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(max-width:512px){.StaticContentRating-module_textLabelJumbo__7981-{font-family:var(--spl-font-family-body-primary),var(--spl-font-family-body-secondary);font-style:normal;font-weight:var(--spl-font-weight-title);line-height:1.3;font-size:1.125rem}}.StaticContentRating-module_textLabelJumboZero__oq4Hc{font-family:var(--spl-font-family-body-primary),var(--spl-font-family-body-secondary);font-style:normal;font-weight:var(--spl-font-weight-body);line-height:1.4;font-size:1.25rem;color:var(--spl-color-text-secondary)}@media (max-width:512px){.StaticContentRating-module_textLabelJumboZero__oq4Hc{font-family:var(--spl-font-family-body-primary),var(--spl-font-family-body-secondary);font-style:normal;font-weight:var(--spl-font-weight-body);line-height:1.4;font-size:1.125rem}}.StaticContentRating-module_textLabelStacked__Q9nJB{margin-left:0}.Textarea-module_wrapper__C-rOy{display:block}.Textarea-module_textarea__jIye0{margin:var(--space-size-xxxs) 0;min-height:112px}.TextFields-common-module_label__dAzAB{font-family:var(--spl-font-family-body-primary),var(--spl-font-family-body-secondary);font-style:normal;font-weight:var(--spl-font-weight-button);line-height:1.5;font-size:1rem;color:var(--spl-color-text-primary);margin-bottom:2px}.TextFields-common-module_helperText__0P19i{font-size:.875rem;color:var(--spl-color-text-secondary);margin:0}.TextFields-common-module_helperText__0P19i,.TextFields-common-module_textfield__UmkWO{font-family:var(--spl-font-family-body-primary),var(--spl-font-family-body-secondary);font-style:normal;font-weight:var(--spl-font-weight-body);line-height:1.5}.TextFields-common-module_textfield__UmkWO{font-size:1rem;background-color:var(--spl-color-background-textentry-default);border:1px solid var(--spl-color-border-textentry-default);border-radius:var(--spl-common-radius);box-sizing:border-box;color:var(--spl-color-text-primary);padding:var(--space-size-xxxs) 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)}80%{background-image:url(data:image/png;base64,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Minigador 465 New Hollan
Minigador 465 New Hollan
Minigador 465 New Hollan
COMPLETE CONTENTS
SECTION 00 - GENERAL INFORMATION......................................................................................................3
SECTION 39 - FRAMES.................................................................................................................................11
SECTION 88 - ACCESSORIES......................................................................................................................16
The following pages are the collation of the contents pages from each section and
chapter of the L160, L170 Repair Manual. Complete Repair Manual part # 87634733.
The sections used through out all New Holland product Repair Manuals may not be used
for each product. Each Repair Manual will be made up of one or several books.
Each book will be labeled as to which sections are in the overall Repair Manual and the
sections that each book contains.
The sections listed above are the sections utilized for the L160, L170 Skid Steer.
1 87634734 05/07
2
SECTION 00 – GENERAL INFORMATION
BOOK 1 - 87634735
CONTENTS
3
SECTION 10 – ENGINE
BOOK 1 - 87634735
4
10 304 38 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
29 100 50 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
10 236 08 Fuel Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96
Turbocharger - L170 N844T Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101
10 250 30 Turbocharger Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103
Miscellaneous Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
10 223 10 Shut-off Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-117
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-119
Labor Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
5
SECTION 27 – REAR DRIVE AXLE (GEARBOXES)
BOOK 2 - 87634738
Chapter 1 – Gearboxes
CONTENTS
CONTENTS
8
SECTION 35 - HYDRAULIC SYSTEM
BOOK -3 - 87634740
Chapter 1 - Valves, Gear Pump, Cylinders, and Pedal Controls
Contents
Section Description Page
35 000 -
General Information
..............................................................................................................................................35-3
Hydraulic System Compatibility ............................................................................................................................35-4
Boom Cylinder Pivot .....................................................................................................................................35-6
Pins
Boom Cylinder Pivot Pin Location and Machine.......................................................................................35-6
Usage
Control Valve Power ................................................................................................................................35-7
Beyond
Specifications
.......................................................................................................................................................35-8
Troubleshooting
..................................................................................................................................................35-12
Auxiliary Boom Hydraulics Troubleshooting .......................................................................................................35-16
Hydraulic System ...................................................................................................................................35-18
Testing
Hydraulic System Oil ..................................................................................................................................35-24
Flow
Control Valve - Bucket Spool .................................................................................................................35-25
Shifted
Control Valve - Boom Spool...................................................................................................................35-26
Shifted
Control Valve - Auxiliary Spool...............................................................................................................35-27
Shifted
35 710 02
Main System Pressure ..............................................................................................................................35-28
Tests
Checking Main System Pressure at Boom Cylinders .........................................................................................35-30
Checking Main System Pressure at Bucket Cylinders .......................................................................................35-31
Checking Main System Pressure at Auxiliary Boom Hydraulic Quick Couplers .................................................35-32
Boom Circuit Relief Valve ...........................................................................................................................35-33
Test
Gear Pump Flow Efficiency ........................................................................................................................35-35
Test
Boom and Bucket Spool Lock Solenoid .....................................................................................................35-39
Test
Hydraulic, Hydrostatic System Air Ingress .................................................................................................35-41
Test
Control Valve Specification ...............................................................................................................................35-43
s
35 724 50
Control Valve Removal.......................................................................................................................................35-44
