7/8-14
1-1/16-12
1-3/16-12
1-5/16-12
1-5/8-12
1-7/8-12
2-1/2-12
NEWTON
METERS
Min.
TORQUE
Max.
FOOT
POUNDS
Min.
Max.
12
16
29
16
20
33
9
12
21
12
15
24
47
72
104
122
54
79
111
136
35
53
77
90
40
53
82
100
149
190
217
305
163
204
237
325
110
140
160
225
120
150
175
240
O RING BOSS PLUGS
ADJUSTABLE FITTING
LOCKNUTS, SWIVEL
JIC - 37
°
SEATS
34
47
81
95
NEWTON
METERS
Min.
TORQUE
Max.
FOOT
POUNDS
Min.
Max.
8
14
20
14
20
27
6
10
15
10
15
20
41
54
95
109
25
35
60
70
30
40
70
80
108
129
163
339
122
158
190
407
80
95
120
250
90
115
140
300
3
These torques are not recommended for tubes of
12.7 mm (1/2 ″ ) OD and larger with wall thickness of
0.889 mm (0.035
″
) or less. The torque is specified for
0.889 mm (0.035
″ ) wall tubes on each application individually.
Before installing and torquing 37
°
flared fittings, clean the face of the flare and threads with a clean solvent or Loctite cleaner and apply hydraulic sealant
Loctite no. 569 to the 37 ° flare and the threads.
Install fitting and torque to specified torque, loosen fitting and retorque to specifications.
00-12
Thread Size
1/8
″
– 27
1/4 ″ – 18
3/8
″
– 14
1/2 ″ – 14
3/4
″
– 14
SECTION 00 - GENERAL INFORMATION
PIPE THREAD FITTING TORQUE
Torque (Maximum)
13 N
⋅ m (10 ft. lbs.)
16 N ⋅ m (12 ft. lbs.)
22 N
⋅ m (16 ft. lbs.)
41 N ⋅ m (30 ft. lbs.)
54 N
⋅ m (40 ft. lbs.)
Before installing and tightening pipe fittings, clean the threads with a clean solvent or Loctite cleaner and apply sealant Loctite no. 567 for all fittings including stainless steel or no. 565 for most metal fittings. For high filtration/zero contamination systems use no. 545.
LUBRICANTS AND COOLANTS
Application
Gearboxes
Final Drive chain case
Hydraulic/Transmission
All lubrication fittings
Engine
Cooling System
New Holland Part Number
1 qt – #9613295
2.5 gal – #9613294
4 L – #9613375
1 qt – #9613313
2.5 gal – #9613314
1 L – #9613358
20 L – #9613360
1 qt – #9613313
2.5 gal – #9613314
1 L – #9613358
20 L – #9613360
Tube – #9613310
1 qt – #9613313
2.5 gal – #9613314
1 L – #9613358
20 L – #9613360
1 gal – #FGCC2701DS
Specification
SAE 80W-90
API Service SH–CG4 10W-30
API Service SH–CG4 10W-30
High viscosity lithium base grease
API Service SH-CG4 10W-30
Refer to Operator’s Manual for
Temperature/Oil Usage Chart
Antitreeze/Water 50/50
Mixture (Ethylene Glycol)
SEALANTS
Description
Thread Lock
Thread Sealants
Silicones
New Holland Part Number Typical Applications
L22200 (222)
L24231 (242)
L29000 (290)
L26231 (262)
L54531 (545)
L56531 (565)
L56747 (567)
L81724 (3.5 oz. tube)
L58775 (10.2 oz. cartridge)
L82180 (3.35 oz. tube)
L59875 (10.2 oz. cartridge)
Small Screws/Hardware
Nuts and Bolts
Wicking Type
Nuts and Bolts
Hydraulic/Pneumatic
Pipe Sealant
Pipe Sealant
Ultra Blue RTV Gasket
Ultra Blue RTV Gasket
Ultra Blue RTV Gasket
Ultra Blue RTV Gasket
Strength
Low
Medium
Medium
High
Non-Fouling
Controlled Strength
High Temperature
Non-corrosive
Non-corrosive
Non-corrosive
Non-corrosive
Color
Purple
Blue
Green
Red
Blue
Blue
Black
Black
00-13
SECTION 00 - GENERAL INFORMATION
PROPERLY SUPPORT A RAISED MACHINE
If servicing neutral adjustment, final drive adjustment or repairs requiring the machine to be raised, securely support the machine with adequate jack stands or blocks as shown.
Support the machine at 1 to the front of the final drive cases and to the rear at 2, making sure the supports are on the flat area of the final drive cases.
PROPERLY SUPPORT BOOM ON BOOM
LOCK PINS
Before servicing the machine or any of its attached equipment, be sure that the attachments are lowered to the ground or the boom arms are supported by the boom lock pins, 1.
If the boom is to be raised on the boom lock pins, remove any attachment. Opening a hydraulic line could cause a mounted attachment to dump over unexpectedly.
RAISING BOOM WITHOUT HYDRAULIC OIL
FLOW
(Engine or Hydraulic System not functioning)
1. Remove any attachment from the boom mounting plate.
2. Block the rear of the skid steer under the rear of the final drive cases, 1, as shown. This will prevent the front wheels from raising during boom lifting.
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4
5
6
00-14
SECTION 00 - GENERAL INFORMATION
3. Attach a chain or strap, 1, to the main boom, 2, and lifting device, 3. Attach chain or strap securely to prevent unhooking during boom lifting.
CAUTION
Attach suitable chains or straps capable of handling the weight of the boom, 454 kg (1000 lbs). Attach chains securely to prevent them from coming loose during lifting of the boom.
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4. With an Operator sitting in the Operator’s seat with the seat belt buckled.
5. Turn the ignition key to the “ON” position. Foot controls, press the toe of the left foot pedal, boom control, or hand controls, pivot the left hand control lever down, into the boom float position.
6. Slowly raise the boom above the boom lock pins,
1.
7. Operator sitting in seat, engage the boom lock pins, 1.
8. Lower the boom and rest on the boom lock pins,
1.
9. Return the boom control to the “NEUTRAL” position.
10. Turn the ignition key to the “OFF” position.
CAUTION
The operator must not leave the operator’s seat until the boom is resting solidly on the boom lock pins. The boom could drop suddenly if lifting devices should fail.
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3
7
8
00-15
SECTION 00 - GENERAL INFORMATION
RAISING BOOM WITHOUT BATTERY
VOLTAGE (12 VOLTS)
1. Remove any attachment from the boom mounting plate.
2. Block the rear of the skid steer under the rear of the final drive cases, 1, as shown. This will prevent the front wheels from raising during boom lifting.
19995757
3. Attach a chain or strap, 1, to the main boom, 2, and lifting device, 3. Attach chain or strap securely to prevent unhooking during boom lifting.
CAUTION
Attach suitable chains or straps capable of handling the weight of the boom, 454 kg (1000 lbs). Attach chains securely to prevent them from coming loose during lifting of the boom.
1
1
19995758
4. Remove the rod end (top) pivot pins, 1, from both cylinders by removing the retaining hardware, 2, from pivot pin and boom.
9
2
3
10
2
1
19995760
11
00-16
SECTION 00 - GENERAL INFORMATION
5. Support the cylinders on the fenders, 1, as shown.
19995761
6. With an Operator sitting in the Operator’s seat with the seat belt buckled, slowly raise the boom above the boom lock pins, 1.
7. Operator (sitting in the seat) engages the boom lock pins, 1.
8. Lower the boom and rest on the boom lock pins,
1.
CAUTION
The operator must not leave the operator’s seat until the boom is resting solidly on the boom lock pins. The boom could drop suddenly if lifting devices should fail.
REATTACHING CYLINDERS AFTER
REPAIR WITH BOOM RESTING ON BOOM
LOCK PINS
1. Support the rod end of cylinders, 1, off the boom upper links, 2, to align with main boom cylinder pivot pin holes, 3.
1
19995762
3
19995763
1
2
1
12
13
14
00-17
SECTION 00 - GENERAL INFORMATION
2. With operator sitting in the Operator’s seat with seat belt buckled, start the engine and hydraulically extend cylinder rods to align cylinder with pivot pin, 1. Stop engine.
3. Turn the ignition key to the “ON” position. Move the boom control into “DETENT” (float) position with the left foot pedal (press toe down) or left hand control (push control lever down). Turn the ignition key to the “OFF” position.
4. If cylinder and boom are not properly aligned, use a pry bar to align cylinder and boom.
5. Install pivot pin, 1, and secure with retaining hardware, 2. Torque bolts to 38 N
⋅ m (28 ft. lbs.).
6. Start the engine and hydraulically extend the second cylinder rod to align cylinder with pivot pin. Stop engine.
7. If cylinder and boom are not properly aligned, sit in the operator’s seat with seat buckled, turn the ignition key to the “ON” position. Move the boom control to the “DETENT (float) position and turn the ignition key to the “OFF” position.
8. Use a pry bar and align cylinder with boom and install pivot pin, 1, and retaining hardware, 2, and torque to 38 N ⋅ m (28 ft. lbs.).
MAJOR UNIT OVERHAUL
For a major hydrostatic component or engine repair, the skid steer cab and boom assembly can be tilted forward for easier access to the components area.
The figure shows the skid steer properly supported and the cab tilted forward.
19995764
2
1
WARNING
Never attempt to tilt the skid steer cab without using the proper tool and instructions. See more detail later in this section of the manual and/or contact your new holland dealer.
15
16
00-18
SECTION 00 - GENERAL INFORMATION
CAB AND BOOM TILT PROCEDURE
The cab and boom assembly can be tilted forward for easier access to the major skid steer hydrostatic transmission or engine components. To tilt the cab, the proper cab tilting tool must be used to ensure safety and to prevent damage to the skid steer frame, cab, and boom structure. Contact your New Holland dealer for major service or repairs of the skid steer.
Using the proper cab tilting tool and following these steps, the cab and boom can be tilted forward.
1. Remove any attachment, bucket, etc. from the boom quick-attach plate.
Cab tilting jack and support brackets:
1 Jack and screw assembly
2 Lower support
3 Upper support
4 Spacer top link
2. Raise the boom and lower onto boom lock pins,
1.
– Raise boom above boom lock pins.
– Engage boom lock pins.
– Stop engine, ignition key off position.
– Turn ignition key to the on position.
– Lower boom onto boom lock pins.
– Turn the ignition key to the “OFF” position.
17
18
19
00-19
SECTION 00 - GENERAL INFORMATION
3. Jack up the skid steer and block it securely with all four wheels off the ground, as shown. Position the front blocks, 1, to the front of the final drive housings and the rear blocks, 2, to the rear of the flat area of the final drive housings.
WARNING
Never attempt to tilt the skid steer cab over unless the skid steer is securely supported.
4. Open the rear door, 1. Raise the top engine shield, 2, and latch in the raised position.
5. Remove engine side covers, 3.
20
21
6. Disconnect the battery negative (-) cable, 1.
22
00-20
SECTION 00 - GENERAL INFORMATION
7. Remove fenders, 1, right and left sides.
8. Remove foam material, 2, from both sides.
9. Remove the rear fender supports, 3, right and left sides.
23
10. Raise the seat and lock in the up position, 1.
Make sure the seat pan assembly is latched securely.
CAUTION
Do not work under the seat and pan unless it is properly latched in the raised position.
11. Remove the front step shield, 1.
4825-11r
1
24
25
00-21
SECTION 00 - GENERAL INFORMATION
12. Remove the cotter pins from the parking brake linkage at 1, unhook link rod, 2, and raise the parking brake lever, 3, to the engaged position.
3
1
2
19992572
13. Install the lower cab jack support, 1. Hook the support over the end of the front left final drive housing and attach with a 1/2
″
x 8
″
cap screw, two spacers, one each side of housing at 2, and
1/2
″
nut.
26
27
14. Install the upper cab jack support, 1. The spacer channel, 2, is used for the LS160 and LS170 models. Pivot the retaining plate, 3, up behind the boom top link and secure with 1/2 ″ x 1-1/4 ″ carriage bolt and 1/2 ″ wing nut. Install retaining bolt, 4, 1/2
″
x 2-1/2
″
cap screw through side of cab with a large 1/2 ″ flat washer, 1/2 ″ wing nut to the inside of cab and tighten.
28
00-22
SECTION 00 - GENERAL INFORMATION
15. Install the jack assembly, 1, between the upper and lower supports using two pins and retaining clips.
16. Loosen the front cab mounting bolts, 2, only enough to allow the bolt to rotate in post. Remove the rear front cab bolts, 3.
CAUTION
Never remove the front cab bolts, 2, as these are the pivot bolts during the cab tilting procedure.
Removal of these bolts could cause the cab to fall and may cause injury and machine damage.
17. Remove the four rear cab post bolts, 4. Note the number and position of washers for reassembly.
CAUTION
Never loosen or remove any cab retaining hardware before the jack assembly is installed.
18. Jack cab and boom assembly over with the skid steer properly supported off the ground. Support the boom at 1 to prevent tipping of the skid steer when heavy components, engine, hydrostatic pumps, etc. are removed from the lower frame.
Jack travel or length of hydraulic hoses will limit the travel of the cab assembly when tilting. Be sure all wire harnesses, hydraulic hoses, and throttle cable clear any obstructions during cab tilting.
WARNING
Never attempt to tilt the skid steer cab without proper instructions and without using the proper tool.
CAUTION
Never attempt to operate or move the skid steer without first installing and properly tightening all cab retaining hardware.
29
30
00-23
SECTION 00 - GENERAL INFORMATION
To jack the cab and boom assembly back into position:
1. Pull the hydrostat control handles forward and hold in this position with rubber tie straps from the handle to the front cab post.
2. Jack the cab and boom back into position.
3. Keep the wire harness, 1, and throttle cable, 2, in position to prevent damage from setting the cab on them.
4. Pull the wire harness through the loop, 3.
CAUTION
Keep the wire harness from being damaged. A damaged wire harness could result in damage to the skid steer electrical components.
5. Remove rubber tie straps from the hydrostatic control handles.
6. Reinstall all cab support bolts front and rear.
Torque the rear bolts, 1, to 108 N·m (80 ft. lbs.).
Make sure the spacers are reinstalled.
NOTE: If spacers were installed under the rear cab support bolts, 1, the spacers must be reinstalled for proper bolt torquing.
7. Reinstall the parking brake linkage, 2.
8. Position the throttle cable, 3, inside frame.
9. Reinstall the rear fender supports, 4. Do not tighten hardware at this time.
10. Torque the front bolts, 1, to 217 N·m (160 ft. lbs.).
11. Reinstall the foam, 2; fenders, 3; and front step shield, 4.
12. Tighten the rear fender supports, 5, at this time.
13. Remove jack and supports.
14. Reconnect the battery cable.
WARNING
Never attempt to operate or move the skid steer without first installing and properly tightening all cab retaining hardware.
31
32
33
00-24
SECTION 00 - GENERAL INFORMATION
CRANING THE SKID STEER
If the skid steer is inoperative and located in an area where it cannot be loaded onto a truck or trailer, the unit may be craned to load the unit.
To crane the skid steer, only use chain or cable with a rated capacity to handle the weight of the model skid steer being craned. Refer to “Specifications” in this manual for the operating weight of the model skid steer being craned. Use three chains minimum of
3.66 m (12
′
) long to prevent sharp angles and damage to the skid steer cab, boom, and lifting chains.
Remove any attachment except a standard bucket from the skid steer boom attaching plate.
CAUTION
Do not lift any attachments on the skid steer mounting plate that weigh 272 kg (600 lbs.) or more. Lift such attachments separately.
The lifting points at the rear of the skid steer, 1.
34
35
36
00-25
SECTION 00 - GENERAL INFORMATION
The front lifting point is in the center of the main frame, 1.
The lifting chains or cables must be minimum of 3.66
m (12
′
). The lifting hook point must be minimum of 1.9
m (75
″
) above the cab, 1, to prevent the chains or cables from damaging the skid steer frame or cab.
WARNING
Always use properly rated lifting devices to prevent personal injury or damage to the skid steer.
37
38
00-26
SECTION 00 - GENERAL INFORMATION
When craning (lifting or lowering) a skid steer, observe these “CAUTIONS.”
CAUTION
1. No riders (including the operator) in or on the machine while lifting or lowering.
2. Do not lift any attachments on the skid steer mounting plate that weigh 272 kg (600 lbs.) or more. Lift such attachments separately.
3. Always use a chain or cable capable of safely hoisting the weight of the skid steer.
4. Before hoisting the skid steer, always inspect the lifting chain or cable and the lifting points on the skid steer main frame to insure they are in good condition. If worn or damaged, do not use.
5. Do not lift the skid steer with any frame-mounted attachments such as a backhoe or rear stabilizers.
6. Do not attach lifting devices to the skid steer boom or attachments on the skid steer.
7. Make sure the skid steer boom is in the completely lowered position.
8. Make sure that any attachment to be lifted on the skid steer is securely fastened to the skid steer mounting plate with the over-center handles and pins fully engaged. Pivot the attachment fully back.
9. Make sure that the engine is off and the parking brake is engaged before lifting.
10. Keep bystanders away from the machine a safe distance while lifting.
00-27
SPECIAL TOOLS
Tilting Cab
Tool Number
86590084
Engine
Tool Number
NH00011
NH00120
NH00117
NH11097
Hydraulic System
Tool Number
238 Bar (3500 PSI) Test Gauge
Flow meter
3/4
″
—16 UNF O ring fitting
1/2
″
Quick coupler
FNH22ESS95
*Recommend Tool
***Essential Tool
SECTION 00 - GENERAL INFORMATION
Order From Description
New Holland Cab Tilting Tool
Order From
OTC
OTC
OTC
OTC
Description
Oil pressure adapter
Compression test adapter
Oil pump port block installer
Oil pump port block remover
Order From
OTC
OTC
Local
Description
Main system pressure
Main system/Hydrostatic pumps
Main system at Boom cylinder
New Holland Main system at Auxiliary boom couplers
OTC Hydraulic tank pressuring tool
LS160 LS170
*** ***
LS160 LS170
***
***
***
***
***
***
***
***
LS160 LS170
*** ***
***
***
*
***
***
*
* *
00-28
SECTION 00 - GENERAL INFORMATION
SPECIFICATIONS
MODEL LS160
ENGINE MANUFACTURER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NEW HOLLAND
MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N844 Diesel
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ASPIRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NATURAL
CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 STROKE
BORE AND STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 90 mm (3.31
″ 3.54
″ )
DISPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1995 cu. cm (121.7 cu. in.)
COMPRESSION RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 1
SPEEDS
-FAST (no load)
-IDLE (no load)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130 to 3180 RPM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 to 1000 RPM
HORSEPOWER
(SAE GROSS)
(SAE NET)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42.5 @2900 RPM
40.0 @2900 RPM
TORQUE - (mfg. rating) Gross . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 N·m (93 ft. lbs.)
VALVE CLEARANCE
-Intake (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.008 in.)
-Exhaust (cold).
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.008 in.)
FIRING ORDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
FUEL CONSUMPTION
(approximate at continuous full load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 LPH (2.5 GPH)
IGNITION TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression
GRADEABILITY (Intermittent duty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Degrees All Directions
AIR CLEANER - Dry type dual element
Primary element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86504145
Safety element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86504143
FUEL SYSTEM
Type of fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Injection type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indirect
Inline filter replaceable
NH#9611973
Inline water trap NH#86504140
CAPACITIES
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 L (10.8 qt.)
Radiator cap 48.3 kPa (7 psi)
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52.9 L (14 gal.)
14.8 L (3.9 gal.)
Chain case (final drive - per side)
Gearbox (per box)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 L (1.8 gal.)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.95 L (1 qt.)
00-29
SECTION 00 - GENERAL INFORMATION
MODEL LS160
ENGINE OIL
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . API SH/CG4 SAE 10W-30
Filter part # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86546618
Engine crankcase capacity w/filter
Dipstick length
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 L (8.8 qt.)
367 mm (14.4
″
)
ELECTRICAL SYSTEM
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator capacity
BCI PC31 - 12V 650 amps @ 0 ° F (–18 ° C)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 amps
Starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition system protection
Key start and relay
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse 15 amps
Headlights (work) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86533429
Taillights (work)
Taillights (road)
Amber flasher
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86533429
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86505510
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #529068
HYDRAULIC SYSTEM
Pump - Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output
Gear pump
Standard Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional High Flow
15.5 GPM (58.7 LPM) @3155 RPM-@1000 PSI
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 GPM (90.8 LPM) @3155 RPM-@2300 PSI
Hydraulic system Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.6 L (8.6 gal.)
Hydraulic Fluid
Control Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 10W-30 - API SH/CG4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Spool Open Center
Main system relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 - 177 bar (2500 - 2600 PSI)
Circuit relief - boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Spin-on canister
238 bar (3500 PSI)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #9842392
BOOM CYLINDERS
Double-acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 mm (2.5
″
) dia. bore
470.0 mm (18.5
″ ) stroke
Cycle time
Raise
Lower
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.0 seconds
3.0 seconds
BUCKET CYLINDERS
Double-acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.8 mm (2.25
″
) dia. bore
450.8 mm (17.88
″ ) stroke
Cycle time
Dump
Curl
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.0 seconds
1.7 seconds
HYDROSTATIC TRANSMISSIONS
Pump
Motor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge Pressure
Variable displacement piston type
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed displacement piston type
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.0 bar (160 PSI)
Relief Pressure (Transmission)
Oil Type
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
238 bar (3500 PSI)
SAE 10W-30 API SH/CG4
TRAVEL SPEEDS - 10.00 16.5 Tires
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.75 KPH (7.3 MPH)
11.75 PPH (7.3 MPH)
00-30
SECTION 00 - GENERAL INFORMATION
MODEL LS160
TIRE SIZES AND INFLATION
Tire
7.00 15 - CHEVRON TREAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.50 15 - HST-HOLLOW SEGMENTED TIRES
Tire Pressure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
414 kPa (60 PSI)
N/A
345 kPa (50 PSI) 10.00 16.5 - R4 CLEAT TREAD
10.00 16.5 HD 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.00 16.5 - HST-HOLLOW SEGMENTED
31 15.5 15 - G1 Flotation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
345 kPa (50 PSI)
N/A
276 kPA (40 PSI)
BASIC WEIGHT - With 157 cm (66
″
) Dirt & Foundry bucket, 79 kg (175-lb.) operator, full fuel tank, battery, and
10.00 16.5 tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2210 kg (5534 lbs)
OPERATING CAPACITY
SAE Operating load capacity per SAE J732, J818, J742 Standard.
. . . . . . . . . 680 kg (1500 lbs.) (mfg. rating)
770.4 kg (1750 lbs.) (SAE rating)*
*SAE operating load rating per J818 specifications.
00-31
SECTION 00 - GENERAL INFORMATION
SPECIFICATIONS
MODEL LS170
ENGINE MANUFACTURER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NEW HOLLAND
MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N844T Diesel
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ASPIRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NATURAL
CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 STROKE
BORE AND STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 90 mm (3.31
″ 3.54
″ )
DISPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1995 cu. cm (121.7 cu. in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1995 cu. cm (121.7 cu. in.)
COMPRESSION RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 1
SPEEDS
-FAST (no load)
-IDLE (no load)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130 to 3180 RPM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 to 1000 RPM
HORSEPOWER
(SAE GROSS)
(SAE NET)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52.0 @2900 RPM
50.0 @2900 RPM
TORQUE - (mfg. rating) Gross . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 N·m (113 ft. lbs.)
VALVE CLEARANCE
-Intake (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-Exhaust (cold).
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.2 mm (0.008 in.)
0.2 mm (0.008 in.)
FIRING ORDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
FUEL CONSUMPTION
(approximate at continuous full load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1 LPH (3.2 GPH)
IGNITION TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression
GRADEABILITY (Intermittent duty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Degrees All Directions
AIR CLEANER - Dry type dual element
Primary element
Safety element
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86504145
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86504143
FUEL SYSTEM
Type of fuel
Injection type
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indirect
Cleaning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inline filter replaceable
NH#9611973
Inline water trap NH#86504140
CAPACITIES
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 L (10.8 qt.)
Cooling system pressure
Fuel tank
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator cap 48.3 kPa (7 psi)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.9 L (14 gal.)
Hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chain case (final drive - per side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.8 L (3.9 gal.)
6.8 L (1.8 gal.)
Gearbox (per box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.95 L (1 qt.)
00-32
SECTION 00 - GENERAL INFORMATION
MODEL LS170
ENGINE OIL
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . API SH/CG4 SAE 10W-30
Filter part # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86546618
Engine crankcase capacity w/filter
Dipstick length
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 L (8.8 qt.)
367 mm (14.4
″
)
ELECTRICAL SYSTEM
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator capacity
BCI PC31 - 12V 650 amps @ 0 ° F (–18 ° C)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 amps
Starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition system protection
Key start and relay
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse 15 amps
Headlights (work) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86533429
Taillights (work)
Taillights (road)
Amber flasher
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86533429
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86505510
NH #529068
HYDRAULIC SYSTEM
Pump - Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output
Gear pump
Standard Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional High Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17.7 GPM (67 LPM) @3155 RPM-@1000 PSI
26.2 GPM (99.2 LPM) @3155 RPM-@2300 PSI
Hydraulic system Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.6 L (8.6 gal.)
Hydraulic Fluid
Control Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 10W-30 - API SH/CG4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Spool Open Center
Main system relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 - 177 bar (2500 - 2600 PSI)
Circuit relief - boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Spin-on canister
238 bar (3500 PSI)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #9842392
BOOM CYLINDERS
Double-acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 mm (2.5
″
) dia. bore
470.0 mm (18.5
″ ) stroke
Cycle time
Raise
Lower
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 seconds
2.3 seconds
BUCKET CYLINDERS
Double-acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.8 mm (2.25
″
) dia. bore
450.8 mm (17.88
″ ) stroke
Cycle time
Dump
Curl
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 seconds
1.5 seconds
HYDROSTATIC TRANSMISSIONS
Pump
Motor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge Pressure
Variable displacement piston type
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed displacement piston type
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.0 bar (160 PSI)
Relief Pressure (Transmission)
Oil Type
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
238 bar (3500 PSI)
SAE 10W-30 API SH/CG4
TRAVEL SPEEDS - 10.00 16.5 Tires
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.75 KPH (7.3 MPH)
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.75 PPH (7.3 MPH)
00-33
SECTION 00 - GENERAL INFORMATION
MODEL LS170
TIRE SIZES AND INFLATION
Tire
7.00 15 - CHEVRON TREAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.50 15 - HST-HOLLOW SEGMENTED TIRES
Tire Pressure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
414 kPa (60 PSI)
N/A
345 kPa (50 PSI) 10.00 16.5 - R4 CLEAT TREAD
10.00 16.5 HD 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.00 16.5 - HST-HOLLOW SEGMENTED
31 15.5 15 - G1 Flotation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
345 kPa (50 PSI)
N/A
276 kPA (40 PSI)
BASIC WEIGHT - With 157 cm (66
″
) Dirt & Foundry bucket, 79 kg (175-lb.) operator, full fuel tank, battery, and
10.00 16.5 tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2513 kg (5540 lbs)
OPERATING CAPACITY
SAE Operating load capacity per SAE J732, J818, J742 Standard.
. . . . . . . . . 771 kg (1700 lbs.) (mfg. rating)
800.6 kg (1765 lbs.) (SAE rating)*
*SAE operating load rating per J818 specifications.
00-34
SECTION 00 - GENERAL INFORMATION
39
DIMENSIONS - LS160 AND LS170 WITH 66 , DIRT AND FOUNDRY BUCKET AND 10 X 16.5 TIRES - CM (IN.)
1 - OVERALL WIDTH w/BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166.6 cm (65.6
″
)
2 - TURNING RADIUS - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189.2 cm (74
″
)
3 - TURNING RADIUS - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.4 cm (60 ″ )
4 - WHEEL TREAD w/10 X 16.5 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138.5 cm (56 ″ )
5 - OVERALL WIDTH w/10 X 16.5 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166.7 cm (65.6
″
)
00-35
SECTION 00 - GENERAL INFORMATION
40
DIMENSIONS - LS160 AND LS170 WITH 66 , DIRT AND FOUNDRY BUCKET AND10 X 16.5 TIRES - CM (IN.)
1 - MAXIMUM OPERATING HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355.7 cm (140.0
″
)
2 - HEIGHT TO HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293.4 cm (115.5
″
)
3 - DUMP HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229.6 cm (90.4
″ )
4 - DUMP ANGLE (MAX.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 °
5 - ROLLBACK FULLY RAISED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
°
6 - BOOM REACH TO PIVOT PIN (At max. reach) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.0 cm (14.56
″
)
7 - DUMP REACH @ MAXIMUM HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70.5 cm (27.75
″ )
8 - OVERALL HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189.9 cm (74.75
″ )
9 - ANGLE OF DEPARTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
°
10- GROUND CLEARANCE
(CHAIN CASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.6 cm (7.7
″ )
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.9 cm (9 ″ )
11- WHEELBASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 cm (42.5
″
)
12- OVERALL LENGTH LESS BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257.8 cm (101.5
″
)
13- OVERALL LENGTH w/BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322.0 cm (126.75
″ )
14- ROLL BACK ANGLE (BOOM DOWN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 °
00-36
SECTION 10 – ENGINE
Chapter 1 – LS160 - N844, LS170 - N844T
Section
CONTENTS
Description Page
10-1
10 304 38
29 100 50
10 236 08
10 250 30
10 223 10
SECTION 10 - ENGINE
Engine Reassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61
Crankshaft and Bearing Holder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
Backplate/Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64
Oil Intake and Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64
Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64
Dipstick and Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64
Front Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64
Idler Gear and Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
Timing Gear Case Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
Adjusting the Fuel Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-67
Spill Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
Reinstallation of Engine into Skid Steer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75
How to Operate the Engine After Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
Cooling System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
Water Pump Assembly and Thermostat Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-79
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
Diesel Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
Fuel System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
Fuel Guage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
Cold Start Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85
Fuel Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
Fuel System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87
Fuel System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90
Fuel Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96
Turbocharger - LS170 N844T Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101
Turbocharger Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103
Miscellaneous Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
Shut-off Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-117
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-119
Labor Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
10-2
SECTION 10 - ENGINE
Op. 10 000
GENERAL ENGINE INFORMATION
New Holland engines, N844 used in the model
LS160 skid steer and N844T turbocharger engine used in the model LS170 skid steer.
GENERAL DESCRIPTION
The N844, N844T Series are four-cylinder stroke, liquid-cooled, compression ignition engines, designed for durability, low weight and compactness.
The engines are IDI (In Direct Injection). The linerless cylinder block, three-piece helical gear train, and flange-mounted fuel injection pump on the engine cam, reduce frictional power loss and engine weight. The special direct-injection or swirl chamber, along with the small bore multi-cylinder design, offers good fuel consumption, low noise, and excellent start-ability.
ENGINE COMPONENT DESCRIPTIONS
19992590
CYLINDER BLOCK
The cylinder block is made from high-grade cast iron with copper and chrome additives and is integral with the crankcase. The crankcase features five main bearings of the tunnel block design, with crankcase walls extending well below the crankshaft centerline for strength and rigidity. The cylinder’s bores are plateau honed for oil retention and extended ring life.
The non-machined surfaces are sealed to ensure cleanliness.
19992591
CRANKSHAFT
The crankshaft is a chrome-molybdenum steel forging, fully machined, static, and dynamically balanced with integral counterweights. All bearing surfaces are induction hardened. The axial location is by thrust washers at the number five main bearing.
The five main journals run in replaceable steel-backed cast copper/lead alloy bearings. The front of the crankshaft is keyed.
1
2
10-3
PISTONS AND CONNECTING RODS
SECTION 10 - ENGINE
Pistons are cast from high silicon aluminum alloy and are heat-treated for low weight with high strength and good thermal conductivity. The piston is fitted with three rings; two cast iron, chrome-faced compression rings and one steel, chrome-faced controlled oil ring. The fully floating gudgeon pin
(wrist pin) is made of chrome molybdenum steel alloy hardened by carburizing and retained by the conventional retaining ring method. The connecting rods are machined from high-strength forged steel.
The big end bearings are renewable steel-backed, copper/lead alloy overlay with tin plating. The small end bearings are a press fit plain bushing of tin-backed lead/bronze.
machined bores in the cylinder block. The rocker shaft is an induction hardened hollow steel tube.
Valve clearances are adjusted by hardened ball-ended screws and locknuts.
ROCKER COVER AND INLET MANIFOLD
The cover is made of cast aluminum with an air intake, oil filler, and crankcase breather. It is located in position by rocker pillar studs and secured by cap nuts.
GEAR TRAIN
The gear train consists of three helical gears – the crankshaft gear located by a woodruff key, the idler gear houses the lube oil pump, and the cam gear incorporates the governor weight cage.
CAMSHAFT
The camshaft is made of forged steel and is induction hardened. Three or four additional lobes at the front operate the fuel injection pump. At the rear, a fuel lift pump eccentric is machined. The camshaft is supported by roller and needle bearings and lubricated by splash feed. The nose of the camshaft supports the cam gear, governor weight cage, and governor slider assembly.
FUEL SYSTEM
A flange-mounted, Bosch-type fuel injection pump is mounted in the cylinder block and operated by lobes machined on the engine cam.
CYLINDER HEAD
The cylinder head is made of high grade copper chrome cast iron, and incorporates replaceable heat-resistant alloy steel valve seats. Inlet and exhaust valves are made of high grade heat-resistant alloy steel with tuftrided stems and induction hardened heads. Each stem is fitted with a chrome molybdenum steel cap for long life.
The valves are operated by cold drawn seamless tube push rods with hardened steel ball and forged cup ends. Flat-based tappets are made from case carburized chrome molybdenum steel operating in
LUBRICATING SYSTEM
A trochoid lobe oil pump located in the center of the idler gear sends lubricating oil to the main oil galley via a relief valve through a spin-on bypass oil filter to the main oil gallery. The rockers are pressure fed via an externally mounted oil pipe from the main oil gallery to the cylinder head.
COOLING SYSTEM
A belt-driven centrifugal water pump circulates coolant via the internal water passages. The coolant is radiator cooled and temperature controlled by a conventional thermostat.
10-4
SECTION 10 - ENGINE
ENGINE MODEL AND SERIAL NUMBER
LOCATION
The engine model number is located on the right side of the engine block at 1. The engine serial number is located at 2.
Throughout this manual, whenever the left- or right-hand side of the engine is referred to, it is that side of the engine when viewed from the flywheel end.
This publication is produced by New Holland North
America, Inc. Every endeavor is made to ensure the information contained in this manual is correct at the date of publication, but due to continuous development, New Holland reserves the right to alter specifications without notice.
TURBOCHARGER LUBRICATION
The turbocharger used on the LS170 diesel engine may not receive adequate lubrication on cool/cold weather (below 5 ° C, 40 ° F) start-up, leading to turbocharger bearing failure.
The following procedure must be used to ensure adequate lubrication oil is supplied to the turbocharger bearings before high-speed engine operation:
1. Set the engine throttle at 1/3 speed.
2. Turn the ignition switch and allow the automatic glow plug timer to preheat the engine until the
EIC “beep” is heard.
3. Start the engine, but DO NOT OPERATE
ABOVE 1,500 RPM for three minutes to allow for adequate oil flow at the turbocharger.
After full load operation, allow the engine to run at low idle for one minute before engine shutdown.
3
10-5
SAFETY PRECAUTIONS
These safety precautions are most important:
CAUTION
Do not change the specification of the engine.
Do not smoke when you put fuel in the tank.
Clean away any fuel which has spilled and move material which has fuel contamination to a safe place.
Do not put fuel in the tank during engine operation.
Never clean, lubricate or adjust the engine during operation unless otherwise specified in this manual. Use extreme caution when working around moving parts to prevent injury.
Do not make any adjustments you do not understand.
Ensure the engine is not in a position to cause a concentration of toxic emissions.
Persons in the area must be kept clear during engine and equipment or vehicle operation.
Do not permit loose clothing or long hair near parts which move.
Keep away from parts which turn during operation. Note that fans cannot be seen clearly while the engine is running.
Do not run the engine with any safety guards removed.
SECTION 10 - ENGINE
Do not remove the radiator cap while the engine is hot and the coolant is under pressure, as dangerous hot coolant can be discharged.
Do not use salt water in the fresh water cooling system or any other coolant which can cause corrosion.
Keep sparks or fire away from batteries
(especially while charging) or combustion can occur. The battery fluid can burn and is also dangerous to the skin and especially the eyes.
Disconnect the battery terminals before you make a repair to the electrical system.
Only one person must be in control of the engine.
Ensure the engine is only operated from the control panel or operator’s position.
If your skin comes into contact with highpressure fuel, get medical assistance immediately.
Diesel fuel and used engine oils can cause skin damage to some persons. Use protection on the hands (gloves or special skin protection solutions).
Do not move equipment unless the brakes are in good condition.
Be sure that the transmission drive control is in
“Neutral” position before the engine is started.
Do not use ether to start these engines.
10-6
SECTION 10 - ENGINE
GENERAL ENGINE SPECIFICATIONS
LOADER MODEL LS160
Engine Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N844
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical in-line 4-stroke naturally aspirated
Basic Thread and Size
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84 mm (3.31
″ )
90 mm (3.54
″ )
Combustion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IDI (Indirect Injection/Special Swirl)
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swept Volume Liter (inch 3 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22:1
1,995 (121.7)
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterclockwise viewed from flywheel
Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 - 1000 RPM
High Idle (Full Throttle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130 - 3180 RPM
Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flange-mounted, Bosch-type plunger and barrel
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch-type throttle
Injector Setting
Kilograms/sq. cm (kgf/cm 2 )
Pounds per sq. inch (PSI)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147 - 157
2132 - 2277
Turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NO
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical all speed
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid with water pump and radiator
Industrial Cooling System Capacity
(less radiator) Liters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Thermostat Operating
Temperature degrees
Oil Pressure Relief
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 ° /203 ° F (82 ° /95 ° C)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 - 50 PSI (2.5 - 3.5 kgf/cm
2
)
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 PSI
Electrical System
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery (625 CCA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12V
12V
Weight, Bare Engine (Industrial)
Height
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
191 kg (421 lbs.)
767 mm (30.2
″
)
Length
Width
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
686 mm (27.0
″
)
428 mm (16.8
″ )
10-7
SECTION 10 - ENGINE
LOADER MODEL LS160
Recommended Engine Fluids
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean soft water. Maximum antifreeze concentration
50% (ethanediol base-ethylene glycol with corrosion inhibitor to BS 6850:1985 or ASTM D3306-74 or
AS 2108-1977)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cetane number-45 minimum, Viscosity -2.5/4.5
centistokes at 104 ° F (40 ° C). Density-0.835/0.855 kg/liter, Sulfur-0.5% of mass maximum. Distillation
85% at 662
°
F (350
°
C). (Aviation fuel JP4 is not recommended; however, JP5 and JET-A are acceptable, providing 5% spindle oil is added).
Lubricating System
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure feed with Trochoid pump
Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . API SH/CG4 SAE 10W-30
(SAE 5W30 for extended cold weather operation)
Filter Part # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86546618
Engine Crankcase Capacity w/Filter
Dipstick Length
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6 L (8 qt.)
367 mm (14.4
″
)
10-8
SECTION 10 - ENGINE
GENERAL ENGINE SPECIFICATIONS
LOADER MODEL LS170
Engine Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N844T
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical in-line 4-stroke naturally aspirated
Basic Thread and Size
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84 mm (3.31
″ )
90 mm (3.54
″ )
Combustion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IDI (Indirect Injection/Special Swirl)
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swept Volume Liter (inch 3 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22:1
1,995 (121.7)
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterclockwise viewed from flywheel
Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 - 1000 RPM
High Idle (Full Throttle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130 - 3180 RPM
Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flange-mounted, Bosch-type plunger and barrel
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch-type throttle
Injector Setting
Kilograms/sq. cm (kgf/cm 2 )
Pounds per sq. inch (PSI)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147 - 157
2132 - 2277
Turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YES
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical all speed
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid with water pump and radiator
Industrial Cooling System Capacity
(less radiator) Liters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Thermostat Operating
Temperature degrees
Oil Pressure Relief
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 ° /180 ° F (71 ° /82 ° C)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 - 64 PSI (3.5 - 4.5 kgf/cm 2 )
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 PSI
Electrical System
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V
Battery (625 CCA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V
Weight, Bare Engine (Industrial)
Height
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
206 kg (454 lbs.)
789 mm (31.1
″ )
Length
Width
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
666 mm (26.2
″
)
482 mm (19.0
″ )
10-9
SECTION 10 - ENGINE
LOADER MODEL LS170
Recommended Engine Fluids
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean soft water. Maximum antifreeze concentration
50% (ethanediol base-ethylene glycol with corrosion inhibitor to BS 6850:1985 or ASTM D3306-74 or
AS 2108-1977)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cetane number-45 minimum, Viscosity -2.5/4.5
centistokes at 104 ° F (40 ° C). Density-0.835/0.855 kg/liter, Sulfur-0.5% of mass maximum. Distillation
85% at 662
°
F (350
°
C). (Aviation fuel JP4 is not recommended; however, JP5 and JET-A are acceptable, providing 5% spindle oil is added).
Lubricating System
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure feed with Trochoid pump
Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . API SH/CG4 SAE 10W-30
(SAE 5W30 for extended cold weather operation)
Filter Part # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86546618
Engine Crankcase Capacity w/Filter
Dipstick Length
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6 L (8 qt.)
367 mm (14.4
″
)
10-10
SECTION 10 - ENGINE
TROUBLESHOOTING
ENGINE WILL CRANK BUT DOES NOT START
CAUSE CORRECTION
Faulty key switch
Blown 5-amp electronic ignition fuse (cab fuse panel)
Fuel solenoid not operating
Correct the connection and/or replace switch
Replace fuse
Check solenoid for battery voltage and correct
Insufficient charging or complete discharging of the battery
Lack of fuel
Air mixed in the fuel system
Charge or replace battery
Fill fuel tank
Bleed the air
Clogged fuel filter
Irregular and faulty fuel supply (injection pump trouble)
Replace
Irregular and faulty fuel supply (electric fuel pump) Check power supply; check fuse in fuse panel; check for corroded internal components (replace pump and in-line filter if corroded)
Repair in an authorized service shop
Glow plug not heating
Improper viscosity of the lubricating oil
Clogged air cleaner
No compression
Failure of the glow plug; replace
Inspect and replace
Clean or replace
Repair in a service shop
Seat belt not fastened
Faulty key switch
CAUSE
ENGINE WILL NOT CRANK OR START
CORRECTION
Insufficient charging or complete discharging of the battery
Blown 5-amp electronic battery fuse (engine fuse panel)
Charge or replace battery
Replace fuse
Blown 15-amp key main fuse (engine fuse panel) Replace fuse
Open in W/O (white-orange) wire between the seat/seat belt connector and start interlock relay
Faulty start interlock relay
Buckle seat belt
Correct the connection and/or replace switch
Check and repair as required
Check and repair as required
CAUSE
IRREGULAR RUNNING OF THE ENGINE
CORRECTION
Air mixed in the fuel system Bleed the air from the system
Uneven fuel injection (faulty fuel injection pump)
Clogged fuel filter
Defective governor
Engine itself defective
Repair at authorized shop
Replace
Check and correct
Repair in a service shop
10-11
SECTION 10 - ENGINE
CAUSE
ENGINE STOPS DURING OPERATION
CORRECTION
Check and repair hydrostatic charge pressure EIC (Electronic Instrument Cluster) shows fault with hydrostatic charge pressure
EIC (Electronic Instrument Cluster) shows fault with engine crankcase oil pressure
Lack of fuel in the tank
Clogged fuel filter
Air mixed in the fuel system
Faulty function of the engine
Check oil level and/or repair engine crankcase oil pressure
Fill fuel tank and bleed air
Replace
Bleed the air
Repair in a service shop
Lack of cooling water
CAUSE
Loose or slipping fan belt
Damaged fan belt
OVERHEAT OF THE ENGINE
CORRECTION
Supply water, inspect for leakage and correct
Clogged radiator
Clogged radiator fin
Remove oil, dust, etc. and tighten
Replace
Flush the radiator
Clean
Dust or scale clogged in the cooling water passage Flush the system
Faulty function of the thermostat Inspect or replace thermostat
Lack of lubricating oil
Overloading
Add oil
Decrease the load
CAUSE
Loose fan belt
Faulty wiring
Faulty battery
Worn out alternator brush
FAULTY CHARGING
CORRECTION
Correct belt tension
Inspect and correct
Repair
Replace
STARTER MOTOR DOES NOT RUN
CAUSE
Loose or disconnected wiring
Blown 5-amp electronic battery fuse (engine fuse panel)
Inspect and tighten
Replace fuse
CORRECTION
Blown 15-amp key main fuse (engine fuse panel)
Low voltage of the battery
Damaged starter motor
Replace fuse
Charge the battery
Repair in a service shop
10-12
SECTION 10 - ENGINE
OIL PRESSURE LAMP NOT TURNED ON
(KEY SWITCH “ON” WITH ENGINE NOT STARTED)
CAUSE CORRECTION
Broken lamp bulb
Broken wire between battery to the lamp
Replace bulb
Correct it
OIL PRESSURE LAMP NOT TURNED OFF
CAUSE CORRECTION
Lack of engine oil
Fault in the pressure switch
Oil leakage from the lubricating system
Clogged oil filter
Short-circuit between EIC panel and oil pressure switch
Fill oil to the specified level
Replace the switch
Inspect and retighten
Replace with new one
Repair
CONDITION
Good power, but misses or smokes at top engine speed
White or blue exhaust smoke during all operating conditions
Blue smoke on cold engine startup
Dark exhaust smoke
EXCESSIVE SMOKE/ENGINE MISS
CAUSE
Top engine speed too high
CORRECTION
Adjust top engine speed to factory limit
Timing off
Excess engine oil
Engine oil viscosity too low
Faulty/late injection timing
Low combustion temperature
Normal warm-up
Fuel cetane rating not optimal
Excess injection
Faulty function of the engine
Overloading
Clogged air cleaner
Leaks
Valve cover vent hose kinked or clogged
Check and adjust engine timing
(refer to Tech Com Video #9701)
Check and correct the level
Check and replace oil
Correct timing
Check fuel injection timing, adjust inlet and exhaust valves, and test the cylinder compression
May be difficult to stop blue smoke on startup completely
Use only fuel with a cetane rating of 50 or higher
Inspect and adjust (in service shop)
Repair in service
Reduce the load
Clean
Seal off all leaks
Shorten hose to 460 mm (18.1
″ )
10-13
SECTION 10 - ENGINE
ENGINE RUNS - NO POWER TO TRANSMISSION
CAUSE CORRECTION
Flex plate failure due to rivets shearing Replace with new design flex plate part #86521866
Flex plate failure due to inadequate lubrication Replace flex plate (part #86521866) and input shaft, applying Never-Seize on splines
LS170 TURBOCHARGER BEARING FAILURES
CAUSE CORRECTION
Lack of lubrication during cold weather startup Warm up below 1500 RPM for three minutes on start-up and allow to run at low idle for one minute before shutdown
CAUSE
Internal muffler restriction
Turbocharger worn
LS170 ENGINE NOISE/WHISTLING
CORRECTION
Replace muffler
Inspect turbocharger components
EXCESSIVE OIL CONSUMPTION (OR OIL SMOKE FROM EXHAUST)
CAUSE CORRECTION
Leaks
Valve cover vent hose kinked or clogged
Seal all leak sources
Shorten hose to 460 mm (18.1
″ )
NOTE: See LS170 Oil Consumption below for more extensive troubleshooting procedures.
10-14
SECTION 10 - ENGINE
LS170 - EXCESSIVE OIL CONSUMPTION
The maximum allowable oil consumption for the turbocharged diesel engine is 0.8%, as measured using a log of fuel consumption to oil consumption.
– Exhaust manifold gasket and hardware.
– Turbocharger gasket and hardware, if equipped.
If a customer complains about excessive engine oil consumption on the Model LS160 or LS170 skid steer, the following steps must be taken. If a cause is found, stop and correct the problem. If a cause is not found, continue to the next step.
– Muffler gasket and hardware.
– Muffler failure (cracks, misalignment).
Remove the hose between the turbocharger outlet and the intake manifold. Check for dirt in the hose, turbocharger outlet, and the air intake manifold.
1. Examine engine for signs of external oil leaks.
– Check gaskets: oil pan, timing gear case, head, head cover, injection pump, oil gallery, and dipstick.
– Oil seals: crankshaft, front and rear.
– Steel tubing and fittings that supply oil to the turbocharger and upper engine.
– Tubing, hose, and fittings for turbocharger oil drain to block.
– Damage to oil pan and drain plug.
– Crankcase breather hose (open and not kinked) preventing proper crankcase breathing.
2. Examine turbocharger area.
– Remove the hose between the turbocharger inlet and the air cleaner. Examine for signs of dirt in the hose and inlet to the turbocharger blower.
If carbon, oil, and dust are found, check:
– Air cleaner assembly for tightness of filter elements.
– Hose between air cleaner and turbocharger for damage or looseness of clamps.
If oil residue is evident on the clean air turbine, it might not be due to failed turbocharger bearings.
NOTE: A film of oil on the clean air side of the turbocharger to the intake manifold is normal for skid steer operation.
Check the air filter and air intake hose for signs of oil residue.
If there is no dirt at the turbocharger inlet but there is a deposit at the turbocharger blower outlet (which is not due to signs of dirt in the hose and inlet to the turbocharger blower), it may be leakage from the turbocharger seals.
Check turbocharger shaft specifications:
Axial movement: maximum 0.09 mm (0.0035
″
)
Radial movement: maximum 0.17 mm (0.0067
″
)
3. Check the blowby hose (valve cover vent hose) for signs of blockage. If the hose is kinked or the end is blocked by debris, correct by cutting off the end of the hose so it is just below the bottom of the engine oil filter.
4. If there is no problem found in the 1, 2, and 3 checking points, then go to the next step to log oil consumption.
5. The customer must log oil consumption using the following procedure:
– Change the engine oil and filter. Use the oil specified in the loader operator’s manual.
– Run the engine for two minutes.
– Check the dipstick and add oil, if required, so the level is at the full mark.
– Fill the fuel tank with fuel.
– Record fuel consumption (in gallons), oil added (in quarts), and hour reading. Record fuel and oil use for 100 hours of operation, which is the recommended oil change interval. Check the dipstick before running the engine each day.
Check the exhaust area for leaks:
10-15
The maximum allowable oil consumption is
0.8%. The following table give examples.
Fuel Consumption,
Gallons
50
A log example is shown in the following table.
The hour level is the EIC (Electronic
Instrumentation Cluster) reading when fuel is added. Dealer must file oil consumption log with customer file.
Fuel
100
200
Full
XX Gallons
XX Gallons
Oil
Full
X Quart
X Quart
Oil Consumption,
Quarts
1.6
3.2
6.4
SECTION 10 - ENGINE
Hour Level
100
150
200
6. If the oil consumption is greater than 0.8% of the fuel consumption, oil usage is excessive. A sample calculation for oil consumption follows:
% Consumption = (quarts oil/4) x 100 gallons fuel
Assume one quart oil is added for 50 gallons fuel.
% Consumption = (1/4) x 100 = 0.5%
50
7. The New Holland dealer must check compression on all four cylinders and record.
The compression specifications are as follows:
Standard Value
More than 429 PSI
(29.5 bar) at 200 - 250 engine cranking RPM
To Be Repaired
Less than 356 PSI
(24.5 bar)
Compression testing can be performed using a special adaptor (see “Special Tools” in the
Additional Information Section) through the glow plug ports. Remove all glow plugs and test each cylinder.
This should be a “dry” compression check (do not put any oil in the cylinder).
If compression is low, recheck the air intake system for signs of dirt ingestion.
10-16
SECTION 10 - ENGINE
SPECIFICATIONS
SERVICE STANDARDS
Inspection Item
CYLINDER HEAD
Compression pressure of cylinder
Standard
Dimension
Standard
Value
To Be
Repaired
Allowable
Limit
Remarks
Tigtening torque of cylinder head
Distortion of face of cylinder head
Valve seat depth
(Both intake and exhaust)
Width
Recess
Valve Seat
Valve seat width (intake)
Valve seat width (exhaust)
CYLINDER BLOCK
Type
Bore
Cylinder block type surface warpage
PISTON
Skirt long-diameter size
Clearance with cylinder
Piston pin hole inside diameter
Piston pin hole to pin clearance
3.307
″
(84 mm)
More than 426.6
PSI (30 kg/cm 2 )
72.3 - 75.9 ft. lbs.
(98 - 103 N·m)
0.002
″ max.
( 0.05 mm)
Less than
355.5 PSI
(25 kg/cm 2 )
0.0047
″
(0.12 mm)
0.026
″ - 0.037
″
(0.65 - 0.95 mm)
0.06
″ -0.08
″
(1.5 - 2.0 mm)
0.076
″ -0.085
″
(1.94 - 2.16 mm)
3.307
″ - 3.308
″
(84 - 84.019 mm)
0.002
″ max.
(0.05 mm)
Dry type (Unit type)
3.315
″
(84.2 mm)
3.354
″
(85.2 mm)
0.0047
″
(0.12 mm)
Oversize 0.02/.04
″
(0.5, 1.0 mm)
3.307
″
(84 mm)
1.1024
″
(28 mm)
3.3050
″
- 3.3056
″
(83.948 - 83.963 )
0.0015
″ - 0.0028
″
(0.038 - 0.072 mm)
1.1023
″ - 1.1025
″
(27.999 - 28.003)
-0.00004
″ ± .00028
″
(0.001 ± 0.007 mm)
0.063
″
(1.6 mm)
0.1
″
(2.5 mm)
0.1
″
(2.5 mm)
Valve seat angle 45 °
3.295
″
(83.7 mm)
0.01
″
(0.25 mm)
Oversize 0.02/.04
″
(0.5, 1.0 mm)
68 ° F
(20
°
C)
0.0008
″
(0.02 mm)
10-17
SECTION 10 - ENGINE
Inspection Item
PISTON PIN
Pin outside diameter
Rod small end bushing to pin clearance
PISTON RING
Piston ring groove to ring clearance
1st ring
2nd ring
Oil ring
Ring width
1st ring
Standard
Dimension
1.1024
″
(28 mm)
2nd ring
Oil ring
0.1378
″
(3.5 mm)
0.1417
″
(3.6 mm)
0.0984
″
(2.5 mm)
Piston ring end gap
1st ring
2nd ring
Oil ring
Standard
Value
1.1022
″ - 1.1024
″
(27.996 - 28.0)
0.0004
″ -0.00098
″
(0.010-0.025 mm)
0.0028
″ -0.0043
″
(0.07 -0.11 mm)
0.0016
″ -0.0031
″
(0.04-0.08 mm)
0.0008
″ -0.0024
″
(0.02-0.06 mm)
0.1339
″ -0.1417
″
(3.4-3.6 mm)
0.1378
″
-0.1457
″
(3.5-3.7 mm)
0.0906
″
-0.1063
″
(2.3-2.7 mm)
0.0079
″ -0.0138
″
(0.2-0.35 mm)
0.0079
″ -0.0157
″
(0.2-0.4 mm)
0.0079
″ - 0.0157
″
(0.2 - 0.4 mm)
To Be
Repaired
Allowable
Limit
0.0098
″ max.
(0.25 mm )
0.006
″ max
(0.15 mm)
Remarks
1.1016
″
(27.98 mm)
0.004
″
(0.1 mm)
Oil clearance
0.0394
″
(1.0 mm)
Inspection Item
CONNECTING ROD
Twist between small and large end holes (per 100 mm)
Straightness at 100mm between small and large end hole
Front-to-rear clearance between connecting rod and crank pin
Connecting rod bearing-to-crank pin clearance
Crush height of large end bearing
Connecting rod bearing (inner diameter x width)
Connecting rod bolt torque
Weight difference with piston assembly
Standard
Dimension
Standard
Value
2.1654
″ x 0.779
″
(55 x 19.8 mm)
0.0031
″ max.
(0.08 mm)
0.0020
″ max.
(0.05 mm)
0.004
″
-0.012
″
(0.1-0.3 mm)
0.0014
″
-0.0033
″
(0.035-0.085 )
1.0833
″
-1.0849
″
(27.517-27.557)
2.1654
″ x 0.779
″
(55 x 19.8 mm)
36.2-39.8 ft. lbs.
(49-54 N·m) less than 0.022
lbs. (10 g)
To Be
Repaired
Allowable
Limit
Remarks
0.0079
″
(0.2 mm)
0.0059
″
(0.15 mm)
0.0276
″
(0.7 mm)
0.0079
″
(0.2 mm)
Oil clearance
10-18
SECTION 10 - ENGINE
Inspection Item
CRANKSHAFT
Diameter of journal
Diameter of pin
Roughness, main journal & crank pin
Cranshaft deflection
Axial play of crankshaft
Thickness of thrust washer
O.D. x I.D. of bushing
(journal bearing)
Clearance between crankshaft journal bushing
O.D. x I.D. of center bearing
Clearance between crankshaft journal and center bearing
CAMSHAFT
For intake/exhaust
Height
Camshaft deflection
Cam gear backlash
For injection pump
For feed pump
2.677
″
(68 mm)
2.047
″
(52 mm)
2.6755
″ -2.6760
″
(67.957-67.970)
2.0458
″ -2.0463
″
(51.964-51.975)
1.6Z
2.8346
″ x 2.6772
″
(72 x 68 mm)
2.8346
″ x 2.6772
″
(72 x 68 mm)
0.0012
″ max.
(0.03 mm)
0.004
″ -0.016
″
(0.1-0.4 mm)
0.116
″ -0.118
″
(2.95-3.0 mm)
2.8346
″ x 2.6772
″
(72 x 68 mm)
0.0017
″ -0.0046
″
(0.044-0.116 )
2.8346
″ x 2.6772
″
(72 x 68 mm)
0.0017
″ -0.0040
″
(0.044-0.102 )
1.3411
″ -1.3433
″
(34.065-34.12 )
1.6512
″ -1.6559
″
(41.94-42.06 )
1.2559
″ -1.2598
″
(31.9-32.0 mm)
0.0012
″ max.
(0.03 mm)
0.00315
″
(0.08 mm)
VALVE
Diameter of intake valve stem
Diameter of exhaust valve stem
Clearance between valve stem and valve guide
Inlet
Exhaust
Standard
Dimension
0.2744
″
(6.97 mm)
0.2736
″
(6.95 mm)
Standard
Value
0.2738
″
-0.2744
″
(6.955-6.97 mm)
0.2732
″ -0.2736
″
(6.94-6.95 mm)
0.0012
″ -0.0024
″
(0.03-0.06 mm)
0.002
″ -0.003
″
(0.05-0.075 mm)
Valve thickness
To Be
Repaired
0.0364
″ -0.0423
″
(0.925-1.075 )
Thickness
Valve clearance (intake & exhaust) 0.02
″
(0.5 mm)
Valve spring Spring force at 1.2
″
(30.4 mm)
Free height
Squareness
0.008
″
(0.2 mm)
17.86 lbs.
(8.2 kg)
1.378
″
(35 mm)
0.047
″ max.
(1.2 mm)
Intake valve
Exhaust valve
Opening angle BTDC
Closing angle ABDC
Opening angle BBDC
Closing angle ABDC
13 °
43 °
43 °
13 °
Allowable
Limit
2.654
″
(67.4 mm)
2.024
″
(51.4 mm)
0.0024
″
(0.06 mm)
0.110
″
(2.8 mm)
0.008
″
(0.2 mm)
0.008
″
(0.2 mm)
1.3268
″
(33.7 mm)
1.6457
″
(41.8 mm)
1.1811
″
(30.0 mm)
0.004
″
(0.1 mm)
0.01
″
(0.25 mm)
0.2713
″
(6.89 mm)
0.2693
″
(6.84 mm)
0.008
″
(0.2 mm)
0.01
″
(0.25 mm)
0.02
″
(0.5 mm)
15.43 lbs.
(7 kg)
1.319
″
(33.5 mm)
0.079
″
(2.0 mm)
Remarks
Undersize
0.01
″
, 0.02
″
(0.25, 0.5)
Undersize
0.01
″
, 0.02
″
(0.25, 0.5)
Oil clearance
Oil clearance
Cold
10-19
SECTION 10 - ENGINE
Inspection Item
PUSHROD
Overall length
Outside diameter
ROCKER ARM
Rocker arm shaft OD
Rocker arm to shaft clearance
OIL PUMP
Oil pressure switch actuating pressure
Relief valve opening pressure
Tip clearance (rotor to vane gap)
Axial clearance (rotor to cover)
INJECTION PUMP
Pump plunger diameter
Pump plunger stroke
Before top dead center
Injection timing
Piston displacement
(BTDC) - N844
Piston displacement
(BTDC) - N844T
INJECTION NOZZLE
Injection pressure
COOLING
Cooling system
Cooling water quantity (1)
(Without radiator)
Thermostat opening temperature
Thermostat full open temperature
V-belt (fan) slack - 0.2
″ (5 kg) at center
STARTER MOTOR
Type
Pinion gear # teeth
Pinion gear shift system
Commutator diameter wear
Commutator diameter eccentric wear
Armature shaft bending
Brush length
Brush spring pressure .
Standard
Dimension
Standard
Value
8.075
″ -8.106
″
(205.1-205.9 )
0.244
″ -0.252
″
(6.2-6.4 mm)
To Be
Repaired
0.5886
″ -0.5894
″
(14.95-14.97)
0.0012
″ -0.0037
″
(0.030-0.093)
Allowable
Limit
Remarks
0.5854
″
(14.87 mm )
0.008
″
(0.2 mm)
Oil
Clearance
4.266 PSI
(0.3 kg/cm
2
)
45.5 PSI
(3.2 kg/cm 2 )
2.844-5.688 PSI
(0.2-0.4 kg/cm 2 )
0.0004
″ -0.006
″
(0.01-0.15 mm)
0.004
″ -0.006
″
(0.1-0.15 mm)
0.217
″
(5.5 mm)
0.276
″
(7.0 mm)
N844 22 °
N844T 21 °
0.1743
″
(4.426 mm)
0.1533
″
(3.895 mm)
N844 21 ° -23 °
N844 T 20 ° -22 °
0.1533
″ -0.1837
″
(3.895-4.655 mm)
0.1393
″ -0.1734
″
(3.539-4.426 mm)
2205 PSI
(152 kg/cm
2
)
2132-2277 PSI
(147-157 kg/cm
2
)
1849 PSI
(130)
0.0098
″
(0.25 mm)
0.008
″
(0.2 mm)
180 ° F
(82 ° C)
203 ° F
(95 ° C)
0.2
″
(5 kg)
11
1.38
″
(35 mm)
0.59
″
(15 mm)
5.9-7.8 lbs.
(2.7-3.6 kg)
Water cooled forced circulation
3.3
NIPPON DENSO (12V-2kw Reduction)
0.0008
″
(0.02 mm)
Magnetic shift
0.002
″
(0.05 mm)
1.34
″
(34 mm)
0.002
″
(0.05 mm)
0.35
″
(9 mm)
4.7 lbs.
(2.2 kg)
10-20
Inspection Item
ALTERNATOR
Type
Rotor shaft bending
Slip rings
Diameter
Diameter eccentric wear
Surface condition
Brush length
Brush spring pressure
SECTION 10 - ENGINE
Standard
Dimension
Standard
Value
To Be
Repaired
MITSUBISHI (12V-40A)
0.0028
″
(0.07 mm)
Allowable
Limit
0.894
″
(22.7 mm)
0.728
″
(18.5 mm)
1.169 lbs.
(530 g)
1.036-1.300
(470-590 g)
0.871
″
(22.1 mm)
0.002
″
(0.05 mm)
If dirty or damaged correct with emery cloth.
0.08
″
(0.02 mm)
2.0
″
(5.0 mm)
0.60 lbs.
(270 g)
Remarks
TORQUE SPECIFICATIONS
COMPONENT
Bearing holder bolts- hex hole type
Rear plate bolts
. . . . . . . . . . . .
- hex bolt type . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel housing bolts
Flywheel bolts
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting rod nuts
Suction filter bolt
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft pulley nut . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head bolts
Injection pump bolts
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
Injection pump nuts
Rocker arm nuts
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Head cover nuts
Cooling fan bolts
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pipe banjo bolts
Oil sump drain bolt
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
Injection nozzle
Injection pipe
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermo switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stop solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Smokeset nut (max fuel) . . . . . . . . . . . . . . . . . . . . .
Adjusting screw nuts . . . . . . . . . . . . . . . . . . . . . . . . .
Setting/Remarks
18-22 ft. lbs. (24-30 N·m)
36-40 ft. lbs. (49-54 N·m)
10-13 ft. lbs. (14-18 N·m)
18-21 ft. lbs. (24-28 N·m)
43-51 ft. lbs. (58-69 N·m)
36-40 ft. lbs. (49-54 N·m)
7-9 ft. lbs. (9-12 N·m)
7-9 ft. lbs. (9-12 N·m)
203-246 ft. lbs. (275-333 N·m)
72-76 ft. lbs. (98-103 N·m)/oiled
7-9 ft. lbs. (9-12 N·m)
7-9 ft. lbs. (9-12 N·m)
20-29 ft. lbs. (27-39 N·m)/4-cylinder engines
9-12 ft. lbs. (12-16 N·m)/4-cylinder engines
7-9 ft. lbs. (9-12 N·m)
7-9 ft. lbs. (9-12 N·m)
22-29 ft. lbs. (30-39 N·m)
43-51 ft. lbs. (58-69 N·m) IDI engines
11-18 ft. lbs. (15-24 N·m)
18-22 ft. lbs. (24-30 N·m)
11-15 ft. lbs. (15-20 N·m)
11-15 ft. lbs. (15-20 N·m)
11-15 ft. lbs. (15-20 N·m)
44-51 ft. lbs. (60-69 N·m)
15-19 ft. lbs. (20-26 N·m)
9-12 ft. lbs. (12-16 N·m)
10-21
SECTION 10 - ENGINE
ENGINE COMPONENTS ELECTRICAL DIAGRAM
TO ENGINE GROUND
19992596
10-22
4
SECTION 10 - ENGINE
Op. 10 001 10
ENGINE REMOVAL
The engine can be removed from the loader by two methods:
Method 1: Removing the rear door, radiator, oil cooler, and support as an assembly.
Method 2: Tilting the cab and boom forward to gain access.
For either method, raise and support the boom on the boom lock pins, 1, to access the engine area.
METHOD 1
(Without Tilting Cab)
1. Open rear door, 1. Remove the top engine hood,
2, and both the right and left engine side covers.
2. Remove the battery.
3. Drain the cooling system, radiator, and engine block, 3.
4. Remove the upper and lower radiator hoses from the engine block and plug the hoses with plastic plugs.
5. Remove the air cleaner hose, 1, from the intake manifold and cap.
6. Unplug the engine wire harness from the main harness, 2, and ground wires from the engine bellhousing, 3.
7. Unhook the control valve hydraulic oil return line at the oil cooler and cap, 4.
5
6
7
10-23
SECTION 10 - ENGINE
8. Unhook the hydraulic oil return line, 1, from the charge check valve and cap.
9. Remove the eight 1/2 ″ cap screws from the support at 1, both sides, and remove the radiator and oil cooler assembly.
The support is shown removed with the air cleaner, radiator, oil cooler, oil filter, and fuel pump attached.
8
9
10
10-24
SECTION 10 - ENGINE
10. Raise the seat to the raised latched position, 1, to access the hydrostatic pumps and engine bellhousing. Remove the neutralizer plate return spring and hardware, 2, from the bellhousing and remove plate.
Remove the hydrostatic pump to bellhousing and pump support retaining hardware at 1 and 2.
11. Attach lifting chains to the engine lift eyes at 1, and hook to the lifting device to support the engine.
12. Remove the engine motor mount hardware and slide the engine to the rear to uncouple the hydrostatic pump assembly from the engine bellhousing. Lift the engine assembly from the skid steer frame.
11
12
13
10-25
SECTION 10 - ENGINE
METHOD 2
(Tilting Cab and Boom Forward)
Follow the cab tilting procedure in Section 00 of this manual for proper instructions.
1. Remove the muffler from the exhaust manifold,
1.
2. Remove the battery.
3. Drain the cooling system, radiator and engine block, raise handles, 1, moving the radiator to the rear and drain the cooling system from drain plug, 2.
4. Remove the upper and lower radiator hoses from the engine block and plug the hoses with plastic plugs.
5. Remove the air cleaner hose, 1, from the intake manifold and cap.
6. Unplug the engine wire harness, 2, from the main harness and ground wires, 3, from the engine bellhousing.
7. Unhook the control valve hydraulic oil return line at the oil cooler and cap at 4.
14
15
16
10-26
SECTION 10 - ENGINE
8. Unhook the hydraulic oil return line, 1, from the charge check valve and cap.
9. Remove the fan from the water pump shaft.
NOTE: The LS160 N844 engine fan is equipped with a cover over the center of the fan.
10. Remove the neutralizer plate return spring and hardware, 1, from the bellhousing and remove plate, 2.
11. Remove the hydrostatic pump to bellhousing and pump support retaining hardware at 1 and 2.
17
18
19
10-27
SECTION 10 - ENGINE
12. Attach lifting chains to the engine lift eyes at 1, and hook to the lifting device to support the engine.
13. Remove the fuse panel support hardware and move the panel for clearance.
14. Remove the engine motor mount hardware and slide the engine to the rear to uncouple the hydrostatic pump assembly from the engine bellhousing. Lift the engine assembly from the skid steer frame.
Op. 10 001 53
ENGINE DISASSEMBLY SEQUENCE
Op. 55 301 10
ALTERNATOR
Disconnect the alternator wire harness and wires, 1.
Remove the alternator pivot and adjusting bracket, hardware, 2.
Op. 10 104 14
REMOVE COOLING FAN AND PULLEY
Remove the fan retaining hardware and spacers.
The LS160 N844 engine fan is equipped with a cover,
1, over the center of the fan.
20
21
22
10-28
SECTION 10 - ENGINE
Op. 10 218 18
FUEL INJECTION PIPE
1. Loosen the fuel pipe nuts from the fuel injection pump and injectors, 1. Remove the pipes as an assembly.
2. Remove the spring clamp and fuel return hose,
2.
Op. 10 218 30
INJECTOR ASSEMBLY
Loosen and remove the securing nuts, 3. Remove the leak-off rail, 4. Remove the aluminum washers and discard. Remove the injectors tagging or marking with the cylinder they were removed from.
Op. 10 402 10
WATER PUMP ASSEMBLY
Loosen the securing bolts and remove the water pump assembly, 1, and set plate, 2.
Op. 10 101 10
ROCKER COVER
Op. 10 254 12
INLET MANIFOLD
Op. 10 254 14
EXHAUST MANIFOLD
Remove the inlet manifold, 1, spacer, 2, and exhaust manifold, 3.
For the N844T turbocharged engine, refer to the turbocharger section of the manual for removal and replacement.
23
24
25
10-29
SECTION 10 - ENGINE
Remove the breather hose, 1. Loosen and remove four cap nuts with washers. Remove the rocker cover assembly, 2.
Op. 10 250 16
EXTERNAL OIL PIPE (LS160)
1. Loosen and remove the two banjo bolts at the cylinder block main oil gallery and cylinder head assembly.
2. Remove the clamp from the fuel injection pump.
Op. 10 250 16/ Op. 10 250 18
EXTERNAL OIL PIPE (LS170)
Loosen and remove the banjo bolts at the turbocharger and the cylinder head assembly.
26
27
28
10-30
SECTION 10 - ENGINE
Op. 10 106 20
ROCKER ASSEMBLY
1. Loosen and remove nuts, lock washers, and flat washers from the rocker pillar stud, 1. Lift the rocker assembly, 2.
2. Remove the push rods, 3, and valve stem caps,
4.
Op. 10 101 20
CYLINDER HEAD ASSEMBLY
Loosen the cylinder head bolts, starting from the center, in a circular pattern, using several steps of equal torque. Remove the head.
TAPPETS
Pull the tappets from the machined bore in the cylinder block.
29
30
31
10-31
Op. 10 223 10
STOP SOLENOID
Unscrew the stop solenoid, if fitted.
SECTION 10 - ENGINE
32
Op. 10 236 10
FUEL INJECTION PUMP
1. Remove the bolts and nuts securing the fuel injection pump to the cylinder block. Slowly lift and position the fuel injection pump until access to the link snap pin is gained.
2. Remove the snap pin and remove the link from the control rack. Remove the fuel injection pump and shim pack.
NOTE: Injection timing is determined by the shim pack between the fuel injection pump flange and cylinder block mounting face. The thickness and number of shims should be checked and recorded to aid reassembly.
Op. 10 414 30
CRANK PULLEY
Loosen the pulley nut, 1, and remove the pulley, 2.
Op. 10 304 10
OIL FILTER
Remove the spin-on type oil filter and discard.
SH0233R
1
33
34
10-32
SECTION 10 - ENGINE
Op. 10 230 24
GEAR COVER AND GOVERNOR ASSEMBLY
Remove the securing bolts and lift the cover assembly off the locating dowels.
NOTE: Remove the fuel injection pump first.
IDLER GEAR AND OIL PUMP ASSEMBLY
Remove the retaining ring. Remove the entire assembly.
Op. 10 230 20
CAMSHAFT ASSEMBLY, TACHOMETER DRIVE
1. Using the access hole in the cam gear, remove the keeper plate, 1.
2. Slide the cam shaft, 2, with the flyweight retainer out of the camshaft bore.
3. Pull the tachometer drive shaft, 3, from its bore.
NOTE: The tachometer drive is not used for the EIC
Board Tach.
Op. 10 102 46
FRONT END PLATE ASSEMBLY
Remove the retaining bolts and lift the front plate off its locating dowels. Remove the gasket and discard.
35
36
37
10-33
SECTION 10 - ENGINE
Op. 10 304 06
DIPSTICK ASSEMBLY
Loosen the retaining bolts and remove the assembly.
Op. 10 304 44
OIL SUMP
Remove all bolts, lower sump, and discard the gasket.
SUCTION PIPE AND STRAINER
Remove two securing bolts. Rotate the suction pipe out of its bore.
Op. 10 105 10
CONNECTING ROD AND PISTON
1. Loosen the connecting rod nuts and remove the rod cap.
2. Remove carbon from the cylinder bore. Push the piston and connecting rod through the cylinder block. Replace the rod cap to the piston assembly. Keep together in cylinder sequence.
Op. 10 103 70
FLYWHEEL
Loosen the bolts and remove the flywheel.
38
39
40
10-34
SECTION 10 - ENGINE
Op. 10 103
BACKPLATE AND REAR OIL SEAL
1. Loosen the two starter retaining nuts and remove the starter.
2. Loosen the backplate retaining bolts and remove the backplate.
3. Remove the oil seal.
Op. 10 103 10
CRANKSHAFT AND MAIN BEARING
1. Remove the retaining bolts, 1, through the crankcase cross members.
2. Slide out the crankshaft and main bearing assembly.
Op. 10 304 38
3. Remove the relief valve assembly.
41
42
43
10-35
SECTION 10 - ENGINE
ENGINE COMPONENT MAINTENANCE
Op. 10 106 20
ROCKER ASSEMBLY
Disassembly
1. Loosen the M8 bolt at the rocker arm shaft end, if fitted.
2. Remove the screw located in the No. 1 cylinder rocker arm bracket, if fitted.
3. Pull out the rocker arm shaft, 1, springs, 2, and rocker arms, 3.
Inspection and Correction
1. Wear of Rocker Arm Shaft
Using a micrometer, check the outside diameter of the rocker arm shaft. If the rocker arm shaft is worn beyond the allowable limit, replace.
Standard dimension: 0.588
″ - 0.589
″ (14.95 mm
- 14.97 mm)
Allowable Limit: 0.585
″
max. (14.87 mm)
2. Rocker Arm-to-Shaft Clearance
Measure the inside diameter of the rocker arm.
Calculate the clearance at, 1, between the rocker arm, 2, and the rocker arm shaft, 3. If the clearance is excessive, replace.
Standard Clearance: 0.0012
″
- .0037
″
(0.030
mm - 0.093 mm)
Allowable Limit: 0.008
″ (0.2 mm)
3. Wear on valve stem contacts face of the rocker arm.
Check the face for step wear or score. Slight wear may be corrected using an oil stone.
19992597
44
45
46
10-36
SECTION 10 - ENGINE
Op. 10 101 21
CYLINDER HEAD ASSEMBLY
1. Using a valve spring replacer, compress the valve spring to remove the valve keepers, 1; retainer, 2; spring, 3; and valve, 4.
2. Remove the valve guide seals and glow plugs.
Inspection and Correction
Op. 10 101 21
Cylinder Head
With a straightedge and a thickness gauge, check for warping of the cylinder head lower face.
Check six positions (1 to 6 lines, as shown) for warping. If found to be warped excessively, correct with a surface grinder.
Standard Value: 0.002
″ (0.05 mm or less)
Allowable Limit: 0.005
″ (0.12 mm)
47
48
49
10-37
SECTION 10 - ENGINE
Op. 10 101 32
Valve Guide and Valve Stem
1. Check the valve stem for excessive wear or damage. If found to be excessively damaged, replace.
2. Check the valve stem diameters at positions 1, 2, and 3 with a micrometer. If the diameter is less than the allowable limit, replace.
Intake Valve
Standard Diameter: 0.2738
″ - 0.2744
″ (6.955
mm - 6.97 mm)
Allowable Limit: 0.271
″
(6.89 mm)
Exhaust Valve
Standard Diameter: 0.2732
″ - 0.2736
″ (6.94 mm
- 6.95 mm)
Allowable Limit: 0.269
″
(6.84 mm)
Thickness of Valve Head
If valve head thickness at 1 is less than the allowable limit, replace the valve.
All Engines
Standard Thickness: 0.036
″ - 0 .042
″ (0.925 mm
- 1.075 mm)
Allowable Limit: 0.020
″
(0.5 mm)
Valve to Valve Guide Clearance
Check the clearance at 1 between the valve and valve guide. If the clearance exceeds the allowable limit, replace.
Intake Valve - All Engines
Standard Clearance: 0.0012
″ - 0.0024
″ (0.03
mm - 0.06 mm)
Allowable Limit: Max. 0.008
″
(0.2 mm)
Exhaust Valve - All Engines
Standard Clearance: 0.002
″ - 0.003
″ (0.05 mm -
0.075 mm)
Allowable Limit: Max. 0.010
″
(0.25 mm)
10-38
50
51
52
SECTION 10 - ENGINE
Op. 10 101 55
VALVE SEAT
Valve Seat Contact Width
If the contact width at 1 of the valve seat is more than the allowable width, check the wear condition of the valve guide first.
Using the seat cutters of 15
°
, 45
°
, and 75
°
, correct the seat.
Intake
Standard Width: 0.06
″ - 0.08
″ (1.5 mm - 2.0 mm)
Allowable Limit: 0.098
″ max. (2.5 mm)
Exhaust
Standard Width: 0.076
″ - 0.085
″ (1.94 mm - 2.16
mm)
Allowable Limit: 0.098
″
max. (2.5 mm)
Valve Seat Recess
If the recess depth, 1, is more than the allowable limit, replace the valve seat (if fitted).
Standard Recess: 0.026
″ - 0.037
″ (0.65 mm -
0.95 mm)
Allowable Limit: 0.063
″ max. (1.6 mm)
Replacement of valve seat insert (where fitted:)
Method 1: Using a gas burner, 1300 ° F to 1475 ° F
(700 ° C to 800 ° C), heat diagonally across the valve seat insert. Leave in air for three to five minutes and remove the valve seat insert by light tapping
(ensuring the head is not damaged).
Method 2: Machine the insert out, taking care not to damage the head.
Clean up the insert bore and fit a new insert, using a press 7,200 lbs. - 10,850 lbs. (1,000 kgf - 1,500 kgf) and a suitable smooth surface tool. To assist the process, chill the valve seat insert with liquid nitrogen, etc., or heat the head to between 140 ° F to
212 ° F (60 ° C and 100 ° C).
SH62052
10-39
53
54
SECTION 10 - ENGINE
Lapping of Contact Face of the Valve Seat
Correct valve seat contact using a valve lapper and lapping compound.
When using a new cylinder head, obtain correct seat contact width and seat recess using the seat cutter, and then carry out lapping.
Valve Spring
Visually inspect the valve spring for damage.
Position the valve spring on a flat surface and check the squareness of it by using a square at 1, as shown.
If it exceeds the allowable limit, replace the spring.
Using a spring tester, check spring force and free length.
Replace, if found to be beyond the allowable limit.
Standard Value
Squareness : 0.047
″ (1.2 mm)
Free length: 1.378
″ (35 mm)
Spring force when compressed to 1.197
″
(30.4
mm): 17.9 ft. lbs. (8.1 kg)
Allowable Limit
Squareness: 0.079
″
(2.0 mm)
Free length: 1.319
″
(33.5 mm)
Spring force when compressed to 1.197
″
(30.4
mm): 15.4 ft. lbs (7 kg)
Inner face of combustion chamber. Check and clean the combustion chamber.
Reassembly
Reassemble the parts in the reverse order of disassembly.
NOTE: When assembling the valve spring, retainer, and keepers, take care not to damage the valve guide seal.
Tighten glow plugs to 11 ft. lbs. - 15 ft. lbs. (15 N·m
- 20 N·m).
10-40
55
56
SECTION 10 - ENGINE
Op. 10 101 56
CYLINDER BLOCK
Inspection and Correction
Cylinder Block Top Face
Inspect the cylinder block top face for cracks, damage, and warping in the same way as for the cylinder head.
If outside the limit, replace the cylinder block.
Standard Value: Less than 0.002
″
(0.05 mm)
Allowable Limit: 0.005
″ (0.12 mm)
Cylinder Bore
1. Visually inspect the cylinder bore. There should be no scoring, rust, or corrosion.
2. Measure the cylinder bore at the upper, middle, and lower areas (piston ring contact area) in the direction of the crankshaft (1 direction) and at right angle to the crankshaft (2 direction).
The upper area described above corresponds to the top ring when the piston is at the T.D.C.
(about 0.40
″ [10 mm] below the cylinder block top surface). The lower area corresponds to the piston oil ring when the piston is at the B.D.C.
(about 3.94
″ [100 mm] from top face).
Check the bore using a cylinder gauge.
3. If the bore is found to be outside the allowable limit, re-bore to the oversize dimension as shown.
Grinding stone size: 100 L x 4 W
Speed: 162 RPM
Feed (shaft direction): 13 m/min.
Gauge pressure: 15 kg/cm
2
(5 kg/cm
2
- finish)
213 PSI [71 PSI - finish]
Finish stroke: 9
Honing depth: 0.0016
″ (0.04 mm) (diameter)
Cross hatch angle: 40 °
Surface roughness: 2-4 micron
10-41
57
SECTION 10 - ENGINE
Bore Specifications
Standard Bore: 3.307
″
- 3.308
″
(84 mm - 84.019
mm)
Allowable Limit: 3.315
″ (84.2 mm)
First Re-bore: 0.02
″ (0.5 mm)
New Standard Bore: 3.327
″ - 3.328
″ (84.5 mm -
84.519 mm)
Allowable Limit: 3.335
″
(84.7 mm)
Second Re-bore: 0.02
″
(0.5 mm)
New Standard Bore: 3.346
″ - 3.347
″ (85 mm -
85.019 mm)
Allowable Limit: 3.354
″
(85.2 mm)
Replace the Block
Op. 10 105 22
PISTON AND PISTON RINGS
Disassembly
1. Remove piston rings, 1, using a piston ring tool.
2. Remove the retaining ring and remove the piston pin, 2.
Inspection
Piston
If the outer surface of the piston is excessively damaged (cracked, scored, burning, etc.), replace.
Piston Skirt
Check the larger diameter of the piston skirt 0.40
″
(10 mm from bottom), and check diameter (thrust direction) of the cylinder. Calculate the clearance between the cylinder and piston. If this clearance is more than allowable, or piston diameter is less than the allowable limit, replace the piston.
10-42
58
59
SECTION 10 - ENGINE
Oversized Piston
When the cylinder is oversized, be sure that an oversized piston is used.
Standard Clearance: 0.0015
″ - 0.0028
″ (0.038
mm - 0.072 mm)
Allowable Limit: 0.010
″ max. (0.25 mm)
Standard Diameter (Piston): 3.3050
″
- 3.3056
″
(83.948 mm - 83.963 mm)
Allowable Limit: 3.2953
″ min. (83.7 mm)
Large Diameter of Piston Skirt:
Standard: 3.3050
″
- 3.3056
″
(83.948 - 83.963
mm)
0.0197
″ (0.5 mm) Oversize: 3.3247
″ - 3.3253
″
(84.448 - 84.463 mm)
0.039
″
(1.0 mm) Oversize: 3.3444
″
- 3.3450
″
(84.948 - 84.963 mm)
Clearance between wrist pin hole and wrist pin.
Check the inside diameter of the wrist pin hole and the outside diameter of the wrist pin, and calculate the clearance between them.
If the clearance is more than the allowable limit, replace.
Standard Clearance: -0.000039
″
to + 0.00028
″
(-0.001 mm to + 0.007 mm)
Allowable Limit: 0.0008
″ (0.02 mm)
Piston Ring
If the piston ring is worn or damaged, replace it.
Piston Ring Gap
Insert the rings into the cylinder at a right angle to the cylinder bore and measure the gaps with a thickness gauge. If the gap is more than the allowable limit, replace.
#1 Ring
Standard Gap: 0.008
″
- 0.014
″
(0.20 mm - 0.35
mm)
Allowable Limit: 0.039
″ (1.0 mm)
#2 Ring
Standard Gap: 0.008
″ - 0.016
″ (0.20 mm - 0.40
mm)
Allowable Limit: 0.039
″
(1.0 mm)
10-43
60
SECTION 10 - ENGINE
Oil Ring
Standard Clearance: 0.008
″ - 0 .016
″ (0.20 mm
- 0.40 mm)
Allowable Limit: 0.039
″
(1.0 mm)
Measure the clearance between the piston ring groove and ring. If the clearance exceeds the allowable limit, replace the ring.
#1 Ring
Standard Clearance: 0.0028
″
- 0.0043
″
(0.07
mm - 0.11 mm)
Allowable Limit: 0.0098
″ (0.25 mm)
#2 Ring
Standard Clearance: 0.0016
″
- 0.0032
″
(0.04
mm - 0.08 mm)
Allowable Limit: 0.0098
″ (0.25 mm)
Oil Ring
Standard Clearance: 0.0007
″
- 0.002
″
(0.02 mm
- 0.06 mm)
Allowable Limit: 0.0059
″ (0.15 mm)
Oversize Piston Ring
If the cylinder is oversized, an oversized piston ring set should be installed.
Mounting Position of the Piston Ring
Confirm the third piston ring is set, as shown here.
IMPORTANT: Fit the third ring as follows:
Put the expander, 1, into position in its groove.
Ensure the ends of the expander do not overlap.
Fit the upper side rail, 2, on top of the expander. Insert the end of the side rail into the groove and hold it in position with the thumb. Slide the rail into position with the other thumb.
Fit the lower side rail, 3, in a similar manner.
Ensure the side rails are free to move in both directions and the gaps of the expander and the side rails are in the correct positions.
Standard OD: 1.1022
″ - 1.1024
″ (27.996 mm -
28.0 mm)
Allowable Limit: 1.1016
″ min. (27.98 mm)
Piston Pin
Check the outside diameter of the piston pin. If it is less than the allowable limit, replace.
10-44
61
SECTION 10 - ENGINE
CONNECTING ROD
Inspection
Distortion or damage
Check the connecting rod for distortion between the large and small ends of the connecting rod with a connecting rod aligner. If the result exceeds the allowable limit, replace.
Distortion –3.937
, (100 mm)
Standard Value: Less than 0.003
″
(0.08 mm)
Allowable Limit: 0.0078
″
(0.2 mm)
Parallel –3.937
,
(100 mm)
Standard Value: Less than 0.0019
″
(0.05 mm)
Allowable Limit: 0.0059
″
(0.15 mm)
1. Gauge
2. Piston pin
3. Distortion
4. Flat surface of the aligner
5. Pin
Clearance between the small end bushing and the piston pin
Measure the inside diameter of the connecting rod small end bushing.
If the clearance exceeds the allowable limit, replace.
Standard Clearance: 0.0004
″ - 0.001
″ (0.010
mm - 0.025 mm)
Allowable Limit: 0.003
″ (0.08 mm)
19992598
Play between the connecting rod and the crankshaft
Assemble the connecting rod to the crankshaft and measure the play in shaft direction. If the play is more than the allowable limit, replace the connecting rod.
Standard Play: 0.0039
″
- 0.0118
″
(0.1 mm - 0.3
mm)
Allowable Limit: 0.0275
″ (0.7 mm)
10-45
62
SECTION 10 - ENGINE
Oil Clearance
Using the plasti-gauge, check the oil clearance as follows:
Remove oil or foreign matter from the bearing and crankshaft.
Cut the plasti-gauge to the same width as the bearing. Place it on the crankshaft at 1. Avoid the oil hole.
Assemble the connecting rod and connecting rod cap and tighten to the specified torque. All engines 36 ft. lbs. - 40 ft. lbs. (49 N·m - 54 N·m).
NOTE: Never rotate the connecting rod.
Remove the connecting rod cap. Measure the oil clearance (plasti-gauge) with the scale printed on the gauge bag.
NOTE: Measure the widest area.
Standard Play: 0.001
″ - 0.003
″ (0.035 mm -
0.085 mm)
Allowable Limit: 0.0078
″
(0.2 mm)
If the oil clearance exceeds the allowable limit, replace the bearing or grind the crankshaft and use an oversize bearing.