Control Valve Disassembly and Inspection ........................................................................................................35-45
Control Valve Parts Inspection ...........................................................................................................................35-49
Control Valve Reassembly .................................................................................................................................35-50
Control Valve Reinstallation ...............................................................................................................................35-53
Hydraulic Pump Specifications ...........................................................................................................................35-54
35 710 10
Hydraulic Pump Removal ...................................................................................................................................35-55
35 710 20
Hydraulic Pump Removal/Disassembly (Without High .............................................................................35-56
Flow)
High Flow Pump Parts Inspection ......................................................................................................................35-58
Hydraulic Pump Parts Inspection .......................................................................................................................35-59
Hydraulic Pump Reassembly/Installation (Without High ...........................................................................35-61
Flow)
Hydraulic Pump and High Flow Pump Reassembly/Installation .........................................................................35-64
New Hydraulic Pump Installation (Without High .......................................................................................35-70
Flow)
New Hydraulic Pump/High Flow Pump Installation ............................................................................................35-72
Gear Pump Start-up Procedure ..........................................................................................................................35-78
Cylinders, Boom and..............................................................................................................................35-79
Bucket
35 710 10
Boom Cylinder Removal .....................................................................................................................................35-81
35 730 18
Boom Cylinder Disassembly ...............................................................................................................................35-83
Boom Cylinder Parts Inspection .........................................................................................................................35-84
Boom Cylinder Reassembly ...............................................................................................................................35-85
Boom Cylinder Reinstallation .............................................................................................................................35-87
9
35 730 10
Bucket Cylinder Removal ...................................................................................................................................35-87
35 730 13
Bucket Cylinder Disassembly .............................................................................................................................35-88
Bucket Cylinder Parts Inspection ........................................................................................................................35-89
Bucket Cylinder Reassembly ..............................................................................................................................35-90
Bucket Cylinder Reinstallation ............................................................................................................................35-92
Pedal Controls
....................................................................................................................................................35-93
35 724 16
Pedal Removal (With Boom and Bucket Pedal Controls) ...................................................................................35-93
Pedal Inspection (With Boom and Bucket Pedal Controls ..................................................................................35-93
Pedal Reinstallation (With Boom and Bucket Pedal Controls ............................................................................35-95
35 724 16
Pedal Removal (With Boom and Bucket Hand Controls ....................................................................................35-98
Pedal Inspection (With Boom and Bucket Hand Controls ..................................................................................35-99
Pedal Reinstallation (With Boom and Bucket Hand Controls ...........................................................................35-100
35 300
Hydraulic Cooling, Filter, Reservoir .....................................................................................................35-103
System
Filter .....................................................................................................................................................35-104
System
Filter Removal
..................................................................................................................................................35-104
35 705 05
Base Removal
..................................................................................................................................................35-104
Reassembly
......................................................................................................................................................35-105
Oil..........................................................................................................................................................35-105
Cooler
35 300 10
Oil Cooler Removal ..........................................................................................................................................35-105
Oil Cooler Reassembly .....................................................................................................................................35-106
35 300
Oil Reservoir
.....................................................................................................................................................35-106
35 300 10
Oil Reservoir Removal ......................................................................................................................................35-107
Oil Reservoir Reinstallation ..............................................................................................................................35-108
Adapting Attachments ......................................................................................................................................35-109
Labor ......................................................................................................................................................35-110
Guide
Machines Equipped With Pilot Controls
Specifications
...................................................................................................................................................35-111
Loader Function Troubleshooting .....................................................................................................................35-112
Pilot Pressure ...........................................................................................................................................35-113
Test