NOTE: When grinding the outside diameter of the crankshaft, be sure that the oil clearance is correct before reassembly.
Crankshaft Pin O.D. Dimension (mm)
S.T.D.: 2.0458
″ - 2.0463
″ (51.964 mm - 51.975
mm)
0.010
″ (0.25 mm): 2.0360
″ - 2.0364
″ (51.714 mm
- 51.725 mm)
0.020
″
(0.50 mm): 2.0261
″
- 2.0266
″
(51.464 mm
- 51.475 mm)
10-46
63
64
SECTION 10 - ENGINE
Reassembly
1. Reassemble the piston on the connecting rod as follows.
2. With a piston heater or the like, heat the piston to approximately 212
°
F (100
°
C). Assemble the piston to the connecting rod by aligning the set marks.
3. Set the “SHIBAURA” marks, or other mark, 1, as shown. Align the set marks on the connecting rod.
4. Replace the piston ring on the piston. Position the scribe mark uppermost.
5. When the connecting rod or piston/piston pin has been replaced, the difference in the weight of the assembly (connecting rod plus piston rings) should not exceed 10 grams between cylinders.
Op. 10 103 10
BEARING HOLDER
Disassembly and Inspection
Center Bearing
1. Remove the bearing holder and check it for peeling, melting, stepped wear, and other damage. If it is excessively damaged, replace.
2. Using the plasti-gauge, measure the oil clearance between the crankshaft center journal and the bearing.
If the oil clearance is more than the allowable limit, replace the bearing or grind the crankshaft center journal and use an undersized bearing
(refer to “Crankshaft”).
Standard Oil Clearance: 0.0017
″ - 0 .0040
″
(0.044 mm - 0.102 mm)
Allowable Limit: 0.0078
″
(0.2 mm)
Crankshaft Center Journal Diameter (mm)
S.T.D.: 2.6755
″ - 2.6760
″ (67.957 mm - 67.970
mm)
0.010
″
(0.25 mm): 2.6656
″
- 2.6661
″
(67.707 mm
- 67.720 mm)
0.020
″ (0.50 mm): 2.6558
″ - 2.6563
″ (67.457 mm
- 67.470 mm)
10-47
65
SECTION 10 - ENGINE
Thrust Clearance
Check the thrust washer for wear, poor contact, burning, or other defects. Defective washers must be replaced.
Standard Thickness: 0.116
″ - 0.118
″ (2.95 mm -
3.0 mm)
Allowable Limit: 0.11
″
(2.8 mm)
Reassembly
Reassemble the bearing holder, center bearing, and thrust washer as follows:
1. Face the chamfered part, 1, of the bearing holder toward the front. Install the bearing holder which has a notch, 2. Install the bearing holder on which the thrust washer is to be mounted at the flywheel side.
2. Install the thrust washer, 5. Face its oil groove toward the thrust face of the crankshaft.
Tightening torque of the bearing holder: 36 - 40 ft. lbs. (49 - 54 N·m).
3. Set the bearing with the oil groove, 3, to the upper part, 4, while setting the bearing without the groove to the lower part.
CRANKSHAFT BEARING (BUSHING)
Inspection
Check the bearing (bushing) for peeling, melting, seizure, or poor contact. If found to be defective, replace.
Using a cylinder gauge and micrometer, measure the oil clearance between the bearing (bushing) and the crankshaft journal.
Measure the inside diameters at positions 1 and 2. At each position, measure in both directions 3 and 4.
The oil clearance can be obtained by subtracting this value from the maximum crankshaft journal diameter.
66
67
10-48
SECTION 10 - ENGINE
Standard Oil Clearance: 0.0017
″
- 0.0046
″
(0.044 mm - 0.116 mm)
Allowable Limit: 0.0078
″ (0.2 mm)
If the oil clearance exceeds the allowable limit, replace the bearing (bushing) or grind the crankshaft journal. In this case, use an undersized bearing
(bushing).
When replacing the crankshaft journal (bushing), use a press to install.
Crankshaft Journal (bushing)
Outside Diameter
Standard: 2.6755
″
- 2.6760
″
(67.957 mm -
67.970 mm)
0.0098
″ (0.25 mm): 2.6656
″ - 2.6661
″ (67.707
mm - 67.720 mm)
0.0196
″ (0.50 mm): 2.6558
″ - 2.6563
″ (67.457
mm - 67.470 mm)
Crankshaft Bushing Replacement
Bushing Removal
Remove the bushing from the housing (cylinder block) using a bushing driving tool to prevent damage.
Press-fitting the bushing
1. Prior to installing the bushing, inspect the bushing housing for marks, scratches, etc.
2. The bushing should be smoothly pressed in to the correct depth by using a bushing driving tool, adjusting the oil hole and direction of bushing.
– Press in the bushing to the cylinder block from the engine front side.
NOTE: Do not press in the bushing to the cylinder block from the opposite side.
The correct pressing side is chamfered, etc., to allow smooth operation.
10-49
68
69
SECTION 10 - ENGINE
– Align the oil hole, 1, of the housing and bushing.
– Install the bushing, confirming the mark and oil groove (hole).
– Lubricate at the outer surface of the bushing.
– Press in the bushing to the housing until correct depth, by using a bushing driving tool.
3. Confirm after installation.
Confirm the alignment of the oil hole of the housing and the bushing. Also make sure the inner diameter is within tolerance.
After grinding the crankshaft journal, check the oil clearance.
Op. 10 103 30
CRANKSHAFT
Inspection
Crankshaft Deflection
Support the crankshaft with V-block. Position a dial gauge on the crankshaft center journal and turn the crankshaft gradually by one full turn. If the gauge reading is more than the allowable limit, correction or replacement of the crankshaft is needed.
Standard Deflection: 0.0011
″
(0.03 mm or less)
Allowable Limit: 0.0023
″
(0.06 mm)
Oil Seal Contact Face and Oil Holes
Check the oil seal contact face for damage or wear.
Check oil holes for clogging.
70
71
10-50
SECTION 10 - ENGINE
Check Crankshaft Journal, 3, and Pin, 4, for stepped wear
Take four measurements (AA and BB diameters at positions 1 and 2, Figure 73). If the maximum difference between the measurements is more than the allowable limit, correction is required.
Allowable Difference (stepped wear): 0.0019
″
(0.05 mm)
Crankshaft Pin Diameter
Standard Diameter
Standard: 2.0458
″ - 2.0463
″ (51.964 mm -
51.975 mm)
0.01
″
(0.25 mm): 2.0360
″
- 2.0364
″
(51.714 mm
- 51.725 mm)
0.02
″ (0.50 mm): 2.0261
″ - 2.0266
″ (51.464 mm
- 51.475 mm)
Allowable Limit
Standard: 2.0433
″ (51.90 mm)
0.01
″
(0.25 mm): 2.0335
″
(51.65 mm)
0.02
″
(0.50 mm): 2.0236
″
(51.4 mm)
Crankshaft Journal Shaft Diameter
Standard Diameter
Standard: 2.6755
″
- 2.6760
″
(67.957 mm -
67.970 mm)
0.01
″ (0.25 mm): 2.6656
″ - 2.6661
″ (67.707 mm
- 67.720 mm)
0.02
″
(0.50 mm): 2.6558 - 2.6563
″
(67.457 mm
- 67.470 mm)
Allowable Limit
Standard: 2.6732
″
(67.90 mm)
0.01
″ (0.25 mm): 2.6634
″ (67.65 mm)
0.02
″ (0.50 mm): 2.6535
″ (67.40 mm)
10-51
72
73
SECTION 10 - ENGINE
NOTE: When grinding the crankshaft, work with the following specifications:
1. Radius at pin/journal: 0.118
″
+ 0.0078
″
(3 mm +
0.2 mm)
2. Finish precision: 1.6Z
3. Radius around oil hole: 0.0787
″ (2 mm) maximum 0.196
″ (5 mm) minimum
Use No. 400 emery cloth for final polishing.
Op. 10 103 76
FLYWHEEL AND RING GEAR
Inspection
Check the ring gear. If it is excessively damaged or worn, replace it.
When wear is not excessive, remove the ring gear and reinstall 90
°
from original position. To install, preheat the ring gear up to 248 ° F - 300 ° F (120 ° C
- 150 ° C).
Op. 10 106 40
CAMSHAFT ASSEMBLY
Inspection
Check the journals and cams for wear and damage.
Replace if the allowable limit is exceeded.
Correct uneven wear or small scratches on the cam surface with oil stone.
Cam Height (intake and exhaust cams)
Standard Value: 1.3411
″
- 1.3433
″
(34.065 mm
- 34.12 mm)
Allowable Limit: 1.3268
″
(33.7 mm)
Height of Cam for Injection Pump
Standard Value: 1.6512
″
- 1.6559
″
(41.94 mm -
42.06 mm)
Allowable Limit: 1.6457
″ (41.8 mm)
Height of Cam for Fuel Feed Pump
Standard Height: 1.2559
″ - 1.2598
″ (31.9 mm -
32.0 mm)
Allowable Limit: 1.1811
″
(30.0 mm)
10-52
74
75
76
SECTION 10 - ENGINE
Op. 10 106 66
CAMSHAFT GEAR AND BEARING
ASSEMBLY
2 Camshaft gear
3 Camshaft
4 Tachometer gear
5 Spacer
6 Roller bearing
8 Slider
If these items have been replaced, it is essential that the spacers, shims, etc. are assembled in the order illustrated here.
To replace the camshaft gear assembly, the assembly will require pressing off and on.
TIMING GEAR
Inspection
Check the timing gears for wear and damage on the contact area. Replace if any defect is found.
Measure the backlash of gears with a thickness gauge or dial gauge. If the allowable limit is exceeded, replace all timing gears.
1 Camshaft gear
2 Idler gear
3 Crankshaft gear
Standard Backlash: 0.003
″
(0.08 mm)
Allowable Limit: 0.010
″
(0.25 mm)
77
78
10-53
SECTION 10 - ENGINE
Op. 10 304 41
OIL PUMP
Disassembly
Remove the snap ring.
Take out the collar spring and shim.
Remove the idler gear vane and oil pump cover together.
Pull out the rotor and thrust washer.
Pull out the oil pump cover from the idler gear.
Remove the spring from the idler gear.
1 Snap ring
2 Collar
3 Spring
4 Shim
5 Oil pump cover
6 Rotor
7 Spring
8 Idler gear
9 Thrust washer
Inspection
Check the oil pump cover, rotor, and vane for wear.
If excessively worn or damaged, replace.
Check the clearance at 1 between the rotor and the vane.
Reassembly (see Idler Gear)
Reassemble the oil pump in the reverse order of disassembly.
Align the set marks on the crankshaft gear and idler gear to reassemble.
Make sure the tip clearance at 1, between the rotor and the vane is 0.0004
″ to 0.006
″ (0.01 mm to 0.15
mm) . Allowable limit is 0.009
″
(0.25 mm) .
19992601
10-54
79
80
SECTION 10 - ENGINE
Op. 10 304 10
OIL FILTER
Construction and Function
This engine employs a cartridge-type filter.
Pressurized oil from the pump enters from 1 and is filtered by a full flow filter before discharge through 2.
When the full flow filter is clogged, the safety valve,
3, opens to bypass the oil.
Maintenance
The oil filter must be replaced every 100 hours of operation.
When installing a new filter, coat its mounting face with clean oil. Hand-tighten only.
Op. 10 402 28
WATER PUMP ASSEMBLY AND
THERMOSTAT HOUSING
Disassembly
Remove the backplate and gaskets.
Remove the thermostat and spring from the thermostat housing.
1 Water pump
2 Gaskets
3 Set plate
Inspection
Op. 10 402 30
THERMOSTAT REMOVAL
Replace the thermostat if the valve opens at ambient temperature.
Place the thermostat into water. Raise the water temperature gradually and inspect the valve opening temperature and valve lift. (Standard values are as described in the “Specifications” section.)
NOTE: Three to five minutes will be required before the valve starts operating.
2
19992544
2
3
19992602
81
1
82
83
10-55
SECTION 10 - ENGINE
Type
Temperature when starting to open
Temperature when fully open
Valve lift fully open
Wax Pellet
Type
176
(80
°
°
N844
- 183
- 84
0.315
″
(8.0 mm)
°
°
F
C)
N844T
Wax Pellet
Type
156
°
- 163
°
F
(69
°
- 73
°
C)
203
°
F (95
°
C) 180
°
F (82
°
C)
0.315
″
(8.0 mm)
Water Pump
Check for cracks, wear, leaks, bearing roughness, or damage. If defective, replace assembly.
Reassembly
Assemble the thermostat and spring in the housing.
Install the gasket and backplate on the water pump.
Rotate the fan holder to confirm there is no obstruction or interference.
84
10-56
SECTION 10 - ENGINE
Op. 10 230 24
GOVERNOR
Construction/Function
A mechanical all-speed governor is used. It is housed in the gear case.
A flyweight assembly is mounted on the camshaft.
The movement of the flyweight is transmitted to the injection pump control rack by way of the slider, control lever, and link, 1. A spring which is hooked to the arm, 3, and tension lever, 4, regulates the movement of the flyweight.
By changing the set angle of the governor lever, tension on this spring is changed. Thus, the engine speed can be regulated by the governor lever.
Maximum Speed Set Bolt
The set bolt is mounted on the cylinder block. This bolt limits the movement of the arm and has been adjusted and sealed at the factory.
Maximum Fuel and Start Spring
These are built into the cylinder block to regulate fuel injection at high speed. Regulation of fuel injection in the middle speed range is by torque spring to realize higher torque.
A start spring, 2, is placed between the gear case and link. This spring automatically functions to increase fuel during the start mode.
An idling spring at the gear case stabilizes engine idling speed.
The maximum fuel has been adjusted at the factory and sealed.
85
10-57
SECTION 10 - ENGINE
9
25
3
7
23
24
23
22
21
1
7
12
11
10
2
20
19
6
18
8
5
17
26
27
13
19992767
1. Timing Gear Cover
2. Pin
3. Gasket
4. Oil Seal
5. Arm Assembly
6. Spring Holder Arm
7. Snap Ring
8. Washer
9. Snap Pin
10. Governor Spring
11. Throttle Arm
12. O Ring
13. Throttle Lever
14. Pivot Shaft
16
15
14
28
15. O Ring
16. Snap Ring
17. Throttle Stay
18. Shutoff Arm
19. Snap Ring
20. O Ring
21. Return Spring
4
26
22. Washer
23. Nut
24. Stop Lever
25. Dampener Spring
26. Cover
27. Gasket
28. O Ring
86
Reassembly
Precautions Before Assembling
Wash parts before assembling (especially oil gallery, bearings, pistons, and cylinder bores should be washed thoroughly).
Apply new oil to sliding and rotating surfaces of cylinder bores, pistons, and bearings, etc.
Replace gasket, packing, etc. Use liquid gasket to prevent oil leakage where necessary.
Never over-tighten bolts and nuts used on aluminum alloy. Tighten to specified tightening torques.
10-58
SECTION 10 - ENGINE
GOVERNOR OPERATION
As the engine speed increases, the throttle arm, 1, contacts the fuel screw adjuster at contact point A, and the high-speed idle stop screw at B. During the engine speed increase, tension is placed on the governor spring, 2.
19993594
As the engine speed increases, the four governor weights, 1, pivot outward and push on the slider cone, 2. The weights and slider cone are located on the end of the camshaft.
The slider cone, 2, Figure 88, contacts the governor linkage arm, 1, at contact pad, C. As the cone moves forward, it pushes the linkage arm, 1, forward, which is connected to the injection pump rack assembly.
When the injection pump rack moves forward, the fuel delivery is decreased and the engine speed decreases.
19993595
19993596
87
88
89
10-59
SECTION 10 - ENGINE
As the engine speed decreases, the governor weights, 1, pivot inward allowing the slider cone, 2, to move rearward.
19993597
As the slider cone, 2, Figure 90, moves rearward, the governor linkage arm, 1, allows the fuel injection pump rack to move rearward to the full fuel position and the engine speed increases.
Engine speed depends upon several factors: the throttle setting determined by governor spring tension; the pressure exerted by the slider cone on the governor linkage; and, positioning of the injection pump rack.
All the governor linkage parts are located inside the engine timing gear cover. To inspect or replace any of the governor linkage parts, the timing gear case and injection pump must be removed from the engine.
19993598
90
91
10-60
SECTION 10 - ENGINE
ENGINE REASSEMBLY SEQUENCE
PRECAUTIONS
Thoroughly wash parts before reassembly. Ensure oil galleys are clean and unobstructed.
Lubricate all rotating and sliding components before assembly.
Clean all gasket surfaces, using care not to scratch mating surfaces. Use special care on aluminum parts. Discard and replace all removed gaskets. Use liquid gasket where necessary.
Never over-tighten threaded fasteners used on aluminum parts. Tighten only to specified torque values.
ENGINE REASSEMBLY SEQUENCE
Op. 10 304 38
OIL PRESSURE RELIEF VALVE ASSEMBLY
Install an O ring on the relief valve assembly.
Relief valve tightening torque: 43 ft. lbs. to 50 ft. lbs.
(58 N·m - 68 N·m)
92
10-61
SECTION 10 - ENGINE
CRANKSHAFT AND BEARING HOLDER
ASSEMBLY
1. Install the bearing holders on the crankshaft.
Insert this in the bushing at the front end of the cylinder block.
2. Align the bolt hole at the lower part of the cylinder block with thread hole on the bearing holder and tighten with bolts. For flywheel end, use two special bolts, hex recess in its head.
Bearing holder tightening torque:
Hex hole bolts - 18 - 22 ft. lbs. (24 - 30 N·m)
Hex bolts - 36 - 40 ft. lbs. (49 - 54 N·m)
3. Measure crankshaft end float.
Standard Play: 0.004
″
- 0.016
″
(0.1 mm - 0.4
mm)
Allowable Limit: 0.020
″
(0.5 mm)
REAR OIL SEAL
This is a press-fit, retained by the backplate.
93
94
95
10-62
SECTION 10 - ENGINE
BACK PLATE/FLYWHEEL HOUSING
Coat the area around the M8 threaded holes with liquid packing solvent-based sealant and fix the backplate with bolts.
Backplate tightening torque: 10 - 13 ft. lbs. (14 - 18
N·m)
Housing tightening torque: 18 - 21 ft. lbs. (24 - 28
N·m)
FLYWHEEL
Fit the flywheel. Note the location of the spring pin.
Flywheel tightening torque: 43 - 50 ft. lbs. (58 - 68
N·m)
PISTON AND CONNECTING ROD
Coat the bearing face, piston, and piston ring with clean engine oil.
Slide the piston ring to permit a sufficient amount of oil to be applied in the groove. Set the piston ring gaps 90
°
apart from each other. However, do not position these gaps toward the piston pin or the right angle of the pin.
Insert the piston using a ring compressor. Face the reference mark, 1, on the piston toward the injection pump side, 2, as indicated. Also face the connecting rod mark towards the fuel pump side.
NOTE: Install pistons from the front in ascending order.
Tighten the connecting rod cap to the specified torque.
Connecting rod tightening torque: 36 - 40 ft. lbs. (49
- 54 N·m)
NOTE: After installation, ensure the crankshaft moves freely. Ensure the axial play of 0.004
to
0.012
(0.1 mm to 0.3 mm) is provided.
10-63
19992603
96
97
98
SECTION 10 - ENGINE
OIL INTAKE AND OIL STRAINER
Fix an O ring on the suction pipe and insert the pipe into the cylinder block.
Fit the end of the suction pipe to the oil strainer and fix the oil strainer.
Suction filter tightening torque: 6.5 - 9.5 ft. lbs. (8.8 -
12.9 N·m)
OIL SUMP
Tighten the bolts diagonally and evenly.
DIPSTICK AND TUBE
Install the dipstick and tube using two O rings.
FRONT PLATE
Camshaft Assembly, Tachometer, and Plate
1. Install the tachometer shaft.
2. Install the camshaft assembly. Avoid damaging bearings.
3. Fix the tachometer shaft and camshaft with the retaining plate.
Plate tightening torque: 6.5 - 9.5 ft. lbs. (8.8 - 12.9
N·m)
IDLER GEAR AND OIL PUMP ASSEMBLY (SEE
SECTION IV OIL PUMP)
Install the thrust washer on the idler gear shaft.
Assemble the vane, knock pin, and spring on the idler gear.
1 Snap ring
2 Collar
3 Spring
4 Shim
5 Oil pump cover
6 Rotor
7 Spring
8 Idler gear
9 Thrust washer
10-64
99
100
101
SECTION 10 - ENGINE
Align set marks on the idler gear, crankshaft gear, and camshaft gear, and assemble on the idler gear shaft.
Install the rotor.
Install the oil pump cover, shim, spring, and collar. Fix them with the retaining ring.
Adjust with shim 0.1, 0.15, 0.2, 0.5 mm so the axial clearance of the oil pump, rotor, and vane is in the range of 0.004
″ - 0.006
″ (0.1 mm to 0.15 mm). The allowable limit is 0.008
″
(0.2 mm) .
NOTE: Coat both faces of the rotor and vane with grease for assembly.
NOTE: NEVER TURN the crankshaft until the timing gear case is fitted.
By turning the oil pump cover to either direction, set the spring pin insert hole to the middle position and fit the gear case.
102
103
104
10-65
SECTION 10 - ENGINE
TIMING GEAR CASE
Install the start spring.
Insert the link through the hole in the cylinder block.
Rotate the oil pump cover to the position spring pin hole to the center position. Install the cover locating pin in the oil pump cover plate (PB094).
NOTE: Do not damage the oil seal when fitting. Turn the mechanical stop lever clockwise to assist assembly.
CRANKSHAFT PULLEY
Align the keyway and key on the crankshaft pulley and crankshaft and assemble them.
Crankshaft pulley tightening torque: 203 - 246 ft. lbs.
(275 - 333 N·m)
INJECTION PUMP INSTALLATION
Reinstall the shim, 1. Connect the control rack of the injection pump with the link, 2, and fix with the snap pin.
Tighten the injection pump bolts and nuts.
105
106
107
10-66
SECTION 10 - ENGINE
ADJUSTING THE FUEL INJECTION TIMING
Normally, this procedure provides correct injection timing. However, when the new injection pump, camshaft assembly, or cylinder block is used, fuel injection timing should be adjusted as explained below.
Reassemble the injection pump according to the procedures above. Use the shim of 0.5 mm thickness.
Remove the delivery valve holder at the front side
(radiator side) of the injection pump.
INJECTION TIMING AND CRANKSHAFT
POSITIONS
Engine
Model
N844T
N844
X
21
22
Degrees Crank BTDC
Y
20
21
Z
22
23
Injection
Timing
20 - 22
21 - 23
Pull out the delivery valve, 1, (IN), and reinstall the spring, 2, and delivery valve holder, 3.
NOTE: When reassembling the delivery holder, adjust the location of the delivery valve (OUT) to correct position using a wire, 4.
Move the governor control lever to “Maximum Fuel” position and send fuel with the No. 1 piston at around
“X” degrees BTDC in its compression stroke. At this time, fuel flows from the delivery holder.
108
109
10-67
SECTION 10 - ENGINE
Piston Position in Relation to the Crankshaft Angle
(BTDC)
N844, N844T
Crankshaft Angle
(BTDC)
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Position
0.0594
″ (1.510 mm)
0.0689
″ (1.749 mm)
0.0789
″
(2.005 mm)
0.0897
″ (2.278 mm)
0.1011
″ (2.569 mm)
0.1132
″
(2.875 mm)
0.1259
″ (3.199 mm)
0.1393
″ (3.539 mm)
0.1533
″
(3.895 mm)
0.1680
″ (4.267 mm)
0.1833
″ (4.655 mm)
0.1991
″
(5.058 mm)
0.2156
″ (5.477 mm)
0.2328
″
(5.912 mm)
Slowly turn the crankshaft clockwise until flowing fuel from the delivery holder is stopped. Check the piston position at this point. If the position is later than “Y”
BTDC, use a thinner shim. If the position exceeds “Z”
BTDC, use a thicker shim.
Changing the shim thickness by 0.004
″
(0.1 mm) will change the timing approximately one degree. Adding shims decreases the angle, while subtracting shims increases the angle.
NOTE: When the shim is not needed, assemble by coating, using liquid sealant.
SPILL-TIMING PROCEDURE
1. Verify that the timing mark on the crankshaft pulley is in line with the “TOP” mark on the timing scale. If the mark on the crankshaft pulley is not in line with the “TOP” mark, verify piston top-dead center with a dial indicator. If the pulley mark is slightly off, re-mark the pulley and proceed.
NOTE: Color the timing mark on the crankshaft pulley and appropriate marks on the timing scale to increase visibility.
2. Reinstall the valve spring, keepers, rocker arm assembly, and valve cover.
3. Shut off the fuel supply to the injection pump at the fuel filter.
10-68
110
111
SECTION 10 - ENGINE
4. Remove the No. 1 injection line from the No. 1 injector, 1.
5. Remove the lock screw, 2, and remove the injector locking plate, 3.
6. Remove the delivery valve piston, 1, from the No.
1 delivery valve.
3
2
1
112
1
113
7. Reinstall the spring and holder, 1, into the injection pump and tighten securely.
1
114
10-69
SECTION 10 - ENGINE
8. Fabricate a spill tube, 1, from a discarded injection line and install the tube on the No. 1 port on the injection pump.
9. Remove the fuel shut-off solenoid from the injection pump.
10. Rotate the crankshaft counterclockwise (viewed from the front of the engine) approximately 40
_
.
11. Turn on the fuel supply to the injection pump.
Fuel should flow out of the spill tube on the No.
1 cylinder port.
12. Rotate the crankshaft clockwise. When the timing mark on the crankshaft pulley, 1, is in line with the 21
_
(N844T) or 22
_
(N844) mark on the scale, 2, fuel should stop flowing from the spill tube.
13. If fuel does not stop flowing at the appropriate timing mark, the injection pump timing must be adjusted by adding or removing shims located between the injection pump and the engine block.
14. Adding shims will retard the pump timing and removing shims will advance the pump timing.
NOTE: A shim thickness of 0.1 mm (0.004 in.) will change the pump timing by approximately 1 _ .
15. Assemble the components that were removed from the engine and fuel system.
2 1
1
115
116
117
10-70
SECTION 10 - ENGINE
Assemble the delivery valve (IN).
NOTE: Delivery holder tightening torques: 29 - 33 ft.
lbs. (39 - 45 N·m).
Oil Filter
Coat the mounting face with a thin film of oil, and then hand-tighten.
Feed Pump
Insert using securing bolts.
Tappet
Coat the tappet with oil, and then assemble.
Cylinder Head
Set the piston to the top, dead center, and measure the amount of protrusion above the cylinder block with a depth gauge or a dial gauge.
NOTE: Take measurement by pressing the piston lightly.
Measure the protrusions for 4 cylinders. Use the highest reading as a reference.
Ensure the cylinder head gasket meets the tolerance levels.
N844, N844T
Measurement
0.019 - 0.023
″
(0.5 - 0.6 mm)
0.023 - 0.031
″
(0.6 - 0.8 mm)
Gasket
No.
111147510
111147520
Tightened
Thickness t=0.047
″
(t=1.2 mm) t=0.051
″
(t=1.3 mm)
NOTE: The last four digits of code numbers are stamped on the head gasket. Install the head gasket with code numbers at the top.
10-71
SECTION 10 - ENGINE
Tighten the cylinder head in 3-step procedures, in the order shown in the illustration. Finally, tighten with specified torque.
Specified torque: 72 - 76 ft. lbs. (98 - 103 N·m)
NOTE: Spring pin is used for positioning.
Coat threads of bolts with grease based with molybdenum disulfide.
Oil Pipe
Eyebolt tightening torque: 7 - 9 ft. lbs. (9 - 12 N·m)
LS160 N844 engine - the oil pipe, 1, will be connected to the block.
LS170 N844T engine - the oil pipe will be connected to the turbocharger.
118
119
120
10-72
SECTION 10 - ENGINE
Cap, Push Rod, and Rocker Arm
Assembly
Install the caps, 1, on the end of the valve stem.
Install the push rods, 2, and rocker arm assembly, 3.
Rocker arm assembly tightening torque: 20 - 29 ft.
lbs. (27 - 39 N·m) 4-cylinder engines.
Valve Clearance Adjustment
Loosen the nut and adjust the clearance of both the intake and exhaust valves to 0.2 mm (0.0078
″
) with the adjust screw.
NOTE: Adjust when the engine is cold. Set the No.
1 piston to TDC of compression stroke and adjust the
No. 1 cylinder intake, exhaust valves, No. 2 cylinder intake valve, and No. 3 cylinder exhaust valve. Turn the crankshaft 360 in a clockwise direction, viewed from the front, and adjust the remaining valves.
Cylinder Head Cover
Evenly tighten the cylinder head cover. Ensure the oil ring gasket remains in location.
Cylinder head cover tightening torque: 9 - 12 ft. lbs.
(12 - 16 N·m)
Water Pump Assembly and Thermostat
Housing
Install in the sequence of the gasket, plate, gasket and water pump assembly.
1 Gasket
2 Plate
3 Gasket
4 Water pump
10-73
123
121
122
SECTION 10 - ENGINE
Connect the thermostat housing and hoses.
1 Thermostat housing
2 Thermostat
3 Gasket
4 Adapter
Glow Plug and Connector
Glow plug tightening torque: 11 - 14.5 ft. lbs. (15 - 20
N·m)
Oil Pressure Switch
Oil pressure switch tightening torque: 11 - 14.5 ft. lbs.
(15 - 20 N·m)
Nozzle/Holder Assembly
Install the nozzle and holder assembly with a socket for the nozzle holder. Install the return pipe.
Nozzle/holder tightening torque: 44 - 51 ft. lbs. (60 -
69 N·m)
Return Pipe and Injection Pipe
After installing the return pipe, 1, install injection pipes, 2.
Injection pipe tightening torque: 11 - 18 ft. lbs. (15 -
24 N·m)
Alternator Assembly
Install the assembly, and check the belt groove alignment.
124
125
126
10-74
SECTION 10 - ENGINE
V-Belt, Fan Pulley and Cooling Fan
After mounting the fan pulley, cooling fan, spacers, and cover plate on the N844 LS160 engines, install the V belt.
Depress the belt at the center between the crankshaft pulley and the alternator pulley, with a force of approximately 5 kg (2.27 ft. lbs.). The fan belt tension should be adjusted so the deflection becomes 0.2
″ (5 mm) upon the above check.
Cooling fan tightening torque: 6.5 - 9.5 ft. lbs. (8.8 -
13 N·m)
The Model LS160 N844 engine fans are equipped with a cover plate, 1, over the center of the fan assembly.
Intake/Exhaust Manifolds
Install in sequence of gasket, 1; spacer, 2; gasket, 3; and intake manifold, 4.
Install exhaust manifold, 5.
Op. 29 100 50
REINSTALLATION OF ENGINE INTO SKID
STEER FRAME
NOTE: Inspect the splines, 1, on the hydrostatic pump flex plate and the splines on the input shaft. If flex plate is damaged, replace.
1
127
128
129
10-75
SECTION 10 - ENGINE
1. Reinstall the hydrostatic pump flex plate to the engine flywheel, 1, using eight 5/16 ″ x 3/4 ″ G5 cap screws and eight M8 lock washers. Torque to 20 ft. lbs. (26 N·m).
Reinstall the flex plate with the center hub of the plate away from the flywheel, 2.
2. When reconnecting the ground wires at 3, place the largest wire (battery ground cable, 4) next to the ground surface. Then stack the remaining ground wires according to size (smallest to largest wires) and secure.
3. When the engine is reinstalled, make sure the ground strap, 5, between the engine block and loader main frame is reinstalled to prevent engine bearing damage.
NOTE: Lubricate the splines of the drive plate and hydrostatic pump shaft with never seize or moly coat lubricant.
4. Check the condition and reinstall or replace the engine isolator mounts. Examine the condition of the rubber mount, 1, and replace the mount if it shows signs of deterioration.
5. Proper assembly of the engine isolator mount.
2 Mount retaining hardware
5 Large flat washer (lower)
6 Small flat washer (upper)
7 Nut
Torque the mount retaining hardware, 2, to 26 ft.
lbs. (35 N·m).
Torque the engine block retaining bolt, 4, to 83 ft.
lbs. (112 N·m).
6. Attach the hydrostatic pump and support to the engine bellhousing as previously removed.
3
130
131
4 4
132
10-76
SECTION 10 - ENGINE
7. Reconnect the battery making sure the positive
(+) battery cable, 1, on LS170 models routes away from the turbocharger hose, 2, and the hose clamp, 3.
8. Reverse the clamp, 3, to avoid unnecessary wear on cables and hoses.
HOW TO OPERATE THE ENGINE AFTER
OVERHAUL
1. Check the quantity of the coolant, engine oil, and fuel.
2. Disconnect the wiring harness connector at the engine stop solenoid.
3. Move the hand throttle lever to the low, 1/3throttle position.
4. Turn the key switch to the start position (rotate the starting motor) until the oil pressure lamp goes off (about 20 - 30 seconds).
5. Connect the wiring harness connector at the engine stop solenoid.
6. Move the hand throttle lever to the 1/3 - to 1/2throttle position, start the engine, and operate at no more than 1500 RPM.
7. Adjust the low speed 1500 RPM with the engine running and warm up for 30 minutes. At the same time:
– Check for abnormal sound
– Check for temperature coolant
– Check temperature of engine oil
– Check leak of engine oil, coolant, and fuel
– Check color of exhaust gas
A gradual running-in of the overhauled engine is necessary for delivery of the lubricating oil to the bearings, etc.
8. Refer to the turbocharger section of this manual for information on operating a turbocharged engine after overhaul.
19988126
10-77
133
SECTION 10 - ENGINE
COOLING SYSTEM
SPECIFICATIONS
Capacity - 10.8 qts. (10.3 L)
Mixture - 50/50 antifreeze/water
Radiator cap - 7 PSI (48.3 kPa)
THERMOSTAT
Opening
180
°
F (82
°
C)
Fully Open
203 ° F (95 ° C)
EIC starts reading degrees at 113 ° F (45 ° C) or 32 °
F (0
°
C)
EIC signals an overheat condition at 216 ° F (102 ° C)
OPERATION
The EIC (Electronic Instrument Cluster) monitors the engine coolant temperature during operation and will signal the operator should an overheat condition occur.
The EIC will read COLD at start-up and will start reading in degrees at 113
°
F (45
°
C) or 32
°
F (0
°
C).
The EIC will default from any other monitored function to the coolant function when a overheat condition occurs at 216
°
F (102
°
C).
The cooling system has a recovery tank, 1, for coolant expansion.
The radiator can easily be cleaned by raising up the two handles, 2, to slide the radiator to the rear and separate it from the oil cooler for cleaning.
IMPORTANT: Always reposition the radiator before closing the rear door; damage to the radiator or expansion tank may occur.
The cooling system must be filled with a 50/50 mixture of antifreeze and water for winter and summer protection.
IMPORTANT: Always top off the cooling system with a 50/50 antifreeze/water mixture. Always refill a drained cooling system with a 50/50 antifreeze/water mixture.
Add coolant to the recovery tank, not the radiator.
10-78
134
SECTION 10 - ENGINE
DANGER
Allow the engine and cooling system to cool off before adding coolant to the cooling system.
Always allow the engine and cooling system to cool off before draining the cooling system.
Op. 10 402 28
WATER PUMP ASSEMBLY AND
THERMOSTAT HOUSING
Disassembly
Remove the backplate and gaskets.
Take out the thermostat and spring from the thermostat housing.
1 Water pump
2 Gaskets
3 Set plate
Op. 104 02 30
THERMOSTAT
Inspection
Replace the thermostat if the valve opens at ambient temperature.
Place the thermostat into water. Raise the water temperature gradually and inspect the valve opening temperature and valve lift. (Standard values are as described in the “Specifications” section.)
NOTE: Three to five minutes will be required before the valve starts operating.
Type
Temperature when starting to open
Temperature when fully open
Valve lift fully open
N844 N844T
Wax Pellet Type Wax Pellet Type
176 ° - 183 ° F
(80 ° - 84 ° C)
156
(69 °
° - 163
- 73 °
° F
C)
203 ° F
(95 ° C)
0.315
″
(8.0 mm)
180 ° F
(82 ° C)
0.315
″
(8.0 mm)
Op. 104 02 28
Water Pump
Check for cracks, wear, leaks, bearing roughness, or damage. If defective, replace assembly.
2
19992544
Reassembly
Assemble the thermostat and spring in the housing.
Install the gasket and set plate on the water pump.
Rotate the fan holder to confirm there is no obstruction or interference.
10-79
2
3
1
135
136
SECTION 10 - ENGINE
RADIATOR
Op. 10 406 02
Radiator Cap
A pressure-type radiator cap 7 PSI (48.3 kPa) is employed to obtain higher cooling efficiency. When the coolant pressure builds up to the range of 0.8 +
0.15 kg/cm2 (6.5 ft. lbs. to 10.8 ft. lbs.), excessive pressure is relieved from the overflow pipe (shown by white arrow).
When coolant temperature falls, coolant pressure may become less than atmospheric pressure. As this may fracture the radiator, the vacuum relief valve opens at 0.04 to 0.05 kg/cm2 (2.9 ft. lbs. to 3.6 ft. lbs.) to protect the radiator (black arrow).
19992604
Inspection
1. Check the radiator for water leaks. If there are water leaks, repair or replace the radiator.
2. Check radiator fins for clogging by mud and/or other foreign matter. If clogged, clean the fins.
3. Check the pressure cap and vacuum pressure relief cap for operating pressure or contacting condition. Replace if defective.
4. Check the radiator hoses; replace if damaged.
Op. 10 406 10
Radiator Removal
Drain the radiator and cooling system by raising up on handles, 1, moving the radiator to the rear.
Remove the drain plug, 2, and drain the coolant into a clean container.
Remove the upper and lower radiator hoses.
137
138
10-80
SECTION 10 - ENGINE
Remove the radiator support hardware and handles,
1, from both sides of the radiator. Remove the overflow hose, 2, from the radiator at the cap.
1
1
2
139
10-81
FUEL SYSTEM
FUEL SPECIFICATIONS
Fuel tank capacity is 14.3 U.S. gal. (54 L).
DIESEL FUEL
Use clean, quality No.1-D or No. 2-D fuel (ASTM
D975).
Use No. 1-D if the ambient temperature is expected to be less than 40 ° F (4 ° C) or if the loader is to be used at an altitude exceeding 5000 ft. (1524 m).
The sulfur content of the fuel should be no more than
0.5%.
The sediment and water content should not exceed
0.05%.
To prevent fuel flow problems in cold weather, use
No. 1-2 diesel fuel with a pour point of at least 10
°
F below the expected ambient temperature.
Minimum cetane number is 40. Low temperature or high altitude operation may require the use of fuel with a higher cetane number.
In most areas, diesel fuel is properly blended for summer and winter grades as ambient temperatures change. In winter, use winter grade diesel fuel only.
Otherwise, the fuel may cloud and block the fuel system. When temperatures are extremely cold, use properly mixed winter fuel.
Use New Holland diesel fuel conditioner part
#251202 to mix with the diesel fuel. Follow the directions for use as indicated on the container.
SECTION 10 - ENGINE
DIESEL FUEL STORAGE
NOTE: Diesel fuels stored for a long time may form gum and plug filters.
Keep fuel in a clean container in a protected area.
Water and sediment must be removed before fuel gets to the engine. Do not use deicers to remove water from fuel. Do not depend on fuel filters to remove water. If possible, remove water and sediment at the storage tank outlet.
IMPORTANT: Do not store diesel fuel in galvanized containers. Diesel fuel stored in galvanized containers reacts with the zinc coating of the container to form zinc flakes. If fuel contains any water, a zinc gel may also form. The gel and flakes will quickly plug fuel filters and may damage the injector pump and injectors.
10-82
SECTION 10 - ENGINE
FUEL SYSTEM COMPONENTS
The fuel system contains a fuel tank located in the left side of the engine compartment at 1. Fuel tank pickup tube, 2; fuel tank sending unit, 3; in-line fuel filter, 4; electric fuel pump, 5; injection pump, 6; and return fuel line, 7, from the injector bleed off to the tank. The fuel flow is controlled by an electronic fuel solenoid, 8, which is controlled by the EIC (Electronic
Instrument Cluster).
Located between the electric fuel pump and the injector pump is an additional fuel filter (water trap),
1. The fuel tank cap, 2, is a vented style.
WARNING
Refuel the loader outdoors with the engine shut off. Replace the fuel cap securely. Use an approved fuel container. Do not smoke when handling fuel. Avoid spilling fuel.
Filling the Tank
The fuel tank filler cap, 2, is located at the rear of the skid steer behind the rear door. Wipe the dust and dirt from around the cap before removing the cap to prevent trash from falling into the tank while filling it.
Use an approved fuel container and keep it clean.
The fuel tank capacity is 14.3 U.S. gal. (54 L).
NOTE: The fuel cap is the vented type. Use only a vented cap to prevent fuel system related problems.
140
141
10-83
SECTION 10 - ENGINE
1
2
FUEL GAUGE
In the center of the EIC panel is the fuel gauge, 1, implemented as a vertical 10-segment green LED bar graph. The lowest segments will flash when the fuel level is low. An audible alarm will accompany the
142 flashing light for about 5 seconds. When the fuel level reaches three bars, 2, the segments will flash.
When the fuel level reaches two bars, the EIC will signal the operator again, with the segments flashing and another five–second audible alarm.
10-84
SECTION 10 - ENGINE
COLD START AID
The EIC controls a timed preheat cold start to assist in cold weather starting. The timed period will vary from 0 to 15 seconds depending on model engine and engine temperature.
STARTING A COLD ENGINE
Move the engine speed control ahead to 1/3 position, maximum 1500 RPM.
Turn the ignition key, 1, to the “RUN” position. The
EIC will automatically activate the engine preheat system and the preheat light, 2, will be on, also at this time the character display, 3, will read the seconds remaining to heat. When the light goes off and the display is 0, turn the ignition key to the “START” position. After the engine starts, allow the key to return to the “RUN” position.
The engine must start within 30 seconds; if the engine does not start preheat again. Allow the starter to cool for one minute before engaging the starter motor. To start the preheat sequence again, turn the ignition key off and then on again.
Always allow the engine to operate at a maximum of
1500 RPM to warm up before applying a load.
NOTE: Following the above starting procedures is very important for any engine but especially a turbocharged engine to insure the turbocharger is lubricated properly.
FUEL FILTER SYSTEM
The unit is equipped with a fuel filter water trap, 1.
Drain the water trap filter every 100 hours of operation, or sooner if water is found in the fuel supply. To drain the water trap, turn the drain cock, 2, on the bottom of the cartridge and allow the water to drain. Replace the filter every 500 hours.
143
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10-85
SECTION 10 - ENGINE
Replace the in-line filter, 1, every 250 hours of operation. To remove the filter, remove the two hose clamps, 2, and remove the hoses from the filter.
Install a new filter, hoses, clamps and tighten.
WARNING
All service should be performed with the engine shut down. If servicing the loader with the boom in the raised position, be sure the boom arms are supported by the boom lock pins.
PRIMING THE FUEL SYSTEM
The skid steer loader is equipped with an electric fuel pump, 1. If the engine has been run out of fuel, add a minimum of 5 gallons (18.9 L) fuel to the tank.
Put the Service/Run switch, 1, in the SERVICE position. Remove the fuel line, 2, Figure 148, at the injector pump.
Turn the ignition switch to the RUN position and allow the electric fuel pump to pump fuel until a full stream of fuel (no air) flows at 2, Figure 148. Reinstall the fuel line. Now start the engine and allow the engine to run until the injection pump self bleeds the air from the pump.
1
19984337
145
146
147
10-86
SECTION 10 - ENGINE
FUEL SYSTEM TESTING
ELECTRIC FUEL PUMP
STEP
1
2
PRETEST
INSTRUCTIONS
Loader on level with parking brake engaged, key “OFF” position
Key “ON” position
TEST
Fuel level in tank
RESULT
NO
YES
PROBABLE CAUSE AND
CORRECTION
Add fuel and bleed system
Go to next step
3
4
Key “ON” position
Key “ON” position
Fuel pump operating
Fuel pump operating but not pumping fuel
Fuel pump operating and pumping fuel
NO
YES
NO
YES
NO
YES
5 Key “ON” position Fuel pump operating and pumping fuel
YES
NOTE: Always check fuel level in tank. Always check fuel filters.
FUEL SHUTOFF SOLENOID
STEP
1
2
PRETEST
INSTRUCTIONS
Loader on level with parking brake engaged, key “ON” position, service “RUN” switch in “RUN” position
Key “ON” position, service “RUN” switch in “SERVICE” position
TEST
Battery voltage to solenoid
Battery voltage to solenoid
RESULT
NO
YES
NO
3 Key “ON” position, service “RUN” switch in “RUN” position
Check EIC board operation
YES
NO
YES
Check power supply (5-amp fuse in cab panel) If OK, replace pump
Go to next step
Check line to tank, air leak, fuel level, tank pickup tube. If
OK, replace pump
Go to next step
Replace pump
Remove fuel line at injector pump and bleed system, if
OK go to next step
Check fuel shutoff solenoid for operation
PROBABLE CAUSE AND
CORRECTION
Check power wire from EIC to solenoid for open, if OK go to next step
Replace solenoid
Check power wire from service run switch to fuel solenoid, if OK go to next step
Replace solenoid
Check power to EIC board
Replace EIC board
10-87
SECTION 10 - ENGINE
FUEL TANK SENDING UNIT(Fuel level)
STEP
1
PRETEST
INSTRUCTIONS
Loader on level with parking brake engaged, key “ON” position
TEST
EIC gauge and sender operation jumper wire from one terminal to other at sender
RESULT
NO (bars light up)
YES (bars light up)
PROBABLE CAUSE AND
CORRECTION
Check wires from sender to
EIC board, if OK, replace
EIC board
Replace sender
10-88
FUEL FLOW
SECTION 10 - ENGINE
19992606
1 Fuel tank
2 Tank pick-up
3 In-line fuel filter
4 Electric fuel pump
FUEL SYSTEM ELECTRICAL DIAGRAM
5 Filter (water trap)
6 Injection pump
7 Fuel shut-off solenoid
148
19992607
1 Key switch
2 EIC board
3 Fuel level sender
4 Electric fuel pump
5 Injector pump
6 Fuel shut-off solenoid
149
10-89
SECTION 10 - ENGINE
FUEL SYSTEM COMPONENTS
Op. 10 216 10
FUEL TANK
Remove and Replace
1. Raise the boom, extend the boom lock pins, 1, and lower the boom down on the lock pins.
2. Stop the engine, turn the ignition key to the “ON” position and operate the boom and bucket control pedals to relieve pressure in the cylinders, turn the key “OFF.”
3. Jack and securely support the loader up off the ground approximately 20 ″ (508 mm).
4. Remove the engine area belly pan, 2.
5. Remove the left fender, 3.
6. Open rear door, 1, raise the top shield, 2, and remove the left side shield.
7. Remove the fill neck retaining hose clamp or screw at the tank and remove fill neck, 3.
8. Unhook the suction fuel line, 4, and return fuel line, 5.
9. Remove the wires from the fuel level sender, 6.
10. Remove the lower engine fuse panel support hardware, 7, and move the panel up.
11. Remove the connecting hose, 1, and drain the fuel tank into a clean container.
12. Remove the front, 2, and rear, 3, tank support hardware.
13. Remove the fuel tank from the bottom of the engine compartment.
150
151
152
10-90
SECTION 10 - ENGINE
Op. 55 410 80
FUEL LEVEL SENDER
1. Support the boom on the boom lock pins.
2. Open the rear door and remove the left engine side shield.
3. Unhook the wires from the sender, 1.
4. Remove the sender retaining screws, 2, and remove the sender, 3, assembly from the tank.
Op. 10 214 12
FUEL TANK PICKUP TUBE
1. Support the boom on the boom lock pins.
2. Open the rear door and remove the left engine side shield.
3. Remove the suction line from the pickup tube, 1.
4. Unthread the tube, 2, from the tank.
Upon reinstallation of the tube, seal the threads with thread sealer.
Op. 10 210 21
ELECTRIC FUEL PUMP
1. Support the boom on the boom lock pins.
2. Open the rear door and remove the left engine side shield.
3. Remove the hose clamps, 1, from the pump and hoses.
4. Remove the pump support hardware, 2, ground wire, and unplug the power wire.
5. Upon reinstallation of the pump, make sure the pump wires are placed to prevent damage. Make sure the ground wire is making good contact.
153
154
155
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SECTION 10 - ENGINE
Op. 10 230 24
GOVERNOR
Construction/Function
A mechanical all-speed governor is used. It is housed in the gear case.
A flyweight assembly is mounted on the camshaft.
The movement of the flyweight is transmitted to the injection pump control rack by way of the slider, control lever, and link, 1. A spring which is hooked to the arm, 3, and tension lever, 4, regulates the movement of the flyweight.
By changing the set angle of the governor lever, tension on this spring is changed. Thus, the engine speed can be regulated by the governor lever.
Maximum Speed Set Bolt
The set bolt is mounted on the cylinder block. This bolt limits the movement of the arm and has been adjusted and sealed at the factory.
Maximum Fuel and Start Spring
These are built into the cylinder block to regulate fuel injection at high speed. Regulation of fuel injection in the middle speed range is by torque spring to realize higher torque.
A start spring, 2, is placed between the gear case and link. This spring automatically functions to increase fuel during the start mode.
An idling spring at the gear case stabilizes engine idling speed.
The maximum fuel has been adjusted at the factory and sealed.
GOVERNOR OPERATION
As the engine speed increases, the throttle arm, 1, contacts the fuel screw adjuster at contact point A, and the high-speed idle stop screw at B. During the engine speed increase, tension is placed on the governor spring, 2.
19993594
10-92
156
157
SECTION 10 - ENGINE
As the engine speed increases, the four governor weights, 1, pivot outward and push on the slider cone, 2. The weights and slider cone are located on the end of the camshaft.
The slider cone, 2, Figure 160, contacts the governor linkage arm, 1, at contact pad, C. As the cone moves forward, it pushes the linkage arm, 1, forward, which is connected to the injection pump rack assembly.
When the injection pump rack moves forward, the fuel delivery is decreased and the engine speed decreases.
19993595
19993596
As the engine speed decreases, the governor weights, 1, pivot inward allowing the slider cone, 2, to move rearward.
19993597
158
159
160
10-93
SECTION 10 - ENGINE
As the slider cone, 2, Figure 162, moves rearward, the governor linkage arm, 1, allows the fuel injection pump rack to move rearward to the full fuel position and the engine speed increases.
Engine speed depends upon several factors: the throttle setting determined by governor spring tension; the pressure exerted by the slider cone on the governor linkage; and, positioning of the injection pump rack.
All the governor linkage parts are located inside the engine timing gear cover. To inspect or replace any of the governor linkage parts, the timing gear case and injection pump must be removed from the engine.
19993598
Op. 10 218 34
NOZZLE AND HOLDER
Specification
Nozzle type: Throttle type
Needle valve diameter: 0.16
″ (4 mm)
Pintle diameter: 0.04
″ (1 mm)
Valve setting pressure: 155 - 165 kg/cm 2 (153 -
163 atm)
Spraying angle: 4 °
Construction/Function
The nozzle has been machined to inject fuel which is pressure-fed from the injection pump to the combustion chamber. Fuel is pressure-fed from the oil hole of the nozzle holder to the nozzle body and sprayed from the nozzle compressing the spring when the pressure exceeds the specified value.
Some fuel lubricates and cools the nozzle and nozzle body and returns via the return pipe.
Throttle-Type Nozzle
1 Valve closed
2 Valve open
3 Full opening (main jet)
161
162
10-94
SECTION 10 - ENGINE
Disassembly/Inspection
1. Place the nozzle holder (body) in a vise and turn the nozzle nut to disassemble.
NOTE: Care should be taken so the needle valves do not fall when the nozzle is removed.
2. Wash the nozzle body and needle valve and inspect the nozzle for seizure, sticking, and fuel leakage on the seat surface. If fuel leakage is detected, replace the nozzle.
3. Inspect the upper and lower contact surfaces of the distance piece and correct so that positive contact can be obtained.
4. Check the nozzle needle valve-contact surface on the push rod for wear and spring seat for cracks.
Reassembly/Adjustment
1. Before fitting a new nozzle assembly, soak it in heated light oil 120 ° F -140 ° F (50 ° C - 60 ° C) to remove the anticorrosive agent from the nozzle.
Slide the body on the needle valve so they slide smoothly.
2. Turn the nozzle body upside down, fit the shim, spring, rod, spacer and nozzle in this order, and tighten with a nozzle nut.
Throttle-Type Nozzle
1 Gasket
2 Nozzle nut
3 Nozzle
4 Spacer
5 Rod
6 Spring
7 Shims
8 Body tighten torque 22 ft. lbs. - 36 ft. lbs. (30
N·m - 49 N·m)
9 Nut tighten torque 18 ft. lbs. - 22 ft. lbs. (24 N·m
- 30 N·m).
163
10-95
SECTION 10 - ENGINE
3. After reassembly, inspect the injection pressure of the nozzle.
Adjust the pressure with adjusting shims, using a nozzle tester so the injection starts at 150 kg/cm 2 (throttle type) and 210 kg/cm 2 (hole type).
(The pressure increases or decreases about 10 kg/cm 2 , 142 PSI, 9.7 atm with a shim of 0.1 mm thick).
4. Spray Condition
– Fuel drops should not be mixed in the spray pattern.
– Fuel should be sprayed in conical shape with respect to the nozzle axis.
– Be sure the fuel is sprayed in a circular shape when tested.
– Hold the pressure at 130 kg/cm
2
, lower by 20 kg/cm 2 , 20 atm than specified (150 kg/cm 2 ) and check that no test oil drops from the nozzle tip.
The cyclonic air cleaner houses a paper element which removes dirt or dust from air drawn in.
Inspection/Replacement
1. When the EIC signals to service the air cleaner, take out the outer element and clean it by blowing compressed air (pressure lower than 100 PSI).
Do not remove the inner safety element.
2. When operating the machine in a dusty environment, increase service frequency.
3. After cleaning the element, put a light inside the element and check it for cracks, holes, or wear.
If damage is found or the gasket is broken, replace the element.
4. When the inner safety element is dirty, do not clean. Replace the element.
Op. 10 236 08
FUEL INJECTION TIMING
FUEL INJECTION PUMP
If trouble has been traced to this pump, disassembly, inspection, assembly, and testing/setting must only be carried out by fuel equipment specialists.
Engine
Model
AIR CLEANER
X
21
22
Degrees Crank BTDC
Y
20
21
Z
22
23
Injection
Timing
20 - 22
21 - 23
Construction/Function
N844T
N844
10-96
SECTION 10 - ENGINE
1. Pull out the delivery valve, 1, (IN), and reinstall the spring, 2, and delivery valve holder, 3.
NOTE: When reassembling the delivery holder, adjust the location of the delivery valve (OUT) to the correct position using a wire, 4.
2. Move the governor control lever to “Maximum
Fuel” position and send fuel with the No. 1 piston at around “X” degrees BTDC in its compression stroke. At this time, fuel flows from the delivery holder.
N844, N844T
Crankshaft Angle
(BTDC)
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Position
0.0594
″
(1.510 mm)
0.0689
″
(1.749 mm)
0.0789
″ (2.005 mm)
0.0897
″
(2.278 mm)
0.1011
″
(2.569 mm)
0.1132
″ (2.875 mm)
0.1259
″
(3.199 mm)
0.1393
″
(3.539 mm)
0.1533
″ (3.895 mm)
0.1680
″
(4.267 mm)
0.1833
″
(4.655 mm)
0.1991
″ (5.058 mm)
0.2156
″
(5.477 mm)
0.2328
″ (5.912 mm)
3. Slowly turn the crankshaft clockwise until flowing fuel from the delivery holder is stopped. Check the piston position at this point. If the position is later than “Y” BTDC, use a thinner shim. If the position exceeds “Z” BTDC, use a thicker shim.
Changing the shim thickness by 0.004
″ (0.1 mm) will change the timing approximately one degree.
Adding shims decreases the angle, while subtracting shims increases the angle.
NOTE: When the shim is not needed, assemble by coating, using liquid sealant.
10-97
166
164
165
SECTION 10 - ENGINE
4. Verify that the timing mark on the crankshaft pulley is in line with the “TOP” mark on the timing scale. If the mark on the crankshaft pulley is not in line with the “TOP” mark, verify piston top-dead center with a dial indicator. If the pulley mark is slightly off, re-mark the pulley and proceed.
NOTE: Color the timing mark on the crankshaft pulley and appropriate marks on the timing scale to increase visibility.
5. Reinstall the valve spring, keepers, rocker arm assembly, and valve cover.
6. Shut off the fuel supply to the injection pump at the fuel filter.
7. Remove the No. 1 injection line from the No. 1 injector, 1.
8. Remove the lock screw, 2, and remove the injector locking plate, 3.
9. Remove the delivery valve piston, 1, from the No.
1 delivery valve.
3
2
1
167
168
1
169
10-98
SECTION 10 - ENGINE
10. Reinstall the spring and holder, 1, into the injection pump and tighten securely.
11. Fabricate a spill tube, 1, from a discarded injection line and install the tube on the No. 1 port on the injection pump.
12. Remove the fuel shut-off solenoid from the injection pump.
13. Rotate the crankshaft counterclockwise (viewed from the front of the engine) approximately 40 _ .
14. Turn on the fuel supply to the injection pump.
Fuel should flow out of the spill tube on the No.
1 cylinder port.
1
1
170
171
172
10-99
SECTION 10 - ENGINE
15. Rotate the crankshaft clockwise. When the timing mark on the crankshaft pulley, 1, is in line with the 21
_
(N844T) or 22
_
(N844) mark on the scale, 2, fuel should stop flowing from the spill tube.
16. If fuel does not stop flowing at the appropriate timing mark, the injection pump timing must be adjusted by adding or removing shims located between the injection pump and the engine block.
17. Adding shims will retard the pump timing and removing shims will advance the pump timing.
NOTE: A shim thickness of 0.1 mm (0.004 in.) will change the pump timing by approximately 1 _ .
18. Assemble the components that were removed from the engine and fuel system.
NOTE: Delivery holder tightening torques: 29 - 33 ft.
lbs. (39 - 45 N·m)
2 1
173
10-100
SECTION 10 - ENGINE
TURBOCHARGER - LS170 N844T ENGINE
The LS170 skid steer is equipped with the N844T turbocharged engine.
Specifications
ITEM
Turbocharger
Turbine
Blower
DESCRIPTION
Lubrication
Axial-flow turbine max. continuous permissible speed (RPM)
Centrifugal blower dry weight lbs. (kg)
SPECIFICATIONS
Pressure-fed from external source
180000
7.0 lbs. (3.2 kg)
TROUBLESHOOTING
TURBOCHARGER IS SLUGGISH IN PICKING UP SPEED
POSSIBLE CAUSE CORRECTION
Change oil (engine oil) The sealed part of turbine wheel is heavily carboned, causing the rotor to offer much resistance to turning.
Disassemble and clean
Incomplete fuel combustion in the engine, due to a faulty condition in the fuel injection system.
Disassemble and clean
Lack of lubrication during cold weather startup
Check the injection system for cause, and repair
Warm up below 1500 RPM for three minutes on startup and allow to run at low idle for one minute before shutdown
EXCESSIVE OR ABNORMAL VIBRATION
POSSIBLE CAUSE
A loose pipe connection at the turbine or blower side or at the bearing
Bearing failure causing the rotor to run rough
Turbine wheel or blower wheel has broken vanes caused by entry of metal or solid objects
Loss of dynamic balance in the rotor
Tighten and repair
CORRECTION
Disassemble and repair
Disassemble and repair damaged parts
Disassemble and repair damaged parts
10-101
SECTION 10 - ENGINE
DIRTY EXHAUST SMOKE
POSSIBLE CAUSE
Not enough intake air
The turbocharger is not running
Not enough gas pressure
CORRECTION
A clogged element in the air cleaner, clean or replace element
Closed air intake inlet, open inlet
Air leakage from a connection, check and repair
Gum or sludge formation in the turbine-side seal, causing the turbine to resist turning, Check the oil quality and change
Disassemble and clean
Seized bearings, disassemble and clean
Disassemble and repair
Oil temperature too high, change engine oil
Dynamic imbalance in the rotor, clean and/or replace rotor parts
Turbine wheel or blower wheel rubbing or broken, disassemble and repair(remove foreign matter, if any, and check air cleaner and engine to locate the cause).
Gas leakage through a connection on upstream side of turbine, check and repair
A large constriction in the exhaust line, due to distorted gas passages, check and repair
WHITE EXHAUST SMOKE
POSSIBLE CAUSE
Oil return pipe is clogged or distorted, causing the lube oil to leak into turbine and blower
Seal rings are abnormally worn or broken due to worn-down bearings
ABNORMALLY HIGH OIL CONSUMPTION
POSSIBLE CAUSE
Seal rings are abnormally worn or broken due to worn-down bearings
ENGINE LACKS OUTPUT POWER
POSSIBLE CAUSE
Gas leakage in the exhaust line
Air leakage in the blower outlet side, resulting in reduced boost pressure
A clogged element in the air cleaner
The turbocharger is internally fouled with foreign matter or its running parts are damaged
Repair or replace the pipe
Disassemble and repair
CORRECTION
Disassemble and repair
Check and repair
Check and repair
Clean or replace
CORRECTION
CORRECTION
Disassemble and repair or replace damaged parts
10-102
SECTION 10 - ENGINE
ABNORMAL RUNNING NOISE
POSSIBLE CAUSE
Restrictions in exhaust gas passage, particularly due to the nozzle ring approaching a clogged condition
Restrictions in the air outlet side of the blower, causing the air to surge at the blower wheel when the engine accelerates
The casing is being rubbed by turbine wheel or blower wheel
CORRECTION
Disassemble and clean
Disassemble and clean
Disassemble and repair or replace damaged parts
Turbocharger Lubrication
The turbocharger used on the Lx665 diesel engine may not receive adequate lubrication on cool/cold weather (below 5 ° C, 40 ° F) start-up, leading to turbocharger bearing failure.
The following procedure must be used to ensure adequate lubrication oil is supplied to the turbocharger bearings before high-speed engine operation:
1. Set the engine throttle at 1/3 speed.
2. Turn the ignition switch and allow the automatic glow plug timer to preheat the engine until the
EIC “beep” is heard.
3. Start the engine, but DO NOT OPERATE
ABOVE 1,500 RPM for three minutes to allow for adequate oil flow at the turbocharger.
After full load operation, allow the engine to run at low idle for one minute before engine shutdown.
Op. 10 250 30
TURBOCHARGER REMOVAL
1. To remove the turbocharger, first remove the muffler from the turbo adapter assembly at 1.
174
10-103
SECTION 10 - ENGINE
2. Remove the turbocharger oil pressure line, 1, at the block and at the turbo housing.
3. Remove the turbocharger oil return line, 1, at the top hose clamp, 2, and from the turbo assembly at 3.
4. Remove the turbocharger assembly and adapter from the exhaust manifold, 1, and support, 2.
175
176
177
10-104
SECTION 10 - ENGINE
Inspection Before Disassembly
Visually check the running clearances of the turbine and blower wheels for evidence of contact between the vanes and casing. Spin the rotor by hand to see if it rotates smoothly.
Check for turbine fin and housing clearance, intake and exhaust.
Check to ensure the rotor and shaft turns smoothly with no bearing roughness or binding.
Using a dial indicator, measure the end play movement of the turbine and shaft,1, by placing a dial indicator on the end of the shaft at 2.
End Play Movement
Standard: 0.001
″
- 0.002
″
(0.03 mm - 0.06 mm)
Allowable Limit: 0.0035
″
(0.09 mm)
Check the radial movement in the turbine shaft by placing a dial indicator through the oil outlet in the turbo housing at, 1. Move the right and left side of the turbine shaft toward the radial, 2, simultaneously and take a reading.
Radial Movement
Standard: 0.003
″
- 0.005
″
(0.08 mm - 0.13 mm)
Allowable Limit: 0.0067
″
(0.17 mm)
Disassembly
NOTE: Before separating the casings (turbine, bearing and blower), be sure to mark across each component and seam so they will be joined together in proper sequence.
1. Remove the waste gate controller assembly, 1.
This can be accomplished with compressed air of about 14 PSI (1 kgf/cm) applied to the control air inlet at 2.
178
179
180
10-105
SECTION 10 - ENGINE
2. Separate the blower housing, 1.
NOTE: Remove the housing carefully and be sure not to damage the blower vanes.
3. Remove the blower wheel, 1, by removing the shaft end nut, 2.
NOTE: The shaft end nut has left-hand screw threads; loosen it by turning clockwise.
4. Separate the turbine housing, 3.
5. Pull out the turbine shaft, 1.
NOTE: If the shaft will not come off easily, you may drive on the shaft end with a wooden mallet; be sure to lightly tap on the end of the shaft.
181
182
183
10-106
6. Remove the seal plate, 1.
SECTION 10 - ENGINE
7. Remove the thrust bearing, 1, and bushing, 2.
8. Remove the floating bearings, 3.
9. Remove the seal rings, 1, from the turbine shaft,
2, and oil slinger, 3.
184
185
186
10-107
SECTION 10 - ENGINE
Inspection
Before washing the disassembled parts clean, visually inspect each part thoroughly:
1. For carbon deposit.
– Turbine shaft, turbine-side seal ring , and back of turbine wheel, 1.
– Bearing casing, mating face of shield plate, and bearing casing bore, 2.
2. For effects of lubrication (wear, burning, sign of seizure).
– Shaft journal, thrust bushing, and oil slinger,
1.
– Floating bearings and thrust bearing, 2.
– Those portions of bearing casing bore holding the floating bearings, 3.
3. For oil leakage.
– Inner walls of turbine casing.
– Outer surface of bearing casing and mating face of shield plate.
– Seal-ring part of rotor shaft at turbine side, and back of turbine wheel.
– Back of blower wheel.
– Inner walls off blower casing.
– Seal plate surface and hole (for admitting seal rings).
187
188
189
10-108
SECTION 10 - ENGINE
Turbine Shaft
Item
1. Journal OD
Standard
Value
0.3146
″ -0.3149
″
(7.99-8.00 mm)
0.0492
″
-0.0504
″
(1.25-1.28 mm)
Service
Limit
0.3142
″
(7.98 mm)
0.0508
″
(1.29 mm)
2. Groove width in turbine-side seal ring
3. Sealing groove width, blower side
4. Groove width in blower-side seal ring
5. Shaft deflection
0.0480
″ -0.0484
″
(1.22-1.23 mm)
0.0516
″
(1.31 mm)
0.0402
0.0
″
″
-0.0405
(1.02-1.03 mm)
-0.0004
″
(0.0-0.01 mm)
″
0.0437
″
(1.11 mm)
0.00043
(0.011
mm)
″
Bearings and Associated Parts
Item
1. Floating bearing ID
2. Floating bearing OD
3. Bearing casing borediameter
Standard
Value
0.315
″ -0.316
″
(8.01-8.03 mm)
0.485
″ -0.4854
″
(12.32-12.33 mm)
0.488
″
-0.4886
″
(12.40-12.41 mm)
Service
Limit
0.3165
″
(8.04 mm)
0.4846
″
(12.31 mm)
0.48898
″
(12.42 mm)
Thrust Bearing
Item
1. Thrust bearing width
2. Groove width in thrust bushing
Standard
Value
0.157
″ -0.1578
″
(3.99-4.01 mm)
0.159
″ -0.1594
″
(4.04-4.05 mm)
Service
Limit
0.1567
″
(3.98 mm)
0.160
″
(4.07 mm)
190
191
192
10-109
SECTION 10 - ENGINE
Holes for Admitting Seal Ring
Item
1. Turbine-side hole diameter (bearing casing)
2. Blower-side hole diameter (in seal plate)
3. Blower-side hole diameter (in seal plate)
Standard
Value
0.590
″ -0.591
″
(15.00-15.02 mm)
Service
Limit
0.5925
″
(15.05 mm)
0.488
0.3937
″
″
-0.4889
-0.3945
″
(12.40-12.42 mm)
″
(10.00-10.02 mm)
0.4901
″
(12.45 mm)
0.3957
″
(10.05 mm)
Turbocharger Reassembly
Installing the Floating Bearings
Fit the R-shaped round snap ring to the bore in bearing casing, and then the floating bearing.
NOTE: When fitting the R-shaped snap ring, be sure to locate its ring gap in the manner shown.
Bring the rounded-edge side of the snap ring to the bearing side.
Oil the bearing just before fitting it, use engine oil.
Align the snap rings in relation to the lube oil inlet, 1.
For the ring closest to the turbine, 2, match the ring end as shown, 3. For the other snap rings, align as shown, 4.
Inserting the Shaft Into Bearing Casing
Insert the seal ring into the turbine shaft.
Attach the shield plate to the bearing casing.
Oil the shaft journal, and insert the shaft into the bearing casing.
NOTE: Insert the shaft slowly, taking care not to damage the floating bearings in the bore.
When installing the seal ring, align it to the shaft and insert it with its gap meeting the lube oil inlet.
2
3
193
4
194
195
10-110
SECTION 10 - ENGINE
Installing the Thrust Bearing
Run the thrust bushing onto the turbine shaft.
Oil the thrust bearing, and fit it to the bearing casing, securing it by tightening its retaining bolts to 87 - 94 ft. lbs. (118 - 127 N·m) torque.
Installing the Seal Plate
Insert seal rings, 1, into the oil slinger. The figure shows the seal rings as seen from the front end.
NOTE: Be sure to stagger the gaps of the seal rings relative to the position of the lube oil inlet, 2.
Apply the liquid gasket (THREE BOND) to the blower side face of the bearing casing on which the seal plate is to seat. Apply liquid gasket, 1, in a thickness of 0.2 mm (0.01
″ ). Keep the inner bore, 2, free of liquid gasket.
2
196
197
198
10-111
SECTION 10 - ENGINE
Insert the oil slinger,1, into the seal plate, 2. Fit the bearing case, 3, to the seal plate and secure with the retaining hardware. Tighten to 87 - 94 ft. lbs. (118 -
127 N·m).
3
1
2
Installing the Blower Wheel
Slide the wheel onto the turbine shaft, and retain it by running the shaft-end nut down the shaft end. Torque nut, 1, to 130 - 159 ft. lbs. (176 - 216 N·m).
199
200
Securing the Turbine Casing
Fit the turbine casing, 1, to the support, 2, bringing the previous aligning marks into alignment, and tighten the securing bolts to 91 - 99.8 in. lbs. (10.3 -
11.3 N·m) torque.
NOTE: Apply the antiseize compound to the thread of each hex-head bolt before installing into the casing.
201
10-112
SECTION 10 - ENGINE
Securing the Blower Casing to the Bearing
Casing
Fit the blower casing in the original angular position by aligning the marks, and secure it in place by tightening the bolts to 34.7 - 43.4 in. lbs. (3.9 - 4.9
N·m) torque.
NOTE: Apply the liquid gasket (THREE BOND) to the mating face, 1, of the bearing casing just before fitting the blower casing to it. The coat thickness of liquid gasket should be 0.004
- 0.008
(0.1 mm - 0.2 mm).
Installing the Waste Gate Controller Assembly
Install the assembly while applying compressed air of about 14 PSI(1kgf/cm) to the controller air inlet, 1.
Checking the Rotor for Movement
Measure the axial (end movement) and radial (up and down movement) of the rotor in the reassembled turbocharger, as described earlier in “Inspection
Before Disassembly.”
Make sure the movement readings are within the following specifications:
Axial movement of rotor - 0.001
″
- 0.0023
″
(0.03 mm
- 0.06 mm).
Radial movement of rotor - 0.003
″ - 0.005
″ (0.08 mm
- 0.13 mm).
NOTE: A movement reading not coming into the above specification means the turbocharger has been reassembled improperly and must be broken apart and rebuilt again.
Preliminary steps for installing the turbocharger on the engine:
Attach the turbocharger and adapter assembly to the exhaust manifold and support with the hardware previously removed.
10-113
202
203
SECTION 10 - ENGINE
Turbocharger Lubrication System
Oil the lubricated parts by pouring clean engine oil into the oil inlet and by rotating the turbine shaft by hand. This will wet the journal, floating bearings, thrust bearing, and other surfaces.
Thoroughly clean the oil inlet pipe and outlet pipe by flushing, making sure the pipes are absolutely free of foreign particles. Be sure the pipes have no restrictions due to denting or bending.
When installing the pipes between the turbocharger and engine, be sure to make each connection leak free.
Intake air system
Clean the parts conveying the intake air, making sure each part is absolutely free of foreign particles.
When connecting the turbocharger to the air cleaner and air duct tube, be sure that each joint is leak free.
204
10-114
After Turbocharger Service, Check the Exhaust
System
1. Make sure the exhaust gas passages are perfectly clean and free of foreign particles.
2. The bolts and nuts used on the joints of the exhaust line are of heat-resistant material; never use ordinary bolts and nuts instead of the heat-resistant hardware. Apply the antiseize compound to the threads of bolts and nuts just before installing them.
SECTION 10 - ENGINE
2. Reconnect wire to the fuel stop solenoid. Move the hand throttle lever to the low, 1/3- throttle position.
3. Operate the engine at no more than 1500 RPM for two to three minutes to insure lubrication oil is getting to the turbo.
NOTE: Listen to the turbocharger to be sure that it is running smoothly without making any abnormal noise.
Secure each connection good and tight, making it perfectly leak free.
Starting the turbocharger for the first time after reinstallation on the engine
1. Disconnect the wire to the fuel stop solenoid to insure that the engine will not start. Prime the lubrication circuit of the turbocharger by cranking the engine with the starting motor for ten seconds at a time. After the first ten seconds of cranking, pause for thirty seconds and then crank the engine again. Repeat the process until the oil warning lamp goes out.
NOTE: Cranking the engine longer than ten seconds at a time is very hard on the battery and may cause damage to the starter motor. Limit each cranking to ten seconds, and pause at least thirty seconds after each cranking to allow the starter motor to cool down.
4. Inspect the oil pipes and connections for any sign of oil leakage.
5. Operate the engine normally.
6. Stopping the engine, move the engine speed control lever to the low idle position. After full load operation, idle the engine for one minute to allow components to cool.
CAUTION
Never stop the engine when it is running at high speed. Doing so may cause serious engine damage.
The high operating speed of the turbocharger makes it essential that adequate lubrication is ensured when the engine is started.
10-115
SECTION 10 - ENGINE
MISCELLANEOUS ENGINE ELECTRICAL
Op. 55 201 76
GLOW PLUG
A sheathed-type glow plus is employed and provides excellent starting.
Specifications: 11 V; 9.0 A
1 Heat wire
2 Sheath
3 Asbestos
4 Body
5 Nut
6 Magnesium oxide powder
7 Insulation bushing
8 Core
6
1
19992987
2
Structure
Coiled thin heat wire is placed in the sintered magnesium oxide powder enclosed by stainless sheath. One end of the heat wire is welded to the sheath end and the other end to the central electrode. By setting the key switch to the run position, the glow plug preheats the air in the combustion chamber.
Disconnection of the Glow Plug
The glow plug operates even when any one of the plugs is disconnected because it is connected in parallel. However, when disconnected, preheating time of the glow signal is extremely extended.
Testing a Glow Plug
Check/remove the connector and check the continuity between each plug terminal and body ground. If continuity is not observed, it shows disconnection and the glow plug should be replaced.
The glow plug is of a simple structure and a short circuit is rarely caused. However, if the central electrode, body, sheath, etc. come in contact, wiring of the preheating circuit is burnt during start-up.
Correction: Remove the connector and measure the resistance of each plug terminal and ground with a tester. The tester reading should be 1.0
±
0.1.
Resistance of 0 indicates a short circuit.
3
4
5
7
8
205
10-116
SECTION 10 - ENGINE
Op. 55 414 12
OIL PRESSURE SWITCH
Oil Pressure Switch Operating Range:
2.8 PSI - 5.7 PSI (0.2 to 0.4 kg/cm
2
)
The oil pressure switch, 1, is a warning device to inform of low engine lubricating oil pressure. When oil pressure becomes less than specified, the warning light is activated.
This pressure switch houses a diaphragm and contact points (max. current draw is 0.42 amps).
Op. 10 223 10
FUEL SHUT-OFF SLOENOID
Engine stop solenoid is in the normal state if the plunger is drawn into the main body when one terminal is connected to battery +, 1, and the other terminal to the main body, 2.
1
206
2
207
10-117
SECTION 10 - ENGINE
MAXIMUM CIRCUIT RESISTANCE
RESISTANCE OF BATTERY CABLES 1, 2, & 3 NOT TO EXCEED 0.0018 OHM
19992989
208
* *
*
19992988
*Maximum current draw for oil pressure switch is
0.42 amps (5-watt max. bulb).
209
**Diode capacity: Current 3 amp. Reverse voltage
600 volt.
10-118
SPECIAL TOOLS
ENGINE
– FNH 00011 - Fitting - 1/8 BSPT x 7/16-20 UNF
–
–
SECTION 10 - ENGINE
Used to test engine oil pressure. Screws in in place of the engine oil pressure sender. Fits normal pressure test line connection.
FNH 00120 - Compression Test Adapter
Used to test engine compression. Screws into the glow plug hole, allows compression testing without removing injectors. Use with FNH 02020
Diesel Compression test kit or equivalent.
FNH 00122 - Compression Test Adapter
Right angle quick disconnect coupling. Use with
FNH 00120 and FNH 02020.
– FNH 00117 - Oil Pump Port Block Installer
Installs engine oil pump port block. Ensures part is installed straight, to the proper depth, with correct oil passage orientation and without damage.
– FNH 11097 - Oil Pump Port Block Remover
Removes engine oil pump port block without removing oil pan.
All of these tools are currently used on various
Compact Tractors and may already be in dealerships.
10-119
SECTION 10 - ENGINE
LABOR GUIDE
The following labor amounts are listed as a guide only. Working conditions and experience will vary the amount of time it actually takes to complete a job.
Op. 10 001 10
ENGINE REMOVAL FROM SKID STEER
Without tilting cab and boom forward. (3.0)
Includes removal of the oil cooler, radiator, oil filter, and air filter as an assembly.
Run engine and check for leaks.
Retighten head and reset valve clearances.
TOP OVERHAUL (CYLINDER HEAD OR
GASKET)
Remove cylinder head and gasket.
Tilting cab and boom forward. (3.5)
Includes fan removal and loosening of the engine fuse and relay panel.
Remove and replace. (0.5)
Includes draining cooling system, removal of hydrostatic pump attaching hardware. Unplugging electrical wire harness.
ENGINE OVERHAUL
MAJOR OVERHAUL (20.30)
Steam clean and completely dismantle, clean all parts, flush all oil and water passages and replace plugs, check crankshaft for size and wear and inspect all parts.
Remove all traces of jointing compound and old gasket.
Check cylinder head and reseat valves.
Fit new gasket and replace head. ( Do not use gasket cement with dry-type gasket).
Check injectors and service as necessary.
Tighten head and set valve clearances.
Run engine, check for leaks.
Retighten head and reset valve clearances.
Additional time - turbocharged engine.
Hone or replace liners or re-bore as required.
Replace or repair pistons with new rings.
Replace or repair where necessary camshaft and auxiliary drive bushings, main and big end bearings and thrust washers.
Inspect and replace timing gears as necessary.
Inspect and repair as required water pump, oil pump, turbocharger, and any cylinder head components.
Reassemble engine completely using new gaskets and seals and tighten to specifications. Set valve clearances. Run engine and check for leaks.
Retighten head and reset valve clearances.
MINOR OVERHAUL (14.30)
Steam clean engine, dismantle, clean and inspect parts.
Replace or repair pistons and check height. Hone liners, fit new main and big end bearings and thrust washers.
Check and rework/repair valves as necessary.
Completely reassemble and tighten to specification using new gaskets and seals.
OIL CONSUMPTION RECTIFICATION (7.30)
Remove cylinder head, lub. oil sump and oil pump.
Remove all pistons and connecting rods.
Deglaze all cylinder bores using “Flexihone” or similar tool (C.l. liners and bores only).
Clean and check pistons for wear, repairing as necessary and replace all piston rings.
Strip and clean cylinder head.
Reseat valves and service injectors.
Check condition of oil pump and repair if necessary.
Reassemble all parts using new gaskets and seals.
Set valve clearances and tighten head to specification.
Run engine and check for leaks.
Retighten head and reset valve clearances.
Additional time - turbocharged engine.
10-120
CYLINDER BLOCK
REPLACE BARE BLOCK (7.00)
CYLINDER HEAD
CYLINDER HEAD/COVER/CAMSHAFT
COVER
Remove and replace. (0.10)
Additional time - turbocharged engine.
SECTION 10 - ENGINE
Additional time - turbocharged engine.
Additional time - replace each valve seat insert as necessary. (0.10)
Steam clean complete engine, dismantle, clean and inspect all parts.
Reassemble engine complete into new bare blocks with same or new pistons, using new rings, main and big-end bearings and thrust washers, gaskets and seals, and tighten to correct specifications.
Run engine and check for leaks.
Retighten head and reset valve clearances.
Additional time - turbocharged engine.
Replace rear main lip-seals. (0.25)
(Additional operations may be added when justified).
VALVE SPRING
Change one-head not removed except for “B” engines, includes C6. (0.30)
Includes remove and replace cylinder head cover/camshaft cover.
Change complete set of valve springs-head not removed except for “B” engines, includes C6. (1.20)
Includes remove and replace cylinder head cover/camshaft cover.
PISTON ASSEMBLY
CONNECTING ROD
Replace one. (3.30)
Includes remove and replace cylinder head, fitting new gaskets, and sump and strainer, remove, clean and reassemble with new gaskets and replace.
Additional time - turbocharged engine.
SMALL END BUSHING
Remove, replace and ream one. (3.40)
Includes remove and replace connecting rod.
Additional time - turbocharged engine.
ROCKER SHAFT ASSEMBLY
Remove and replace. (1.10)
Includes remove and replace cylinder head cover/camshaft cover.
Dismantle and clean, fitting new levers where necessary. (2.10)
Includes remove and replace rockershaft assembly.
Check/adjust valve clearances. (0.40)
Includes remove and replace cylinder head cover/camshaft cover.
CYLINDER HEAD
Remove and replace, fitting new gasket(s). (2.30)
Includes remove and replace rocker shaft assembly and check/adjust valve clearances.
Additional time - turbocharged engine.
Remove, and either reseat and replace, or repair all valves. (3.30)
Includes remove and replace cylinder head, fitting new gaskets
Additional time - cut one valve seat. (0.10)
PISTON
Replace one, checking piston height. (3.30)
Includes remove and replace cylinder head, fitting new gaskets, and sump and strainer, remove, clean and reassemble with new gaskets and replace.
Additional time - turbocharged engine.
Replace all pistons, checking heights. (3.40)
Includes remove and replace cylinder head, fitting new gaskets, and sump and strainer, remove, clean and reassemble with new gaskets and replace.
Additional time - turbocharged engine.
Re-ring all pistons. (5.00)
Includes replace all pistons, checking heights, remove and replace cylinder head, fitting new gaskets, and sump and strainer, remove, clean and reassemble with new gaskets and replace.
Additional time - turbocharged engine.
10-121
CRANKSHAFT ASSEMBLY
REPLACE CRANKSHAFT (4.30)
SECTION 10 - ENGINE
Turn engine to “nip” push rod. Reset valve clearance.
Refit top cover.
Run engine and test.
“Pin check” only on “B” engines.
Includes replace rear main lip seal, replace damper and pulley, replace thrust washers, sump and strainer, remove, clean and reassemble with new gaskets and replace, and remove and replace flywheel and flywheel housing.
Replace damper and pulley, as a separate operation from crankshaft replacement. (0.10)
SUMP ASSEMBLY
SUMP AND STRAINER (0.30)
Remove, clean and reassemble with new gaskets and corks and replace.
THRUST WASHERS (3.50)
Replace.
Includes remove sump and strainer, remove, clean and reassemble with new gaskets and replace.
SUCTION PIPE (0.20)
Remove and replace (oil pump on bench).
OIL PUMP (1.10)
Remove and replace
Includes remove, clean and reassemble with new gaskets and corks and replace
(includes H3, F13 and F18 on “B” engines).
CAMSHAFT, TIMING CASE AND GEAR
ASSEMBLY
CAMSHAFT
Remove and replace. (1.10)
Includes remove and replace rocker shaft assembly, check/adjust valve clearances, remove sump and strainer, remove, clean and reassemble with new gaskets and replace.
Includes C24 and C5/1 on “B” engines.
RELIEF VALVE (0.10)
Strip, check, clean and reassemble.
(oil pump on bench).
TAPPETS
Remove and replace all. (2.40)
(includes G1, F5 on engine types E, G, H, L, T and
Z).
(includes C6 on engine types C and J).
(includes F5 on “B” engines).
FUEL SYSTEM
INJECTION PUMP (0.40)
Remove and replace.
Includes check and adjust fuel pump timing, and remove and replace high-pressure pipes.
INJECTION PUMP TIMING (1.10)
Check and adjust.
TIMING GEAR COVER
Remove and replace. (0.30)
Includes remove and replace damper and pulley.
GOVERNOR (0.40)
Adjust on running engine.
TIMING CASE FRONT SEAL
Remove and replace. (0.15)
Additional to remove and replace timing gear cover.
LEFT PUMP (ELECTRIC PUMP) (0.15)
Remove and replace.
VALVE TIMING CHECK (1.15)
Remove cylinder head cover. Set No. 1 inlet valve to specified clearance).
HIGH-PRESSURE PIPES
Remove and replace one. (0.05)
Remove and replace set. (0.20)
Bleed fuel system. (0.15)
10-122
INJECTOR
SECTION 10 - ENGINE
Remove and replace one. (0.10)
Includes remove and replace one high-pressure pipe.
Remove, test and replace all. (0.40)
Includes remove and replace set of high- pressure pipes.
FLYWHEEL AND FLYWHEEL HOUSING
(0.35)
Remove, replace and align.
Includes removal of engine from loader or hydrostatic pump removal.
THERMOSTAT UNIT (0.20)
Remove, check and replace.
Dismantle and clean one injector. (0.20)
Includes remove and replace one injector.
Dismantle and clean all injectors. (1.20)
Includes remove, test and replace all injectors.
FUEL FILTER ELEMENT (0.10)
Change.
Includes bleed the fuel system.
TURBOCHARGER (0.25)
Remove and replace.
STARTER RING (0.15)
Remove and replace.
Includes remove and replace flywheel and flywheel housing.
IN-LINE FUEL FILTER
Remove and replace. (0.10)
GLOW PLUGS (0.40)
Remove and replace set.
FUEL PUMP STOP SOLENOID (0.10)
Remove and replace.
STARTER SOLENOID (0.15)
Remove and replace.
FUEL TANK (1.0)
Remove and replace.
FAN (0.10)
Remove and replace.
FUEL LEVEL SENDER (TANK) (0.5)
Remove and replace.
FAN BELT (0.10)
Remove and replace.
FUEL PICKUP TUBE (0.5)
Remove and replace.
WATER PUMP (FRESH) (0.30)
Remove and replace.
FUEL LINES COMPLETE (0.5)
Remove and replace.
WATER PUMP (1.00)
Dismantle, clean, recondition and reassemble.
Includes water pump removal and replacement.
AUXILIARY EQUIPMENT
OIL FILTER (0.10)
Remove and replace.
RADIATOR (0.45)
Remove and replace.
10-123
SECTION 10 - ENGINE
10-124
SECTION 27 – REAR DRIVE AXLE (GEARBOXES)
Chapter 1 – Gearboxes
Section
CONTENTS
Description Page
27-1
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
Op. 27 000
GENERAL INFORMATION
The power is transmitted to the final drive from the engine which is connected to the hydrostatic pumps,
1, with a flex plate drive coupler. The hydrostatic pumps then transmit hydraulic power to the hydrostatic motors, 2, which are connected to gearboxes, 3, located on the inside of the final drive cases. The left and right drives are separate from each other and are operated independently.
2
3
19992569
The power is then transmitted through gears to a double drive sprocket, 1, in the final drive case. The drive sprocket is connected to the axle sprockets, 2, with chains, 3, one endless chain to the front axle and one endless chain to the rear axle.
1
1
2
The axle sprocket, 1, is splined to the axle shaft and hub assembly, 2. A large O ring, 3, seals the assembly to the frame.
3
27-2
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
The parking brake discs are connected to the hydrostatic motor coupler shafts at 1. The parking brake is made up of two discs, actuator shaft, pads, and control linkage. The hydrostatic system is the primary braking system, and the parking brake is used when the unit is stopped.
CAUTION
Always engage the parking brake before exiting the loader.
4
1 - HYDROSTATIC PUMP RH
2 - HYDROSTATIC PUMP LH
3 - HYDROSTATIC MOTOR RH
4 - HYDROSTATIC MOTOR LH
5 - GEARBOXES (2)
6 - FINAL DRIVE SPROCKET ASSEMBLIES (2)
7 - DRIVE CHAINS(FRONT AND REAR)(4)
8 - AXLE DRIVE SPROCKETS(4)
9 - AXLES ASSEMBLIES(4)
27-3
5
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
SPECIFICATIONS
Chain Case
Side Cover Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N·m (11 ft. lbs.)
Brake Caliper Mounting Bolt (center) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N·m (15 ft. lbs.)
Brake Caliper Mounting Bolts (outer) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 N·m (52 ft. lbs.)
Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #80
Front Chain Length (68 pitches)
Rear Chain Length (66 pitches)
Chain Tension
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1727.2 mm (68 ″ )
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1676.4 mm (66 ″ )
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 – 6 mm (0 - 1/4
″
) movement at tire tread
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 liters (2 gal.) each side - 10W-30API service SG-CE Oil
Gearbox
Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 N·m (125 ft. lbs.)