Illustration - Loader ..............................................................................................................................35-114
Control
Right Control Handle - Removal .......................................................................................................................35-115
Right Control Handle - Installation ....................................................................................................................35-118
Hydraulic Schematic - Frame 3 - (Mechanical Control Machines) ...................................................................35-120
Hydraulic Schematic - Frame 4- (Mechanical Control Machines) ....................................................................35-121
Hydraulic Schematic - Frame 5- (Pilot Control Machines) ................................................................................35-122
Hydraulic Schematic - Frame 6- (Pilot Control Machines) ................................................................................35-123
Hydraulic Schematic - Frame 7- (Pilot Control Machines) ................................................................................35-124
Hydraulic Schematic - Frame 8- (Pilot Control Machines)...................................................................35-125
Hydraulic Schematic - Frame 9- (Pilot Control Machines) ................................................................................35-126
10
SECTION 37 – TOWING HOOKS AND BALLASTING
BOOK 3 - 87634740
CONTENTS
SECTION 39 – FRAMES
BOOK 3 - 87634740
CONTENTS
11
SECTION 44 – AXLES AND WHEELS
BOOK 3 - 87634740
Chapter 1 – Axles
CONTENTS
12
SECTION 50 - CAB CLIMATE CONTROL
CHAPTER 1 - HEATER/DEF ROSTER/AIR CONDITIONER
Book 3 - 87634740
CONTENTS
Section Description Page
50 100 Heater/Defroster (Cab)..............................................................................................................50-2
Labor Guide........................................................................................ ......................................50-8
Air Conditioning System Special Tools................................................................ ......................50-9
Air Conditioning System General Specifications.......................................................................50-11
Air Conditioning System Discharging and Evacuate and Recovery..........................................50-13
Air Condit ioning System Charging............................................................................................50-19
Compressor Removal................................................................................ ............................... 50-21
Compressor Installation............................................................................................................ 50-23
Compress or Oil Level Check........................................................................ ............................ 50-25
Compressor Belt Measure and Tension Adjust........................................................ ................. 50-28
Compressor Magnetic Clutch Disassemble.............................................................................. 50-29
Compressor Magnetic Clutch Assembly............................................................... .................... 50-37
Air Conditioning System Removal.............................................................................................. 50-43
Air Condit ioning System Installation.........................................................................................50-45
Air Conditioning System Condenser Removal.............................................................................50-46
Air Conditioning System Condenser Installation......................................................
.................... 50-47
Air Conditioning System Evaporator Removal..........................................................
................... 50-48
Air Conditioning System Evaporator Installation.....................................................
..................... 50-49
Receiver/Drier Removal and Installation................................................................................... 50-51
Air Conditioning System Visual Inspection and Troubleshooting........................................ .......50-53
Air Condit
ioning System Testing...................................................................... ............................ 50-54
Air Conditioning System Leakage Test........................................................................................ 50-55
Air Condition ing System Problem Solving...................................................................................50-56
Air Condition ing System Problem Solving...................................................................................50-57
13
SECTION 55 - ELECTRICAL SYSTEM
15
SECTION 55 - ELECTRICAL SYSTEM
10 223 Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-104
Fuel Shutoff Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-104
10 223 10 Replacement of Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-105
55 414 14 Air Filter Restriction Indicator Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . 55-106
55 414 10 Engine Coolant Temperature Sender Removal and Installation . . . . . . . . . . . . . . . . . . . 55-106
55 414 12 Engine Oil Pressure Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-107
55 414 28 Hydrostatic Charge Pressure Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . 55-107
55 414 24 Hydraulic Oil Filter Restriction Switch Removal and Installation . . . . . . . . . . . . . . . . . . . 55-108
55 414 20 Hydraulic Oil Temperature Sender Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-108
Hydraulic Oil Temperature Sender Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-109
35 724 90 Boom/Bucket Control Valve Spool Lock Solenoid Removal and Installation . . . . . . . . . . 55-110
55 404 Road/Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-111
55 301 Alternator (55 Amp Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-114
Alternator Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-116
Alternator - System Testing and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-117
Initial Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-120
55 301 10 Alternator Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-125
55 301 12 Alternator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-126
Alternator Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-132
55 201 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-133
Starter Motor Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-134
55 201 50 Starter Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-135
Starter Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-140
Starter Motor Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-144
Starter Motor Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-150
Starter Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-153
Miscellaneous Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-154
Glow Plugs and Glow Plug Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-154
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-155
Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-155
Labor Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-156
16
SECTION 82 – FRONT LOADER (BOOM AND MOUNTING PLATE)
BOOK 4 - 87634741
Chapter 1 – Buckets
CONTENTS
17
SECTION 88 – ACCESSORIES
BOOK 4 - 87634741
CONTENTS
18
SECTION 90 – PLATFORM, CAB, BODYWORK, AND DECALS
BOOK 4 - 87634741
CONTENTS
19
NOTES
20
SECTION 00 – GENERAL INFORMATION
CONTENTS
00-1
SECTION 00 - GENERAL INFORMATION
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.