Drive Motor Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 N·m (63 ft. lbs.)
Brake Disc to Gearbox Shaft Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 N·m (26 ft. lbs.)
Front Cover Plate Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N·m (15 ft. lbs.)
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 liters (2 qts.) each side - 80W-90 API Service GL-5 Gear Oil
Other Materials
Description Use
Ultra/Blue Silicone sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearbox mounting bolts
Axle housing bolts
Chain case cover and bolts
Gearbox to chain case
Brake caliper bolts
Gearbox cover and bolts
Sealing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH Ultra Blue silicone sealer
NH #L81724 - 3.35-oz. tube (cord)
NH #L82519DS - 8-oz. tube
NH #L58775 - 10.2-oz. cartridge
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE10W-30 motor oil-API Service SG-CE
NH #9613313 - 1 qt.
NH #9613314 - 2 1/2 gal.
NH #9613358 - 1 L
NH #9613360 - 20 L
Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80W-90 API Service GL-5 Gear Oil
NH #9613295 - 1 qt.
NH #9613294 - 5 gal.
NH #9613375 - 4 L
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High viscosity lithium base
NH #9613310 tube
NOTE: Always use a noncorrosive silicone sealer to seal where required to prevent corrosion during the silicone curing process.
27-4
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
TROUBLESHOOTING
FINAL DRIVE SYSTEM
Before servicing or adjusting on the final drive system, the skid-steer loader should be jacked up with the wheels off the ground.
Remove any attachment from the skid-steer loader boom, bucket, etc. Lower the boom to the lowered position or, if servicing requires the boom to be in the raise position, support the boom on the boom locks.
Raise the boom and lower onto boom lock pins, 1.
1. Raise boom above boom lock pins.
2. Engage boom lock pins.
3. Stop engine, ignition key “OFF” position.
4. Turn ignition key to the “ON” position.
5. Lower boom onto boom lock pins.
6. Turn the ignition key to the “OFF” position.
CAUTION
Never exit the loader with the boom in the raised position unless the boom is supported on the boom lock pins.
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment mounted. always remove the attachment from the loader.
Jack up the loader and support the loader with the wheels off the ground using adequate jack stands or blocks to securely support the loader.
Support the loader at the front of the final drive cases at 1, and at the rear at 2.
CAUTION
Never service a raised loader unless it is securely supported with adequate jack stands or blocks.
6
7
27-5
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
FINAL DRIVE SYSTEM
PROBLEM
Both drive wheels on one side not powered
POSSIBLE CAUSES
No hydrostatic motor shaft rotation
No gearbox output drive
Broken drive chains
CORRECTION
Check for pump to motor oil flow and repair
Check gearbox shaft rotation and repair
Check chains and repair
One drive wheel not powered Broken drive chain
Axle or drive sprocket splines worn
Check chain and repair
Check axle and sprocket, replace
Chain case noise
Excessive axle play
Noise in gearbox
Axle outer bearing failure
Loose drive chains
No oil in final drive
Worn drive sprockets
Bearing failure
Bearing failure on axle shaft
Snap ring failure on axle shaft
Check and adjust chains
Check oil level
Check sprockets and repair
Check axle and gearbox bearings and repair
Check bearings and repair
Check axle bearing pre-load, repair
No or low oil in gearbox
Bearing failure
Bearing or shaft failure in drive motor
Gears in gearbox worn
Check oil level
Check shafts and bearings, repair
Check drive motor and repair
Check and replace
Prolonged operation in liquid or semi-liquid material
Decrease lubrication interval to every 500 hours
27-6
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
TESTING
Pre-test instructions:
* Operator in seat with seat belt buckled.
* Engine running at high idle (full throttle).
* Park brake disengaged position.
STEP
1
2
3
TEST
Push both drive controls forward equally and loader should move in a straight line.
Pull both drive controls rearward equally and loader should move in a straight line.
RESULT PROBABLE CAUSE AND CORRECTION
YES Drive system OK.
NO
YES
NO
Engine stalls, wheels appear locked, check parking brake for engaged. If OK go to step 2.
Slow or no power, Refer to hydrostatic drive section.
Check final drive chain, broken repair.
Drive system OK.
Engine stalls, wheels appear locked, go to step 1.
Wheels rotate slow or no power, go to step 1.
One side of loader drags, go to step 2.
Pre-test instructions:
* Lower boom and attachment to the ground.
* Stop engine.
* Jack loader with wheels off the ground.
* Release parking brake.
STEP
1
2
3
4
TEST
Rotate each tire by hand, tires move less than 1/4
″
at tread.
Tires rotate but are noisy.
RESULT PROBABLE CAUSE AND CORRECTION
YES
NO
YES
Drive system OK.
Tires move more than 1/4 ″ at tread, check chain tension.
One tire rotates freely, broken chain, or axle spline worn.
Both tires on one side rotate freely together, inspect drive gearboxes. If OK, check drive motor.
Check drive chains, axle bearings.
NO Drive system OK.
27-7
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
Op. 27 126
GEARBOXES
Op. 27 126 40
REMOVAL AND INSPECTION
The hydrostatic motor is connected to the gearbox and the gears in the gearbox transmit power to the final drive chains.
The boom and cab may be tilted forward for gearbox access. Refer to Section 00 of this manual for the
“Tilting the Cab and Boom Procedure.”
Gearbox Removal Without Tilting the Cab
The seat will need to be raised, step shield and hydrostatic control lever assemblies removed. The axle housing assemblies will require loosening and the final drive case cover will need to be removed to access the gearboxes.
1. Lower the boom and attachment to the ground.
2. If the work is going to be done with the boom in the raised position, remove the attachment and raise the boom and rest on the boom lock pins,
1.
CAUTION
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment. Always remove the attachment from the loader.
3. Securely block the skid-steer loader with all four wheels off the ground. Refer to Section 1 for more detailed information on properly supporting the skid-steer loader. Support the loader at the front of the final drive cases at 1, and at the rear at 2.
CAUTION
Failure to securely support the skid steer could result in movement of the loader causing serious injury or damage to the equipment.
8
9
27-8
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
4. Slide the seat to the rearmost position, unlatch the seat pan, and raise the seat and pan assembly to the raised latched position, 1.
CAUTION
Before working under a raised seat make sure it is securely latched in the raised position.
5. Remove the step shield, 2.
10
6. Remove the hydrostatic control lever assemblies, 1, to access the gearboxes.
– Remove the linkage at 2.
– Unhook electrical wires, horn, high flow switch, etc.
– Unhook control linkage to the auxiliary or boom and bucket control at 3.
– Remove the support retaining hardware, 4, and lift the control lever assemblies from the loader.
4
19992568
3
1
2
1
3
7. Remove the tires and wheels from the final drive being serviced.
8. Clean the axle and final drive area to prevent debris from entering the final drive case.
9. Loosen the axle retaining hardware, 1, and remove the axles.
10. Remove the fender and retaining bolts, 2.
11. Remove final drive inspection cover, 3.
4
11
12
27-9
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
12. Remove the drive chains from the double drive sprocket, 1.
13. Parking brake engaged, remove the brake disc retaining bolt and washer, 2.
14. Release the parking brake.
15. Loosen the caliper retaining hardware, 3, from the inside of the cab. Thread the two bolts from the outside caliper assembly, 4. DO NOT remove bolts from caliper support at this time.
16. Remove the outside disc, 5.
17. Remove center section of caliper, 1, spacers, 2, and now remove the retaining bolts.
18. Remove inside disc, 3.
13
14
19. Remove brake friction puck, 1, and spacer plate,
2.
NOTE: The spacer plate is thinner than the friction puck and must be inserted into brake caliper first upon reassembly.
15
27-10
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
20. Remove the hydrostatic motor retaining hardware, 1.
NOTE: For clearance, the high pressure lines may require removal. If lines are removed, cap lines and fittings to prevent loss of oil and contamination of the hydrostatic system.
21. Install a flat bearing puller in the groove in the motor coupler at 1. Install a bolt in the end of the motor shaft at 2. Attach another puller to the flat puller and push the hydrostatic motor loose from the coupler. Remove the motor from the gearbox.
NOTE: The motor shaft and the coupler have tapered splines.
IMPORTANT: DO NOT drive on the motor shaft with a hammer to remove the motor from the coupler or internal damage to the motor may occur.
22. Remove the gearbox mounting hardware, 1; this will allow the gearbox oil to drain into the final drive case. Remove the remaining bolts, 2, from the final drive case and gearbox.
23. With a suitable hoist, lift the gearbox from the loader.
CAUTION
The gearbox is heavy and a suitable hoist/lift should be used.
The gearbox is heavy and a suitable hoist/lift should be used.
16
17
18
27-11
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
Op. 27 126 48
DISASSEMBLY
1. Thoroughly clean the gearbox.
2. Remove the cover, 1.
3. Remove the shaft cover, 2, by prying it from the gearbox housing.
4. Remove the gearbox breather, 3.
5. Remove the external snap ring, 1.
19
20
6. Place the gearbox in a press, support the gearbox housing next to the sprocket and shaft assembly at 1 as close as possible and press the shaft assembly, 2, from the snap ring side of gearbox and shaft.
The shaft sprocket and sealed bearing, 3, will come from the gearbox as an assembly.
7. Remove the two bearings from the housing.
8. Remove the spacer.
9. Remove the large gear, 4, from the housing.
10. Remove the small gear and shaft assembly from the gearbox.
21
27-12
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
11. Remove the external snap ring, 1, from the shaft.
With a bearing separator puller, remove the small sealed bearing, 2, from the shaft.
12. With a bearing separator puller, remove the large sealed bearing, 3, from the shaft and sprocket assembly.
Gearbox and Related Parts
Ref.
Description
1 Gearbox housing
2 Small gear and shaft
3 Small sealed bearing
4 Retaining ring
5 Drive sprocket and shaft assembly
6 Large sealed bearing
7 Spacer
8 Bearing (no seals)
9 Retaining ring
10 Cover
11 Breather
12 Gear
13 Cover
14 Fill and check plug
PARTS INSPECTION
1. Thoroughly clean all parts of old sealant, oil, etc., before inspection.
2. Examine the shaft bearing surfaces for wear.
3. Check the shaft splines for wear.
4. Check the operation of the gearbox breather.
5. Check the gearbox housing for any cracks, etc., as a result of pressing shaft out.
22
23
27-13
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
6. Inspect the gearbox housing bearing areas for severe wear.
NOTE: The bearings, 1, are a hand press fit into the housing, not an interference fit.
7. Examine the mounting bolt threads for damage to prevent secure gearbox retention.
REASSEMBLY
1. Press the small sealed bearing, 1, onto shaft and gear assembly.
2. Install external snap ring, 2, making sure it is seated properly in groove.
3. Press the large sealed bearing, 3, onto sprocket and shaft assembly.
NOTE: The bearings are sealed on both sides, so bearings can be installed with either side up.
4. Place the motor coupler shaft and gear assembly, 1, into housing.
Thoroughly clean the bearing surface, 2, and outer surface of the large sealed bearing with
Loctite cleaner.
24
25
26
27-14
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
5. Insert the large gear, 1, into the gearbox; note the gear will fit only one way.
6. Put a bead of medium-strength Loctite around the outer surface of the bearing at 1, between the bearing race and gearbox surface.
7. Slide the sprocket, shaft and bearing assembly,
3, into the gearbox, aligning shaft splines with gear splines.
8. Place the shaft spacer, 1, recess side towards the gear. Place the spacer over the end of the splines on the shaft. The tapered side of the spacer, 2, should be to the outside of the gearbox housing.
27
28
9. Place the unsealed bearing, 1, over the end of the shaft.
10. Install the large external snap ring, 2, in groove on shaft, making sure it is properly seated into the groove.
29
27-15
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
11. Put a bead of noncorrosive silicone sealer around the outer lip of the shaft cover, 2, and place the cover in the gearbox on the unsealed bearing side of the gearbox. Tap the cover with a hammer to seat in the gearbox.
12. Put a bead of noncorrosive silicone sealer around the end of the gearbox and install the cover, 1. Tighten hardware to 20 N·m (15 ft. lbs.).
13. Reinstall the gearbox breather, 3, if removed.
NOTE: The breather, 4, must be a breather with a spring-loaded center pin, part #572820.
Op. 27 126 40
REINSTALLATION
1. Clean the mating surfaces of the final drive case and hydrostatic motor. Clean the oil, etc., from the final drive case.
2. Put a bead of noncorrosive silicone sealer around the bearings at 1 and the mounting holes,
2.
3. Using a hoist, place the gearbox assembly back into the loader.
4. Position the gearbox against the final drive case, put a bead of noncorrosive silicone sealer around the heads and the threads of the retaining bolts,
1. Install the retaining bolts and torque to 170
N·m (125 ft. lbs.).
30
31
32
27-16
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
5. Put a bead of noncorrosive silicone sealer around the flange of the hydrostatic motor. Align the motor splines with coupler splines and place motor shaft into coupler. Install the motor retaining bolts, 1, and torque to 85 N·m (63 ft.
lbs.).
IMPORTANT: DO NOT force the hydrostatic motor shaft into the coupler. If the splines are not aligned, damage to the motor housing may occur.
6. Reconnect the high pressure lines, if removed.
7. Fill the gearboxes with 80/90 gear oil to the proper level at check plug, 2.
8. Reinstall the hydrostatic control assemblies, 1, and connect all linkages, 2 and 3, and electrical connections removed. Tighten the support retaining hardware, 4, securely.
1
2
1
4
19992568
3 3
Reassemble the Parking Brake
9. Install the spacer plate, 2, next to the end of shaft, then the brake friction puck, 1.
4
33
34
35
27-17
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
10. Install the inside brake disc, 1, onto splined motor coupler shaft.
11. Put a bead of silicone sealer around the caliper retaining bolts and insert in support.
12. Slide the spacers, 2, and center of caliper, 3, over bolts.
13. Install outer brake disc, 5, on motor shaft.
14. Thread caliper retaining bolts, 3, into outer section, 4, of caliper and tighten to 70 N·m (52 ft.
lbs.). Check the center section of the caliper to insure it is free to move.
15. Put a bead of sealer on end of motor coupler.
Install the brake disc retaining bolt and large flat washer at 2. Tighten to 35 N·m (26 ft. lbs.).
16. Reinstall the drive chains over the drive sprocket,
1.
17. Install the final drive axles. Slide each axle assembly to tighten the drive chain to obtain a movement of 0 - 6 mm (0 - 1/4
″
) movement at the outer tire tread.
Tighten the retaining bolts, 1, to 190 N·m (140 ft.
lbs.).
18. Reseal and install the final drive cover, 2.
19. Check the final drive case oil level at 3, and add as required.
20. Reinstall all shields (step, fenders, tires, etc.) removed for the repair.
21. Remove the loader from the blocking.
36
37
3
2
38
27-18
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
LABOR GUIDE
The following labor amounts are listed as a guide only. Working conditions and experience will vary the time the job actually takes to complete each job.
Hours Job Description
Gearbox
Remove and replace
Rebuild
2.0 hrs.
1.5 hrs.
27-19
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
27-20
SECTION 29 - HYDROSTATIC TRANSMISSION
Chapter 1 - Neutralizer, Pumps, Motors
CONTENTS
Section
Description Page
Start-up Procedure After Rebuild (After Pump or Motor Replacement) . . . . . . . . . . . . 29-88
29-1
SECTION 29 - HYDROSTATIC TRANSMISSION
Left Control Handle With No Boom Hand Control Reassembly . . . . . . . . . . . . . . . . . . . 29-98
Right Control Handle With Auxiliary or Bucket Control Disassembly . . . . . . . . . . . . . 29-107
29-2
SECTION 29 - HYDROSTATIC TRANSMISSION
Op. 29 100
GENERAL INFORMATION
The hydrostatic system provides a means to transfer power from the engine to the final drive for the wheels. It provides infinitely variable speed forward and reverse and steering of the skid steer.
The hydrostatic pumps receive power from the engine through a flex plate drive. The pumps transfer hydraulic power to the motors and then through gearboxes to the final drives, axles, and wheels.
The hydrostatic pumps are controlled separately from each other and power each side independently.
OPERATION
The hydrostatic system is a closed loop fluid power system that provides smooth transition of power from the engine to the wheels. The hydrostatic system is made up of two piston pumps, 1, and two piston motors, 2. The hydrostatic charge system is a back pressure valve in the hydraulic system return line located in the engine compartment. This provides replenishing oil for the oil that is lost due to leakage for lubrication and cooling purposes.
Steering is controlled by two hand levers, 3, located in the operators cab. These hand levers control direction forward and reverse and amount of oil flow for speed of the skid steer by rotation of the pump cam plates in the individual pumps. The further the control levers are pushed from neutral the greater the cam plate angle. More oil is pumped to the motors increasing the wheel speed. The greatest wheel torque is when the control levers are closer to neutral. When operating the skid steer, more power
(torque) is available by destroking the control levers, thus increasing the loader efficiency.
3
19992568
2
1
2
3
1
29-3
SECTION 29 - HYDROSTATIC TRANSMISSION
13
3
2
12
10 9
4
13
11
1
13
7 6
8
5
4
19997771
The hydrostatic system consists of the following components:
1. Hydraulic reservoir - Right front of engine compartment
2. Suction line - From reservoir to the gear pump under the operator’s seat.
3. Pressure line - From the gear pump to the control valve under the operator’s seat.
4. Return line - From control valve to oil cooler.
5. Oil cooler - Engine side of radiator in engine compartment.
6. Oil filter - After the oil cooler engine compartment rear door.
7. Charge check valve - In return line between oil filter and reservoir.
2
8. Hydrostatic transmission charge line - From the charge check valve to the hydrostatic pumps under the operator’s seat.
9. Hydrostatic pump for left drive - Under operator’s seat.
10. Hydrostatic pump for right drive - Under operator’s seat.
11. Hydrostatic motor for left drive - Under operator’s seat.
12. Hydrostatic motor for right drive - Under operator’s seat.
13. Hydrostatic system case drain line - From pumps and motors to the hydraulic reservoir.
29-4
SECTION 29 - HYDROSTATIC TRANSMISSION
SPECIFICATIONS
HYDROSTATIC PUMPS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Displacement Piston Pump
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.3 L/min (21.47 GPM) @ 2000 RPM
Pressure Relief Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 bar (3500 PSI)
Minimum Pump Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80%
Maximum Pump Case Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 L/min (1.5 GPM) per pump
Maximum Pump Case Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 bar (25 PSI)
HYDROSTATIC MOTORS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Torque Axial Piston Motors
Minimum Motor Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80%
Maximum Motor Case Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 L/min (1.5 GPM) per motor
Maximum Motor Case Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 bar (25 PSI)
CHARGE PRESSURE SYSTEM
Back Pressure Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.0 - 11.7 bar (160 - 170 PSI)
OIL REQUIREMENTS
Type and Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE SH/CG4 10W-30
TORQUE SPECIFICATIONS
Pump Seal Cover Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 N·m (48 in. lbs.)
Pump Relief Valve Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 N·m (100 ft. lbs.)
Pump Valve Plate Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N·m (29 ft. lbs.)
Pump to Pump Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 N·m (57 ft. lbs.)
Motor Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 N·m (75 ft. lbs.)
Motor Valve Plate Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N·m (17 ft. lbs.)
Flywheel Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 N·m (45 ft. lbs.)
OTHER MATERIALS
Sealing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH Ultra Blue silicone sealer
NH #L81724 - 3.35 oz. tube (cord)
NH #L82519DS - 8 oz. tube
NH #L58775 - 10.2 oz. cartridge
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE10W-30 motor oil-API Service SH/CG4
NH #9613313 - 1 qt.
NH #9613314 - 2 1/2 gal.
NH #9613358 - 1 L
NH #9613360 - 20 L
NOTE: Always use a noncorrosive silicone sealer to prevent damage to the components being sealed during the silicone curing process.
29-5
SECTION 29 - HYDROSTATIC TRANSMISSION
Op. 29 100 01
TROUBLESHOOTING
When performing tests on the hydrostatic system, use the proper test procedures and test equipment.
Before testing, lower the attachment to the ground or remove attachment from the loader.
If testing is to be performed with a raised boom, make sure the boom is raised above and resting on the boom lock pins, attachment removed.
Before opening the hydraulic system, clean the area thoroughly to prevent contaminating the system.
Before opening the hydraulic system, relieve all pressure from the system.
Before testing the hydrostatic system, check the hydraulic oil level.
Before testing the hydrostatic system, the oil must be at normal operating temperature.
If testing requires the skid steer to be raised, use adequate blocking and/or jack stands to securely support the loader.
CAUTION
When connecting test equipment into the hydrostatic system, relieve the pressure in the system. Stop the engine, with seat belt fastened turn the ignition switch to the “on” position and operate all hydraulic control valve circuits to relieve pressure. Turn the ignition switch to the
“off” position.
WARNING
Gauges, gauge fittings, and hoses must have operating pressure ratings of at least 25% higher than the highest pressures of the system.
Never adjust or replace the relief valves to get higher pressures than those specified by the equipment manufacturer.
Fluid under pressure can have sufficient force to penetrate the skin, causing serious personal injury. Always protect the skin and eyes from escaping fluid under pressure.
Before disconnecting lines or fittings, be sure to turn off the skid loader engine and relieve all pressure. Before applying pressure to the system, be sure all connections are tight and that lines, pipes, and hoses are not damaged.
If injured by escaping fluid, obtain medical assistance at once. Serious infection or reaction can develop if medical treatment is not administered immediately.
Remove any attachment from the mounting plate before loosening or disconnecting any hydraulic lines.
CAUTION
Use adequate blocking and/or jack stands to insure that the loader is safely supported with all four wheels off the ground.
29-6
PROBLEM
SECTION 29 - HYDROSTATIC TRANSMISSION
POSSIBLE CAUSE CORRECTION
Low hydraulic oil
Low charge pressure
Incorrect oil
Check oil level
Check charge pressure/repair
Drain and replenish with proper oil
Air in system
Water in system
Purge air and repair system
Drain, clean, and replace oil
Output pressure too low Check pressure/replace relief valve
Internal pump or motor damaged Check pump/motor case drain flow
Linkages loose or broken Check and repair
One side moves, other side does Relief valve stuck open Check and repair
Noisy pump or motor
Broken drive chain
Gearbox damaged
Air in system
Wrong kind of oil
Water in system
Internal pump or motor damaged
Check and repair
Check and repair
Purge air and repair system
Drain, clean system and replace oil
Drain, clean, and replace oil
Check pump/motor case drain flow
Low power Low hydraulic oil
Low charge pressure
Relief valve stuck open
Air in system
Check oil level
Check charge pressure/repair
Check and repair
Purge air and repair system
Sluggish response to changes in
Internal pump or motor damaged Check pump/motor case drain flow
Relief valve stuck open Check and repair operating
Drain, clean system and replace oil Wrong kind of oil
29-7
SECTION 29 - HYDROSTATIC TRANSMISSION
HYDROSTATIC DRIVE SYSTEM TESTING
Hand controls - forward and reverse
Pretest instructions:
*Operator in seat
*Seat belt buckled
*Service/Run switch in “RUN” position
*Key switch in the “OFF” position
STEP
1
2
3
TEST
Levers should move freely
Stroke both levers forward or reverse, the levers should return to neutral position
Stroke both levers forward or reverse and release one lever, both levers should stay in direction stroked
RESULT
NO
YES
YES
NO
YES
NO
PROBABLE CAUSE AND CORRECTION
Check control linkage from levers to the pumps.
System OK
System OK
Check neutralizer system for binding or adjustment.
System OK
Check neutralizer system for binding or adjustment
Hand controls - forward and reverse
Pretest instructions:
*Operator in seat
*Seat belt buckled
*Service/Run switch in “RUN” position
*Parking brake disengaged
*Key switch in the “RUN” position
*Engine operating at low idle speed
STEP
1
2
TEST
Control levers in neutral, unit should not move
Stroke both levers forward or reverse, unit should accelerate smoothly
3
RESULT
YES
NO
YES
NO
4
5
6
7
8
9
10
Control levers in neutral park brake engaged, pumps should be quiet
Control levers in full forward, machine should go in straight line
YES
NO
YES
NO
PROBABLE CAUSE AND CORRECTION
System OK
Check and adjust for neutral
System OK
Check for loose or damaged control linkage, if
OK go to next step.
Check hydraulic oil level and add as required, if
OK go to next step.
Check hydrostatic hoses, tubing, and connections for leaks, if OK go to next step.
Check parking brake for being engaged or adjustment, if OK go to next step.
Check hydrostatic charge pressure, if OK go to next step.
Check forward or reverse relief valve operation and pressure settings.
Control System OK
Check and adjust for neutral, if OK go to next step.
Check for loose or damaged control linkage, if
OK go to next step.
Control System OK
Reset control lever stops
29-8
SECTION 29 - HYDROSTATIC TRANSMISSION
Before performing any hydraulic test, operate the skid steer to get the hydraulic oil to operating temperature (about 38 ° C or 100 ° F above ambient temperature).
For access to hydrostatic testing, remove any attachment from the loader attaching face plate and support the boom on the lockpins.
1. Raise the boom, extend the boom lockpins, 1, and lower the boom down on the lockpins.
2. Stop the engine, turn the ignition key to the run position, and operate the boom and bucket control pedals to relieve pressure in the cylinders. Turn off the key.
3. Raise and support the skid steer with all four wheels off the ground. Support the front of the loader at 1 to the front of the final drive case and at 2 to the rear of the case.
CAUTION
Failure to securely support the skid steer could result in movement of the loader during testing causing serious injury or damage to the equipment.
4. Put the “SERVICE/RUN” switch, 1, in the
“SERVICE” position.
1
3
4
5
29-9
SECTION 29 - HYDROSTATIC TRANSMISSION
5. Raise the operator’s seat and latch in the raised position, 1.
CAUTION
Never work under a raised seat unless it is securely latched in the raised position.
6. Check the hydraulic oil level and add, if required, to proper level.
WARNING
Gauges, gauge fittings, and hoses must have operating pressure ratings of at least 25% higher than the highest pressures of the system.
Never adjust or replace the relief valves to get higher pressures than those specified by the equipment manufacturer.
Fluid under pressure can have sufficient force to penetrate the skin, causing serious personal injury. Always protect the skin and eyes from escaping fluid under pressure.
Before disconnecting lines or fittings, be sure to turn off the skid loader engine and relieve all pressure. Before applying pressure to the system, be sure all connections are tight and that lines, pipes, and hoses are not damaged.
If injured by escaping fluid, obtain medical assistance at once. Serious infection or reaction can develop if medical treatment is not administered immediately.
Remove any attachment from the mounting plate before loosening or disconnecting any hydraulic lines.
6
29-10
SECTION 29 - HYDROSTATIC TRANSMISSION
6
5
4 1
5
2
3
2
19997776
HYDROSTATIC SYSTEM OIL FLOW
Hydrostatic Pumps and Motors High- Pressure
Flow
The hydrostatic pumps are driven by the engine through a flex plate drive coupler.
The rear hydrostatic pump, 1, supplies highpressure oil through high-pressure lines, 2, to the left hydrostatic motor, 3, when the left forward/reverse control lever is stroked in either direction.
The front hydrostatic pump, 4, supplies highpressure oil through high-pressure lines, 5, to the
7 right hydrostatic motor, 6, when the right forward/reverse control lever is stroked in either direction.
The hydrostatic system is protected by four highpressure relief valves, two each pump, one for forward and one for reverse. All four high- pressure relief valves are the same and factory set at 238 bar
(3500 PSI). Do not try changing the pressure setting of these relief valves. If during testing the relief valves are found to be incorrectly set, replace the complete valve cartridge.
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SECTION 29 - HYDROSTATIC TRANSMISSION
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19997777
Hydrostatic Pump and Motor Charge Pressure
Oil Flow
During the operation of the hydrostatic pumps and motors, oil from the high-pressure system is used for lubrication of the internal rotating parts of the pumps and motors. The lubrication oil drains into the pump and motor housings.
8
A charge check valve in the return line after the filter at 1, builds backpressure in the return circuit and forces oil through the charge line, 2, into the hydrostatic pump back plate at 3. This charge oil provides replacement oil in the high-pressure circuits that was used for lubrication purposes.
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SECTION 29 - HYDROSTATIC TRANSMISSION
1
1
3
2
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19997778
Hydrostatic Pump and Motor Case Drain Flow
During operation of the hydrostatic pumps and motors, oil from the high-pressure circuit used for lubrication oil drains into the pump and motor housings.
The lubrication oil will fill the housings approximately half full. This oil then becomes cooling oil and will
9 drain from the pumps and motor housings (cases) through drain lines, 1.
The front hydrostatic pump drains internally to the rear pump at 2. The oil will drain from the rear pump and tees into the drain line from the motors. The case drain oil returns to the hydraulic reservoir, 3.
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SECTION 29 - HYDROSTATIC TRANSMISSION
HYDROSTATIC CHARGE SYSTEM
PRESSURE TEST
Hydrostatic charge pressure oil is the return oil from the boom, bucket, and auxiliary hydraulic circuits from the return side of the control valve. This oil is required for replenishing oil to the hydrostatic system for lubrication and cooling of the hydrostatic pumps and motors.
IMPORTANT: Do not change the route of the return oil from the main control valve or the hydrostatic system may be damaged.
The charge pressure can be checked at the test port,
1, near the charge check valve, 2.
The charge system pressure is factory set. Changes to the settings should not be necessary. The charge check relief valve is located at 2. If there is some reason to suspect incorrect pressure, check the pressure as follows:
Checking Charge System Pressure
Fittings and gauge required:
1. 22 bar (300 PSI) gauge (minimum)
2. 1/8 ″ pipe to gauge
Test Procedure
1. Raise the boom and rest on the boom locks.
2. Put the “SERVICE/RUN” switch in the
“SERVICE” position.
3. Disengage the parking brake.
4. Securely block the skid steer with all four wheels off the ground. Support the front of the loader at
1, to the front of the final drive case and at 2, to the rear of the case.
CAUTION
Failure to securely support the skid steer could result in movement of the loader during testing causing serious injury or damage to the equipment.
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11
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SECTION 29 - HYDROSTATIC TRANSMISSION
5. Remove the right engine side shield to access the charge check valve and test port.
6. Install the pressure test gauge in the test port at
1.
IMPORTANT: Check the hydraulic oil level and add if required to insure sufficient oil for the test.
7. Start the engine and run it at full throttle (3070 -
3150 RPM) and take a pressure reading,11.0 -
11.7 bar (160 - 170 PSI).
8. Operate the hydrostatic control levers in forward and reverse until the system bypasses and take a pressure reading. Return the controls to neutral. The pressure should be 10.3 - 11.7 bar
(150 - 170 PSI).
CAUTION
Always stay clear of moving parts during testing or serious injury could occur.
9. The check valve is not adjustable. Replace the check valve, 2, if the pressure is not within specifications in step 7. If the pressure is not correct in step 8, further testing is required, refer to pump case drain testing.
HYDROSTATIC PUMP CASE DRAIN TEST
The hydrostatic pump drain oil can be checked by a pressure test and/or oil flow drain test.
Pump Case Pressure Test Procedure
1. Raise the boom and rest on the boom locks.
2. Put the Service/Run switch in the “SERVICE” position.
3. Engage the parking brake.
4. Securely block the skid steer with all four wheels off the ground.
CAUTION
Failure to securely support the skid steer could result in movement of the loader during testing causing serious injury or damage to the equipment.
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SECTION 29 - HYDROSTATIC TRANSMISSION
5. Raise the operator’s seat and latch in the raised position, 1.
CAUTION
Never work under a raised seat unless it is securely latched in the raised position.
6. Remove the step shield to access the hydrostatic pumps and motors.
1
7. To check the pump case pressure, tee in a 7 bar
(100 PSI) gauge at the pump drain line, 1. The tee must be at the drain port of the pump housing not in the combined line from the motors.
NOTE: The front pump drains internally to the rear pump so the oil from this pump drain line will be oil from both pumps.
IMPORTANT: Check the hydraulic oil level and add if required to insure sufficient oil for the test.
8. Start the engine and run it at full throttle
(3070 - 3150 RPM) and take a reading, 0 - 41.2
kPa (0 - 6 PSI) allowable range.
9. Stroke the hydrostatic control levers forward and reverse and take a pressure reading in both directions; the pressure should not exceed 172 kPa (25 PSI). If the pressure exceeds 172 kPa
(25 PSI) there is excessive leakage from the forward and/or reverse high pressure loops. If the pressure is within specifications, the problem may be in the motors.
CAUTION
Always stay clear of moving parts during testing or serious injury could occur.
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15
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SECTION 29 - HYDROSTATIC TRANSMISSION
Pump Case Drain (Oil Flow) Test Procedure
1. Raise the boom and rest on the boom locks.
2. Put the Service/Run switch in the “SERVICE” position.
3. Engage the parking brake.
4. Securely block the skid steer with all four wheels off the ground.
CAUTION
Failure to securely support the skid steer could result in movement of the loader during testing causing serious injury or damage to the equipment.
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19992569
5. Raise the operator’s seat and latch in the raised position.
6. Remove the step shield.
7. Remove the pump case drain line at 1, from the pump housing and cap. Connect a hose into the pump housing and run into a container.
IMPORTANT: Check the hydraulic oil level and add if required to insure sufficient oil for the test.
NOTE: The front pump drains internally to the rear pump so the oil from this pump drain line will be oil from both pumps.
8. Hold the hose, or hoses, over a container, 1, and start the engine and run it at full throttle
(3070 3150 RPM). Take a flow reading, maximum 1.5 GPM each pump, 3 GPM total from both pumps.
9. Stroke the hydrostatic control levers forward and reverse and take a flow reading in both directions. If the flow exceeds the maximum 1.5
GPM per pump, there is excessive leakage from the forward and/or reverse high pressure loops.
If the pressure is within specifications, the problem may be in the motors.
CAUTION
Always stay clear of moving parts during testing or serious injury could occur.
1
16
17
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SECTION 29 - HYDROSTATIC TRANSMISSION
HYDROSTATIC PUMP HIGH-PRESSURE
TEST
The hydrostatic drive system has a high-pressure relief valve for forward and reverse, two relief valves per pump or side. The relief valves, 1, for both pumps and for forward and reverse are the same and the same setting, 238 bar (3500 PSI).
If one relief valve is in question, the valve can be switched with a known good valve; if the problem follows the switched valve, replace the suspect valve. Switching forward and reverse relief valves on the same pump should reverse the problem if a relief valve is the problem. If the problem remains, the problem is most likely internally in the pump or motor.
Refer to the pump case drain test for further testing to locate the problem.
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19992569
Relief Valve Test Procedure
1. Raise the boom and rest on the boom locks.
2. Put the Service/Run switch in the “SERVICE” position.
3. Engage the parking brake.
4. Securely block the skid steer with all four wheels off the ground.
CAUTION
Failure to securely support the skid steer could result in movement of the loader during testing causing serious injury or damage to the equipment.
5. Raise the operator’s seat and latch in the raised position.
6. Remove the step shield.
7. Install a tee fitting in the high-pressure loop being tested as shown at 1, motor fitting and install a
340 bar (5000 PSI) pressure gauge.
IMPORTANT: Check the hydraulic oil level and add if required to insure sufficient oil for the test.
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18
19
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SECTION 29 - HYDROSTATIC TRANSMISSION
The following pump relief valves protect the direction of motor (tire) rotation forward or reverse.
Front pump controls right motor:
1
1 - Forward (bottom)
2 - Reverse (top)
Rear pump controls left motor:
3 - Forward (bottom)
4 - Reverse (top)
8. Start the engine and run it at full throttle (3070 -
3150 RPM).
9. Stroke the hydrostatic control lever on the side being tested and in the direction being tested and take a pressure reading, the pressure should be
238 bar (3500 PSI). If the pressure is not at specification, 238 bar (3500 PSI), replace the suspect relief valve.
NOTE: All four directional relief valves can be tested in this manner.
If the pressure is within specification, refer to the pump/motor case drain test for further testing to locate the problem.
CAUTION
Always stay clear of moving parts during testing or serious injury could occur.
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SECTION 29 - HYDROSTATIC TRANSMISSION
19997776
HYDROSTATIC PUMP EFFICIENCY TEST
This test can be used to check the operating efficiency of the pump.
IMPORTANT: When connecting a flowmeter into the pump circuit, make sure the meter is connected properly and the control lever is stroked in the direction being tested. If not, the hydrostatic system and/or flowmeter may be damaged.
Efficiency Test Procedure
1. Raise the boom and rest on the boom locks.
2. Put the Service/Run switch in the “SERVICE” position.
3. Disengage the parking brake.
4. Securely block the skid steer with all four wheels off the ground.
21
CAUTION
Failure to securely support the skid steer could result in movement of the loader during testing causing serious injury or damage to the equipment.
5. Raise the operator’s seat and latch in the raised position.
6. Remove the step shield.
7. Remove the high-pressure line from the pump, for the direction to be tested.
8. Connect the test hose from the fitting on the pump to the inlet side of the flowmeter and the line from the motor to the outlet side of the flowmeter. Turn the pressure regulator valve out on the flowmeter to zero pressure.
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SECTION 29 - HYDROSTATIC TRANSMISSION
The following pump ports control direction of motor (tire) rotation forward or reverse.
Front pump controls right motor:
1 - Forward (bottom)
2 - Reverse (top)
Rear pump controls left motor:
3 - Forward (bottom)
4 - Reverse (top)
IMPORTANT: Check and make sure the flowmeter is connected properly, so when the pump is stroked the flow from the pump goes to the inlet side of the flowmeter.
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3
IMPORTANT: Check the hydraulic oil level and add if required to insure sufficient oil for the test.
9. Using the EIC or a photo tach, set the engine speed to 2900 RPM.
10. With the flowmeter regulator valve completely opened, 1, stroke the control lever for the direction to be tested and take a free flow reading and record. The pump free flow is at “0” pressure.
CAUTION
Always stay clear of moving parts during testing or serious injury could occur.
2
4
22
1
23
11. Turn the pressure regulator valve, 1, in on the flowmeter until a pressure reading of 136 bar
(2000 PSI) is obtained and record.
12. Pump efficiency specifications:
When figuring the pump efficiency it should not be less than 80%. The pump free flow should not be less than 81 LPM (21.2 GPM).
a. Pump flow recorded at 136 bar (2000 PSI) divided by the free flow reading at zero pressure will determine the pump efficiency.
EXAMPLE:
Pump free flow - 23.5
Pump flow at 2000 PSI - 22.4
Pump efficiency: 22.4
23.5
= 0.95 or 95%
24
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SECTION 29 - HYDROSTATIC TRANSMISSION
HYDROSTATIC MOTOR CASE DRAIN TEST
The motors can be checked for excessive internal leakage which will cause a unit to be weak in the ground drive. The excessive leakage is caused by damage to the motor rotating group or camp plate to allow high-pressure oil to leak into the case.
Motor Case Drain Test Procedure
1. Raise the boom and rest it on the boom locks.
2. Put the Service/Run switch in the “SERVICE” position.
3. Engage the parking brake.
4. Securely block the skid steer with all four wheels off the ground.
5. Raise the seat to the raised latched position.
6. Remove the step shield to access the hydrostatic motor.
7. Unhook the case drain line from the motor being tested at 1 and cap the line.
8. Connect another line in the port of the motor and allow the hose to drain into a suitable container.
IMPORTANT: Check the hydraulic oil level and add if required to ensure sufficient oil for the test.
9. Start the engine and set engine speed at 2900
RPM using the EIC or a photo tach.
10. Stroke the control lever for the side being tested, forward and reverse and take a flow reading,
MAXIMUM 1.5 GPM.
CAUTION
Always stay clear of moving parts during testing or serious injury could occur.
11. Return control lever to neutral and stop the engine.
12. If the test results are within specification, the problem may be in the pump. If the results are over the specification, remove and repair or replace the motor.
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25
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SECTION 29 - HYDROSTATIC TRANSMISSION
19997776
HYDROSTATIC MOTOR EFFICIENCY TEST
This test can be used to check the operating efficiency of the motor.
IMPORTANT: When connecting a flowmeter into the pump/motor circuit, make sure the meter is connected properly and the control lever is stroked in the direction being tested. If not, the hydrostatic system and/or flowmeter may be damaged.
Efficiency Test Procedure
1. Raise the boom and rest on the boom locks.
2. Put the Service/Run switch in the “SERVICE” position.
3. Disengage the parking brake.
4. Securely block the skid steer with all four wheels off the ground.
26
CAUTION
Failure to securely support the skid steer could result in movement of the loader during testing causing serious injury or damage to the equipment.
5. Raise the operator’s seat and latch in the raised position.
6. Remove the step shield to access the hydrostatic motors.
7. Remove the high-pressure line from the pump for the direction to be tested.
8. Connect the test hose from the fitting on the pump to the outlet side of the flowmeter and the line from the motor to the inlet side of the flowmeter. Turn the pressure regulator valve on the flowmeter to zero pressure.
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SECTION 29 - HYDROSTATIC TRANSMISSION
The following pump ports control direction of motor (tire) rotation forward or reverse.
Front pump controls right motor:
1 - Forward (bottom)
2 - Reverse (top)
Rear pump controls left motor:
3 - Forward (bottom)
4 - Reverse (top)
IMPORTANT: Check and make sure the flowmeter is connected properly, so when the pump is stroked the flow from the pump goes to the motor and to the inlet side of the flowmeter.
19997770
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3
IMPORTANT: Check the hydraulic oil level and add if required to insure sufficient oil for the test.
9. Using the EIC or a photo tach, set the engine speed to 2900 RPM.
10. Stroke the control lever for the direction to be tested and take a free flow pressure reading and record.
CAUTION
Always stay clear of moving parts during testing or serious injury could occur.
11. Turn the pressure regulator valve, 1, in on the flowmeter until a pressure reading of 136 bar
(2000 PSI) is obtained and record.
12. Motor efficiency specifications:
When figuring the motor efficiency, it should not be less than 80%. The motor free flow should not be less than 81 LPM (21.2 GPM).
a. Motor flow recorded at 136 bar (2000 PSI) divided by the free flow reading at zero pressure will determine the motor efficiency.
EXAMPLE:
Motor free flow - 25.5
Motor flow at 2000 PSI - 22.6
Pump efficiency: 22.6
25.5
= 0.886 or 89%
2
4
27
28
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SECTION 29 - HYDROSTATIC TRANSMISSION
HYDRAULIC, HYDROSTATIC SYSTEM AIR
INGRESS TEST
Hydraulic system air ingress, causing oil aeration, can affect performance of the hydraulic oil. This may be evident on a machine by jerky or uneven movement of the loader boom or bucket.
To assist in testing and finding leaks, a tool has been developed (part #FNH22ESS95). This tool comprises a cap which replaces the reservoir filler breather for testing purposes, a pressure gauge and a relief valve. The cap has fittings for air pressure to be applied to the hydraulic reservoir.
CAUTION
Do not start the engine with the test tool installed, as the hydraulic system must be able to breathe.
Test Procedure:
1. Remove the filler/breather cap.
2. Remove the self-tapping screws around the cap base and screen assembly.
3. Remove the base, screen and gasket assembly, clean all sealing surfaces.
4. Re-install new gaskets and base, taking care not to overtighten the screws.
5. Make sure the tank has 10W-30 oil visible.
6. Pressurize the tank using an air pressure line.
The tool is equipped with a 3 PSI relief valve and a pressure gauge. The reservoir should not be pressurized beyond 4 PSI.
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SECTION 29 - HYDROSTATIC TRANSMISSION
The following checks should then be performed to trace the source of the air ingress.
– Examine the suction tubes and fittings to the hydraulic gear pump and the return tubes from the filter to the reservoir.
– Examine the transmission case drain tubes/hoses and fittings from the hydraulic motors and pumps to the suction side of the hydraulic pump. Also check the cam plate shaft seals and the pump and motor casing gaskets.
– Potential leakage areas could also be input shaft seals in the engine bell housing, gearbox or output shaft seals in motors and gearboxes and the chain case.
– It may be necessary in some instances (where leakage is occurring on shaft seals into gearboxes or bell housing), to pressurize the reservoir for 2 - 4 hours and monitor the oil level in the gearboxes.
– If the prior checks do not locate the source of the leak, it may be necessary to pressurize each hydrostatic component individually.
To do this it will be necessary to disconnect each case drain line in turn and pressurize using an air line to a maximum pressure of 10 PSI.
NOTE: A check valve can be installed in the case drain tube which maintains a 5 PSI pressure in the pump and motor cases. This helps prevent air ingress into the system.
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SECTION 29 - HYDROSTATIC TRANSMISSION
HYDROSTATIC PUMPS
Op. 29 100 40
REMOVAL
The hydrostatic pump assembly can be removed from the top and front or the cab and boom can be tilted forward for more access, refer to Section 00 for the cab tilting procedure.
To remove the hydrostatic pump assembly without tilting the cab forward:
1. Lower the boom and bucket to the lowered position, resting on the ground or remove any attachment and raise the boom and rest on the boom lock pins, 1.
CAUTION
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment. Always remove the attachment from the loader.
2. Stop the engine, turn the ignition key to the run position and operate the boom and bucket control pedals to relieve pressure in the boom and bucket circuits. Turn off the key.
3. Put the Service/Run switch in the “SERVICE” position.
4. Engage the parking brake.
5. Securely block the skid steer at 1 and 2, with all four wheels off the ground. Refer to Section 00 for more detailed information on properly supporting a skid steer.
CAUTION
Failure to securely support the skid steer could result in movement of the loader causing serious injury or damage to the equipment.
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31
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SECTION 29 - HYDROSTATIC TRANSMISSION
6. Raise the operator’s seat and latch in the raised position, 1.
CAUTION
Never work under a raised seat unless it is securely latched in the raised position.
1
7. Remove the step shield to access the hydrostatic pump area. For more access, remove the right and left hydrostatic control handle assembly.
8. Relieve all pressure in the hydraulic and hydrostatic systems.
CAUTION
Never loosen any hydraulic lines without first relieving all pressure in the systems to avoid serious injury.
4825-11r
Draining the hydraulic oil reservoir is not required if the suction and return lines are capped to prevent loss of oil unless the hydraulic system requires cleaning.
9. Drain the hydraulic reservoir.
– Loosen the return line clamp, 1.
– Remove the return line at 2, and rotate the line into a suitable drain pan.
32
33
10. Remove the inspection plate, 1, from under the center of the loader frame to access the front hydrostatic pump support.
11. Remove the two hydrostatic pump support bolts from the main frame and the pump support plate.
34
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SECTION 29 - HYDROSTATIC TRANSMISSION
12. Remove the two pin retaining nuts, 1, securing the pins, 2, to the front of the neutralizer plate.
13. Remove the centering spring retaining bolt, 3, and spring from the engine bellhousing. When removing the retaining bolt the spring will be under slight pressure. Lift the plate from the unit.
14. Remove the control link hardware, 4, at the control handles.
15. Remove the link and dampener hardware, 5, at the pintle arms.
16. Remove the left dampener hardware, 6, at the support bracket.
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1
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2
4
5
17. On units equipped with high flow, loosen and remove the boom circuit hydraulic lines, 1 and 2, and the high flow supply line, 3.
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2
1
6
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3
19998077
2
18. Remove the cam arm securing hardware, 1, and remove the arms from the trunnion shafts.
19. Remove the plastic guides, 2, from the support bracket.
20. Mark all hydraulic hoses and lines, 3, to identify them for proper installation. Remove the hoses from the gear pumps and hydrostatic pumps.
21. Remove the pump mounting bolts, 4, and remove the pump assembly from the unit.
3
2
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3
1
3
3
4
4
1
36
37
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SECTION 29 - HYDROSTATIC TRANSMISSION
22. Note the model and serial number markings, 1, on the rear pump housing. The model number for pump assemblies without high flow is
78364–RAV; with high flow it is 78364–RAW.
NOTE: Dealer warranty requests for any hydrostatic component repair must include the machine model, serial numbers, transmission model number, and date codes. These codes are stamped into the flange of the pump housing, 1.
19997815
23. Remove the side/top support bracket hardware,
1, and remove the bracket.
1
1
38
24. Remove the O ring, 1, and dust shield, 2, from each hydrostatic pump control arm.
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1
2
39
40
29-30
SECTION 29 - HYDROSTATIC TRANSMISSION
Op. 29 100 46
DISASSEMBLY
1. Remove the port fittings and plug all the ports to prevent dirt or solvent from entering the pump body. Thoroughly clean the complete pump assembly before disassembly.
2. To ensure proper reassembly, use a marker to mark lines across the pump housing and backplates. Also mark the location of the control shafts for proper assembly.
Without High Flow - The hydrostatic pump assembly consists of:
1 Left side pump (rear)
2 Dual back plate
3 Right side pump (front)
4 Hydraulic gear pump
The back plate carries high pressure oil from the pumps to the motors through the high pressure hoses. The low pressure return oil from the motors flows back to the pump through the back plates to complete the closed loop circuit.
3. Remove the gear pump mounting bolts, 5, and tap the pump body with a plastic or rubber mallet to separate the pump from the hydrostatic pump.
Try not to disturb the internal gear pump seal at
6.
4. Remove the front pump mounting bolts, 7, and tap the housings with a plastic or rubber mallet to separate the pump from the dual backplate.
19997796
1 2 3
7
4 5
6
41
29-31
SECTION 29 - HYDROSTATIC TRANSMISSION
High Flow - The complete high flow pump assembly consists of:
1 Left side pump (rear)
2 Dual back plate
3 Right side pump (front)
4 Hydraulic gear pump
5 High flow pump
The back plate carries high pressure oil from the pumps to the motors through the high pressure hoses. The low pressure return oil from the motors flows back to the pump through the back plates to complete the closed loop circuit.
5. Remove the gear pump mounting bolts, 6, and tap the high flow pump body with a plastic or rubber mallet to separate the pump from the hydraulic system pump. Try not to disturb the internal gear pump seal at 7. Tap the hydraulic system pump body with a plastic or rubber mallet to separate the pump from the hydrostatic pump.
Try not to disturb the internal gear pump seal at
8.
6. Remove the front pump mounting bolts, 9, and tap the housings with a plastic or rubber mallet to separate the pump from the dual backplate.
7. Discard the gasket, 1, and note the two alignment dowel pins, 2, on each side of the backplate.
8. Remove the replaceable bearing plate, 3, from the backplate. The two bearing plates in this assembly are not identical; the metering slots point in opposite directions. The slots toward the front pump point clockwise.
9. Remove the rear pump mounting bolts, 4, and tap the housings with a plastic or rubber mallet to separate the pump from the dual backplate.
19997797
1
4
2
3
3
9
2
19997798
4 5 6
8
1
2
7
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SECTION 29 - HYDROSTATIC TRANSMISSION
10. Discard the gasket, 1, and note the two alignment dowel pins, 2, on each side of the backplate.
11. Remove the replaceable bearing plate, 3, from the backplate. The two bearing plates in this assembly are not identical; the metering slots point in opposite directions. The slots toward the rear pump point counterclockwise.
2
3
2
19997799
12. Hold the rotating piston block, 1, in one hand and tilt the open end of the housing down. Turn the rotating piston block and pull it out as a complete unit without scratching or burring the parts.
NOTE: Keep the rotating group as an assembly until the piston positions are properly marked.
13. Mark the piston, 1, and hole, 2, positions with a soft marker (do not scratch any surface) so the pistons and holes can be inspected and reassembled in the same configuration.
14. Lift the rotating group, 3, out of the pump piston block, 4, and carefully set the pistons on cardboard to avoid scratches.
19998066
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4 3
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1
44
1
45
46
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SECTION 29 - HYDROSTATIC TRANSMISSION
15. Remove the front pump drive shaft, 1, by pulling it out of the pump housing bearings.
1
16. Remove the rear pump drive shaft, 1, by removing the large snap ring, 2. The pump shaft seal, 3, should be replaced any time the shaft is removed. Tap the other end of the shaft to remove the shaft, seal, and seal thrust washer from the housing.
19998068
2 3
47
17. Remove the retaining rings, 1, to remove the thrust washers, 2, and needle thrust bearing, 3.
19998072
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1
48
OPS5548
2 3 2
49
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SECTION 29 - HYDROSTATIC TRANSMISSION
18. Remove the trunnion bearing cover, 1, and support bracket, 2, by removing the three capscrews, 3. Pry the cover off by inserting screwdrivers in the notches on the side of the cover.
2
3
1
19. Remove the O ring, 1, and discard. The tapered bearing, 2, and the bearing race, 3, on this side are press fit and are not removed unless damaged.
19997800
20. Remove the control arm side bearing cover, 1, by removing the three capscrews, 2. Pry the cover off by inserting screwdrivers in the notches on the side of the cover.
19997801
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2
19997802
3
2
1
3
50
51
52
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SECTION 29 - HYDROSTATIC TRANSMISSION
21. Remove the bearing race, 1, and crush ring, 2, from the bearing cover. Discard the crush ring.
Remove and discard the control arm seal, 3.
1 2 3
22. Remove the camplate, 1, from the housing by sliding the short end out first.
19997803
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19998069
PARTS INSPECTION
Pump Housings
1. Inspect the front pump housing for any obvious damage. Inspect the shaft needle bearing, 1, for a loose fit, and for missing or loose needles.
2. The shaft needle bearing is a tight fit in the housing. If the pump shaft needle bearing needs to be replaced, use a puller to pull the bearing toward the inside of the pump body.
3. Make sure the needle bearing is installed with the numbered end to the inside of the pump body.
4. All oil seals and O rings should be replaced during reassembly.
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53
54
55
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SECTION 29 - HYDROSTATIC TRANSMISSION
5. Inspect the rear pump housing for any obvious damage. Inspect the shaft needle bearing, 1, for a loose fit, and for missing or loose needles.
6. The shaft needle bearing is a tight fit in the housing. If the pump shaft needle bearing needs to be replaced, press the bearing from the inside after the camplate is removed.
7. Make sure the needle bearing is installed with the numbered end to the outside seal of the pump shaft.
19997808
Pump Shafts
1. Check the rear pump shaft areas contacting the needle roller bearings, 1, for wear and a rough bearing.
2. Check for a bent or worn shaft.
3. Check the spline areas, 2, for wear or twist.
4. Check the thrust bearing, 3, races, 4, and retaining rings, 5, and grooves, 6. If bearing or races show wear or roughness, they must be replaced.
OPS5559
5. Check the front pump shaft areas contacting the needle roller bearings, 1, for wear and a rough bearing.
6. Check for a bent or worn shaft.
7. Check the spline areas, 2, for wear or twist.
2
1
2
1
6
1
56
57
19998068
58
29-37
SECTION 29 - HYDROSTATIC TRANSMISSION
Cam Plates
1. Shoes of the pump pistons rotate at high speeds against the camplate wear plate surface, 1. The surface must be smooth with no metal flaked away and no scoring. Circular scratches centered on this machined surface are due to contamination. If scratches can be felt with a fingernail, replace the camplate wear plate.
2. Check the camplate wear plate surface for smearing. This surface must be smooth, bright, and even with no discoloration or brass smearing.
3. Inspect the bearings, 2, for wear, looseness or roughness; replace if damaged.
Piston and Shoe Assemblies - replace the rotating group if:
1. The piston skirt area, 1, shows signs of scratches or wear.
2. The edges of the shoes, 2, are worn (shoe roll) from contact with the camplate.
3. There is wear on the underside of the slipper between the slipper and shoe plate, 3.
4. The shoes are a loose, sloppy fit on the ball end of the piston at 4.
5. The flat surfaces of the shoes, 5, show metal flaking or are deeply scratched. Light or shallow scratches in the shoes will not cause excessive wear. Do not lap the shoes.
Rotating Group
1. Check for cracks at the holes, 1, for the spherical washer and shoes. The shoe plate is only available as part of the rotating group.
2. Check for wear in the area of the slippers, 2. This area should be flat, smooth, and have no grooves.
3. Check the internal splines of the piston block, 3, for wear.
4. Check for wear on the top surface of the spherical washer, 4, where the shoe plate fits. The spherical washer is only available as part of the rotating group. Check the side curved area for cracks.
19998065
OPS5561
3
19998070
2
4
1
1
2
59
60
61
29-38
SECTION 29 - HYDROSTATIC TRANSMISSION
Piston Block - replace the rotating group if:
1. The cylinders, 1, are worn or scored so the pistons do not move freely. The pistons do have side play in the piston block.
2. The surface, 2, is worn or grooved or shows metal buildup. Nicks must not extend from the cylinders to the edge of the raised area, 3.
3. The loading pins, 1, are spring loaded, held in place by the pin keeper (split bushing), 2.
4. Make sure that the pins are the same height, the pins are seated in their special grooves, and the head of the pins are seated between the washer and block.
OPS5563
62
OPS5564
Replaceable Bearing Plate
1. Check the plate for overall flatness.
2. Check for scratches on the brass side of the plate, extending across the area where the piston block contacts the plate at 1.
3. Check for scratches between lubrication holes,
2, and metering slots, 3.
NOTE: The two bearing plates in this assembly are not identical; the metering slots point in opposite directions. The slots on the front pump plate point clockwise and the slots on the rear pump plate point counterclockwise.
1
19997807
2
1
3
1
63
64
29-39
SECTION 29 - HYDROSTATIC TRANSMISSION
Back Plate
1. Check the needle bearings for wear, 1. These bearings are pressed into the back plate with the bearing numbers facing out.
2. Check the backplate for flatness along perpendicular lines, 2.
1
2
3. Two directional relief valves, 1, in each pump limit the maximum system pressure to 238 bar (3500
PSI). Relief valve pressure is factory set and should never be readjusted. The factory set relief pressures are marked on the side of the cartridge.
19997806
1
65
4. Check the relief valves for scratches in the seat areas, 1. Check for broken springs, 2. The springs should all be the same length.
5. Check the seat area, 3, in the backplate for scratches that will prevent the relief valves from sealing properly.
19997809
3
2
19997810
1
2
3
66
67
29-40
SECTION 29 - HYDROSTATIC TRANSMISSION
REASSEMBLY
1. Use a suitable solvent to thoroughly clean all parts. Lay the parts on clean cardboard and air dry.
IMPORTANT: Due to tight tolerances and the finish of the pump internal surfaces, it is very important to maintain absolute cleanliness during reassembly.
2. Use clean SAE 10W-30 SH/CG4 oil to lubricate all moving parts as they are reassembled. Fill the transmission cases with oil through the case drain hole after completing assembly of the component.
IMPORTANT: Lubrication of the pump components during assembly is required to ensure lubrication oil for start-up.
3. Use the new gaskets, O rings, seals, and snap rings included in the repair kit.
4. Place the camplate wear plate, 1, over the machined camplate surface.
2
1
19998065
5. Place the camplate, 1, into the housing with the control arm, 2, toward the boss as marked at the beginning of disassembly.
NOTE: The machined surface of the camplate and wear plate, 3, face the open end of the housing.
2
1
19998069
3
68
69
29-41
SECTION 29 - HYDROSTATIC TRANSMISSION
6. Install a new O ring, 1, and place the trunnion bearing cover, 2, on the pump housing.
7. Attach the trunnion bearing cover, 1, and support bracket, 2, with the three capscrews, 3, and washers removed during disassembly. Tighten the capscrews to 40 N·m (30 ft. lbs.).
19997801
2
1
3
2
1
70
8. Install a new O ring, 1, on the control shaft side of the housing.
19997800
3
1
71
19997811
72
29-42
SECTION 29 - HYDROSTATIC TRANSMISSION
9. Install a new camplate arm seal, 1, in the bearing cover, 2. Install a new crush ring, 3, into the bearing cover, 2. Place the bearing race, 4, over the crush ring in the bearing cover.
NOTE: A new crush ring, 3, must be used for proper camplate bearing pre-load.
4
3
1
2
19997803
10. Attach the control arm bearing cover, 1, with the three capscrews, 2, and washers removed during disassembly. Tighten the capscrews to 40
N ⋅ m (30 ft. lbs.).
NOTE: Tightening the cover capscrews to the specified torque will crush ring, 3, Figure 73, and set the proper camplate bearing pre-load.
19997802
2
11. Install a retaining ring, 1, on the pump drive shaft.
Install one thrust washer, 2, the thrust bearing, 3, and the second thrust washer, 4. Secure the washers and bearing with the second retaining ring, 5.
1
73
74
OPS5572
75
29-43
SECTION 29 - HYDROSTATIC TRANSMISSION
12. Install the shaft and bearing assembly, 1, into the housing. Install the seal thrust washer and new shaft seal, 2. Tap the seal to seat the washer and seal in the pump housing. Secure the seal with the retaining ring, 3.
3 2
1
76
13. Check the three piston block loading pins, 1.
Make sure the pins are seated properly in the oversize grooves in the splines and held in place with the retaining ring, 2.
19998072
OPS5574
14. Install the pistons with plate, 1, and pivot, 2, into the piston block. Make sure the pivot rests on the loading pins, 3. Use the reference marks made during disassembly to place the pistons in their previous spots.
3
19998070
2
1
77
78
29-44
SECTION 29 - HYDROSTATIC TRANSMISSION
15. Invert the housing and insert the rotating group assembly, 1, into the housing. In the front pump, it may be easier to install the drive shaft, 2, and rotating group together.
NOTE: Piston shoes must contact the camplate.
Make sure all parts are in their proper position before proceeding.
NOTE: If the rotating group does not slide over the splined shaft easily, DO NOT FORCE. One or more of the three loading pins may be out of their groove or pin head is not seated properly between the washer and block. Forcing the rotating group may cause pin failure and early transmission failure.
IMPORTANT: Make sure all mating surfaces are well lubricated with SAE SH/CG4 10W-30 motor oil to ensure proper lubrication for start-up.
16. Install new O rings on the relief valve caps, 1, and install the valves into the valve plate with springs and caps. Tighten to 135 N
⋅ m (100 ft. lbs.).
19998066
1
1
2
79
19997809
17. Install a new bearing, 1, in the backplate if the bearing is damaged or loose. Install the bearing with the numbers facing out, pressing the bearing down to 2.38 mm (3/32
″
) above the plate, 2. The bearing is a pilot for the bearing plate during assembly.
NOTE: When installing bearings in the plate or housing, be careful not to damage the outer bearing race. If the outer race is damaged, early bearing and shaft failure could result.
2
1
19997806
80
81
29-45
SECTION 29 - HYDROSTATIC TRANSMISSION
18. Lubricate the replaceable valve plate, 1, and place the steel side to the back plate, aligning the small groove with pin, 2. The metering slots, 3, must face out.
NOTE: The two bearing plates in this assembly are not identical; the metering slots point in opposite directions. The slots on the front pump plate point clockwise and the slots on the rear pump plate
(shown here) point counterclockwise.
1
19. Install a new gasket, 4, between the plate and housing.
19997812
2
20. Attach the pump housings to the back plate, 1, making sure the replaceable plates stay in position; a small amount of Vaseline between the plate and backplate will hold it in place.
21. Install the four capscrews for each pump and tighten to 37 - 42 N ⋅ m (27 - 31 ft. lbs.).
NOTE: When the backplate assembly is in place before tightening the capscrews, a small gap (about
1/8
,
) between the housing gasket and valve plate is normal. Tightening the bolts brings the housing against the rotating group spring, resulting in the internal spring load to the valve plate and the piston slippers. After tightening the housing bolts, the shaft should turn easily using 8 , pliers. The shaft should have some rolling resistance but should not be tight, locked down, or rotate freely. If one of these conditions occurs, the pump is assembled incorrectly and must be reassembled.
19997813
1
3
4
82
83
29-46
SECTION 29 - HYDROSTATIC TRANSMISSION
HYDRAULIC SYSTEM PUMP
INSTALLATION (WITHOUT HIGH FLOW)
1. Remove the through bolts and separate the gear assemblies and wear plate from the pump body by removing the drive gear, 1, and idler gear, 2.
Do not disturb the seal between the pump body and the backplate.
1
2
19997780
The hydraulic system gear pump consists of:
1 Wear plate assembly
2 Idler gear assembly
3 Drive gear assembly
4 Pump body
5 Pump back plate
Coat all parts with a thin coat of petroleum jelly or oil to aid in reassembly.
2. Clean the mounting plate surface and hydrostatic pump housing thoroughly and install a new O ring, 1.
1
19997794
1
2
84
4
5
3
1
85
19997782
86
29-47
SECTION 29 - HYDROSTATIC TRANSMISSION
3. Install the wear plate assembly, 1, with the gasket/seal side towards the pump mounting plate with the mid section cut away on the suction side, 2, of the pump.
2
19997783
4. Install the drive shaft, 1, making sure to engage the splines inside the hydrostatic pump. Install the idler gear assembly, 2, into the bushing.
Rotate the gears to help slide the idler gear into place.
NOTE: The drive shaft and gear, 1, must be properly seated into the hydrostatic pump drive shaft splines with the end of the gear teeth against the wear plate.
2
19997784
1
5. Install the pump backplate, 1, and center section together over the gear shafts.
6. Install the housing hardware with the eight bolts,
2, and sealing washers. Tighten the bolts evenly in a criss-cross pattern to 34 - 38 N
⋅ m (25 - 28 ft.
lbs.).
1
87
2
88
19997796
1
89
29-48
SECTION 29 - HYDROSTATIC TRANSMISSION
HYDRAULIC SYSTEM PUMP / HIGH FLOW
PUMP INSTALLATION
1. Remove the through bolts, 1, and washers.
2. Separate the pumps at 2, taking care not to disturb the seals between the pump bodies and backplates.
2
3. Remove the small round drive key, 1, from the pump drive shaft, 2, and remove the drive gears, idler gears, and wear plates from the pumps, taking care not to disturb the seals between the pump body and backplate.
IMPORTANT: The small round key must be removed to remove drive shaft from pump center sections. Do not lose drive key.
19997790
19997791
1
2
1
90
91
29-49
SECTION 29 - HYDROSTATIC TRANSMISSION
The hydraulic system pump consists of:
1 Wear plate assembly
2 Idler gear assembly
3 Drive gear assembly
4 Key
5 Pump body
6 Pump back plate
Coat all parts with a thin coat of petroleum jelly or oil to aid in reassembly.
1
19997795
2
The high flow pump consists of:
1 Wear plate assembly
2 Idler gear assembly
3 Drive gear
4 Key (Figure 92)
5 Pump body
6 Pump back plate
Coat all parts with a thin coat of petroleum jelly or oil to aid in reassembly.
4. Clean the mounting plate surface and hydrostatic pump housing thoroughly and install a new O ring, 1.
1
19997759
2
1
3
3
4
4
5
6
1
5
92
93
19997782
94
29-50
SECTION 29 - HYDROSTATIC TRANSMISSION
Install the wear plate assembly, 1, with the gasket/seal side towards the pump mounting plate with the mid section cut away on the suction side, 2, of the pump.
2
19997783
5. Install the drive shaft, 1, making sure to engage the splines inside the hydrostatic pump. Install the idler gear assembly, 2, into the bushing.
Rotate the gears to help slide the idler gear into place.
NOTE: The drive shaft and gear, 1, must be properly seated into the hydrostatic pump drive shaft splines with the end of gear teeth against the wear plate.
Position the key slot, 3, up.
2
19997788
1
6. Install the pump body and back plate together, 1, over the gear shafts, taking care not to disturb the seals between the pump body and backplate.
1
1
96
3
95
19997792
97
29-51
SECTION 29 - HYDROSTATIC TRANSMISSION
7. Clean the mounting plate surface thoroughly and install a new O ring, 2. Install the shaft key, 3, in the drive shaft.
1
8. Install the wear plate assembly, 1, with the gasket/seal side towards the pump mounting plate with the mid section cut away on the suction side, 2, of the pump.
19997762
19997763
9. Install the drive gear, 1, on the drive shaft, slipping the groove over the shaft key, 2. Install the idler gear assembly, 3, into the bushing.
Rotate the gears to help slide the idler gear into place.
NOTE: When installing drive gear, 1, on to the shaft, be careful not the knock the round drive key, 2, from the shaft.
3
1
19997764
2
2
100
2
3
98
1
99
29-52
SECTION 29 - HYDROSTATIC TRANSMISSION
10. Install the high flow pump body and end plate together, 1, taking care not to disturb the seals between the pump body and backplate. Make sure there are no gaps between the pump bodies and plates.
11. Install the housing hardware with the eight bolts,
1, and sealing washers. Tighten the bolts evenly in a criss-cross pattern to 34 - 38 N
⋅ m (25 - 28 ft.
lbs.).
19997793
19997797
1
101
1
102
29-53
SECTION 29 - HYDROSTATIC TRANSMISSION
REINSTALLATION
1. Install the side/top support bracket, 1, with the capscrews, 2, and washers removed during disassembly.
1
2. Install the dust shields, 1, and new O rings, 2, around each hydrostatic pump control arm.
19998046
1
2
1
103
19998073
3. Install the neutralizer cam arms, 1, over the trunnion shafts, with the bearings facing the rear of the unit. Secure the arms with the 3/8
″
Grade
8 bolts, 3, lockwashers and nuts removed during disassembly. Tighten to 65 N ⋅ m (48 ft. lbs.).
4. Fill the pump assembly with oil through the case drain port. Install all the port fittings, but do not tighten the fitting nuts at this time as aligning hoses and fittings will be required.
Refer to the “Hydraulic System Cleaning After a
Rebuild” section of this manual before installing the pump assembly in the loader.
19998075
2
2
3
1
1
2
2
104
3
105
29-54
SECTION 29 - HYDROSTATIC TRANSMISSION
5. Lubricate the engine flex plate splines and pump shaft splines with MOLY COATE GN PASTE or
NEVER SEIZE. Lower the pump assembly into the unit and align the pump shaft with the drive coupler. Do not force the shaft into the drive coupler. Secure the assembly with two 1/2 ″ x
1-1/4
″
capscrews, 1. Tighten to 61 N
⋅ m (45 ft.
lbs.).
6. Install the four pump mounting bolts under the pump, securing the pump support bracket to the frame. Tighten the bolts to 40 N ⋅ m (30 ft. lbs.).
7. Install the plastic guides, 2, on the support bracket.
2
19997770
8. Right Motor - Reattach all the hydraulic hoses to the pumps. The pump to motor connections are top-to-top and bottom-to-bottom. The top hose,
1, from the motor routes under the motor to the top port of the motor, 2. The bottom hose from the motor, 3, routes over the motor. The case drain line, 4, also routes over the motor.
When tightening fittings, first align hoses and tubes for clearance, then tighten to seat the fittings. After seated, loosen and retighten.
NOTE: Make sure that the hoses are connected to the correct ports. If the hoses are reversed at the pump or motor, the wheels will turn opposite the control handle direction.
9. Left Motor - Reattach all the hydraulic hoses to the pumps. The pump to motor connections are top-to-top and bottom-to-bottom, and both hoses route over the motor. The hose from the top pump port, 1, goes to the top motor port, 2. The hose from the bottom motor port, 3, goes to the bottom motor port, 4. The case drain line, 5, routes under the hydraulic pumps.
When tightening fittings, first align hoses and tubes for clearance, then tighten to seat the fittings. After seated, loosen and retighten.
NOTE: Make sure that the hoses are connected to the correct ports. If the hoses are reversed at the pump or motor, the wheels will turn opposite the control handle direction.
2
19998078
4
19998079
4
3
2
5
3
1
1
106
107
1
108
29-55
SECTION 29 - HYDROSTATIC TRANSMISSION
10. Install the high pressure port fitting, 1, and the high pressure line, 2. Tighten the high pressure line connections securely.
11. Install the suction tube port fitting, 3, and turn the fitting up. Add SH/CG4 10W-30 oil to fill the bottom of the hydraulic pump.
3
1
19998081
12. Install the high pressure port fittings, 1, and the high pressure lines, 2. Tighten the high pressure line connections securely.
13. Install the suction tube port fitting, 3, and turn the fitting up. Add SH/CG4 10W-30 oil to fill the bottom of the hydraulic pump.
14. Turn the suction tube fitting down and install the suction tube, 4. TIghten all hydraulic connections securely.
19998080
15. Turn the suction tube fitting, 1, down and install the suction tube, 2. TIghten all hydraulic connections securely.
1
3
4
2
2
109
1
110
19998082
2
111
29-56
SECTION 29 - HYDROSTATIC TRANSMISSION
16. Install the left dampener hardware, 1, at the support bracket.
17. Install the link and dampener hardware, 2, at the pintle arms.
18. Install the control link hardware, 3, at the control handles.
19. Install the centering spring retaining bolt, 4, and spring into the engine bellhousing. When removing the retaining bolt the spring will be under slight pressure.
20. Install the two pin retaining nuts, 5, and lockwashers securing the pins, 6, to the front of the neutralizer plate.
21. Refer to the Operator’s Manual for neutral adjustment procedures.
22. On units equipped with high flow, reinstall the boom circuit hydraulic lines, 1 and 2, and the high flow supply line, 3.
23. Refer to “Start-Up Procedure After a Rebuild” section of this manual for the start-up procedure.
24. Switch the Service/Run switch to the SERVICE position.
25. Operate the unit and check for oil leaks and repair as necessary.
CAUTION
Securely support the skid-steer loader with all four wheels off the ground, or movement of the loader may cause serious injury or damage to the equipment.
5
6
19992569
4
19998077
2
1
3
2
3
26. Reinstall the step shield, fenders, etc. removed for the repair.
27. Fill the hydraulic reservoir with SAE SH/CG4
10W-30 oil.
6
5
1
112
113
29-57
SECTION 29 - HYDROSTATIC TRANSMISSION
HYDROSTATIC MOTOR
Op. 29 100 60
REMOVAL
The hydrostatic motor assembly can be removed from the top and front or the cab and boom can be tilted forward for more access, refer to Section 1 for the cab tilting procedure.
To remove the hydrostatic motor assembly without tilting the cab forward:
1. Lower the boom and bucket to the lowered position, resting on the ground or remove any attachment and raise the boom and rest on the boom lock pins, 1.
CAUTION
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment. Always remove the attachment from the loader.
2. Stop the engine, turn the ignition key to the run position and operate the boom and bucket control pedals to relieve pressure in the boom and bucket circuits. Turn off the key.
3. Put the Service/Run switch, 1, in the “SERVICE” position.
4. Engage the parking brake.
1
5. Securely block the skid steer with all four wheels off the ground. Refer to Section 00 for more information on properly supporting a skid steer.
CAUTION
Failure to securely support the skid steer could result in movement of the loader causing serious injury or damage to the equipment.
19984593
114
115
116
29-58
SECTION 29 - HYDROSTATIC TRANSMISSION
6. Raise the operator’s seat and latch in the raised position, 1.
CAUTION
Never work under a raised seat unless it is securely latched in the raised position.
7. Remove the step shield, 1, to access the hydrostatic pump and motor area. For more access, remove the right or left hydrostatic control handle assembly, 1 or 2.
8. Relieve all pressure in the hydraulic and hydrostatic systems.
CAUTION
Never loosen any hydraulic lines without first relieving all pressure in the systems to avoid serious injury.
Draining the hydraulic oil reservoir is not required if the suction and return lines are capped to prevent loss of oil. Drain the hydraulic oil if the hydraulic system requires cleaning.
9. Remove the rear engine belly pan hardware, 1, and remove the belly pan.
CAUTION
Use a floor jack to support the belly pan to prevent serious injury.
117
118
119
29-59
SECTION 29 - HYDROSTATIC TRANSMISSION
10. Drain the hydraulic reservoir.
– Loosen the return line clamp, 1.
– Remove the return line at 2, and rotate the line into a suitable drain pan.
11. Remove the fender, 1, on the side the motor is being removed from. Remove the final drive cover, 2, to access the parking brake. Engage the parking brake.
120
121
12. For more access to the final drive, remove the tires and loosen the rear axle retaining hardware.
Slide the axle to the center to loosen the drive chain. Loosen the brake disk retaining bolt, 3.
Disengage the parking brake at this time.
13. Remove the brake caliper bolts, 2, from inside the unit and remove the disk from the splined coupler.
122
29-60
SECTION 29 - HYDROSTATIC TRANSMISSION
14. Right Motor – Remove the high-pressure and case drain lines from the motor and cap to prevent loss of oil. Remove the two motor retaining bolts, 1.
NOTE: The large fittings may need to be removed for clearance.
1
15. Left Motor – Remove the high-pressure and case drain lines from the motor and cap to prevent loss of oil. Remove the two motor retaining bolts, 1.
NOTE: The large fittings may need to be removed for clearance.
19998078
16. With the brake disc removed from the coupler, locate a groove, 1, in the coupler and place a flat bearing puller in the groove. Place a nut or heavy flat washer inside the coupler next to the end of the motor shaft at 2. Insert a second puller into the coupler and hook over the flat puller. Now tighten the puller and push the motor shaft free of the coupler.
CAUTION
Do not use a hammer and drive on the motor shaft to remove from the coupler. Severe damage to the motor may occur.
19998079
123
1
124
125
29-61
SECTION 29 - HYDROSTATIC TRANSMISSION
17. Remove the motor from the loader. Thoroughly clean the motor before disassembly.
Op. 29 100 66
DISASSEMBLY
This section describes the basic overhaul information for the high torque motor. This motor consists of one rotating block with pistons on either end that travel on replaceable cam plates. This motor must be shimmed on rebuilding to insure proper hydrostatic braking of the loader.
NOTE: Dealer adjustment requests for oil leak repairs, other repairs, or overhaul of the transmission motor must include the model number of the transmission motor and the date code. These are stamped in the flange of the motor housing, 1.
1. Thoroughly clean the outside of the motor housing before disassembly. Plug the ports to prevent dirt and solvent from entering the motor housing.
2. Remove the snap ring, 1, from the housing, and remove the seal, 2; the seal will be damaged upon removal.
126
127
128
29-62
SECTION 29 - HYDROSTATIC TRANSMISSION
3. Mark the motor housing, as indicated at 1, for proper reassembly of the motor. Clamp the motor in a vise, as shown, on the housing flange.
4. Remove the cap screws, 2, from the back plate assembly, and lift the plate straight from the housing to prevent damage to the shaft and bearings.
NOTE: The back plate assembly should pop up with the removal of the six cap screws. If the plate does not pop up, use a plastic mallet and tap on the ports to remove the back plate assembly.
IMPORTANT: The motor housing is aluminum and can be easily damaged. Do not use sharp objects to pry the back plate from the housing or damage to the machined surfaces may occur.
5. After the back plate is removed, there is a shim washer, thrust bearing, 1, and two races, 2, on the end of the shaft. The shim washer, bearing, and one race may remain in the back plate as shown at 1.
129
130
6. Remove connector plate, 1, after noting how it is installed in the spider assembly, raised area, 2, towards the back plate and flat side towards the pistons.
131
29-63
SECTION 29 - HYDROSTATIC TRANSMISSION
7. Remove two pistons noting the holes they are from, then remove the spider and remaining piston assembly. Be sure to lay all parts being removed from the motor on clean cardboard to prevent contamination. Do not drop any parts on removal or reassembly, as the parts may be damaged.
NOTE: When reassembling, the piston must be reinstalled in the same holes due to fit and wear.
IMPORTANT: Do not drop any parts from the motor or damage may occur.
8. Remove the pilot assembly, 1.
9. Remove the pivot assembly, 2.
10. Remove any shim washers, 3, and spring, 4.
11. Remove snap ring collar, 5.
132
133
12. Remove the motor assembly from the vise and position a hand around the shaft, as shown. This will prevent the solid pistons remaining in the rotating block from sliding out when the block is turned.
134
29-64
SECTION 29 - HYDROSTATIC TRANSMISSION
13. Pull the case straight up and remove it from the shaft. The heavy thrust bearing, 1, and piston race, 2, can now be removed.
14. A replaceable bearing race, 1, is installed in the housing assembly and will normally remain in the housing when other parts are removed. This race should be checked for any signs of scoring or turning in the housing. Replace the race as necessary. Be sure to clean the case thoroughly for reassembly.
15. Remove pivot, 1, and spacer, 2.
16. The nine solid pistons, 3, can now be removed.
Remove the pistons from the snap ring end of the piston block. Note that the tapered end of the piston faces the bearing race previously removed.
135
136
137
29-65
SECTION 29 - HYDROSTATIC TRANSMISSION
IMPORTANT: There is a burr around the holes in the piston block at 1; this is normal, do not remove. DO
NOT place the piston block on the ends or the burr around the holes may be damaged, causing a piston to stick during operation.
17. The piston block can be removed from shaft, 1.
The block is keyed onto the shaft with a long, square key, 2. Remove the snap ring, 3, from the shaft if it requires replacement.
138
139
18. A complete layout of the parts used in the hydrostatic motor is shown.
140
29-66
SECTION 29 - HYDROSTATIC TRANSMISSION
PARTS INSPECTION
Clean all parts in a suitable solvent and air dry prior to inspection.
IMPORTANT: Due to close tolerances and finish of motor internal surfaces, it is important to maintain absolute cleanliness during inspection and reassembly or damage to the components may occur.
1. Examine the needle bearing in the housing assembly and the back plate assembly, 1, for excessive play in the needles. If the needles are free from excessive play and remain in the bearing case, there is no need to replace the bearing. Inspect the thrust bearing, 2, and races,
3, for scratches and wear.
2. Inspect the flat surface of the back plate around the kidney ports for scratches. Inspect the area between the kidney ports, 4; there should be no scratches that you can catch a fingernail in. Wear in this area will cause loss of hydraulic power to the wheels.
When a back plate assembly must be replaced, the connector plate should also be replaced.
3. Inspect the shaft for any wear in the bearing or seal areas, 1. If wear is noted, the shaft should be replaced. Also check the shaft splines, 2, and key, 3, areas for wear.
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SECTION 29 - HYDROSTATIC TRANSMISSION
4. Inspect the piston block for any wear in the key or shaft area, 1.
5. The hollow pistons with slippers must be installed into the piston block holes on the side of the block with the tapered shaft opening, 2. Examine the holes in the block for scoring and wear. If the pistons’ skirts show scoring, the corresponding holes in the block will be worn.
6. The pistons should be free to move in the block bore. Check each individual piston in a block hole to be sure it moves freely when well lubricated.
If it does not move freely, check the piston for scoring or block bore for wear or contamination.
NOTE: There is a burr around each hole at 3; be careful not to damage the burr.
7. The outside of the pistons, 1, should not show any deep scratches or wear. It is normal to see minor scratches, such as brush marks, that cannot be felt with a fingernail. The piston shoes,
2, should fit snugly on the ball end, 3, of the piston. There should not be any wear to the outside edge of the shoe at 5, which can be noted by a rolled edge. If necessary, replace the piston assemblies.
8. Check the internal opening in each piston to be sure it is open for oil flow, 1. The flat surface of the piston shoe should be smooth and not show any scratches, 2.
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SECTION 29 - HYDROSTATIC TRANSMISSION
9. The solid piston assemblies should be individually checked in the block bores to be sure they move freely when lubricated. The solid pistons go in the end of the block with the shoulder, 1. Install the solid pistons from the tapered end of the block, 2, with the tapered end of the piston, 3, towards the shoulder end of block, 1. Check the tapered end of the piston and the piston race for wear. If the pistons do not move freely in the bores, replace the pistons or block as needed.
10. Check the connecter plate for wear in the band area, 1, or any connecting scratches between the kidney ports, 2.
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11. Check the bearing races and bearing for scratches or damage to the bearings or the flat surfaces. A race failure due to a sticking solid piston will result in a broken race. Check the solid piston for interference with the piston block. This type failure is normally caused by contamination in the hydrostatic system.
If the bearing race, 1, is removed and is in two or three pieces, it will require replacement.
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SECTION 29 - HYDROSTATIC TRANSMISSION
REASSEMBLY
IMPORTANT: Due to close tolerances and finish of motor internal surfaces, it is important to maintain absolute cleanliness during inspection and reassembly or damage to the components may occur.
Be sure all parts are clean and air-dried before reassembly. Prior to assembling the motor, dip all parts in the oil, SH/CG4 10W-30, that will be used in the hydraulic reservoir. This motor must be shimmed during reassembly. The shim kit gauge block used to determine the shim pack is included in the seal kit for the motor assembly.
1. Install the key, 1, in the shaft and the round retaining ring, 2, in the groove.
Slide the piston block on the shaft with the 45 ° chamfer, 3, in the inside diameter of the piston block toward the round retaining ring, 2, on the shaft.
2. Lubricate the solid pistons, 1, with system oil and install them in the piston block bores from the tapered end of the block, 2, with the tapered ends facing outward. Be sure each piston moves freely in its bore. It is suggested that the assembly be held with one hand, as shown, so the pistons do not fall completely through the block.
IMPORTANT: Do not damage the burr around the piston holes in the block.
3. Slide spacer, 3, and pivot, 4, over the shoulder on the shaft. Be sure the block assembly is resting on the snap ring on the opposite end of the shaft.
NOTE: If the spacer and pivot assembly are not completely down over the shoulder on the shaft as a result of the block being off the snap ring, the shimming procedure and motor operation will be incorrect.
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SECTION 29 - HYDROSTATIC TRANSMISSION
4. Lubricate the piston race assembly, 1, and place it on the pivot, as shown, with the bearing locating ring, 2, up.
5. Lubricate the thrust bearing, 1, and install it over the bearing race at 2.
151
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6. Insert the outer bearing race into the housing, 1.
The bearing race must be inserted squarely into the recess in the housing.
NOTE: The dull or unfinished side of the bearing race
MUST be inserted into the housing first.
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SECTION 29 - HYDROSTATIC TRANSMISSION
Slide the housing down over the complete shaft assembly. Be sure the shaft extends through the housing approximately 38 mm (1-1/2 ″ ). If the shaft does not protrude through the housing the distance shown, the spacer and/or pivot is installed incorrectly.
7. Turn over the housing and clamp it in a vise on the flanged end of the housing.
Inspect the piston block and the retaining ring to be sure they are seated properly in the taper of the block at 1.
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155
Motor Shimming Procedure
1. Place a spring collar over the shaft and snap ring at 1. Place the gauge block, 2, marked XDB-1756 or 74600-624 over the shaft and next to the collar previously installed.
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SECTION 29 - HYDROSTATIC TRANSMISSION
Install spring, 1, over the shaft. Lubricate pivot,
2, with STP, and make sure it slides easily over the shoulder on the shaft, 3. Install pilot, 4, over the pivot assembly.
2. Lubricate the pistons with SAE SH/CG4 10W-30 oil and install the pistons and spider assembly, 1, making sure the spider plate is properly positioned over the pivot support, 2.
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3. Lubricate both sides of the connector plate and install it as shown with the flat side next to the pistons and the raised side up.
NOTE: Be sure the connector plate sits inside the locators on the spider at 1.
4. Set the connector plate and spider, 2, at the angle to match the fixed angle of the back plate. Center the connector plate, spider, and pivot around the shaft at 3.
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SECTION 29 - HYDROSTATIC TRANSMISSION
5. Lubricate the small thrust bearing and races with a thin coating of STP and stack race, 2; bearing,
3; race, 4; and thin shim washer, 5, on the end of the shaft at 1.
NOTE: Reinstall the thin shim washer at 5, if one was previously removed.
6. Install the back plate assembly and pull down evenly with two hands until the pivot is felt to move over the shoulder of the shaft. This will enable the back plate to move within approximately 3 mm (1/8
″
) of the housing assembly at 1. If there is more than 3 mm (1/8 ″ ) clearance, remove the back plate and check the assembly.
IMPORTANT: DO NOT force; damage to the pivot, pilot, or spider plate may occur.
7. While holding the back plate assembly against the spring load, install two bolts opposite each other as shown at 1. Torque these two cap screws evenly to 3.5 N·m (20 in. lbs.).
NOTE: The 3.5 N·m (20 in. lb.) torque must be accurately gauged for the correct shim pack to be installed.
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29-74
8. With a feeler gauge, measure the gap between the two opposite pads, 1. If either gap is over 5 mm (0.200
″ ), the motor has been incorrectly assembled and must be disassembled before further shimming.
9. Shim pack calculation:
Add the two feeler gauge figures obtained in step
8.
Example: 0.155
″
+ 0.145
″
0.300
″
Divide the total by 2.
Example: 0.300
″
2
= 0.150
″
7.62 mm
2
= 3.8 mm
SECTION 29 - HYDROSTATIC TRANSMISSION
0.015
″
0.015
″
0.015
″
0.135
″
3.94 mm
+ 3.68 mm
7.62 mm
A constant of 7.14 mm (0.281
″
) is used to complete the calculation. Subtract the total from
7.14 mm (0.281
″
) to determine the correct shim pack.
Example: 0.281
″
- 0.150
″
0.131
″
7.14 mm
- 3.81 mm
3.33 mm
The shim kit includes two 1.91 mm (0.075
″
) shims and four 0.38 mm (0.015
″ ) shims. Use a combination of these shims to obtain the shim pack calculated.
NOTE: Shim pack specifications are
"
0.25 mm
0.38 mm
0.38 mm
0.38 mm
3.43 mm
(
"
0.010
,
). When possible, shim to the +0.25 mm
(+0.010
, ) side of the shim pack calculated.
Example: To obtain the 3.3 mm (0.131
″
) dimension calculated in the example, use one
1.91 mm (0.075
″ ) shim and four 0.38 mm
(0.015
″
) shims.
0.075
″
0.015
″
1.91 mm
0.38 mm
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SECTION 29 - HYDROSTATIC TRANSMISSION
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SECTION 29 - HYDROSTATIC TRANSMISSION
10. Disassemble and replace the shim gauge block,
1, with the required number of shims from the seal kit. When two 1.91 mm (0.075
″ ) shims are used, the 0.38 mm (0.015
″
) shims must be placed between them. When only one 1.91 mm
(0.075
″ ) shim is used, place the 1.91 mm
(0.075
″
) shim against the spring, as shown.
11. Complete reassembly of the motor by checking the snap ring and piston block are properly seated at 2. Install the collar, 3, over the snap ring. Install shims at 1, spring, 4.