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 MODEL
N844 40 L160
N844T 50 L170
00-3
SECTION 00 - GENERAL INFORMATION
00-4
SECTION 00 - GENERAL INFORMATION
SAFETY PRECAUTIONS ground battery cable. This will shut off power
to the eic and prevent damage to the eic
CAUTION board or blowing the 5-amp fuses if the board
Unsafe operating practices and improper use of is accidentally grounded.
the skid steer and its attachments on the part of
the operator can result in injuries. Observe the 16. If welding is required on the skid steer,
following safety precautions at all times: disconnect the (–) negative ground cable.
failure to disconnect the battery may result in
1. For servicing, the skid steer should be on damage to the EIC (Electronic Instrument
level terrain, engine stopped with the wheels Cluster) monitoring system and other
blocked or the entire skid steer solidly electrical components.
supported with the wheels off the ground
before servicing any component of the 17. If welding is required on an attachment,
drivetrain. remove the attachment from the skid steer.
2. For servicing under the operator’s seat, raise 18. Give complete and undivided attention to the
the seat and pan assembly up to the raised job at hand so that complete control of the
latched position and securely latch. skid steer is maintained at all times.
3. Do not operate the skid steer unless the seat 19. Drive slowly over rough ground and on
is latched in the operate position. slopes; keep alert for holes, ditches and
other irregularities that may cause the skid
4. Do not service the skid steer with a raised steer to overturn.
boom unless the boom is resting on the
boom lock pins. 20. Avoid steep hillside operation which could
cause the skid steer to overturn.
5. Do not service the skid steer with the engine
running unless the skid steer is properly and 21. Never transport a loaded bucket at full height.
securely supported with all four wheels off Operate the skid steer with the load as low as
the ground. possible until it becomes necessary to raise
the boom to discharge the load into a truck,
6. Use caution when servicing the unit around container, etc.
moving parts.
22. Reduce speed when turning so there is no
7. Do not tilt the boom and cab without proper danger of the skid steer overturning.
instruction.
23. Never drive up or back up a hill or incline with
8. Do not tilt the boom and cab without using a raised boom or the skid steer could over
the proper cab tilting tool. turn.
9. Reinstall all shields removed for service. 24. Always look behind you before backing the
10. Never loosen any hydraulic connections skid steer.
before relieving the pressure in the hydraulic 25. Maintain proper transmission oil level to
system. prevent loss of hydrostatic braking.
11. Wear eye protection such as goggles, etc. 26. Do not allow passengers to ride on the skid
12. Wear ear protection such as ear plugs, etc. steer at any time.
When you feel the noise level is 27. Do not allow children to operate the skid
uncomfortable. steer or ride on the skid steer at any time.
13. If any servicing or adjustments require the 28. Do not allow anyone to operate the skid steer
battery to be disconnected, disconnect the without proper instruction. OSHA requires
(–) negative ground cable. that all operators be instructed on the proper
14. When servicing electrical components, operation of the machine before they operate
disconnect the (–) negative ground cable. the unit.
15. If the electronic instrument cluster (eic) 29. Do not operate the skid steer in any position
requires removal from the dash area or the other than while in the operator’s seat with
skid steer, disconnect the (–) negative the seat belt securely fastened.
00-5
SECTION 00 - GENERAL INFORMATION
30. Before starting the engine, be sure that all 43. Always properly tie down the skid steer to a
operating controls are in neutral and the truck or trailer before transport.
parking brake is engaged.
44. Make sure all bystanders are at a safe
31. Never operate the skid steer engine in a distance away from the skid steer before
closed building without adequate ventilation. starting the engine.
32. Refuel the skid steer outdoors with the 45. Do not allow anyone near the skid steer while
engine shut off. Replace the fuel cap the engine is running and the skid steer is
securely. Use an approved fuel container. Do operational.
not smoke when handling fuel. Avoid spilling
fuel. 46. When using the skid steer to crane objects,
do not allow any person to ride on objects
33. After operating the engine, never touch the being craned.
muffler, exhaust pipe, engine or radiator until
they have had time to cool. 47. Do not use the skid steer as a work platform
for supporting materials.