12. Install the pivot, 1, and the pilot, 2.
IMPORTANT: Lubrication of the motor components during assembly is required to insure lubrication oil for start-up.
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165
13. Install the spider and piston assembly as shown, making sure the spider is seated over the pivot as shown at 1. Lubricate the piston slippers with a thin coating of STP for a good sliding surface.
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SECTION 29 - HYDROSTATIC TRANSMISSION
14. Install the connector plate, 1, and lubricate both sides with a thin coating of STP. Install it as shown with the flat side next to the pistons and the raised side up. Check the connector plate and make sure it is seated over the locating tabs,
2, on the spider plate.
15. Set the connector plate and spider, 1, at the angle to match the fixed angle of the back plate. Center the connector plate, spider, and pivot around the shaft at 3.
16. Lubricate the small thrust bearings and races with a thin coating of STP and stack race, 2; bearing, 3; race, 4; and thin shim washer, 5, on the end of the shaft, 1.
NOTE: Reinstall the thin shim washer at 5 if one was previously removed.
17. Install the back plate assembly with a new O ring.
Tighten the six bolts, 1, down evenly using opposite bolts and torque to 23 N·m (17 ft. lbs.).
Use caution not to disturb the thrust bearing.
Align the marks on the back plate and housing to ensure correct assembly.
NOTE: Push the back plate by hand to make sure the pivot seats over the shoulder on the shaft properly;
DO NOT force.
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SECTION 29 - HYDROSTATIC TRANSMISSION
18. Install a bolt in the drive end of the motor shaft and use an inch pound torque wrench to check the rolling torque of the motor shaft. If the rolling torque exceeds 6.8 N·m (5 ft. lbs.) or 10.5 N·m
(60 in. lbs.), the motor is too tight; the assembly and shimming procedure must be rechecked and recalculated.
NOTE: Check the spider, connector plate, and pivot for proper assembly if the motor is too tight.
19. Install a new seal, 1, and snap ring, 2, in the housing at 3. Fill the motor housing with
SH/CG410W-30 oil to the case drain level to ensure lubrication oil on start-up.
170
171
20. Using a dial indicator, check the end movement of the motor shaft, 1. If the end movement is over
1.02 mm (0.040
″
), add a shim washer on the end of the shaft at 5, Figure 168, between the back plate and thrust bearing race.
The motor assembly is now ready for installation in the loader.
Refer to the “Hydraulic System Cleaning
Procedure After Transmission Overhaul” section of this manual before installing the motor assembly in the loader.
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SECTION 29 - HYDROSTATIC TRANSMISSION
RENSTALLATION
1. Clean all previously sealed surfaces, motor to gearbox, final drive cover, brake disk retaining bolt and washer.
When resealing, use a noncorrosive silicone sealer to prevent rust and corrosion of parts after assembled.
2. Place a bead of New Holland Ultra-Blue silicone sealer around the face of the motor housing.
3. Align the motor assembly tapered splines with the coupler splines in the gearbox and slide the motor shaft into the coupler. Install two 1/2
″
x
1-1/2 ″ cap screws and washers, torque to 101
N·m (75 ft. lbs.).
IMPORTANT: The motor shaft and coupler splines are tapered. Use caution to insure that the splines mate properly during assembly. DO NOT FORCE or damage could occur to the motor housing.
19998078
1
4. Reinstall the motor fittings if removed.
5. Reinstall the brake disc, 1, and caliper, 2.
6. Put a bead of silicone sealer around the end of the coupler and install the retaining bolt and washer, 3. Engage the parking brake and check the retaining bolt, torque to 44 N·m (33 ft. lbs.).
7. Reinstall the drive chain on the drive sprocket if removed.
8. Slide the axle assembly to the rear and tighten the drive chain, and torque the axle retaining hardware, 1, to 190 N·m (140 ft. lbs.).
9. Reseal the final drive cover plate, 2, and install.
10. Check the final drive oil level with check plugs, 3, and add SAE 10W-30 oil as required.
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SECTION 29 - HYDROSTATIC TRANSMISSION
11. Right Motor – Reinstall the motor high-pressure hoses and case drain line. The hoses connect the pump and motor parts top-to-top and bottom-to-bottom. The top motor hose, 1, from the top pump port, 2, routes under the motor. The bottom motor hose, 3, routes over the motor. The case drain line, 4, routes over the motor. Tighten the connections to seat the fittings, then loosen and retorque.
NOTE: Make sure that the hoses are connected to the correct ports. If the hoses are reversed at the pump or motor, the wheels will turn opposite the control handle direction.
3
1
4
2
12. Left Motor – Reinstall the motor high-pressure hoses and case drain line. Both hoses are completely on top of the motor. The hose from the top pump port, 1, goes to the top motor port, 2.
The hose from the bottom pump port, 3, goes to the bottom motor port, 4. Tighten the connections to seat the fittings, then loosen and retorque.
NOTE: Make sure that the hoses are connected to the correct ports. If the hoses are reversed at the pump or motor, the wheels will turn opposite the control handle direction.
4
2
3
19998079
13. Reinstall the hydrostatic control lever that was removed. Reconnect all control linkage. Refer to the operator’s manual for neutral adjustment procedures.
14. Refer to the “Start-Up Procedure After Rebuild” section of this manual for the start-up procedure.
15. Put the Service/Run switch in the “SERVICE” position.
16. Operate the unit and check for oil leaks and repair.
CAUTION
Securely support the skid steer with all four wheels off the ground, or movement of the loader may cause serious injury or damage to the equipment.
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29-81
SECTION 29 - HYDROSTATIC TRANSMISSION
17. Return the cab and boom to the operating position if the cab was tilted.
18. Install the step shield and fender.
19. Check and refill the hydraulic system to the proper oil level.
Hydraulic System Cleaning Procedure After a
Hydraulic System or Transmission Overhaul
The hydraulic/hydrostatic system must be cleaned if during repair the cause was from contamination and the transmissions show wear on the pistons and shoes, rotating piston blocks, valve plate or cam plate.
IMPORTANT: Do not use the gear pump and charge pump to flush the system with solvent. The solvent will not provide enough lubrication to protect moving parts inside the transmissions or gear pump.
1. Drain all remaining oil from the hydraulic system.
2. Remove fill cap, 1, and screen by removing the six retaining screws, 2, from the reservoir fill.
Thoroughly clean the screen and fill breather cap in solvent.
3. Drain and flush the hydraulic oil reservoir.
Remove the rear engine belly pan, hardware, 1, and belly pan.
CAUTION
Use a floor jack to support the belly pan to prevent serious injury.
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180
181
29-82
SECTION 29 - HYDROSTATIC TRANSMISSION
Loosen the return line clamp, 1.
Remove the return line at 1, and rotate the line into a suitable drain pan. Thoroughly flush the reservoir with a suitable clean solvent or clean
10W-30 oil.
4. Remove the charge check valve, 2, and thoroughly flush the oil cooler with solvent by forcing the solvent through the cooler.
5. Disassemble the check valve by removing the snap ring, 1; washer, 2; spring, 3; and plunger, 4.
Clean the check valve parts thoroughly.
NOTE: The spring in the check valve will be slightly compressed, use caution when removing the snap ring.
1
182
183
184
29-83
SECTION 29 - HYDROSTATIC TRANSMISSION
6. Remove the filter and base, clean the base, and check the bypass valve, 1, for operation.
7. Clean and flush all hydraulic lines. If the failure was hydrostatic, be sure to flush and clean the high-pressure hoses from the pumps to the motors.
8. After the system is cleaned, thoroughly flush the solvent used to clean the system with fresh clean
SAE SH/CG4 10W-30 oil.
9. Reconnect all lines removed for cleaning.
10. Install a new oil filter, 1.
11. Before start-up, fill the hydraulic system, pumps, motors, etc., as full as the case drain lines permit with system oil, SAE SH/CG4 10W-30 oil.
12. Fill the hydraulic reservoir with SAE 10W-30 oil.
Start-up Procedure After Rebuild (Pump or
Motor Replacement)
1. Fill the reservoir with SAE SH/CG4 10W-30 oil to the proper level.
2. Install a 21 bar (300 PSI) gauge in charge pressure test port, 1.
185
186
187
29-84
SECTION 29 - HYDROSTATIC TRANSMISSION
3. Remove the fuel solenoid power wire, 1, to prevent the engine from starting.
CAUTION
Never crank the starter for more than 30 seconds or damage to the starter may occur. Crank the starter for 30 seconds and cool 1 minute.
188
4. Put the Service/Run switch, 1, in the “SERVICE” position.
5. Put the steering levers in the neutral position.
6. Turn the ignition key to the start position and allow the engine to crank for 30 seconds at a time until the pressure gauge starts to move. If after trying three times and the gauge does not move, loosen the gear pump pressure line at the control valve to bleed the air from the hydraulic system.
Re-crank the engine until the gauge moves. After the gauge moves, stop cranking and reconnect the fuel solenoid.
7. Start the engine and monitor the charge pressure gauge to ensure charge oil for the hydrostatic system; the pressure reading should be 6.8 - 8.2
bar (100 - 120 PSI).
IMPORTANT: If charge pressure remains below 3.4
bar (50 PSI) for more than 10 seconds, stop the engine and locate the cause. If the unit is operated with low or no charge pressure, severe damage will occur to the hydrostatic system.
Do not stroke the hydrostatic controls or operate the boom and bucket control at this time.
8. Allow the engine to operate at 1500 RPM for about 30 minutes. Stop the engine; check the oil level and fill as required.
9. Start the engine and operate at 1500 RPM and slowly operate the hydrostatic system to remove air, monitor the charge pressure. Operate the boom and bucket for a few cycles to remove the air from the hydraulic system.
10. Stop the engine; recheck the hydraulic system oil level and add as required.
11. Remove the charge pressure test gauge.
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1
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190
SECTION 29 - HYDROSTATIC TRANSMISSION
12. Adjust the neutral system if required; refer to the operator’s manual for procedures.
13. Run the engine at 1500 RPM for an additional 30 minutes to filter the oil. Stop the engine and change the oil filter.
14. Check for oil leaks and repair as required.
15. Reinstall all shields removed for repair.
16. Lower the skid steer to the ground and operate.
HYDRAULIC SYSTEM CLEANING
PROCEDURE
After A Hydraulic System Or Transmission
Overhaul
The hydraulic/hydrostatic system must be cleaned if during repair the cause was from contamination and the transmissions show wear on the pistons and shoes, rotating piston blocks, valve plate or cam plate.
IMPORTANT: Do not use the gear pump and charge pump to flush the system with solvent. The solvent will not provide enough lubrication to protect moving parts inside the transmissions or gear pump.
1. Drain all remaining oil from the hydraulic system.
2. Remove fill cap, 1, and screen by removing the six retaining screws, 2, from the reservoir fill.
Thoroughly clean the screen and fill breather cap in solvent.
3. Drain and flush the hydraulic oil reservoir.
a. Remove the rear engine belly pan hardware,
1, and remove the belly pan.
CAUTION
Use a floor jack to support the belly pan to prevent serious injury.
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192
193
29-86
SECTION 29 - HYDROSTATIC TRANSMISSION b. Loosen the return line clamp, 1.
c. Remove the return line at 1, and rotate the line into a suitable drain pan. Thoroughly flush the reservoir with a suitable clean solvent or clean 10W-30 oil.
4. Remove the charge check valve, 2.
5. Disassemble the check valve by removing the snap ring, 1; washer, 2; spring, 3; and plunger, 4.
Clean the check valve parts thoroughly.
NOTE: NOTE: The spring in the check valve will be slightly compressed, use caution when removing the snap ring.
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SECTION 29 - HYDROSTATIC TRANSMISSION
6. Remove the filter and base, clean the base, and check the bypass valve, 1, for operation.
7. Remove tube, 1, between the top of the oil cooler and the inlet to the hydraulic filter base. Also disconnect the tube at the inlet to the oil cooler.
Thoroughly flush the oil cooler with solvent by forcing the solvent through the cooler.
8. Clean and flush all hydraulic lines. If the failure was hydrostatic, be sure to flush and clean the high pressure hoses from the pumps to the motors.
9. After the system is cleaned, thoroughly flush the solvent used to clean the system with fresh clean
SAE 10W-30 oil.
10. Reconnect all lines removed for cleaning.
11. Install a new oil filter, 1.
12. Before start-up, fill the hydraulic system, pumps, motors, etc., as full as the case drain lines permit with system oil, SAE 10W-30 oil.
13. Fill the hydraulic reservoir with SAE 10W-30 oil.
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198
199
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SECTION 29 - HYDROSTATIC TRANSMISSION
START-UP PROCEDURE AFTER REBUILD
(AFTER PUMP OR MOTOR
REPLACEMENT)
1. Fill the reservoir with SAE 10W-30 oil to the proper level.
2. Install a 21 bar (300 PSI) gauge in charge pressure test port, 1.
200
3. Remove the fuel solenoid power wire, 1, to prevent the engine from starting.
CAUTION
Do not crank the starter for more than 30 seconds or damage to the starter may occur. Crank the starter for 30 seconds and cool 1 minute.
201
4. Put the Service/Run switch, 1, in the “SERVICE” position.
5. Put the steering levers in the neutral position.
6. Turn the ignition key, 2, to the start position and allow the engine to crank for 30 seconds at a time until the pressure gauge starts to move. If after trying three times and the gauge does not move, loosen the gear pump pressure line at the control valve to bleed the air from the hydraulic system.
Re-crank the engine until the gauge moves. After the gauge moves, stop cranking and reconnect the fuel solenoid.
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1
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SECTION 29 - HYDROSTATIC TRANSMISSION
7. Start the engine and monitor the charge pressure gauge to ensure charge oil for the hydrostatic system; the pressure reading should be 6.8 -
8.2 bar (100 - 120 PSI).
IMPORTANT: If charge pressure remains below 3.4
bar (50 PSI) for more than 10 seconds, stop the engine and locate the cause. If the unit is operated with low or no charge pressure, severe damage will occur to the hydrostatic system.
Do not stroke the hydrostatic controls or operate the boom and bucket control at this time.
8. Allow the engine to operate at 1500 RPM for about 30 minutes. Stop the engine; check the oil level and fill as required.
9. Start the engine and operate at 1500 RPM and slowly operate the hydrostatic system to remove air, monitor the charge pressure. Operate the boom and bucket for a few cycles to remove the air from the hydraulic system.
10. Stop the engine; recheck the hydraulic system oil level and add as required.
11. Remove the charge pressure test gauge.
12. Adjust the neutral system if required; refer to the operator’s manual for procedures.
13. Run the engine at 1500 RPM for an additional 30 minutes to filter the oil. Stop the engine and change the oil filter.
14. Check for oil leaks and repair as required.
15. Reinstall all shields removed for repair.
16. Lower the skid-steer loader to the ground and operate.
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29-90
SECTION 29 - HYDROSTATIC TRANSMISSION
CHARGE CHECK VALVE
Op. 29 100 36
REMOVAL AND REPLACEMENT
1. Lower the boom and bucket to the lowered position, resting on the ground, or remove any attachment and raise the boom and rest on the boom lock pins, 1.
CAUTION
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment. Always remove the attachment from the loader.
2. Stop the engine, turn the ignition key to the run position and operate the boom and bucket control pedals to relieve pressure in the boom and bucket circuits. Turn off the key.
3. Put the Service/Run switch, 1, in the “SERVICE” position.
4. Engage the parking brake.
1
19984593
5. Securely block the skid steer at 1 and 2 with all four wheels off the ground. Refer to Section 1 for more information on properly supporting a skid steer.
CAUTION
Failure to securely support the skid steer could result in movement of the loader causing serious injury or damage to the equipment.
205
206
207
29-91
SECTION 29 - HYDROSTATIC TRANSMISSION
6. Remove the right engine side shield to access the check valve, 1.
7. Remove the return line at 2, and cap to prevent the loss of oil.
8. Remove the check valve from the oil filter base at 3.
The charge check valve is nonadjustable and not serviceable. If the valve does not operate, it will need to be replaced. The only procedure you can perform on the valve is to clean the valve assembly.
9. Remove the snap ring, 1. Disassemble and clean the check valve.
10. The check valve is marked for oil flow for installation.
208
209
Op. 29 100
STEERING SYSTEM
HYDROSTATIC SYSTEM CONTROLS
Before any control linkage adjustments or repairs are made to the skid steer, do the following:
1. Lower the boom and bucket to the lowered position, resting on the ground, or remove any attachment and raise the boom and rest on the boom lock pins, 1.
CAUTION
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment. Always remove the attachment from the loader.
2. Stop the engine, turn the ignition key to the run position and operate the boom and bucket control pedals to relieve pressure in the boom and bucket circuits. Turn off the key.
29-92
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SECTION 29 - HYDROSTATIC TRANSMISSION
3. Put the Service/Run switch, 1, in the “SERVICE” position.
4. Engage the parking brake.
5. Securely block the skid steer at 1 and 2 with all four wheels off the ground. Refer to Section 1 for more information on properly supporting a skid steer.
CAUTION
Failure to securely support the skid steer could result in movement of the loader causing serious injury or damage to the equipment.
19984593
6. Raise the operator’s seat and latch in the raised position, 1.
CAUTION
Never work under a raised seat unless it is securely latched in the raised position.
7. Remove the step shield to access the control linkages.
4825-11r
1
1
211
212
213
29-93
SECTION 29 - HYDROSTATIC TRANSMISSION
NEUTRALIZER ASSEMBLY
Op. 29 130 10
Neutralizer Removal
1. Remove the two retaining nuts, 1, securing the pins to the front of the neutralizer plate.
2. Remove the centering spring, 2, from the engine bellhousing. When removing the retaining bolt, 3, the spring will be under slight pressure. Lift the plate from the unit.
1
3
2
19992569
Neutralizer Parts Inspection
1. Inspect the plastic guides, 1, for breaks or wear.
If worn or damaged, replace.
2. Inspect the guide pins, 2, for excessive wear. If worn, replace.
3. Inspect the cam blocks, 3, for wear in the area the cam arm bearings contact. If worn, rotate the blocks to the unused side.
4. Inspect the neutralizer plate for wear in the centering bolt area, 4. If worn, replace the plate.
5. Inspect the spring, 5, for proper free length: 114.3
± 2.4 mm (4.5
″ ± 3/32 ″ ). If not within specification, replace the spring.
6. Inspect the spring guides, 6, and the bolt, 7, in the guide area; if worn, replace.
Op. 29 130 30
Control Linkage Removal
1. Remove the two pin retaining nuts, 1, securing the pins, 2, to the front of the neutralizer plate.
2. Remove the centering spring retaining bolt, 3, and spring from the engine bellhousing. When removing the retaining bolt the spring will be under slight pressure. Lift the plate from the unit.
3. Remove the control link hardware, 4, at the control handles.
4. Note the number and position of the spacers and washers for the dampener mounting hardware at
5 and 6. Remove the link and dampener hardware, 5, at the pintle arms. Remove the dampener hardware, 6, at the support brackets.
6
3
1
1
19998067
2
19992569
2
6
7
5
4
3
1
215
2
6
1
216
214
6
5
4
29-94
SECTION 29 - HYDROSTATIC TRANSMISSION
5. Remove the cam arm securing hardware, 1, and remove the arms.
1
1
Control Linkage Parts Inspection
1. Inspect the bushings, 1, in the control links; replace if worn, loose, or damaged.
2. Inspect the dampeners, 2, for unequal pressures, leaks, or binding shafts. If damaged, replace.
19997770
1
2
217
3. Inspect the rubber bushings, 1, in the cam arms; if loose or worn, replace. Inspect the arms in the clamping area, 2, for damage. Check that the bearings, 3, are not damaged and can move freely.
NOTE: Bearings are a press fit and replaceable separately; however, cam arms come from parts with bearings already installed. To replace bearings, use a puller to remove the old bearing.
19997805
1
2
19998074
3
3
2
218
1
219
29-95
SECTION 29 - HYDROSTATIC TRANSMISSION
4. Inspect the blocks, 1, that the bearings ride on.
If worn, turn the blocks around for a new surface.
1
1
220
Op. 29 130 06
Control Linkage and Neutralizer Reassembly and Adjustment
1. Install a new O ring, 1, around each cam plate shaft.
2. Slide the cam arms, 1, onto the cam plate shafts.
The bearings, 2, should be toward the engine side of the cam arms. Install 3/8
″
x 2-1/2
″
Grade
8 bolts, 3, and locknuts. Tighten to 65 N ⋅ m (48 ft.
lbs.).
19998073
1
2
3
19997770
221
2
3
1
222
29-96
SECTION 29 - HYDROSTATIC TRANSMISSION
3. Loosely install the blocks, 1, to the neutralizer plate with 1/2 ″ x 3/4 ″ capscrews, 2, and large
1/12 ″ flat washers.
2
1
2
19998067
4. Install the dampener hardware, 1, at the support brackets with the bolts, washers and spacers removed during disassembly. Install the link and dampener hardware, 2, at the pintle arms.
Tighten the hardware securely.
5. Install the control link hardware, 3, at the control handles.
6. Install the neutral return spring assembly with the long bolt, 4. Slide the short spring retainer over the shoulder bolt first. Slide the spring on the bolt, and then slide the longer retainer on the bolt.
Install the bolt into the bellhousing cover, compressing the spring by hand. Screw the bolt into the housing until it bottoms, and then tighten to 55 N
⋅ m (40 ft. lbs.).
7. Install the two pin retaining nuts, 5, securing the pins, 6, to the front of the neutralizer plate.
1
4
5
6
19992569
2
3
223
1
6
5
224
29-97
SECTION 29 - HYDROSTATIC TRANSMISSION
LEFT CONTROL HANDLE WITH NO BOOM
HAND CONTROL
Op. 29 100 10
REMOVAL
1. Securely latch the seat in the raised and latched position. Remove the step shield and front step cover to access the control handle, linkage and valve area.
2. Disconnect the hydrostatic pump control link, 1.
1
4802-10
3. Remove the handle mounting bolts, 1, and remove the handle assembly from the unit.
DISASSEMBLY
1. Loosen the boot securing bolts, 1, and slide the boot, 2, off the handle.
2. Remove the roll pin, 3, and shim washers, 4.
Take note of the number and position of all shim washers for reassembly.
3. Remove the bearings, 5, from the handle, retaining any shim washers at 6.
4. Slide the handle sideways and remove from the stub shafts.
1
225
1
226
1
2
5
4
3
227
29-98
SECTION 29 - HYDROSTATIC TRANSMISSION
INSPECTION
1. Inspect the handle pivot bearings, 1; replace if worn or damaged.
2. Inspect the control handle for excessive wear or bends in the bearing mounting plates, 2, and pivot stub shafts, 3.
3
REASSEMBLY
1. Slide the handle sideways over the stub shafts.
2. Install the bearings, 1, on the handle. Install shim washers, 2, to center the handle in the slot, 3.
3. Install shim washers, 4, to reduce side play on the stub shafts. Retain the shims on the stubs shaft with a roll pin, 5.
4. Slide the boot, 6, over the handle and tighten the boot securing bolts.
5. Install a new hand grip, 7, if grip is worn.
REINSTALLATION
1. Place the handle assembly in the unit and install the five handle mounting bolts, 1, and tighten securely.
2
3
1
228
7
6
1
2
4
3
229
1
1
230
29-99
SECTION 29 - HYDROSTATIC TRANSMISSION
2. Connect the hydrostatic pump control link, 1.
3. Reinstall all shields removed for the repair.
1
4802-10
231
29-100
SECTION 29 - HYDROSTATIC TRANSMISSION
LEFT CONTROL HANDLE WITH BOOM
HAND CONTROL
Op. 29 100 11
REMOVAL
1. Securely latch the seat in the raised and latched position. Remove the step shield and front step cover to access the control handle, linkage and valve area.
2. Disconnect the hydrostatic pump control link, 1.
1
4802-10
3. Remove the boom control rod, 1, from the left control handle arm, 2.
232
4. Remove the four handle mounting bolts, 1, and remove the handle assembly from the unit.
19996848
1
1
2
1
233
234
29-101
SECTION 29 - HYDROSTATIC TRANSMISSION
DISASSEMBLY
1. Take note of the number and position of all shim washers for reassembly.
2. Remove the bolt, 1, securing the ball end to the control arm.
3. Remove the jam nut, 2, and ball end, 3, from the rod, 4.
4. Remove the groove pin, 5, from the arm, 6.
5. Loosen the set screw, 7, on the set collar.
Remove the cotter pins, 8, and shim washers, 9, taking note of the number of shim washers for reassembly.
6. Remove the bearings, 10, from the control handle and the bearings, 11, from the handle mounting plates. Slide the handle sideways and remove from the stub shafts.
7. Remove the nuts, 1, lock washers, and carriage bolts securing the handle support to the handle tube. Remove the handle support, 2, and control rod, 3, from the handle tube, 4.
10
11
4
7
2 3
6 5
1 10
8
8 9
9
11
235
1
2
3
4
19996838
236
8. Remove the locknut, 1, and bolt to separate the handle from the handle support.
9. Remove the ball end, 2, from the handle by removing the capscrew, 3, flat washer and locknut. Remove the ball end, 2, and jam nut, 4, from the rod, 5.
1
3
2
4
5
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SECTION 29 - HYDROSTATIC TRANSMISSION
10. Loosen the boot securing bolts, 1, and slide the boot, 2, off the handle.
1
1
INSPECTION
1. Inspect the handle pivot bearings, 1; replace if worn or damaged.
2. Inspect the pivot stub shafts, 2, for any obvious bends or deformation.
3. Inspect the control handle for excessive wear or bends in the bearing mounting plates, 3.
19997750
2
2
3
19997747
4. Inspect the pivot handle linkage for looseness in the ball joints, 1; replace if worn.
5. Inspect the pivot handle, 2, and handle support,
3, for damage or deformation. Replace as necessary.
2
3
1
238
1
1
239
240
29-103
SECTION 29 - HYDROSTATIC TRANSMISSION
REASSEMBLY
1. Install a new hand grip on the top of the handle,
1, if grip is worn.
2. Attach the ball end, 2, and jam nut, 3, to the rod,
4. Fasten the ball end to the handle, 5, with the capscrew, 6, flat washer and locknut. Position the flat washer between the ball end and handle. Do not tighten the jam nut at this time.
3. Attach the handle assembly to the handle support, 7, with the long bolt, 8, and locknut, 9.
4. Tighten the locknut to remove any movement between the handle assembly and support, but do not overtighten. The support should be loose enough to allow the handle to pivot without binding.
5. Slide the handle tube up through the slot, 1, in the handle support base.
6. Slide the handle sideways over the stub shafts.
7. Install the bearings, 2, on the handle, install shim washers, 3, to center the handle in the slot, 1.
Fasten each bearing with two 5/16 ″ x 3/4 ″ carriage bolts, lock washers, and nuts at 4.
8. Install shim washers, 5, to reduce side play on the stub shafts. Retain the shims on the stubs shaft with a roll pin, 6.
9. Slide the rubber boot, 7, down over the end of the control handle, one side at a time, and secure with the the hardware removed during disassembly.
10. Attach the handle and rod assembly, 1, to the control handle by first sliding the rod down through the control handle tube, 2.
11. Attach the handle assembly to the handle tube arms, 3, with the short carriage bolts, 4, lock washers, 5, and nuts, 6. Tighten securely.
19996839
9
1
2
4
6
6
5
2
3
4
3
7
1
5
8
4
7
3
5
6
241
242
4
1
2
19996838
243
29-104
SECTION 29 - HYDROSTATIC TRANSMISSION
12. Assemble the pivot shaft, 1, shim washers, 2, arm, 3, set collar, 4, and bearings, 5, into the control arm housing. Fasten each bearing with two 5/16
″
x 3/4
″
carriage bolts, lock washers, and nuts at 6.
13. Rotate the pivot shaft, 1, to position the arm upward as shown at 7.
14. Note the position of the arm, 3, on the shaft in relation to the arm at 7. Insert groove pin, 8, through arm, 3, and into shaft just far enough to position the arm. Do not hammer into place at this time.
6
5
4
8
3
2
5
1
8
7
2
1
3
4
244
15. Attach the ball end and jam nut, 1, onto rod, 2.
Install spacer, 12, (OD - 7/16
″
; length - 15/32
″
) between the ball end and arm, 3. Secure with a
5/16 ″ x 1-3/4 ″ bolt, lock washer, and nut at 4.
16. Install shim washers at 5, between the cotter pin,
6, and bearing, 7, to center rod, 2, in the control handle tube at 8. Secure the cotter pin and slide the set collar, 9, against the opposite bearing to remove any side movement of the shaft and tighten the setscrew.
17. Drive the groove pin, 12, in the arm completely into place.
18. With the handle in the neutral position angle, adjust the length of the rod, 2, so the ball stud at the arm, 3, aligns with the pivot bearings at 10.
This will also set the pivot arm, 11, in a vertical position.
19. Rotate the handle to make sure the rod, 2, does not interfere at the top or bottom of the control handle tube. Move the control handle back and forth (forward and reverse) and make sure the control arm, 3, does not move. When there is no movement, tighten the jam nuts at both ends of the rod.
REINSTALLATION
1. Place the handle assembly, 1, in the unit and install the handle mounting bolts, 2.
10
10
9
12
6 5 7
11
245
1
2
2
246
29-105
SECTION 29 - HYDROSTATIC TRANSMISSION
2. Install the boom control rod, 1, on the left control handle arm, 2.
3. Connect the hydrostatic pump control link, 1.
4. Reinstall all shields removed for the repair.
19996848
1
2
247
1
4802-10
248
29-106
SECTION 29 - HYDROSTATIC TRANSMISSION
RIGHT CONTROL HANDLE WITH
AUXILIARY OR BUCKET CONTROL
Op. 29 100 15
REMOVAL
1. Securely latch the seat in the raised and latched position. Remove the step shield and front step cover to access the control handle, linkage and valve area.
2. Disconnect the hydrostatic pump control link, 1.
4802-10
3. Remove the auxiliary hydraulic control or bucket control rod, 1, from the right control handle arm,
2.
1
249
4. Remove the five handle mounting bolts, 1, and remove the handle assembly from the unit.
19996848
2
1
1
250
251
29-107
SECTION 29 - HYDROSTATIC TRANSMISSION
DISASSEMBLY
1. Take note of the number and position of all shim washers for reassembly.
2. Remove the bolt, 1, securing the ball end to the control arm.
3. Remove the jam nut, 2, and ball end, 3, from the rod, 4.
4. Remove the groove pin, 5, from the arm, 6.
5. Loosen the set screw, 7, on the set collar.
6. Remove the cotter pins, 8, and shim washers, 9, taking note of the number of shim washers for reassembly.
7. Remove the bearings, 10, from the control handle and the bearings, 11, from the handle mounting plates. Slide the handle sideways and remove from the stub shafts.
Op 29 100 15
Auxiliary Boom Control Handle (Only)
8. Boom hydraulics control - Remove the setscrew,
1, and remove the handle support, 2, and control rod, 3, from the handle tube, 4.
10
11
4
7
2 3
6 5
1 10
8
8 9
9
11
252
3
1
2
4
19996890
253
9. Boom hydraulics control - Remove the roll pin, 1, the L-pin, 2, and the spring and ball at 3.
3
2
1
19997746
254
29-108
SECTION 29 - HYDROSTATIC TRANSMISSION
10. Boom hydraulics control - Remove the locknut, 1, and bolt, 2, to separate the handle, 3, from the handle support, 4. Retain the bushing and capscrew. Remove the ball end, 5, from the handle by removing the capscrew, 6, flat washer and locknut. Remove the ball end, 5, and jam nut,
7, from the rod.
1
6
5
19996889
Bucket Control Handle
11. Bucket control - Remove the nuts, 1, lock washers, and carriage bolts securing the handle support to the handle tube. Remove the handle support, 2, and control rod, 3, from the handle tube, 4.
1
3
2
7
4
255
3
4
2
256
12. Bucket control - Remove the locknut, 1, and bolt to separate the handle from the handle support.
Remove the ball end, 2, from the handle by removing the capscrew, 3, flat washer and locknut. Remove the ball end, 2, and jam nut, 4, from the rod, 5.
19996838
1
3
2
19996839
4
5
257
29-109
SECTION 29 - HYDROSTATIC TRANSMISSION
13. Loosen the boot securing bolts, 1, and slide the boot, 2, off the handle.
1
1
INSPECTION
1. Inspect the handle pivot bearings, 1; replace if worn or damaged.
2. Inspect the pivot stub shafts, 2, for any obvious bends or deformation.
3. Inspect the control handle for excessive wear or bends in the bearing mounting plates, 3.
19997750
2
2
3
19997747
4. Bucket control - Inspect the pivot handle linkage for looseness in the ball joints, 1; replace if worn.
5. Bucket control - Inspect the pivot handle, 2, and handle support, 3, for damage or deformation.
Replace as necessary.
2
19997751
3
1
1
1
258
259
260
29-110
SECTION 29 - HYDROSTATIC TRANSMISSION
6. Boom Hydraulics Control - Inspect the pivot handle linkage for looseness in the ball joints, 1; replace if worn.
7. Boom Hydraulics Control - Inspect the pivot handle, 2, and handle support, 3, for damage or deformation. Replace as necessary.
8. Boom Hydraulics Control - Inspect the handle lock components, 4. Replace the spring if bent or broken.
2
3
1
REASSEMBLY
1. Bucket control - Install a new hand grip on the top of the handle, 1, if grip is worn.
2. Bucket control - Attach the ball end, 2, and jam nut, 3, to the rod, 4, and fasten to the handle, 5, with the capscrew, 6, flat washer and locknut.
Position the flat washer between the ball end and handle. Do not tighten the jam nut at this time.
3. Bucket control - Attach the handle assembly to the handle support, 7, with the long bolt, 8, and locknut, 9.
4. Bucket control - Tighten the locknut to remove any movement between the handle assembly and support, but should be loose enough to all the handle to pivot without binding.
5. Bucket control - Slide the handle tube up through the slot, 1, in the handle support base.
6. Bucket control - Slide the handle sideways over the stub shafts.
7. Bucket control - Install the bearings, 2, on the handle, install shim washers, 3, to center the handle in the slot, 1. Fasten each bearing with two 5/16 ″ x 3/4 ″ carriage bolts, lock washers, and nuts at 4.
8. Bucket control - Install shim washers, 5, to reduce side play on the stub shafts. Retain the shims on the stubs shaft with a roll pin, 6.
9. Bucket control - Slide the rubber boot, 1, down over the end of the control handle, one side at a time, and secure with the the hardware, 2, removed during disassembly.
19996839
9
2
6
7
6
5
4
4 3
2
1
1
4
4
4
3
1
5
8
7
261
262
263
29-111
SECTION 29 - HYDROSTATIC TRANSMISSION
10. Bucket control - Attach the handle and rod assembly, 1, to the control handle by first sliding the rod down through the control handle tube, 2.
11. Bucket control - Attach the handle assembly to the handle tube arms, 3, with the short carriage bolts, 4, lock washers, 5, and nuts, 6. Tighten securely.
6
5
19996838
1
2
12. Boom hydraulics control - Install a new hand grip on the top of the handle, 1, if grip is worn.
13. Boom hydraulics control - Attach the ball end, 2, and jam nut, 3, to the rod, 4, and fasten to the handle, 5, with a 5/16
″
x 1-1/4
″
capscrew, 6, flat washer and locknut. Position the flat washer between the ball end and handle. Do not tighten the jam nut at this time.
14. Boom hydraulics control - Attach the handle assembly to the handle support, 8, with the long bushing, 3/8 ″ x 3-1/4 ″ capscrew and locknut at 9.
15. Boom hydraulics control - Tighten the locknut to remove any movement between the handle assembly and support, but should be loose enough to all the handle to pivot without binding.
16. Boom hydraulics control - Slide the handle tube up through the slot, 1, in the handle support base.
17. Boom hydraulics control - Slide the handle sideways over the stub shafts.
18. Boom hydraulics control - Install the bearings, 2, on the handle, install shim washers, 3, to center the handle in the slot, 1. Fasten each bearing with two 5/16 ″ x 3/4 ″ carriage bolts, lock washers, and nuts, 4.
19. Boom hydraulics control - Install shim washers,
5, to reduce side play on the stub shafts. Retain the shims on the stubs shaft with a roll pin, 6.
20. Boom hydraulics control - Slide the rubber boot,
7, down over the end of the control handle and secure with the the hardware removed during disassembly.
19996889
9
1
5
2
7
6
5
4
4 3
2
6
8
3
7
4
1
4
3
4
264
265
266
29-112
SECTION 29 - HYDROSTATIC TRANSMISSION
21. Boom hydraulics control - Attach the handle and rod assembly, 1, to the control handle, 2, by first sliding the rod, 3, down through the control handle tube.
22. Boom hydraulics control - Position the handle support on the tube by aligning the setscrew, 4, with the drilled hole in the tube. Tighten the setscrew and locknut.
4
19996890
23. Boom hydraulics control - Insert the spring and ball at 1. Insert the L-pin, 2, and drive the roll pin,
3, in flush to retain the L-pin.
3
2
1
267
24. Assemble the pivot shaft, 1, shim washers, 2, arm, 3, set collar, 4, and bearings, 5, into the control arm housing. Fasten each bearing with two 5/16 ″ x 3/4 ″ carriage bolts, lock washers, and nuts at 6.
25. Rotate the pivot shaft, 1, to position the arm upward as shown at 7.
26. Note the position of the arm, 3, on the shaft, 1, in relation to the arm at 7. Insert groove pin, 8, through arm, 3, and into shaft, 1, just far enough to position the arm. Do not hammer into place at this time.
1
2
3
19997746
268
3
5
6
5
4
8
2
1
7
269
29-113
SECTION 29 - HYDROSTATIC TRANSMISSION
27. Attach the ball end and jam nut, 1, onto rod, 2.
Install spacer, 12, (OD - 7/16 ″ ; length - 15/32 ″ ) between the ball end and arm, 3. Secure with a
5/16
″
x 1-3/4
″
bolt, lock washer, and nut at 4.
28. Install shim washers at 5, between the cotter pin,
6, and bearing, 7, to center rod, 2, in the control handle tube at 8. Secure the cotter pin and slide the set collar, 9, against the opposite bearing to remove any side movement of the shaft and tighten the setscrew.
29. Drive the groove pin, 12, in the arm completely into place.
30. With the handle in the neutral position angle, adjust the length of the rod, 2, so the ball stud at the arm, 3, aligns with the pivot bearings at 10.
This will also set the pivot arm, 11, in a vertical position.
31. Rotate the handle to make sure the rod, 2, does not interfere at the top or bottom of the control handle tube. Move the control handle back and forth (forward and reverse) and make sure the control arm, 3, does not move. When there is no movement, tighten the jam nuts at both ends of the rod.
8
10
9
2
12
1
6
3
5
4
10
7
11
270
REINSTALLATION
1. Place the handle assembly in the unit, install the handle mounting bolts, 1, and tighten securely.
1
271
2. Install the auxiliary hydraulic control or bucket control rod, 1, on the right control handle arm, 2.
19996848
2
29-114
1
272
SECTION 29 - HYDROSTATIC TRANSMISSION
3. Connect the hydrostatic pump control link, 1.
4. Reinstall all shields removed for the repair.
4802-10
1
273
29-115
SECTION 29 - HYDROSTATIC TRANSMISSION
Op. 29 130 06
DRIVE CONTROL ADJUSTMENT
PROCEDURE
If the machine creeps (tires rotate slowly with steering control in neutral) and the transmissions make a noise indicating they are being slightly stroked, a neutralizing adjustment is required.
CAUTION
To make a neutralizer adjustment, block the machine off the ground so that the wheels turn freely. Raise the boom and place it on the boom lockpins. When the engine is running, stay clear of the rotating wheels.
To make any transmission control linkage adjustments, first block the loader off the ground with the boom in the raised position resting on the boom lockpins. Unlatch the seat and raise it to the up locked position to access the transmission area.
CAUTION
Never work under a raised seat unless it is securely latched in the raised position.
Control lever, 1; link, 2; and arm, 3, control the right side. Control lever, 4; link, 5; and arm, 6 control the left side. There are shock absorbers, 7, connected to the steering linkage to dampen the hydraulic vibration from the control levers and the operator’s hands. The neutralizer plate, 8, is spring loaded to return the arms, 3 and 6, to their neutral position.
When the operator strokes both control levers in the same direction, the operator can release one lever and the unit will still run straight until the levers are stroked differently to change direction or both levers are released and then the unit will neutralize.
7
3
2
1
19992569
8
6
5
4
7
274
29-116
SECTION 29 - HYDROSTATIC TRANSMISSION
Op. 29 130 06
NEUTRAL ADJUSTMENT
Before making any adjustments, make sure there is no binding in the control linkage, shock absorbers or neutralizer plate. The neutralizer plate, 1, should be free to move on the spring retaining bolt at the engine bell housing, 2, and on the front slides, 3. The neutralizer plate should be against the stop on the engine bell housing at 4.
The skid steer must be raised and supported with the tires off the ground. Use adequate blocking or jack stands to securely support the skid steer.
19992569
4
1
3
The engine must be started and running to make neutral adjustments. Place the “Service/Run”
Switch, 1, in the “SERVICE” position to allow the engine to be started and to prevent movement of the boom and bucket.
To access the “Service/Run” switch located under the fuse panel cover, 2, loosen the two thumbscrews,
3, and rotate the cover to the side.
3
1
2
2
19984593
To adjust the right side, loosen the block retaining bolts, 1, slightly and move the control arm, 2, to stop wheel rotation. Now move the block so it contacts both cams on arm, 2, and tighten the retaining bolts,
1.
To adjust the left side, loosen the block retaining bolts, 3, slightly and move the control arm, 4, to stop wheel rotation. Now move the block so it contacts the cams on arm, 4, and tighten the retaining bolts, 3.
Stop the engine after adjustments are made and recheck hardware torque.
NOTE: The blocks must be set square and firmly contact both cams on the arms. If the block is not square against both cams on the arms, the unit may creep after neutral adjustments are made.
2
19992569
3
1
4
275
276
277
29-117
SECTION 29 - HYDROSTATIC TRANSMISSION
Control Lever Parallel Adjustment
The control levers, 1 and 2, are set at the factory at
9 degrees to the front. The levers can be adjusted so the two levers are parallel. To adjust the levers, loosen bolts, 3, and move the levers to the desired position and retighten the hardware. Moving the control levers too far one direction will change maximum speeds.
1
19992568
3
Control Lever Stop Adjustment
If the control lever location has been changed for any reason, the control lever stops will require adjustment. The control lever stops must be adjusted properly to prevent damage to the linkage and internal transmission components. The lever stops are the lower control lever boot assembly, 1.
To adjust the stops, follow these steps:
1. Loosen the four cap screws, 2, each lever stop.
2. Pull the control lever forward until the internal transmission stop is felt and hold the linkage against the internal stop.
3. Slide the boot stop assembly to the rear to contact the control lever and then push the stop and lever another 1 mm (1/32 ″ ). This will ensure that when the control levers are fully stroked, the lever will contact the external stop and not the internal transmission stop.
4. Check wheel speed using a hand tach from side to side and slow down the faster side by moving the boot stop and lever to the rear on the fast side.
CAUTION
T he skid steer must be raised and supported with the tires off the ground. Use adequate blocking or jack stands to securely support the skid steer.
5. Check and tighten all control lever linkage hardware.
IMPORTANT: If the external control lever stops are not adjusted properly, the control linkage and transmission may be damaged.
6. Return the “Service/Run” switch to the “RUN” position.
2
19992573
1
2
1
2
2
278
279
29-118
SECTION 29 - HYDROSTATIC TRANSMISSION
LABOR GUIDE
HYDROSTATIC SYSTEM AND STEERING SYSTEM
The following labor amounts are listed as a guide only. Working conditions and experience will vary the time it actually takes to complete each job.
Job Hours
Hydrostatic pump - RH & LH assembly - remove/replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 hrs.
Hydrostatic pump - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 hr.
Hydrostatic motor RH - remove/replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 hrs.
Hydrostatic motor LH - remove/replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 hrs.
Hydrostatic motor - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 hr.
Charge check valve - remove/replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hr.
Neutralizer plate assembly - remove/replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hr.
Hydrostatic control handle assembly - remove/replace one assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 hr.
Hydrostatic control handle assembly - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hr.
Neutral adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hr.
Time required to tilt cab and boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 hr.
29-119
Section
SECTION 33 – BRAKES AND CONTROLS
Chapter 1 – Parking Brake
CONTENTS
Description Page
33-1
SECTION 33 - BRAKES AND CONTROLS
Op. 33 000
GENERAL INFORMATION
The power is transmitted to the final drive from the engine which is connected to the hydrostatic pumps,
1, with a flex plate drive coupler. The hydrostatic pumps then transmit hydraulic power to the hydrostatic motors, 2, which are connected to gearboxes,
3, located on the inside of the final drive cases. The left and right drives are separate from each other and are operated independently.
2
3
19992569
The power is then transmitted through gears to a double drive sprocket, 1, in the final drive case. The drive sprocket is connected to the axle sprockets, 2, with chains, 3, one endless chain to the front axle and one endless chain to the rear axle.
1
1
2
The axle sprocket, 1, is splined to the axle shaft and hub assembly, 2. A large O ring, 3, seals the assembly to the frame.
3
33-2
SECTION 33 - BRAKES AND CONTROLS
The parking brake discs are connected to the hydrostatic motor coupler shafts at 1. The parking brake is made up of two discs, actuator shaft, pads, and control linkage. The hydrostatic system is the primary braking system, and the parking brake is used when the unit is stopped.
CAUTION
Always engage the parking brake before exiting the loader.
1
1
4
1 - PARKING BRAKE DISCS
5
33-3
SECTION 33 - BRAKES AND CONTROLS
SPECIFICATIONS
Chain Case
Side Cover Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N·m (11 ft. lbs.)
Brake Caliper Mounting Bolt (center) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N·m (15 ft. lbs.)
Brake Caliper Mounting Bolts (outer) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 N·m (52 ft. lbs.)
Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #80
Front Chain Length (68 pitches)
Rear Chain Length (66 pitches)
Chain Tension
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1727.2 mm (68 ″ )
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1676.4 mm (66 ″ )
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 – 6 mm (0 - 1/4
″
) movement at tire tread
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 liters (2 gal.) each side - 10W-30API service SG-CE Oil
Other Materials
Description Use
Ultra/Blue Silicone sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearbox mounting bolts
Axle housing bolts
Chain case cover and bolts
Gearbox to chain case
Brake caliper bolts
Gearbox cover and bolts
Sealing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH Ultra Blue silicone sealer
NH #L81724 - 3.35-oz. tube (cord)
NH #L82519DS - 8-oz. tube
NH #L58775 - 10.2-oz. cartridge
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE10W-30 motor oil-API Service SG-CE
NH #9613313 - 1 qt.
NH #9613314 - 2 1/2 gal.
NH #9613358 - 1 L
NH #9613360 - 20 L
Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80W-90 API Service GL-5 Gear Oil
NH #9613295 - 1 qt.
NH #9613294 - 5 gal.
NH #9613375 - 4 L
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High viscosity lithium base
NH #9613310 tube
NOTE: Always use a noncorrosive silicone sealer to seal where required to prevent corrosion during the silicone curing process.
33-4
SECTION 33 - BRAKES AND CONTROLS
TROUBLESHOOTING
FINAL DRIVE/PARKING BRAKE SYSTEM
Before servicing or adjusting on the final drive/parking brake system, the skid-steer loader should be jacked up with the wheels off the ground.
Remove any attachment from the skid-steer loader boom, bucket, etc. Lower the boom to the lowered position or, if servicing requires the boom to be in the raise position, support the boom on the boom locks.
Raise the boom and lower onto boom lock pins, 1.
1. Raise boom above boom lock pins.
2. Engage boom lock pins.
3. Stop engine, ignition key “OFF” position.
4. Turn ignition key to the “ON” position.
5. Lower boom onto boom lock pins.
6. Turn the ignition key to the “OFF” position.
CAUTION
Never exit the loader with the boom in the raised position unless the boom is supported on the boom lock pins.
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment mounted. Always remove the attachment from the loader.
Jack up the loader and support the loader with the wheels off the ground using adequate jack stands or blocks to securely support the loader.
Support the loader at the front of the final drive cases at 1, and at the rear at 2.
CAUTION
Never service a raised loader unless it is securely supported with adequate jack stands or blocks.
6
7
33-5
SECTION 33 - BRAKES AND CONTROLS
TROUBLESHOOTING
PARKING BRAKE SYSTEM
PROBLEM
Parking brake will not hold loader
POSSIBLE CAUSES
Park brake not engaged
Brake not adjusted properly
Handle not operating or latching
Loose brake linkage
Worn brake pad
CORRECTION
Engage parking brake
Adjust parking brake
Check handle components repair or replace
Inspect and repair linkage
Inspect and repair brake pad
Parking brake will not release Brake not adjusted properly
Handle not operating properly
Brake caliper not releasing
Parking brake handle will not move or release
Handle not operating properly
Control linkage not moving
Brake caliper not releasing
Grinding noise when operating Handle not releasing properly
Brake not adjusted properly
Brake caliper not releasing
Adjust parking brake
Check handle components repair or replace
Check brake caliper and repair
Check handle components repair or replace
Check and repair linkage
Check brake caliper and repair
Check handle components repair or replace
Adjust parking brake
Check brake caliper and repair
33-6
SECTION 33 - BRAKES AND CONTROLS
TESTING
PARKING BRAKE
Pre-test instructions:
* Operator in seat with seat belt buckled.
* Engine running at 1500 RPM.
* Park brake disengaged position.
STEP
1
2
3
TEST
Push both drive controls forward equally and loader should move without restriction.
RESULT PROBABLE CAUSE AND CORRECTION
YES Brake system OK.
NO Parking brake not releasing, check control handle. If
OK go to next step.
Parking brake linkage not free, check for loosen or binding linkage. If OK go to next step.
Parking brake not releasing check caliper and brake pad and repair.
Pre-test instructions:
* Operator in seat with seat belt buckled.
* Engine running at 1500 RPM.
* Park brake engaged position.
STEP
1
2
3
TEST
Push both drive controls forward equally and loader should not move.
RESULT PROBABLE CAUSE AND CORRECTION
NO Parking brake OK.
YES Parking brake not adjusted properly. If OK go to next step.
Parking brake linkage loose or broken. If OK go to next step.
Parking brake caliper not operating properly. Check and repair.
33-7
SECTION 33 - BRAKES AND CONTROLS
Op. 33 110
PARKING BRAKE
OPERATION
The parking brake system is a mechanically activated double disc brake system. The brake discs are attached to the hydrostatic motor shafts, 1, with a separate system located in each final drive case.
Both brake systems are activated by a single control lever.
1
The parking brake control lever, 1, is located to the right of the operator’s seat. When the lever is in the lower unlatched position, the brake is disengaged.
When the lever is in the raised latched position, the brake is engaged.
When the parking brake is engaged and the hydrostatic control levers are stroked, the skid-steer loader should not move if the brake is adjusted properly.
The hydrostatic system is the primary brake for the skid-steer loader when the unit is in operation. The parking brake system is only for a stopped machine, to hold the unit in place and prevent rolling or creeping when parked.
The parking brake should always be engaged before exiting the skid-steer loader.
CAUTION
Always activate the parking brake before leaving the operator station. Never operate the skid-steer loader unless the brake is released.
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1
8
9
33-8
SECTION 33 - BRAKES AND CONTROLS
REMOVAL AND INSPECTION
To access and remove the parking brake control linkage, the seat can be raised and latched in the raised position. To access the brake disc and caliper assembly, the final drive inspection cover will need to be removed.
Op. 33 110 48
Removal
1. Lower the boom and attachment to the ground.
2. If the work is going to be done with the boom in the raised position, remove the attachment and raise the boom and rest on the boom lock pins,
1.
CAUTION
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment. Always remove the attachment from the loader.
3. Securely block the skid-steer loader with all four wheels off the ground. Refer to Section 1 for more detailed information on properly supporting the skid-steer loader.
Support the loader at the front of the drive cases at 1, and at the rear at 2.
CAUTION
Failure to securely support the skid-steer loader could result in movement of the loader causing serious injury or damage to the equipment.
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11
33-9
SECTION 33 - BRAKES AND CONTROLS
4. Slide the seat to the most rear position and unlatch the seat pan and raise the seat and pan assembly to the raised latched position.
CAUTION
Before working under a raised seat make sure it is securely latched at 1, in the raised position.
5. Remove the rear tire and wheel from the final drive and brake being serviced.
6. Clean the rear axle and final drive area to prevent debris from entering the final drive case.
7. Loosen the eight axle housing retaining nuts and washers, 1, on the rear axle and slide the axle forward to loosen the drive chain.
8. Remove the fender retaining hardware at 2, and remove the fender to access the spring and linkage.
9. Remove the final drive case center cover, 3.
Op. 33 110 14
Brake Control Linkage Removal
1. Remove the handle retaining bolts, 1, slide the handle, button and spring, and latch plate assembly, 2, from the link, 3.
Note the positioning of the internal latch plate for reassembly.
OPS5461
12
13
14
33-10
SECTION 33 - BRAKES AND CONTROLS
Op. 33 110 30
2. To remove the control rod assembly, 1, remove the cotter pins from the spring links, 2.
3. Remove the left support bracket and hardware,
3, then pivot the rod assembly down and slide the control rod from the right support bracket.
Remove the pivot bushings from supports and friction pad from rod.
4. Remove the lower cotter pin, 4, and remove the spring assemblies, 5, from the brake caliper actuator arm, 6.
5
2
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4
6
1
Parking Brake Control Linkage and Related
Parts
Ref.
Description
1 Control handle and related parts
2 Control shaft, bearings, support
3 Spring assembly a. Spring b. Spring links (2)
4 Arm
5 Friction pad
2
3
5
15
16
Spring Disassembly
1. Compress spring plate and spring, 1, to expose enough shaft to clamp vise grips, 2.
2. Remove roll pin, 3.
1
3
2
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17
33-11
Spring Brake Assembly Parts
1. Shaft Weld Assembly
2. Roll Pin
3. Spring Plate
4. Threaded Rod
5. Spring
SECTION 33 - BRAKES AND CONTROLS
1
2
3
5
19995773
Inspection of Control Linkage Parts
1. Examine the latch plate, 1, and tab, 2, for bends or damage. If the latch plate looks like 1, replace with a new latch plate, 2, part #9844477.
2. Inspect the spring, 3, for correct free spring length, 66.7 ± 3.2 mm (2-5/8 ± 1/8 ″ ), 4. Replace if not within specification.
3. Inspect the button and rod assembly, 5. If worn in the hook area of the rod, replace.
4. Inspect the latch plate pivot bushing, 6. Replace if worn.
5. Inspect the control rod assembly, 1, friction pad,
2, and pivot bushings, 3, for wear. If worn, replace.
6. Inspect the spring assembly and check the spring free length, 1, 335.0
±
12.7 mm (13-3/16
±
1/2
″
). Replace if not within specification.
4
18
19
20
33-12
SECTION 33 - BRAKES AND CONTROLS
Installation of Brake Control Linkage
1. Install the control rod assembly, 1, friction pad, 2, on right end of rod. Insert pivot bushing, 3, into supports, and slide the right end into support and pivot link, 3, up and install the left support, 4.
21
2. Insert the button rod, 1; spring, 2; and flat washer,
3, into lever at 4.
3. Insert the latch plate, 5, and bushing, 6, with the extended area, 7, as shown to the rear (engine side) of lever and position the button rod so the hook is back of the latch plate at 8. Reinstall the two retaining bolts, nuts and washers, through the lever assembly and the control rod.
22
Spring Reassembly
1. Reassemble the spring, 1, rod weld assembly, 2, and spring plate, 3.
2. Compress spring, 1, and plate, 3, enough to clamp vise grips onto end of rod weld assembly at 4, to install roll pin, 5.
3. Install roll pin, 5.
4. Thread rod assembly, 6, into rod weld assembly.
6
5
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4
3
1
2
23
33-13
SECTION 33 - BRAKES AND CONTROLS
5. Adjust the spring assembly length by threading rod, 1, in or out to obtain an overall length of
8-5/8 ″ at 2.
2
1
Op. 33 110 48
Brake Caliper and Disc Removal
The loader must be properly supported with all four wheels off the ground.
1. Remove the rear axle assembly.
2. Remove the rear drive chain from the drive sprocket and push chain to the rear.
3. Engage the parking brake.
4. Remove the center brake disc retaining bolt and washer, 1.
5. Disengage the parking brake.
6. Loosen the caliper retaining hardware, 2, from the inside of cab. Thread the two bolts from the outside caliper assembly, 3. DO NOT remove bolts from caliper support at this time.
7. Remove the outside disc, 4.
8. Remove center section of caliper, 1, spacers, 2, and now remove the retaining bolts.
9. Remove inside disc, 3.
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25
26
33-14
SECTION 33 - BRAKES AND CONTROLS
10. Remove brake friction puck, 1, and spacer plate,
2.
NOTE: The spacer plate is thinner than the friction puck and must be inserted into brake caliper first upon reassembly.
11. Remove the caliper support retaining bolt, 1, and remove the support from the loader.
12. Remove the setscrew, 2, from the arm, 3, and slide the arm from the shaft, 4.
13. Rotate the caliper shaft, 4, from the support.
Brake Caliper and Disc Parts Inspection
Thoroughly clean all parts of sealing material etc. before inspection.
Brake caliper and related parts
Ref.
Description
1 Brake disc retaining hardware
2 Brake disc (2)
3 Brake puck (1)
4 Spacer plate (1)
5 Caliper support and hardware
6 Shaft
7 Center caliper plate
8 Bushings and hardware
9 Outer caliper section
27
28
29
33-15
SECTION 33 - BRAKES AND CONTROLS
1. Inspect the brake disc for wear in the clamp area,
1, and splines, 2. The disc should also be flat. If worn severely or bent, replace.
2. Inspect the brake friction puck, 1. If worn severely, replace.
3. The spacer plate, 2, will show a small amount of wear in the center next to the shaft at 3. This is normal.
NOTE: The spacer plate, 2, must be installed into the caliper support, 4, first during reassembly.
4. Inspect the caliper center plate, 1, and bushings,
2, for wear. Replace if worn.
30
31
32
33-16
SECTION 33 - BRAKES AND CONTROLS
Inspect the caliper outer plate for wear. Replace if worn.
Inspect the thread area, 2, and if damaged, replace outer plate.
5. Inspect the caliper support, 1, and shaft thread area, 2. If damaged and shaft rotates hard in support, replace the damaged part. Inspect the shaft seal, 3; replace if damaged. Inspect the control arm, 4, for damaged splines; replace as required.
NOTE: The brake caliper support and shaft will be right or left thread depending which side of machine it is from. The right threaded assembly is for the right side of unit; the left threaded assembly is for the left.
Brake Caliper and Disc Reassembly
1. Install a new seal, 1, in support at 2, if required.
Apply a coating of never-seize lubricant on the threads of the shaft, 3, and in the support and thread the shaft into the support at 2. Put a bead of noncorrosive silicone sealer around the end of support at 4.
NOTE: The brake caliper support and shaft will be right or left thread depending which side of machine it is from. The right threaded assembly is for the right side of unit; the left threaded assembly is for the left.
33
34
35
33-17
SECTION 33 - BRAKES AND CONTROLS
2. Install the correct, right or left, caliper support, 1, in the final drive case. Position and install retaining bolt, 2, and tighten to 12 N·m (9 ft. lbs.).
3. Install the spacer plate, 2, next to the end of shaft, then the brake friction puck, 1.
NOTE: The thin spacer plate must be inserted into the caliper support first, then the friction puck, to insure proper brake operation.
4. Install the inside brake disc, 1, onto splined motor coupler shaft.
5. Put a bead of silicone sealer around the caliper retaining bolts and insert in support.
6. Slide the spacers, 2, and center of caliper, 3, over bolts.
36
37
38
33-18
SECTION 33 - BRAKES AND CONTROLS
7. Install outer brake disc, 1, on motor shaft.
8. Thread caliper retaining bolts into outer section of caliper, 2, and tighten to 70 N·m (52 ft. lbs.).
Check the center section of the caliper, 3, to make sure it is free to move.
9. Put a bead of sealer on end of motor coupler and install the brake disc retaining bolt and large flat washer, 1. Tighten to 35 N·m (26 ft. lbs.).
39
40
10. Thread the shaft, 1, into the support, 2, to remove all play in brake caliper and disc.
11. Rotate and position the control arm, 3, so the spring link can be reconnected at 4.
– Then slide the control arm onto the shaft.
– Position the control arm on the shaft for clearance between arm and other components when the brake is engaged and disengaged.
– Tighten the retaining screw, 5, in the control arm.
– Install cotter pin in spring link at 4.
41
33-19
SECTION 33 - BRAKES AND CONTROLS
12. Reinstall the drive chain over the drive sprocket at 1.
42
13. Install the rear axle assembly. Slide the axle assembly to the rear and tighten the drive chain to obtain a movement of 0 - 6 mm (0 - 1/4
″
) movement at the outer tire tread.
Tighten the retaining bolts, 1, to 190 N·m (140 ft.
lbs.).
14. Reseal and install the final drive cover, 3.
15. Check the final drive case oil level and add as required, 4.
16. Reinstall fender, 5, and all other shields removed for the repair.
Parking Brake and Linkage Adjustment
When the parking brake is properly adjusted and engaged it will hold a powered loader.
Spring Adjustment
Parking brake in the disengaged position.
1. Measure the spring length from the top to the bottom of the spring retainer at 1.
2. Adjust the spring assembly by threading rod, 2, in or out to obtain an overall length of 8-5/8
″
at 1.
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44
33-20
SECTION 33 - BRAKES AND CONTROLS
Caliper Adjustment
Parking brake in the disengaged position.
1. Unhook the lower pin of the spring assembly, 1, from the control arm at 3.
2. Push the arm, 2, down to turn the shaft into the caliper support to remove any play in caliper and disc.
3. Loosen the setscrew in arm at 4, and slide arm off the shaft.
4. Rotate the arm up so the spring can be rehooked and slide the arm on the corresponding shaft splines.
5. Position the control arm on the shaft for clearance between arm and other components when the brake is engaged and disengaged.
6. Tighten the retaining screw in the control arm.
7. Connect the spring to the arm and install cotter pin in spring link at 3.
NOTE: The parking brake control lever must be in the lower (disengaged position) for parking brake adjustment.
45
33-21
SECTION 33 - BRAKES AND CONTROLS
LABOR GUIDE
The following labor amounts are listed as a guide only. Working conditions and experience will vary the time the job actually takes to complete each job.
Hours Job Description
Brake
Handle - remove, rebuild, replace
Spring - remove, rebuild, replace
Disc - remove and replace
Caliper - remove and replace
Friction Disc (puck) - remove and replace
Adjust parking brake
1.0 hr.
0.5 hr.
1.0 hr.
1.5 hr.
1.0 hr.
0.5 hr.
33-22
SECTION 35 - HYDRAULIC SYSTEM
Chapter 1 - Valves, Gear Pump, Cylinders, and Pedal Controls
Section
CONTENTS
Description Page
Checking Main System Pressure at Auxiliary Boom Hydraulic Quick Couplers . . . . . 35-32
Hydraulic System Pump Removal/Disassembly (Without High Flow) . . . . . . . . . . . . . . 35-56
Hydraulic System Pump and High Flow Removal/Disassembly . . . . . . . . . . . . . . . . . . 35-56
35-1
SECTION 35 - HYDRAULIC SYSTEM
Hydraulic System Pump Reassembly/Installation (Without High Flow) . . . . . . . . . . . . 35-61
Hydraulic System Pump and High Flow Pump Reassembly/Installation . . . . . . . . . . . 35-64
35-2
12
SECTION 35 - HYDRAULIC SYSTEM
10 9
1
13
14
14
13
11
6 5
4
14
2
7
3
8
19997771
11
12
Op. 35 000
GENERAL INFORMATION
The hydraulic system provides hydraulic oil to the boom and bucket, and the return oil provides charge oil for the hydrostatic drive system. On skid steers equipped with the auxiliary boom hydraulic kit, system oil will be provided to quick couplers at the front of the boom to operate hydraulic attachments. The hydraulic system is an open center type system. The gear pump provides continuous oil flow through the system to the boom, bucket circuits, auxiliary boom circuit, if equipped, and the hydrostatic drive charge circuit.
A open center system means the first control valve function has priority over the next function in line.
NOTE: The return oil must follow the normal return path from the control valve to the oil cooler/filter and back to the hydrostatic charge pressure inlet on the transmissions or severe damage to the hydrostatic system may occur.
Figure 1 shows the hydraulic circuit and components for the LS160 and LS170 skid steers.
The hydraulic system is built with the following components and their location.
1
1. Hydraulic reservoir - Right front of engine compartment
2. Suction line - From reservoir to the gear pump under operator’s seat
3. Gear pump - Under the operator’s seat
4. Pressure line - From gear pump to control valve
5. Control valve (three spool) - Under operator’s step shield
6. Main system relief valve - In control valve
7. Return line - From control valve to oil cooler
8. Oil cooler - Engine side of radiator in engine compartment
9. Filter - Right rear of engine compartment through rear door
10. Charge check valve - After filter and before the reservoir
11. Bucket cylinders
12. Boom cylinders
13. Auxiliary boom hydraulics
14. Optional high flow kit - Dealer installed kit - Refer to Section 88 - “Accessories” for more information.
35-3
SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC SYSTEM COMPATIBILITY
There are six questions that must be answered before adapting attachments that require hydraulic oil power.
1. What is the hydraulic pressure requirement, minimum and maximum? Are they higher than the maximum pressure of the model?
Model Maximum Pressure
LS160 and LS170 170-176 bar
(2500 - 2600 PSI)
2. What is the hydraulic oil flow requirement? Is it more than the highest total flow rate of the skidsteer loader model?
2
Model
LS160
LS170
Standard Hydraulics
15.5 GPM (58.7 l/min.) @2900 RPM
@1000 PSI (68 bar)
17.7 GPM (67.0 l/min.) @2900 RPM
@1000 PSI (68 bar)
NOTE: When using the High-Flow system, 3/4
,
quick couplers must be used or high system backpressure may result.
3. Will the attachment accept oil flow in both directions?
If “YES”, nothing is required.
If “NO”, install a check valve or cross into the attachment return line to prevent reverse oil flow to the attachment.
Examples: Backhoes and trees spades with a separate control valve do not accept oil flow in both directions.
4. Must the attachment “Free Wheel” to a STOP?
If “YES”, a crossover relief connection must be installed on the attachment side to allow the attachment to free wheel to a stop after the skidsteer loader hydraulics is turned off.
If “NO”, nothing is required.
Example: Snow blowers must free wheel to a stop.
High Flow Hydraulics
24.0 GPM (90.8 l/min.) @2900 RPM
@1000 PSI (68 bar)
26.2 GPM (99.2 l/min.) @2900 RPM
@1000 PSI (68 bar)
5. Will the attachment accept hydraulic system backpressure?
If “YES”, nothing is required.
If “NO”, the attachment will not function properly on a New Holland skid-steer loader. Normal backpressure for New Holland skid-steer skid steers is between 200 - 250 PSI.
Examples: Post drivers, some breakers, and some hand held hydraulic tools do not accept system backpressure.
If all the skid-steer loader oil flow is not required to operate an attachment (e.g., shaver post driver), a flow divider can be installed into the hydraulic oil circuit on the attachment. The flow divider sends the required oil flow to the attachment and the remainder back to the normal skid-steer loader hydraulic circuits.
Model LS160 and LS170 skid steers must have a minimum of 22.7 l/min. (6 GPM) returning through the main hydraulic system at all times, required to charge the hydrostatic system.
35-4
SECTION 35 - HYDRAULIC SYSTEM
6. Does the attachment have a separate case drain oil line?
If “NO”, nothing is required.
If “YES”, install a separate case drain line to return the attachment case drain oil directly to the hydraulic oil reservoir.
Example: Cold planners have a separate case drain oil line.
NOTE: Most attachment case drains will not accept backpressure and must drain directly into the reservoir.
NOTE: Skid steers equipped with High Flow
Hydraulics have a separate case drain coupler and return line attached to the right boom arm.
7. Does the attachment require circuit relief in the bucket circuit?
If “NO”, nothing is required.
If “YES”, install a bucket circuit relief valve on front of the control valve.
Example: Some mini-backhoes attach like a bucket, and require a bucket circuit relief.
35-5
SECTION 35 - HYDRAULIC SYSTEM
BOOM CYLINDER PIVOT PINS
When the main boom, upper and lower boom links and cylinders are removed, the figure and chart here may be used for proper pin placement.
The figure and chart show the boom and cylinder tapered and straight pivot pins, location/description, quantity used, and part number.
BOOM AND CYLINDER PIVOT PIN
LOCATION AND MACHINE USAGE
1 Mounting Plate Pivot
2 Upper Bucket Cylinder Pivot
3 Lower Bucket Cylinder Pivot
4 Upper Boom Cylinder Pivot
5 Lower Boom Cylinder Pivot
Qty.
Part Number
2
2
86501434
86501430
2
2
9614349
86521982
2 86504316
3
35-6
SECTION 35 - HYDRAULIC SYSTEM
CONTROL VALVE POWER BEYOND
Control valve, used on all skid-steer skid steers, has a plugged power-beyond port, 1. This port is not normally used with New Holland-supplied attachments, as these can be operated through the auxiliary boom hydraulics (the third control valve spool), 2.
2
19987103
1
To use the power-beyond port for a second oil supply to additional attachments, remove the factory powerbeyond plug to access inner hole, 1. This hole must be plugged to divert oil to the power beyond instead of normal oil flow to the out port.
19987104
1
Install part #236622 allen head type pipe plug in the inner port, 1. Tighten the plug securely. A regular
O ring type fitting can now be inserted in the powerbeyond port.
IMPORTANT: Once the power-beyond fitting and plug is installed, oil must be constantly returned from the attachment valve into the return line, 2. If oil is blocked at the power-beyond port, hydraulic system overheating and component damage could occur.
Also, engine horsepower requirements will increase.
A tee fitting can be inserted in the return line at 2, for attachment oil return.
19987105
1
2
4
5
6
35-7
SECTION 35 - HYDRAULIC SYSTEM
SPECIFICATIONS
SKID STEER MODEL
MAIN CONTROL VALVE
LS160
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-spool open center
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 - 177 bar (2500 - 2600 PSI) Nonadjustable
Circuit Relief (boom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 bar (3500 PSI) Nonadjustable
Electrical solenoid boom and bucket spool locks (controlled by the EIC) will lock the control valve spools when the operator is out of the seat or the ignition key is in the “OFF” position with the spools in the neutral position.
HYDRAULIC PUMP
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump
Output @ 2900 RPM - @ 1000 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5 GPM (58.7 LPM)
BOOM CYLINDERS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double Acting
Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5 mm (2.5
″
)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470.15 mm (18.51
″
)
Cycle Times (Seconds)
Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5
3.5
BUCKET CYLINDERS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double Acting
Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.15 mm (2.25
″ )
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454.15 mm (17.88
″ )
Cycle Times (Seconds)
Curl back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Curl down (dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
2.8
RESERVOIR
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 gal. (22.7 L)
Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 10W-30 API Service SH/CG4 motor oil
Filter Spin-on Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 micron
35-8
SECTION 35 - HYDRAULIC SYSTEM
TORQUE SPECIFICATIONS
SKID STEER MODEL
Control Valve
LS160
Control Valve Retaining Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N·m (18 ft. lbs.)
Control Valve Plugs (large) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Control Valve Plugs (small) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 N·m (23 ft. lbs.)
Circuit Relief Valve (boom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Spool Lock Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N·m (11 ft. lbs.)
Solenoid Mounting Block Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 N·m (12 ft. lbs.)
Main System Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 N·m (38 ft. lbs.)
Spool Cap Assembly Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 N·m (12 ft. lbs.)
Plug, BYD Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Boom Cylinders
Piston Locknut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 N·m (170 ft. lbs.)
Cylinder Gland Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 N·m (225 ft. lbs.)
Lower Pivot Pin Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 N·m (250 ft. lbs.)
Upper Pivot Pin Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Bucket Cylinders
Piston Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 N·m (285 ft. lbs.)
Cylinder Head Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 N·m (210 ft. lbs.)
Lower Pivot Pin Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Upper Pivot Pin Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 N·m (80 ft. lbs.)
Gear Pump
Pump Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N·m (29 ft. lbs.)
Pump Body Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 N·m (26 ft. lbs.)
OTHER MATERIALS
Sealing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH Ultra Blue silicone sealer
NH #L81724 - 3.35 oz. tube (cord)
NH #L82519DS - 8 oz. tube
NH #L58775 - 10.2 oz. cartridge
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE10W-30 motor oil-API Service SH/CG4
NH #9613313 - 1 qt.
NH #9613314 - 2 1/2 gal.
NH #9613358 - 1 L
NH #9613360 - 20 L
NOTE: Always use a noncorrosive silicone sealer to prevent damage to the components being sealed during the silicone curing process.
35-9
SECTION 35 - HYDRAULIC SYSTEM
SPECIFICATIONS
SKID STEER MODEL
MAIN CONTROL VALVE
LS170
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-spool open center
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 - 177 bar (2500 - 2600 PSI) Nonadjustable
Circuit Relief (boom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 bar (3500 PSI) Nonadjustable
Electrical solenoid boom and bucket spool locks (controlled by the EIC) will lock the control valve spools when the operator is out of the seat or the ignition key is in the “OFF” position with the spools in the neutral position.
HYDRAULIC PUMP
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump
Output @ 2900 RPM - @ 1000 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.7 GPM (67.0 LPM)
BOOM CYLINDERS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double Acting
Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5 mm (2.5
″
)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470.15 mm (18.51
″
)
Cycle Times (Seconds)
Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7
2.3
BUCKET CYLINDERS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double Acting
Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.15 mm (2.25
″ )
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454.15 mm (17.88
″ )
Cycle Times (Seconds)
Curl back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Curl down (dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.54
1.75
RESERVOIR
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 gal. (22.7 L)
Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 10W-30 API Service SH/CG4 motor oil
Filter Spin-on Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 micron
35-10
SECTION 35 - HYDRAULIC SYSTEM
TORQUE SPECIFICATIONS
SKID STEER MODEL
Control Valve
LS170
Control Valve Retaining Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N·m (18 ft. lbs.)
Control Valve Plugs (large) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Control Valve Plugs (small) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 N·m (23 ft. lbs.)
Circuit Relief Valve (boom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Spool Lock Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N·m (11 ft. lbs.)
Solenoid Mounting Block Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 N·m (12 ft. lbs.)
Main System Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 N·m (38 ft. lbs.)
Spool Cap Assembly Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 N·m (12 ft. lbs.)
Plug, BYD Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Boom Cylinders
Piston Locknut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 N·m (170 ft. lbs.)
Cylinder Gland Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 N·m (225 ft. lbs.)
Lower Pivot Pin Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 N·m (250 ft. lbs.)
Upper Pivot Pin Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Bucket Cylinders
Piston Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 N·m (285 ft. lbs.)
Cylinder Head Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 N·m (210 ft. lbs.)
Lower Pivot Pin Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Upper Pivot Pin Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 N·m (80 ft. lbs.)
Gear Pump
Pump Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N·m (29 ft. lbs.)
Pump Body Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 N·m (26 ft. lbs.)
OTHER MATERIALS
Sealing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH Ultra Blue silicone sealer
NH #L81724 - 3.35 oz. tube (cord)
NH #L82519DS - 8 oz. tube
NH #L58775 - 10.2 oz. cartridge
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE10W-30 motor oil-API Service SH/CG4
NH #9613313 - 1 qt.
NH #9613314 - 2 1/2 gal.
NH #9613358 - 1 L
NH #9613360 - 20 L
NOTE: Always use a noncorrosive silicone sealer to prevent damage to the components being sealed during the silicone curing process.
35-11
TROUBLESHOOTING
When performing a test on the hydraulic system, use the proper test procedures and test equipment.
Before testing, lower the attachment to the ground or remove the attachment from the loader.
If testing is to be performed with a raised boom, make sure the boom is raised above and resting on the boom lock pins.
Before opening the hydraulic system, clean the area thoroughly to prevent contaminating the system.
Before opening the hydraulic system, relieve all pressure from the system.
Before testing the hydraulic system, check the hydraulic oil level.
Before testing the hydraulic system, the oil must be at normal operating temperature.
If testing requires the skid-steer loader to be raised, use adequate blocking and/or jack stands to securely support the loader.
CAUTION
When connecting test equipment into the hydraulic system, relieve the pressure in the system. stop the engine, turn the ignition switch to the “ON” Position and operate all hydraulic control valve circuits to relieve pressure. Turn the ignition switch to the “OFF” Position.
SECTION 35 - HYDRAULIC SYSTEM
WARNING
Gauges, gauge fittings, and hoses must have operating pressure ratings of at least 25% higher than the highest pressures of the system.
Never adjust or replace the relief valves to get higher pressures than those specified by the equipment manufacturer.
Fluid under pressure can have sufficient force to penetrate the skin, causing serious personal injury. Always protect the skin and eyes from escaping fluid under pressure.
Before disconnecting lines or fittings, be sure to turn off the skid steer engine and relieve all pressure. Before applying pressure to the system, be sure all connections are tight and that lines, pipes, and hoses are not damaged.
If injured by escaping fluid, obtain medical assistance at once. Serious infection or reaction can develop if medical treatment is not administered immediately.
Remove any attachment from the mounting plate before loosening or disconnecting any hydraulic lines.
CAUTION
Use adequate blocking and/or jack stands to insure that the loader is safely supported with all four wheels off the ground.
35-12
PROBLEM
Noisy system pump
SECTION 35 - HYDRAULIC SYSTEM
POSSIBLE CAUSE
Oil level too low
CORRECTION
Add proper oil and amount
Suction line plugged
Reservoir air vent plugged
Clean or replace line
Clean reservoir cap
Tighten or replace line and fittings
Check for air leak in hydrostatic
Hydraulic reservoir oil foaming/milky
Air or water in system
Low system pump oil flow, under pressure
Plugged inlet line
Low oil level in reservoir hydrostatic pumps to section side of gear pump
Check for air leak on suction side of pump and check reservoir fill neck for leak to allow water to enter system
Check for air leak in hydrostatic pump case drain line from hydrostatic pumps to section side of gear pump
Clean or replace line
Add proper oil and amount
Air leaks at pump inlet line and fittings
Tighten or replace line and fittings
No system pressure
Worn pump body
Inoperative relief valve hydrostatic pumps to section side of gear pump
Replace body if ID of body exceeds acceptable limits. Refer to service manual.
Replace valve repair pump cylinders
Boom and bucket will not function Service/Run switch in the service position
Put Service/Run switch in the run position
Boom and bucket solenoids malfunctioning
Check solenoid operation
Pump shaft broken Replace relief valve and replace or repair pump
35-13
PROBLEM
Boom arms will not raise or raise
SECTION 35 - HYDRAULIC SYSTEM
POSSIBLE CAUSE
Low oil flow from pump
CORRECTION
Plugged inlet line or worn pump
Boom and bucket overloaded
Cylinder shafts are bent
Reduce load
Rebuild or replace cylinders
Boom arms are binding at pivots Remove binding and lubricate linkage
Boom circuit relief valve Check circuit relief valve pressure
Bucket tilt valve spool is not Correct binding, spool centering binding
Boom or bucket leaks down or low pressure
Auxiliary hydraulic handle locked in detent position
Control valve O rings leaking on plugs or circuit relief valve
Return handle to neutral position
Repair control valve with seal kit and replace O rings and back-up rings
Air leaks at pump line and fittings Tighten or replace line and fittings Boom and/or bucket will not move smoothly, jerky.
Bucket will not tilt back, tilts back Low oil flow from pump Plugged inlet line, clean or replace
Worn or damaged pump Check pump flow, rebuild or
Valve spool is not in correct Free control linkage, centering
Bucket is overloaded
Bucket cylinder pin will not take grease in detent position
Pin drilled incorrectly
Reduce load
Replace with new pin
35-14
PROBLEM
Hydraulic system hot
SECTION 35 - HYDRAULIC SYSTEM
POSSIBLE CAUSE
Low oil flow pump
CORRECTION
Plugged inlet line, clean or replace line
Main control valve linkage or spool Check and correct linkage
Auxiliary boom hydraulic control Lock handle in neutral when not in
Hydraulic oil cooler restricted Clean oil cooler
Oil filter indicator light stays on pressure used
Oil filter clogged
Incomplete circuit
Filter base
DO NOT operate at or close to relief pressure
Change filter
Check the DkGn/O wire and connections hoses, or fittings
Replace if pressure differential across filter is over 40 PSI
35-15
SECTION 35 - HYDRAULIC SYSTEM
AUXILIARY BOOM HYDRAULICS TROUBLESHOOTING
PROBLEM
No oil flow to quick couplers
POSSIBLE CAUSES
Broken control linkage
Inoperative quick coupler
Plugged supply line
Control valve plugs leaking oil to return
Inoperative gear pump
CORRECTION
Check and repair linkage
Repair or replace
Clean or replace
Check O ring and back-up washer on plugs
Check and repair
Control will not hold in detent position
Loose linkage
Misadjusted linkage
Inoperative control valve spool
(binding)
Inoperative control valve detent cap
Repair
Repair
Check and repair
Check and repair
Hydraulic system overheats when auxiliary hydraulics is in use
Restriction in return line
Inoperative quick coupler
Restriction in attachment
Operating at, or close to, relief pressure
Relief pressure to low
Plugged oil cooler not allowing cooling air to pass through
Check and repair
Repair or replace
Check and repair
Operate at lesser loads
Check operating pressure
Clean oil cooler
Hydraulic system overheats when auxiliary hydraulics is not in use
Control handle shifted slightly
Control linkage not adjusted properly
Control valve spool binding
Return control to neutral and lock
Adjust linkage
Check and repair
35-16
SECTION 35 - HYDRAULIC SYSTEM
Adjustments Control Handle Locked, 1, In
Neutral
Adjust the length of rod, 2, by threading the ball joints,
3, on or off, at both ends of the rod to set the link, 4, vertical. Check adjustment by shifting the hydrostatic control lever forward and reverse. If the rod length is set correctly, there should be no movement in the link, 4, as the rod, 5, moves.
With the control handle locked in neutral and the control valve spool centered in the neutral position, adjust the length of rod, 6, with yoke, 7, to allow the installation of the yoke pin.
When the loader is operated, there should be no noise in the hydraulic system when in neutral.
NOTE: When using a hydraulic attachment, all oil must be returned through the standard return system to provide charge oil to the hydrostatic system.
IMPORTANT: If sufficient oil is not provided for the hydrostatic system, severe damage to the hydrostatic system will occur.
7
35-17
SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC SYSTEM TESTING
Foot or hand controls and control valve spool locks:
Pretest instructions:
* Hydraulic oil reservoir oil at proper oil level
* Operator in seat
* Service/Run switch in “RUN” position
* Seat belt fastened
* Ignition switch in the “OFF” position
STEP
1
2
3
4
TEST
Foot and/or hand controls,
(boom and bucket)
Controls should not move
RESULT
NO
YES
PROBABLE CAUSE AND CORRECTION
System OK
Check linkage to control valve spools, if OK go to next step.
Check control valve spools for centering, if OK go to next step.
Check for bent control valve spools, if OK go to next step.
Check spool lockout solenoid operation, if not OK refer to solenoid testing
Foot or hand controls and control valve spool locks:
Pretest instructions:
* Hydraulic oil reservoir oil at proper oil level
* Operator in seat
* Service/Run switch in “RUN” position
* Seat belt fastened
* Ignition switch in the “ON” position
STEP
1
2
3
4
TEST
Foot and/or hand controls,
(boom and bucket)
Controls should move
RESULT
YES
NO
PROBABLE CAUSE AND CORRECTION
System OK
Check linkage to control valve spools, if OK go to next step.
Check control valve spools for centering, if OK go to next step.
Check for bent control valve spools, if OK go to next step.
Check spool lockout solenoid operation, if not OK refer to solenoid testing
35-18
SECTION 35 - HYDRAULIC SYSTEM
Foot or hand control and control valve spool lock solenoids:
Pretest instructions:
* Hydraulic oil reservoir oil at proper oil level
* Operator in seat
* Service/Run switch in “RUN” position
* Seat belt fastened
* Ignition switch in the “ON” position
STEP
1
TEST
Solenoid
Solenoid plunger should move from valve spool.
RESULT
YES
NO
PROBABLE CAUSE AND CORRECTION
System OK
Check for battery voltage at solenoid wire connection, if OK replace solenoid. If not OK go to next step.
Set in seat and buckle seat belt in sequence, if not
OK check operation of seat belt buckle. If OK go to next step.
Check wires from solenoid to EIC board, if OK go to next step.
Check EIC board operation
Electronic instrument cluster (EIC) hydraulic oil temperature light:
Pretest instructions:
* Hydraulic oil reservoir oil at proper oil level
* Operator in seat
* Service/Run switch in “RUN” position
* Seat belt fastened
* Ignition switch in the “ON” position
* Engine running half throttle, 1500 RPM
STEP
1
TEST
Electronic instrument cluster
(EIC)
Hydraulic oil temperature light should be off
2
3
RESULT
YES
NO
PROBABLE CAUSE AND CORRECTION
System OK
Check hydraulic oil temperature, if OK go to step 3.
If not OK go to next step.
Check oil cooler and radiator for restricted air flow.
Check oil temperature sender for proper operation.
35-19
SECTION 35 - HYDRAULIC SYSTEM
Electronic instrument cluster (EIC) hydraulic oil filter light:
Pretest instructions:
* Hydraulic oil reservoir oil at proper oil level
* Operator in seat
* Service/Run switch in “RUN” position
* Seat belt fastened
* Ignition switch in the “ON” position
* Engine running half throttle, 1500 RPM
STEP
1
TEST
Electronic instrument cluster
(EIC)
Hydraulic oil filter light should be off.
2
RESULT
YES
PROBABLE CAUSE AND CORRECTION
System OK
NO
Replace oil filter, if problem still exists go to next step.
Check filter sender and wires.
Boom operation:
Pretest instructions:
* Operator in seat
* Service/Run switch in “RUN” position
* Seat belt fastened
* Ignition switch in the “ON” position
* Engine running half throttle, 1500 RPM
STEP
1
TEST
Boom movement
Boom should move freely through full range when the foot or hand controls are moved.
2
3
RESULT
YES
NO
PROBABLE CAUSE AND CORRECTION
System OK
Check for binding in boom linkage, if OK go to next step.
4
5 Boom movement
Boom should raise smoothly with no jerking
YES
NO
Check for bent cylinders, if OK go to next step.
Check hydraulic system oil flow and pressure, if
OK go to next step.
Check cylinders for internal damage.
System OK
Check for air in the hydraulic system. Check, tighten, or replace suction line and fittings.
Check for air leak in hydrostatic pump case drain line from the hydrostatic pumps to the suction side of gear pump.
35-20
SECTION 35 - HYDRAULIC SYSTEM
Boom lift check test:
Pretest instructions:
* Operator in seat
* Service/Run switch in “RUN” position
* Seat belt fastened
* Ignition switch in the “ON” position
* Engine running half throttle, 1500 RPM
STEP
1
TEST
Boom stopped midrange and restarted, the boom should start raising without dropping first
2
3
RESULT
YES
NO
PROBABLE CAUSE AND CORRECTION
System OK
Check for a leaking lift check valve, broken spring, or scored plunger and/or seat. If OK go to next step.
Check cylinders for leaking packing.
Check O ring and backup washer on circuit relief valve and O ring on front plug in control valve.
Boom drift down test:
Pretest instructions:
* Operator in seat
* Service/Run switch in “RUN” position
* Seat belt fastened
* Ignition switch in the “ON” position
* Engine running half throttle, 1500 RPM
STEP
1
TEST
Boom stopped midrange should hold in position with no visual movement
2
3
4
5
RESULT
YES
NO
PROBABLE CAUSE AND CORRECTION
System OK
Check control valve spool for centering, if OK go to next step.
Check for leaking packing on cylinders, if OK go to next step.
Check boom circuit relief valve, if OK go to next step.
Check control valve for leakage.
Check O ring and backup washer on circuit relief valve and O ring on front plug in control valve.
35-21
SECTION 35 - HYDRAULIC SYSTEM
Bucket operation:
Pretest instructions:
* Operator in seat
* Service/Run switch in “RUN” position
* Seat belt fastened
* Ignition switch in the “ON” position
* Engine running half throttle, 1500 RPM
STEP
1
TEST
Bucket movement
Bucket should move freely through full range when the foot or hand controls are moved.
2
3
RESULT
YES
NO
PROBABLE CAUSE AND CORRECTION
System OK
Check for binding in the bucket pivots, if OK go to next step.
4
5 Boom movement
Boom should raise smoothly with no jerking
YES
NO
Check for bent cylinders, if OK go to next step.
Check hydraulic system oil flow and pressure, if
OK go to next step.
Check cylinders for internal damage.
System OK
Check for air in the hydraulic system. Check, tighten, or replace suction line and fittings.
Check for air leak in hydrostatic pump case drain line from the hydrostatic pumps to the suction side of gear pump.
Bucket lift check test:
Pretest instructions:
* Operator in seat
* Service/Run switch in “RUN” position
* Seat belt fastened
* Ignition switch in the “ON” position
* Engine running half throttle, 1500 RPM
STEP
1
TEST
Bucket stopped midrange and restarted, the bucket should not drop first
2
3
RESULT
YES
NO
PROBABLE CAUSE AND CORRECTION
System OK
Check for a leaking lift check valve, broken spring, or scored plunger and/or seat. If OK go to next step.
Check cylinders for leaking packing.
Check O ring and backup washer on front and rear plug in control valve.