34. Dress appropriately - wear relatively
tight-fitting clothing when operating the skid 48. Do not lift personnel or allow personnel to
steer. Loose or torn clothing can catch in work while standing in the bucket or on other
moving parts or controls. attachments. This is not a man-lift.
35. Before servicing the skid steer or any of its OSHA requirements now make it the
attached equipment, be sure that the employer’s responsibility to fully instruct
attachments are lowered to the ground or each operator in the proper and safe
that the boom arms are supported by the operation of all operative equipment. Both
boom lock pins. employer and employee should thoroughly
familiarize themselves with the following
36. Do not work under overhangs, electric wires, sections.
or where there is danger of a slide.
00-6
SECTION 00 - GENERAL INFORMATION
Do not store flammable material in open containers. AVOID HEATING NEAR PRESSURIZED FLUID
LINES
Store flammable fluids away from fire hazards. Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
Do not incinerate or puncture pressurized yourself and bystanders.
containers.
Do not heat by welding, soldering, or using a torch
Make sure machine is clean of trash, grease, oil, and near pressurized fluid lines.
debris.
Pressurized lines can be accidentally cut or
Do not store oily rags; they can ignite and burn damaged when heat goes beyond the immediate
spontaneously. flame area.
WARNING
If any servicing or adjustments require the
battery to be disconnected, or welding is
USE CARE AROUND HIGH-PRESSURE FLUID required on the skid steer, disconnect the (–)
LINES negative ground cable. Failure to disconnect the
Escaping fluid under pressure can penetrate the skin battery may result in damage to the eic
causing serious injury. (electronic instrument cluster) monitoring
system and other electrical components.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines.
WARNING
Tighten all line connections before applying If welding on an attachment is required, first
pressure. remove the attachment from the skid steer boom
attaching plate.
Check for leaks with a piece of cardboard.
00-7
SECTION 00 - GENERAL INFORMATION
Wear safety glasses or face shield as required. Check seat belt for proper operation, wear, and
damage - Replace as needed.
Wear other safety equipment appropriate to the job.
Check operator restraint system - EIC for proper
Wear earplugs or earmuffs as required. operation.
00-8
SECTION 00 - GENERAL INFORMATION
2534-05
1
ENGINE MODEL AND SERIAL NUMBER
LOCATION
The engine model and serial number is located on
the left side of the block at 1.
4800-11
2
For the tightening torques for reassembly, use the
following hardware torque chart unless the torque is
specified in the instructions.
00-9
SECTION 00 - GENERAL INFORMATION
NOMINAL UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED GR.B GR.C NOMINAL
SIZE or W/ZnCr or W/ZnCr or W/ZnCr w/GR5 w/GR8 SIZE
PLATED PLATED PLATED BOLT BOLT
SILVER GOLD SILVER GOLD SILVER GOLD
1/4 55* (6.2) 72* (8.1) 86* (9.7) 112* (13) 121* (14) 157* (18) 61* (6.9) 86* (9.8) 1/4
5/16 115* (13) 149* (17) 178* (20) 229* (26) 250* (28) 324* (37) 125* (14) 176* (20) 5/16
3/8 17 (23) 22 (30) 26 (35) 34 (46) 37 (50) 48 (65) 19 (26) 26 (35) 3/8
7/16 27 (37) 35 (47) 42 (57) 54 (73) 59 (80) 77 (104) 30 (41) 42 (57) 7/16
1/2 42 (57) 54 (73) 64 (87) 83 (113) 91 (123) 117 (159) 45 (61) 64 (88) 1/2
9/16 60 (81) 77 (104) 92 (125) 120 (163) 130 (176) 169 (229) 65 (88) 92 (125) 9/16
5/8 83 (112) 107 (145) 128 (174) 165 (224) 180 (244) 233 (316) 90 (122) 127 (172) 5/8
3/4 146 (198) 189 (256) 226 (306) 293 (397) 319 (432) 413 (560) 160 (217) 226 (306) 3/4
7/8 142 (193) 183 (248) 365 (495) 473 (641) 515 (698) 667 (904) 258 (350) 364 (494) 7/8
1 213 (289) 275 (373) 547 (742) 708 (960) 773 (1048) 1000 (1356) 386 (523) 545 (739) 1
LOCKNUTS
GRADE A NO MARKS
GRADE B LETTER B
GRADE C LETTER C
GRADE IDENTIFICATION
00-10
SECTION 00 - GENERAL INFORMATION
M4 15* (1.7) 19* (2.2) 23* (2.6) 30* (3.4) 33* (3.7) 42* (4.8) 16* (1.8)
M6 51* (5.8) 67* (7.6) 79* (8.9) 102* (12) 115* (13) 150* (17) 56* (6.3)
M8 124* (14) 159* (18) 195* (22) 248* (28) 274* (31) 354* (40) 133* (15)
M10 21 (28) 27 (36) 32 (43) 41 (56) 45 (61) 58 (79) 22 (30)
M12 36 (49) 46 (63) 55 (75) 72 (97) 79 (107) 102 (138) 39 (53)
M16 89 (121) 117 (158) 137 (186) 177 (240) 196 (266) 254 (344) 97 (131)
M20 175 (237) 226 (307) 277 (375) 358 (485) 383 (519) 495 (671) 195 (265)
M24 303 (411) 392 (531) 478 (648) 619 (839) 662 (897) 855 (1160) 338 (458)
MANUFACTURER’S IDENTIFICATION
PROPERTY CLASS
MANUFACTURER’S IDENTIFICATION
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
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.