35-22
SECTION 35 - HYDRAULIC SYSTEM
Bucket drift down test:
Pretest instructions:
* Operator in seat
* Service/Run switch in “RUN” position
* Seat belt fastened
* Ignition switch in the “ON” position
* Engine running half throttle, 1500 RPM
STEP
1
TEST
Bucket stopped midrange should hold in position with no visual movement
2
3
4
5
RESULT
YES
NO
PROBABLE CAUSE AND CORRECTION
System OK
Check control valve spool for centering, if OK go to next step.
Check for leaking packing on cylinders, if OK go to next step.
Check boom circuit relief valve, if OK go to next step.
Check control valve for leakage.
Check O ring and backup washer on front and rear plug in control valve.
Spool lock solenoid test:
Pretest instructions:
* Operator in seat
* Service/Run switch in “RUN” position
* Seat belt fastened
* Ignition switch in the “ON” position
STEP
1
TEST
Battery voltage at solenoid
2
3
4
5
6
RESULT
YES
NO
PROBABLE CAUSE AND CORRECTION
System OK, go to step 5.
Check seat belt operation, if OK go to next step.
Check wires to the solenoid valves for open circuit, if OK go to next step.
Check EIC board operation, if OK go to next step.
Check EIC board operation, if not OK refer to
ELECTRICAL SECTION of the SERVICE
MANUAL.
Remove solenoid coil and check operation, if OK go to next step.
Check control valve spools for centering, binding, and binding between solenoid and block, if OK replace solenoid valve.
35-23
6 5
4
SECTION 35 - HYDRAULIC SYSTEM
3
2 1
10 9
11
7
8
7
19997772
HYDRAULIC SYSTEM OIL FLOW
Control Valve - Spools in Neutral Position
1. Hydraulic oil reservoir, 1, storage for system oil.
2. Oil flows through suction line, 2, from reservoir,
1, to gear pump, 3.
3. Oil flows from gear pump, 3, through pressure line, 4, to control valve, 5.
4. Control valve, 5, is equipped with a system relief valve, 6.
8
5. With the control valve spools in neutral position, the oil flows through center of control valve, 5, to return line, 7.
6. The oil flows through return line, 7, to oil cooler,
8.
7. Oil passes through the oil cooler, 8, being cooled with the air blast from engine fan through the cooler.
8. Oil flows from the oil cooler, 8, through filter, 9, and check valve, 10, to return line, 11, and reservoir, 1.
35-24
SECTION 35 - HYDRAULIC SYSTEM
4
6
3
5
2
1
19997773
CONTROL VALVE - BUCKET SPOOL
SHIFTED
Bucket Control Operation
Foot Controls
When the toe of the control pedal is pushed down, it will shift the control valve spool in, dumping the bucket. When the heel of the control pedal is pushed down, it will shift the control valve spool out curling the bucket back.
Hand Controls
When the right control handle is pivoted up it will shift the control valve spool in, dumping the bucket. When the right control handle is pivoted down it will shift the control valve spool out, curling the bucket back.
9
1. Oil flows from the gear pump, 1, through pressure line, 2, to control valve, 3.
2. When the bucket valve spool, 4, is pulled out, the oil flows from the rear work port, 5, to the shaft side of the bucket cylinder to curl the bucket back.
3. When the bucket valve spool, 4, is pushed in, the oil flows from the front work port, 6, to the base
(piston) end of bucket cylinder to dump the bucket.
4. When the bucket circuit is operated to maximum pressure or cylinders are bottomed, the main system relief valve will relieve the high pressure oil into the return oil galley in the control valve, returning the oil to the reservoir.
5. The return oil from the opposite side of the cylinder being pressured will return through the control valve to the reservoir.
35-25
SECTION 35 - HYDRAULIC SYSTEM
4
3
7
2
6 5
1
19997774
CONTROL VALVE - BOOM SPOOL
SHIFTED
Boom Control Operation
Foot Controls
When the toe of the control pedal is pushed down, it will shift the control valve spool in, lowering the boom.
When the heel of the control pedal is pushed down it will shift the control valve spool out, raising the boom.
Hand Controls
When the left control handle is pivoted down, it will shift the control valve spool in, lowering the boom.
When the left control handle is pivoted up, it will shift the control valve spool out, raising the boom.
1. Oil flows from the gear pump, 1, through pressure line, 2, to control valve, 3.
2. When the boom valve spool, 4, is pulled out, the oil flows from the rear work port, 5, to the base
(piston) end of the boom cylinder raising the boom.
10
3. When the boom valve spool, 4, is pushed in, the oil flows from the front port, 6, to the shaft end of boom cylinders, to lower the boom.
4. When the boom circuit is operated to maximum pressure or cylinders are bottomed, the main system relief valve will relieve the high pressure oil into the return oil valley in the control valve, returning the oil to the reservoir.
5. The return oil from the opposite side of cylinders being pressured will return through the control valve to the reservoir.
6. When the boom cylinders are extended, the boom control valve spool is in neutral, and a load is put on the boom cylinders causing them to retract the circuit. Relief valve, 7, will relieve the pressure in the base (piston) side of cylinders protecting the cylinder and lines. The oil relieved from the circuit relief valve enters the return oil galley in the control valve and returns to the reservoir.
7. When the boom valve spool, 4, is pushed in all the way, it will put the spool into detent position, holding the spool, opening both work ports 5 and
6 to the return allowing the boom to float.
35-26
SECTION 35 - HYDRAULIC SYSTEM
4
6
8
7 5
9
3
2 1
9
19997775
CONTROL VALVE - AUXILIARY SPOOL
SHIFTED
Auxiliary Control Operation
Hand Controls
When the right control handle is pivoted down, it will shift the control valve spool in, supplying oil to the male quick coupler. When the right control handle is pivoted up, it will shift the control valve spool out, supplying oil to the female quick coupler.
Foot Control
When the toe of the control pedal is pushed down, it will shift the control valve spool in, supplying oil to the male quick coupler. When the heel of the control pedal is pushed down, it will shift the control valve spool out, supplying oil to the female quick coupler.
1. Oil flows from the gear pump, 1, through pressure line, 2, to control valve, 3.
2. When the auxiliary valve spool, 4, is pulled out, the oil flows from the rear work port, 5, and supplies oil to the female quick coupler, 6, at the front of the boom.
11
3. When the auxiliary valve spool, 4, is pushed in, the oil flows from the front work port, 7, and supplies oil to the male quick coupler, 8, at the front of the boom.
4. When the auxiliary circuit is operated to maximum pressure, the main system relief valve will relieve the high pressure oil into the return oil galley in the control valve, returning the oil to the reservoir.
5. The return oil from the opposite quick coupler being pressured will return through the control valve to the reservoir.
NOTE: The return oil from the quick couplers must be returned through the normal return line, 9, to replenish the hydrostatic system; hydrostatic charge oil is required for lubrication of the hydrostatic pumps and motors.
6. When the auxiliary valve spool, 4, is pushed in all the way, it will put the spool into detent position, holding the spool for continuous oil flow to the male quick coupler.
35-27
SECTION 35 - HYDRAULIC SYSTEM
Op. 35 710 02
MAIN SYSTEM PRESSURE TESTS
Check the main system pressure to insure the main relief valve is within specifications to provide adequate working pressure to the hydraulic system.
The main system pressure can be checked at the base end of the boom cylinders at 1.
1
The main system pressure can also be checked at the base end of the left bucket cylinder at 1 or at the auxiliary boom hydraulic quick couplers, 2, if equipped.
To check main system pressure at the boom cylinders, the boom must be up and resting on the boom lockpins, 1.
12
13
14
35-28
SECTION 35 - HYDRAULIC SYSTEM
The hydraulic system pressures are factory set.
Changes to the settings should not be necessary.
To access the control and relief valve area, remove the step shield, 1.
Raise the seat and seat pan to the raised latched position, 1. Be sure the seat support rod is latched securely at 2, before working under a raised seat.
CAUTION
Do not work under raised seat unless securely latched in the raised position.
15
16
35-29
SECTION 35 - HYDRAULIC SYSTEM
The main system relief valve, 1, is located in the control valve. If there is some reason to suspect incorrect pressure, check the pressures as follows:
WARNING
Gauges, gauge fittings, and hoses must have operating pressure ratings of at least 25% higher than the highest pressures of the system.
Never adjust or replace the relief valves to get higher pressures than those specified by the equipment manufacturer.
Fluid under pressure can have sufficient force to penetrate the skin, causing serious personal injury. Always protect the skin and eyes from escaping fluid under pressure.
Before disconnecting lines or fittings, be sure to turn off the skid steer engine and relieve all pressure. Before applying pressure to the system, be sure all connections are tight and that lines, pipes, and hoses are not damaged.
If injured by escaping fluid, obtain medical assistance at once. Serious infection or reaction can develop if medical treatment is not administered immediately.
Remove any attachment from the mounting plate before loosening or disconnecting any hydraulic lines.
1
19997742
CHECKING MAIN SYSTEM PRESSURE AT
BOOM CYLINDERS
NOTE: Before performing any hydraulic test, operate the skid-steer loader to get the hydraulic oil to operating temperature (about 55
5
C [100
5
F] above ambient temperature).
Fittings and gauge required:
1. 238 bar (3500 PSI) gauge (minimum)
2. 3/4 ″ - 16 UNF O ring fitting
Test Procedure
1. Raise the boom, extend the boom lockpins, 1, and lower the boom down on the lockpins.
2. Stop the engine, turn the ignition key to the run position, and operate the boom and bucket control pedals to relieve pressure in the cylinders.
Turn off the key.
35-30
17
18
SECTION 35 - HYDRAULIC SYSTEM
3. Install the pressure test gauge in the boom cylinder at 1.
4. Start the engine and run it at full throttle
(3070 - 3150 RPM) to bring the hydraulic oil to operating temperature.
5. Operate the boom control to raise the boom to the fully raised position until the system bypasses and take a pressure reading. Lower the boom down to the boom lockpins and relieve pressure in the system.
6. The pressure should be from 177 - 190 bar (2600
- 2800 PSI) when the hydraulic oil is at operating temperature.
7. The relief valve is a cartridge type and is not adjustable. Replace the relief valve cartridge, 1, if the pressure is not within specifications.
CAUTION
Do not attempt to change the pressure setting or alter the pressure to a higher setting as the hydraulic components, hoses, tubes, and cylinders may be damaged and could cause injury.
1
19997742
CHECKING MAIN SYSTEM PRESSURE AT
BUCKET CYLINDERS, 1
Fittings and gauge required:
1. 238 bar (3500 PSI) gauge (minimum)
2. 3/4
″
- 16 UNF O ring fitting
Test Procedure
1. Lower the boom and attachment to the ground.
2. Stop the engine, turn the ignition key to the run position and operate the boom and bucket control pedals to relieve pressure in the cylinders.
Turn off the key.
1
19
20
21
35-31
SECTION 35 - HYDRAULIC SYSTEM
3. Install the pressure test gauge in the left bucket cylinder at 1.
4. Start the engine and run it at full throttle (3070 -
3150 RPM).
5. Operate the bucket control to dump the bucket to the fully dumped position until the system bypasses and take a pressure reading. Curl the bucket back to relieve pressure in the system.
6. The pressure should be from 177 - 190 bar (2600
- 2800 PSI) when the hydraulic oil is at operating temperature.
7. The relief valve is a cartridge type and is not adjustable. Replace the relief valve cartridge, 1, if the pressure is not within specifications.
CAUTION
Do not attempt to change the pressure setting or alter the pressure to a higher setting as the hydraulic components, hoses, tubes, and cylinders may be damaged and could cause injury.
1
19997742
CHECKING MAIN SYSTEM PRESSURE AT
AUXILIARY BOOM HYDRAULIC QUICK
COUPLERS, 1
Fittings and gauge required:
1. 238 bar (3500 PSI) gauge (minimum)
2. 1/2
″
quick coupler fitting
Test Procedure
1. Lower the boom and attachment to the ground.
2. Stop the engine, turn the ignition key to the run position and operate the boom, bucket, and auxiliary controls to relieve pressure in the systems.
Turn off the key.
22
1
23
24
35-32
SECTION 35 - HYDRAULIC SYSTEM
3. Install the pressure test gauge in one of the quick couplers at 2.
4. Start the engine and run it at full throttle (3070 -
3150 RPM).
5. Operate the auxiliary control to pressurize the auxiliary circuit until the system bypasses and take a pressure reading. Move the control handle in the opposite direction to relieve pressure in the system.
NOTE: Pivoting the control handle down supplies oil to the male quick coupler.
6. The pressure should be from 177 - 190 bar (260
- 2800 PSI) when the hydraulic oil is at operating temperature.
7. The relief valve is a cartridge type and is not adjustable. Replace the relief valve cartridge, 1, if the pressure is not within specifications.
CAUTION
Do not attempt to change the pressure setting or alter the pressure to a higher setting as the hydraulic components, hoses, tubes, and cylinders may be damaged and could cause injury.
1
19997742
BOOM CIRCUIT RELIEF VALVE TEST
The boom circuit is equipped with a circuit relief valve, 1, located in the boom control valve. This valve will protect the cylinders and lines when the control valve spool is in the neutral (centered) position.
Fittings and gauge required:
1. 238 bar (3500 PSI) gauge (minimum)
2. 3/4 ″ - 16 UNF O ring fitting
3. Hydraulic hand pump
NOTE: The relief valve is factory set at 241
+
3 bar
(3500
+
50 PSI). The boom circuit relief valve is not adjustable. All replacement valves are set at 3500
PSI.
25
26
27
35-33
SECTION 35 - HYDRAULIC SYSTEM
Test Procedure
1. Lower the boom and attachment to the ground.
2. Stop engine, turn ignition key to the run position and operate the boom and bucket control pedals to relieve pressure in the cylinders. Turn off the key.
3. Remove the step shield, 1, to access the control valve and circuit relief valve area.
4. Boom control valve spool in the neutral (centered) position.
5. Remove the rear boom hydraulic line, 1, and cap the line. Install the hydraulic hand pump and pressure gauge to the rear port in the control valve.
6. Using the hand pump, build pressure against the circuit relief valve and monitor the pressure gauge to read the pressure at the point the relief valve starts to open.
CAUTION
Do not increase pressure over 3800 psi. If the relief valve does not open when pressure reaches 3600 psi, discontinue the test and replace the valve.
7. If there is an operational complaint and the boom circuit relief valve releases pressure under 235 bar (3400 PSI), replace the valve, 1. If the valve does not release pressure by 248 bar (3600 PSI), also replace the valve. All replacement boom circuit relief valves are set at 241 bar (3500 PSI) and are not adjustable.
28
29
30
35-34
SECTION 35 - HYDRAULIC SYSTEM
GEAR PUMP FLOW EFFICIENCY TEST
Fittings and gauges required:
1. Hydraulic flow tester (30 GPM capacity).
2. Male and female 1/2 ″ quick couplers for units equipped with auxiliary boom hydraulics.
3. Two male 3/4 ″ UNF 37 flare-to-tester fittings for units without auxiliary boom hydraulics.
Test Procedure
Gear pump flow test with units equipped with auxiliary boom hydraulics.
1. Lower the boom and bucket to the lowered position, resting on the ground.
2. Stop engine, turn ignition key to the run position and operate the boom and bucket control pedals to relieve pressure in the cylinders. Turn off the key.
3. Attach the pressure (inlet) hose from the flow tester with the female quick coupler to the male half on the loader at 1.
4. Attach the return (outlet) hose from the flow tester with the male coupler to the female half on the loader at 2.
IMPORTANT: Make sure the flow tester is connected into the hydraulic system properly for proper oil flow through the tester to prevent damage to the hydraulic test equipment or hydraulic system.
CAUTION
Never position tester between the gear pump and control valve as the system relief valve will be out of the test circuit, and pump over pressure may cause a pump failure by splitting the center section or twisting off the input shaft.
31
35-35
SECTION 35 - HYDRAULIC SYSTEM
5. Turn the resistance valve on tester to “O” setting.
6. Start the engine and run it at full throttle
(2900 RPM).
7. Operate the auxiliary control handle by pivoting down to pressurize the male quick coupler and inlet hose to tester.
8. Take a free flow and pressure reading and record it. The flow at this time is oil flow through the hydraulic system and the pressure reading at this point is force required to pump the oil through the system. The pressure is called back pressure.
9. Turn the resistance valve, 1, on the tester to apply resistance in the hydraulic system to obtain the following specifications:
LS160 - 2900 RPM (engine) 68 bar (1000 PSI) -
15.5 GPM (58.7 LPM) Maximum without high flow
L170 - 2900 RPM (engine) 68 bar (1000 PSI) -
17.7 GPM (67.0 LPM) Maximum without high flow
If the gear pump flow in step 9 is not at least 80% of the pump flow in step 8, remove and repair or replace the pump.
EXAMPLE:
16 GPM free flow Step 8.
12.5 GPM flow Step 9.
80% of 16 GPM = 12.8 GPM
The pump is not at least 80% of free flow. Repair or replace pump.
NOTE: The oil must be at operating temperature before any hydraulic testing.
If the pressure cannot be obtained, replace the main system relief valve.
32
35-36
SECTION 35 - HYDRAULIC SYSTEM
Test Procedure
Gear pump flow test with units NOT equipped with auxiliary boom hydraulics.
1. Lower the boom and bucket to the lowered position, resting on the ground.
2. Stop the engine, turn the ignition key to the run position and operate the boom and bucket control pedals to relieve pressure in the cylinders.
Turn off the key.
3. Unhook line, 1, from the base end of the bucket cylinder, cap cylinder port.
4. Attach the pressure (inlet) hose from the flow tester to line, 1, with 3/4 ″ UNF 37 flare fitting to tester.
5. Unhook line, 2, and cap the hose fitting.
6. Attach the return (outlet) hose from the flow to line, 2, with 3/4
″
UNF 37 flare fitting to tester.
IMPORTANT: Make sure the flow tester is connected into the hydraulic system properly for proper oil flow through the tester to prevent damage to the hydraulic test equipment or hydraulic system. Refer to the test equipment manufacturer’s Operator’s Manual.
7. Turn the resistance valve, 1, on the tester to “O” setting.
8. Start the engine and run it at full throttle
(2900 RPM).
9. Operate the bucket control to dump the bucket for proper oil flow to the inlet hose and tester.
10. Take a free flow and pressure reading and record it. The flow at this time is oil flow through the hydraulic system and the pressure reading at this point is force required to pump the oil through the system. The pressure is called back pressure.
33
34
35-37
SECTION 35 - HYDRAULIC SYSTEM
11. Turn the resistance valve on the tester to apply resistance in the hydraulic system to obtain the following specifications:
LS160 - 2900 RPM (engine) 68 bar (1000 PSI) -
15.5 GPM (58.7 LPM) Maximum without high flow
LS170 - 2900 RPM (engine) 68 bar (1000 PSI) -
17.7 GPM (67.0 LPM) Maximum without high flow
If the gear pump flow in step 11 is not at least 80% of the pump flow in step 10, remove and repair or replace the pump.
EXAMPLE:
16 GPM free flow Step 10.
12.5 GPM flow Step 11.
80% of 16 GPM = 12.5 GPM
The pump is not at least 80% of free flow. Repair or replace pump.
NOTE: The oil must be at operating temperature before any hydraulic testing.
If the pressure cannot be obtained, replace the main system relief valve.
35-38
SECTION 35 - HYDRAULIC SYSTEM
BOOM AND BUCKET SPOOL LOCK
SOLENOID TEST
The boom and bucket control valve solenoid spool locks are controlled by the EIC (Electronic Instrument Cluster). The operator must be in the operator’s seat with the seat belt buckled for the EIC to unlock the control valve spool lock solenoids.
Operational check procedure:
1. Service/Run switch, 1, in “RUN” position.
2. Sit in seat.
3. Turn ignition key switch, 2, to the “ON” position.
4. Attempt to move boom and bucket foot or hand controls. The controls should not move the control valve spools from the neutral position.
5. Fasten the seat belt.
6. Attempt to move boom and bucket foot or hand controls. The controls should move the control valve spools from the neutral position.
NOTE: If the EIC shows an FOA fault in the readout display, this is an indication of a shorted/open circuit to the solenoid locks.
Electrical test procedure:
1. Lower the boom and attachment to the ground or rest the boom on the boom lock pins, 1; remove attachment if on boom locks.
35
35-39
SECTION 35 - HYDRAULIC SYSTEM
2. Raise the seat and latch securely in the raised latch position, 1. Remove the step shield, 2, from over the control valve to access the solenoid locks.
3. Unplug one solenoid, 1, at a time and check for battery voltage at the main wire harness plugs, pink/light-blue and black wires. The operator must be in the seat with the seat belt buckled and the ignition key in the “ON” position.
NOTE: If both solenoids are unplugged, the EIC will show an FOA fault and there will be no voltage from the EIC to the solenoids.
4. If there is battery voltage at the solenoids, remove the coils and check their operation. If the plunger moves in when power is applied, check for binding when the coil is threaded into the body. Check for spool centering to allow the coil plunger to seat into the groove in the spool.
DANGER
If the lockout solenoids are loosened or removed from the control valve body, the pedal(s) are no longer locked. Pedal or hand control movement will result in spool movement and boom/bucket movement.
1
19997742
1
36
37
35-40
SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC, HYDROSTATIC SYSTEM AIR
INGRESS TEST
Hydraulic system air ingress, causing oil aeration, can affect performance of the hydraulic oil. This may be evident on a machine by jerky or uneven movement of the loader boom or bucket.
To assist in testing and finding leaks, a tool has been developed (part #FNH22ESS95). This tool comprises of a cap which replaces the reservoir filler breather for testing purposes, a pressure gauge and a relief valve. The cap has fittings for air pressure to be applied to the hydraulic reservoir.
CAUTION
Do not start the engine with the test tool installed, as the hydraulic system must be able to breathe.
Test Procedure:
1. Remove the filler/breather cap.
2. Remove the self-tapping screws around the cap base and screen assembly.
3. Remove the base, screen and gasket assembly.
Clean all sealing surfaces.
4. Re-install new gaskets and base, taking care not to overtighten the screws.
5. Make sure the tank has 10W-30 oil visible.
6. Pressurize the tank using an air pressure line.
The tool is equipped with a 3 PSI relief valve and a pressure gauge. The reservoir should not be pressurized beyond 4 PSI.
38
35-41
The following checks should then be performed to trace the source of the air ingress.
– Examine the suction tubes and fittings to the
–
– hydraulic gear pump and the return tubes from the filter to the reservoir.
Examine the transmission case drain tubes/hoses and fittings from the hydraulic motors and pumps to the suction side of the hydraulic pump. Also check the cam plate shaft seals and the pump and motor casing gaskets.
Potential leakage areas could also be input shaft seals in the engine bell housing, gearbox or output shaft seals in motors and gearboxes and the chain case.
SECTION 35 - HYDRAULIC SYSTEM
– It may be necessary in some instances (where leakage is occurring on shaft seals into gearboxes or bell housing) to pressurize the reservoir for 2 - 4 hours and monitor the oil level in the gearboxes.
– If the prior checks do not locate the source of the leak, it may be necessary to pressurize each hydrostatic component individually. To do this it will be necessary to disconnect each case drain line in turn and pressurize using an air line to a maximum pressure of 10 PSI.
NOTE: A check valve can be installed in the case drain tube which maintains a 5 PSI pressure in the pump and motor cases. This helps prevent air ingress into the system.
35-42
SECTION 35 - HYDRAULIC SYSTEM
CONTROL VALVE
SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-spool open center
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170-177 bar (2500-2600 PSI) Nonadjustable
Circuit Relief (boom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 bar (3500 PSI)
Electrical Solenoid Spool Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bucket and Boom
Torque Specifications
Control Valve Retaining Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N·m (18 ft. lbs.)
Control Valve Plugs (large) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Control Valve Plugs (small) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 N·m (23 ft. lbs.)
Circuit Relief Valve (boom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Spool Lock Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N·m (11 ft. lbs.)
Main System Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 N·m (38 ft. lbs.)
Spool Cap Assembly Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 N·m (12 ft. lbs.)
Plugs, BYD Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Labor Required
Remove and Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 hours
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 hour
35-43
SECTION 35 - HYDRAULIC SYSTEM
CONTROL VALVE
Op. 35 724 50
REMOVAL
1. Lower the boom and bucket to the lowered position (resting on the ground), or remove any attachment and raise the boom and rest on the boom lock pins, 1. Roll the attachment plate to the fully “DUMPED” position.
2. Stop the engine, turn the ignition key to the run position and operate the boom and bucket control pedals to relieve pressure in the boom and bucket circuits. Turn off the key.
3. Raise the seat and seat pan to the raised latched position, 1.
4. Remove the step shield, 2, to access the gear pump area. For more access, remove the right or left hydrostatic control handle assembly, 3 or 4.
CAUTION
Do not work under a raised seat unless it is securely latched in the raised latched position.
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment. Always remove the attachment from the loader.
Never loosen any hydraulic lines without first relieving all pressure in the system.
Draining the hydraulic oil reservoir is not required if the suction and return lines are capped to prevent loss of oil. Drain the reservoir when the hydraulic system requires cleaning.
5. To drain the system, remove the small access door, 1, at the front right corner of the engine belly pan by removing the two rear bolts, 2, loosening the front two bolts, 3, and sliding the door rearward.
39
40
41
35-44
SECTION 35 - HYDRAULIC SYSTEM
6. Drain the hydraulic reservoir by disconnecting the return line, 1, at tee, 2, and drain the oil into a suitable container.
42
7. Unplug the spool lock solenoids, 1.
8. Remove the pressure line, 2, and return line, 3; cap both lines to prevent loss of oil and contamination from entering the hydraulic system.
9. Remove the hydraulic lines connected to the work ports of the control valve, 4, four or six lines, if unit is equipped with auxiliary boom hydraulics and cap.
10. Remove the line from the power beyond port, 5, if equipped with auxiliary hydraulics and cap.
11. Unhook the control linkage from the control valve spools at 6.
12. Remove the control valve retaining hardware, 7.
Lift the control valve assembly from the loader.
Op. 35 724 54
DISASSEMBLY AND INSPECTION
Main System Relief Valve
The non-serviceable, non-adjustable, cartridge- type main system relief valve, 1, is set at 170 - 177 bar
(2500 - 2600 PSI). The relief valve should not be replaced with a valve of a higher pressure setting, as structural damage to the boom and/or main frame or internal damage to hydraulic system may occur.
CAUTION
Component failure from high hydraulic pressure could result in injury.
19984464
1
19984465
2
4
1
6
7
3
5
43
44
35-45
SECTION 35 - HYDRAULIC SYSTEM
Lift Check Valves
There is a check valve in each circuit - bucket, boom, and auxiliary.
The only time the check valves serve a function is after the control spools have been shifted. If the valves are operating properly, they prevent any movement of either the boom or bucket until pressure opens the lift checks.
Inspect the lift check components for damage to the seat, 1, spring, 2, or cap, 3.
1
19984466
Op. 35 724 90
Spool Locks (Boom and Bucket)
Remove the solenoid plunger assemblies, 1, from the ports, 2, over the control spool ends.
2
2 3
45
19984467
Remove the boom circuit relief valve, 1, from the valve body.
NOTE: The boom circuit relief valve protects the lift circuit against high pressure related damage caused by external forces acting against the boom. The valve is factory set at 241 bar (3500 PSI), is nonadjustable, and must be replaced if malfunctioning.
Remove the plugs, 2, over the bucket and auxiliary spool caps.
19984468
2
1
46
1
2
47
35-46
SECTION 35 - HYDRAULIC SYSTEM
Remove the plug, 1, from the port, 2, over the main relief valve port. Remove the plug, 3, from the port,
4, over the auxiliary control spool.
2
1
19984469
Spools, Caps, and O Rings
Oil is directed through the housing to the different ports by way of the spools: the bucket spool, 1, the boom spool, 2, and the auxiliary spool, 3.
Some oil circulates around the spools for lubrication and smooth operation. If an oil leak appears on the outside of the valve and all lines connected to the ports are tight, check the O rings on each end of the spools. The spools can be pulled from the control valve housing while the valve is still in the loader by disconnecting the control linkage and removing the spool caps.
CAUTION
If removing spool caps on the tractor, make sure all system pressure has been relieved first.
Notice that the bucket spool has a plain cap, 4. The boom spool and auxiliary spools have detent caps, 5, to hold the spools in position for float position boom circuit or continuous flow auxiliary circuit operation.
1. Thoroughly clean the control valve and unscrew the allen head capscrews, 1, on the caps.
2. Remove the caps, 2, from the rear of the valve body.
1
2
3
19984470
19984471
4
4
3
48
5
49
2
1
50
35-47
SECTION 35 - HYDRAULIC SYSTEM
NOTE: Before removing the spools, make sure the exposed portion of the spool is free from any paint or corrosion which could damage the internal porting of the valve.
3. Remove the spools, 1, from the valve body.
NOTE: Each spool is different. Make sure to replace the correct spool in the correct part of the valve body.
19984472
4. Remove the O rings from the spool ports. Inspect the O ring seating area for burrs, and remove them before installing new O rings.
1
51
1
19984473
5. The complete control valve components include:
1. Main system relief valve
2. Boom circuit relief valve
3. Plugs
4. Caps
5. Plain control spool cap
6. Detent control spool caps
7. Centering springs and hardware
8. Bucket control spool
9. Boom control spool
10. Auxiliary control spool
11. Lift check, springs, and caps
12. Bucket and boom solenoids
13. Boom lower circuit orifice plate
3
2
19984474
1
3
52
5
6
7
11
13
12 3 4 8 9
10
53
35-48
SECTION 35 - HYDRAULIC SYSTEM
PARTS INSPECTION
Inspect the control valve components thoroughly for scratches or nicks, weak centering springs, weak lift check springs, and scored lift checks or valve seats.
Valve Body, 1
-Check for cracks in casting that allow an oil leak.
-Check the lift check seats, 2.
-Check O ring seating surfaces.
-Damaged fitting thread areas.
Control Spools, 3
-Check the spool lands for scratches.
-Check spool straightness.
IMPORTANT: The spools are matched to the control valve body. If excessively worn or damaged, replace the control valve assembly.
1
2
19984475
NOTE: The three spools are different. Do not mix spools and return spring assemblies during reassembly.
Detent Caps, 3
-Check the detent pins and springs for proper operation. All pins should move freely and return to position with spring pressure.
-Clean the caps thoroughly and lubricate the pins with a light grease.
Lift Checks, 4
-Check the lift check seat surface for wear or scratches.
-Check the lift check springs.
-Check the caps to ensure free movement of lift checks into the caps.
Orifice Plate, 5 (Boom Lower Circuit)
-Check the flat surface for scratches.
-Check the hole in the plate for dirt and clean.
Solenoid Spool Locks
-Check solenoid operation
19984472
5
3
1
3
4
54
55
35-49
SECTION 35 - HYDRAULIC SYSTEM
REASSEMBLY
1. Install O rings, 1, in the boom control spool ports, the bucket control spool ports, and auxiliary control spool ports.
2. Install the O ring seals, 1, on the boom circuit relief valve, 2, and all the plugs, 3.
3. Install small O rings, 4, and backup rings, 5, on the relief valve and plugs.
19984473
1
56
57
4. Install the boom circuit relief valve, 1, into the valve body.
5. Install the plugs, 2, over the bucket and auxiliary spool caps.
19984468
2
1
2
58
35-50
SECTION 35 - HYDRAULIC SYSTEM
6. Install the plug, 1, into the port, 2, over the main relief valve port. Install the plug, 3, into the port,
4, over the auxiliary control spool.
2
1
19984469
7. Install new O rings, 1, on the spools.
8. Install the washers, 2, spring retaining plate with small hole, 3, centering spring, 4, spring plate with large hole, 5, and end screw, 6, on each spool.
NOTE: The spring retaining plate with the small hole must go next to the valve. The plate with the large hole, 5, must be over the end pin, 6, for proper spool.
9. Tighten the end screw, 6, securely.
4
3
59
60
61
35-51
SECTION 35 - HYDRAULIC SYSTEM
10. Install the control spools into the valve body bucket, 1, boom, 2, auxiliary, 3.
11. Reinstall the boom lower orifice plate, 4, with the slot towards the fitting in port, 5.
NOTE: The three spools are different. Do not mix spools and return spring assemblies during reassembly.
5
4
1 2 3
62
1
19984472
12. Install the plain cap, 1, over the bucket control spool and the detent caps, 2, over the boom and auxiliary control spools. Tighten the allen head screws, 3, securely.
NOTE: If any spool binds in the housing, rotate the spool 180 _ and check it. If the spool still binds, check the end caps for proper alignment. If a spool still binds, the complete control valve must be replaced.
NOTE: On the tractor, binding can be caused by mounting hardware that is too tight (valve to main frame).
13. Install the solenoid plunger assemblies, 1, into the ports, 2, over the control spool ends.
19984470
3
2
63
2
19984467
1
64
35-52
SECTION 35 - HYDRAULIC SYSTEM
14. Add O rings to the lift check valve caps, 1. Install the lift checks, 2, springs, 3, and caps.
15. Install the two caps, 4, with O rings into the valve body.
19984466
2
16. Install an O ring on the main system relief valve,
1, and install into the valve body.
4
3 1
65
1
19984465
REINSTALLATION
1. Place the rubber isolation mount, 1, in place under the control valve space.
2. Reinstall the control valve into the loader with the retaining hardware previously removed. Align the valve with the control linkage and torque the valve retaining hardware to 24 N·m (18 ft. lbs.).
3. Reconnect the control linkage and wiring harness to the lockout solenoids.
4. Reinstall the hydraulic lines and tighten to seat the fittings, then loosen the lines and retorque.
5. Refill the hydraulic reservoir with 10W-30 oil.
6. With the unit supported off the ground, start the unit and check for any oil leaks and repair.
7. Reinstall the step shield and belly pan.
8. Recheck the hydraulic oil level and add as required.
1
19984464
66
67
35-53
SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC PUMP
Specifications
Type
LS160
Output @2900 RPM - 69 bar (1000 PSI)
LS170
Output @2900 RPM - 69 bar (1000 PSI)
Rotation (Viewed from shaft end)
Gear teeth
Wear plate
Bushings
Internal lubrication system
Labor Required
R&R Pump
Disassembly, Inspection and Reassembly
26000 Series
Gear Pump
58.7 L/min (15.5 GPM)
67.0 L/min (17.7 GPM)
Clockwise
13 per gear
Black, powdered metal with Teflon coating
Teflon coated
Inlet (suction) side
1.5 hrs.
0.5 hrs.
35-54
SECTION 35 - HYDRAULIC SYSTEM
Op. 35 710 10
PUMP REMOVAL
1. Lower the boom and bucket to the lowered position (resting on the ground), or remove any attachment and raise the boom and rest on the boom lock pins.
2. Stop the engine, turn the ignition key to the run position and operate the boom and bucket control pedals to relieve pressure in the boom and bucket circuits. Turn off the key.
3. Raise the seat and seat pan to the raised latched position.
4. Remove the step shield, 1, to access the gear pump area. For more access remove the right or left hydrostatic control handle assembly.
CAUTION
Do not work under a raised seat unless it is securely latched in the raised latched position.
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment. Always remove the attachment from the loader.
Never loosen any hydraulic lines without first relieving all pressure in the system.
68
35-55
SECTION 35 - HYDRAULIC SYSTEM
Op. 35 710 20
HYDRAULIC SYSTEM PUMP REMOVAL/
DISASSEMBLY (WITHOUT HIGH FLOW)
1. Remove the suction tube, 1, from the gear pump port fitting, 2, and cap the tube to prevent oil loss.
Remove the fitting from the housing.
2. Remove the high pressure hose, 3, from the pump fitting, 4, and cap the tube. Remove the fitting from the housing.
3. Clean the pump thoroughly and mark the pump assembly, 5, to ensure proper reassembly.
4. Remove the pump housing hardware, 6, and separate the end plate and body sections.
IMPORTANT: The pump body is aluminum and can be easily damaged. BE CAREFUL not to damage machined surfaces. DO NOT use a screwdriver or other hard, sharp objects to pry the pump from the plate.
The hydraulic system gear pump consists of:
1. Wear plate assembly
2. Idler gear assembly
3. Drive gear assembly
4. Pump body
5. Pump back plate
Separate the hydraulic system pump end plate and body sections.
2
19998082
1
2
1
6
3
19997794
5
4
4
5
3
69
70
Op. 35 710 20
HYDRAULIC SYSTEM PUMP AND HIGH
FLOW PUMP REMOVAL/DISASSEMBLY
1. On units equipped with high flow, loosen and remove the boom circuit hydraulic lines, 1 and 2, and the high flow supply line, 3.
1
2
19998077
71
35-56
SECTION 35 - HYDRAULIC SYSTEM
2. Remove the suction tube, 1, from the gear pump port fitting, 2, and cap the tube to prevent oil loss.
Remove the fitting from the housing.
3. Remove the high pressure hoses, 3, from the pump fittings, 4, and cap the tubes. Remove the fittings from the housing.
4. Clean the pump thoroughly and mark the pump assembly, 5, to ensure proper reassembly.
5. Remove the pump housing hardware, 6, and separate the end plate and body sections.
IMPORTANT: The pump body is aluminum and can be easily damaged. BE CAREFUL not to damage machined surfaces. DO NOT use a screwdriver or other hard, sharp objects to pry the pump from the plate.
The high flow gear pump consists of:
1. Wear plate assembly
2. Idler gear assembly
3. Drive gear
4. Pump body
5. Pump back plate
Separate the high flow pump body, 4, and back plate,
5, sections.
19997758
1
2
2
1
5
6
3
3
19997759
The hydraulic system pump consists of:
1. Wear plate assembly
2. Idler gear assembly
3. Drive gear assembly
4. Key
5. Pump body
6. Pump back plate
Separate the hydraulic system pump backplate and body sections.
1
2
3
19997795
4
4
5
72
73
4
5
6
74
35-57
SECTION 35 - HYDRAULIC SYSTEM
HIGH FLOW PUMP PARTS INSPECTION
1. Inspect the pump back plate for excessive wear.
The oil grooves in the back plate bushings, 1, should be at approximately 37
°
to the pressure side. If the bushing oil grooves are not positioned as noted, the bushings have turned in the plate.
The plate should be replaced under this condition.
The bushings in the plate should be 3.20 mm
(0.126
″
) below the surface of the plate. Replace the back plate if the I.D. of a bushing exceeds
19.2 mm (0.755
″
).
Check for scoring on the face of the back plate,
2. Replace the back plate if wear exceeds 0.038
mm (0.0015
″
).
2. Inspect the pump body, 3, for excessive wear.
Check the pump body inside the gear pockets for excessive scoring or wear.
Replace the pump body if the I.D. of gear pockets, 4, exceed 43.7 mm (1.719
″ ).
3. The wear plate, 1, seal, 2, and backup gasket, 3, should be replaced when the pump is rebuilt. Inspect for damage, such as nicks and tears, to determine if any problem existed. The flat Teflon– coated surface towards the gears and should not show any scratches or grooves that can be caught with a fingernail.
2
19997761
1
3
4
4
75
76
4. Inspect the pump gear teeth, 1, for excessive wear. Inspect the drive gear key, 2, to ensure it is not sheared.
The idler gear shaft should measure greater than or equal to 0.748
″
(19.0 mm) in the bushing area,
3. Both gears should be at least 12.95 mm
(0.51
″
) wide. If the assemblies measure less than specified, replace both gears.
NOTE: If replacement of the gear assemblies is necessary, the gear assemblies should be replaced in pairs.
19997760
2
1
3
77
35-58
SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC SYSTEM PUMP PARTS
INSPECTION
1. Inspect the pump mounting plate for excessive wear. The oil grooves in the bushings, 1, should be line up with the dowel pin holes and be approximately 180 ° apart. If the bushing oil grooves are not positioned as noted, the bushings have turned in the plate - the plate should be replaced.
The bushings in the plate should be 3.20 mm
(0.126
″ ) above the surface of the plate. Replace the plate if the I.D. of the idler gear bushing exceeds 19.2 mm (0.755
″
).
2. Check the seal areas, 2, for scratches or damage that could prevent a good seal.
3. With High Flow - Inspect the pump back plate for excessive wear. The oil grooves in the back plate bushings, 1, should be at approximately 37
°
to the pressure side. If the bushing oil grooves are not positioned as noted, the bushings have turned in the plate. The plate should be replaced under this condition.
The bushings in the plate should be 3.20 mm
(0.126
″ ) below the surface of the plate. Replace the back plate if the I.D. of a bushing exceeds
19.2 mm (0.755
″
).
Check for scoring on the face of the back plate,
2. Replace the back plate if wear exceeds 0.038
mm (0.0015
″
).
4. Without High Flow - Inspect the pump back plate for excessive wear. The oil grooves in the back plate bushings, 1, should be at approximately
37
°
to the pressure side. If the bushing oil grooves are not positioned as noted, the bushings have turned in the plate. The plate should be replaced under this condition.
The bushings in the plate should be 3.20 mm
(0.126
″
) below the surface of the plate. Replace the back plate if the I.D. of a bushing exceeds
19.2 mm (0.755
″ ).
Check for scoring on the face of the back plate,
2. Replace the back plate if wear exceeds 0.038
mm (0.0015
″
).
19997782
2
19997786
1
19997761
2
1
2
78
1
79
80
35-59
SECTION 35 - HYDRAULIC SYSTEM
5. Inspect the pump body, 1, for excessive wear.
Check the pump body inside the gear pockets for excessive scoring or wear.
Replace the pump body if the I.D. of gear pockets, 2, exceed 43.7 mm (1.7195
″ ).
1
2
2
19997761
6. The wear plate, 1, seal, 2, and backup gasket, 3, should be replaced when the pump is rebuilt. Inspect for damage, such as nicks and tears, to determine if any problem existed. The flat Tefloncoated surface towards the gears and should not show any scratches or grooves that can be caught with a fingernail.
81
7. With High Flow - Inspect the pump gear teeth, 1, for excessive wear.
The gear shaft assemblies should measure greater than or equal to 0.7485
″ (19.0 mm) in the bushing area, 2. LS160 gears should be at least
22.56 mm (0.888
″
) wide. LS170 gears should be at least 22.76 mm (1.014
″ ) wide. Replace the gears if they do not meet specifications.
NOTE: If replacement of the gear assemblies is necessary, the gear assemblies should be replaced in pairs.
19997787
2
2
1
2
2
2
82
83
35-60
SECTION 35 - HYDRAULIC SYSTEM
8. Without High Flow - Inspect the pump gear teeth,
1, for excessive wear.
The gear shaft assemblies should measure greater than or equal to 0.748
″
(19.0 mm) in the bushing area, 2. LS160 gear should be at least
22.56 mm (0.888
″
) wide. LS170 gears should be at least 22.76 mm (1.014
″
) wide. Replace the gears if they do not meet specifications.
NOTE: If replacement of the gear assemblies is necessary, the gear assemblies should be replaced in pairs.
2
2
19997814
HYDRAULIC SYSTEM PUMP
REASSEMBLY/ INSTALLATION (WITHOUT
HIGH FLOW)
NOTE: If installing a new pump, refer to “New
Hydraulic System Pump Installation (Without High
Flow)” below.
1. Coat all parts with a thin coat of petroleum jelly or oil to aid in reassembly.
2. Clean the mounting plate surface and hydrostatic pump housing thoroughly and install a new O ring, 1.
19997782
1
3. Install the seal, 1, and backup gasket 2, on the wear plate, 3. BE SURE that the flat area, 4, on the gasket AND seal, 5, are properly aligned and lay flat when installed in the wear plate.
1
2
85
2
2
84
86
35-61
SECTION 35 - HYDRAULIC SYSTEM
NOTE: The gasket AND seal must align and lay flat when installed in the wear plate.
4. Install the wear plate assembly, 1, with the gasket/seal side towards the pump mounting plate with the mid section cut away on the suction side,
2, of the pump.
2
19997783
5. Install the drive shaft, 1, making sure to engage the splines inside the hydrostatic pump. Install the idler gear assembly, 2, into the bushing. Rotate the gears to help slide the idler gear into place.
NOTE: The drive shaft and gear, 1, must be properly seated into the hydrostatic pump drive shaft splines with the end of gear teeth against the wear plate.
2
19997784
1
1
87
88
89
35-62
SECTION 35 - HYDRAULIC SYSTEM
6. Make sure the dowel pins, 1, are in place and install the body on the plate with the half-moon cavities, 2, in the body facing out away from the plate. Check that the reference marks made during disassembly align correctly.
NOTE: The small half-moon cavity, 2, must be on the pressure side of the pump.
2
19997785
7. Install a new O ring, 1, in the back plate.
1
1
1
90
19997761
8. Install the pump back plate, 1, over the gear shafts. Check that the reference marks made during disassembly align correctly.
9. Install the housing hardware with the eight bolts,
2, and sealing washers. Tighten the bolts evenly in a criss-cross pattern to 34 - 38 N
⋅ m (25 - 28 ft.
lbs.).
10. Install the high pressure port fitting, 3, and the high pressure line, 4. Tighten the high pressure line connections securely.
11. Install the suction tube port fitting, 5, and turn the fitting up. Add SH/CG4 10W-30 oil to fill the bottom of the hydraulic pump.
19998081
5
1
2
3
91
4
92
35-63
SECTION 35 - HYDRAULIC SYSTEM
12. Turn the suction tube fitting, 1, down and install the suction tube, 2. Tighten all hydraulic connections securely.
1
HYDRAULIC SYSTEM PUMP AND HIGH
FLOW PUMP REASSEMBLY/ INSTALLATION
NOTE: If installing a new pump assembly, refer to
“New Hydraulic System Pump / High Flow Pump
Installation” below.
1. Coat all parts with a thin coat of petroleum jelly or oil to aid in reassembly.
2. Clean the mounting plate surface and hydrostatic pump housing thoroughly and install a new O ring, 1.
19998082
1
19997782
3. Install the seal, 1, and backup gasket 2, on the wear plate, 3. BE SURE that the flat area, 4, on the gasket AND seal, 5, are properly aligned and lay flat when installed in the wear plate.
2
93
94
95
35-64
SECTION 35 - HYDRAULIC SYSTEM
NOTE: The gasket AND seal must align and lay flat when installed in the wear plate.
4. Install the wear plate assembly, 1, with the gasket/seal side towards the pump mounting plate with the mid section cut away on the suction side,
2, of the pump.
2
5. Install the drive shaft, 1, making sure to engage the splines inside the hydrostatic pump. Install the idler gear assembly, 2, into the bushing. Rotate the gears to help slide the idler gear into place.
NOTE: The drive shaft and gear, 1, must tbe properly seated into the hydrostatic pump drive shaft splines with the end of gear teeth against the wear plate.
Position the keyway, 3, up.
2
19997788
1
1
96
97
3
98
35-65
SECTION 35 - HYDRAULIC SYSTEM
6. Make sure the dowel pins, 1, are in place and install the body, 2, on the plate with the half-moon cavities, 3, in the body facing out away from the plate. Check that the reference marks made during disassembly align correctly.
NOTE: The small half-moon cavity, 3, must be on the pressure side of the pump.
1
19997789
7. Install a new O ring, 1, in the back plate.
2
3
1
99
8. Install the pump back plate, 1, over the gear shafts. Check that the reference marks made during disassembly align correctly.
9. Clean the mounting plate surface thoroughly and install a new O ring, 2. Install the shaft key, 3, in the drive shaft.
19997761
1
19997762
100
2
3
101
35-66
SECTION 35 - HYDRAULIC SYSTEM
10. Install the seal, 1, and backup gasket 2, on the wear plate, 3. BE SURE that the flat area, 4, on the gasket AND seal, 5, are properly aligned and lay flat when installed in the wear plate.
NOTE: The gasket AND seal must align and lay flat when installed in the wear plate.
102
11. Install the wear plate assembly, 1, with the gasket/seal side towards the pump mounting plate with the mid section cut away on the suction side,
2, of the pump.
19997763
2
1
103
104
35-67
SECTION 35 - HYDRAULIC SYSTEM
12. Install the drive gear, 1, on the drive shaft, slipping the groove over the shaft key, 2. Install the idler gear assembly, 3, into the bushing. Rotate the gears to help slide the idler gear into place.
NOTE: When installing drive gear, 1, onto the shaft, be careful not to knock the round key, 2, from the shaft.
3
1
19997764
13. Make sure the dowel pins, 1, are in place and install the body, 2, on the plate with the half-moon cavities, 3, in the body facing out away from the plate. Check that the reference marks made during disassembly align correctly.
NOTE: The small half-moon cavity, 3, must be on the pressure side of the pump.
19997765
14. Install a new O ring, 1, in the back plate.
2
105
1
2
3
1
106
19997761
107
35-68
SECTION 35 - HYDRAULIC SYSTEM
15. Install the pump backplate, 1, over the gear shafts. Check that the reference marks made during disassembly align correctly.
16. Install the housing hardware with the eight bolts,
2, and sealing washers. Tighten the bolts evenly in a criss-cross pattern to 34 - 38 N·m (25 - 28 ft.
lbs.).
17. Install the high pressure port fittings, 3, and the high pressure lines, 4. Tighten the high pressure line connections securely.
18. Install the suction tube port fitting, 5, and turn the fitting up. Add SH/CG4 10W-30 oil to fill the bottom of the hydraulic pump.
19998080
1
5
19. Turn the suction tube fitting, 1, down and install the suction tube, 2. Tighten all hydraulic connections securely.
1
2
4
3
108
20. Reinstall the boom circuit hydraulic lines, 1, and high flow line, 2, and tighten securely.
19997758
2
1
19998077
2
109
110
35-69
SECTION 35 - HYDRAULIC SYSTEM
NEW HYDRAULIC SYSTEM PUMP
INSTALLATION (WITHOUT HIGH FLOW)
1. Remove the through bolts and separate the gear assemblies and wear plate from the pump body by removing the drive gear, 1, and idler gear, 2.
Do not disturb the seal between the pump body and the backplate.
1
2
19997780
The hydraulic system gear pump consists of:
1 Wear plate assembly
2 Idler gear assembly
3 Drive gear assembly
4 Pump body
5 Pump back plate
Coat all parts with a thin coat of petroleum jelly or oil to aid in reassembly.
1
2
2. Clean the mounting plate surface thoroughly and install a new O ring, 1.
19997794
1
111
3 4 5
112
19997782
113
35-70
SECTION 35 - HYDRAULIC SYSTEM
3. Install the wear plate assembly, 1, with the gasket/seal side towards the pump mounting plate with the mid section cut away on the suction side,
2, of the pump.
2
1
19997783
4. Install the drive shaft, 1, making sure to engage the splines inside the hydrostatic pump. Install the idler gear assembly, 2, into the bushing. Rotate the gears to help slide the idler gear into place.
NOTE: The drive shaft and gear, 1, must be properly seated into the hydrostatic pump drive shaft splines with the end of gear teeth against the bearing plate.
2
19997784
1
5. Install the pump backplate, 1, and body together over the gear shafts.
6. Install the housing hardware with the eight bolts,
2, and sealing washers. Tighten the bolts evenly in a criss-cross pattern to 34 - 38 N·m (25 - 28 ft.
lbs.).
7. Install the high pressure port fitting, 3, and the high pressure line, 4. Tighten the high pressure line connections securely.
8. Install the suction tube port fitting, 5, and turn the fitting up. Add SH/CG4 10W-30 oil to fill the bottom of the hydraulic pump.
19998081
5
1
2
3
114
115
4
116
35-71
SECTION 35 - HYDRAULIC SYSTEM
9. Turn the suction tube fitting, 1, down and install the suction tube, 2. Tighten all hydraulic connections securely.
1
NEW HYDRAULIC SYSTEM PUMP / HIGH
FLOW PUMP INSTALLATION
1. Remove the through bolts, 1, and washers.
2. Separate the pumps at 2, taking care not to disturb the seals between the pump bodies and backplates.
19998082
2
2
3. Remove the small round drive key, 1, from the pump shaft, 2, and remove the drive gears, idler gears, and wear plates from the pumps, taking care not to disturb the seals between the pump body and backplate.
IMPORTANT: The small round key must be removed to remove drive shaft from center section. Do not lose key.
19997790
19997791
1
2
1
117
118
119
35-72
SECTION 35 - HYDRAULIC SYSTEM
The hydraulic system pump consists of:
1 Wear plate assembly
2 Idler gear assembly
3 Drive gear assembly
4 Key
5 Pump body
6 Pump back plate
Coat all parts with a thin coat of petroleum jelly or oil to aid in reassembly.
1
2
19997795
The high flow pump consists of:
1 Wear plate assembly
2 Idler gear assembly
3 Drive gear assembly
4 Key (Figure 120)
5 Pump body
6 Pump back plate
Coat all parts with a thin coat of petroleum jelly or oil to aid in reassembly.
1
2
19997759
4. Clean the mounting plate surface thoroughly and install a new O ring, 1.
1
3 4
5
6
120
3 4 5
121
19997782
122
35-73
SECTION 35 - HYDRAULIC SYSTEM
Install the wear plate assembly, 1, with the gasket/seal side towards the pump mounting plate with the mid section cut away on the suction side,
2, of the pump.
2
19997783
5. Install the drive shaft, 1, making sure to engage the splines inside the hydrostatic pump. Install the idler gear assembly, 2, into the bushing. Rotate the gears to help slide the idler gear into place.
NOTE: The drive shaft and gear, 1, must tbe properly seated on the hydrostatic pump drive shaft splines with the end of gear teeth against the wear plate.
Position the keyway, 3, up.
2
19997788
1
6. Install the pump body and back plate together, 1, over the gear shafts, taking care not to disturb the seals between the pump body and backplate.
1
123
3
1
124
19997792
125
35-74
SECTION 35 - HYDRAULIC SYSTEM
7. Clean the mounting plate surface thoroughly and install a new O ring, 2. Install the shaft key, 3, in the drive shaft.
1
8. Install the wear plate assembly, 1, with the gasket/seal side towards the pump mounting plate with the mid section cut away on the suction side,
2, of the pump.
19997762
19997763
2
9. Install the drive gear, 1, on the drive shaft, slipping the groove over the shaft key, 2. Install the idler gear assembly, 3, into the bushing. Rotate the gears to help slide the idler gear into place.
NOTE: When installing drive gear, 1, onto shaft, be careful not to knock the round drive key, 2, from the shaft.
3
1
19997764
2
128
2
3
126
1
127
35-75
SECTION 35 - HYDRAULIC SYSTEM
10. Install the high flow pump body and end plate together, 1, taking care not to disturb the seals between the pump body and backplate. Make sure there are no gaps between the pump bodies and plates.
1
19997793
11. Install the housing hardware with the eight bolts,
1, and sealing washers. Tighten the bolts evenly in a criss-cross pattern to 34 - 38 N·m (25 - 28 ft.
lbs.).
12. Install the high pressure port fittings, 2, and the high pressure lines, 3. Tighten the high pressure line connections securely.
13. Install the suction tube port fitting, 4, and turn the fitting up. Add SH/CG4 10W-30 oil to fill the bottom of the hydraulic pump.
14. Turn the suction tube fitting, 1, down and install the suction tube, 2. Tighten all hydraulic connections securely.
19998080
1
4
1
3
130
129
2
19997758
2
131
35-76
SECTION 35 - HYDRAULIC SYSTEM
15. Reinstall the boom circuit hydraulic lines, 1, and high flow line, 2, and tighten securely.
1
2
19998077
132
35-77
SECTION 35 - HYDRAULIC SYSTEM
GEAR PUMP START-UP PROCEDURE
This procedure must be performed if the gear pump has been removed for repair purposes or any gear pump hydraulic lines have been removed.
1. Fill the reservoir with SAE SH/CG4 10W-30 oil to the proper level.
2. Loosen suction line, 1, at the gear pump. When oil flows from the connection, tighten the connection.
3. Start the engine and run it at 1500 RPM. Operate all hydraulic controls to remove remaining air from the system.
4. Check reservoir level and add oil as necessary.
1
19998082
2
133
35-78
SECTION 35 - HYDRAULIC SYSTEM
CYLINDERS, BOOM AND BUCKET
BOOM CYLINDERS - LS160
Specifications
Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5 mm (2.5
″
)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470.15 mm (18.51
″ )
Rod Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.1 mm (1.5
″ )
Cycle Times (seconds)
Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Torque
Piston Locknut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 N·m (170 ft. lbs.)
Cylinder Head (gland) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 N·m (225 ft. lbs.)
Lower Pivot Pin Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 N·m (250 ft. lbs.)
Upper Pivot Pin Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Labor Required
Remove and Replace (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hour
Repair (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hour
BUCKET CYLINDERS - LS160
Specifications
Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.15 mm (2.25
″
)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454.15 mm (17.88
″ )
Rod Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.8 mm (1.25
″
)
Cycle Times (seconds)
Curl Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Curl Down (dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
2.8
Torque
Piston Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 N·m (285 ft. lbs.)
Cylinder Head (gland) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 N·m (210 ft. lbs.)
Lower Pivot Pin Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Upper Pivot Pin Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 N·m (80 ft. lbs.)
Labor Required
Remove and Replace (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hour
Repair (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hour
35-79
SECTION 35 - HYDRAULIC SYSTEM
BOOM CYLINDERS - LS170
Specifications
Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5 mm (2.5
″ )
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470.15 mm (18.51
″
)
Rod Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.1 mm (1.5
″ )
Cycle Times (seconds)
Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Torque
Piston Locknut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 N·m (170 ft. lbs.)
Cylinder Head (gland) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 N·m (225 ft. lbs.)
Lower Pivot Pin Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 N·m (250 ft. lbs.)
Upper Pivot Pin Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Labor Required
Remove and Replace (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hour
Repair (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hour
BUCKET CYLINDERS - LS170
Specifications
Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.15 mm (2.25
″
)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454.15 mm (17.88
″ )
Rod Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.8 mm (1.25
″
)
Cycle Times (seconds)
Curl Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Curl Down (dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.54
1.75
Torque
Piston Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 N·m (285 ft. lbs.)
Cylinder Head (gland) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 N·m (210 ft. lbs.)
Lower Pivot Pin Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft. lbs.)
Upper Pivot Pin Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 N·m (80 ft. lbs.)
Labor Required
Remove and Replace (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hour
Repair (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hour
35-80
SECTION 35 - HYDRAULIC SYSTEM
BOOM CYLINDER
Op. 35 710 10
REMOVAL
CAUTION
Before removing the boom cylinders, the boom must be in the up, locked position supported by the boom lock pins.
Never loosen any hydraulic lines without first relieving all pressure in the system.
1. Remove any attachment from the loader boom attaching plate, bucket, etc.
2. Raise the boom above the boom lock pins, extend the boom lock pins, and lower the boom on the boom lock pins, 1.
3. After stopping the engine and before removing the seat belt and dismounting from the loader, turn the ignition switch to the “RUN” position.
4. Push both the boom and bucket pedals to relieve all residual hydraulic pressure in both hydraulic circuits.
5. Turn off the ignition switch.
6. Disconnect both the upper, 1, and lower, 2, boom hydraulic hoses from the cylinder.
134
135
7. Using a screwdriver, remove the plastic plug, 1, from inside the cab to access the lower cylinder pivot retaining hardware.
8. Loosen the LOWER boom pin retaining hardware.
NOTE: DO NOT remove the retaining hardware at this time.
136
35-81
SECTION 35 - HYDRAULIC SYSTEM
9. Support the cylinder and with a hammer strike the cylinder at the base area, 1, to loosen the tapered pivot pin from the loader main frame.
10. Remove the UPPER boom pin retaining bolt, 1, and boom pin, 2.
11. Remove the cylinder.
12. Shown here is the boom cylinder, 1, lower tapered pivot pin and hardware, 2, and the upper pivot pin and retaining hardware, 3.
137
138
139
35-82
SECTION 35 - HYDRAULIC SYSTEM
Op. 35 730 18
DISASSEMBLY
1. Thoroughly clean the outside of the cylinder.
2. Pull the piston rod out slowly, and drain the oil from the barrel into a suitable container.
3. Clamp the base of the cylinder in a vise at 1, and unscrew the cylinder head (gland), 2.
NOTE: Do not clamp the cylinder barrel in the vise to unscrew the cylinder head. Flattening of the barrel will cause damage to the piston and piston seals.
2
4. Remove the piston rod assembly, 1, from the barrel, 2.
1
140
141
5. Remove the piston retaining nut, 1; the piston, 2; spacer, 3; and cylinder head (gland), 4, from the piston rod, 5.
142
35-83
SECTION 35 - HYDRAULIC SYSTEM
6. Remove the wiper seal, 1; O ring and backup washer, 2; and inner seal and wear ring, 3, from the cylinder head (gland), 4.
7. Remove the wear ring, 1, and seal, 2, from the piston, 3.
143
144
PARTS INSPECTION
1. Thoroughly clean all parts and remove any nicks or burrs with a fine emery cloth.
2. Inspect the inner diameter of the barrel, 1, for excessive wear or scoring.
3. Inspect the threaded area of the barrel, 2, for damaged threads that would prevent proper tightening of the cylinder head.
4. Inspect the O ring seal area, 3, and remove any burrs or nicks that could damage or prevent the
O ring from sealing properly.
145
35-84
SECTION 35 - HYDRAULIC SYSTEM
5. Inspect the outer diameter of the piston, 1, for excessive wear or scoring. If the piston is damaged, the inner surface of the barrel will also most likely be damaged. Inspect the barrel thoroughly. If the piston is not damaged, do not replace.
6. Inspect the cylinder head (gland) inner and outer seal areas, 1 and 2, for sharp edges and scoring.
Inspect the threaded area of the gland, 3, for damaged threads that would prevent proper tightening of the retaining nut. Replace the gland if necessary. All seals should be replaced during reassembly.
REASSEMBLY
1. Clean and dry all parts. The metal parts should be lightly oiled prior to assembly.
2. Install a new O ring, 1, and backup washer, 2, in the outer groove of the cylinder head, 3. Install a new shaft seal, 4, and wear ring, 5, in the inner grooves.
NOTE: Install the shaft oil seal, 4, with the lip of the seal facing the piston.
3. Install a new shaft wiper seal, 6, into the cylinder head. The seal lip should face outward.
146
147
148
35-85
SECTION 35 - HYDRAULIC SYSTEM
4. Examine the piston assembly prior to installation.
Replace the wear ring, 1, and T-seal, 2, making sure they are firmly in their groove and snug against the piston. Insert the L shaped back-up rings, 3, on both sides of the T-seal with the short leg of the L shaped back-up rings towards the Tseal as shown.
3
2
3
1
5. Install the cylinder head assembly, 1, and spacer,
2, onto the piston rod, 3.
6. Prior to installing the piston, clean and apply a bead of hydraulic sealant between the piston and piston rod at 4. Install the piston assembly, 5, and new locknut, 6. The wear ring on the piston should be toward the threaded end of the rod.
NOTE: The flat side of the piston must face the spacer, and the recessed side must face toward the end of the rod. The effective length of the piston rod must be maintained, with the locknut fitting into the recessed area of the piston.
7. Torque the locknut to 230 N·m (170 ft. lbs.).
8. Lubricate the piston and cylinder head assemblies with 10W-30 oil and install the piston rod assembly, 1, into the barrel, 2.
9. Prior to threading the cylinder head into the barrel, apply a coat of grease around the cylinder head, in the area between the backup washer and the cylinder head flange at 3.
10. Torque the cylinder head assembly to 338 N·m
(250 ft. lbs.).
19987106
149
150
151
35-86
SECTION 35 - HYDRAULIC SYSTEM
REINSTALLATION
1. Lubricate the boom pivot pins, 1, with an antiseize-type lubricant.
2. Install the cylinder onto the loader.
NOTE: Refer to Service Bulletins 5/96 - I6 and 7/96
- I6 for updated pivot pin support information and proper pin, spacer, and bolt part numbers.
3. Install a 3/8 ″ bolt, 2; flat washer, 3; and spacer, 4, through the pivot pin retaining strap and boom side plate. Secure with flat washer, 5, and locknut, 6.
4. Torque the upper pivot pin hardware to 38 N·m
(28 ft. lbs.).
5. Torque the lower pivot pin hardware, 1, to 338
N·m (250 ft. lbs.).
6. With a six-pound hammer and using a piece of 2 x 4 hardwood to protect the pin, hit the pivot pin and retaining hardware to properly seat the tapered pin and retorque to 338 N·m (250 ft. lbs.).
7. Reinstall lines, 2, and position to prevent contact with other components, fenders, etc. at 3.
8. Reinstall the plastic plug into the cap inner shell.
9. Cycle the boom several times to remove the air from the system and check the cylinder for leaks.
19997745
6
5
4
3
1
2
152
153
BUCKET CYLINDER
Op. 35 710 10
REMOVAL
CAUTION
Never loosen any hydraulic lines without first relieving all pressure in the system.
1. Remove any attachment, bucket, etc. from the boom attaching plate and lower the boom to the lowered position.
2. Extend the cylinders, 1, to the fully extended position.
3. After stopping the engine and before removing the seat belt and dismounting from the loader, turn the ignition switch to the “RUN” position.
4. Push both the boom and bucket pedals to relieve all residual hydraulic pressure in both circuits.
5. Turn off the ignition switch.
1
154
35-87
SECTION 35 - HYDRAULIC SYSTEM
6. Remove the hydraulic hoses from both ends of the cylinder, 1, and cap the lines to prevent loss of oil.
7. Remove the retaining bolt and pin, 2, from the lower end of the cylinder.
8. Loosen the upper tapered pivot pin retaining hardware, 3.
9. Support the cylinder and, with a hammer, strike the cylinder at the base area, 4, to loosen the tapered pivot pin.
10. Remove the cylinder.
11. Shown here is the bucket cylinder,1, with the upper tapered pivot pin, 2, and hardware.
1
2
155
156
Op. 35 730 13
DISASSEMBLY
There are two designs of bucket cylinders, and the parts are not interchangeable between designs. The piston rods are a different length, and a different seal repair kit is required.
1. Clean the outside of the cylinder and clamp the cylinder base, 1, in a vise.
2. Use a spanner wrench to remove the cylinder gland, 2. The gland is threaded into the cylinder.
3. Pull the cylinder rod assembly from the barrel.
157
35-88
SECTION 35 - HYDRAULIC SYSTEM
4. Remove piston retaining stud, 1, from the cylinder rod, piston, 2, and gland, 3, from the piston rod.
5. Remove seals from the gland, the outer O ring seal and backup ring, 1, the inner shaft seal, 2, and the wiper seal, 3.
PARTS INSPECTION
1. Thoroughly clean all parts and remove all nicks and burrs with a fine emery cloth.
2. Inspect the inner diameter of the barrel for excessive wear or scoring.
3. Inspect the gland thread area, 1, for damaged threads that would prevent proper tightening of the gland.
4. Inspect the O ring seal area, 2, and remove burrs or nicks that would prevent the O ring from sealing properly.
158
159
160
35-89
SECTION 35 - HYDRAULIC SYSTEM
5. Inspect the outer diameter of the piston, 1, for excessive wear or scoring. If the piston is damaged, the inner surface of the barrel will also most likely be damaged. Inspect the barrel thoroughly. If the piston is not damaged, do not replace.
161
6. Inspect the cylinder head (gland) inner and outer seal areas, 1 and 2, for sharp edges and scoring.
Inspect the threaded area of the gland, 3, for damaged threads that would prevent proper tightening of the retaining nut. Replace the gland if necessary. All seals should be replaced during reassembly.
162
REASSEMBLY
1. Clean and dry all parts. The metal parts should be lightly oiled prior to assembly.
2. Examine the piston assembly prior to installation.
Replace the wear ring, 1, and T-seal, 2, making sure they are firmly in their groove and snug against the piston. Insert the L shaped back-up rings, 3, on both sides of the T-seal with the short leg of the L shaped back-up rings towards the Tseal as shown.
19987106
3
2
3
1
163
35-90
SECTION 35 - HYDRAULIC SYSTEM
3. Install a new shaft seal, 1.
4. Install a wiper seal, 2.
NOTE: Install shaft wiper seal, 1, with the lip of the seal facing the piston.
5. Install O ring, 1, and backup washer, 2, on the cylinder gland.
164
165
6. Slide cylinder gland, 1, and new piston with seals installed, 2, onto the piston rod.
NOTE: The piston recess must be positioned over the end of the rod, with the locknut inside the recess.
NOTE: Seals, 3, should be clamped with a ring compressor and chilled before being installed in the barrel.
7. Use a hydraulic sealant to seal the piston and rod. Install piston retaining locknut, 4, with medium-strength 242 Loctite
and torque to 386
N·m (285 ft. lbs.).
4
19997769
3
2
1
166
35-91
SECTION 35 - HYDRAULIC SYSTEM
8. Liberally oil the piston and place it inside the barrel, being careful not to damage the seals.
9. Thread the cylinder gland into the barrel, 1, and torque to 285 N·m (210 ft. lbs.).
REINSTALLATION
1. Lubricate the pivot pins with a never seize type lubricant.
2. Install the cylinder on the loader.
3. Torque the upper pivot pin hardware to 108 N·m
(80 ft. lbs.).
4. With a hammer and using a piece of 2 x 4 hardwood to protect the pin, hit the pivot pin and retaining hardware at 1, to properly seat the tapered pin and retorque to 108 N·m (80 ft. lbs.).
5. Torque the lower pivot pin hardware to 38 N·m
(28 ft. lbs.).
6. Cycle the boom several times to remove the air from the system and check the cylinder for leaks.
7. Check the hydraulic oil level and add 10W-30 oil as required.
167
168
35-92
SECTION 35 - HYDRAULIC SYSTEM
PEDAL CONTROLS
Op. 35 724 16
REMOVAL
With Boom and Bucket Pedal Controls
1. Remove the step shield hardware and step shield.
2. Remove the bolt, 1, washer, lock washer, and nut, that connects the control rod, 2, to the pedal hub arm.
2
3. Remove the bolts, 1, connecting the two bracket halves.
4. Disconnect the control valve links, 2, at the control valve.
5. Remove the pedal mounting bolts, 3, and remove both pedals from the loader.
3
PEDAL INSPECTION
With Boom and Bucket Pedal Controls
1. Remove the control valve links, 1, from the hub control arms, 2.
1
2
2
1
1
1
3
169
170
19996895
171
35-93
SECTION 35 - HYDRAULIC SYSTEM
2. Inspect the control valve links for any obvious damage, bends or twisting.
19996894
3. Inspect the auxiliary hydraulic hub arm, 1, the boom hub arm, 2, and the bucket hub arm, 3, for any deformation or cracks.
4. To disassemble hub arms, remove the roll pins,
4, from the hub arms and control shaft.
5. Inspect the control shafts, 5, for any obvious damage or bends.
6. To remove control shafts, remove bolt, 1, securing shaft arm to pedal. Take note of the position and number of any spacer washers or shims. Remove the nuts, 2, holding the bearings on the pedal support. Separate the shaft from the pedal and bearing.
5
19996893
2
1
4
2 3
4
5
172
173
19996891
2
1
174
35-94
SECTION 35 - HYDRAULIC SYSTEM
7. Inspect the shaft bearings, 1, for excessive wear.
If bearings do not move easily, replace.
1
8. Inspect the pedals, 1, and pedal supports, 2, for any excessive wear or deformation.
19996826
175
2
1
PEDAL REINSTALLATION
With Boom and Bucket Pedal Controls
1. Reinstall the bearings, 1, shafts, 2, brackets, 3, and control arms, 4, using the same number and position of washers or shims.
19996827
1
3
1
176
19996896
2
4
4
2
177
35-95
SECTION 35 - HYDRAULIC SYSTEM
2. Install the left pedal assembly, 1, and attach the front plate with hardware, 2, previously removed.
Do not tighten the hardware at this time.
1
2
3. Slide the pedal assembly to align the auxiliary boom hydraulic hub arm and boom hub arm as shown. Align the inside edge of each hub arm, 1, with the slot in the control valve spool, 2. Tighten the pedal mounting hardware.
4. Recheck the alignment of the hub arm and spool.
1
2
5. Install the right pedal, 1, adding shim washers as necessary so pedal mounting holes line up correctly. Check that the inside edge of the bucket hub arm aligns with the slot in the control valve spool as described above. Install the pedal with hardware, 2, previously removed, and tighten securely. Connect the two-piece bracket with the two bolts, 3, washers and nuts.
6. Check for free operation of the foot pedals and hub control arm assemblies. If any components are binding, adjust or reshim the pedal assemblies.
3
1
178
179
2
180
35-96
SECTION 35 - HYDRAULIC SYSTEM
7. Install the control spool links, 1, with clevis pins,
2, and cotter pins, 3.
8. Attach each link to each hub arm with 3/8 ″ hex head bolts, 4, flat washer, 5, two link washers, 6, lock washer, 7, and nut, 8.
3
5
4
1
6
9. Connect the auxiliary hydraulic control rod, 1, to the pedal hub arm, 2, with the bolt, washer, lock washer, and nut.
10. Install the step shield and hardware.
1
2
7
8
2
181
182
35-97
SECTION 35 - HYDRAULIC SYSTEM
Op. 35 724 16
PEDAL REMOVAL
With Boom and Bucket Hand Controls
1. Remove the step shield hardware and step shield.
2. Remove the bolts, 1, washers, lock washers, and nuts, that connect the control rods, 2, to the pedal hub arms.
1
2
19997768
3. Disconnect the control valve links, 1, from the control valve spools by removing the cotter pins,
2, and clevis pins, 3.
4. Disconnect the control valve links, 1, from the control hub arms by removing the bolts, 4, washers, lockwashers, and nuts.
2
3
1
4
1
183
19996833
5. Remove the right pedal mounting bolts, 1, and remove the right pedal, 2.
6. Remove the left pedal mounting bolts, 3, and remove the left pedal, 4.
3
3
19996832
4
1
1
2
184
185
35-98
SECTION 35 - HYDRAULIC SYSTEM
PEDAL INSPECTION
With Boom and Bucket Hand Controls
1. Remove the bucket hub arm assembly, 1, and the boom hub arm assembly, 2. Inspect the hub arm assemblies for any deformation or cracks.
2. Inspect the control shaft, 3, for any obvious damage or bends. To remove control shafts, remove the two allen screws, 4, securing the auxiliary hydraulic hub, 2, to the control shaft. Then remove the bolt, 5, securing shaft arm to pedal. Take note of the position and number of any spacer washers or shims.
5
19996824
2
4
3. Remove the two allen screws, 1, securing the boom hydraulics hub, 2, to the control shaft. Inspect the boom hydraulics hub for any deformation or cracks.
1
2
3
1
186
4. Inspect the shaft bearings, 1, for excessive wear.
If bearings do not move freely, replace.
19996825
1
187
19996826
188
35-99
SECTION 35 - HYDRAULIC SYSTEM
5. Inspect the pedals, 1, and pedal supports, 2, for any excessive wear or deformation.
6. Inspect the control valve spool links, 1, for bends or excessive wear.
19996827
2
1
1
189
19996829
PEDAL REINSTALLATION
With Boom and Bucket Hand Controls
1. Insert the control shaft, 1, through the left pedal,
2, and left pedal support, 3, fitting three washers,
4, between the pedal and support.
2. Slide the auxiliary boom hydraulic hub assembly,
5, onto the control shaft and secure with allen screws, 6.
2
19996824
4
3
6
5
1
190
191
35-100
SECTION 35 - HYDRAULIC SYSTEM
3. Install the left pedal assembly, 1, and attach the front plate with hardware, 2, previously removed.
Do not tighten the hardware at this time.
4. Install the boom hub assembly, 3, and bucket hub assembly, 4, onto the pivot shaft, 5.
1
2
2
19996831
5. Slide the pedal assembly to align the auxiliary hydraulic hub arm as shown. Align the inside edge of the hydraulic hub arm, 1, with the slot in the control valve spool, 2. Tighten the pedal mounting hardware.
6. Recheck the alignment of the hub arm and spool.
7. Check the alignment between the hub arms and control valve spools. Add shim washers if necessary to correct alignment.
1
2
3
4
5
192
8. Install the right pedal, 1, adding shim washers as necessary at 2, fitting inside the bearing, 3, so pedal mounting holes line up correctly. Install the pedal with hardware, 4, previously removed, and tighten securely.
9. Check for free operation of the foot pedals and hub assemblies. If any components are binding, adjust or reshim the right pedal assembly.
2
3
4
193
19996832
1
194
35-101
SECTION 35 - HYDRAULIC SYSTEM
10. Install the control spool links, 1, with clevis pins,
2, and cotter pins, 3.
11. Link the boom valve link and the bucket valve link to the hub arms with 3/8 ″ hex head bolts, 4, flat washer, 5, thick link washer, 6, lock washer, 7, and nut, 8.
12. Install the auxiliary hydraulic link with 3/8 ″ hex head bolts, flat washer, two flat washers, 9, lock washer, and nut.
3
7
6
8
19996833
2
1
5
4
13. Install control rods, 1, to the pedal hub arms, 2, with the bolts, washers, lock washers and nuts removed during pedal removal.
14. Install the step shield and step shield hardware.
1
2
19997768
9
195
196
35-102
SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC COOLING, FILTER,
RESERVOIR SYSTEM
Specifications
Filter (spin-on canister) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 micron
Reservoir (filter screen at fill cap) capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.7 L (6 gal.)
Labor Required
Remove and replace oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hour
Remove and replace filter and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 hour
Remove and replace oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 hours
Remove and replace reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 hours
35-103
SECTION 35 - HYDRAULIC SYSTEM
Op. 35 705
FILTER SYSTEM
The skid-steer loader is equipped with a single spinon filter canister type located at 1, to the right of the engine radiator. The filter is a 10-micron element.
NOTE: Allow the hydraulic oil to cool before changing the filter.
CAUTION
The hydraulic oil filter will be under pressure when the oil is at operating temperature.
The filter base is equipped with a bypass valve, 1, to allow cold oil to bypass the filter without damaging the filter or starving the hydrostatic system of lubrication oil during cold weather start-ups.
In cold weather start-ups, allow the hydraulic oil to warm up before operating the boom, bucket, or the hydrostatic ground drive system, to prevent possible damage to the systems.
The filter base is also equipped with a pressure sensor that is monitored by the EIC (Electronic
Instrument Cluster) to signal the operator of a plugged oil filter.
Op. 35 705 04
FILTER REMOVAL
Op. 35 705 05
BASE REMOVAL
The filter base can be removed by opening the rear door and removing the right engine side panel.
1. Remove the sensor wires, 1.
2. Remove the inlet, 2, and outlet, 3, oil lines and cap to prevent loss of oil.
3. Remove the filter base mounting hardware, 4.
4. Remove the filter assembly from the unit.
197
198
199
35-104
SECTION 35 - HYDRAULIC SYSTEM
REASSEMBLY
1. Reinstall the filter base with the hardware previously removed and reconnect the ground wire,
1. Torque the mounting hardware to 20 N·m (15 ft. lbs.).
2. Reinstall the hydraulic lines, tighten the lines to seat line on fittings and loosen and retorque.
3. Reinstall the filter sensor and connect the sensor wires, 2.
4. Reinstall a new filter, coat the filter seal ring with
10W-30 oil, and tighten the filter unit until it contacts the base, and then tighten another half to three-quarter turn.
OIL COOLER
The hydraulic oil cooler is located to the inside of the radiator next to the engine cooling fan.
To access the cooler for cleaning, move the radiator to the rear by lifting up on the two handles, 1, to gain clearance between the radiator and cooler at 2.
Op. 35 300 10
OIL COOLER REMOVAL
1. Drain the engine cooling system.
2. Unhook the inlet line to the reservoir and cap to prevent loss of oil.
3. Unhook the return (outlet) line and cap to prevent loss of oil.
4. Remove the radiator to engine hoses.
5. Remove the filter sender wires.
6. Remove the radiator overflow hose, 1, to the overflow tank.
7. Remove the eight bolts from the support at 2, four bolts each side, and lift the radiator and cooler assembly from the loader frame.
200
201
202
35-105
SECTION 35 - HYDRAULIC SYSTEM
8. Remove the fan shroud retaining hardware, 1, to access the oil cooler.
9. Remove the oil cooler, 2, retaining hardware to separate the cooler from the radiator.
REASSEMBLY
1. Reattach the oil cooler to the support with the previously removed hardware.
2. Reinstall the support with the oil cooler and radiator attached into the frame.
3. Position the support square with the loader frame at 1, and install retaining hardware and tighten securely.
4. Reconnect the hydraulic lines to the cooler.
Tighten the lines to seat to fittings, then loosen lines and retorque.
5. Reconnect the radiator lines and refill cooling system with 50/50 water-antifreeze mixture.
6. Reconnect the filter hydraulic lines. Tighten the lines to seat to fittings, then loosen lines and retorque.
7. Reconnect the filter sensor wires.
8. Check hydraulic oil level and add 10W-30 oil if required.
9. Start the unit, operate the hydraulic system, check for oil leaks and coolant leaks, and repair as required.
10. Check the oil level and engine coolant level and add as required.
Op. 35 300
OIL RESERVOIR
The hydraulic oil reservoir fill is accessed through the top engine shield. The fill cap assembly is the hydraulic system breather and is equipped with a screen to help prevent contamination into the system.
Op. 35 300 28
Filter/Breather Cap Cleaning
To clean the breather cap, 1, remove the cap from the reservoir and back flush the cap assembly with a clean solvent. Blow dry with low- pressure air.
To clean the fill screen, remove the six screws and washers, 2, and lift the screen assembly from the reservoir neck.
35-106
203
204
205
SECTION 35 - HYDRAULIC SYSTEM
Back flush the screen, 1, with a clean solvent and blow dry with low-pressure air.
Reinstall the screen assembly making sure the screen is sealed between the screen and reservoir neck with gaskets, 2. Use a silicone sealer with gaskets to seal between the screen and reservoir is recommended.
The hydraulic reservoir is equipped with a temperature sender, 1, which allows the EIC (Electronic Instrument Cluster) to monitor the hydraulic oil temperature and signal the operator of an oil overheat condition.
IMPORTANT: Do not over tighten the sender or damage to the reservoir may occur.
Op. 35 300 10
OIL RESERVOIR REMOVAL
To access the reservoir, open the rear door and remove the right engine side shield.
To remove the reservoir from the loader, the cab and boom must be tilted forward. Refer to “Section 00”
For the cab tilting procedure.
19997779
1
206
207
208
35-107
SECTION 35 - HYDRAULIC SYSTEM
With the cab tilted forward:
1. Drain the reservoir by lowering the engine belly pan, removing the return line from the charge check valve and rotating the line into a container.
Allow the oil to drain.
2. Remove the hydraulic oil temperature sender wires, 1.
3. Remove the suction and return lines from the reservoir at 2.
4. Remove the front and rear mounting hardware,
3.
5. Lift the reservoir from the loader.
NOTE: If the reservoir tank should leak due to a hole or crack, DO NOT repair. Replace the tank, as the type of material used in the molded tank is not reliably fixed.
REINSTALLATION
1. Reinstall the reservoir into the loader frame, position and reinstall the tank retaining hardware.
2. Reattach the suction, 1, and return, 2, lines and tighten the hose clamps securely.
3. Refill the reservoir with 10W-30 oil and operate the hydraulic system to remove all air from the system. Check for oil leaks, repair as required.
4. Check the oil level, fill as required.
5. Reinstall the engine belly pan.
6. Tilt the cab and boom back into operating position.
7. Reinstall all shields previously removed.
1
1
19998076
19997804
2
3
2
209
210
35-108
SECTION 35 - HYDRAULIC SYSTEM
ADAPTING ATTACHMENTS WITH
PREVIOUS-STYLE NH-SUPPLIED
BALL/PIN COUPLERS TO FLAT-FACED
COUPLERS
If the attachment to be used has the 1/2 I ball/pintype couplers, adaptors, 1 and 2, can be used to attach to the loader flat-faced couplers.
Part
Number Description
86539404 1/2
I
male flat-faced/
1/2 I female ball/pin-type
86539403 1/2 I female flat-faced/
1/2
I
male ball/pin-type
Item#
1
2
1
2
NOTE: These adaptors are useful for occasionally adapting attachments; however, they significantly lengthen the coupler assembly and make assembly more likely to be damaged in usage. It is preferred for heavy attachment usage to convert the attachment quick couplers or loader quick couplers to the flat-faced style.
211
35-109
SECTION 35 - HYDRAULIC SYSTEM
LABOR GUIDE
HYDRAULIC SYSTEM
The following labor amounts are listed as a guide only. Working conditions and experience will vary the time it actually takes to complete each job.
Job
Hours
Remove and replace control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 hr.
Repair control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 hr.
Remove and replace gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 hr.
Repair gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hr.
Remove and replace one boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hr.
Repair one boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 hr.
Remove and replace one bucket cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hr.
Repair one bucket cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hr.
Remove and replace pedal controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 hr.
Repair one pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hr.
Remove and replace oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 hr.
Remove and replace filter and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 hr.
Remove and replace oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 hrs.
Remove and replace hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 hrs.
35-110
SECTION 37 – TOWING HOOKS AND BALLASTING
Chapter 1 – Rear Counterweights
Section
37 140 10
37 140 12
CONTENTS
Description Page
Rear Counterweights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-2
Rear Counterweight Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-2
37-1
SECTION 37 - TOWING HOOKS AND BALLASTING
Op. 37 140 10
REAR COUNTERWEIGHTS
Counterweights can be installed to improve the stability of the loader when handling heavy loads or when operating the skid-steer loader with a heavy front-mounted attachment.
Four 27.2 kg (60.0 lbs.) weights, 1, (two per side) may be added to the rear of the loader as shown.
The rear counterweights should be removed when not required. Operating the skid-steer loader with rear counterweights installed and with light front loads, may cause uneven tire wear.
2
1
Weight Removal
1. To remove weights, remove cotter pin at 2, and remove pin, 3, from the weights and support bracket.
2. Lift the weights from support by pivoting the bottom of weights out at bottom and then lift straight up.
Op. 37 140 12
REAR COUNTERWEIGHT SUPPORT
REMOVAL
3
1
37-2
SECTION 39 – FRAMES
Chapter 1 – Lower Main, ROPS
Section
CONTENTS
Description Page
39-1
SECTION 39 - FRAMES
GENERAL INFORMATION
ROPS
The ROPS is a welded frame structure to provide rollover protection for the operator and pivot point locations for the boom assembly.
Shown here is the loader and ROPS with the inner shell removed.
ROPS FRAME
Op. 90 152 46
REMOVAL
The ROPS can be removed from the lower frame with the cab inner shell and boom attached in place or removed.
To remove the ROPS with the inner shell and boom removed:
Follow the instructions for “Cab Inner Shell Removal”
(refer to Section 90 of this manual) and “Boom, Upper and Lower Link Removal” (refer to Section 82 of this manual).
1. Remove the rear attaching bolts, 1, left and right sides. If there are washer spacers under the bolt heads, make sure to replace them on installation for proper torquing.
2. Support the ROPS with a suitable lifting device and remove the front attaching bolts, 1, two each side.
3. Lift the ROPS frame from the lower main frame and move to a level area. Lower the ROPS to the floor.
1
2
3
39-2
SECTION 39 - FRAMES
To remove the ROPS with the cab inner shell and boom attached:
1. Remove any attachment from the loader mounting plate, raise the boom and rest on the boom lock pins.
CAUTION
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment. Always remove the attachment from the loader.
2. Remove the front step shield, 1.
3. Remove the right and left fenders, 2.
4. Lower the boom to the lowered position and turn the ignition (key) switch to the “OFF” position. Do not unbuckle the seat belt and exit the loader.
5. Relieve the hydraulic pressure from the boom and bucket circuits.
– Turn the ignition (key) switch to the “ON” position.
– Operate the boom and bucket controls relieving all pressure in the system.
– Turn the ignition switch “OFF” and exit the loader.
6. Raise the operator’s seat/seat pan support to the raised latched position.
CAUTION
Do not work under a raised seat unless it is securely latched in the raised position.
4
5
6
39-3
SECTION 39 - FRAMES
7. Disconnect the parking brake linkage at 1.
8. Raise the parking brake control lever to the raised engaged position.
1
9. Remove the engine side panels, 1, and top engine screen, 2.
10. Disconnect the (-) negative ground battery cable.
19992572
7
8
11. Unplug the engine wire harness from the main harness, 1.
12. Remove the ground wires from the engine bell housing, 2.
13. Remove the wires from the electric fuel pump and wire harness from along the fuel tank on the left side of the engine.
14. Remove the wires from the hydrostatic charge pressure sender, oil filter sensor, and remove the wire harness from the right side of the engine.
9
39-4
SECTION 39 - FRAMES
15. Remove the wire harness clamps and plastic ties along the left side of the lower frame at 1, 2, and
3.
16. Remove the ground strap, 1, from the cab inner shell and lower main frame.
17. Remove the engine fuse/relay panel support hardware, 1, and raise and tie the panel assembly to the back of the cab assembly.
10
11
12
39-5
SECTION 39 - FRAMES
18. Remove the throttle control cable, 1, from the control lever at 2. Remove the cable retaining nut, 3, and slide the cable down through the right side shield at 4.
19. With the boom in the lowered position and the hydraulic pressure relieved in the boom and bucket circuits, disconnect the boom, bucket, and auxiliary boom hydraulics hose connections, 1, and cap all connections.
CAUTION
Never loosen any hydraulic lines without first relieving all pressure in the system.
20. Rotate the boom lock pin control lever, 1, to extend (engage) the boom lock pins.
1 1
13
14
15
39-6
SECTION 39 - FRAMES
21. Remove the left and right rear attaching hardware, 1. If there are washer spacers under the bolt heads, make sure to replace them on installation for proper torquing.
22. With a suitable lifting device support the boom at the rear.
23. With a suitable lifting device support the boom at the front as shown, and raise the boom assembly up, from both front and rear, until it contacts the boom lock pins at 2.
16
17
18
39-7
SECTION 39 - FRAMES
24. Remove the right and left front retaining bolts, 1.
25. Lift the ROPS and boom assembly from the lower main frame and move to a level area. Rest the assembly on the floor, lowering the boom to the floor.