These torques are not recommended for tubes of solvent or Loctite cleaner and apply hydraulic sealant
12.7 mm (1/2″) OD and larger with wall thickness of Loctite no. 569 to the 37° flare and the threads.
0.889 mm (0.035″) or less. The torque is specified for
0.889 mm (0.035″) wall tubes on each application Install fitting and torque to specified torque, loosen
individually. fitting and retorque to specifications.
00-12
SECTION 00 - GENERAL INFORMATION
PIPE THREAD FITTING TORQUE Before installing and tightening pipe fittings, clean
the threads with a clean solvent or Loctite cleaner
Thread Size Torque (Maximum) and apply sealant Loctite no. 567 for all fittings
including stainless steel or no. 565 for most metal
1/8″ – 27 13 N⋅m (10 ft. lbs.) fittings. For high filtration/zero contamination
1/4″ – 18 16 N⋅m (12 ft. lbs.) systems use no. 545.
3/8″ – 14 22 N⋅m (16 ft. lbs.)
1/2″ – 14 41 N⋅m (30 ft. lbs.)
3/4″ – 14 54 N⋅m (40 ft. lbs.)
SEALANTS
Description New Holland Part Number Typical Applications Strength Color
Thread Lock L22200 (222) Small Screws/Hardware Low Purple
L24231 (242) Nuts and Bolts Medium Blue
L29000 (290) Wicking Type Medium Green
L26231 (262) Nuts and Bolts High Red
Thread Sealants L54531 (545) Hydraulic/Pneumatic Non-Fouling
L56531 (565) Pipe Sealant Controlled Strength
L56747 (567) Pipe Sealant High Temperature
Silicones L81724 (3.5 oz. tube) Ultra Blue RTV Gasket Non-corrosive Blue
L58775 (10.2 oz. cartridge) Ultra Blue RTV Gasket Non-corrosive Blue
L82180 (3.35 oz. tube) Ultra Blue RTV Gasket Non-corrosive Black
L59875 (10.2 oz. cartridge) Ultra Blue RTV Gasket Non-corrosive Black
00-13
SECTION 00 - GENERAL INFORMATION
4
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.
5
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.
1
19995757
6
00-14
SECTION 00 - GENERAL INFORMATION
19995758
7
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 1
pins, 1.
8. Lower the boom and rest on the boom lock pins,
1.
19995759
9. Return the boom control to the “NEUTRAL”
8
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.
00-15
SECTION 00 - GENERAL INFORMATION
19995757
9
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.
1
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 3
coming loose during lifting of the boom.
2
19995758
10
4. Remove the rod end (top) pivot pins, 1, from both
cylinders by removing the retaining hardware, 2,
from pivot pin and boom.
2 1
19995760
11
00-16
SECTION 00 - GENERAL INFORMATION
19995761
12
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 1
until the boom is resting solidly on the boom lock
pins. The boom could drop suddenly if lifting
devices should fail. 19995762
13
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 3
pivot pin holes, 3.
1
19995763
14
00-17
SECTION 00 - GENERAL INFORMATION
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.
16
00-18
SECTION 00 - GENERAL INFORMATION
2 Lower support
3 Upper support
18
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.
19
00-19
SECTION 00 - GENERAL INFORMATION
20
4. Open the rear door, 1. Raise the top engine
shield, 2, and latch in the raised position.