REINSTALLATION
1. Lift the ROPS and boom assembly onto the lower frame, resting the rear ROPS post on the lower frame pads. Supporting the front of the ROPS install the front retaining hardware. With the front hardware installed, align the rear ROPS posts and install the rear hardware.
2. Torque the front hardware, 1, to 217 N·m (160 ft.
lbs.).
3. Torque the rear hardware, 1, to 108 N·m (80 ft.
lbs.). Replace any washers used for proper spacing.
4. With the ROPS and boom securely attached to the lower frame and the boom in the lowered position, remove the lifting device from the
ROPS.
19
20
21
39-8
SECTION 39 - FRAMES
5. Reinstall the wire harness along the main frame and attach the engine fuse/relay panel.
6. Reconnect the main harness to the engine harness, re-route the wire harness along the fuel tank and the right side of the engine installing all clamps and ties previously removed at 1, 2, and
3.
7. Reconnect the ground wires to the bell housing at 1. Place the largest wire next to the ground surface, stacking the remaining wire by size, largest to smallest, to ensure proper grounding. Reconnect the main wiring harness connector, 2.
1
8. Reconnect all hydraulic lines, 1, and position for clearances between other components. Install any hose clamps removed.
1
22
2
23
24
39-9
SECTION 39 - FRAMES
9. Slide the throttle cable up through the hole in the left cab panel and secure with retaining nut at 1.
Attach the control lever, 2, to the cab panel at 3, with 3/8
″
x 1-1/2
″
cap screw; friction disc, 4; spring, 5; 3/8 ″ flat washer; and locknut. Tighten the pivot hardware to hold the control lever in set position. Over tightening will require more effort to set the throttle.
10. Reconnect the parking brake spring links, 1, to the control rod at 2, and install the cotter pins.
11. Reconnect the (-) negative ground battery cable.
2
1
12. After all wires and hydraulic hoses are connected, start the unit, raising the boom checking for oil leaks.
NOTE: The boom and bucket hydraulic circuits may require cycling several times to purge the air from the hydraulic system.
13. Reinstall all fenders, shields, etc., removed; including the front step shield, 1. Tighten the fender hardware, 2, securely.
14. After the fenders are reinstalled, raise and lower the boom and recheck the hoses and tubes for clearance at 3. Readjust the hoses and tubes if they contact the fenders.
19992572
25
26
27
39-10
SECTION 39 - FRAMES
LABOR GUIDE
The following labor amounts are listed as a guide only. Working conditions and experience will vary the time it actually takes to complete each job.
Job Description Hours
Remove and replace ROPS frame (Includes seat, boom lock linkage, boom removal, inner shell) 18.5 hrs.
39-11
SECTION 39 - FRAMES
39-12
SECTION 44 – AXLES AND WHEELS
Chapter 1 – Axles
CONTENTS
Section
Description Page
44-1
SECTION 44 - AXLES AND WHEELS
Op. 44 100
GENERAL INFORMATION
The power is transmitted to the final drive from the engine which is connected to the hydrostatic pumps,
1, with a flex plate drive coupler. The hydrostatic pumps then transmit hydraulic power to the hydrostatic motors, 2, which are connected to gearboxes,
3, located on the inside of the final drive cases. The left and right drives are separate from each other and are operated independently.
19992569
The power is then transmitted through gears to a double drive sprocket, 1, in the final drive case. The drive sprocket is connected to the axle sprockets, 2, with chains, 3, one endless chain to the front axle and one endless chain to the rear axle.
2
3
1
1
2
The axle sprocket, 1, is splined to the axle shaft and hub assembly, 2. A large O ring, 3, seals the assembly to the frame.
3
44-2
SECTION 44 - AXLES AND WHEELS
1 - HYDROSTATIC PUMP RH
2 - HYDROSTATIC PUMP LH
3 - HYDROSTATIC MOTOR RH
4 - HYDROSTATIC MOTOR LH
5 - GEARBOXES (2)
6 - FINAL DRIVE SPROCKET ASSEMBLIES (2)
7 - DRIVE CHAINS(FRONT AND REAR)(4)
8 - AXLE DRIVE SPROCKETS(4)
9 - AXLES ASSEMBLIES(4)
44-3
4
SECTION 44 - AXLES AND WHEELS
SPECIFICATIONS
Drive Axles
Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 N·m (125 ft. lbs.)
Mounting Bolt Torque (Axle housing to case) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 N·m (140 ft. lbs.)
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High temperature lithium grease
Chain Case
Side Cover Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N·m (11 ft. lbs.)
Brake Caliper Mounting Bolt (center) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N·m (15 ft. lbs.)
Brake Caliper Mounting Bolts (outer) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 N·m (52 ft. lbs.)
Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #80
Front Chain Length (68 pitches)
Rear Chain Length (66 pitches)
Chain Tension
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1727.2 mm (68 ″ )
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1676.4 mm (66 ″ )
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 – 6 mm (0 - 1/4
″
) movement at tire tread
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 liters (2 gal.) each side - 10W-30API service SH/CG4 Oil
Other Materials
Description Use
Ultra/Blue Silicone sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearbox mounting bolts
Axle housing bolts
Chain case cover and bolts
Gearbox to chain case
Brake caliper bolts
Gearbox cover and bolts
Sealing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH Ultra Blue silicone sealer
NH #L81724 - 3.35-oz. tube (cord)
NH #L82519DS - 8-oz. tube
NH #L58775 - 10.2-oz. cartridge
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE10W-30 motor oil-API Service SH/CG4
NH #9613313 - 1 qt.
NH #9613314 - 2 1/2 gal.
NH #9613358 - 1 L
NH #9613360 - 20 L
Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80W-90 API Service GL-5 Gear Oil
NH #9613295 - 1 qt.
NH #9613294 - 5 gal.
NH #9613375 - 4 L
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High viscosity lithium base
NH #9613310 tube
NOTE: Always use a noncorrosive silicone sealer to seal where required to prevent corrosion during the silicone curing process.
44-4
SECTION 44 - AXLES AND WHEELS
TROUBLESHOOTING
FINAL DRIVE SYSTEM
Before servicing or adjusting on the final drive system, the skid-steer loader should be jacked up with the wheels off the ground.
Remove any attachment from the skid-steer loader boom, bucket, etc. Lower the boom to the lowered position or, if servicing requires the boom to be in the raise position, support the boom on the boom locks.
Raise the boom and lower onto boom lock pins, 1.
1. Raise boom above boom lock pins.
2. Engage boom lock pins.
3. Stop engine, ignition key “OFF” position.
4. Turn ignition key to the “ON” position.
5. Lower boom onto boom lock pins.
6. Turn the ignition key to the “OFF” position.
CAUTION
Never exit the loader with the boom in the raised position unless the boom is supported on the boom lock pins.
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment mounted. Always remove the attachment from the loader.
Jack up the loader and support the loader with the wheels off the ground using adequate jack stands or blocks to securely support the loader.
Support the loader at the front of the final drive cases at 1, and at the rear at 2.
CAUTION
Never service a raised loader unless it is securely supported with adequate jack stands or blocks.
5
6
44-5
SECTION 44 - AXLES AND WHEELS
PROBLEM
Both drive wheels on one side not powered
POSSIBLE CAUSES
No hydrostatic motor shaft rotation
No gearbox output drive
Broken drive chains
CORRECTION
Check for pump to motor oil flow and repair
Check gearbox shaft rotation and repair
Check chains and repair
One drive wheel not powered Broken drive chain
Axle or drive sprocket splines worn
Check chain and repair
Check axle and sprocket, replace
Chain case noise
Excessive axle play
Loose drive chains
No oil in final drive
Worn drive sprockets
Bearing failure
Bearing failure on axle shaft
Snap ring failure on axle shaft
Check and adjust chains
Check oil level
Check sprockets and repair
Check axle and gearbox bearings and repair
Check bearings and repair
Check axle bearing pre-load, repair
Noise in gearbox
Axle outer bearing failure
No or low oil in gearbox
Bearing failure
Bearing or shaft failure in drive motor
Gears in gearbox worn
Check oil level
Check shafts and bearings, repair
Check drive motor and repair
Check and replace
Prolonged operation in liquid or semi-liquid material
Decrease lubrication interval to every 500 hours
44-6
SECTION 44 - AXLES AND WHEELS
TESTING
FINAL DRIVE
Pre-test instructions:
* Operator in seat with seat belt buckled.
* Engine running at high idle (full throttle).
* Park brake disengaged position.
STEP
1
2
3
TEST
Push both drive controls forward equally and loader should move in a straight line.
Pull both drive controls rearward equally and loader should move in a straight line.
RESULT PROBABLE CAUSE AND CORRECTION
YES Drive system OK.
NO
YES
NO
Engine stalls, wheels appear locked, check parking brake for engaged. If OK go to step 2.
Slow or no power, Refer to hydrostatic drive section.
Check final drive chain, broken repair.
Drive system OK.
Engine stalls, wheels appear locked, go to step 1.
Wheels rotate slow or no power, go to step 1.
One side of loader drags, go to step 2.
Pre-test instructions:
* Lower boom and attachment to the ground.
* Stop engine.
* Jack loader with wheels off the ground.
* Release parking brake.
STEP
1
2
3
4
TEST
Rotate each tire by hand, tires move less than 1/4
″
at tread.
Tires rotate but are noisy.
RESULT PROBABLE CAUSE AND CORRECTION
YES
NO
YES
Drive system OK.
Tires move more than 1/4
″
at tread, check chain tension.
One tire rotates freely, broken chain, or axle spline worn.
Both tires on one side rotate freely together, inspect drive gearboxes. If OK, check drive motor.
Check drive chains, axle bearings.
NO Drive system OK.
44-7
SECTION 44 - AXLES AND WHEELS
Op. 44 106
AXLES
Op. 44 106 10
AXLE HOUSING ASSEMBLY REMOVAL
The axle housings must be removed to service axle seals, axle bearings, drive chains, drive sprockets, and axle housing mounting bolts.
NOTE: The axle housings may be removed without removing the final drive side cover or draining the case oil.
1. Lower the boom and attachment to the ground.
2. If the work is going to be done with the boom in the raised position, remove the attachment, raise the boom, and rest on the boom lock pins, 1.
CAUTION
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment. Always remove the attachment from the loader.
3. Securely block the skid-steer loader with all four wheels off the ground, refer to Section 1 for more information on properly supporting a skid-steer loader.
CAUTION
F ailure to securely support the skid-steer loader could result in movement of the loader causing serious injury or damage to the equipment.
NOTE: When repairing a rear axle, the front of the unit should be supported slightly higher than the rear for easier rear axle assembly reinstallation.
7
8
44-8
SECTION 44 - AXLES AND WHEELS
4. Remove the tire and wheel from the axle being serviced.
5. Clean the axle and final drive area to prevent debris from entering the final drive case.
6. Remove the eight axle housing retaining nuts and washers, 1.
7. Slide the axle housing from the retaining studs and lift the assembly from the final drive case.
CAUTION
Axle assembly is heavy and may require two persons to adequately support if handling manually.
NOTE: When the axle assembly is removed, the drive sprocket and chain will drop slightly to the bottom of the case.
8. There is a large O ring at 1 that seals the axle housing to the side of the final drive case. Remove the O ring from the case or the axle housing.
Op. 44 106 16
DISASSEMBLY
NOTE: A press is required to remove the axle shaft and hub assembly from the housing.
1. Remove the retaining ring, 1, from the axle shaft.
2. Remove the shims, 2. Note the thickness and number of shims.
3. Place the housing assembly in a press, support the housing as close to the center housing as possible to prevent damage to the housing.
4. Press the axle and hub assembly, 3, from the housing.
9
10
11
44-9
SECTION 44 - AXLES AND WHEELS
5. The outer axle seal, 1, may be replaced at this time without further disassembly. The seal can be replaced without removing the bearing, 2.
6. Install a bearing separator/puller and remove the outer axle bearing, 2.
7. Remove the inner bearing race, 1, by driving it from the housing with a suitable hammer and driver.
12
13
8. Remove the outer replaceable seal sleeve, 1, by prying it from the axle housing.
9. Remove the outer bearing race, 2, and seal, 3, by driving them from the housing with a suitable hammer and driver.
Note the positioning of the oil seal before removal, as the replacement seal should be located in the same position.
14
44-10
SECTION 44 - AXLES AND WHEELS
10. The axle hub wheel studs, 1, can be removed from the hub, by pressing them from the hub.
11. Shown here are the related parts used in the axle assembly.
Ref.
Description
1 Housing
2 Axle and hub assembly
3 Outer seal
4 Outer bearing assembly
5 Inner bearing assembly
6 Shims
7 Retaining ring
8 Inner seal
9 Outer seal sleeve
10 O ring
PARTS INSPECTION
Thoroughly clean all parts before inspection.
1. Inspect the housing flange, 1, and bearing race areas, 2. Replace the seals and replaceable seal sleeve if worn or damaged.
15
16
17
44-11
SECTION 44 - AXLES AND WHEELS
2. Inspect the axle shaft and hub assembly.
– Inspect the bearing areas, 1, for wear.
– Inspect the splines, 2, and retaining groove,
3, for wear.
– Inspect the seal area.
– Inspect the wheel lug studs for damaged threads or looseness in the hub, replace studs if required.
REASSEMBLY
1. Install the outer seal, 1, as shown, on the axlehub assembly. Fill the grooves in the seal with grease.
2. Pack the bearing with grease and install the outer bearing, 2, with a suitable bearing driver.
3. Wrap the axle in the retaining ring groove area,
3, with a single layer of plastic tape to prevent damage to the seal during assembly.
4. Install inner seal, 1, in housing as shown with the flat side of seal to the center of housing and retainer and lip of seal to the outside.
5. Install bearing race, 2.
6. Install replaceable seal sleeve, 3, in housing.
18
19
20
44-12
SECTION 44 - AXLES AND WHEELS
7. Place the housing over the axle and hub assembly making sure the outer bearing is seated in race properly.
8. Remove tape from axle shaft.
9. Install the inner bearing race, 1, into housing.
10. Pack the bearing with grease and install the inner bearing, 1.
Press the inner bearing on axle shaft and into the housing to obtain housing rolling torque of 4 - 7 kg (9 - 15 lbs.).
NOTE: To check housing rolling torque, hook a spring scale in one of the housing flange slots, 2, and pull on the scale to rotate the housing.
11. Add shims to fill the space between the bearing race, 3, and retaining ring, 4.
12. Install the retaining ring in groove, 5.
13. Fill the outer seal area with grease until the grease appears around the hub at 1; spin the axle housing while adding grease.
NOTE: If bearing failed because of contamination, use green Loctite 609 on the seal housing to axle shoulder press-fit joint. If the axle shoulder is worn from previous seal rotation, use a new axle, seal, and loctite in place. When reinstalling the axle into the axle housing, be sure both bearings are packed with grease. The cavity in between the triple lip seal and axle seal, where the outer bearing is positioned, must be full of grease. If any old/hardened grease is in a housing that will be reused, be sure to clean the housing and fill it with new grease.
14. Install the O ring in the groove in the axle housing flange at 2, wipe a layer of grease over the O ring to help hold the O ring in place during assembly.
44-13
21
22
23
SECTION 44 - AXLES AND WHEELS
REINSTALLATION
1. Clean the final drive case.
2. Inspect the axle opening in the case to insure it is flat for a good seal between the case and axle housing. To check surface flatness, lay a straightedge across the axle opening in the horizontal and vertical planes, 1. Straighten if required.
3. Inspect the axle assembly retaining bolts, 2, and replace if damaged.
– To replace a stud, the old stud can be driven out with a hammer and suitable driver.
– Thoroughly clean the inside and outside of case in stud area.
– Wipe the new stud with a wicking-type sealant. The new stud can be installed into case, using 3/4 ″ thick spacer over the stud and then use the nut and a flat washer to pull the stud in place.
– Wipe around the stud with a wicking-type sealant to insure an oiltight seal.
4. The axle shaft pivots inside a pilot plate, 1. Inspect for damage.
1
5. Position the drive sprocket, 1, in the axle opening. Make sure the drive sprocket is placed in the drive chain properly.
6. Lift the axle housing assembly and mate the splines on the axle shaft, 2, and the drive sprocket and slide together. Lifting the axle housing assembly over the retaining studs pilot the center of the housing, 3, into the hole in the case and slide housing tight against the case.
NOTE: When installing the final drive axle, the axle housing must lay flat against the frame and the pilot must rest on the edge of the frame opening.
44-14
24
25
26
SECTION 44 - AXLES AND WHEELS
7. With the axle housing, 1, tight against the case, install the retaining nuts and flat washers, 2, to hold the housing against the case.
8. Slide the axle housing assembly to tighten the drive chains.
NOTE: The chains are properly tensioned when there is 0 - 6 mm (0 - 1/4 , ) movement at the outer edge of tire tread.
9. Torque the axle retaining hardware to 190 N·m
(140 ft. lbs.).
CAUTION
W hen tightening the axle retaining hardware, the axle housing must be tight against the case at 1, or damage to the case may occur.
10. Check the final drive case oil level at check plug,
1; add SAE 10W-30 oil as required.
Replace any shields that were removed for the repair.
The skid-steer loader can now be lower to the ground.
FINAL DRIVE
Op. 44 106 48
DRIVE CHAIN AND SPROCKET REMOVAL
The axle housing assemblies and final drive case cover will need to be removed to access the drive chains and drive sprockets.
The four final drive chains are an endless design, with no connector link.
1. Lower the boom and attachment to the ground.
2. If the work is going to be done with the boom in the raised position, remove the attachment and raise the boom and rest on the boom lock pins,
1.
CAUTION
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment. Always remove the attachment from the loader.
44-15
27
28
29
SECTION 44 - AXLES AND WHEELS
3. Securely block the skid-steer loader with all four wheels off the ground. Refer to Section 00 for more detail information on properly supporting a skid-steer loader.
Support the loader at the front of the final drive cases at 1, and at the rear at 2.
CAUTION
Failure to securely support the skid-steer loader could result in movement of the loader causing serious injury or damage to the equipment.
4. Remove the tires and wheels from the final drive being serviced.
5. Clean the axle and final drive area to prevent debris from entering the final drive case.
6. Remove the eight axle housing retaining nuts and washers, 1, from each axle.
7. Slide the axle housing from the retaining studs and lift the assembly from the final drive case.
NOTE: When the axle assembly is removed, the drive sprocket and chain will drop slightly to the bottom of the case.
8. Remove the final drive cover, 2.
9. There is a large O ring that seals the axle housing to the side of the final drive case, 1. Remove the
O ring from the case or the axle housing.
30
31
32
44-16
SECTION 44 - AXLES AND WHEELS
Drive Chain And Sprocket Removal
10. Remove the drive chains from the drive sprocket,
1.
Rear Drive Sprocket and Chain
11. To remove the rear chain and sprocket, the parking brake disc and caliper will need to be removed first.
Brake Disc Removal
– Engage the parking brake.
– Remove the center brake disc retaining bolt and washer, 1.
– Disengage the parking brake.
– Remove the caliper retaining hardware, 2, from the inside of cab. Thread the two bolts from the outside caliper, 3.
– Remove the outside disc, 4.
– Remove center section of caliper, 1, spacers,
2, and retaining bolts.
– Remove inside disc, 3.
33
34
35
44-17
SECTION 44 - AXLES AND WHEELS
– Remove brake friction puck, 1, and spacer plate, 2.
12. Slide the rear chain and sprocket to the case opening and remove the chain from the sprocket and the case.
13. Remove the drive sprocket and note the position of the center hub, 1 (long or short shoulder in or out).
Front Drive Sprocket and Chain
14. Remove the front chain from the drive sprocket.
15. Slide the chain and sprocket to the center case opening. Remove the chain from the sprocket and remove the chain from the case.
16. Remove the sprocket from the case and note the position of the center hub, 1 (long - short shoulder in or out).
36
37
38
44-18
SECTION 44 - AXLES AND WHEELS
17. Shown here are the final drive components.
Ref. Description
1 Drive sprockets (2 each side)
2 Front drive chain
3 Rear drive chain
NOTE: The front drive chain is 68 links and the rear chain is 66 links.
PARTS INSPECTION
Thoroughly clean all parts before inspection.
1. Inspect the drive sprockets in the center spline area, 1, for excessive wear and the tooth area, 2, for wear.
2. Inspect the drive chains for broken or cracked rollers, 1.
3. Inspect the drive chains for cracked or broken side bars, 2.
4. Inspect the side bar to pin wear or looseness at
3.
5. Inspect the drive chains for excessive stretch
(bushing wear).
39
40
41
44-19
SECTION 44 - AXLES AND WHEELS
REASSEMBLY
1. Clean all surfaces of old silicone sealer, dirt, etc.
that will require resealing.
2. If the oil requires replacement, the oil will have to be syphoned from the case. Thoroughly clean the inside of the case to remove all debris.
3. Install the front drive sprocket with the longer center hub, 1, to the outside of the case.
NOTE: The drive sprockets are not centered on the splined hub. The front sprocket is installed with the longer center hub, 1, to the outside and rear is installed with the longer center hub to the inside of case.
4. Install the front drive chain, 1.
NOTE: The front drive chain is longer than the rear drive chain.
5. Place the chain over the inside drive sprocket, 2.
6. Install the rear drive sprocket, with the long center hub to the inside of the case, and the short hub to the outside as shown at 1.
7. Install the rear drive chain, the shorter chain, over the sprocket and slide the chain and sprocket to the rear.
8. Place the drive chain over the outside drive sprocket.
NOTE: If the hydrostatic motor and coupler was moved to gain clearance, the motor will require repositioning.
42
43
44
44-20
SECTION 44 - AXLES AND WHEELS
9. Reassemble the parking brake:
– Clean the old sealant from the brake hardware.
– Install the spacer plate, 2, and brake friction puck, 1, into caliper at 3.
NOTE: The spacer plate is thinner than the brake friction puck and must be inserted into the caliper first.
– Install the inside brake disc, 1.
– Put a bead of noncorrosive sealant around the head of the caliper bolts and install from the inside of loader.
– Install spacers, 2, on bolts and center section of caliper, 3.
– Install outer brake disc, 4.
– Install outer section of caliper, 1, and attach with hardware previously installed and tighten to 70 N·m (52 ft. lbs.).
– Put a bead of sealer around the end of the motor coupler and install the brake disc retaining bolt and flat washer, 2, and tighten.
– Engage the parking brake and torque the retaining bolt to 35 N·m (26 ft. lbs.).
45
46
47
44-21
SECTION 44 - AXLES AND WHEELS
10. Install the axle housings, 1, and tighten the drive chains. Refer to the “Axle Housing” section of this manual for details.
11. Put a bead of sealer around the cover hole in final drive case and install the cover, 2.
12. Check the final drive oil level at the check plug,
3, and add SAE 10W-30 oil as required.
13. Reinstall all shields removed for the repair.
14. Lower the loader to the ground.
Op. 44 511
TIRES/WHEELS
TIRE OPTIONS
1. 7.50 x 15 HST-Hollow segmented
2. 10.00 x 16.5 HST-Hollow segmented
3. 10.00 x 16.5 PHD- Premium heavy-duty
4. 10.00 x 16.5 R4-Cleat tread
5. 7.00 x 15 Chevron tread
6. 31.0 x 15.5-15 G1 Cleat tread
Tire Pressures
Tire
7.00 x 15 Chevron tread
7.50 x 15 HST-Hollow segmented
10.00 x 16.5 R4-Cleat tread
10.00 x 16.5 PHD- Premium heavy-duty
10.00 x 16.5 HST-Hollow segmented
31.0 x 15.5-15 G1 Flotation
Pressure
60 PSI (414 kPa)
N/A
50 PSI (345 kPa)
50 PSI (345 kPa)
N/A
40 PSI (276 kPa)
MAINTAIN PROPER TIRE INFLATION!
NOTE: Iatco “Air Boss” segmented tires are approved for all new generation New Holland loader models. These tires must be mounted with the wheel dish “in” to the frame (narrowest wheel tread position). Reversing the wheels with the dish “out” is not recommended, as increased axle and frame loading occurs, which may lead to eventual axle bearing and/ or main frame failure.
44-22
48
49
SECTION 44 - AXLES AND WHEELS
TIRE AND TRACK INSTALLATION
Tire Installation on Loader
The 7.50 x 15 HST-Hollow segmented and the 10.00
x 16.5 HST-Hollow segmented tires must be mounted with the wheel dish “IN” to the frame
(narrowest wheel tread position). Reversing the wheels with the dish “OUT” is not recommended, as increased axle and frame loading occurs. This may lead to eventual axle bearing and/or main frame failures.
Op. 44 511 28
When replacing the sections of the hollow segmented tires, torque the section hardware to 13.6
N·m (10 ft. lbs.).
Track Installation on Loader
Correct tire/track combinations are important to prevent damage to the tracks, tires/wheels, and loader main frame.
Installing tracks on skid-steer loaders equipped with segmented tires, solid tires, foam-filled tires, or any hard-type non-pneumatic tires is not recommended.
If these tire combinations are used with steel tracks, track or loader main frame damage may occur.
These tires do not provide a cushion when debris comes between the track and tire. A pneumatic tire will absorb this type of stress and, in severe cases, may deflate before damage to the loader or track occurs.
New Holland only recommends pneumatic tires be installed with tracks.
44-23
50
51
52
SECTION 44 - AXLES AND WHEELS
LABOR GUIDE
The following labor amounts are listed as a guide only. Working conditions and experience will vary the time the job actually takes to complete each job.
Hours Job Description
Axle
Remove and replace
Rebuild
Final Drive
Drive chain, sprocket (front) - replace
Drive chain, sprocket (rear) - replace
0.5 hr.
1.0 hr.
1.5 hrs.
3.0 hrs.
44-24
Section
SECTION 50 – CAB CLIMATE CONTROL
Chapter 1 – Heater/Defroster
CONTENTS
Description Page
50-1
SECTION 50 - CAB CLIMATE CONTROL
Op. 50 100
HEATER/DEFROSTER (CAB)
Switch and Control Panel
1. Disconnect the negative (–) battery cable to prevent possible shorting of the electrical system.
2. Remove the retaining hardware, 1, and pull the panel from the rear support, 2.
3. Disconnect the switch wires and control cable.
1 2
Switch Wiring
The heater switch, 1, has four terminals marked, L,
M, H, and B, that the wire harness must be connected to.
19990481
1
2
Relay and Fuse Block
1 - Fuse block - 20 amp
2 - Relay
3
50-2
SECTION 50 - CAB CLIMATE CONTROL
Heater Wiring Diagram
Louver Replacement
1. To remove the louver, use a small flat screwdriver and pry the louver from the support base at 1.
2. Remove the two #6 self-tapping screws from the base and remove the base from the headliner.
4
5
50-3
SECTION 50 - CAB CLIMATE CONTROL
Heater Core, Shutoff Valve and Fan Assembly
Access
To access the heater core and/or fan assembly, the rear light bar, 1, (if equipped with lights) and top heater cover, 2, must be removed. Remove the heater cover mounting screws, 3, to remove the cover and light bar together.
2
3
Op. 50 104 24
Heater Core Replacement
1. Drain the cooling system enough to drain the coolant from the core, about 2 liters (2 quarts).
2. Remove the heater hose clamps, 1, from the heater core, remove the hoses from the core and cap hoses.
3. Remove the heater core retaining hardware, 2, and remove the core from the heater support.
1
19997753
Op. 50 104 23
Heater Shutoff Valve Replacement
1. Drain the cooling system enough to drain the coolant from the core, about 2 liters (2 quarts).
2. Remove the electrical connector,1.
3. Remove the heater hose clamps, 2, from the heater shutoff valve and remove the hoses from the valve and cap hoses.
4. Remove the heater shutoff valve securing hardware, 3, and remove the valve.
1
2
3
19997755
3 2
2
6
7
8
50-4
SECTION 50 - CAB CLIMATE CONTROL
Op. 50 104 20
Heater Fan Assembly Replacement
1. Remove the heater core retaining hardware and pivot the core away from the fan support.
2. Disconnect the fan power wire, 1.
3. Remove the retaining hardware for the fan and motor assembly, 2.
2
1
19997754
Op. 50 100 10
Heater Hose to Engine Connections
1. Heater hose from the heater core to the front plug, 1.
2
9
10
2. Heater hose from the heater shutoff valve to the plug in the top of the water pump at 1.
NOTE: If the heater is installed on an LS170 turbocharged loader, this hose will be at the tee at 2.
11
50-5
SECTION 50 - CAB CLIMATE CONTROL
Op. 50 100 10
Heater Core Connections
Connect the pressure hose to the left side hose, 1, and the return hose, 2, to the right side. Secure with hose clamps. The hoses from the engine will have to be cut to length for proper fit.
Op. 50 104 10
Filter
Replacement filter #86504784
The heater contains an air filter element in the rear right side at 1.
Remove cover plate, 2, by removing two self- tapping screws, 3.
Check the filter element, 1, periodically, especially if running in dirty applications and using the fresh air ventilation. The element can be blown off with a low-
pressure air gun and reused or replaced. The element must be placed with the rubber seal toward the heater core. Be sure the seal is behind the top clamp,
2, and lower screw, 3.
12
13
14
50-6
SECTION 50 - CAB CLIMATE CONTROL
Bleeding Air from Heater (LS170)
The LS170 utilizes an engine crankcase oil cooler which is teed into the water pump supply side of the cab heater.
To completely bleed air from the heater lines and heater core:
1. After component installation is completed, refill the coolant system, per the installation instructions.
2. Leave the radiator cap off and run the loader engine, circulating coolant. Stop the engine and refill the radiator.
3. Temporarily “pinch off” the oil cooler supply hose at the new tee to force coolant through the heater hoses and heater core.
CAUTION
Stop the engine while working around these hoses.
4. Start and run the engine. When the system is completely bled, remove the “pinch off” device.
5. Finish system filling, per the installation instructions.
NOTE: Do not install a shut-off valve or orifice in the oil cooler supply hose. Restricting coolant flow to the engine oil cooler may result in overheating and engine failure. Should this type of overheating cause a failure, it is NOT covered by warranty.
50-7
SECTION 50 - CAB CLIMATE CONTROL
LABOR GUIDE
The following labor amounts are listed as a guide only. Working conditions and experience will vary the time it actually takes to complete each job.
Job Description
Heater/Defroster
Remove and replace electrical switch
Remove and replace water shutoff switch
Remove and replace heater core
Remove and replace heater fan assembly
Remove and replace heater hoses (1)
Hours
0.25 hrs.
1.5 hrs.
1.5 hrs.
1.5 hrs.
0.5 hrs.
50-8
SECTION 55 – ELECTRICAL SYSTEM
Chapter 1 – Advanced Warning System, Circuits, Alternator, and Starter
Section
CONTENTS
Description Page
55-1
SECTION 55 - ELECTRICAL SYSTEM
55-2
SECTION 55 - ELECTRICAL SYSTEM
55-3
SECTION 55 - ELECTRICAL SYSTEM
55-4
SECTION 55 - ELECTRICAL SYSTEM
55-5
SECTION 55 - ELECTRICAL SYSTEM
Op. 55 000
GENERAL ELECTRICAL INFORMATION
The electrical system is a 12-volt negative (–) ground system that provides battery voltage to the Electronic
Instrument Cluster (EIC), starting circuit, and other electrical components.
The electrical system is made up of the following components:
1. Battery - Power supply and storage.
2. Alternator/Regulator - Power supply and source to maintain fully charged system.
3. Starter motor - To crank engine for starting.
4. Ignition switch - Used to control electrical circuits and direction of battery voltage.
5. Electronic Instrument Cluster (EIC)
* Monitors engine and operator functions and signals operator of disruptions or faults in the circuits.
* Displays monitored functions.
* Controls engine fuel system (fuel shut off).
* Provides engine shutdown if fault occurs in engine oil pressure or hydrostatic charge pressure circuits.
* Provides safety interlock for the boom and bucket control valve spools.
* Provides a diagnostic mode for checking EIC board circuits.
* Provides an anti-theft mode to electrically lock the loader boom and bucket; the engine will start with the Service/Run switch in the
“SERVICE” position.
6. Fuse blocks/ fuses/ circuit breakers, cab and engine - Used to protect the electrical circuits and glow plug circuit.
7. Fuel pump - Supplies fuel from the tank to the injection pump.
8. Glow plugs - Used to provide aid in cold engine starting.
9. Fuel solenoid - Controls fuel flow and is controlled by the EIC.
10. Switches - Used to control other electrical circuits, lights, etc.
IMPORTANT: Do not connect any electrical circuits at the ignition key switch or cab fuse block(s) unless there are written instructions telling you to do so or damage to the EIC board may occur.
IMPORTANT: If any servicing or adjustments require the battery to be disconnected, or welding is required on the skid-steer loader, disconnect the negative (–) ground cable. Failure to disconnect the battery may result in damage to the EIC (electronic instrument cluster) monitoring system and other electrical components.
IMPORTANT: If the EIC requires removal from the dash area or the skid-steer loader, disconnect the negative (–) ground battery cable. This will shut off power to the EIC and prevent damage to the EIC board, or prevent blowing the 5-amp fuses, if the board is accidentally grounded.
55-6
SECTION 55 - ELECTRICAL SYSTEM
DEFINITION OF TERMS
ALTERNATING CURRENT (A.C.) - A flow of electrons which reverses its direction of flow at regular intervals in a conductor.
AMMETER - Measures the flow of electrical current in amperes. Ammeters are connected in series with the circuit to be tested.
AMPERE - A unit of measure for the flow of current in a circuit. The ampere is used to measure electricity such as “gallons per minute” is used to measure liquid flow.
CIRCUIT - A continuous, unbroken path along a conductor through which electrical current can flow from a source, through various components, and back to the source.
CIRCUIT BREAKER - A device to protect an electrical circuit from overloads and can be reset, or will automatically reset.
COLD CRANK RATING (CCA) - The cranking load capacity of a battery at low temperatures (cold cranking amperes at 0 F).
CONTINUITY - Unbroken path along a conductor through which electrical current can flow.
CURRENT - Movement of electricity along a conductor. Current is measured in amperes.
DIODE - An electrical device that will allow current to pass through itself in one direction only.
DIODE (RESISTOR TYPE) - An electrical device that will allow current to pass through itself in one direction only and will cause resistance as the electricity passes through. The electricity coming from this type diode will be less than what is going in.
DIRECT CURRENT (D.C.) - A flow of electrons moving in the same direction along a conductor from a point of high potential to one of lower potential.
FUSE - A device to protect an electrical circuit from overloads that needs to be replaced when blown.
OHM - The standard unit for measuring resistance to flow of an electrical current.
OHMMETER - An instrument for measuring the resistance in ohms of an electrical circuit.
OPEN CIRCUIT - An open circuit occurs when a circuit is broken which interrupts the flow of current through the circuit.
RELAY - An electrical switch which opens and closes a circuit automatically when activated.
RESISTANCE - The opposing force offered by a circuit. Resistance is measured in ohms.
SHORT CIRCUIT - A part of a circuit that comes in contact with part of the same circuit or unintentionally touches a metallic object.
SOLENOID - A circular coil used for producing a magnetic field.
SWITCHES - A device used to control and direct current to circuits and will remain in this position until changed.
SWITCHES (MOMENTARY) - Momentary switches are used to direct current to circuits and these switches will return to the neutral position when released.
VOLT - A unit of electrical pressure which caused current to flow in a circuit.
VOLTAGE - The force which is generated to cause current to flow in an electrical circuit. Voltage is measured in volts.
VOLTMETER - An instrument for measuring the force in volts of electrical current. Voltmeters are connected in parallel to the points where voltage is to be measured.
55-7
SECTION 55 - ELECTRICAL SYSTEM
The following are common terms used in electrical diagnostics and how they may affect the circuit and electrical components.
The term “OPEN CIRCUIT” means there is no voltage getting from the control point to the operating point. This means the wire carrying the voltage is open/broken and voltage cannot continue to flow.
The effect is the operating component will not function.
The term “SHORT CIRCUIT” means there is voltage being lost to another component wire or to ground.
This could result in the wrong component being operated or the blowing of the circuit protection device (fuse or breaker).
The term “GROUNDED CIRCUIT” means the voltage is going directly to ground and usually results in no component operation and/or blown fuse-breaker.
To test for an “OPEN CIRCUIT,” use a volt/ohm meter and check from one end of the wire to the other. If voltage is not present, trace the circuit from control point to operating point until the open is found.
To test for a “SHORT CIRCUIT,” use a volt/ohm meter and check for very low resistance in different parts of the circuit or continuity between the circuit wire and ground.
To test for a “GROUNDED CIRCUIT,” use a volt/ohm meter and check for continuity between the circuit wire and ground.
The following chart shows the abbreviations for the various wire colors used to identify the electrical circuits.
WIRE ABBREVIATIONS TO INDICATE WIRE
COLOR
WIRE
COLOR DESIGNATION
Black
Dark
Blue
Light
Blue
Dark
Brown
Gray
Dark
Green
Light
Green
B
DKBL
LTBL
DKBR
GY
DKGN
LTGN
WIRE
COLOR DESIGNATION
White
Orange
W
O
Pink
Purple
Red
Tan
Yellow
PK
PU
R
T
Y
Drilling Holes In Overhead Dash, Electronic
Instrument Cluster (EIC) Board, and Ignition
Switch Area
Always install the rearview mirrors as shown in the mirror instruction sheet. Otherwise, you must unhook the negative battery cable and remove the EIC board panel, 1, and ignition switch panel, 2, from the overhead dash. If holes and attaching screws are installed into the dash area, 3, make sure the screws will not contact the EIC board, the ignition switch, or wiring, as electrical system damage will occur.
IMPORTANT: Failure to unhook the negative battery cable before removal of the EIC board or switch may result in an accidental grounding, causing component damage.
IMPORTANT: Retaining hardware contacting the
EIC board or switch may cause an electrical short, damaging the loader electrical system.
1
3
2
1
55-8
SECTION 55 - ELECTRICAL SYSTEM
ADAPTING ATTACHMENTS REQUIRING
12V ELECTRICAL POWER
There are important rules that must be followed when adapting attachments that require 12 volt electrical power. Proper wiring of electrical devices and power and ground connections is very important to prevent other electrical component damage. Attaching electrical connections to locations other than recommended may allow electric current to feed back through the EIC board, creating false EIC board readings and warnings, or causing EIC board damage or failure.
1. ALWAYS FOLLOW the instructions for New
Holland kit installation to ensure proper function and operation.
2. NEVER CONNECT an electrical device to any wires, fuses, switches or grounds inside the cab area. This includes any terminals of the ignition switch, fuse panel, or ground terminal.
3. NEVER INSTALL an electrical device, music radio, two-way radio, or unapproved New
Holland attachment into the cab area.
4. ONLY USE the 12-volt accessory power outlet for attachments requiring less than 10 amps. The accessory outlet is connected to the engine fuse/relay panel and protected with a 15 amp fuse.
5. ALWAYS CONNECT new electrical attachments to the engine fuse/relay panel, 1, and connect the grounds to the engine bell housing. USE ONLY vacant connections and fuses not in use for specified attachments.
2
3
55-9
SECTION 55 - ELECTRICAL SYSTEM
Engine Fuse Panel
Wires and connections are available providing electrical attachments were not previously installed.
Ref.
1
2
Color
R/B
R/GY
Destination
To turn signal relay
To accessory relay
5
6
3
4
R/LTGN
LTGN/R
R/W
R
To EIC board pin #14 P2 connector
To seat switch(es)
To key switch (battery terminal)
From preheat circuit breaker
7
8
R
R/O
From start relay
To heater power relay
9 R/T Spare
10 DKGN/R To high flow, horn, power outlet
11 O/LTGN From accessory relay
12 O/W
13 O/LTGN
To Back-up alarm switch
From road/work light fuse (cab panel)
Fuse Battery Voltage
10-amp All times
25-amp All times
Status
Available
Available
5-amp All times
5-amp All times
15-amp All times
50/40-amp All times
Occupied
Occupied
Occupied
Occupied
All times
20-amp All times
Occupied
Available
7.5-amp All times Available
15-amp Key “ON” position Available
Key “ON” position Occupied
5-amp Key “ON” position Available
Key “ON” position Occupied
1
2
3
4
5
7
8
9
10
12
6
11
13
4
55-10
SECTION 55 - ELECTRICAL SYSTEM
A completely new auxiliary wiring circuit can be installed as shown in Figures 5 and 6, depending on electrical requirements. Mounting holes for the added circuit breakers must be drilled in the panel.
Disconnect the battery before drilling and installing new wiring.
Protect the panel’s electrical components from drilling shavings that could cause electrical shorting of components. Figure 4 shows circuits for intermittent high current loads up to 15 amps.
The Figure 6 shows the circuit for intermittent high current loads up to 30 amps.
New Holland sealed circuit breakers that can be purchased from parts.
Part Number
9827329
9828493
9840279
9840280
Capacity
15 amp
20 amp
25 amp
30 amp
When attaching ground wires, always place the heaviest ground wire next to the ground surface and then stack the remaining ground wires according to size on top of the heaviest wire.
IMPORTANT: Additional electrical attachments must have circuits properly connected to prevent damage to the Advanced Warning System (EIC board) and other electrical components.
CAUTION
Always disconnect the battery before installing any electrical attachment to prevent accidental shorting of system.
55-11
5
6
SECTION 55 - ELECTRICAL SYSTEM
SPECIFICATIONS
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 amp
Tachometer output (“P” terminal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 6.5 AC Volts
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE PC31 - 12 volt - 625 amps @ -18 ° C (0 ° F) Top stud
System Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative (–)
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse blocks in cab and engine areas
Cab panel (standard)
Fuel pump . . . . . . . . . . . . . . . . . . . . . . 7.5A
Electronics ignition . . . . . . . . . . . . . . . 5A
Wiper . . . . . . . . . . . . . . . . . . . . . . . . . .
Lights (road/work) . . . . . . . . . . . . . . .
7.5A
15A
Engine panel (standard)
Turn signals
Accessory
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
Electronic (EIC) . . . . . . . . . . . . . . . . . .
10A
25A
5A
Key main . . . . . . . . . . . . . . . . . . . . . . . 15A
Cab panel (optional equipment)
Beacon light . . . . . . . . . . . . . . . . . . . . 7.5A
Engine panel (optional equipment)
Heater
Spare
. . . . . . . . . . . . . . . . . . . . . . . . . 20A
. . . . . . . . . . . . . . . . . . . . . . . . . . 7.5A
Attach/Horn . . . . . . . . . . . . . . . . . . . . .
Backup alarm . . . . . . . . . . . . . . . . . . . .
15A
5A
Electronic Instrument Cluster (EIC)
Low Voltage
High Voltage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EIC will fault at 11.9 volts (low)
EIC will fault at 16.5 volts (high)
Fuel gauge sensor resistance
Full tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Empty tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 ohms
240 ohms
Fuel shutoff solenoid
Pull-in amperage
Hold-in amperage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 to 1.8 amps
1.3 to 1.7 amps
Engine air filter sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch is normally closed
EIC will fault at 1.6
″ Mercury or 22 ″ Water
Engine coolant temperature sensor -
(Silver color borders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EIC will read “COLD” until 45
°
C (113
°
F)
EIC will fault at 102 ° C (216 ° F)
Engine coolant temperature sensor -
(Gold color borders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EIC will read “COLD” until 0
°
C (32
°
F)
EIC will fault at 102 ° C (216 ° F)
Engine coolant temperature sensor resistance . . . . . . . . . . . . . . . . . . . . . . At 20 ° C (68 ° F) 2.21 - 2.69 K ohms
At 0
°
- 30
°
C (32
°
- 86
°
F) 1.65 - 5.88 K ohms
Engine crankcase oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EIC will fault at 0.3 BAR (4.3 PSI)
NOTE: The EIC will not alarm unless coolant temperature is above 64 F or two minutes have passed since starting.
55-12
SECTION 55 - ELECTRICAL SYSTEM
Hydraulic oil temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EIC will read “COLD” until 45
°
C (113
°
F)
EIC will fault at 99 ° C (210 ° F)
Hydraulic oil temperature sensor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . At 20 ° C (68 ° F) 2.21-2.69 K ohms
At 0
°
-30
°
C (32
°
-86
°
F) 1.65-5.88 K ohms
Hydraulic oil filter sensor (differential between in/out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch normally closed
EIC will fault at 2.7 ± 0.3 bar (40 PSI ± 4 PSI)
EIC will reset at 2.0 bar (30 PSI)
NOTE: This alarm is locked out until the oil temperature is at 110 F. The switch must be open for over 5 seconds to alarm.
Hydrostatic charge pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EIC will fault at 3.4 bar (50 PSI)
Glow plug resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 ohms
Solenoid (boom and bucket spool lock) resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 to 18 ohms
Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key start and relay
Headlights and rear work lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.5 watt halogen
NH#86533429
Taillights (road) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.5 watt halogen
NH#86505510
Amber Flasher lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sealed
NH#529068
Electronic Instrument panel indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.080 amp C-2F
55-13
SECTION 55 - ELECTRICAL SYSTEM
ALTERNATOR SERVICE SPECIFICATIONS (40 amp)
Item How Rated
Normal Output (V - A)
Polarity
Weight
Rotational direction (viewed from the pulley)
Load characteristics (cold)
(kg, lbs)
Brush length
Brush spring tension
Slip ring diameter
Field coil resistance
Adjusting voltage
Terminal voltage (V)
Current (A)
Revolution (RPM)
Original (mm-in)
Limit (mm-in)
Original (g-lbs)
Limit (g-lbs)
Original (mm-in)
Limit (mm-in) ohms at 20
°
C (68
°
F)
(V) at 5000 RPM
Standard Or Service Limit
12 V - 40 A
Negative ground
3.7 kg (8.2 lbs)
Clockwise
13.5 V
Min. 30 A
2500 RPM
18.5 mm (0.728
″
)
5.0 mm (0.20
″ )
470 - 590 g (1.36 -1.30 lbs)
270 g (0.60 lbs)
22.7 mm (0.0894
″
)
22.1 mm (0.871
″ )
2.8 ohms
14.4 - 15.0 V
STARTER MOTOR SPECIFICATIONS (12 volt)
Rated voltage
Output
Motor type
Engaging system
Rotation
Weight
12 volts
2 kw
Four-pole series wound motor
Magnetic shift
Clockwise (viewed from pinion side)
Approximate 5 kg (11 lbs)
ALTERNATOR SERVICE SPECIFICATIONS (40 amp)
Item How Rated
No Load Test Volts (V)
Current (A)
Commutator
Brush
Brush spring
Rotating Speed (RPM)
Outer dia. (mm-in.)
Service limit (mm-in.)
Length (mm-in.)
Service limit (mm-in.)
Tension (kg-lbs)
Service limit (kg-lbs)
Standard Or Service Limit
11.5 V
130 A Max.
4000 RPM Max.
35 mm (1.38
″ )
34 mm (1.34
″
)
15 mm (0.59
″ )
9 mm (0.35
″
)
2.7 - 3.6 kg (5.9 - 7.8 lbs)
2.2 kg (4.7 lbs)
55-14
SECTION 55 - ELECTRICAL SYSTEM
ELECTRICAL DIAGRAM
55-15
SECTION 55 - ELECTRICAL SYSTEM
55-16
SECTION 55 - ELECTRICAL SYSTEM
55-17
7
SECTION 55 - ELECTRICAL SYSTEM
55-18
8
SECTION 55 - ELECTRICAL SYSTEM
Op. 55 418
ADVANCED WARNING SYSTEM
ELECTRONIC INSTRUMENT CLUSTER
(EIC)
The Skid-Steer Loader advanced warning system, 1, monitors engine functions and operator controls and reports conditions to the operator and provides safety interlocks to the hydraulic control valve spools to the boom and bucket.
The instrument cluster has three kinds of visual displays: backlighted symbols, an LED character display, and a segmented bar graph.
The EIC (Electronic Instrument Cluster) board employs incandescent lamps to backlight symbols representing monitored functions. Active sensor symbols are backlighted with either yellow
(WARNING) or red (FAULT). Inactive sensor symbols are visible as a dim gray outline when the backlighting is not active. An audible alarm accompanies most visual alarm lights.
The front panel of the instrument cluster has several components and display areas. Read the following paragraphs to understand each item and area.
1
19984335
9
55-19
SECTION 55 - ELECTRICAL SYSTEM
(EIC) ELECTRONIC INSTRUMENT
CLUSTER FRONT PANEL
1. AUDIBLE ALARM
The audible alarm will sound if there is an unusual condition in any of the monitored areas.
The audible alarm is located behind the front panel at 1.
2. CHARACTER DISPLAY
The character display will display the item that the operator has chosen to monitor. The display shows one function at a time. After the engine is started, the display defaults to the last function viewed at power off. Any of the other functions may be selected by the operator during operation by briefly pressing the “ARROW” selector switch,
3. When the EIC is turned off and then powered up, the display default will be the newly selected function.
10
3. RIGHT ARROW DISPLAY SELECTOR
SWITCH
The display selector switch, covered with an
“ARROW” symbol, will cause an audible “chirp” when pressed if the ignition key is in the “RUN” position. Pressing the “ARROW” symbol during operation will select the function that the operator chooses to monitor and will be displayed in the character display, 2. If a sensor causes a warning or fault, the appropriate lamp will flash, accompanied by an audible alarm. Pressing this switch also cancels any audible alarm that is sounding.
4. OPEN BOOK SELECTOR SWITCH
This selector switch covered with the symbol of an “OPEN BOOK” (instruction manual) is used to select other functional modes of the EIC panel.
The “OPEN BOOK” switch has no function during normal operation.
55-20
SECTION 55 - ELECTRICAL SYSTEM
11
EIC FUNCTIONAL GROUPS
The EIC display panel is divided into four functional groups, 1 through 4.
FUNCTIONAL GROUP 1
Those symbols in display group 1, backlighted white are:
5. Engine hours, displayed to 0.1 hours (no light).
1. Right arrow display selector switch. (no light)
This switch is used to change the displayed function.
6. Engine coolant temperature displayed to the nearest degree, expressed as degrees
Fahrenheit or degrees Celsius, depending on setting (C or F).
2. Loader engine RPM, displayed in increments of
10 RPM.
3. Battery voltage, displayed to the nearest 0.1 volt.
NOTE: The EIC monitors battery voltage only, not alternator output.
7. Transmission/hydraulic oil temperature to nearest degree, Celsius or Fahrenheit, depending on setting (C or F).
NOTE: The monitored functions and symbols in group 1 are backlighted in white except the Engine
Hours. When this function is monitored the symbol is not lit.
NOTE: The Engine Coolant and hydraulic oil temperatures will show “COLD” until the systems reach 0 Celsius or 32 Fahrenheit operating temperature. At that time the Character display will start reading the temperature in Celsius or
Fahrenheit degrees.
4. Character display.
The character display will display the chosen function or the function with the fault within this functional group.
55-21
SECTION 55 - ELECTRICAL SYSTEM
12
FUNCTIONAL GROUP 2
Those symbols in display group 2, backlighted yellow are:
1. Hydraulic oil filter condition.
The EIC continuously monitors the condition of the oil filter. A yellow warning lamp will signal a warning when the filter becomes dirty. The lamp will flash continuously, accompanied by a
5-second audible alarm, when the filter requires replacement.
4. Parking brake.
Used to remind operator to engage the parking brake when exiting the loader. An audible alarm will sound when the operator begins to exit the machine with the engine running.
5. Stop engine warning.
When this warning lamp flashes, stop the engine and determine the cause to prevent damage to the engine.
2. Air filter condition.
When the air filter requires replacement, the lamp will flash indicating a dirty element.
3. Blank (not used).
6. Engine preheat symbol (lights when engine is preheating).
The EIC controls a timed preheat system for starting aid.
55-22
SECTION 55 - ELECTRICAL SYSTEM
2
1
FUNCTIONAL GROUP 3
The symbol in display group 3 is:
1. Fuel gauge.
The fuel gauge, 1, is a vertical 10-segment green
LED bar graph. When the fuel level reaches three bars, 2, the segments will flash accompanied by an audible alarm for about 5 seconds.
When the fuel level reaches two bars, the EIC will signal the operator again with the segments flashing and another 5-second audible alarm.
NOTE: The lower fuel gauge segments accurately read the lower fuel levels so an operator is less likely to run out of fuel. However, if a machine is operated on a hillside, the fuel gauge should be monitored closely to avoid running out of fuel, as the fuel can still move freely from one end of the tank to the other.
13
55-23
SECTION 55 - ELECTRICAL SYSTEM
1 2
3
4 5 6
14
FUNCTIONAL GROUP 4
Symbols in display group 4 are backlighted red.
When a fault occurs, the flashing lamp is accompanied by the audible alarm.
5. Coolant temperature.
When the engine coolant temperature is above operating temperature of 102 ° C (216 ° F) the lamp will flash with a 5-second alarm.
1. Transmission charge pressure.
When the pressure drops below normal operating pressure, the lamp will flash with a continuous alarm.
2. Transmission/Hydraulic oil temperature.
When the oil temperature is above operating temperature of 99 ° C (210 ° F), the lamp will flash with a 5-second alarm.
3. Battery voltage.
When battery voltage drops below normal voltage, the lamp will flash with a 5-second alarm.
4. Engine oil pressure.
When the engine oil pressure drops below normal pressure, the lamp will flash with a continuous alarm.
55-24
6. Operator “FASTEN SEAT BELT” symbol.
When the operator is in the seat, the lamp will flash until the seat belt is fastened.
These symbols are backlighted RED and are intended to complement the audible alarm should a fault occur.
7. Alternator/water pump drive belt warning.
If the drive belt breaks, the EIC will signal the operator with the battery symbol light, 3, flashing continuously and a 5 second audible alarm.
NOTE: If during Skid-Steer Loader operation the
Engine Coolant or Hydraulic Oil Temperatures show an overheat condition, the EIC will default to that function and read the temperature. When this happens, back off on loader operation and allow the systems to cool down to within normal operating temperature ranges. If the temperatures don’t cool down, stop operating the unit, find the cause and correct.
SECTION 55 - ELECTRICAL SYSTEM
15
CONTINUOUSLY MONITORED ELEMENTS
The following machine elements are continuously monitored by the EIC:
5. Hydrostatic charge pressure.
When the pressure drops below normal operating pressure the lamp will flash with a continuous alarm.
1. Engine air filter.
Monitors the condition of the air cleaner element and will signal when the element is dirty and requires replacement.
6. Engine oil pressure.
When the engine oil pressure drops below normal pressure the lamp will flash with a continuous alarm.
2. Hydraulic oil filter.
Monitors the condition of the filter and will signal when the filter is dirty and requires replacement.
3. Engine coolant temperature.
When the engine coolant temperature is above operating temperature of 102 ° C (216 ° F), the lamp will flash with a 5-second alarm.
7. Transmission/Hydraulic oil temperature.
When the oil temperature is above operating temperature of 99
°
C (210
°
F), the lamp will flash with a 5-second alarm.
Whenever the EIC senses any unusual condition in a monitored function, the associated lamp will flash. The audible alarm will “beep” continuously for 5 seconds.
4. Battery Voltage.
When battery voltage drops below normal voltage the lamp will flash with a 5-second alarm.
55-25
ENGINE PREHEAT
SECTION 55 - ELECTRICAL SYSTEM
The EIC controls a timed pre-heat cold start aid to assist in cold weather starting. The timed pre-heat cycle will vary from 0 to 40 seconds automatically based on engine coolant temperature. For additional pre-heat if the loader does not start, turn the ignition key to the “OFF” position. Then turn the ignition key back to the “RUN” position again. This will restart the preheat timed cycle.
again be removed from the fuel solenoid in another
30 seconds and the engine will again stop. During the
30-second alarm period, the “ENGINE STOP” symbol will flash. If this condition continues, locate the fault and repair.
IMPORTANT: Use caution when restarting the loader because of the possibility of NO
LUBRICATING OILS for the engine and/or the hydrostatic transmission. DO NOT restart the loader more than once or operate the engine at high speeds. Damage to the engine and/or transmissions may occur. Contact your New Holland dealer for assistance.
AUTOMATIC SHUTDOWN
If either the engine oil pressure, or hydrostatic charge pressure fall below certain limits, the EIC will remove power from the fuel solenoid after 30 seconds, stopping the engine.
If this condition occurs, turn off the ignition key.
Before unbuckling the seat belt, turn the ignition key to the “ON” position and lower the boom and attachment to the ground or rest the boom on the boom lockpins. Turn the ignition key to the “OFF” position.
The operator may immediately restart the engine again. Should the function remain faulted, power will
WARNING
When the engine stop symbol flashes for the
30-second period, immediately lower the boom and move the loader to a non-traffic area for problem evaluation.
If an alarm is caused by 3, 4, or 7, the CHARACTER
DISPLAY will change to show the numeric value of the function that caused the alarm.
55-26
SECTION 55 - ELECTRICAL SYSTEM
1 2 3 7 4 5 6
OPERATING MODE
By pressing and releasing the “ARROW” switch, 1, during normal skid-steer loader operation, the operator can select a function to be monitored. Only one function can be monitored and displayed at a time in the display, 7. By pressing and releasing the
“ARROW” switch once, the EIC will select the next monitored function. Functional symbols are located across the top of the EIC display and will light up when selected. Note that the engine hour symbol, 4, is not illuminated.
Monitored functions are:
2.
ENGINE RPM
3.
BATTERY VOLTAGE
4.
ENGINE HOURS (No Light)
5.
ENGINE COOLANT TEMPERATURE -
Reads COLD until 0 ° C (32 ° F)
6.
TRANSMISSION/HYDRAULIC OIL
TEMPERATURE - Reads COLD until 0
°
C
(32 ° F)
16
If a fault occurs in the following monitored functions, the EIC will automatically show that function’s reading in the character display, accompanied by a flashing light and a five second audible alarm.
FAULT READING
Battery Voltage
(Low & High)
Battery Voltage
Engine Coolant (High) Temperature in
Degrees
Transmission/
Hydraulic Oil (High)
Temperature in
Degrees
55-27
SECTION 55 - ELECTRICAL SYSTEM
1
17
If a fault occurs in the following monitored functions a fault code will appear in the EIC character display,
1, accompanied by a five second audible alarm. By turning the ignition key switch to the “OFF” position the EIC will return to the normal operating mode. If when the loader is restarted and the fault still exists, the code will reappear with an alarm indicating there is an open or short in that circuit. Contact your New
Holland dealer for assistance.
FAULT
Hydraulic Boom/Bucket Solenoid
Engine Preheat Relay Coil
Fuel Solenoid
CODE
(F0A)
(F03)
(F04)
_______________________________________________________________________________________________
1 2
If a fault occurs in the following monitored functions the EIC will signal the operator with a flashing light accompanied by a five second audible alarm indicating the filter(s) require service.
FAULT
1. Hydraulic Oil Filter
2. Engine Air Cleaner
55-28
18
SECTION 55 - ELECTRICAL SYSTEM
2
3
1
If a fault occurs for more than 30 seconds in the following monitored functions the EIC will signal the operator with a flashing light, a continuous audible alarm and will stop the engine after 30 seconds of operation.
FAULT
1. Engine Oil Pressure
2. Hydrostatic Transmission Charge Pressure
If a fault occurs in one of these functions, the engine can be restarted and the skid-steer loader moved to a safe inspection area with the boom resting on the boom lock pins or on the ground. If the fault still exists, the EIC will stop the engine after another 30 seconds.
IMPORTANT: Use caution when restarting the loader because of the possibility of NO
LUBRICATING OILS for the engine and/or the hydrostatic transmissions. DO NOT restart the loader more than once or operate the engine at high engine speeds. Damage to the engine and/or transmission may occur. Contact your New Holland dealer for assistance.
19
BROKEN ALTERNATOR/WATER PUMP
BELT WARNING, 3
If the drive belt breaks the EIC will signal the operator with the battery symbol light, 3, flashing, accompanied by an audible alarm.
NOTE: The engine will shut down automatically.
Then immediately turn the ignition key to “OFF” position to prevent engine overheating or damage.
55-29
SECTION 55 - ELECTRICAL SYSTEM
FUEL LEVEL
Fuel level is shown to the operator by the fuel gauge bar lights located in the center of the EIC display at
1. The operator will be signaled when the level is at three bars and again at two bars. The bar lights, 2, will flash continuously accompanied by an audible alarm for about five seconds at each signal level.
1
EIC INTERLOCKS
EIC controls the fuel solenoid circuit. The operator must be in the seat, with the seat belt fastened before the engine will start and continue to run.
The EIC will lock the boom and bucket control valve spools in neutral if the operator unfastens the seat belt, leaves the seat, or turns the ignition key off. If the operator is out of the seat for more than two seconds, the seat belt must be unfastened and refastened to enable the boom and bucket hydraulic systems to function.
The unit is equipped with a “SERVICE/RUN” switch for use during servicing and troubleshooting of the skid-steer loader. To access the Service/Run switch located under the cab fuse panel cover, 1, loosen the two thumbscrews, 2, and rotate cover, 1, to the side.
When the “SERVICE/RUN” switch, 3, is in the
“SERVICE” position, the engine will start but the boom and bucket hydraulic system will be inoperative.
19984593
2
3
1
2
20
21
55-30
1
SECTION 55 - ELECTRICAL SYSTEM
3
2
EIC LOCK MODE
A two digit code can be entered into the EIC which will lock the boom and bucket spool lock solenoids when the spools are in the neutral position. This will prevent movement of the boom and bucket.
The same two digit code must be reentered to unlock the solenoids and return the loader to normal operation.
To enter a security code:
1. Lower the boom and bucket to the ground and position the bucket to prevent movement of the loader.
2. Turn “OFF” the ignition key.
3. Unbuckle the seat belt, raise your weight off the seat, and wait until all EIC lights are off.
4. While out of the seat, press and hold the “OPEN
BOOK” switch, 2, then sit in the seat and turn the ignition key to the “ON” position; Do Not engage the starter.
5. Display, 3, will show the program level of the EIC board (example r0100). At this time release the
“OPEN BOOK” switch.
6. Display, 3, will show “LOC_ _” for lock.
7. Press and hold the “OPEN BOOK” switch until two (2) zeros appear “LOC 0 0” with the left zero flashing, then release the “OPEN BOOK” switch.
8. Press and release the “OPEN BOOK” switch and enter any number from “0” to “9” for the left digit.
9. Press and release the “ARROW” switch, 1, the right zero will start to flash.
10. Press and release the “OPEN BOOK” switch and enter any number from “1” to “9” for the right digit.
22
11. With the two (2) digit code entered, “01 to 99”, turn the ignition key to the “OFF” position and exit the loader, allowing all the EIC board lights to go
“OFF”, locking the EIC.
When the EIC board lights go off, the lock code will enter the EIC memory, locking the EIC until the same two digit code is reentered.
To reenter the same two (2) digit code to return the loader to normal operation:
1. Sit in the operator’s seat.
2. The EIC will display “LOC 0 0” with the left digit flashing.
3. Turn the ignition key switch to the “ON” position;
Do Not engage the starter.
4. Press and release the “OPEN BOOK” switch and enter the left number of the code previously used to lock the loader.
5. Press and release the “ARROW” switch, the right zero will flash.
6. Press and release the “OPEN BOOK” switch to enter the right number of the code previously used to lock the loader.
7. Turn the ignition key to the “OFF” position and allow the EIC to return to the operating mode.
8. Buckle the seat belt and proceed with normal skid-steer loader operation.
If the two digit code is forgotten, the EIC can be unlocked by using a (MASTER CODE). Contact your
NEW HOLLAND dealer for assistance.
The dealer will require your name, address and the skid-steer loader model and serial numbers.
55-31
SECTION 55 - ELECTRICAL SYSTEM
EIC ENGINE PREHEAT
The engine preheat is governed automatically by the
EIC based on coolant temperature and engine code.
Preheat is initiated when the ignition key is turned to the “RUN” position and the cycle time will vary from
0 to 20 seconds.
Turn the ignition key to the “RUN” position, and the
EIC character display, 1, will show seconds remaining for engine preheat time. The preheat indicator light, 2, will be lit during the preheat cycle.
The operator should wait until the display zeros “0”, the indicator light goes “off”, and the audible alarm sounds to start the engine. If the loader does not start, re-cycle the engine preheat timer by turning the ignition key “OFF” then “ON”. This will restart the timed preheat cycle.
2
1
23
55-32
SECTION 55 - ELECTRICAL SYSTEM
TROUBLESHOOTING
ELECTRONIC INSTRUMENT CLUSTER (EIC)
PROBLEM POSSIBLE CAUSE CORRECTION
EIC board will not light up when operator sits in seat
Service/run switch in service position
Push switch to run position
Faulty seat switch Replace switch
No battery voltage to seat switch Blown 5-amp fuse electronic battery in engine panel, replace fuse
Open in power wire from 5-amp fuse to seat switch, repair open in wire
No battery voltage to 5-amp fuse from supply, check and/or replace battery
Blown 5-amp fuse (electronic battery) in engine panel
Replace fuse
EIC board backlighting is dim
No battery voltage from seat switch to EIC board
Open in power wire from seat switch to EIC board, repair open in wire
Poor or no connection at EIC board, repair connection
Battery voltage from seat switch to EIC board
Brightness variations due to production differences between models and/or EIC board changes
If battery voltage from seat to board is OK, replace EIC board
None -- overlay decal material variations cause differences in brightness
EIC board seat belt light will not go off with seat belt buckled
Backlights dim when the loader worklights are activated
Seat belt not buckled
Faulty seat belt buckle switch
None -- EIC board circuitry automatically dims the backlighting when the work lights are on, to reduce board glare at night
Buckle seat belt
Replace seat belt assembly
No battery voltage from seat switch to seat belt switch
Open in wire from seat switch to seat belt switch, repair open
No battery voltage from seat belt switch to EIC board
Open in wire from seat belt switch to
EIC board, repair open
Poor or no connection at EIC board, repair connection
Battery voltage from seat belt switch to EIC board
If voltage OK, replace EIC board
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SECTION 55 - ELECTRICAL SYSTEM
PROBLEM
EIC will not read correct engine
RPMs, varies more than ± 50 RPMs
POSSIBLE CAUSE
Incorrect engine configuration
CORRECTION
Correct configuration
No AC voltage at tachometer terminal at alternator
Repair alternator
Loose or corroded connection at tachometer terminal at alternator
Repair connection alternator board, repair open
AC voltage from alternator to EIC board
Repair loose or corroded connection at EIC board
EIC will not unlock boom and bucket spool locks
Wire connection from alternator to EIC board
If OK, replace EIC board
Service/Run switch in
“SERVICE” position
Push switch to “RUN” position
Seat belt unbuckled
Faulty seat belt buckle
Buckle seat belt
Replace seat belt assembly
No battery voltage from seat belt switch to EIC
Open in power wire from seat belt switch, repair open
No battery voltage from EIC to spool lock solenoids
Open in power wire from EIC to solenoids, repair open
Battery voltage to lock solenoids If OK, check inoperative solenoids, check solenoid coils, repair or replace
55-34
SECTION 55 - ELECTRICAL SYSTEM
PROBLEM
Engine will not start and/or run
POSSIBLE CAUSE
Seat belt unbuckled
CORRECTION
Buckle seat belt
Incorrect engine configuration
(EIC)
Correct configuration
No battery voltage to start relay Open in power wire from key switch
“start” to relay, or through seat/seat belt circuits to relay, repair open
No battery voltage from EIC to fuel solenoid
Open in power wire from EIC to fuel solenoid, repair open
Open in the W/O wire from the seat/seat belt plug to the start interlock relay
Repair open in W/O wire
Inoperative start interlock relay Repair or replace
Fuel solenoid inoperative
Inoperative manifold heater system
Incorrect engine configuration, correct configuration
No power to manifold heater
Repair or replace fuel solenoid
Manifold heater preheat relay or
LTBL/B wire open, repair or replace
Inoperative manifold heater
Circuit breaker open, replace
Replace manifold heater
No fuel to manifold heater
EIC will not read monitored circuits Incorrect engine configuration
Check fuel feed tube and fuel supply from injection pump
Correct engine configuration
Open or short in wire from sensor to EIC
Repair open/short
Faulty sender or sensor Repair/replace sender or sensor
55-35
SECTION 55 - ELECTRICAL SYSTEM
ADVANCED WARNING SYSTEM (AWS)
This skid-steer loader is equipped with an Advanced
Warning System (AWS) that provides information to the operator about the operation of the skid-steer loader.
The AWS provides an interlock system with the seat and seat belt to prevent movement of the boom and bucket if the operator is out of the seat or the seat belt is unbuckled and the controls are in neutral.
The AWS provides an automatic engine preheat system to aid in cold weather starting.
The AWS provides information to the operator about the following monitored functions:
• Hydraulic Oil Filter
•
Engine Air Filter
• Engine Preheat Relay Coil
•
Fuel Level
• Fuel Solenoid
• Engine Coolant Temperature
•
Hydrostatic Transmission Charge Pressure
• Transmission/Hydraulic Oil Temperature
•
Battery Voltage
• Engine Oil Pressure
• Alternator/Water Pump Belt
Breakage Warning
•
Operator Seat and Seat Belt
•
Hydraulic Boom/Bucket Solenoid
• Engine RPM
•
Engine Hours
The AWS provides the following features for dealer technician use in diagnostics and troubleshooting of the monitored function circuits:
Diagnostics
•
Test individual monitored circuits.
Fault/Warning History
•
Fault occurrence with hour level of last occurrence.
Clear Faults
• Clear Faults to zero.
Engine Code
• Set EIC to loader engine model.
Select Displayed Temperature Units, Fahrenheit or
Celsius
•
Temperature displayed in Metric (Celsius) or
English (Fahrenheit).
Adjust Engine RPM
• Calibrate EIC display to external RPM tach reading.
The AWS provides an engine shut down feature if the engine oil pressure or the hydrostatic transmission charge pressure are low.
The AWS will signal the operator if the alternator/water pump drive belt fails.
The AWS provides a security feature allowing the operator to enter a two digit security code, preventing starting of the engine and movement of the boom and bucket.
Clear Memory
• Return EIC to original factory settings.
•
Engine code reset to (01).
• Hours reset to (0000.0) zero.
•
Temperature displayed (Fahrenheit).
• Engine RPM calibration cleared.
Adjust skid-steer loader hours
•
Change unit hours when installing a new EIC board in a loader.
55-36
SECTION 55 - ELECTRICAL SYSTEM
1
2
EIC BOARD SELF TEST
When first sitting in the operator’s seat and/or before entering Diagnostics, allow the EIC board to self test.
(Service/Run switch in the “RUN” position)
Sit in operator’s seat.
1. The EIC board should light all symbol lights.
2. The character display should read “8888.8”, 1, and the fuel gauge (light bar), 2, should light showing 9 bars.
3. The EIC will enter the normal start up mode.
24
4. Turning the ignition key to the “ON” position will start the automatic engine preheat system (if required).
NOTE: The preheat times will vary from 0 to 20 seconds, depending on engine temperature.
If the EIC does not function as described, check the seat and seat belt switches for proper operation and
EIC board power and ground circuits.
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SECTION 55 - ELECTRICAL SYSTEM
3
2
DIAGNOSTIC AND SETUP MODES
When in the Diagnostic Mode, the technician can test the individual monitored circuit wiring. When in the
Setup Mode, the technician can make changes to the
EIC and perform additional troubleshooting.
To Enter Diagnostic Or Setup Mode:
1. Lower the boom and bucket to the ground or remove any attachment and rest the boom on the boom lock pins.
2. Turn “OFF” the ignition key.
3. Unbuckle the seat belt, raise your weight off the seat, and wait until all EIC lights are off.
4. While out of the seat, press and hold the “OPEN
BOOK” switch, 2, sit in the seat and turn the ignition key to the “ON” position; Do Not engage the starter.
25
5. Display, 3, will show the program level of the EIC board (example - r0100); at this time, release the
“OPEN BOOK” switch.
6. Display will show “LOC_ _” for lock.
7. Press and release the “ARROW” switch, 1;
“dIAg” (for Diagnostic) will appear in the character display.
8. Press and release the “ARROW” switch again will move to the “SEtUP” mode in the display.
Pressing and holding the “OPEN BOOK” switch when in either mode will enter the selected mode for tests or changes to the EIC.
55-38
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SECTION 55 - ELECTRICAL SYSTEM
2
EIC Diagnostics and Setup Items
26
1. Press and release the “ARROW” switch, 1;
“dIAg” will appear in the character display, 2.
Diagnostics Mode
With display showing “LOC_ _” for lock.
_______________________________________________________________________________________________
2
1
2. Press and hold the “OPEN BOOK” switch, 1, until a low case “d” appears in the character display,
2, release the “OPEN BOOK” switch. The EIC is now in Diagnostics.
Each individual monitored circuit can now be tested for proper operation.
When in Diagnostics and any circuit is activated the
EIC board will light all lights and an audible alarm will sound.
The Diagnostic test will not verify the performance of a sensor or sender. Only the EIC board and wires to the sender or sensor are tested.
The following circuits can be tested:
27
1. EIC board bulbs
2. EIC board circuits
3. EIC board arrow and open book switches
4. Audible beeper
5. Engine air filter circuit
6. Hydraulic oil filter circuit
7. Hydrostatic transmission charge pressurecircuit
8. Engine oil pressure circuit
9. Engine Coolant temperature circuit
10. Transmission/hydraulic oil temperaturecircuit
11. Fuel level circuit
12. Seat switch(es) and circuit
13. Seat belt switch and circuit
14. Service/Run switch
55-39
SECTION 55 - ELECTRICAL SYSTEM
ARROW, OPEN BOOK, AND AUDIBLE
ALARM TEST
In this mode, by pressing the “ARROW,” 1, or “OPEN
BOOK,” 2, switches, all of the display segments are turned on for verification and at the same time with an audible beep. If all segments do not light the circuit bulb or wires to the switches, sensors or senders may be defective.
To check the individual EIC board circuits and circuits to the switches, sensors, and senders, perform the following “EIC CIRCUIT TESTS”.
Whenever any of the sensors or switches are toggled on or off, the EIC board will light and the audible alarm will briefly beep. This indicates that the wire to the sensor or switch is intact, but does not yield any information about the condition of the sensor.
DIAGNOSTIC MODE EIC CIRCUIT TESTS
To simulate a fault condition while in the diagnostic mode do the following:
NOTE: When in the diagnostic mode and a circuit is triggered, all the board lights will light up accompanied by an audible beep.
1. Hydraulic Oil Filter Restriction Switch
Remove the DKGN/O filter sensor wire, 1, from the sender.
The EIC board lights will all light up and the board will beep when this test is performed.
If the EIC board lights and beeps, the EIC and circuit wire to the sensor is OK. The problem is in the sensor; replace the sensor. If the EIC board fails to light and beep, check the wire from the sensor to the EIC board.
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55-40
2. Air Cleaner Switch
SECTION 55 - ELECTRICAL SYSTEM
Remove one wire at a time from the sensor switch, 1, on the air cleaner canister. Remove the
B wire, and the EIC board will light and beep when the wire is removed from the switch.
Remove the B/Y wire, and the EIC board will light and beep.
If the EIC board lights and beeps, the EIC and circuit wire to the sensor is OK. The problem is in the sensor; replace the sensor. If the EIC board fails to light and beep, check the wires from the sensors to the EIC board.
3. Hydrostatic Charge Pressure Switch, 1
Remove one wire at a time from the sensor switch at the charge check valve. Remove the
Y/GY wire and the EIC board will light and beep.
Remove the B wire and the EIC board will light and beep.
If the EIC board lights and beeps, the EIC and circuit wire to the sensor is OK. The problem is in the sensor; replace the sensor. If the EIC board fails to light and beep, check the wires from the sensor to the EIC board.
4. Engine Oil Pressure Sensor
Remove the Y/B wire, 1, from the sensor and the
EIC board will light and beep.
If the EIC board lights and beeps, the EIC and circuit wire to the sensor is OK. The problem is in the sensor; replace the sensor. If the EIC board fails to light and beep, check the wires from the sensor to the EIC board.
55-41
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31
32
5. Coolant Temperature Sensor
SECTION 55 - ELECTRICAL SYSTEM
Remove the PU/LTGN wire, 1, from the sensor and short the wire to ground.
The EIC board will light and beep when the wire is removed from the sender and grounded.
If the EIC board lights and beeps, the EIC and circuit wire to the sensor is OK. The problem is in the sensor; replace the sensor. If the EIC board fails to light and beep, check the wires from the sensor to the EIC board.
6. Transmission/Hydraulic Oil Temperature Sensor
Remove the PU/LTBL wire from the sensor, 1, and short the wire to ground.
The EIC board will light and beep when the wire is removed from the sender and grounded.
If the EIC board lights and beeps, the EIC and circuit wire to the sensor is OK. The problem is in the sensor; replace the sensor. If the EIC board fails to light and beep, check the wires from the sensor to the EIC board.
7. Fuel Gauge
Disconnect one wire, 1, and use a jumper wire and connect sender terminal to other terminal, 2, and the EIC board will light and beep. If the EIC board lights and beeps, the EIC and circuit wires to the sender are OK. If the EIC board fails to light, check the wires to the EIC board.
55-42
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34
2
35
SECTION 55 - ELECTRICAL SYSTEM
8. Seat Switch and Circuit
Raise your weight off the center of the seat and then sit back on the seat. The EIC board will light and beep. If the board lights and beeps, the switch and circuit are OK. If the board fails to light and beep, check the seat switch and circuit to the seat switch for battery voltage. If there is battery voltage to the switch, check the switch for operation and the circuit from the switch to the
EIC board. If there is no battery voltage to the switch, check the circuit to the switch.
19984338
9. Seat Belt Switch and Circuit
The operator must be sitting in the seat.
Unbuckle and rebuckle the seat belt. The EIC board will light and beep. If the board lights and beeps, the switch and circuit are OK. If the board fails to light and beep, check the seat belt switch and circuit from the seat switch for battery voltage. If there is battery voltage to the switch, check the switch for operation and the circuit from the seat belt switch to the EIC board. If there is no battery voltage from the seat switch, check the seat switch for operation and the wire to the seat belt switch.
10. Service/Run Switch, 1
The operator must be sitting in the seat.
Switch between “SERVICE” and “RUN”. The EIC board will light and beep. If the board fails to light and beep, check the switch and circuit for battery voltage.
To exit Diagnostics and move to the next item, press and hold the “ARROW” switch until “dIAg” is displayed in the character display, then release the switch. Pressing the “ARROW” switch again will move the EIC to the SETUP Mode. To exit and return to the Normal Operating Mode turn the ignition key switch to the “OFF” position.
19984337
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55-43
EIC SETUP MODE
SECTION 55 - ELECTRICAL SYSTEM
The EIC Setup Mode is made up of several items:
FAULt - Fault/Warning history
• Fault occurrence with hour level of last occurrence.
r-CAL - Adjust Engine RPM
• Calibrate EIC display to external RPM tach reading.
CLr F - Clear Faults
•
Clear Faults to zero.
Eng 0 0 - Engine Code
•
Set EIC to loader engine model.
HourS - Adjust skid-steer loader hours
• Change unit hours when installing a new EIC board in a loader.
Unit F or Unit C - Select Displayed Temperature
Units, Fahrenheit or Celsius
• Temperature displayed in Metric (Celsius) or
English (Fahrenheit).
CLr E - Clear Memory
•
Return EIC to original factory settings.
• Engine code reset to (01).
•
Hours reset to (0000.0) zero.
• Temperature displayed (Fahrenheit).
•
Engine RPM calibration cleared.
55-44
1
SECTION 55 - ELECTRICAL SYSTEM
2
39
FAULt - Fault/Warning history
With display showing “LOC_ _” for lock.
1. Press and release the “ARROW” switch, 1;
“dIAg” will appear in the character display. Then press and release the “ARROW” switch again;
“SEtUP” will appear in the display, 2.
_______________________________________________________________________________________________
2
1
2. Press and hold the “OPEN BOOK” switch, 1, until
“FAULt” appears in the character display, 2.
40
55-45
SECTION 55 - ELECTRICAL SYSTEM
3
1
2
Press and hold the “OPEN BOOK” switch, 1, until
“F0-XX” appears in the display. The “F0” is the fault and the “XX” is the number of occurrences of that fault since the fault memory was last cleared. The fault code display will be accompanied by an illuminated front panel symbol identifying the fault.
Thus, “F0” is identified via the illuminated oil filter symbol, 2, example “F0-02” is showing in display, 3,
F0 code with 02 occurrences.
Press and release the “OPEN BOOK” switch will display the hour of the last occurrence, for this code, example “0565.3” hours. Pressing and releasing the
“OPEN BOOK” switch will return the EIC to the fault code.
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55-46
SECTION 55 - ELECTRICAL SYSTEM
Pressing and releasing the “ARROW” switch again will forward to the next fault “F1-00” and pressing and releasing the “OPEN BOOK” switch again will display the hour of the last occurrence if any fault occurrences were shown. Use this procedure to go through all the fault codes:
FAULT
CODES FAULT
F0-00
F1-00
F2-00
F3-00
F4-00
Hydraulic oil filter
Engine air cleaner
Not used
Engine preheat
Fuel solenoid
SYMBOL
LIGHT
Oil filter
Air cleaner
Blank
Preheat
Fuel level bar lights
F5-00
F6-00
F7-00
Engine coolant temperature Engine coolant
Hydrostatic transmission charge pressure Charge pressure
Transmission/Hydraulic
F8-00
F9-00
FA-00 oil temperature
Battery voltage
Oil temperature
Battery
Engine oil pressure Oil pressure
Hydraulic boom/bucket solenoid Seat belt
43
55-47
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SECTION 55 - ELECTRICAL SYSTEM
2
44
Once all faults have been identified, the fault history can be cleared to zero.
To return to “FAULt” and clear the faults, press and hold the “ARROW” switch, 1, until the original
“FAULt” item is displayed in the character display.
Press and release the “ARROW” switch, 1, until “CLr
F” appears in the character display, 2.
_______________________________________________________________________________________________
2
1
Press and hold the “OPEN BOOK” switch, 1, until
“CLEAr” appears in the display, 2. Then release the switch to clear all fault occurrences from the fault history memory.
To exit this item, press and hold the “ARROW” switch to return to the “SEtUP” mode, or turn the ignition key switch to the “OFF” position to return the EIC to the
Normal Operating Mode.
55-48
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SECTION 55 - ELECTRICAL SYSTEM
Eng 0 0 - Engine Code
With display showing “LOC_ _” for lock:
1. Press and release the “ARROW” switch; “dIAg” will appear in the character display. Then press and release the “ARROW” switch again; “SEtUP” will appear in the display.
2. Press and hold the “OPEN BOOK” switch until
“FAULt” appears in the character display; release switch.
3. Press and release the “ARROW” switch until
“EngXX” (XX=current engine code) appears in the display, 1.
4. Press and hold the “OPEN BOOK” switch until the left digit starts to flash; release switch.
5. Press and release the “OPEN BOOK” to enter a zero (0) into the left digit of the engine code.
6. Press and release the “ARROW” switch; the right digit will flash.
7. Press and release the “OPEN BOOK” switch to enter the right number of the engine code
(Example “Eng 01” for the LS160 and LS170 skid steers is shown in display 1).
The engine code is as follows:
01 - LS160, LS170
To exit this item, press and hold the “ARROW” switch two times to return to the “SEtUP” mode item list, or turn the ignition key switch to the “OFF” position to return the EIC to the normal operating mode.
1
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55-49
SECTION 55 - ELECTRICAL SYSTEM
Unit F or Unit C (EIC Reading Fahrenheit or
Celsius)
With display showing “LOC_ _” for lock.
1. Press and release the “ARROW” switch; “dIAg” will appear in the character display. Then press and release the “ARROW” switch again; “SEtUP” will appear in the display.
2. Press and hold the “OPEN BOOK” switch until
“FAULt” appears in the character display; release switch.
3. Press and release the “ARROW” switch until
“Unit F” or “Unit C” appears in the character display, 1.
4. Press and hold the “OPEN BOOK” switch until the rightmost letter flashes, then release the switch.
5. Press and release the “OPEN BOOK” to change from C to F or F to C.
• Unit F will read temperature degrees in
Fahrenheit
• Unit C will read temperature degrees in
Celsius
To exit this item press and hold the “ARROW” switch two times to return to the “SEtUP” mode item list or turn the ignition key switch to the “OFF” position to return the EIC to the Normal Operating Mode.
r-CAL - Adjust Engine RPMS
With display showing “LOC_ _” for lock.
1. Press and release the “ARROW” switch; “dIAg” will appear in the character display. Then press and release the “ARROW” switch again; “SEtUP” will appear in the display.
2. Press and hold the “OPEN BOOK” switch until
“FAULt” appears in the character display, release switch.
3. Press and release the “ARROW” switch until
“r-CAL” appears in the character display, 1.
1
1
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55-50
SECTION 55 - ELECTRICAL SYSTEM
4. Press and hold the “OPEN BOOK” switch until all zeros are displayed in the character display.
Upon releasing of the switch only the right zero will be showing in display, 1.
5. Buckle the seat belt and start the engine. Using a hand held photo-tach or other accurate measuring device, check the engine RPM at high idle (full throttle). Compare the hand held tach reading to the EIC RPM reading.
6. Press and release the “OPEN BOOK” or
“ARROW” switches to change the EIC reading to match the tach at high idle. Pressing the “OPEN
BOOK” switch will decrease the reading and pressing the “ARROW” switch will increase the reading.
For best results, RPM should be calibrated at full throttle only.
NOTE: The “OPEN BOOK” or “ARROW” switches may have to be pressed multiple times to change the reading, this is normal. When changing the high idle reading, the low idle reading will have a slight change.
To exit this item, turn the ignition key switch to the
“OFF” position to return the EIC to the Normal
Operating Mode.
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55-51
SECTION 55 - ELECTRICAL SYSTEM
ELECTRONIC INSTRUMENT CLUSTER
(EIC) AND STARTER CIRCUITS:
BLOWN FUSE SYMPTOMS AND TESTING
Electronic Ignition Fuse, 1
(Cab Fuse Panel - 5A)
Service/Run Switch “Run” Position
1. Board shows self test (with operator in seat).
2. Board shows 5.2 volts.
3. Board seat belt and park brake lights will flash.
4. Board seat belt light will go off when seat belt is buckled. Park brake light will still flash.
5. Key “ON” position - board will show 5.2 volts and no preheat cycle.
6. Engine will crank but will not start.
7. Toggle Service/Run switch to “SERVICE” position - unit will start.
19984337
Electronic Battery Fuse, 1
(Engine Fuse Panel - 5A)
Service/Run Switch “Run” Position
1. When operator sits in seat, the board will not power up - no readings.
2. Unit will not crank.
3. Toggle Service/Run Switch to - “SERVICE” position - unit will crank and may start if engine is warm, NO preheat is available.
Key Main Fuse, 2
(Engine Fuse Panel - 15A)
Service/Run Switch “Run” Position
1. Board will power up and self test.
2. Board seat belt and park brake lights will flash.
3. Board seat belt light will go off when seat belt is buckled; the park brake light will still flash.
4. Key on - system dead.
5. Toggle Service/Run Switch to “SERVICE” position - system dead.
1
1
2
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55-52
SECTION 55 - ELECTRICAL SYSTEM
IMPORTANT: If any servicing or adjustments require the battery to be disconnected, or welding is required on the skid-steer loader, disconnect the negative (–) ground cable. Failure to disconnect the battery may result in damage to the EIC (Electronic Instrument
Cluster) monitoring system and other electrical components.
IMPORTANT: If the EIC requires removal from the dash area or the skid-steer loader, disconnect the negative (–) ground battery cable. This will shut off power to the EIC and prevent damage to the EIC board, or prevent blowing the 5-amp fuses, if the board is accidentally grounded.
IMPORTANT: Do not use magnetized tools while working around the EIC board or damage to the EIC may occur.
To test for a blown fuse, remove the fuse from the fuse block and visually examine the fuse link. If the fuse link is blown, replace the fuse.
If the fuse link appears OK, check the fuse with an ohmmeter and check for continuity across the fuse legs; if there is continuity, the fuse is OK.
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SECTION 55 - ELECTRICAL SYSTEM
TESTING OTHER EIC FUNCTIONS
NOTE: These tests are performed with the EIC in the normal operating mode and the “SERVICE/RUN” switch in the “RUN” position.
1. Parking Brake Light
Sit in the seat with the seat belt buckled. After the
EIC board self test, the parking brake light, 1, should flash. Turn the ignition key to the “ON” position and the light should go off. If the light fails to go off, check the 5-amp fuse in the cab fuse panel.
When exiting the loader, the light should flash for about 2 seconds after the seat belt is unbuckled and the operator is out of the seat.
If the light does not flash when the seat belt is unbuckled, check operation of the seat belt switch and the seat switch.
2. Seat Belt Light
Sit in the seat. After the EIC board self tests, the seat belt light, 1, will flash until the seat belt is buckled.
If the light continues to flash after the seat belt is buckled, check operation of the seat belt switch.
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55-54
SECTION 55 - ELECTRICAL SYSTEM
3. Boom and Bucket Spool Locks, 1
(Control valve spools in neutral and boom and bucket resting on the ground) a. Sit in the seat. After the EIC board self tests, turn the ignition switch to the “ON” position.
The boom and bucket controls should not move. If OK, go to the next step. If the controls can be moved, check the solenoids for operation and check the control linkage and valve spool centering for binding causing the spools not to center to the neutral position.
b. Sit in the seat, buckle the seat belt and try moving the boom and bucket controls. The controls should not move. If OK, go to the next step. If the controls can be moved, check the solenoids for operation and check the control linkage and valve spool centering for binding causing the spools not to center to the neutral position.
c. Sit in the seat, buckle the seat belt, and turn the ignition switch to the “ON” position. If the controls move allowing boom and bucket operation, go to the next step. If the controls do not move, check the solenoids for operation and for battery voltage at the solenoids.
d. Sit in the seat, buckle the seat belt, and turn the ignition switch to the “ON” position. Move the controls and return the controls to the centered (neutral) position. Unbuckle the seat belt. Try moving the controls; they should be locked. Rebuckle the seat belt; the controls should move allowing boom and bucket movement.
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55
55-55
SECTION 55 - ELECTRICAL SYSTEM
4. Boom and Bucket Spool Lock Solenoid Test
(Voltage Test)
To perform the following test, the operator must be sitting in the seat, seat belt buckled, and the ignition “key” switch in the “RUN” position.
a. Unplug one solenoid at a time and check for battery voltage at the main wire harness connector, 1, between the PK/LTBL wire side of the connector and the B wire side of the connector. If there is battery voltage, proceed to checking solenoid resistance.
b. If there is no battery voltage between the
PK/LTBL wire and the B wire, check for battery voltage between the PK/LTBL wire and frame ground. If there is battery voltage, check the “B” ground wire of the solenoid circuit for open circuit. If there is no battery voltage, check the PK/LTBL power wire for an open circuit.
(Ohms Test)
With the ignition “key” switch in the “OFF” position: a. Unplug one solenoid at a time, 1, and check ohms resistance of the solenoid coils, 15 to
18 ohm range.
b. If solenoid coils are not within the ohms resistance range, 15 to 18 ohms, replace the solenoid coil.
19997742
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56
55-56
SECTION 55 - ELECTRICAL SYSTEM
EIC BOARD READING ACCURACY
EIC board readings for the digital display, including
RPM, Battery Voltage, Hourmeter, Engine Coolant
Temperature, or Hydraulic Oil Temperature may not be accurate or may have no reading when selected.
Complaints usually follow installation of an optional kit or customer-installed option, or complaints can arise after a machine repair such as engine overhaul or cab tilting. However, occasionally a concern on a standard machine with no modifications is reported.
If the EIC board was operating correctly before any repair or kit installation occurred, the possible cause may be improper electrical system grounding. If working on a new machine, grounding points should be checked before any replacement of components is considered.
THE ONLY ACCEPTABLE GROUND POINTS IN
THE CAB AREA ARE TO THE GROUND STUD ON
THE ROPS RIGHT SIDE NEAR ELECTRICAL
PANEL, 1, OR TO THE AUXILIARY POWER KIT
SOCKET WHICH IS WIRED TO THE BELL
HOUSING GROUND. NO ACCESSORIES MAY BE
GROUNDED TO THE CAB INTERLINER ON
THESE skid steers BECAUSE SOME OR ALL OF
THE CURRENT COULD PASS THROUGH THE
EIC.
NOTE: When attaching ground wires to the cab ground stud, always place the heaviest ground wire next to the ground surface and then stack the remaining ground wires according to wire size, largest on the bottom and smallest last.
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55-57
SECTION 55 - ELECTRICAL SYSTEM
All grounding locations should be checked for tight hardware and absence of paint between parts for good connecting, as follows:
1. Check the grounding strap from the engine to main frame, 1.
2. Check the wiring harness from the EIC to the bell housing.
3. Check the grounding strap from the cab ROPS structure to main frame, 1.
On the grounding strap from the ROPS to the main frame, be sure the strap is attached between the ROPS and the main frame (yellow lower frame). DO NOT attach the strap between the cab interliner (cab side screen sections) and the main frame, as the cab interliner on these skid steers is rubber-mounted to the ROPS and, therefore, insulated from the ROPS. However, a second strap may be added between the cab interliner and the main frame and should cause no ill effect.
4. Check the wiring harness grounds to the bell housing, 1.
NOTE: When attaching multiple ground wires, always place the heaviest ground wire (battery ground cable) next to the ground surface (bell housing). Stack the remaining ground wires according to wire size, largest on the bottom and smallest last. Two wires in a terminal are considered to be larger than a single wire of the same size.
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58
59
60
55-58
SECTION 55 - ELECTRICAL SYSTEM
EIC BOARD CLAIMS WARRANTY
When filing a warranty claim for a defective EIC
(Electronic Instrument Cluster) board, include the part number and serial number on the white tag of the defective board.
The EIC board part number, 1, and this number must be used as the causal part number.
Also include the EIC board serial number located at
2, in the description of failure section of the warranty claim, along with a description of the type of EIC board failure.
19986414
Handling the EIC Board
The EIC board is shipped in an anti-static bag and box. The board must be kept in this bag and box, until required for a repair, to prevent damage to the EIC board.
When returning the EIC board for warranty or repair, it must be returned in the anti-static bag and box to prevent damage.
When installing a new EIC board, always disconnect the negative battery cable to prevent damage to the board from accidental grounding.
The board versions listed below are the EIC boards used on skid steers.
DO NOT replace a prior version board unless it is defective.
Troubleshoot any problems and only replace the board if it is determined to be the problem.
Boards returned as warranty and determined not to be defective will be debited back. All EIC boards claimed as warranty must be returned for review.
2
1
61
55-59
SECTION 55 - ELECTRICAL SYSTEM
ELECTRICAL CIRCUITS
EIC (ELECTRONIC INSTRUMENT
CLUSTER)
The EIC board receives power from five different points.
MAIN POWER CIRCUIT TO EIC BOARD
1. Main power circuit, 12-volt battery, from the
5-amp fuse in the engine fuse panel.
2. The ignition switch, 12-volt ignition circuit.
3. Seat switch circuit.
4. The seat belt switch circuit.
5. The ignition switch, 12-volt accessory circuit.
Battery voltage
The power originates at the battery and proceeds through the (R) battery cable to the starter solenoid.
From there power continues through the (R) wire to the battery side of the start relay. The power continues through the (R) wire to the preheat circuit breaker, then through the (R) wire to the engine fuse panel (standard fuse block), battery side of the key main 15-amp fuse with a terminal bus to the battery side of the electronics 5A fuse. The power continues through the (R/LTGN) wire to pin number 14 of connector P2 (12-volt battery terminal) at the EIC board.
EIC BOARD GROUND CIRCUIT
The EIC board is grounded from connector P2 terminal 13 through the (B) wire to the engine ground at the bell housing.
R
55-60
15A
62
SECTION 55 - ELECTRICAL SYSTEM
R
R
15A
SEAT SWITCH CIRCUIT TO EIC BOARD
Battery voltage
The power originates at the battery and proceeds through the (R) battery cable to the starter solenoid.
From there power continues through the (R) wire to the battery side of the start relay.
The power continues through the (R) wire to the preheat circuit breaker, then through the (R) wire to the engine fuse panel (standard fuse block) battery side of the key main 15-amp fuse with a terminal bus to the battery side of the electronics 5A fuse.
63
The power continues through the (LTGN/R) wire to the seat switch. When one seat switch (only 1 switch needs to be closed as switches are in parallel wiring) is pressed closed, the power then continues through the (T) wire to the Service/Run switch. When the service/run switch is in the “SERVICE” position, the power stops.
With the Service/Run switch in the “RUN” position, the power continues through the (T/W) wire to the
EIC board terminal 4 of connector P2.
55-61
SECTION 55 - ELECTRICAL SYSTEM
SEAT BELT SWITCH CIRCUIT TO EIC
BOARD
Battery voltage
The power originates from the seat switch(es) through the (T) wire to the seat belt switch.
64
When the seat belt is buckled, the power proceeds through the (LTGN) wire to the EIC board terminal 11 of connector P2.
When the seat belt is buckled, power is sent through the (W/O) wire to the start interlock relay. This allows the unit to start when the seat belt is buckled.
55-62
SECTION 55 - ELECTRICAL SYSTEM
IGNITION SWITCH CIRCUIT TO EIC BOARD
Battery voltage
The power originates at the battery and proceeds through the (R) battery cable to the starter solenoid.
From there power continues through the (R) wire to the battery side of the start relay.
The power continues through the (R) wire to the preheat circuit breaker, then through the (R) wire to the engine fuse panel (standard fuse block) battery side of the key main 15-amp fuse.
The power continues through the (R/W) wire to the battery terminal of the ignition switch.
65
When the ignition key switch is turned to the “ON” position, power continues through the (O/PU-2) wire to the Electronics 5-amp fuse in the cab fuse panel.
The power continues through the (O) wire to terminal
12 of connector P2 at the EIC board.
NOTE: Also, with Key Switch “ON” Engine “OFF,” voltage travels from the switch “ACC” terminal via the
LTGN/B wire to terminal 11 of connector P1 to provide a warning of Key “ON” should the operator exit the loader.
55-63
SECTION 55 - ELECTRICAL SYSTEM
CRANKING CIRCUIT (STARTER MOTOR)
Operating conditions with “SERVICE/RUN” switch in the “RUN” position:
To start the engine with the “SERVICE/RUN” switch in the “RUN” position, 1, the operator must be in the seat with the seat belt buckled. Then turn the key switch to the “START” position to activate the starter.
1
19984337
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55-64
SECTION 55 - ELECTRICAL SYSTEM
“SERVICE/RUN” SWITCH IN THE “RUN”
POSITION
The power originates at the battery and flows through the (R) positive battery cable to the starter solenoid.
From here the power flows through the (R) wire to the battery side of the start relay.
The power then flows through the (R) wire to the preheat circuit breaker and to the engine fuse panel to the 15A key main fuse.
The power then flows through the (R/W) wire to the battery terminal on the ignition key switch.
With the key switch in the “START” position, current flows through the (W) wire to the service/run switch.
Power also flows through the (W) wire to connector
P2 terminal 10-key start at the EIC board.
67
Power then flows from the service/run switch through the (W/LTGN) wire to the start interlock relay coil terminal.
With the interlock energized, the power from the seat/seat belt circuit (W/O) wire flows through the
(W/DKBL) wire to the start relay to activate the relay.
Power also flows from the start interlock relay through the LTBL/O wire to the fuel solenoid to open the solenoid, allowing fuel flow to the injection pump.
When the start relay is activated, power goes through the (W/R) wire to the starter solenoid, which connects battery power to the starter motor.
55-65
SECTION 55 - ELECTRICAL SYSTEM
68
CRANKING CIRCUIT GROUND
The start interlock relay is grounded through the
(B-4) wire to the ground terminal on the start relay.
The system ground (B-6) wire then goes to the ground terminal of the preheat relay. The system ground (B-8) wire then goes to the engine ground at the bell housing.
OPERATING CONDITIONS “SERVICE/RUN”
SWITCH IN THE “SERVICE” POSITION
To start the engine with the “SERVICE/RUN” switch,
1, in the “SERVICE” position, the starter will be activated any time the key switch is turned to the
“START” position.
NOTE: If manual preheat is required, the operator must be in the seat.
NOTE: The boom and bucket control valve spool locks will remain inoperative with the
“SERVICE/RUN” switch in the “SERVICE” position.
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55-66
SECTION 55 - ELECTRICAL SYSTEM
SERVICE/RUN SWITCH IN THE “SERVICE”
POSITION
The power originates at the battery and flows through the (R) positive battery cable to the starter solenoid.
From here the power flows through the (R) wire to the battery side of the start relay.
The power then flows through the (R) wire to the preheat circuit breaker and to the engine fuse panel to the 15A key main fuse.
The power then flows through the (R/W) wire to the battery terminal on the ignition key switch.
With the key switch in the “START” position, current flows through the (W) wire to the service/run switch.
70
With the service/run switch in the “SERVICE” position, power goes through the (W/DKBL) wire from the service/run switch to the start relay to activate the relay.
When the start relay is activated, power goes through the (W/R) wire to the starter solenoid, which connects battery power to the starter motor.
With the service/run switch in the “SERVICE” position, power goes through the LTBL/O wire from the service/run switch to the fuel solenoid, opening the solenoid to allow the engine to start.
55-67
SECTION 55 - ELECTRICAL SYSTEM
71
CRANKING CIRCUIT GROUND
The start interlock relay is grounded through the
(B-4) wire to the ground terminal on the start relay.
The system ground (B-6) wire then goes to the ground terminal of the preheat relay. The system ground (B-8) wire then goes to the engine ground at the bell housing.
START RELAY OPERATION
The start relay allows for smaller wires to be used in the switch circuits. The larger wires are then only used between the power supply, start relay, and starter motor. The start relay provides a short path for the high current required to pull in the starter solenoid with minimal voltage drop.
The start relay, 1, and the preheat relay, 2, may be wired in either position. Check wire colors for proper relay location.
55-68
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SECTION 55 - ELECTRICAL SYSTEM
START RELAY CIRCUIT
The power originates at the battery and flows through the (R) positive battery cable to the starter solenoid.
From here the power flows through the (R) wire to the battery side of the start relay.
The power then flows through the (R) wire to the preheat circuit breaker and to the engine fuse panel to the 15A key main fuse.
The power then flows through the (R/W) wire to the battery terminal on the ignition key switch.
When the service/run switch is in the “RUN” position, the operator is in the seat with the seat belt buckled,
73 and the start interlock relay is energized by the
W/LTGN wire from the service/run switch, the start relay receives energizing power from the seat/seat belt circuit via the W/O wire, then the (W/DKBL) wire from the start interlock relay.
When the service/run switch is in the “SERVICE” position, the start relay receives energizing power through the (W/DKBL) wire from the service/run switch.
When the start relay is activated, it connects the battery side of the relay to the start side and sends power to the starter solenoid through the (W/R) wire, activating the starter motor.
55-69
SECTION 55 - ELECTRICAL SYSTEM
START RELAY GROUND CIRCUIT
The start relay is grounded through the (B-6) wire to the ground terminal on the preheat relay and then through the (B-8) wire to the engine bell housing.
START INTERLOCK RELAY OPERATION
The start interlock relay, 1, controls the starting circuit when the “SERVICE/RUN” switch is in the “RUN” position, allowing the engine to start.
1
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75
55-70
SECTION 55 - ELECTRICAL SYSTEM
START INTERLOCK CIRCUIT
“SERVICE/RUN” switch in the “RUN” position.
The start interlock relay coil receives power from the service/run switch, with the switch in the “RUN” position, through the W/LTGN wire. The interlock receives power from the seat/seat belt plug when the operator is sitting in the seat with the seat belt buckled through the W/O wire.
76
When the interlock is “satisfied” that the service/run switch is in the “RUN” position and the operator is sitting in the seat with the seat belt buckled, power will travel through the W/DKBL wire to the start relay and through the LTBL/O wire to the fuel solenoid, allowing the engine to start. The source for the fuel solenoid power is from key switch “Ign,” then through the O/PU wire to the cab 5-amp fuse, then via the O wire to the relay.
55-71
SECTION 55 - ELECTRICAL SYSTEM
START INTERLOCK GROUND CIRCUIT
The interlock is grounded through the B-4 wire to the start relay, through B-6 wire to the preheat relay, through B-8 wire to the engine bell housing ground.
START CIRCUIT
“SERVICE/RUN” switch in the “SERVICE” position.
The interlock relay is not functional with the service/run switch in the “SERVICE” position. With
77 the switch in the “SERVICE” position, power flows from the key switch “START” terminal via the W wire to the service/run switch, then through the LTBL/O wires to the fuel solenoid, allowing the engine to start and continue to run. The start relay receives power from the service/run switch via the W/DKBL wire to activate the start relay. The EIC plays no supporting role in this mode.
55-72
SECTION 55 - ELECTRICAL SYSTEM
Op. 55 100
REMOVAL, INSTALLATION AND WIRING
OF ELECTRICAL COMPONENTS
This section will show and explain the correct wiring of switches and relays, and when and where battery voltage should be with the key switch (ignition) “ON” or “OFF” for the electrical components.
This section will also explain the removal and installation of the switches, relays, EIC board, and main wire harness.
Before servicing, changing or adding any electrical components, read the following precautionary statements.
on the skid-steer loader, disconnect the negative (–) ground cable. Failure to disconnect the battery may result in damage to the EIC (Electronic Instrument
Cluster) monitoring system and other electrical components.
IMPORTANT: If the EIC requires removal from the dash area of the skid-steer loader, disconnect the negative (–) ground battery cable. This will shut off power to the EIC and prevent damage to the EIC board or blowing the 5-amp fuses if the board is accidentally grounded.
IMPORTANT: Do not connect any electrical circuits at the ignition key switch, the cab electrical fuse panel, or the cab ground terminal in the fuse panel area unless there are written instructions telling you to do so or damage to the EIC board may occur.
IMPORTANT: Do not service the EIC board with magnetized tools (wrenches, screwdriver, etc.) or magnets. Severe damage to the EIC board may occur.
IMPORTANT: If any servicing or adjustments require the battery to be disconnected, or welding is required
55-73
SECTION 55 - ELECTRICAL SYSTEM
BATTERY
Op. 55 301 40
REMOVAL
1. Raise the boom and rest on the boom lock pins.
CAUTION
Never work under a raised boom unless it is properly supported by the boom lock pins.
2. Open the rear door and remove the right engine side shield to access the battery.
3. Disconnect the negative (–) battery cable, 1.
4. Disconnect the positive (+) battery cable, 2.
5. Loosen the top muffler support hardware at 3, and remove the lower support hardware, 4, and pivot the support in towards the engine.
6. Remove the battery hold-down hardware, 5, and remove the battery from the loader.
INSTALLATION
1. Orient the battery with the positive post toward the rear of the loader. Install the battery and the hold-down strap and hardware. Position the hold-down strap to clear other components.
2. Connect the positive (+) RED cable to positive (+) terminals and negative (–) BLACK cable to negative (–) terminals. Do not over tighten.
Observe the tightening specifications on the battery label.
IMPORTANT: Crossing of terminals may cause damage to the electrical system, alternator and
Advanced Warning System (EIC).
NOTE: Make sure the positive (+) battery cable, 1, on
LS170 models routes outside the hose, 2, and away from the turbocharger hose clamp, 3. Reverse the clamp to avoid unnecessary wear on cables and hoses.
3. Install protective caps over the battery terminals and cable connections.
2
1
3
19988126
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55-74
SECTION 55 - ELECTRICAL SYSTEM
Op. 55 418 10
EIC (ELECTRONIC INSTRUMENT
CLUSTER) BOARD REMOVAL
1. Disconnect the negative (–) battery cable.
2. Remove the retaining hardware, 1, and remove the EIC board from the overhead dash area.
3. Unplug the two wire harness connectors, 1, from the EIC, taking care to not stress or bend the plastic locking ramps on the connectors.
NOTE: Note the positioning of the connectors to the
EIC board and reconnect to the new board in the correct position. If the connector is not connected properly, damage to the EIC may occur.
1
80
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55-75
SECTION 55 - ELECTRICAL SYSTEM
EIC (Electronic Instrument Cluster) WIRING
NOTE: There are two different style EIC board connectors as shown here.
Board
Connector #1
(J1)
Pin Number
1
2
5
6
3
4
11
12
13
14
7
8
9
10
Wire Color
NOT USED
NOT USED
NOT USED
PU/W
PU/LTGN
PU/LTBL
PU/R
NOT USED
Y/LTGN
Y/B
Y/GY
DKGR/O
B/Y
LTGN/B
Harness
Connector #1
(P1)
Pin Number
-
-
2
3
-
1
8
9
10
11
6
7
4
5
Board
Connector #2
(J2)
Pin Number
1
4
5
2
3
10
11
12
13
14
8
9
6
7
Wire Color
NOT USED
LTBL/Y
PK/LTBL
T/W
LTBL/O
NOT USED
NOT USED
NOT USED
PK
W
LTGN
O
B
R/LTGN
10
11
12
13
14
8
9
6
7
Harness
Connector #2
(P2)
Pin Number
1
4
5
2
3
55-76
82
SECTION 55 - ELECTRICAL SYSTEM
EIC (Electronic Instrument Cluster) BOARD
INSTALLATION
1. Connect the wire harness connectors P1 to J1 and P2 to J2 on the EIC board, making sure the connectors are properly aligned and fully seated.
IMPORTANT: If the connector is not connected correctly, damage to the EIC may occur:
•
•
•
Board circuits may burn out.
Display may not light up.
Board memory may be lost.
2. Position the EIC board into the overhead dash flat against the support and secure with the hardware previously removed. Make sure that wires are not pinched between the EIC board and dash frame.
3. Reinstall the negative (–) battery cable.
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55-77
SECTION 55 - ELECTRICAL SYSTEM
IGNITION (KEY) SWITCH WIRING
Ref Color Destination
1 O/LTBL To Four-Way Flashing lights 10A Fuse (cab panel)
To Beacon Light 7.5A
Fuse (cab panel)
2 LTGN/B To EIC Board Pin #11
(small connector)
3 LTGN/B To Accessory Relay
4
5
W
W
(engine panel)
To Service/Run Switch
To EIC Board Pin #10
(large connector)
Battery
Voltage
Key “ON” position
Key “ON” position
Key “ON” position
Key
“START” position
Key
“START” position
All times 6
7
R/W From 15A Fuse
(engine panel)
GY/B Power to dome light
(not available)
8 O/PU-2 To Electronics 5A
Fuse (cab panel)
All times
Key “ON” position
Op. 55 201 10
REMOVAL
1. Disconnect the negative (–) battery cable.
2. Remove the retaining hardware, 1, and remove the switch panel, 2, from the overhead dash area.
3. Remove the wires from the switch terminals.
4. Remove the switch retaining nut, 1, from the switch and remove the switch from the panel.
INSTALLATION
1. Attach the switch to the panel and secure with nut, 1, previously removed.
2. Reconnect the wires to the terminals as shown above.
3. Reinstall the switch panel to the overhead dash.
4. Reinstall the negative (–) battery cable.
55-78
84
85
1
86
SECTION 55 - ELECTRICAL SYSTEM
CAB FUSE PANEL WIRING
Ref Color Destination
1 O/LTGN (15A Fuse) From
Accessory Relay
(engine panel)
2
3
4
5
6
O/B (15A Fuse) To Road/
Work Light Switch
O/GY (7.5A Fuse) To Wiper Motor Switch
O (5A Fuse) To EIC
Board Pin #12
(P2 connector)
O (5A Fuse) To Start
Interlock Relay
(engine panel)
PU/O (5A Fuse) To Fuel
Pump
7 O/PU-1 To Service/Run
Switch
8 O/PU-2 From Key Switch
(Ign. terminal)
9 O/LTBL From Key Switch
(Acc. terminal)
10 O/Y (7.5A Fuse) To
Beacon, Four-Way
Warning Lights
Switch
Key “ON” position
Key “ON” position
Key “ON” position
Key “ON” position
Key “ON” position
Key “ON” position
Battery
Voltage
Key “ON” position
(If equipped with lights or other accessories).
Key “ON” position
Key “ON” position
Key “ON” position
STANDARD FUSE BLOCK
OPTIONAL EQUIPMENT FUSE
10
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55-79
SECTION 55 - ELECTRICAL SYSTEM
CAB FUSE BLOCK AND PANEL
REMOVAL
1. Disconnect the negative (–) battery cable.
2. Remove panel, 1; retaining hardware, 2; and lower panel from the support. Removal of panel,
3, may be required for easier access.
3. Unplug the wires from the fuse block.
4. Remove the fuse block retaining hardware.
NOTE: The standard fuse block is part of the main harness and cannot be completely removed.
INSTALLATION
1. Attach the wires to the proper side of the fuses as shown at 1, and as shown in the “CAB FUSE
PANEL WIRING” figure, Figure 92. Check that the fuses, 2, are in their proper slots.
2. Reinstall the block retaining hardware.
3. Reinstall the panel to the support.
4. Reconnect the negative (–) battery cable.
19984337
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88
89
55-80
SECTION 55 - ELECTRICAL SYSTEM
SERVICE/RUN SWITCH WIRING
SERVICE POSITION RUN POSITION
SERVICE/RUN SWITCH - SERVICE
POSITION
Ref Color Destination
1 W/DKBL To Start Relay
(engine panel)
2
3
LTBL/O From EIC Board Pin #5
(large connector)
LTBL/O To Start Interlock Relay
(engine panel)
4 LTGN/O To Manual Preheat
Switch
5 T From Seat Switch(es)
6
9
T/W
W
To EIC Board Pin #4
(large connector)
7 O/PU 1 From 5A Fuse (cab panel)
8 W/LTGN To Start Interlock Relay
(engine panel)
From Key Switch
(ignition)
Battery
Voltage
Key
“START” position
Key “ON” position
Key “ON” position
Sitting in
Seat
Sitting in
Seat
No
Voltage
Anytime
Key “ON” position
No
Voltage
Anytime
Key
“START” position
SERVICE/RUN SWITCH - RUN POSITION
90
Ref
1 W/DKBL To Start Relay
2
3
4
5
9
Color
LTBL/O
LTBL/O
LTGN/O
T
W
Destination
(engine panel)
From EIC Board Pin
#5 (large connector)
To Start Interlock
Relay (engine panel)
To Manual Preheat
Switch
From Seat Switch(es)
6
7
T/W To EIC Board Pin #4
(large connector)
O/PU 1 From 5A Fuse (spare)
(cab panel)
8 W/LTGN To Start Interlock
Relay (engine panel)
From Key Switch
(Ignition)
Sitting in
Seat
Sitting in
Seat
Sitting in
Seat
Key “ON” position
Key
“START” position
Key
“START” position
Battery
Voltage
Key
“START” position
(backfed from start interlock relay)
Key “ON” position
(will read
0.5 - 1.0 volt below battery voltage)
Key “ON” position
(will read
0.5 - 1.0 volt below battery voltage)
55-81
SECTION 55 - ELECTRICAL SYSTEM
SERVICE/RUN SWITCH
Op. 55 418 30
REMOVAL
1. Disconnect the negative (–) battery cable.
2. Remove panel, 1; retaining hardware, 2; and lower panel from the support. Removal of panel,
3, may be required for easier access.
3. Remove the wires from the switch terminals.
4. Push the switch retaining tabs in and remove the switch from the panel.
19984337
INSTALLATION
1. Insert the switch into the panel and make sure the locking tabs secure the switch.
2. Reconnect the wires to the proper terminals as shown in the “SERVICE/RUN SWITCH WIRING” figure, Figure 95.
3. Reinstall the panel to the support.
4. Reconnect the negative (–) battery cable.
1
91
92
55-82
SECTION 55 - ELECTRICAL SYSTEM
SEAT AND SEAT BELT SWITCH WIRING
Ref Color
1 LTGN
Destination
To EIC Board Pin
#11 (large connector)
2
3
T
T
From Seat
Switch(es)
To Seat Belt switch
Battery
Voltage
Seat Belt
Buckled
Sit in
Seat
Sit in
Seat
All Times 4 LTGN/R From Electronics 5A
Fuse (engine panel)
5 T To Service/Run
Switch
Sit in
Seat
Op. 55 201 15
SEAT SWITCH REMOVAL
1. Disconnect the negative (–) battery cable.
2. Raise the seat and securely latch in the raised latched position, 1.
CAUTION
Never work under a raised seat unless it is securely latched in the raised position.
3. Remove the seat retaining hardware, 2.
4. Holding the seat in place, lower the seat pan and seat and unplug the seat switch(es).
5. Remove the seat from the loader.
6. Disconnect the wire harness from the switch(es) by releasing the latch away from the switch.
7. Remove the switch(es) from the seat pan. The standard seat uses one switch, 1, and the deluxe seat uses two switches, 2.
4825-11r
2 1
93
94
95
55-83
SECTION 55 - ELECTRICAL SYSTEM
SEAT SWITCH INSTALLATION
1. Install the switch(es) into the seat pan, making sure the switch is seated into the hole in the seat pan, 1.
IMPORTANT: If the switch is not seated properly when the retaining hardware is tightened, the switch flange will be broken.
2. Reconnect the wire harness to the switch(es) and reinstall the seat retaining hardware. Make sure the harness connector latches are engaged.
3. Reconnect the negative (–) battery cable.
Op. 55 201 14
SEAT BELT BUCKLE AND SWITCH
ASSEMBLY REMOVAL
1. Disconnect the negative (–) battery cable.
2. Unplug the seat belt wire harness, 1.
3. Remove the clamp hardware and clamp, 2, and save for reuse.
4. Remove the seat belt retaining hardware, 3.
SEAT BELT BUCKLE INSTALLATION
1. Reinstall the seat belt buckle retaining hardware.
Tighten the locknut to hold the belt in position that will allow the belt assembly to move front or rearward.
2. Reconnect the wire harness.
3. Reinstall clamp holding harness above seat track.
4. Reconnect the negative (–) battery cable.
96
97
55-84
SECTION 55 - ELECTRICAL SYSTEM
ROAD LIGHT AND WORK LIGHT SWITCH
WIRING
Switch Pushed in at Top
Ref Color
1 PK/B
Destination
To Taillights
2 DKBL/W To Front Road/Work
Light
3 DKBL/W To Front Road/Work
Light
4 DKBL To Rear Work Light
5
6
O/B From 15A Fuse (cab panel)
PK To EIC Board Pin #9
P2 connector (to dim
EIC board lights)
Battery
Voltage
Yes
Yes
Yes
Yes
Key “ON” position
Yes
Switch Pushed in at Bottom
Ref Color
1 PK/B
Destination
To Taillights
2 DKBL/W To Front Road/Work
Light
3 DKBL/W To Front Road/Work
Light
4 DKBL To Rear Work Light
5
6
O/B From 15A Fuse (cab panel)
PK To EIC Board Pin #9
P2 connector (to dim
EIC board lights)
Battery
Voltage
Yes
Yes
Yes
NO
Key “ON” position
Yes
98
55-85
SECTION 55 - ELECTRICAL SYSTEM
ROAD LIGHT AND WORK LIGHT SWITCH
Op. 55 404 20
REMOVAL
1. Disconnect the negative (–) battery cable.
2. Remove the switch panel retaining hardware, 1, and lower the panel.
3. Remove the wires and connector from the switch terminals.
4. Press in the switch retaining tabs and remove the switch from the panel.
INSTALLATION
1. Insert the switch into the panel and insure the locking tabs secure the switch, 1.
2. Reconnect the wires and connector to the proper terminals with the PK/B and PK wires toward the top of the panel.
3. Reattach the switch panel to the overhead dash.
4. Reconnect the negative (–) battery cable.
99
100
55-86
SECTION 55 - ELECTRICAL SYSTEM
ENGINE FUSE AND RELAY PANEL
The engine panel electrical components are shown here:
1. Accessory relay
2. Heater power relay (if equipped)
3. Preheat circuit breaker
4. Start interlock relay
5. Optional equipment fuse block
6. Standard fuse block
7. Alternator excite resistor
8. Start relay
9. Preheat relay
To access the electrical components in the engine compartment, raise the boom and rest it on the boom lock pins.
CAUTION
Never work under a raised boom unless it is properly supported by the boom lock pins.
101
55-87
SECTION 55 - ELECTRICAL SYSTEM
ACCESSORY RELAY WIRING
Ref Color Destination
1 O/LTGN To Attachment/Horn
15A Fuse
2 LTGN/
B-2
To Turn Signal Relay or Heater Power
Relay
3 LTGN/B From Key Switch
(accessory terminal)
4 B-7 To Turn Signal Relay or Heater Power
Relay
5 B-5 To Start Relay
6
Battery
Voltage
Key “ON” position
Key “ON” position
Key “ON” position
Ground
Circuit
R/GY From Accessory 25A
Fuse
Ground
Circuit
All Times
1
2
ACCESSORY RELAY
Op. 55 100 34
REMOVAL
1. Disconnect the negative (–) battery cable.
2. Unplug the relay, 1, from the socket, 2. The corners provide an area to insert screwdriver and twist to assist removal.
INSTALLATION
1. Insert new relay fully into socket.
2. Reconnect the negative (–) battery cable.
102
103
55-88
SECTION 55 - ELECTRICAL SYSTEM
PREHEAT CIRCUIT BREAKER WIRING
Ref Color Destination
1 R/LTBL To Preheat Relay
2
3
R
R
To Start Relay
From 15A Key Main
Fuse Engine Fuse
Block
Battery
Voltage
All Times
All Times
All Times
PREHEAT CIRCUIT BREAKER
Op. 55 100 24
REMOVAL
1. Disconnect the negative (–) battery cable.
2. Disconnect wires from the terminals, 1.
3. Remove the circuit breaker retaining hardware.
INSTALLATION
1. Reinstall the retaining hardware.
2. Reconnect the wires to the proper terminals.
3. Reconnect the negative (–) battery cable.
1
104
105
55-89
SECTION 55 - ELECTRICAL SYSTEM
START INTERLOCK RELAY WIRING
Service/Run Switch - Run Position
Ref Color Destination
1 W/LTGN From
Service/Run
Switch
2 O From Cab Fuse
Panel 5A
Electronic
Ignition Fuse
3 LTBL/O To Fuel Solenoid
Battery
Voltage
Key “START” position
Key “ON” position
4 LTBL/O From EIC Board
Pin #5, P2 connector
5 W/DKBL To Start Relay
Key “ON” position *
Key “ON” position *
6
7
W/O
B-4
From Connector at Boom/Bucket
Control Valve
To Start Relay
Key “START” position
Sitting in Seat with Seat Belt
Buckled
Key “START” position
Sitting in Seat with Seat Belt
Buckled
Ground
Circuit
* Voltage will be 0.5 - 1.0 volt below battery voltage.
Service/Run Switch - Service Position
Ref Color Destination
1 W/LTGN From
Service/Run
Switch
2 O From Cab Fuse
Panel 5A
Electronic Ignition
Fuse
3 LTBL/O To Fuel Solenoid
Battery
Voltage
No Voltage
Anytime
Key “ON” position
4
5
6
7
LTBL/O From EIC Board
Pin #5
W/DKBL To Start Relay
W/O
B-4
From the
Seat/Seat Belt
Connector and
Connector at
Boom/Bucket
Control Valve
To Start Relay
Key “ON” position
Key “ON” position
Key “START” position
Sitting in Seat with Seat Belt
Buckled
Ground
Circuit
55-90
106
SECTION 55 - ELECTRICAL SYSTEM
Op. 55 100 34
START INTERLOCK RELAY REMOVAL
1. Disconnect the negative (–) battery cable.
2. Disconnect the wires from the terminals, 1.
3. Remove the interlock relay retaining hardware.
START INTERLOCK RELAY INSTALLATION
1. Reinstall the retaining hardware.
2. Reconnect the wires to the proper terminals as shown in the “START INTERLOCK RELAY
WIRING” figure, Figure 111.
3. Reconnect the negative (–) battery cable.
1
107
55-91
SECTION 55 - ELECTRICAL SYSTEM
ENGINE FUSE PANEL WIRING
Ref
1
Color
R/B
Destination
(10A Fuse) To Turn
Signal Relay
2 R/GY (25A Fuse) To
Accessory Relay
3 R/LTGN (5A Fuse) To EIC board Pin #14 P2 connector.
4 LTGN/R (5A Fuse) To Seat
Switch(es)
5 R/W (15A Fuse) To Key
Switch (Battery
Terminal)
6 R
7 R
From Preheat Circuit
Breaker
From Start Relay
8
9
R/O (20A Fuse) To
Heater Power Relay
R/T (7.5A Fuse) Spare
10 DKGN/R (15A Fuse) To High
Flow, Horn, Power
Outlet
11 O/LTGN From Accessary
Relay
12 O/W (5A Fuse) To Back
Up Alarm Switch
13 O/LTGN From Road/Work light fuse (cab panel)
Battery
Voltage
All Times
All Times
All Times
All Times
All Times
All Times
All Times
All Times
All Times
Key “ON” position
Key “ON” position
Key “ON” position
Key “ON” position
STANDARD FUSE BLOCK
OPTIONAL EQUIPMENT FUSE BLOCK
108
55-92
SECTION 55 - ELECTRICAL SYSTEM
ENGINE FUSE BLOCK REMOVAL
1. Disconnect the negative (–) battery cable.
2. Remove the fuse block retaining hardware.
NOTE: The standard fuse block, 1, is part of the main harness and cannot be completely removed.
3. The optional equipment fuse block , 2, locks into the standard fuse block. Insert a 1/4 ″ blade screwdriver at the center of the fuse block bases and twist to release the lock. Slide the optional block up past the fuses on the standard block to separate.
4. Unplug the wires from the fuse block assembly.
ENGINE FUSE BLOCK INSTALLATION
1. Insert the lock tabs, 1, into slots, 2, and slide the two blocks together to lock securely as shown.
NOTE: The optional equipment fuse block slides down over the standard block guides and is positioned toward the center of the panel.
2. Attach the wires to the proper side of the fuses as shown in the “ENGINE FUSE PANEL WIRING“ figure, Figure 113.
1 Standard fuse block
2 Optional equipment fuse block
3. Reinstall the block retaining hardware.
4. Reconnect the negative (–) battery cable.
109
110
111
55-93
SECTION 55 - ELECTRICAL SYSTEM
ALTERNATOR EXCITE RESISTOR WIRING
Ref
1
2
3
Color Destination
Y/DKBL To Alternator
LTGN/B-1 From Accessory Relay
LTGN/B-3 To Alternator
112
Op. 55 301 16
ALTERNATOR EXCITE RESISTOR
REMOVAL
1. Disconnect the negative (–) battery cable.
2. Unplug the wires from the resistor terminals.
3. Remove the resistor, 1, retaining hardware.
Testing the resistor using an ohmmeter, the resistance should read approximately 50 ohms
±
5 ohms.
ALTERNATOR EXCITE RESISTOR
INSTALLATION
1. Reinstall the resistor retaining hardware.
2. Reconnect the wires to the proper terminals.
1
113
55-94
SECTION 55 - ELECTRICAL SYSTEM
START RELAY WIRING
Ref
1
2
3
4
Color
R
R
Destination
To 20A Heater Fuse
(optional fuse block)
To Preheat Circuit
Breaker
R From Starter
Solenoid
W/R To Starter Solenoid
Battery
Voltage
All Times
All Times
All Times
5 W/DKBL From Start Interlock
Relay
6 W/DKBL From Service/Run
Switch
7
8
9
B-4
B-5
B-6
To Start Interlock
Relay
To Accessory Relay
To Preheat Relay
Key
“START” position
Key
“START” position
Key
“START” position
Ground
Circuit
Ground
Circuit
Ground
Circuit
Op. 55 100 34
START RELAY REMOVAL
1. Disconnect the negative (–) battery cable.
2. Remove the relay cover, 1, attaching hardware and cover.
3. Remove the wires from the relay terminals.
4. Remove the relay retaining hardware.
5. Remove the barrier from between the large terminals and install on new relay.
START RELAY INSTALLATION
1. Reattach the relay, 1, to the support.
2. Reconnect the wires to the proper relay terminals.
3. Reinstall the relay cover.
4. Reconnect the negative (–) battery cable.
55-95
114
115
116
SECTION 55 - ELECTRICAL SYSTEM
PREHEAT RELAY WIRING
Service/Run Switch - Service Position
Ref Color Destination
1 R/LTBL From Preheat Circuit
Breaker
2 LTBL/B To Glow Plugs
3
4
5
LTBL/Y
B-6
B-8
From Manual
Preheat Button
To Start Relay
To Engine
Bellhousing Ground
Battery
Voltage
All Times
Push Button
Push Button
Ground
Circuit
Ground
Circuit
Service/Run Switch - Run Position
Ref Color Destination
1 R/LTBL From Preheat Circuit
Breaker
2 LTBL/B To Glow Plugs
3
4
5
LTBL/Y
B-6
B-8
From Manual
Preheat Button
To Start Relay
To Engine
Bellhousing Ground
Battery
Voltage
All Times
EIC
Preheat
Cycle
EIC
Preheat
Cycle
(Voltage will be 0.5 to
1.0 volt less than battery voltage).
Ground
Circuit
Ground
Circuit
117
55-96
SECTION 55 - ELECTRICAL SYSTEM
Op. 55 100 34
PREHEAT RELAY REMOVAL
1. Disconnect the negative (–) battery cable.
2. Remove the relay cover, 1, attaching hardware and cover.
3. Remove the wires from the relay terminals.
4. Remove the relay retaining hardware.
5. Remove the barrier from between the large terminals and install on new relay.
PREHEAT RELAY INSTALLATION
1. Reattach the relay, 1, to the support.
2. Reconnect the wires to the proper relay terminals.
3. Reinstall the relay cover.
4. Reconnect the negative (–) battery cable.
118
119
55-97
SECTION 55 - ELECTRICAL SYSTEM
Op. 55 201 76
PREHEAT GLOW PLUG REMOVAL
1. Disconnect the negative (–) battery cable.
2. Disconnect the LTBL/B wire, 1, from the glow plug bus bar.
3. Remove the bus bar retaining nuts, 2, and remove the bus bar from the glow plugs.
4. Remove glow plugs from the head.
PREHEAT GLOW PLUG INSTALLATION
1. Install glow plugs into the head and, using new sealing washers, tighten to 15 - 19 N·m (11 - 14 ft. lbs.).
2. Reinstall the bus bar onto the glow plugs.
3. Reconnect the LTBL/B wire to glow plug bus bar.
4. Reconnect the negative (–) battery cable.
120
55-98
SECTION 55 - ELECTRICAL SYSTEM
FUEL SYSTEM COMPONENTS
The fuel system consists of a fuel tank located in the left side of the engine compartment at 1; fuel tank pickup tube, 2; fuel tank sending unit, 3; in-line fuel filter, 4; electric fuel pump, 5; injection pump, 6; and return fuel line, 7, from the injector bleed off to the tank. The fuel flow is controlled by an electric fuel solenoid, 8, which is controlled by the EIC (Electronic
Instrument Cluster).
FUEL GAUGE
In the center of the EIC panel is the fuel gauge, implemented as a vertical 10-segment green LED bar graph. The lowest segments will flash when the fuel level is low. An audible alarm will accompany the flashing light for about 5 seconds.
121
FUEL TANK SENDING UNIT (Fuel level)
STEP PRETEST INSTRUCTIONS
1 Loader on level with parking brake engaged, key “ON” position
TEST
EIC gauge and sender operation
2
Symptom: No bars lit
Symptom: Fuel level does not read lower on gauge (too many bars lit)
Jumper wire from one terminal to other at sender
Disconnect
PU/W wire
RESULT
NO bars light up
PROBABLE CAUSE AND
CORRECTION
Check wires from sender to
EIC board, if OK, replace
EIC board
YES (bars light up) Replace sender
Bars stay lit Check for PU/W wire shorted to ground. If OK, replace EIC board.
Bars go out Replace sender
FUEL SYSTEM ELECTRICAL DIAGRAM
PU/W
PU/O
LTBL/O
T
122
1.
Key switch
2.
EIC board
3.
Fuel level sender
55-99
4.
Electric fuel pump
5.
Injector pump
6.
Fuel shutoff solenoid
SECTION 55 - ELECTRICAL SYSTEM
TESTING FUEL GAUGE IN DIAGNOSTIC MODE
Use a jumper wire and connect sender terminals, 1, and the EIC board will light and beep. If the EIC board lights and beeps, the EIC and circuit wires to the sender are OK. If the EIC board fails to light, check the wires to the EIC board.
If the fuel gauge is not working and the wiring and the fuel sender are found to be good, the complete EIC board will require replacement.
Op. 55 410 80
REMOVAL OF FUEL LEVEL SENDER
1. Support the boom on the boom lock pins.
2. Open the rear door and remove the left engine side shield.
3. Disconnect the wires from the sender, 1.
4. Remove the sender retaining screws, 2, and remove the sender, 3, assembly from the tank.
TESTING OF THE FUEL LEVEL SENDER
Using a volt/ohmmeter, put one lead on one terminal and the second lead on the other terminal. Rotate the sender from full tank to empty tank, and the ohms reading should be between 35 ohms full and 240 ohms empty.
If the fuel gauge is not working and the wiring and the fuel sender are found to be good, the complete EIC board will require replacement.
1
123
124
125
55-100
SECTION 55 - ELECTRICAL SYSTEM
ELECTRIC FUEL PUMP
The electric fuel pump, 1, is located in the left side of the engine compartment.
ELECTRIC FUEL PUMP TESTING
STEP
PRETEST
INSTRUCTIONS
1
2
Loader on level with parking brake engaged, key “OFF” position
Key “ON” position
3
4
5
Key “ON” position
Key “ON” position
Key “ON” position
TEST
Fuel level in tank
Fuel pump operating
Fuel pump operating but not pumping fuel
Fuel pump operating and pumping fuel
Fuel pump operating and pumping fuel
RESULT
NO
YES
NO
YES
NO
YES
NO
YES
YES
126
PROBABLE CAUSE AND
CORRECTION
Add fuel and bleed system
Go to next step
Check power supply (5-amp fuse in cab panel). If OK, check ground; if OK, replace pump
Go to next step
Check line to tank, air leak, fuel level, tank pickup tube; if OK, replace pump
Go to next step
Replace pump
Replace fuel line at injector pump and bleed system; if OK, go to next step
Check fuel shutoff solenoid for operation
NOTE: Always check fuel level in tank. Always check fuel filters.
55-101
SECTION 55 - ELECTRICAL SYSTEM
Op. 10 210 21
ELECTRIC FUEL PUMP REMOVAL
1. Support the boom on the boom lock pins.
2. Open the rear door and remove the left engine side shield.
3. Remove the hose clamps, 1, from the pump and hoses.
4. Remove the pump support hardware, 2, ground wire, and unplug the power wire, 3.
5. Upon reinstallation of the pump, make sure the pump wires are placed to prevent getting damaged. Make sure the ground wire is making good contact.
Op. 10 223
FUEL SHUTOFF SOLENOID
The fuel shutoff solenoid is located at the injection pump at 1. The solenoid is controlled through the starting circuit during cranking. After the engine is started, the EIC takes control of the solenoid for normal operation.
If a fault occurs in either the engine oil pressure or the hydrostatic charge pressure circuits, the EIC will remove power from the solenoid, stopping the engine within 30 seconds.
FUEL SHUTOFF SOLENOID TESTING
STEP
1
2
3
PRETEST
INSTRUCTIONS
Loader on level with parking brake engaged, key “ON” position, service “RUN” switch in
“RUN” position
Key “ON” position, service “RUN” switch in
“SERVICE” position
Key “ON” position,
“SERVICE/RUN” switch in “RUN” position
TEST
Battery voltage to solenoid
Battery voltage to solenoid
Check EIC board operation
127
RESULT
NO
YES
NO
YES
NO
YES
128
PROBABLE CAUSE AND
CORRECTION
Check power wire from EIC to solenoid for open; if OK, go to next step
Replace solenoid
Check power wire from service/run switch to fuel solenoid; if OK, go to next step
Replace solenoid
Check power to EIC board.
Check 5-amp electronics Ign.
fuse in cab fuse panel.
Replace EIC board
55-102
SECTION 55 - ELECTRICAL SYSTEM
Op. 10 223 10
REPLACEMENT OF FUEL SHUTOFF
SOLENOID
1. Support the boom on the boom lock pins.
2. Open the rear door and remove the left engine side shield.
3. Remove the power wire from the solenoid, 1.
4. Remove the solenoid from the injection pump.
5. Solenoid pull-in amperage 1.5 to 1.8 amps.
Solenoid hold-in amperage 1.3 to 1.7 amps.
6. Reinstall the solenoid and tighten securely.
Reinstall the power wire.
129
55-103
SECTION 55 - ELECTRICAL SYSTEM
AIR FILTER RESTRICTION INDICATOR
SWITCH
Op. 55 414 14
REMOVAL
1. Support the boom on the boom lock pins.
2. Open the rear door and remove the left engine side shield to access the sender.
3. Remove the B/Y, 1, and B, 2, wires from the sender.
4. Remove the sender, 3, from the air cleaner tube.
INSTALLATION
Install the sender and reinstall the B/Y and B wires to the sender terminals.
ENGINE COOLANT TEMPERATURE
SENDER
Op. 55 414 10
REMOVAL
1. Support the boom on the boom lock pins.
2. Open the rear door and remove the right engine side shield to access the sender.
3. Remove the PU/LTGN wire, 1, from the sender terminal.
4. Drain the cooling system down below the sender level to prevent loss of coolant.
5. Remove the sender, 2, from the engine block.
INSTALLATION
1. Remove and clean the engine block thread area.
2. Apply pipe sealant to the threads of the sender.
3. Install the sender into the engine block.
4. Reinstall the PU/LTGN wire to the sender terminal.
5. Refill the cooling system with coolant previously removed or a 50/50 mixture of a permanent-type antifreeze.
6. Operate the unit to remove air from the cooling system and recheck the coolant level.
55-104
130
131
SECTION 55 - ELECTRICAL SYSTEM
ENGINE OIL PRESSURE SWITCH
Op. 55 414 12
REMOVAL
1. Support the boom on the boom lock pins.
2. Open the rear door and raise the top engine shield to access the switch.
3. Remove the Y/B wire, 1, from the switch terminal.
4. Remove the switch, 2, from the engine head.
INSTALLATION
1. Install the switch.
2. Attach the Y/B wire to the switch terminal.
HYDROSTATIC CHARGE PRESSURE
SWITCH
Op. 55 414 28
REMOVAL
1. Support the boom on the boom lock pins.
2. Open the rear door, raise the top engine shield and remove the right engine side shield to access the switch.
3. Remove the Y/GY wire, 1, and B wire, 2.
4. Remove the charge pressure switch, 3, from the return line tee.
INSTALLATION
1. Install the charge pressure switch into the tee.
2. Reinstall the Y/GY and B wires to the switch.
132
133
55-105
SECTION 55 - ELECTRICAL SYSTEM
HYDRAULIC OIL FILTER RESTRICTION
SWITCH
Op. 55 414 24
REMOVAL
1. Support the boom on the boom lock pins.
2. Open the rear door, raise the top engine shield and remove the right engine side shield to access the switch.
3. Remove the DKGN/O wire, 1.
4. Remove the restriction switch, 2, from the filter base.
INSTALLATION
1. Install the switch into the filter base.
2. Attach the DKGN/O wire to the switch terminal.
HYDRAULIC OIL TEMPERATURE SENDER
Op. 55 414 20
REMOVAL
1. Remove any attachment from the boom face plate and support the boom on the boom lock pins.
CAUTION
Never work under a raised boom unless it is properly supported by the boom lock pins.
2. Raise the operator’s seat and latch in the raised latched position.
CAUTION
Never work under a raised seat unless it is securely latched in the raised position.
3. Drain the hydraulic reservoir.
Remove the rear engine belly pan hardware, 1, and lower the pan from the loader.
CAUTION
Use a floor jack to support the belly pan and prevent serious injury.
2
134
135
55-106
SECTION 55 - ELECTRICAL SYSTEM
4. Loosen the return line clamp at 1.
5. Remove the return line at 2, and rotate the line so the oil drains into a clean suitable pan for reuse.
6. After the reservoir is drained, reconnect the return lines and tighten all fittings and connections.
7. Remove the PU/LTBL wire and B wire from the sender, 1.
8. Remove the sender from the reservoir by rotating the sender counterclockwise.
9. Remove the grounding ring and washer from the old sender.
INSTALLATION
1. Install grounding ring and washer over threads of sender.
2. Use hydraulic thread sealant on the sender threads and install the sender, 1, into the reservoir.
IMPORTANT: Do not over tighten the sender or damage to the reservoir threads may occur resulting in oil leakage.
3. Reconnect the sender wires, B wire on the ground blade, and the PU/LTBL wire to the center sender terminal.
4. Refill the hydraulic reservoir with the oil previously removed or new SAE 10W/30 API
Service SG-CE motor oil.
5. Reinstall the engine belly pan, and tighten the retaining hardware.
6. Operate the unit and check for leaks. Repair if required.
55-107
136
137
138
SECTION 55 - ELECTRICAL SYSTEM
BOOM/BUCKET CONTROL VALVE SPOOL
LOCK SOLENOIDS
Op. 35 724 90
REMOVAL
1. Remove any attachment from the loader attaching plate.
2. Raise the boom and support on the boom lock pins.
3. Stop the engine, turn the ignition key to the
“RUN” position and operate the boom and bucket controls to relieve pressure in the boom and bucket circuits. Turn “OFF” the key.
CAUTION
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment. Always remove the attachment from the loader.
4. Raise the operator’s seat and latch in the raised latched position.
CAUTION
Never work under a raised seat unless it is securely latched in the raised position.
5. Remove the step shield to access the control valve area.
6. Unplug the solenoid coil wires, 1, and remove the coils, 2, from the control valve spool by turning the coils counterclockwise.
2
1
19997742
139
55-108
SECTION 55 - ELECTRICAL SYSTEM
INSTALLATION
1. Thoroughly clean the control valve block.
2. Install the solenoid coil into block and tighten the coils to 15 N·m (11 ft. lbs.).
3. Reconnect the coil wires to the main wire harness.
4. Reinstall the step shield.
5. Lower the seat to the operate position and securely latch.
CAUTION
Do not operate the loader unless the seat/seat support is properly latched in the latched position.
55-109
SECTION 55 - ELECTRICAL SYSTEM
WIRE HARNESS
Op. 55 100 74
MAIN WIRE HARNESS REMOVAL
1. Remove any attachment from the loader attaching plate.
2. Raise the boom and support on the boom lock pins.
3. Stop the engine, turn the ignition key to the
“RUN” position and operate the boom and bucket controls to relieve pressure in the boom and bucket circuits. Turn “OFF” the key.
CAUTION
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment. Always remove the attachment from the loader.
4. Disconnect the negative (–) battery cable.
5. Unplug the seat and seat belt wire harness at connector, 1, behind the seat assembly.
6. Remove the rear window and frame assembly retaining hardware, 1.
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SECTION 55 - ELECTRICAL SYSTEM
7. Remove the right side plate, 1, and headliner, 2, if equipped. Unhook all wire connections at the service/run switch, preheat button, and fuse block(s) at this time. Removal of fuse block/switch panel, 3, may be required for easier switch access.
2
1
3
19984337
8. Remove the upper rear support retaining hardware, 1, right and left side and remove support, 2.
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143
9. Remove the EIC board retaining hardware, 1, unplug the EIC board and remove from the dash.
Remove the ignition key switch panel, 2, and remove wires from the switches. Remove the panel. Loosen the front support (dash) retaining hardware, 3, and remove the hardware from the right side.
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SECTION 55 - ELECTRICAL SYSTEM
10. Unplug the seat wire harness from the main harness.
11. Remove the seat and seat pan assembly retaining hardware, 1, unlatch the seat assembly at 2, and remove the assembly from the loader.
1
2
12. Remove the four retaining screws from the front shield, 1, and the eight retaining bolts from the step shield, 2. Remove both shields from the loader.
19984338
145
2
13. Remove the rear seat support, 1, hardware at 2, and the isolator mount hardware, 3.
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147
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SECTION 55 - ELECTRICAL SYSTEM
14. Remove the right hydrostatic control handle assembly, 1, retaining hardware. Unhook the hydrostatic control linkage and auxiliary boom hydraulic linkage (if equipped). Lift the control assembly from the loader.
1
15. Remove the right fender to access and loosen the right front isolator mount bolt, 1.
19992568
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149
16. Remove the left fender.
17. Remove all wire harness retaining clamps from the main wire harness at the rear and left side of the loader frame, 1 and 2.
(Cut wire ties along the right side of the rear window if so equipped and any ties retaining the optional harness to the main harness. Cut the wire tie at the keeper bar at the left front to rear of cab pivot).
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SECTION 55 - ELECTRICAL SYSTEM
18. Remove harness from left rear of engine area after disconnecting wires from fuel sender, 1, and fuel pump, 2. Remove tubing from the harness that is located in fuel tank groove, 3.
151
19. Thoroughly clean the connector between the main and engine harness. Make sure the connector is dry.
20. Unplug the main wire harness from the engine wire harness, 1, and remove the ground wires from the engine bellhousing ground stud, 2.
Remove wires from the engine fuse and relay panel, 3.
21. Remove the hydraulic oil temperature sender wires, 4, and remove the harness from the clamps on the face of bellhousing, 5. Remove the remaining bellhousing clamps.
22. Disconnect the control valve connectors, 1, remove the harness from the J clamp, 2, on the valve and pull the harness out through the left fender area.
19992568
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2
3
1
4
5
1
152
2
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SECTION 55 - ELECTRICAL SYSTEM
23. Now the right side panel, 1, can be pivoted into the center of the cab area at the rear and the wire harness can be removed from the corner of the side panel.
MAIN WIRE HARNESS INSTALLATION
1. Install the wire harness up the right rear corner of the side panel with the EIC board connector toward the front of the loader cab. Position the service/run and fuse block connectors at their location. Place the wire in the upper rear corner of the cab side panel at 1, to prevent the wire harness from contacting the cab panel retaining hardware. Install two wire ties or clamp at the upper right side of the rear window and one tie at the bottom to hold the harness up and maintain clearance from the cab panel hardware and headliner support.
2. Place the main wire harness to the front side of the boom lock linkage at 1, and reinstall the wire clamps. Route the harness across the loader to the left side of the loader.
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156
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SECTION 55 - ELECTRICAL SYSTEM
3. Route the wire harness to the front of the loader on the left side, 1 and 2, and install wire clamps where previously installed. Place the harness into the loop (keeper) and secure with a wire tie at 1, and then along the top of the lower frame to the rear of the loader to the engine fuse/relay panel area.
4. Route the harness branch to the inside of the frame with the hydraulic lines and down to the floor and front of the control valve. Refasten in the J clamp and route the connectors between valve bosses and plug in solenoids. Tuck the connectors between valve bosses to protect the harness.
5. Connect the main wire harness connector to the engine wire harness, 1. Reconnect the wires to the proper components in the panel.
6. Route the harness branch along the fuel tank groove, 2, install tubing over the harness and connect to the fuel sender, 3, and fuel pump.
3 1
157
2
158
7. Attach the ground wires at the engine bellhousing ground stud, 1.
NOTE: When attaching ground wires, always place the heaviest ground wire (battery ground cable) next to the ground surface (bellhousing). Then stack the remaining ground wires according to wire size; largest on bottom, smallest on top of the heaviest wire.
8. Continue harness routing to the hydraulic temperature switch and secure in the bell housing clamps, 2. Clamp harnesses to the bellhousing.
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2
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SECTION 55 - ELECTRICAL SYSTEM
9. Reattach the wires to the service/run switch, 1; fuse block(s), 2; preheat switch, 3; and any ground wires if removed at 4.
NOTE: When attaching ground wires, always place the heaviest ground wire next to the ground surface and then stack the remaining ground wires according to wire size on top of the heaviest wire.
10. Reposition the right side panel, 1, and reinstall the front dash support hardware.
11. Reinstall the right front isolator, 2, if removed.
12. Reinstall the upper rear support.
13. Reinstall the lower rear support, 3, and the isolators, 4. Tighten all cab support and side shield hardware at this time.
14. Reinstall all wire harness clamps previously removed, position the wire harness to prevent damage, and tighten the clamp hardware at this time.
15. Reinstall the seat and seat pan assembly and tighten the hardware. Reconnect the seat harness to the main harness. Check the loop for clearance when the seat is raised and lowered.
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161
162
55-117
SECTION 55 - ELECTRICAL SYSTEM
16. Route the wire harness to the front of the cab to the ignition switch and EIC board area. Attach the wires to the ignition switch and position the wire harness to prevent damage. Reinstall the switch panel, 1.
17. Attach the wire harness connectors, 2, to the proper EIC board connector and position the wire harness across the front of the dash area to prevent damage. Reinstall the EIC board.
18. Reconnect the negative (–) battery cable.
19. Check the electrical system for proper operation.
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SECTION 55 - ELECTRICAL SYSTEM
Op. 55 404
ROAD/WORK LIGHTS
The road and work lights provide illumination for road travel and work operations. The rear work lights are not recommended for road travel.
Road/work light switch, 1, is located in the ignition key switch panel in the upper right corner of the overhead dash. To remove the switch, disconnect the negative (–) ground battery cable. Remove the key switch panel hardware, 2, and tilt the panel down.
Disconnect wires from the switch, squeeze the switch retaining tabs in, and remove the switch from the panel.
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55-119
Road/Work Light Switch Wiring
SECTION 55 - ELECTRICAL SYSTEM
Road/Work Light Wiring Diagram
NOTE: When attaching ground wires, always place the heaviest ground wire next to the ground surface and then stack the remaining ground wires according to size on top of the heaviest wire.
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55-120
168
Bulb Replacement
Clear lens with bulb #86533429
Bulb only (clear) #86533428
Red lens with bulb #9829515
Bulb only (red) #C6AB13465A
SECTION 55 - ELECTRICAL SYSTEM
Op. 55 404 10
Front Road/Work Light
1. Facing the lens of the light assembly, push the lens assembly to the left and lift the right side of the assembly from the support.
2. Unplug the wire harness from the bulb, unlatching the connector at 1, and sliding the harness from the bulb.
1
169
3. Facing the back of the assembly, rotate the bulb holder, 1, counterclockwise and remove the bulb from the support.
4. Position the bulb so when it is locked in position the connector, 2, is pointed down with the clip, 3, to the right.
IMPORTANT: DO NOT touch the bulb during removal and installation. The bulb may become damaged or a premature failure may occur.
55-121
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170
2
171
SECTION 55 - ELECTRICAL SYSTEM
Op. 55 404 10
Rear Work and Taillight
1. Remove the center work light, 1, by pushing the lens assembly to the left and lift the right side of the assembly from the support.
2. Remove the red taillight lamps, 2, by unscrewing the bezel self-tapping screws, and removing the bezels, 3.
3. Unplug the wire harness from the bulb, unlatching the connector, and sliding the harness from the bulb.
3
4. Facing the back of the assembly, rotate the bulb holder, 1, counterclockwise and remove the bulb from the support. Replace the bulb.
5. For the clear rear work lamp, position the bulb so when it is locked in position the connector, 2, is pointed down with the clip, 3, to the right.
IMPORTANT: DO NOT touch the bulb during removal and installation. The bulb may become damaged or a premature failure may occur.
2
3
3
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SECTION 55 - ELECTRICAL SYSTEM
Indicator lamp
Op. 55 301
ALTERNATOR (40-AMP VERSION)
CHARGING CIRCUIT
Description
1. The charging circuit and internal connection are shown here. The charging system consists of an
IC regulator built-in alternator, a battery, and connecting wires. Because of the use of IC, the voltage regulator is very compact and is built into the alternator.
2. The field current flows directly from the diode trio to the field coil without passing through the external circuit. Consequently, there are no voltage drops caused by the key switch or the wiring, as with the conventional vibrating-contact regulators mounted separately from the alternator. To help the initial voltage buildup when the engine is started, the field current is supplied through the indicator lamp from the battery.
3. Since the frequency pulse output of 1/10 the alternator speed develops at “P” terminal, this terminal is used for speed detection by the EIC board for engine RPM readings.
174
Principle of Integrated Circuit Regulator
The basic circuit of the IC regulator is shown here.
The part enclosed by a dotted line represents the IC regulator.
The basic function of the IC regulator to make terminal voltage constant by detecting generated voltage and increasing/decreasing field current is not different from that of the vibration- contact regulator.
As indicated, the regulator consists of two basic sections: a voltage control device and an output device to handle the field current. The voltage control device includes a voltage divider network (R1, R2), a Zener diode (DZ) for voltage reference, and a signal amplifying transistor (Tr1). The output device is a Darlington-type amplifier which is called power transistor (Tr2). The transistor Tr2 is placed in series with the alternator field coil and ground.
The transistor Tr1 senses the generated voltage and turns the transistor Tr2 on and off many times per second most of the time the engine is in operation.
55-123
Field Coil
SECTION 55 - ELECTRICAL SYSTEM
The basic operating principles are explained as follows:
1. When the key switch is closed, current from the battery flows through the indicator lamp and resistor R6, which are in parallel, to the field coil.
From here it continues to flow on through the field coil to ground, completing the circuit back to the battery.
Battery
Alternator terminal L
Key Switch
Indicator lamp
Terminal R-
Resistor R6
Tr2 Ground
3. When the generated voltage is low, no current flows in the Zener diode (DZ) since the voltage at point A is lower than the Zener voltage.
4. As the speed and voltage increases, the voltage at point A also increases until it reaches the limiting value set by the factory. As the Zener diode (DZ) breaks down, current flows through
R1, DZ, and the base-emitter circuit of Tr1 to ground. This renders Tr1 conductive, so that much of the current flows through the collector-emitter circuit of Tr1. This reduces the base current of Tr2 thereby reducing the field current. This means that Tr1 turns on and Tr2 turns off.
Regulator
Terminal L
Regulator
Terminal R
R1
R6
DZ
R5
Tr1 Ground
2. When the alternator begins to rotate, A.C.
voltages are generated in the stator coil. The diodes in the rectifier assembly change the stator
A.C. voltages to a D.C. voltage which appears between the ground and terminal, B.
The stator also supplies D.C. field current through the diode trio, the field coil, Tr2, and then through the diodes in the rectifier assembly, back to the stator.
Diode trio Field Coil Tr2 Ground
5. When the generated voltage decreases, the
Zener diode (DZ) again turns off and Tr1 also turns off.
This cycle then repeats many times per second and the alternator output voltage is, therefore, regulated within a narrow limit.
In other words, the action is similar to the conventional vibrating-contact regulator, in that current to the field coil is varied to limit the output voltage, but in place of the voltage coil and spring system, there is a potential divider (R1 and R2) and a Zener diode.
55-124
SECTION 55 - ELECTRICAL SYSTEM
ALTERNATOR SERVICE SPECIFICATIONS
Item How Rated
(V - A) Normal Output
Polarity
Weight
Rotational direction (viewed from the pulley)
Load characteristics (cold)
(kg, lbs)
Brush length
Brush spring tension
Slip ring diameter
Field coil resistance
Adjusting voltage
Terminal voltage (V)
Current (A)
Revolution (RPM)
Original (mm-in)
Limit (mm-in)
Original (g-lbs)
Limit (g-lbs)
Original (mm-in)
Limit (mm-in) ohms at 20 ° C (68 ° F)
(V) at 5000 RPM
Standard Or Service Limit
12 V - 40 A
Negative ground
3.7 kg (8.2 lbs)
Clockwise
13.5 V
Min. 30 A
2500 RPM
18.5 mm (0.728
″ )
5.0 mm (0.20
″
)
470 - 590 g (1.036 - 1.300 lbs)
270 g (0.60 lbs)
22.7 mm (0.0894
″ )
22.1 mm (0.871
″
)
2.8
Ω
14.4 - 15.0 V
55-125
SECTION 55 - ELECTRICAL SYSTEM
ALTERNATOR - SYSTEM TESTING AND TROUBLESHOOTING
NO CHARGING
FAULT LOCATION
Wiring
Alternator
Regulator
POSSIBLE CAUSE
Loose connection, short circuit
Loose connection, no ground, short circuit
Repair
CORRECTION
Repair or replace
Defective rectifier Replace
Loose connection of RF resistor Replace
Defective regulator
Loose connection of alternator or regulator
Replace
Repair or replace
INSUFFICIENT CHARGING
FAULT LOCATION
Wiring
Alternator
Regulator
Battery
POSSIBLE CAUSE
Loose connection or short circuit Repair
Loose drive belt Repair
Short in rotor coil
Short in stator coil
Defective rectifier
Insufficient brush contact
Defective regulator
Loose connection of alternator and regulator
Defective battery
Replace
Replace
Replace
CORRECTION
Repair or replace
Replace
Repair
Replace
OVERCHARGE
FAULT LOCATION
Battery
Regulator
POSSIBLE CAUSE
Internal short
Defective regulator
Replace
Replace
CORRECTION
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SECTION 55 - ELECTRICAL SYSTEM
UNSTABLE CHARGING CIRCUIT
FAULT LOCATION
Wiring
Alternator
Regulator
POSSIBLE CAUSE
Loose connection or open wire
Loose drive belt
Short in rotor coil
Short in stator coil
Insufficient brush contact
Broken brush or spring
Loose connections
Defective regulator
Loose connection at alternator and regulator
CORRECTION
Repair or replace
Repair
Replace
Replace
Repair or replace
Replace
Repair
Replace
Repair or replace
ABNORMAL NOISE OF ALTERNATOR
FAULT LOCATION
Alternator
POSSIBLE CAUSE
Loose mounting hardware
Defective bearings
Rotor core and stator in contact
Defective diode
Short in stator coil
CORRECTION
Repair
Repair or replace
Replace
Replace
Replace
55-127
SECTION 55 - ELECTRICAL SYSTEM
Alternator Construction
Sectional view of the IC alternator
The principal components of the IC alternator are the stator, the rotor, the rectifier assembly, the IC voltage regulator, the front bracket, the rear bracket, and the pulley.
The rectifier assembly consists of two heat sinks, one positive and one negative, and diode trio. The diode trio is used as a field supply diode and is connected to the field coil and terminal L on the alternator.
The built-in IC regulator is a solid-state unit so that it can only be serviced as an assembly.
1. IC voltage regulator
2. Rotor
3. Pulley
4. Rectifier
5. Rear support bracket
6. Stator
7. Front support bracket
Check on the Equipment
Checking the regulator adjusting voltage.
A. In the case of equipment without an ammeter, connect a test ammeter (50A capacity) at the position shown.
In the case of equipment with an ammeter, make use of the ammeter on the equipment.
B. Connect a voltmeter between terminal 1 of the alternator and the ground.
1. In this state, confirm the reading on the voltmeter indicates the battery voltage.
2. If the voltmeter reading is zero, the wiring between terminal 1 and the battery is faulty.
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55-128
SECTION 55 - ELECTRICAL SYSTEM
3. With the test ammeter terminals short-circuited, start the engine.
CAUTION
In the case of where the test ammeter is connected at the position shown in Figure 181, make sure no starting current is applied to the ammeter when the engine is started.
4. Remove the short circuit across the test ammeter terminals and increase the engine speed immediately to approximately 2000 RPM. Take the ammeter reading.
5. If the ammeter reading is 5A or less, take the voltmeter reading without changing the engine speed (approximately 2000 RPM). The reading is the adjusting voltage.
6. If the ammeter reading is more than 5A, continue to charge the battery until the reading falls to less than 5A or replace the battery with a fully charged one.
An alternative method is to limit the charging current by connecting a 1/4 (25W) resistor in series with the battery.
Checking Output
If the previous section “A” check is satisfactory, check the output as follows:
1. After opening the battery switch, disconnect terminal B of the alternator and connect an ammeter (50-amp capacity) at the position shown.
2. Connect the voltmeter between terminal B of the alternator and the ground. Confirm the voltmeter indicates the battery voltage.
3. Close the key switch.
4. Start the engine and turn on all the lamps.
Immediately accelerate the engine to 2000 RPM or more and measure the maximum value indicated on the ammeter.
5. If this value is more than 70% of the nominal output (refer to the section on “Service
Specifications”), the alternator can be considered as working almost satisfactorily.
NOTE: To make the above judgement more accurate, remove the alternator from the engine and check it on a test bench.
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SECTION 55 - ELECTRICAL SYSTEM
ALTERNATOR
Op. 55 301 10
ALTERNATOR REMOVAL
1. Open the rear door, 1, raise the top engine shield,
2, and remove the right engine side shield, 3, to access the alternator.
2. For easier access, remove any attachment from the loader boom face plate and raise the boom and rest it on the boom lock pins.
CAUTION
Never work under a raised boom unless it is properly supported by the boom lock pins.
Never work under a raised boom with an attachment. Always remove the attachment from the loader.
2512-08
1
2
1
3. Disconnect the negative (–) battery cable to prevent possible damage to the alternator and electrical system.
4. Disconnect the wire connections from the alternator noting their location.
5. Remove the top strap retaining hardware, 1, and lower pivot, 2.
3
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SECTION 55 - ELECTRICAL SYSTEM
Op. 55 301 12
DISASSEMBLY
1. Mark both brackets and the stator with a scribe mark for assembly.
2. Remove the four through bolts. Pry between the stator and front bracket with the blade of a screwdriver. Carefully separate the front bracket, pulley, and rotor assembly away from the stator and rear bracket assembly.
3. Place the rotor in a vise with soft jaws and remove the pulley nut, washer, pulley, spacer, and rear bracket from the rotor.
Nut
Pulley
180
181
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SECTION 55 - ELECTRICAL SYSTEM
Unsolder three stator leads, 1, and remove the stator.
Stator
Lead wire
1
4. Remove the voltage regulator assembly, 1, and rectifier assembly, 2.
2
182
1
183
55-132
SECTION 55 - ELECTRICAL SYSTEM
Op. 55 301 14
ALTERNATOR COMPONENT TEST
Rotor
1. Inspection of slip ring surface, 1.
Correct stain or scratches on the slip ring surface with a sandpaper of about 400# - 600#.
A badly roughened slip ring or slip ring worn down beyond the service limit should be replaced.
2. Check for continuity between both the slip rings.
If there is no continuity, the field coil is defective.
Replace the rotor assembly.
184
185
3. Check for continuity between the slip ring and shaft (or core). If there is continuity, it means the coil or slip ring is grounded. Replace the rotor assembly.
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SECTION 55 - ELECTRICAL SYSTEM
Stator
1. Check for continuity between the leads of the stator coil. If there is no continuity, the stator coil is defective. Replace the stator assembly.
2. Check for continuity between any stator lead and stator core. If there is continuity, it means the coil is grounded. Replace the stator assembly.
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55-134
SECTION 55 - ELECTRICAL SYSTEM
Rectifier Assembly
Positive Heat Sink
Check for continuity between the positive (+) heat sink and stator coil lead connection terminal with a circuit tester. If there is continuity in both directions, the diode is short-circuited. Replace the rectifier assembly.
Negative Heat Sink
Check for continuity between the negative (–) heat sink and stator coil lead connection terminal. If there is continuity in both directions, the diode is short-circuited. Replace the rectifier assembly.
Diode Trio
Using a circuit tester, check the three small diodes for continuity in both directions. If there is either continuity or an open circuit in both directions, the diode is defective. Replace the rectifier assembly.
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SECTION 55 - ELECTRICAL SYSTEM
Brush and Brush Spring
Check the length of the brush. A brush worn down to the wear limit line should be replaced.
Check the brush spring pressure and make sure the brush moves smoothly in the brush holder.
Reassembly
Reverse the disassembly, except for the following:
Installing Rotor
1. Push brushes, 1, into the brush holder and insert a wire, 2, to hold them in the raised position.
Install the rotor and remove the wire.
NOTE: The rear bearing and rear bracket, 3, fit is tight; heat the bearing box in the rear bracket to 50
- 60 C (122 - 140 F) before installing the rotor.
2. Lubrication to the bearing box. Do not apply grease to a bearing with a resin band. Remove grease and oil from the bearing box in the rear bracket.
2
3
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SECTION 55 - ELECTRICAL SYSTEM
Bench Check
To check the alternator on a test bench, proceed as follows:
1. Make the connection as shown, except leave the load resistor disconnected.
2. Slowly increase the alternator speed and observe the voltage.
3. If the voltage is uncontrolled with speed, and increases above 15.5 V, check the alternator.
4. If voltage is below 15.5 V, connect the load resistor as shown.
5. Operate the alternator at 2500 RPM and adjust the load resistor as required to obtain maximum output.
6. Measure the output current. The output must be within the limits shown in the section on “Service
Specifications.” If the output is less than the specified value, disassemble and check the alternator.
SM463-183
IMPORTANT:
1. Reversed battery connections will damage the alternator and/or wiring.
2. When connecting a booster battery, make certain to connect the negative battery terminals together and the positive battery terminals together.
3. When a fast charger is used to charge the battery, disconnect the equipment battery cables.
4. Grounding of the alternator output terminal will damage the alternator and/or circuit.
5. Do not connect a load of over 1A to the terminal
L.
6. If the alternator is operated with terminal L and B short-circuited, it may damage the diode trio.
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SECTION 55 - ELECTRICAL SYSTEM
ALTERNATOR REINSTALLATION
1. Attach the alternator to the lower pivot, 1, and the upper support strap, 2.
2. Reattach the wires to the alternator terminals.
3. Pivot the alternator to tighten the belt to obtain proper belt tension. The belt is tightened properly when a force of 1 kg (2 lbs.) is applied perpendicular to the belt at the center of the span,
3, with a 3 mm (1/8”) deflection.
4. Reconnect the negative (–) battery cable, 4.
5. Reinstall the engine side shield, close the top engine cover and rear door.
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SECTION 55 - ELECTRICAL SYSTEM
Op. 55 201
STARTER
STARTER MOTOR TROUBLESHOOTING
Starter Motor Specifications
Rated voltage
Output
Motor type
Engaging system
Rotation
Weight
12 volts
2 kw
Four-pole series wound motor
Magnetic shift
Clockwise (viewed from pinion side)
Approximate 5 kg (11 lbs)
Starter Motor Service Specifications
ITEM
No load test Volts (V)
Current (A)
HOW RATED
Commutator
Brush
Rotating speed (RPM)
Outer dia. (mm-in)
Service limit (mm-in)
Length (mm-in)
Brush spring
Service limit (mm-in)
Tension (kg-lbs)
Service limit (kg-lbs)
STANDARD OR SERVICE LIMIT
11.5 V
130 A Max.
4000 RPM Min.
35 mm (1.38
″ )
34 mm (1.34
″
)
15 mm (0.59
″ )
9 mm (0.35
″
)
2.7 - 3.6 kg (5.9 - 7.8 lbs)
2.2 kg (4.7 lbs)
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SECTION 55 - ELECTRICAL SYSTEM
STARTER MOTOR TROUBLESHOOTING
Use the diagnostic charts as a guide when repairing the starting system. Before diagnosis, be certain the battery is fully charged and inspect the starter and battery cables for clean and tight connections.
IMPORTANT: Do not operate the starter longer than
30 seconds at a time.
Do not disconnect or short any lead wire while the starter is operating.
With key switch in “start” position:
Starter does not crank engine, solenoid switch clicks.
1. Disconnect the three cables from the solenoid.
2. Using an ohmmeter, touch one probe to the solenoid spade terminal and the other to the starter case. There should be continuity.
If none, the hold-in winding is open-circuited.
Replace the solenoid.
If continuity, the fault is in the starter motor. Refer to repair procedures.
Starter does not crank engine, solenoid does not click.
1. Disconnect battery cable from starter.
2. Connect a jumper wire to the battery positive post. Ensure the negative cable is attached to battery and starter ground.
3. Briefly touch the jumper wire to the spade terminal on the solenoid.
If the solenoid clicks, the probable cause is in the key switch, relay or wiring.
If the solenoid does not click, replace it.
Starter cranks engine very slowly.
1. Check battery condition, should be a minimum of
12.5 volts.
2. Check starting system circuit.
Voltage drop between battery positive post and starter terminal should not exceed 0.2 volts.
Voltage drop between battery negative post and starter ground should not exceed 0.2 volts.
If voltage drop exceeds 0.2 volts, clean connections or replace the cable.
3. If battery is charged and voltage is within specification, repair or replace starter.
Engine starts but pinion does not disengage.
1. Check voltage at spade terminal of solenoid. If 12 volts with key switch “off”, fault is in the key switch or start circuit.
2. If 0 volts with key switch “off” but starter turns, fault is in the solenoid or overrunning clutch assembly.
55-140
SECTION 55 - ELECTRICAL SYSTEM
STARTER MOTOR
Op. 55 201 50
REMOVAL
1. The starter can be accessed through the right engine side shield with the boom up or down or from the operator’s area with the seat raised.
2. To access the starter, 1, through the right engine side shield, open the rear door, raise the top engine side shield and remove the right engine side shield.
If the boom is in the raised position, make sure the boom is resting on the boom lock pins.
CAUTION
Never work under a raised boom unless it is properly supported by the boom lock pins.
3. To access the starter, 1, from the front, raise the seat and seat pan and securely latch in the raised position.
CAUTION
Never work under a raised seat unless it is properly latched in the raised position.
4. Disconnect the negative (–) battery cable.
5. Remove the wires from the starter solenoid and starter, noting their location.
6. Remove the starter retaining hardware and remove the starter from the engine bellhousing.
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SECTION 55 - ELECTRICAL SYSTEM
Starter Motor Description
1. Drive Gear
2. Housing
3. Field Coil
4. Armature
5. Brush Spring
6. Brush
7. Plunger
8. Electric Solenoid
9. Overrunning Clutch
10. Pinion
11. Idler Gear
The starter assembly is a positive pinion shift, reduction type starter consisting of the motor, reduction gearset, overrunning clutch and electric solenoid.
The reduction type design allows use of a small, high speed, compact motor.
The sliding pinion and the electric solenoid are arranged on the same axis. The sliding pinion mechanism is totally enclosed, preventing dirt and water entry resulting in a more durable mechanism.
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SECTION 55 - ELECTRICAL SYSTEM
Starter Construction
The reduction type starter consists of the armature, housing, electric solenoid, drive pinion assembly and reduction gears. In a conventional type starter the armature and pinion rotate at the same speed on a common shaft. In a reduction type starter the pinion speed is reduced to about one-fourth armature speed by the reduction gear. Armature, 1, rotation is transmitted to the pinion, 2, via an idler gear, 3, and the overrunning clutch, 4.
The overrunning clutch assembly consists of the pinion, 1, pinion shaft, 2, ball bearings and overrunning clutch which is a conventional design with clutch rollers, 3, and roller springs, 4. Due to the screw splines cut on the pinion shaft, the pinion gear advances while rotating to mesh with the flywheel ring gear.
2
4
SM463-189
3
1
199
200
55-143
SECTION 55 - ELECTRICAL SYSTEM
Starter Operation
Circuit diagram of reduction type starter.
1. Drive Pinion
2. Idler Gear
3. Field Coil
4. Armature
5. Brush
6. Commutator
7. Ball Bearing
8. Plunger
9. Main Contacts
10. Battery
11. Starter Switch
12. Clutch Gear
13. Overrunning Clutch
14. Flywheel Ring Gear
The field windings are connected in series with the armature windings, through the brushes and commutator segments.
SM463-190
201
55-144
SECTION 55 - ELECTRICAL SYSTEM
Electric Solenoid Operation
The electric solenoid consists of the pull-in coil, 1, hold-in coil, 2, main contacts, 3, plunger, 4 and return spring, 5. The mechanism is sealed against entry of dirt and moisture.
When the starting switch is closed, battery current flows through both the pull-in coil and the hold-in coil.
This moves the plunger to the engaged position.
When the plunger closes the main contacts in the engaged position, the pull-in coil circuit is opened, leaving the hold-in coil to retain the plunger in the engaged position. At the same time, current flows through the main contacts to the motor.
When the starting switch is released, the magnetic field in the hold-in circuit is reduced allowing the plunger spring to move the plunger out, opening the main contacts.
Drive Spring Operation
The drive spring, 1, is fitted on the pinion shaft, 2, in order to provide a smooth and positive pinion gear engagement. When the starting switch is closed, the plunger, 3, is pulled in moving the pinion, 4, toward the ring gear, 5. If the gear teeth do not mesh, the spring will be compressed, pressing on the pinion gear. With the first rotation of the pinion, the teeth will line up and the gears will mesh.
SM463-191
1
2
1
5
2
3
4
4
SM463-192
5
4
202
203
55-145
SECTION 55 - ELECTRICAL SYSTEM
STARTER DISASSEMBLY
1. Disconnect the lead wire from the electric solenoid.
2. Scribe a line between the drive housing and motor to aid in proper reassembly. Remove the bolts securing the motor to the drive housing. The motor is now free to be separated from the drive housing.
NOTE: New starter assembly #SBA185086530 has a different housing with two drawbolts. The testing and overhaul procedures are identical to the prior model (#SBA185086520).
SM463-193
SM463-194
204
205
SM463-195
206
55-146
SECTION 55 - ELECTRICAL SYSTEM
3. Extract the insulated brushes, 1, from the brush holders. Hold the springs away and remove the brushes. Slide the brush plate, 2, from the commutator, 3.
2
1
3
SM463-196
4. Remove the armature, 1, from the motor housing, 2. The rear bearing, 3, is a light press fit in the rear housing. It may be necessary to pull the armature from the housing, griping behind the front bearing, 4.
4
1
3
207
2
208
5. Remove the screws securing the drive end frame to the solenoid.
SM463-197
1
SM463-198
209
55-147
SECTION 55 - ELECTRICAL SYSTEM
6. Remove the drive end frame, 1, from the solenoid, 2. The idler gear with bearings, 3, and the pinion gear, 4, will be free to fall out. Work over a clean bench, using care to avoid losing these pieces.
2
SM463-199
7. Remove the overrunning clutch from the drive end frame.
4
3
1
210
8. Remove the steel ball from the center of the overrunning clutch.
SM463-200
SM463-201
211
212
55-148
SECTION 55 - ELECTRICAL SYSTEM
9. Remove the idler gear and small pinion from the drive end frame if they were not dislodged when the housing was separated.
10. Remove the idler gear bearing rollers and retainer.
SM463-202
11. Remove the return spring from the electric solenoid.
SM463-203
SM463-204
213
214
215
55-149
SECTION 55 - ELECTRICAL SYSTEM
INSPECTION AND REPAIR
Inspect the following components, using conventional test methods, and repair or replace as necessary.
Armature
Inspect the armature for internal short circuits with a growler.
Replace the armature if a short circuit is indicated.
SM463-205
Inspect the armature for a short to ground using a continuity tester.
Replace the armature if there is any continuity between the commutator, 1, and armature shaft, 2, or core, 3.
1
3
SM463-206
2
Check the armature for runout with a dial indicator and V-blocks. If the commutator is rough, or more than 0.05 mm (0.002
″
) out of round, turn it down or replace it. Undercut the separators between the segments if the depth is less than 0.2 mm (0.01
″ ).
The distance, 1, from the commutator segment and insulation should be between 0.5 mm and 0.8 mm
(0.02
″ and 0.03
″ ).
SM463-207
216
217
0.5 to
0.8mm
218
55-150
SECTION 55 - ELECTRICAL SYSTEM
Check the spline teeth for wear or damage, and replace the armature as necessary.
Check the bearings for signs of roughness or dryness. Lubricate or replace as necessary.
Field Coil
Inspect the field coil for an open circuit with a continuity tester. Replace the motor housing if there is no continuity between the two brushes.
SM463-208
Inspect the field coils for short to ground with a continuity tester. If any continuity is noted between the brush and motor housing, locate the fault in the insulation, and repair or replace the motor housing as appropriate.
Check field poles and coils for tightness. Replace the motor housing if loose or improperly seated coils are detected.
219
220
221
55-151
SECTION 55 - ELECTRICAL SYSTEM
Brushes
Clean brushes and adjacent parts, removing carbon particles by wiping with a clean cloth.
Check each brush for wear. Replace brushes if they are worn to the service limit.
The positive brushes are welded to the field windings. If the positive brushes must be replaced, it will be necessary to replace the motor housing.
The negative brushes are welded to the brush plate.
If the negative brushes must be replaced, it will be necessary to replace the brush holder assembly.
Standard Length
15 mm
(0.59
″ )
Service Limit
9 mm
(0.35
″ )
Move each brush in the holder to be sure that it is capable of sliding smoothly.
Check brush spring tension. Replace the brush holder assembly if the tension is not within specified limits.
Standard Tension
2.7 - 3.6 kg
(5.9 - 7.8 lbs)
Service Limit
2.2 kg
(4.7 lbs)
5.9 lbs.
7.8 lbs.
222
223
Check the brush holder assembly for short to ground.
Touch one probe of a continuity tester to the plate and the other to each of the insulated holders. Replace the brush holder assembly if any continuity is noted.
224
55-152
SECTION 55 - ELECTRICAL SYSTEM
Overrunning Clutch
While holding the clutch housing, rotate the pinion.
The pinion should rotate smoothly in one direction
(not necessarily easily), but should not rotate in the opposite direction. If the clutch does not function properly, replace it.
Reduction Gears
Inspect the pinion gear, 1, the idler gear, 2, and the overrunning clutch gear for wear or damage.
Inspect the idler gear bearing rollers and retainer, 3.
Replace any parts found worn or damaged.
SM463-214
SM463-215
3
2
1
225
226
55-153
SECTION 55 - ELECTRICAL SYSTEM
Electric Solenoid
The following tests should be performed with the motor removed from the starter assembly.
Each test should not last more than 3 - 5 seconds to avoid overheating the solenoid.
Tests should be performed with a fully charged
12 volt battery.
Pull-in Test
Connect a lead from the positive battery post to the spade terminal, 1, (starter switch wire) on the solenoid. Connect a lead from the battery negative post to the solenoid housing, 2.
Touch a second negative lead to the heavy solenoid terminal leading to the field coil, 3. This completes the circuit through both the pull-in and hold-in coil windings. The pinion should jump forward.
Remove the negative lead from the field coil terminal,
3. The pinion should stay extended, held by the hold-in coil.
Remove the positive lead from the spade terminal.
The pinion should retract immediately.
If the solenoid fails to perform as described, replace it.
SM463-216
3
1
3
1
2
2
227
SM463-217
228
55-154
SECTION 55 - ELECTRICAL SYSTEM
REASSEMBLY
Reassemble the starter in the reverse order of disassembly. Observe the following cautions and procedures.
1. Lubricate the following components with a light coating of White Lithium Grease (Part Number
RL 666).
Idler gear retainer and rollers.
Overrunning clutch.
Steel ball and return spring.
Armature bearings.
Reduction gears.
2. Install the return spring into the electric solenoid and the steel ball into the center of the overrunning clutch. The ball should be held in place by the coating of grease.
SM463-218
3. Install the idler gear bearing rollers and retainer.
SM463-219
SM463-220
229
230
231
55-155
SECTION 55 - ELECTRICAL SYSTEM
4. Install the overrunning clutch assembly part way into the housing. Mesh the idler gear with the driven gear, then fully install both pieces together.
5. Position the pinion gear, 1,over the armature hole shaft then install the drive end frame, 2. Install the retaining screws and torque to 7 - 12 N·m (5 - 9 ft. lbs.).
SM463-221
1
2
232
SM463-222
6. Install the armature into the motor housing.
Gently tap the armature into place with a soft hammer to seat the rear bearing.