5. Remove engine side covers, 3.
21
6. Disconnect the battery negative (-) cable, 1.
22
00-20
SECTION 00 - GENERAL INFORMATION
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 1
properly latched in the raised position.
4825-11r
24
11. Remove the front step shield, 1.
25
00-21
SECTION 00 - GENERAL INFORMATION
19992572
26
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.
27
14. Install the upper cab jack support, 1. The spacer
channel, 2, is used for the L160 and L170
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
17. Remove the four rear cab post bolts, 4. Note the 29
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. 30
CAUTION
Never attempt to operate or move the skid steer
without first installing and properly tightening all
cab retaining hardware.
00-23
SECTION 00 - GENERAL INFORMATION
32
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.
33
00-24
SECTION 00 - GENERAL INFORMATION
CAUTION
Do not lift any attachments on the skid steer
mounting plate that weigh 272 kg (600 lbs.) or
more. Lift such attachments separately.
35
The lifting points at the rear of the skid steer, 1.
36
00-25
SECTION 00 - GENERAL INFORMATION
37
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.
38
00-26
SECTION 00 - GENERAL INFORMATION
00-27
SECTION 00 - GENERAL INFORMATION
SPECIAL TOOLS
Tilting Cab
Tool Number Order From Description L160 L170
86590084 New Holland Cab Tilting Tool *** ***
Engine
Tool Number Order From Description L160 L170
NH00011 OTC Oil pressure adapter *** ***
NH00120 OTC Compression test adapter *** ***
NH00117 OTC Oil pump port block installer *** ***
NH11097 OTC Oil pump port block remover *** ***
Hydraulic System
Tool Number Order From Description L160 L170
238 Bar (3500 PSI) Test Gauge OTC Main system pressure *** ***
Flow meter OTC Main system/Hydrostatic pumps *** ***
3/4″—16 UNF O ring fitting Local Main system at Boom cylinder *** ***
1/2″ Quick coupler New Holland Main system at Auxiliary boom * *
couplers
FNH22ESS95 OTC Hydraulic tank pressuring tool * *
*Recommend Tool
***Essential Tool
00-28
SECTION 00 - GENERAL INFORMATION
SPECIFICATIONS
MODEL L160
00-29
SECTION 00 - GENERAL INFORMATION
MODEL L160
ENGINE OIL
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . API SH/CG4 SAE 10W-30
Filter part # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86546618
Engine crankcase capacity w/filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7 L (9.2 qt.)
Dipstick length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367 mm (14.4″)
ELECTRICAL SYSTEM
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BCI PC31 - 12V 650 amps @ 0°F (–18°C)
Alternator capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 amps
Starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key start and relay
Ignition system protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse 15 amps
Headlights (work) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86533429
Taillights (work) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86533429
Taillights (road) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86505510
Amber flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #529068
HYDRAULIC SYSTEM
Pump - Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump
Output
Standard Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5 GPM (58.7 LPM) @3155 RPM-@1000 PSI
Optional High Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 GPM (90.8 LPM) @3155 RPM-@2300 PSI
Hydraulic system Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.6 L (8.6 gal.)
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 10W-30 - API SH/CG4
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Spool Open Center
Main system relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 - 177 bar (2500 - 2600 PSI)
Circuit relief - boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 bar (3500 PSI)
Filter Spin-on canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #9842392
BOOM CYLINDERS
Double-acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 mm (2.5″) dia. bore
470.0 mm (18.5″) stroke
Cycle time
Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 seconds
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 seconds
BUCKET CYLINDERS
Double-acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.8 mm (2.25″) dia. bore
450.8 mm (17.88″) stroke
Cycle time
Dump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 seconds
Curl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 seconds
HYDROSTATIC TRANSMISSIONS
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable displacement piston type
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed displacement piston type
Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.0 bar (160 PSI)
Relief Pressure (Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 bar (3500 PSI)
Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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)
00-30
SECTION 00 - GENERAL INFORMATION
MODEL L160
00-31
SECTION 00 - GENERAL INFORMATION
SPECIFICATIONS
MODEL L170
00-32
SECTION 00 - GENERAL INFORMATION
MODEL L170
ENGINE OIL
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . API SH/CG4 SAE 10W-30
Filter part # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86546618
Engine crankcase capacity w/filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7 L (9.2 qt.)