4
SM463-223
1
3
233
2
234
55-156
SECTION 55 - ELECTRICAL SYSTEM
7. Install the brush plate onto the motor housing.
Install the insulated brushes into the holder.
Ensure the insulated brush leads are not grounded. Avoid getting oil or grease on the brushes or commutator.
8. Install the motor into the drive housing observing the scribe marks. Install the retaining bolts and torque to 7 - 12 N·m (5 - 9 ft. lbs.).
SM463-224
9. Reconnect the lead wire from the electric solenoid.
SM463-225
SM463-226
235
236
237
55-157
SECTION 55 - ELECTRICAL SYSTEM
Performance Test
After reassembly, a no-load test should be conducted.
Clamp the starter securely in a vise. Connect a heavy wire (jumper cable) from a 12 volt battery positive terminal, through a suitable ammeter, to the battery cable post of the starter, 1. Connect a second cable from the battery negative post to the starter case or vise. Connect a jumper wire from the positive cable to the spade terminal on the solenoid, 2.
The pinion gear should jump forward and the starter turn smoothly. Current draw should not exceed 130 amps.
SM463-227
1
Maximum Circuit Resistance
Resistance Of Battery Cables 1, 2, & 3 Not To
Exceed 0.0018 Ohm
Circuit
Cable
No
4
7, 11
4
5
6
Circuit
Current
35 Amp
Resistance
0.0143 OHM
15.75 Amp 0.04 OHM
27 Amp 0.0185 OHM
36 Amp 0.0139 OHM
Maximum
Circuit Volt
Drop
0.5 Volt
Rewards
See Glow Plugs Circuit
0.63 Volt
0.5 Volt
0.5 Volt
See Glow Plugs Circuit
See Glow Plugs Circuit
3 cyl Engines
4 cyl Engines
2
238
55-158
**
SECTION 55 - ELECTRICAL SYSTEM
*
* Maximum current draw for oil pressure switch is
0.42 amps (5-watt max. bulb).
** Diode capacity: Current 3 amp. Reverse voltage
600 volt.
STARTER REINSTALLATION
1. Attach the starter to the bellhousing and tighten the hardware, 1. When installing the starter into the bellhousing, make sure it is properly seated before installing and tightening the hardware.
2. Reconnect the wires to the proper terminals, 2, on the starter solenoid and starter.
3. Reconnect the negative (–) battery cable.
4. Reinstall and close any shields removed.
239
240
55-159
SECTION 55 - ELECTRICAL SYSTEM
LABOR GUIDE
The following labor amounts are listed as a guide only. Working conditions and experience will vary the time it actually takes to complete each job.
Job Description Hours
Air filter sensor, remove and replace
Alternator, remove and replace
Battery, remove and replace
Electronic instrument cluster
Engine coolant sensor, remove and replace
Engine oil pressure sender, remove and replace
Fuel level sender, remove and replace
Fuel pump, remove and replace
Fuel shutoff solenoid, remove and replace
Hydraulic oil temperature sensor, remove and replace
Hydraulic oil filter sensor, remove and replace
Hydrostatic charge pressure sensor, remove and replace
Ignition (key) switch, remove and replace
Light (road/work) switch, remove and replace
Preheat manual switch, remove and replace
Preheat circuit breaker, remove and replace
Preheat relay, remove and replace
Resistor, alternator charge circuit, remove and replace
Road/work/taillight bulb, remove and replace
Seat belt (buckle) switch, remove and replace
Seat switch(es), remove and replace
Service/run switch, remove and replace
Solenoid, control valve spool locks, remove and replace
Start interlock relay, remove and replace
Starter, remove and replace
Starter relay, remove and replace
Wire harness (main), remove and replace
Wire harness (engine), remove and replace
Wire harness (seat/seat belt), remove and replace
0.25 hr.
0.25 hr.
0.5 hr.
0.5 hr.
0.5 hr.
0.5 hr.
0.25 hr.
0.25 hr.
0.5 hr.
0.5 hr.
0.5 hr.
0.5 hr.
0.75 hr.
0.5 hr.
6.0 hrs.
1.5 hrs.
1.0 hr.
0.5 hr.
0.5 hr.
0.25 hr.
0.25 hr.
0.25 hr.
0.25 hr.
0.5 hr.
0.5 hr.
0.25 hr.
2.0 hrs.
0.5 hr.
0.5 hr.
55-160
SECTION 82 – FRONT LOADER (BOOM AND MOUNTING PLATE)
Chapter 1 – Buckets
Section
CONTENTS
Description Page
82-1
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
Op. 82 100
GENERAL INFORMATION
BUCKETS
Bucket Types
1. LP - Low profile
The low-profile bucket has a shorter back and is longer from bucket heel to cutting edge for optimum cutting edge visibility. This is important for finish grading and accurate cut and fill jobs.
2. D & F - Dirt and foundry
The dirt and foundry bucket is shorter from bucket heel to cutting edge to provide maximum breakout force for tough digging conditions.
3. M & F - Manure and fertilizer (slurry)
The manure and slurry bucket is for handling loose or fluid materials with more rollback to minimize spillage.
4. LM - Light material
The light-material bucket is for light, high- volume materials for more productivity handling light material.
Select bucket styles and sizes to provide both adequate breakout force and reasonable carrying ca-
1 pacity. Handle dense materials with a relatively small bucket. Handle lighter materials with higher capacity buckets. Refer to the following bucket capacity chart and the material weight chart in the operator’s manual when choosing the bucket for a job.
Bucket Capacity Cubic Feet
Bucket Bucket
Width
66 ″ Utility fork
60 ″ Low profile
60 ″ Dirt and foundry
66 ″ Low profile
66 ″ Dirt and foundry
72 ″ Low profile
72 ″ Dirt and foundry
72 ″ Manure and fertilizer
72 ″ Light material
84 ″ Light material
(cu ft)
N/A
11.5
11.5
13.2
15.2
14.5
16.7
15.5
23.7
27.9
(cu ft)
N/A
8.9
8.7
9.7
11.6
10.6
12.7
15.5
19.0
22.3
82-2
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
Op. 82 100 77
BOOM LOCK PINS AND LINKAGE
The operator can engage the boom lock pins from the operator’s seat. The control is located to the right rear of the operator’s seat at 1. Pivoting the handle towards the outside of the cab extends and engages the lock pins. Pivoting the handle in will retract the lock pins.
To engage the boom lock pins:
1. Raise the boom above the boom lock pins and engage the pins.
2. Turn the ignition key to the “OFF” position to stop the engine.
3. Turn the ignition key to the “ON” position and operate the boom and bucket hydraulic controls to lower the boom until it rests on the lock pins, 1, and relieves pressure in the boom and bucket hydraulic circuits.
4. Turn the ignition key to the “OFF” position.
CAUTION
Never work under a raised boom unless the boom is resting on the boom lock pins, 1.
Never work under a raised boom with an attachment, always remove any attachment from the loader boom mounting plate.
BOOM
The boom assembly consists of:
Op. 82 100 50
1 Main boom frame
Op. 82 100 52
2 Lower link, right and left
Op. 82 100 53
3 Upper link, right and left
The boom and links are supported on the ROPS main frame with tapered pivot pins at all pivot locations.
2
3
4
82-3
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
Op. 82 100 70
ATTACHMENT MOUNTING PLATE
The attaching plate is attached to the main boom frame with two tapered pivot pins. The attachments used on the skid steer can be easily attached or removed from the loader with the over center levers and pins. The control levers and pins are spring loaded to hold the levers over center when unlatched to assist in changing attachments. When the control levers are in the latched position the spring-loaded pins are forced into the latch points on the attachment. The control levers and pins are shown in the latched position.
BOOM AND CYLINDER PIVOT PINS
When the boom, upper and lower boom links and cylinders are removed, the following figures and charts may be use for proper pin placement. The following charts and figures list the pivot pin, part number, location, and size for identification and locations.
5
6
BOOM AND CYLINDER PIVOT PIN LOCATION AND MACHINE USAGE
Ref.#
3
4
1
2
5
6
7
Description
Mounting Plate Pivot
Upper Bucket Cylinder Pivot
Lower Bucket Cylinder Pivot
Upper boom Cylinder Pivot
Lower boom Cylinder Pivot
Boom Lower Link Pivot
Boom Upper Link Pivot
Qty.
2
2
2
2
2
4
4
Part Number
86501434
86501430
9614349
86521982
86504316
86501422
86501420
Torque
108 N·m (80 ft. lbs.)
108 N·m (80 ft. lbs.)
38 N·m (28 ft. lbs.)
38 N·m (28 ft. lbs.)
338 N·m (250 ft. lbs.)
338 N·m (250 ft. lbs.)
338 N·m (250 ft. lbs.)
6
82-4
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
BOOM/CYLINDER PIVOT PINS SIZE
PART NUMBER
9614349
86501420
86501422
86501430
86501434
86504316
86521982
A
95 mm (3-3/4 I )
49 mm (1-15/64
I
)
77 mm (3-1/32
I
)
72.3 mm (2-7/8 I )
57.8 mm (2-9/32
I
)
40.0 mm (1-5/32 I )
117 mm (4-39/64 I )
NOTE: After the tapered pivot pin retaining hardware is torqued, the pins must be properly seated. Using a hammer, strike the head of the bolt and pin several times to seat the tapered pin in the taper of the boom and/or ROPS. Retorque the hardware to the specified torque. Repeat this process until the torque is maintained
B
38 mm (1-1/2 I )
60.3 mm (2-3/8
I
)
60.3 mm (2-3/8
I
)
38.10 mm (1-1/2 I )
38.1 mm (1-1/2
I
)
60.3 mm (2-3/8 I )
38.1 mm (1-1/2 I )
C
113 mm (4-29/64
I
)
141 mm (5-9/16
I
)
112.5 mm (4-7/16 I )
92 mm (3-5/8
I
)
113 mm (4-7/16 I )
7
82-5
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
Op. 82 100 30
PALLET FORK
The pallet fork (shown) has a frame and guard assembly, with different length forks available. The fork pairs can be 36
″
, 42
″
, or 48
″
long. Also available is a multi-fork block fork set for lifting cinder blocks.
To adjust fork spacing, raise the lock pins, 1, slide the forks to the required spacing, and relatch lock pins into notches.
1
19990486
To install or remove the forks from the frame, slide the forks to the center of the frame at 1, and pick the end of the fork up to remove fork from frame.
Pallet Fork Capacity
Max. Reach
Height
2489 mm
(98
″
)
Tip Load
1290 kg
(2840 lbs.)
50%
645 kg
(1420 lbs.)
WITHOUT WEIGHT KIT
Max. Reach
Height
2489 mm
(98
″
)
WITH WEIGHT KIT
Tip Load
1140 kg
(2510 lbs.)
50%
570 kg
(1255 lbs.)
SAE
Rating
645 kg
(1420 lbs.)
SAE
Rating
570 kg
(1255 lbs.)
Capacities listed are LS160/LS170 with 10 x 16.5
tires at 3.5 bar (50 PSI), full fluids, 79 kg (175 lb.) operator, 48
″
pallet forks w/back guard, weight kit two
27 kg (60 lbs.) per side, per SAE rating specification
J1197.
19990487
1
8
9
82-6
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
Op. 82 100 20
UTILITY FORK
The utility fork is for handling matted, stringy material which is difficult to load into a standard bucket.
The standard tine spacing, center to center, is 21.8
cm (8-1/2
″
). The fork frame is equipped with additional holes for additional tines, reducing the tine spacing to 10.9 cm (4-1/4 ″ ).
10
11
Op. 82 100 11
Tine Installation
1. Slide each tine, 1, into the fork backplate for the desired tine spacing, until the 1/2
″
x 2-3/4
″
bolt,
2, can be inserted through the fork backplate and tine with the nut to the inside of the fork backplate.
2. Position the spacer, 3, as shown with the angle end of the spacer next to the floor of the backplate. Secure the assembly with 1/2 ″ lock washer and nut. Tighten securely.
12
82-7
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
BUCKETS
Op. 82 100 12
CUTTING EDGE (REPLACEMENT)
Cut or grind the old cutting edge from the bucket floor and sides. Remove all old weld and foreign material from the welding area.
1. Straighten the bucket floor and sides if required.
2. Thoroughly clean the area where the new cutting edge will be welded.
3. Use dry AWS-E7018 low hydrogen electrodes or either of the following equivalent low hydrogen wire feed electrodes: Gas metal arc welding
(CO
2
or argon CO
2
) AWS-E70S6 or flux cored arc welding AWS-E70T1.
4. Preheat the parts to be welded (both tack and final welds) to a minimum of 204
°
C (400
°
F). The preheat temperature must be throughout the entire thickness of the parts joined, and at least 51 mm (2
″
) back from the joint. Maintain preheat throughout the entire welding operation.
NOTE: This is a hardened steel edge. If not preheated, the cutting edge may later crack during use.
5. Tack weld the preheated parts starting at the center of the bucket and working toward the outside ends.
6. Finish welding the preheated parts starting at the center of the front edge of the bucket floor and working toward the outside ends. Repeat this operation at the back side of the cutting edge to bucket floor.
7. Do not remove the bucket from the welding environment until the weld and metal temperature drops to the ambient temperature. Do not force the cooling rate of the welds and material.
Follow the same welding procedure for welding the side cutting edges and bottom wear plates to the bucket.
13
14
82-8
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
Op. 82 100
BUCKET LATCH PLATE INSTALLATION
PROCEDURE
1. Remove the bucket from the loader before welding to prevent damage to the loader electrical system.
Material to be welded is low carbon, grade 50 steel; use welding rods marked 6011 or comparable.
CAUTION
Good quality welds are necessary for new plates to be properly retained. Use a professional welder if required.
2. Turn the bucket over and support it about
305 mm (12 ″ ) off the floor.
3. Cut the old lower retaining plates, 1, off the bucket and grind the area flat.
4. For locating the new lower attaching plates, remove the quick-attach plate from the loader boom. To remove the plate from the boom, remove the cylinder pins, 1, and the pivot pins, 2.
15
16
5. Rest the attaching plate in the saddle area, 1, of the bucket with the latch handles in the unlatched position as shown at 2. Put two 152 mm (6 ″ ) long pieces of 4.8 mm (3/16 ″ ) square key stock at 3, to position the attaching plate properly against the back of the bucket.
17
82-9
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
6. Position the first plates against the back of the bucket at 1, and rest on the quick-attach plate, 2.
Locate the center of the latch plate notches, 4, and center the outer half of the notch over the latch pin, 3. Spot weld the plate to the bucket at
1 to hold the plate in position.
NOTE: The material to be welded is low carbon, grade 50 steel; use welding rods marked 6011 or comparable.
7. Position the second plates as shown at 1, with the plates contacting each other at 2, and about
28.6 mm (1-1/8
″
) spacing at 3. On low-profile buckets, the second plate will be at the rear corner of the bucket at 4. Spot weld the second plate to the bucket at 4 and the two plates together at
5.
8. Remove the 4.8 mm (3/16
″
) square key stock and push the latch handles to the latched position making sure the latch pins engage the bucket latch plates. The latch handles must fully latch.
The latch pin will only contact the top latch plate,
6.
9. If the latch handles will not fully latch, the top plate may require some grinding in the pin area at 1, or the plates are not located properly.
18
19
20
82-10
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
10. Weld the plates to the bucket at 2; also weld the two plates at 3.
11. Reinstall the bucket quick-attach plate to the loader boom with the pins previously removed.
12. Attach the bucket to the loader by engaging the top of the plate, 1, under the lip of the bucket at
2. Curl the bucket back to allow the bucket to contact the loader quick-attach plate and engage the latch handles and pins, making sure the latch pins engage the bucket plates properly.
Op. 82 100
DIRT TOOTH KIT INSTALLATION
Bucket Dirt Tooth Kit
The dirt tooth kit consists of six teeth that are welded to the bucket cutting edge as indicated below. The teeth are used when rough digging conditions are anticipated to break up the material for easier bucket filling. The teeth are intended to be used only on dirt and foundry or low-profile buckets.
21
22
23
82-11
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
Op. 82 100 10
Tooth Point Replacement
The points of the teeth are a replaceable “pin-on” design and can be obtained from Parts.
To replace the “pin-on” points, use a punch that just fits into the pin hole, 1, and drive the old retaining pin from the shank.
Place the new point over the shank and insert the retaining pin into pin hole, 1. With a punch that contacts both sides of the metal part of the retaining pin, drive the pin until it is centered in the shank.
NOTE: If the punch or driver is too small and just contacts the rubber center of the retaining pin, the pin will be damaged and will not retain the point.
Tooth Location and Installation
1. The bucket should be flat on the floor when placing and welding the teeth.
IMPORTANT: Remove the bucket from the loader while welding teeth to prevent damage to the loader electrical system.
Slide the replaceable points in place but do not attach with the steel/rubber pins as the rubber may be damaged during the welding process.
24
82-12
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
2. Locate the teeth on the bucket edge as indicated.
BUCKET TOOTH SPACING
Bucket
Width From End
1
62 ″
66
″
70 ″
76
″
82 ″
52 ″
54
″
58 ″
60
″
2
1-13/16 ″
1-13/16
″
1-13/16 ″
1-13/16
″
1-13/16 ″
1-13/16
″
1-13/16 ″
1-13/16
″
1-13/16 ″
2nd Tooth
3
9-1/2 ″
9-3/4
″
10-11/16 ″
10-15/16
″
11-3/8 ″
12-3/16
″
13 ″
14-3/16
″
15-3/8 ″
3rd Tooth
4
18-15/16 ″
19-1/2
″
21-5/16 ″
21-7/8
″
22-3/4 ″
24-5/16
″
26 ″
28-5/16
″
30-3/4 ″
4th Tooth
5
28-3/8 ″
29-3/16
″
32 ″
32-3/4
″
34-1/8 ″
36-1/2
″
38-15/16 ″
42-1/2
″
46-1/8 ″
5th Tooth
6
37-13/16 ″
38-15/16
″
42-5/8 ″
43-3/4
″
45-1/2 ″
48-11/16
″
51-7/8 ″
56-11/16
″
61-1/2 ″
6th Tooth
7
47-5/16 ″
48-5/8
″
53-5/16 ″
54-5/8
″
56-7/8 ″
60-7/8
″
64-7/8 ″
70-7/8
″
76-13/16 ″
NOTE: Position the teeth at these spacings, then re-center if necessary for equal spacing.
25
82-13
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
3. Weld, 1, is high carbon steel (tooth) to high carbon steel (bucket). Use welding rods marked
7018 or comparable rods. Weld on both sides of the tooth from the back of the tooth towards the replaceable point.
1
4. Stop welding 13 mm (1/2
″
) from the cutting edge as noted. A minimum 5 mm (3/16 ″ ) fillet weld is required for this application.
5. Weld in the direction shown at 1.
6. Weld a 5 mm (3/16
″
) bevel groove weld on both sides of the tooth, 2, high carbon steel to high carbon steel.
26
13 mm
(1/2
″
)
5 mm
(3/16
″
)
5 mm
(3/16
″
)
27
82-14
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
BOOM LOCK PIN LINKAGE
Op. 82 100 77
REMOVAL
1. Lower the boom to the lowered position.
2. Open the rear door, 1, and the top engine, 2, access cover.
3. Remove the right and left engine side covers, 3.
3
19985917
1
4. Unhook the spring, 1, from control rod by sliding spring to the side and removing spring at bottom hook, 2.
5. Remove the push nuts, 3, from the control rod, 4.
6. Remove the linkage to pin through bolt, 5.
7. Remove the linkage support retaining hardware,
6.
2
3
28
29
8. Remove the plastic handle grip, 1, from the control lever.
30
82-15
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
9. Remove the control rod, 2, from the lever at 5, and slide the handle from the rear of the cab.
10. Slide the boom pins, 1, right and left, from the loader ROPS post.
11. The boom lock pins and linkage include:
1. Boom Lock Pins (2)
2. Control Rod (1)
3. Push Nuts (2)
4. Support Angle (1)
5. Control Lever Assembly (1)
6. Plastic Handle Grip (1)
7. Spring
REINSTALLATION
1. Install the boom lock pins, 1, right and left, into the ROPS posts at 2.
2. Install a rubber grommet at 3. Insert the control handle assembly, 4, through the right cab side shield at 5.
31
32
82-16
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
3. Position the control handle over the lock pin, 1, and install the support hardware at 2.
4. Install the handle and lock pin through bolt at 3.
5. With the handle properly positioned tighten the support hardware at 2, and the through bolt lock nut, 3.
NOTE: Do not over-tighten the through bolt because the handle must pivot at the lock pin.
6. Install the control rod, 4, in the handle assembly, positioning the wire harness, 5, to the seat side of the control rod as shown.
7. Install the control rod, 4, in the handle assembly and the left boom lock pin, 1. Slide new push retaining nuts onto rod at 6, Figures 33 and 34.
33
34
8. Slide the plastic handle grip, 1, onto the handle.
9. Operate the control handle to insure proper operation.
a. Pivot the handle towards the outside of the operator’s cab. The lock pins should extend from the cab post.
b. Pivot the handle towards the inside of the operator’s cab. The lock pins should retract into the cab post far enough to allow boom movement without contacting the lock pins.
10. Reinstall the engine side shields. Close the top engine cover and rear door.
35
82-17
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
BOOM, UPPER AND LOWER LINK
REMOVAL
1. Remove any attachment (bucket, fork, etc.) from the boom mounting plate and lower the boom to the lowered position.
2. Attach a chain or strap suitable for handling the weight of the boom (approximately 800 lbs.) to the boom grab handles as shown at 1. Support the boom about level with the top of the loader
ROPS.
CAUTION
Always use a suitable lifting device and chains or straps to support and remove the boom.
3. Support the rear of the boom with the rear lower link pivot above the top of the engine shielding as shown.
NOTE: This will enable the removal of the link pivot hardware.
36
37
38
82-18
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
Op. 82 100 52
Lower Link Removal
1. Remove the plastic plugs, 1, from the cab inner shell to access the boom lower link and cylinder pivot hardware.
2. Remove the fenders to gain access to the boom and bucket hydraulic tube and hose connections.
3. With the boom properly supported and all hydraulic oil pressure removed from the boom and bucket circuits, disconnect the hydraulic lines at
1. Cap open ends of lines and hoses. Remove the boom hose clamps, 2, retaining the hoses to the lower boom links. Remove the hoses from the lower hose retainer, 3.
CAUTION
Always use a suitable lifting device and chains or straps to support and remove the boom.
Do not disconnect any hydraulic lines until all hydraulic pressure is removed from the boom and bucket hydraulic circuits.
4. Loosen the lower link rear pivot pin retaining hardware.
CAUTION
Do not remove the pin retaining hardware until the tapered pivot pin is broken loose at the tapered end of pin or the link and pin may fall.
5. With a soft-faced sledge hammer, strike the lower link as shown to break the tapered pivot pin loose in the main boom link.
39
40
41
82-19
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
6. Loosen the front lower link pivot pin retaining hardware, 1, and strike the link at 2, to break the tapered pivot pin loose in the ROPS frame.
7. Remove the retaining pin hardware from the front and rear pins. Lift the lower link and pins from the loader.
NOTE: Both the right and left lower links can be removed as described.
Op. 82 100 53
Upper Link Removal
1. The boom must be properly supported at the front and rear of the boom with the boom in the lowered position or the front of the boom above the front upper link pivot. Remove all hydraulic oil pressure from the boom and bucket hydraulic circuits.
NOTE: Supporting of the boom will keep the boom in position during removal of the upper links.
CAUTION
Do not remove the pin retaining hardware until the tapered pivot pin is broken loose at the tapered end of pin or the link and pin may fall.
2. Loosen the rear link retaining bolt, 1; do not remove. With a soft-faced sledge hammer, strike the link at 2, to break the tapered pivot pin loose in the main boom.
82-20
42
43
44
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
3. Loosen the front link pivot hardware, 1, and with a soft-faced sledge hammer, strike the link at 1, to loosen the tapered pin in the ROPS post.
4. Remove the front and rear pivot pin retaining bolts and tapered pins and lift the link from the loader.
Op. 82 100 50
Main Boom Removal
1. Remove the plastic plugs, 1, from the cab inner shell to access the boom lower link and cylinder pivot hardware.
2. Remove the fenders to gain access to the boom and bucket hydraulic tube and hose connections.
3. With the boom properly supported and all hydraulic oil pressure removed from the boom and bucket circuits, disconnect the hydraulic lines at
1. Cap open ends of lines and hoses. Remove the boom hose clamps, 2, retaining the hoses to the lower boom links. Remove the hoses from the lower hose retainer, 3.
CAUTION
Always use a suitable lifting device and chains or straps to support and remove the boom.
Do not disconnect any hydraulic lines until all hydraulic pressure is removed from the boom and bucket hydraulic circuits.
45
46
47
82-21
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
4. Remove the hoses from the rear hose support, 1, remove the tube clamps, 2, and disconnect the tubes at the Z-bracket and quick couplers, 3.
5. Remove the right and left upper boom cylinder pivot pin retaining hardware, 1, and pin, 2, from cylinders and boom.
NOTE: If only the main boom is being removed, the cylinders can remain attached at the bottom pivot.
6. Loosen the right and left lower link rear pivot pin retaining hardware, 1.
CAUTION
Do not remove the pin retaining hardware until the tapered pivot pin is broken loose at the tapered end of pin or the link and pin may fall.
7. With a soft-faced sledge hammer, strike the lower link as shown to brake the tapered pivot pin loose in the main boom link.
1
48
49
50
82-22
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
8. Remove the pin retaining hardware and pin from the link and main boom. Lower the link and rest it on the loader frame.
9. Loosen the right and left upper link rear retaining bolts, 1; do not remove. With a soft-faced sledge hammer, strike the link at 2, to break the tapered pivot pin loose in the main boom.
10. Remove the hardware and pins from the ROPS and link, resting the link on the lower link.
11. Lift the boom assembly from the loader.
51
52
82-23
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
Op. 82 100 70
FRONT BOOM MOUNTING PLATE PIVOT
HUB REPLACEMENT
1. Remove any attachment, bucket, etc., from the boom mounting plate.
2. Pivot the mounting plate out flat and remove all hydraulic pressure from the bucket circuit.
3. Remove the cylinder rod pivot pin retaining hardware and pin from the mounting plate and cylinder.
4. Remove the mounting plate from the main boom.
a. Loosen the mounting plate pivot hardware. DO NOT remove the hardware.
b. With a sledge hammer (8 lbs.) or larger, strike the mounting plate at 1, to loosen the tapered pivot pin.
c. Remove the retaining hardware, pins, and mounting plate from the boom.
5. Raise the boom and support the boom 609.6 mm
(24
I
) off the ground on jack stands or suitable blocking at 1.
6. Remove the negative (-) battery cable.
53
54
7. Using a cutting torch, cut the weld around the hub to separate the hub from the main boom. DO NOT cut any material from the main boom. Grind to remove any remaining weld and hub from the boom.
8. Position the hubs on the boom straight, from side to side, with center spacing, 2, as follows, and tack weld the hubs to the boom.
Hub Center Spacing - 822 mm (32.36
″
)
9. Reinstall the mounting plate and tapered pivot pins and hardware. Pivot the mounting plate up and down to ensure there is no binding between the mounting plate and pivot pins. Weld the hubs to the boom.
10. Install the hub reinforcement gussets described earlier in these instructions.
11. Lubricate the pivots and torque and hammer seat the tapered pins and hardware. Refer to
“MOUNTING PLATE REPAIR,” in this section.
A5323-12
82-24
55
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
BOOM, UPPER AND LOWER LINK REIN-
STALLATION
1. If the upper and lower boom links and boom cylinders were removed, attach the upper and lower links to the ROPS before installing the main boom assembly.
2. Install the lower link pivot pins, 1, through the links, 2, and insert the tapered end of the pin into the ROPS frame. Install the pin retaining hardware and tighten, making sure the tapered pin is inserted into the ROPS straight.
3. Install the upper link pivot pins through the links and insert the tapered end of the pin into the
ROPS post. Install the pin retaining hardware and tighten, making sure the tapered pin is inserted into the ROPS post straight.
4. Position the main boom assembly over the loader positioning the boom against the boom stops
(front of the final drive case).
56
57
5. Attach the upper link rear with tapered pivot pins,
1, and retaining hardware. Tighten the hardware, making sure the pin is straight in the main boom.
1
1
58
82-25
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
6. Attach the lower link rear with tapered pivot pins and retaining hardware. Tighten the hardware, making sure the pin is straight in the main boom.
7. With the main boom, upper and lower links attached, the pivot pins and hardware must be properly seated.
Torque the pin retaining hardware to the following torques:
1 - Lower link - 338 N·m (250 ft. lbs.)
2 - Upper link - 338 N·m (250 ft. lbs.)
3 - Cylinder pivot (lower) - 338 N·m (250 ft. lbs.)
4 - Cylinder pivot (upper) - 38 N·m (28 ft. lbs.)
8. After the pivot pin retaining hardware is torqued the pins must be properly seated. Using a hammer, strike the head of the bolt and pin several times to seat the tapered pin in the taper in the
ROPS. Retorque the hardware to specified torque. Repeat this process until the torque is maintained.
9. Reinstall the cylinders to the boom upper pivot.
10. Reinstall the boom hydraulic tubes and hoses if removed. Position the tube at 1, the front of the boom to maintain clearance between boom and tubes. The tubes must be properly positioned or the tubes will contact the corner of the ROPS
(cab) when the boom is raised and lowered.
11. Reattach the tubes to the Z-bracket, 2, and install the quick couplers. Install the tube clamps, 3, front shown.
3
2
1
2
59
1
60
61
82-26
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
12. Route the tubes and hoses to the rear of the boom through the rear hose supports, 1, and on the top side of the lower link at 2.
13. Position the hoses with one on each side of the lower link retaining clips, 1, and through the hose retainer at 2. Do not tighten clamps at this time; further adjustment will be required later.
14. Insert the hoses through the hose support on the end of link at 3.
15. Reconnect the hoses to the tubes at 4, positioning the hoses and tubes for clearance at the fender when the boom is raised and lowered.
16. When all boom links and pivot pins are properly seated and torqued and all hydraulic connections are tightened, operate the boom up and down. Check the clearance between the tube and ROPS (cab) at 1.
62
63
64
82-27
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
17. Check the hoses, 1, around the rear supports with the boom in the fully raised position. The hoses should be routed as shown. Remove any slack from the hoses to the boom tubes and tighten the hose clamp, 2.
18. Remove any slack between the top clamp, 1, and second clamp, 2, and then tighten the second clamp.
65
66
19. Install the front step shield, 1, the fenders, and fender hardware, 2. Raise and lower the boom checking the hose/tube clearance to fenders at
3, and readjust if required. Check for any oil leaks and repair if required.
NOTE: The boom may require several cycles up and down to remove the air from the boom hydraulic circuit.
67
82-28
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
20. Reinstall the boom mounting plate if removed.
Torque the pivot bolts, 1, to 108 N·m (80 ft. lbs.).
The tapered pivot pins and retaining hardware must be hammer seated by striking the head of the bolt and pin and retorquing the bolt. This step must be repeated until the torque is maintained.
21. Reinstall any shields removed for the repair.
1
ATTACHMENT MOUNTING PLATE
Op. 82 100 70
REMOVAL
1. Remove any attachment from the loader attachment mounting plate.
2. Lower the boom to the fully lowered position.
3. Tilt the attachment mounting plate forward until the face is level with the ground.
4. Remove the cylinder attachment mounting plate pivot pins by removing the pin retaining bolts, 1, and sliding the pins from the mounting plate and cylinders.
CAUTION
Support the mounting plate during removal to prevent dropping the plate when pins are removed.
5. Remove hub caps, 2, from the pivots.
6. Loosen the attachment mounting plate to boom pivot pin hardware, 3. DO NOT remove the bolts at this time.
7. With a soft-faced sledgehammer, strike the mounting plate pivot area, 4. This will free the tapered pivot pin in the boom link.
8. Remove the pivot pin retaining hardware and remove the tapered pins.
3
19984476
4
2
1
1
68
3
69
82-29
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
REPAIR/REBUILD MOUNTING PLATE
Op. 82 100 74
LATCH LEVER AND PIN REMOVAL/REPAIR
1. Remove any attachment from the loader attachment mounting plate.
2. Lower the boom to the lowered position.
3. Tilt the attachment mounting plate forward until the face is level with the ground.
4. With an allen wrench, remove the setscrew, 1, from the backside of the mounting plate for both the left and right sides.
1
5. Move the latch handle, 1, to align the groove pin in the setscrew hole, 2. Drive out the groove pin with a hammer and punch. Repeat this procedure on other side.
6. Remove the latch pin from each side from the bottom of the mounting plate.
1
2
7. Remove the cylinder attachment mounting plate pivot pins to allow access to the latch handle pivot pin snap ring clips.
CAUTION
Support the mounting plate during removal of the mounting plate pivot pins to prevent dropping the plate down when pins are removed.
8. Remove the pin retaining bolts, 1, and slide the pins from the mounting plate and cylinders.
1
19984476
70
71
1
72
82-30
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
9. Enter the skid-steer loader. Sitting in the operator’s seat with the seat belt buckled, start the loader and retract the attachment mounting plate actuating cylinders, 1, fully to clear the attachment mounting plate, 2.
1
2
10. Remove the retaining ring, 1, from the latch handle pivot pin, 2, from the rear of the mounting plate on the LEFT and RIGHT sides.
11. Using a punch and hammer drive the latch handle retaining pin, 2, downward and out through the front of the attachment mounting plate on both sides. If there is insufficient ground clearance to fully remove the latch handle pivot pins, lift the attachment mounting plate up as necessary to clear the pins.
12. Remove the handle/spring assembly, 1, from the attachment mounting plate on the LEFT and
RIGHT sides of the attachment mounting plate.
1
2
73
74
19984481
1
75
82-31
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
PARTS INSPECTION
Mounting Plate Assembly
1. Inspect the plate, 1, for straightness. If the mounting plate pods are not straight with each other it may be difficult to hook up to attachments.
Refer to the “Checking Procedure for Buckets and Attachments” in Section 8 - Optional Equipment for further details. If the mounting plate is not within specifications, replace the assembly.
2. Inspect the latch pin area for excessive wear, which can result in loose attachments. If the pins,
2, do not slide freely, remove the pins, clean and lubricate.
3. Inspect the mounting plate pivot pins, 3, and bushings, 4, for wear, which can result in loose attachment to the mounting plate boom cylinders.
4. Inspect the cylinder pivot pins, 5, for wear. Inspect the pivot pin holes for wear that could cause a sloppy fit. Replace the bushings in the mounting plate or pivot pins, if necessary.
Latch Handle/Spring Assemblies
1. Inspect the latch handle pivot holes, 6, for excessive wear and binding in the mounting plate.
2. Check that the spring, 7, is not bent, damaged, or has broken coils. Replace if necessary.
4
1
1998482
6
5
3
7
2
Latch Pins
1. Examine the latch pins, 2, for excessive wear and binding in the mounting plate.
2. Check the tapered area of the pins for wear or chips. Replace if necessary.
Op. 82 100 57
Pivot Bushings Replacement
1. Use a suitable bushing driver and remove the old bushings.
2. Clean the bushing area to remove any dirt, debris and burrs.
3. Using a bushing driver, install the new pivot bushings from each end of hole, 1. Drive bushings flush with the outer edge of the hub.
NOTE: There will be a space in the center between the two bushings.
6
1
4
76
77
82-32
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
Op. 82 100 74
Latch Lever and Spring Repair/Rebuild
1. Clamp the lower spring guide, 1, in a vise. Turn the step bolt, 2, to remove the lower spring guide from the step bolt and remove spring, 3.
CAUTION
W hen removing the step bolt, the spring will have some compression pressure. Remove the bolt while applying downward pressure on the bolt.
1
3
19984483
2. Remove the upper spring guide, 1, pivot block, 2, and step bolt, 3, from handle, 4.
2
4
78
1 2
3
19984484
79
Reassembly
1. Insert the pivot block, 1, and step bolt, 4, into the handle, 2. Install the upper spring guide, 3, onto step bolt, 4.
2. Install spring, 5, over the upper spring guide, 3.
Install the lower spring guide, 6, onto step bolt, 4, and tighten.
NOTE: Apply slight pressure to the lower spring guide to compress the spring slightly and start threading the lower guide onto the step bolt.
1
3
4
5
6
19984485
2
80
82-33
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
3. Slide the latch handle/spring assembly, 1, into the mounting plate, pointing the spring down.
4. Install the handle pivot pin, 1, from the front of the plate and install the snap ring retaining clip, 2.
The pivot pins will have a snap ring on both ends of the pins.
NOTE: The handle pivot pin should have one snap ring retaining clip already installed prior to reinstallation in the attachment plate. If the snap ring retaining clip is not present, install the clip prior to pin installation.
19984481
19984486
5. Move the latch handle, 1, to align hole with the groove and insert the latch pin with the tapered side towards the loader boom, away from the attachment.
6. With a hammer and punch, drive the grooved pin,
2, through the lower spring guide and latch pin.
1
2
1
2
1
81
82
83
82-34
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
7. Reinstall the setscrew, 1.
1
8. Reinstall the boom mounting plate, if removed, by installing the pivot taper pins and retaining hardware, 2.
9. Torque the pivot bolts, 2, to 108 N·m (80 ft. lbs.).
NOTE: The tapered pivot pins and retaining hardware must be hammer seated by striking the head of the bolt and pin, and then re-tightening. This step must be repeated until the torque remains constant.
10. Reinstall hub caps, 3, into the plate pivots.
11. Extend the attachment mounting plate cylinders until they align with their mounting holes on the attachment mounting plate.
12. Install the cylinder attachment mounting plate pins through the mounting plate and into the cylinder rod ends. Install the pin retaining hardware,
1, and tighten.
13. Grease the two boom mounting plate pivot pins and the two cylinder mounting plate pivot pins prior to moving the attachment mounting plate to prevent any damage to the pivot points.
2
19984476
3
1
84
2
85
82-35
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
Attachment Plate Over-Center Latch Pins Wear/
Bend
The loader attachment may become loose at the mounting plate. Inspection of the over-center latch pins part #9822358, shows the pin ends worn and bent, 1.
The over-center pins are NOT heat-treated. Thus, if an attachment does not fit correctly and hammers against the pins, the pins will wear and bend. New pins and ones used with properly fitted attachments should be straight, as shown at 2.
If worn pins are encountered, the pins must be replaced. Additionally, an inspection of all the customer’s attachments must be made to determine the improperly fitted attachment which is causing the pin problem. Usually, an old attachment used on a previous loader can be worn and can be the problem.
CHECKING PROCEDURE FOR
BUCKETS AND ATTACHMENTS
The bucket/attachment does not fit or appears to come loose on the boom faceplate.
The loader boom faceplate is worn or out of height dimensions and/or the bucket latch points are worn or out of dimensions.
Inspection
The LS160 and LS170 loader latching system requires that the faceplate wedge into the attachment.
The faceplate must contact the attachment at 1, 2, and 3, and must have clearance between the attachment and faceplate at 4, when the attachment is latched properly.
86
87
82-36
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
The following are some quick visual checks of the loader faceplate and attachment.
1. The attachment must have a 850.1 mm
±
0.8 mm
(33-15/32 ″ ± 1/32 ″ ) center to center latch point,
1, to be compatible with the latch system.
2. Check the latch pins and levers for proper operation and lubrication. If the latch pins do not move freely, the system will not function properly.
a. Control levers pivot over center into the lowered latched position.
b. Latch pins fully extend from the faceplate.
c. Control levers pivot over center into the raised unlatched position and hold in this position.
Loader faceplate, 5, and attachment, 6, engagement.
3. Check the saddle area of the attachment at 1, for interference, weld, debris, etc. to prevent the attaching plate and attachment from seating properly.
4. The loader latch pin should engage the lower latch plates as shown at 2.
5. Check for clearance between the faceplate and attachment at 3, minimum 0.8 mm (1/32 ″ ) and maximum 9.5 mm (3/8
″
), with the latch pins fully engaged.
a. If there is no clearance at 3, the loader faceplate is too short or the distance between the top saddle area and lower latch plates is too great, 2,
Figure 91.
b. If the clearance is too great or the latch pins will not engage into the latch plates on the attachment, the loader faceplate is too long or the distance between the top saddle area and lower latch plates is too short, 2, Figure 91, or the latch plates are located incorrectly, 1, Figure 91.
6. When the latch pins are fully engaged, New Holland buckets only, the end of the pin should not extend beyond the lower plate at 4.
a. If the latch handles do not fully engage, the dimension from the back of the attachment to the rear of the slot in the latch plates is too short at
1, Figure 91.
b. If the latch pins extend below the lower plate at 4, the dimension from the back of the attachment to the rear of the slot in the latch plate is too long at 1, Figure 91.
88
89
82-37
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
CHECKING PROCEDURE
The following are the procedures used to measure the skid-steer loader faceplate and how to measure the attachment.
Checking the Attachment
1. Check the placement of the lower latch plates at
1. Measure from the back surface of the attachment to the rear of the latch plate slot at 1: 235.8
mm ± 0.8 mm (1-9/32 ″ ± 1/32 ″ ).
a. If this dimension is too short, the slot can be widened by grinding out the slot 1/16 ″ maximum or replace the latch plates.
If grinding is required, the rear of the slot must be ground square with the top surface of the plate to ensure proper pin engagement, 2, Figure 89.
b. If the dimension is too long, replace the latch plates.
2. Check the height of the attachment at 2. Insert a
1/2 ″ x 2 ″ with 1/2 ″ standard nut as shown at 3.
Measure from the top of the bolt, 4, to the rear of the latch plate slot at 5: 403.2 mm
±
0.8 mm
(15-7/8 ″ ± 1/32 ″ ).
If this dimension is incorrect, the lower latch plates will require replacement.
NOTE: If new latch plates are required, order four plates #86506587 (102 mm [4 ] slot) through Parts and follow the latch plate installation procedure.
1-9/32 I
15-7/8 I
90
82-38
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
CHECKING THE LOADER FACEPLATE
1. Check the height of the loader faceplate from the top of the plate at 1, to the bottom of the plate at
2: 396.9 mm ± 0.8 mm (15-5/8 ″ ± 1/32 ″ ). To check the faceplate, place a 24 ″ square over the top of the plate as shown at 4, and a straightedge at 5.
If the faceplate is not within specifications, the plate will require replacement.
15-5/8
I
2. Check the faceplate pods to ensure they are straight with each other and not twisted. Place a straightedge across both pods as shown at 1, across the front flat surface and at 2, the top of the pods.
If the pods are not straight, the faceplate will require straightening or replacement.
91
92
82-39
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
3. Check the center dimension between the faceplate pods and the overall outside dimension.
Inside Dimension 1: 647.7 mm (25-1/2
″
)
Outside Dimension 2: 1122.4 mm (44-3/16
″
)
Latch Pin Dimension 3: 850.1 mm
±
0.8 mm
(33-15/32 ″ ± 1/32 ″ ) center
CAUTION
Do not cut or grind the loader faceplate to adapt any buckets or other attachments.
Do not cut or grind the loader faceplate latch pins.
When attaching unapproved attachments, the latch points on the attachment must meet the correct dimensions and be strong enough to maintain the correct dimensions during operation.
93
82-40
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
LABOR GUIDE
The following labor amounts are listed as a guide only. Working conditions and experience will vary the time it actually takes to complete each job.
Job Description
Remove and replace boom lock pins and linkage
Remove and replace main boom
Removal and replace one upper link
Removal and replace one lower link
Remove and replace attachment mounting plate
Rebuild attachment mounting plate
Hours
2.5 hrs.
4.5 hrs.
1.0 hrs.
2.0 hrs.
1.0 hrs.
1.5 hrs.
82-41
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
82-42
Section
SECTION 88 – ACCESSORIES
Chapter 1 – Dealer Installed Options
CONTENTS
Description Page
88-1
SECTION 88 - ACCESSORIES
Op. 88 100
GENERAL INFORMATION
ADAPTING ATTACHMENTS REQUIRING
12V ELECTRICAL POWER
There are important rules that must be followed when adapting attachments that require 12 volt electrical power. Proper wiring of electrical devices and power and ground connections is very important to prevent other electrical component damage. Attaching electrical connections to locations other than recommended may allow electric current to feed back through the EIC board, creating false EIC board readings and warnings, or causing EIC board damage or failure.
1. ALWAYS FOLLOW the instructions for New Holland kit installation to ensure proper function and operation.
2. NEVER CONNECT an electrical device to any wires, fuses, switches or grounds inside the cab area. This includes any terminals of the ignition switch, fuse panel, or ground terminal.
3. NEVER INSTALL an electrical device, music radio, two-way radio, or unapproved New Holland attachment into the cab area.
4. ONLY USE the 12-volt accessory power outlet for attachments requiring less than 10 amps. The accessory outlet is connected to the engine fuse/ relay panel and protected with a 15 amp fuse.
5. ALWAYS CONNECT new electrical attachments to the engine fuse/relay panel, 1, and connect the grounds to the engine bell housing. USE ONLY vacant connections and fuses not in use for specified attachments.
1
2
88-2
SECTION 88 - ACCESSORIES
Wire connections available if electrical attachments were not previously installed.
11
12
13
7
8
9
10
Engine Fuse Panel
Ref.
1
2
3
Color
R/B
R/GY
Destination
To turn signal relay
To accessory relay
R/LTGN To EIC board pin #14 P2 connector
4
5
6
LTGN/R
R/W
R
To seat switch(es)
To key switch (battery terminal)
From preheat circuit breaker
R
R/O
R/T
DKGN/R
O/LTGN
O/W
O/LTGN
From start relay
To heater power relay
Spare
To high flow, horn, power outlet
From accessory relay
To Back-up alarm switch
From road/work light fuse (cab panel)
Fuse Battery Voltage
10-amp All times
25-amp All times
5-amp All times
5-amp All times
15-amp All times
50/40-amp All times
Status
Available
Available
Occupied
Occupied
Occupied
Occupied
All times
20-amp All times
Occupied
Available
7.5-amp All times Available
15-amp Key “ON” position Available
Key “ON” position Occupied
5-amp Key “ON” position Available
Key “ON” position Occupied
1
2
3
4
5
7
8
9
10
12
6
11
13
3
88-3
SECTION 88 - ACCESSORIES
A completely new auxiliary wiring circuit can be installed as shown in Figures 4 and 5, depending on electrical requirements. Mounting holes for the added circuit breakers must be drilled in the panel. Disconnect the battery before drilling and installing new wiring. Protect the panel’s electrical components from drilling shavings that could cause electrical shorting of components. Figure 4 shows circuits for intermittent high current loads up to 15 amps.
The Figure 5 shows the circuit for intermittent high current loads up to 30 amps.
New Holland sealed circuit breakers that can be purchased from parts.
Part Number
9827329
9828493
9840279
9840280
Capacity
15 amp
20 amp
25 amp
30 amp
NOTE: When attaching ground wires, always place the heaviest ground wire next to the ground surface and then stack the remaining ground wires according to size on top of the heaviest wire.
IMPORTANT: Additional electrical attachments must have circuits properly connected to prevent damage to the Advanced Warning System (EIC board) and other electrical components.
CAUTION
Always disconnect the battery before installing any electrical attachment to prevent accidental shorting of system.
88-4
4
5
SECTION 88 - ACCESSORIES
HYDRAULIC SYSTEM COMPATIBILITY
There are six questions that must be answered before adapting attachments that require hydraulic oil power.
1. What is the hydraulic pressure requirement, minimum and maximum? Are they higher than the maximum pressure of the model?
Model
LS160
LS170
Maximum Pressure
170 - 176 bar
(2500 - 2600 PSI)
170 - 176 bar
(2500 - 2600 PSI)
2. What is the hydraulic oil flow requirement? Is it more than the highest total flow rate of the skid-steer loader model?
6
Model
LS160
LS170
Standard Hydraulics
58.7 l/min. (15.5 GPM) @2900 RPM
@68 bar (1000 PSI)
67.0 l/min. (17.7 GPM) @2900 RPM
@68 bar (1000 PSI)
NOTE: When using the High-Flow system, 3/4 quick couplers must be used or high system backpressure may result.
3. Will the attachment accept oil flow in both directions?
If “YES”, nothing is required.
If “NO”, install a check valve or cross into the attachment return line to prevent reverse oil flow to the attachment.
Examples: Backhoes and trees spades with a separate control valve do not accept oil flow in both directions.
4. Must the attachment “Free Wheel” to a
STOP?
If “YES”, a crossover relief connection must be installed on the attachment side to allow the attachment to free wheel to a stop after the skidsteer loader hydraulics is turned off.
If “NO”, nothing is required.
Example: Snow blowers must free wheel to a stop.
High Flow Hydraulics
90.8 l/min. (24.0 GPM) @2900 RPM
@156 bar (2300 PSI)
99.2 l/min. (26.6 GPM) @2900 RPM
@156 bar (2300 PSI)
5. Will the attachment accept hydraulic system backpressure?
If “YES”, nothing is required.
If “NO”, the attachment will not function properly on a New Holland skid-steer loader. Normal backpressure for New Holland skid-steer loaders is between 14 - 17 bar (200 - 250 PSI).
Examples: Post drivers, some breakers, and some hand held hydraulic tools do not accept system backpressure.
NOTE: LS160 and LS170 model loaders must have a minimum of 22.7 l/min. (6 GPM) returning through the main hydraulic system at all times to charge the hydrostatic system.
If all the skid-steer loader oil flow is not required to operate an attachment (e.g., shaver post driver), a flow divider can be installed into the hydraulic oil circuit on the attachment. The flow divider sends the required oil flow to the attachment and the remainder back to the normal skid-steer loader hydraulic circuits.
88-5
6. Does the attachment have a separate case drain oil line?
If “NO”, nothing is required.
If “YES”, install a separate case drain line to return the attachment case drain oil directly to the hydraulic oil reservoir.
Example: Cold planners have a separate case drain oil line.
SECTION 88 - ACCESSORIES
7. Does the attachment require a circuit relief in the bucket circuit?
If “NO”, nothing is required.
If “YES”, install a bucket circuit relief valve on front of the control valve in the bucket circuit.
Example: Some mini-backhoes attach like a bucket, and require a bucket circuit relief.
NOTE: Most attachment case drains will not accept backpressure and must drain directly into the reservoir.
NOTE: Skid-steer loaders equipped with High Flow
Hydraulics have a separate case drain coupler and return line attached to the right boom arm.
88-6
SECTION 88 - ACCESSORIES
Op. 90 000
ARM PADS FOR CAB SIDE PANELS
The cab arm pads provide additional operator comfort and may be used separately or in combination with the seat armrest.
The arm pads, 1, require gluing in place to the cab side panels with Loctite
454 gel adhesive.
The area where the arm pads are to be located must be cleaned thoroughly to ensure a secure bond to the cab side panel. If the area is not cleaned, the adhesive will not adhere to the metal side panels. Clean with methyl ethyl ketone, isopropyl alcohol, or equivalent cleaning solvent that will not leave a residue.
NOTE: Position arm pads quickly because the adhesive begins to bond in a few seconds.
CAUTION
Read the adhesive label warnings. Loctite
)
454 gel is a superglue-type material and can bond skin, eyes, etc. Use with adequate ventilation.
Op. 90 000
ARMRESTS FOR DELUXE SEAT
Right and left side armrests, 1, can be installed to the back of the deluxe seat only, at 2, for operator comfort.
NOTE: The standard seat mounting holes are not provided to attach the armrests.
There are two styles of armrest:
• Bolts attach armrests to the back of the steel back seat support.
• Bolts attach armrests to the sides of the plastic back seat supports.
Armrest Adjustment
The armrest can be adjusted up or down for operator comfort by turning adjusting screws, 1.
88-7
7
8
9
SECTION 88 - ACCESSORIES
Op. 90 000
FOREARM RESTS
The forearm rests are attached to the side of the operator’s cab (one each side) to be used to support the operator’s arms while operating the skid steer. The armrest may be pivoted up when not being used or for operator entry and exit of the operator’s area. The armrest may be used in any combination of controls, boom/bucket hand controls or boom/bucket foot controls. Using the armrest in combination with the boom and bucket hand controls provides the operator with arm support during boom and bucket operations.
19990495
NOTE: The cab armrest pad kit cannot be installed in combination with the forearm rest kit. The armrest pads are glued to the same area of the operator’s cab that the forearm rests are attached.
The LS160 and LS170 armrests mount with the bracket, 1, over the cab side panel, 2.
Pivot the armrest up and down and adjust the two clamp bolts, 3, if binding occurs, or to retain the armrest in the raised position.
1
2
3
The right and left armrests are shown installed and pivoted down in the operating position.
19990509
10
11
19990510
12
88-8
SECTION 88 - ACCESSORIES
Op. 55 000
BACK-UP ALARM
The back-up alarm serves as an audible warning device to alert bystanders and other machine operators of machine movements. The alarm will only sound when both hydrostatic control levers are stroked into reverse. Refer to local codes for requirements.
IMPORTANT: Before servicing any switches or alarm, disconnect the negative (–) battery ground cable to avoid accidental shorts in the wiring system when removing or installing components.
Alarm Location
The back-up alarm sound device should be located to the inside and in the upper right rear corner of the engine rear door at 1.
Adjustment
With the battery connected, and both hydrostatic control levers in the neutral position, loosen and slide both strikers, 1, rearward until the alarm sounds.
Move the strikers forward until the alarm stops
(approximately 1.5 mm [1/16
″
]) and tighten the hardware.
19984978
Back-up Alarm Wiring
The alarm is a negative (–) ground system.
13
14
15
88-9
SECTION 88 - ACCESSORIES
Op. 10 300
BLOCK HEATER (ENGINE)
The engine block heater, 1, may be required in colder climate areas to assist in starting of the diesel engine.
The block heater is a 115-volt, 400-watt immersion type.
WARNING
The block heater must be installed and operated per the instructions provided with the kit or damage to the engine, heater element, and/or personal injury could occur.
Position the heater into the engine block so that the element is pointing to the 7 o’clock position for proper heater operation.
WARNING
Before connecting the heater to the power source, be sure that the element is immersed in coolant. Never energize the heater in air. If so energized, the element sheath could burst and cause personal injury.
Do not operate the heater until the engine cooling system is filled with a 50/50 mixture of a permanenttype antifreeze and water.
Operate the engine and check for any coolant leaks and purge the air from the cooling system; repair accordingly.
IMPORTANT: Failure to fill the cooling system and purging the air will cause premature failure of the block heater.
CAUTION
This is a 115-volt heater. Use caution when installing and using the heater. Properly grounded electrical outlets and properly sized extension cords are essential for the use of the heater.
To insure continued protection against shock hazard, connect to properly grounded electrical outlets only.
First connect a grounded extension cord of the proper rating for the length used to the heater plug. Then connect the extension cord to the grounded electrical outlet.
CAUTION
Disconnect the extension cord from the grounded electrical outlet first and then from the heater before starting the loader. Inspect the heater wires periodically for broken or frayed wires and/or wire coverings. If wires and/or coverings are broken or frayed, do not use the heater.
88-10
16
SECTION 88 - ACCESSORIES
Op. 55 000
ELECTRIC POWER SUPPLY
(12 VOLT, 15 AMP)
The electric power outlet can be installed on the loader to provide an auxiliary 12-volt power outlet rated at 15 amp.
If the horn kit is installed, the power kit wire harness is incorporated in the horn harness.
If the horn kit is not installed, the power kit receives its power from the 15-amp attachment/horn fuse in the engine fuse panel.
Electric Power Wiring
17
18
88-11
SECTION 88 - ACCESSORIES
Op. 10 254
EXHAUST (ENGINE)
CATALYTIC MUFFLER
The catalytic muffler kit can be installed on diesel engines being operated in applications where cleaner exhaust emissions are required.
The catalytic muffler, 1, is a direct replacement for the standard muffler without adding other parts.
When operating a skid-steer loader equipped with the catalytic muffler, the unit must be operated at full engine speed.
The engine exhaust system must be operated at operating temperature for the catalytic purifier muffler to function properly.
If the temperature is not high enough, the catalytic purifier muffler will not function properly and not reduce the carbon monoxide level. The operating life of the purifier muffler will also be reduced.
Op. 10 254
ASPIRATOR PRECLEANER MUFFLER
The precleaner aspirator muffler kit can be installed on diesel engines being operated in dusty applications to prolong air cleaner element life.
The aspirator muffler, 1, is a direct replacement for the standard muffler and standard air cleaner.
NOTE: When the aspirator muffler is installed, the engine must be operated at/or near full engine speed to reduce the recirculating of exhaust gases through the air cleaner. If an air cleaner element is sooted with diesel smoke, the engine is being operated at reduced speeds.
The aspirator muffler hose connects to the air cleaner at 1.
1
19
20
21
88-12
SECTION 88 - ACCESSORIES
Aspirator or Spark Arrester Muffler Cleaning
Clean the muffler every 250 hours of use to ensure proper operation and prolong muffler life.
1. To clean the muffler, first move the loader to an area clear of any flammable material.
2. Allow the engine and muffler to cool before cleaning the muffler.
3. Remove the plug, 1, and allow the accumulated particles to drain from the muffler; a wire or stiff bottle brush might help to begin the particles to drain.
4. Start the engine and idle in neutral, alternate between low and high idle engine speeds for a couple of minutes to thoroughly clean the muffler.
5. Turn off the engine and allow the muffler to cool, then reinstall the drain plug.
CAUTION
Clean the precleaner or spark arresting mufflers in an area clear of flammable material. Allow the engine and muffler to cool before removing and reinstalling the drain plug.
22
88-13
SECTION 88 - ACCESSORIES
Op. 35 000
HIGH FLOW HYDRAULICS
When the high flow hydraulics circuit is used, it will allow the operator to utilize more available engine horsepower through the auxiliary hydraulic circuit.
The high flow increases the hydraulic flow:
LS160
From 15.5 GPM, 1000 PSI at 2900 RPM to 24.0
GPM, 1000 PSI at 2900 RPM (= 32.2 HP).
LS170
From 17.7 GPM, 1000 PSI at 2900 RPM to 26.6
GPM, 1000 PSI at 2900 RPM (= 35.7 HP).
During warm climate operation, be conscious of the
EIC (Electronic Instrument Cluster) temperature monitoring system. Adjust the attachment load (rate of feed) and length of continuous operation (duty cycle times) accordingly.
This high flow is not intended to replace a fully dedicated, specialized machine.
When the attachment is not in use, be sure the high flow switch, 1, is in the “OFF” position to prevent overheating of the hydraulic oil.
1
When the high-flow is being used, 3/4 ″ quick couplers, 1, must be used on the loader and attachment or overheating of the hydraulic oil may occur. The
1/2 ″ quick couplers, 2, can be used for other attachments that do not require the added oil flow.
19987112
23
24
25
88-14
SECTION 88 - ACCESSORIES
Attachment Case Drain
When the high flow kit is installed, there is a separate case drain return line, 1, for the attachment case
(housing) to drain oil. The case drain line drains into the hydrostatic pump/motor case drain system with
0.0 - 1.7 bar (0 - 25 PSI) system back pressure. Most auxiliary hydraulic drive attachments equipped with a separate case drain line require no system back pressure for the drain line.
26
88-15
SECTION 88 - ACCESSORIES
HIGH FLOW HYDRAULICS TROUBLESHOOTING
PROBLEM
No switch operation
No selector valve operation
Hydraulic oil overheats
POSSIBLE CAUSE
No battery voltage to switch
CORRECTION
Check power supply at 15-amp fuse (attachment) engine fuse panel
Check DKGN/R (Dark Green/Red) wire from fuse to switch
Inoperative switch
No battery voltage to selector valve
Replace switch
Check switch for proper operation
No circuit ground
Check W/T (White/Tan) wire from switch to selector valve
Check B (Black) ground wire for proper grounding
No selector valve spool movement
Using 1/2
″
quick couplers
Check valve spool for binding and sticking
Must use 3/4
″
quick couplers
Control valve and boom steel lines and hoses were not changed from
5/8 ″ to 3/4 ″
Change lines and hoses to 3/4 ″
Operating high flow when not required
Turn high flow switch to the “OFF” position
Operating high flow at relief pressure continuously
Operate attachment at lesser load
Operating attachment when not applying a load to the attachment
Stop attachment when not loaded
(moving from one work area to another)
Operating attachment when high oil flows are not required
Turn high flow switch to the “OFF” position
Restriction in pressure or return lines
Check and repair
Oil cooler restricted not allowing cooling air to flow properly
Clean oil cooler and radiator
88-16
SECTION 88 - ACCESSORIES
PROBLEM
No increase in hydraulic oil flow when switch is in the “ON” position
POSSIBLE CAUSE
No switch operation
No selector valve operation
Low hydraulic power
CORRECTION
Check power supply circuit
Check power supply from switch
Selector valve spool binding Check for spool binding and repair
Drive belt slipping or broken
Low high flow relief valve pressure setting
Check drive belt adjustment or replace
Check and replace relief valve
Low main system relief valve setting
Check and replace relief valve
Leaking control valve plugs, leaking oil to return
Check O ring and backup washer on plugs
Inefficient gear pump (main)
Inefficient gear pump (high flow)
Check pump efficiency, repair or replace
Check pump efficiency, repair or replace
88-17
SECTION 88 - ACCESSORIES
HIGH FLOW HYDRAULICS
COMPONENT REPLACEMENT
Op. 35 724
High Flow Selector Valve Replacement
To access the selector valve, 1, the seat must be raised and latched in the raised position.
The left hydrostatic control lever assembly must be removed.
The cab may be tilted forward for easier access.
1
Rebuild the selector valve with new O rings on the spool and fittings at 1, and on both ends of the coil at
2.
To check the coil, use an ohmmeter and put one lead on one wire and the other on the other wire; the ohms reading should be between 7.5 and 11.5. If the coil is not within specification, replace it.
27
28
88-18
SECTION 88 - ACCESSORIES
Op. 35 710
High Flow Pump Removal / Disassembly
1. Clean the pump thoroughly and mark the pump assembly, 1, to ensure proper reassembly.
2. Remove the high pressure tube, 2, from the pump fitting, 3. Remove the fitting, 3, from the pump.
3. Remove the pump housing hardware, 4, and separate the end plate and body sections.
IMPORTANT: The pump body is aluminum and can be easily damaged. BE CAREFUL not to damage machined surfaces. DO NOT use a screwdriver or other hard, sharp objects to pry the pump from the plate.
The high flow gear pump consists of:
19997758
4
1. Wear plate assembly
2. Idler gear assembly
3. Drive gear
4. Pump body
5. Pump back plate
1
2
1
19997759
Op. 35 710 20
High Flow Pump Parts Inspection
1. Inspect the pump mounting plate for excessive wear. The oil grooves in the bushings, 1, should be at approximately 37
°
to the pressure side. If the bushing oil grooves are not positioned as noted, the bushings have turned in the plate - the plate should be replaced.
The bushings in the plate should be 3.20 mm
(0.126
″
) above the surface of the plate. Replace the plate if the I.D. of the idler gear bushing exceeds 19.2 mm (0.755
″ ).
2. Check the seal areas, 2, for scratches or damage that could prevent a good seal.
19997762
2
3
29
3
4
5
30
1
2
31
88-19
SECTION 88 - ACCESSORIES
3. Inspect the pump back plate for excessive wear.
The oil grooves in the back plate bushings, 1, should be at approximately 37 ° to the pressure side. If the bushing oil grooves are not positioned as noted, the bushings have turned in the plate.
The plate should be replaced under this condition.
The bushings in the plate should be 3.20 mm
(0.126
″
) below the surface of the plate. Replace the back plate if the I.D. of a bushing exceeds
19.2 mm (0.755
″ ).
Check for scoring on the face of the back plate,
2. Replace the back plate if wear exceeds 0.038
mm (0.0015
″ ).
4. Inspect the pump body, 3, for excessive wear.
Check the pump body inside the gear pockets for excessive scoring or wear.
Replace the pump body if the I.D. of gear pockets, 4, exceed 43.7 mm (1.719
″
).
5. The wear plate, 1, seal, 2, and backup gasket, 3, should be replaced when the pump is rebuilt. Inspect for damage, such as nicks and tears, to determine if any problem existed. The flat Tefloncoated surface towards the gears and should not show any scratches or grooves that can be caught with a fingernail.
2
19997761
3
1
3
2
4
1
32
19984487
6. Inspect the pump gear teeth, 1, for excessive wear. Inspect the drive gear key, 2, to ensure it is not sheared.
The gear shaft assemblies should measure at least 19.0 mm (0.748
″
) in the bushing area, 3. If the shaft measures less than the specified diameter, replace the gear assembly.
The gear width should be close to when new:
12.45 mm (0.51 in.). If the gears measure much less than the specified width, the gear pump will not develop sufficient flow/pressure for loader application.
NOTE: If replacement of the gear assemblies is necessary the gear assemblies should be replaced in pairs.
19997760
2
1
3
33
34
88-20
SECTION 88 - ACCESSORIES
High Flow Pump Reassembly / Installation
1. Coat all parts with a thin coat of petroleum jelly or oil to aid in reassembly.
2. Clean the mounting plate surface thoroughly and install a new O ring, 1. Install the shaft key, 2, in the drive shaft.
1
3. Install the seal, 1, and backup gasket 2, on the wear plate, 3. BE SURE that the flat area, 4, on the gasket AND seal, 5, are properly aligned and lay flat when installed in the wear plate.
19997762
1
5
2
2
3
35
4
19984487
36
NOTE: The gasket AND seal must align and lay flat when installed in the wear plate.
3
1
19997767
37
88-21
SECTION 88 - ACCESSORIES
4. Install the wear plate assembly, 1, with the gasket/seal side towards the pump mounting plate with the mid section cut away on the suction side,
2, of the pump.
1
2
19997763
5. Install the drive gear, 1, on the drive shaft, slipping the groove over the shaft key, 2. Install the idler gear assembly, 3, into the bushing. Rotate the gears to help slide the idler gear into place.
3
6. Make sure the dowel pins, 1, are in place and install the body on the plate with the half-moon cavities in the body facing out away from the plate. Check that the reference marks made during disassembly align correctly.
NOTE: The small half-moon cavity, 2, must be on the pressure side of the pump.
19997764
1
1
19997765
1
2
2
38
39
40
88-22
SECTION 88 - ACCESSORIES
7. Install a new O ring, 1, in the back plate.
1
19997761
8. Install the pump back plate, 1, over the gear shafts. Check that the reference marks made during disassembly align correctly.
9. Install the housing hardware with the eight bolts,
2, and sealing washers. Tighten the bolts evenly in a criss-cross pattern to 34 - 38 N
⋅ m (25 - 28 ft.
lbs.).
10. Install the pump port fitting, 3, and the high pressure tube, 4, and tighten securely.
19997758
2
1
4
41
3
42
88-23
High Flow Electrical Wiring Diagram
SECTION 88 - ACCESSORIES
43
High Flow Hydraulic Oil Flow Diagram
19997766
88-24
44
SECTION 88 - ACCESSORIES
Op. 55 000
HORN
The horn kit provides an operator-controlled device to alert bystanders and other machine operators.
The horn button, 1, is located in the top of the left hydrostatic control lever.
19984626
Horn Wiring Diagram
1
45
46
88-25
SECTION 88 - ACCESSORIES
Op. 90 000
SHOULDER BELT (SEAT)
The shoulder belt can be installed with the lap seat belt.
The shoulder belt is recommended anytime a front cab door is installed.
If the shoulder belt becomes completely retracted or the belt becomes locked, the web must move back into the retractor approximately 1/2
″
with the retractor in 90/90 degree or proper mounting position.
When the belt is retracted 1/2 ″ , hold the belt straight up and pull the belt up slowly, 1. The belt will not unlock and pull out in any other position.
The shoulder belt support pivot bolt, 1, must be loose enough to allow the belt to pivot. If the belt will not pivot properly, it will not adjust to fit the operator.
47
48
49
88-26
SECTION 88 - ACCESSORIES
Op. 88 000
SLOW-MOVING VEHICLE (SMV) SIGN KIT
The Slow-Moving Vehicle (SMV) kit mounts to the rear door of the skid-steer loader when the loader is operated on roadways.
On the louvered rear door, a bracket, 1, must be installed to hold the SMV sign in place on top of the door.
1. Attach the angle, 1, with one 5/16 ″ x 1-1/4 ″ carriage bolt from the kit and nut and M8 lock washer previously removed at 2.
2. Attach the spade socket to the angle at 3 using two 5/16
″
x 1
″
carriage bolts, M8 lock washers, and nuts.
3. Assemble the SMV sign, 4, to the support, 5, using two #10 x 1/2 ″ machine screws and flange nuts at 6.
4. Mount the SMV sign assembly in the spade socket as shown at 7.
50
51
88-27
SECTION 88 - ACCESSORIES
Op. 55 000
WARNING LIGHT (ROTARY BEACON)
The beacon light is a visual alerting device for bystanders and other machine operators. The beacon light’s magnetic base mounts the light securely to any part of the roof or frame.
The beacon light switch, 1, is located in the ignition key switch panel in the upper right corner of the overhead dash.
To remove the switch, disconnect the negative (–) ground battery cable, remove the key switch panel hardware, 2, and tilt the panel down.
Disconnect wires from the switch, squeeze the switch retaining tabs in, and remove the switch from the panel.
52
53
54
88-28
Beacon Switch Wiring
SECTION 88 - ACCESSORIES
Beacon Wiring Diagram
NOTE: When attaching ground wires, always place the heaviest ground wire next to the ground surface and then stack the remaining ground wires according to size on top of the heaviest wire.
55
88-29
56
SECTION 88 - ACCESSORIES
Beacon Bulb Replacement
Bulb only #69AG13009AA (H1 12V 55W)
To replace the bulb, remove the three screws attaching the lens to the base and lift the lens from the base.
Squeeze the bulb retaining tabs to separate the bulb from the holder.
Remove the bulb assembly from the wire connector.
57
58
88-30
SECTION 88 - ACCESSORIES
Op. 55 000
WARNING LIGHTS (FOUR-WAY FLASH-
ERS/TURN SIGNAL/HORN)
The four-way flashing lights on the front and rear of the loader provide a visual alerting device to bystanders and other machine operators.
The warning light switch, 1, is located in the ignition key switch panel in the upper right corner of the overhead dash.
To remove the switch, disconnect the negative (–) ground battery cable, remove the key switch panel hardware, 2, and tilt the panel down.
Disconnect the wires from the switch. Squeeze the switch retaining tabs in and remove the switch from the panel.
59
60
61
88-31
Warning Light Switch Wiring
SECTION 88 - ACCESSORIES
62
88-32
SECTION 88 - ACCESSORIES
19985531
63
Warning Light (Four-way) Wiring Diagram
NOTE: When attaching ground wires, always place the heaviest ground wire next to the ground surface and then stack the remaining ground wires according to size on top of the heaviest wire.
88-33
SECTION 88 - ACCESSORIES
Warning Light Bulb Replacement
Amber lens with bulb #9841566
Bulb only #529068
Op. 55 404 10
Front Light
1. Remove the bezel, 1, retaining screws and remove lens from support.
2. Disconnect the wire harness from the bulb holder.
3. Rotate the light bulb holder and element assembly from the lens and remove from the lens.
4. Insert the new bulb into the lens and rotate to lock into position, using caution not to touch the bulb element.
IMPORTANT: Touching the light bulb element may damage the element and cause a premature failure.
Op. 55 404 10
Rear Light
1. Remove the bezel, 1, retaining hardware and remove the lens from the light bar.
NOTE: The remaining light lens will be loose in the light bar.
2. Disconnect the wire harness from the bulb holder.
3. Rotate the light bulb holder and element assembly from the lens and remove from the lens.
4. Insert the new bulb into the lens and rotate it to lock into position, using caution not to touch the bulb element.
IMPORTANT: Touching the light bulb element may damage the element and cause a premature failure.
64
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88-34
SECTION 88 - ACCESSORIES
LABOR GUIDE
The following labor amounts are listed as a guide only. Working conditions and experience will vary the time it actually takes to complete each job.
Job Description Hours
Arm pads (cab)
Remove and replace (2)
Armrest (seat)
Remove and replace (1)
Attachment 12-Volt Electric Power Supply
Remove and replace outlet
Remove and replace wire harness
Back-Up Alarm
Remove and replace back-up alarm
Remove and replace back-up alarm linkage and adjust
Remove and replace back-up alarm wire harness
Block Heater (engine)
Remove and replace block heater (engine)
High Flow Hydraulics
Remove and replace gear pump
Remove and replace selector valve (includes tilting cab/boom forward)
Remove and replace wire harness
Horn
Remove and replace horn button
Remove and replace horn
Remove and replace horn wire harness
Seat/Shoulder Belt
Remove and replace belt (must replace complete assembly)
Warning Light (rotary beacon)
Replace bulb
Warning Lights (four-way flashing lights)
Remove and replace switch
Remove and replace lamp bulb or lamp assembly (1)
Remove and replace wire harness
0.5
0.25
0.25
0.5
0.25
1.0
0.5
0.5
2.0
2.5
0.5
0.5
0.25
0.5
1.0
0.25
0.05
0.25
2.0
88-35
SECTION 88 - ACCESSORIES
88-36
SECTION 90 – PLATFORM, CAB, BODYWORK, AND DECALS
Chapter 1 – Cab and Seat
Section
CONTENTS
Description Page
90-1
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
GENERAL INFORMATION
Op. 90 108
SAFETY DECALS
The safety decals located on the skid steer are intended for the personal safety of you and those working with you.
Keep the decals legible. If they are not legible, replace as necessary.
SEAT AND SEAT PAN SUPPORT
Incorporated in the seat and seat belt buckle are switches that tie the seat and seat belt into the EIC
(Electronic Instrument Cluster) Advanced Warning
System. When the seat belt is unbuckled and/or the operator is out of the operator’s seat, the boom and bucket control valve spools will be locked in the neutral position. The operator will have to properly sequence the system to unlock the controls, sit in the seat and buckle the seat belt.
The seat and seat pan support can be locked up in the raised position as shown at 1.
CAUTION
Do not work under a raised seat unless it is securely latched in the raised position.
1
2
The seat/pan support assembly support rod, 1, is shown in the raised latched position at 2.
To lower the seat assembly, raise the seat upward to the top of the cab and pull the support rod, 1, forward to unlatch and lower the seat assembly.
2
1
3
90-2
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
When the operator’s seat is returned to the operating position, make sure it is securely latched at 1.
1
CAUTION
Do not operate the skid steer unless the operator’s seat is securely latched in the operating position.
1
Op. 90 152
CAB INNER SHELL
The operator’s seat and inner shell assembly (shown removed) are isolated on rubber mounts located at 1, one each side at front and at 2, one each side at rear.
19984338
4
5
Op. 90 120 10
SEAT REMOVAL
This section describes how to remove the seat and seat pan support assembly.
Op. 90 120 12
SEAT PAN SUPPORT REMOVAL
1. Disconnect the negative (-) battery cable.
IMPORTANT: Disconnect the (-) negative ground cable. Failure to disconnect the battery may result in damage to the EIC (Electronic Instrument Cluster) monitoring system and other electrical components.
2. Disconnect the seat and seat belt wire harness connector, 1.
6
90-3
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
3. Remove retaining pin from latch rod at 1 and remove rod.
4. Remove the seat pan support hardware at 2.
5. Unlatch the seat pan support at 3, and lift the seat and pan support assembly from the loader.
2
1
3
6. The right side of the seat and pan support holds the seat belt buckle, 1, wire harness, 2, and seat latch rod, 3.
7. To remove the seat belt buckle, remove the wire harness retaining clamp, 4, and buckle hardware, 5.
NOTE: When reinstalling the seat belt buckle hardware, 5, tighten the pivot bolt tight enough to hold the belt in a set position but still allow movement of the buckle to the front or rear as required by the operator.
8. Remove the seat retaining hardware, 1, to separate the seat and seat track from seat pan support. Remove the wire clamp at 2, if the seat/seat belt wire harness is being replaced.
9. Holding the seat in place, unplug the seat switch(es). Disconnect the wire harness from the switch(es) by releasing the latch away from the switch.
19984338
7
8
9
90-4
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
10. To remove the seat tracks from the seat assembly remove the track retaining hardware,
1.
Op. 55 201 15
11. Remove the switch(es) from the seat pan, 2.
Note the standard seat uses one switch and the deluxe seat uses two switches as shown.
12. To remove the seat/seat belt wire harness, remove the grommet at 1, and pull the harness from the seat pan.
13. Remove the seat pan latch rod, 2, remove the retaining hardware, 3.
10
11
SEAT, SWITCH AND PAN REINSTALLATION
1. Install the switch(es) into the seat pan, making sure the switch is seated into the hole in the seat pan, 1.
IMPORTANT: If the switch is not seated properly when the retaining hardware is tightened, the switch flange will be broken.
2. Reconnect the wire harness to the switch(es) and reinstall the seat retaining hardware. Make sure the harness connector latches are engaged.
12
90-5
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
3. Reattach the seat to the seat pan support with retaining hardware at 1.
NOTE: If the seat/seat belt wire harness was removed, reinstall the wire grommet in seat pan at 2, and wire clamp on back of seat, 3, to retain the wire harness.
4. Reinstall the seat and seat pan support assembly into the loader and attach with hardware at 1.
If the seat pan latch rod, 2, or latch plates, 3, were removed, they may require adjustment to ensure proper seat latching.
3 1
2
3
13
5. To adjust the latches, 1, lower the seat down to the operating position and slide the latches, 1, to obtain full engagement of latches and latch rod.
After the latches are adjusted, release latch rod, raise seat and lower seat to operating position.
Try lifting on the front of the seat to verify seat pan support is latched securely.
19992567
14
15
90-6
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
6. Reconnect the seat/seat belt wire harness connector to the main wire harness behind the seat at 1.
NOTE: Position the seat/seat belt and main wire harness to the front of the boom lock linkage, 2, to prevent interference. If the wires are to the back side of the linkage, the wires will not stay connected when the seat is raised.
CAB INNER SHELL
This section describes how to remove and install the cab inner shell.
Op. 90 152 34
REMOVAL
1. Disconnect the negative (-) battery cable.
IMPORTANT: Disconnect the (-) negative ground cable. Failure to disconnect the battery may result in damage to the EIC (Electronic Instrument Cluster) monitoring system and other electrical components.
2. Disconnect the seat and seat belt wire harness connector, 1.
3. Remove the EIC board retaining hardware, 1, and remove the EIC board from the overhead dash area.
4. Unplug the two wire harness connectors from the
EIC, taking care to not stress or bend the plastic locking ramps on the connectors.
NOTE: Note the positioning of the connectors to the
EIC board, and reconnect in the correct position during installation. If the connector is not connected properly, damage to the EIC may occur.
IMPORTANT: Do not service the EIC board with magnetized tools, wrenches, screwdrivers, etc., or magnets. Severe damage to the EIC board may occur.
16
17
18
90-7
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
5. Remove the right and left headliner supports retaining hardware, 1, right side shown, and remove both supports and headliner.
6. Remove the fuse panel retaining hardware, 2, and lower the fuse panel.
DO NOT remove any wires from any switches or fuse blocks.
1
2
19984336
7. Remove the ignition switch panel hardware, 1, and lower the switch panel.
DO NOT remove any wires from any switches.
19
20
8. Remove any ground wires attached to cab ground terminal at 1.
9. Remove any wire harness ties or clamps in the upper cab area at this time. Remove the wire harness, fuse and switch panels from the right cab side sheet.
10. If the unit is equipped with front lights, the light harness and light bulbs must be removed.
IMPORTANT: Touching the light bulb element may damage the element and cause a premature failure.
21
90-8
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
11. Remove the light assembly, 1, from the pod by pushing the light assembly to the left, unlatching it from the pod.
12. Remove light pod retaining hardware, 2, and remove the pod assembly.
2
A5371-9
1
13. Remove the front cross support, 1, by removing hardware, 2, separating the cross member from the right and left side panels.
22
23
14. Remove the rear window and frame assembly retaining hardware, 1, and lift the window and frame from the loader.
24
90-9
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
15. Remove the retaining pin from latch rod at 1, and remove the rod.
16. Disconnect the seat/seat belt wire harness from the main harness, unless previously unplugged.
Remove the seat pan support hardware at 2.
17. Unlatch the seat pan support at 3, and lift the seat and pan support assembly from the loader.
2
1
3
18. Remove the four retaining screws from the front shield, 1, and the eight retaining bolts from the step shield, 2. Remove both shields from the loader.
19984338
25
19. Remove the retaining hardware, 1, of the right and left fenders to access the front isolator mount bolts and wire harness.
1 1
26
27
90-10
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
20. Remove all wire harness retaining clamps and ties, 1, from the side panels.
Cut wire tie at keeper bar at left front to rear of cab pivot.
1 1 1
1
28
21. Remove any wire harness clamps and cut wire ties along the rear of the seat support and side panels, 1.
22. Remove the upper rear support retaining hardware, 1, right and left side and remove support.
1
1
1
1
29
30
90-11
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
23. Remove the rear seat support, 1, hardware at 2, and the isolator mount hardware, 3.
31
24. Remove the right and left hydrostatic control handle assembly retaining hardware, 1. Unhook the hydrostatic control linkage and auxiliary boom hydraulic linkage (if equipped). Unplug any electrical connections, and lift the control assemblies from the loader.
25. Remove the left and right side shield isolator and hardware at 1 (right side shown).
19992568
1
32
33
90-12
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
26. Lift the wire harness, 1, with the switch and fuse panels from the right side shield. Remove any remaining wire ties or clamps from the wire harness and right side shield, if not previously removed.
34
27. Remove the throttle control cable, 1, from the control lever at 2. Remove the cable retaining nut, 3, and slide the cable down through the right side shield at 4.
35
28. Remove the cotter pins from the parking brake control link spring at 1. Unhook the spring link from the control rod, 2.
29. Remove the control rod support hardware.
30. Remove the control lever hardware.
31. Rotate the control rod down to remove link from the side shield, and slide the rod from the support.
Now the side shields can be removed from the loader
ROPS frame.
19992572
1
2
36
90-13
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
Cab inner shell removed from the loader ROPS.
1. Right side shield
2. Left side shield
3. Headliner supports
4. Upper rear support
5. Lower seat support
6. Front support (dash) not shown
The loader ROPS with the seat and inner shell removed.
37
38
REINSTALLATION
1. Position the right and left side shields inside the loader frame.
2. Install the front side isolators and retaining hardware, 1. Do not tighten at this time.
39
90-14
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
3. Lay the main cab wire harness along the inside of the right side shield, 1, at the top and right rear corner.
40
4. Position the side shields and install the rear lower support hardware, 1, isolators and retaining hardware, 2. Do not tighten at this time.
5. Install the upper rear support, 1, and hardware,
2. Do not tighten at this time.
41
2
42
90-15
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
6. Install the front cross member, 1, and retaining hardware. Do not tighten at this time.
7. Position the inner shell assembly squarely with the ROPS frame. Make sure the wire harness, 2, is positioned to prevent damage to the harness when the inner shell isolators and support hardware are tightened.
8. Tighten the front support hardware.
9. Tighten the hardware, 1, for the upper rear support, 2.
2
43
44
10. With the inner shell positioned and cross supports securely tightened, tighten the front, 2, and rear, 3, isolator support hardware at this time.
45
90-16
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
11. Reinstall all wire harness retaining clamps and plastic ties to secure the harness, 1, in the upper right rear corner of the operator’s cab.
1
12. Reinstall the wire harness clamps and ties along the rear of the operator’s seat. Make sure the harness is positioned to the inside of the boom lock linkage at 2 to prevent interference.
13. Reinstall the wire harness clamps and ties along the left side of the operator’s cab at 1.
14. Position the rear of the harness and engine relay/fuse panel and install harness clamps and ties at 2.
15. With the harness positioned pull a loop (excess) of harness through the support at 3, to retain the excess wire harness.
46
47
48
90-17
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
16. Reinstall the light pods, light wire harness and lights.
17. Reconnect the wire harness to all switches and
EIC (Electronic Instrument Cluster) previously removed.
NOTE: Plug the two wire harness connectors into the
EIC, noting the correct positioning of the connectors.
If the connectors are not connected properly, damage to the EIC may occur.
IMPORTANT: Do not service the EIC board with magnetized tools, wrenches, screwdrivers, etc., or magnets. Severe damage to the EIC board may occur.
18. Remove any paint from the ground surface and attach ground wires at 1.
NOTE: When attaching ground wires, always place the heaviest ground wire next to the ground surface and then stack the remaining ground wires according to size on top of the heaviest wire.
19. Remove any paint from the ground surface and attach the ground strap, 1, from the cab inner shell to the lower main frame.
49
50
20. Reinstall the wire harness along the right side shield at 1. Install wire clamps and ties to prevent harness damage. Install the service/run switch, fuse panel and ignition switch panel.
51
90-18
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
21. Reinstall the parking brake control rod and pivot bearings. Install the right bearing into the right support, 1.
Slide control rod, 2, into right bearing, place the left bearing and support over rod at 3, and rotate control rod link into cab at 4. Attach the left bearing support to the cab at 5.
Assembly the brake handle and attach to the control link at 6.
5
6
2
3
4
1
52
22. Slide the spring, 1, and washer, 2, over the end of rod, 3. Insert the rod and spring assembly into the handle at 4. Insert bushing, 5, into latch plate,
6, and insert the latch plate into handle at 7, with the extended area, 8, to the rear (engine side) of lever and position the rod assembly, 3, so the hook is back of the latch plate at 9.
53
23. Attach the handle assembly, 1, to the control link at 2. Slide the handle grip, 3, over end of handle,
1. Use silicone or weather strip glue to hold grip in position.
54
90-19
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
24. Reconnect the spring links, 1, to the control rod at 2 and install the cotter pins.
2
1
19992572
25. Reinstall the seat/seat pan support assembly and connect the seat/seat belt wire harness to the main wire harness, 1. Make sure the wire harness, 2, is to the inside of the boom lock linkage to prevent interference when the seat pan support assembly is pivoted up to the raised, latched position.
26. Reinstall the headliner and supports.
55
56
27. Reinstall the right and left hydrostatic control lever assemblies, 1.
After the assemblies are installed, check the levers for parallel, external stop, and neutral adjustment. If adjustment is required, refer to the operator’s manual for detailed adjustment information.
28. Reinstall the rear window assembly.
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1
57
90-20
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
29. Slide the throttle cable up through the hole in the left cab panel and secure with retaining nut at 1.
Attach the control lever, 2, to the cab panel at 3, with 3/8
″
x 1-1/2
″
cap screw; friction disc, 4; spring, 5; 3/8 ″ flat washer; and locknut. Tighten the pivot hardware to hold the control lever in set position. Over tightening will require more effort to set throttle.
30. Reconnect the (-) negative ground battery cable.
31. Reinstall any shields and fenders previously removed.
58
90-21
Op. 90 108
SAFETY DECALS
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
The following safety decals have been placed on your machine in the areas indicated. They are intended for the personal safety of you, and those working with you. Please take this manual, walk around your machine and note the content and location of these warning signs. Review these decals with your machine operators.
Keep the decals legible. If they are not, obtain replacements from your New Holland dealer. The decal part numbers are listed with each decal.
1. Danger: Do not allow passengers to ride on the skid steer at any time. Do not get under boom unless supported by the boom lock pins.
Part #86521685
2. Caution: Do not allow anyone to operate the skid steer without proper instruction.
Part #86521688
90-22
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
3. Danger: Before exiting the skid steer, lower the lift arms and attachment to the ground or rest lift arms on the boom stops. Stop engine and engage the parking brake.
Part #86521683
4. Warning: Do not overload! Never lift more than the maximum SAE load rating of the skid steer.
Never transport a loaded bucket at full height.
Operate the skid steer with the load as low as possible.
Part #86521716
LS160 - 682 kg/1500 lbs. (Mfg. Rating)
Part #86521717
LS170 - 770 kg/1700 lbs. (Mfg. Rating)
5. Warning: Never operate the skid steer without the seat belt securely fastened.
Part #86521686
90-23
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
6. Warning: Keep clear of moving parts. Keep bystanders clear of the skid steer at all times unless the boom is down on the ground or the boom is resting on the boom lock pins and engine is off. Never extend any part of the body outside of the operator’s area.
Part #86521673
7. Warning: Keep clear! Rotating fan - stop engine.
Part #9828825
8. Warning: Do not allow anyone near the skid steer while the engine is running and the skid steer is operational.
Part #86509972
9. Caution: Do not spray ether into air intake.
Explosion and injury could result.
Part #796286
90-24
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
10. Danger: Use only the New Holland cab jack kit to tilt the cab. Read instructions before tilting cab.
Do not remove cab hardware until cab jack is installed. Failure to do so may cause cab to fall causing serious injury or death.
Part #86521713
11. Danger: New Holland skid steer cab tilting tool.
Read cab tilting instructions and use with proper mounting brackets before tilting cab. (Located on the cab tilting jack).
Part #86508506
90-25
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
LABOR GUIDE
The following labor amounts are listed as a guide only. Working conditions and experience will vary the time it actually takes to complete each job.
Job Description
Remove and replace seat, seat support
Remove and replace switches (1)
Remove and replace seat support lock linkage
Remove and replace cab inner shell
Hours
1.5 hrs.
0.5 hrs.
0.5 hrs.
6.5 hrs.
90-26
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Key Features
- Compact size and agile maneuverability for working in confined spaces and on uneven terrain
- High lifting capacity and breakout force for handling heavy loads and tough digging jobs
- Comfortable operator's cab with excellent visibility and intuitive controls for operator comfort and productivity
- Optional two-speed transmission for increased travel speed and efficiency
- Optional hydraulic quick-attach system for fast and easy attachment changes
- Optional enclosed cab for protection from the elements
- Wide range of attachments available to expand the machine's versatility
Related manuals
Frequently Answers and Questions
What is the lifting capacity of the LS170?
What is the breakout force of the LS170?
What is the top travel speed of the LS170?
What are the dimensions of the LS170?
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