Dipstick length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367 mm (14.4″)
ELECTRICAL SYSTEM
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BCI PC31 - 12V 650 amps @ 0°F (–18°C)
Alternator capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 amps
Starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key start and relay
Ignition system protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse 15 amps
Headlights (work) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86533429
Taillights (work) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #86533429
Taillights (road) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86505510
Amber flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #529068
HYDRAULIC SYSTEM
Pump - Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump
Output
Standard Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.7 GPM (67 LPM) @3155 RPM-@1000 PSI
Optional High Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.2 GPM (99.2 LPM) @3155 RPM-@2300 PSI
Hydraulic system Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.6 L (8.6 gal.)
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 10W-30 - API SH/CG4
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Spool Open Center
Main system relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 - 177 bar (2500 - 2600 PSI)
Circuit relief - boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 bar (3500 PSI)
Filter Spin-on canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #9842392
BOOM CYLINDERS
Double-acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 mm (2.5″) dia. bore
470.0 mm (18.5″) stroke
Cycle time
Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 seconds
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 seconds
BUCKET CYLINDERS
Double-acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.8 mm (2.25″) dia. bore
450.8 mm (17.88″) stroke
Cycle time
Dump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 seconds
Curl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 seconds
HYDROSTATIC TRANSMISSIONS
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable displacement piston type
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed displacement piston type
Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.0 bar (160 PSI)
Relief Pressure (Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 bar (3500 PSI)
Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 L170
00-34
SECTION 00 - GENERAL INFORMATION
39
DIMENSIONS - L160 AND L170 WITH 66, DIRT AND FOUNDRY BUCKET AND 10 X 16.5 TIRES - CM (IN.)
00-35
SECTION 00 - GENERAL INFORMATION
40
DIMENSIONS - L160 AND L170 WITH 66, DIRT AND FOUNDRY BUCKET AND10 X 16.5 TIRES - CM (IN.)
00-36
SECTION 00 - GENERAL INFORMATION
ROPS - TILT
(CAB UPGRADE MACHINES ONLY)
CAB AND BOOM TILT PROCEDURE
1. 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 insure a safe operation 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.
BD07E007 Figure 1
BS07D179 Figure 2
00-37
SECTION 00 - GENERAL INFORMATION
BD04K015 Figure 3
4. Jack up the skid steer and block it securely with
all four wheels off the ground, as shown. Position
the front blocks to the front of the final drive
housing and the rear blocks to the rear of the flat
area of the final drive housing.
ATTENTION: Never attempt to tilt the skid steer
Cab over unless the skid steer is securely supported. 1
5. Remove the right and left fenders (1).
BS07D178 Figure 4
6. Open the rear door and raise and latch the top
engine shield, (2), in the raised position.
7. Remove air cleaner canister support hardware at
(1). Allow the air cleaner canister assembly to
rest on the engine.
8. Remove upper and lower engine side covers.
2
BD04E111 Figure 5
00-38
SECTION 00 - GENERAL INFORMATION
BD04E120 Figure 6
10. Remove the door from the door hinges (1).
BD07D176 Figure 7
11. Remove the door hinges (1), and door frame (2).
BD07D176 Figure 8
00-39
SECTION 00 - GENERAL INFORMATION
BD07D040 Figure 9
13. Raise the seat and lock in the up position. Make
sure the seat pan assembly is latched securely
(1).
BD07D039 Figure 10
00-40
SECTION 00 - GENERAL INFORMATION
16. 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,
(2).
BS07D173 Figure 11
17. Install the upper Cab jack support, (1). Pivot the
retaining plate, (3) up behind the boom top link
1
and secure with 1/2” x 1-1/4” carriage bolt and 3
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 the
Cab and tighten.
4
BS07D175 Figure 12
BS04H138 Figure 13
00-41
SECTION 00 - GENERAL INFORMATION
BS07D177 Figure 14
20. Loosen the front Cab mounting bolts, (1), (one
on each side) only enough to allow the bolt to
rotate in post.
21. Remove the rear front Cab bolts, (2), one each
side.
ATTENTION: Never remove the front Cab bolts,
(1), as these are the pivot bolts during the Cab tilting 2
procedure. Removal of these bolts could cause Cab
to fall, and may cause injury and machine damage. 1
BD07D178 Figure 15
00-42
SECTION 00 - GENERAL INFORMATION
BD04H092 Figure 16
23. Jack Cab and boom assembly over with the unit
properly supported off the ground. Support the
boom at (1), and Cab to prevent tipping of the
skid steer when heavy components, engine,
hydrostatic pump etc. are removed from the
lower frame. Jack travel will limit the travel of the
Cab assembly to prevent over travel. Be sure all
wire harnesses, hydraulic hoses and throttle
cable clear any obstructions during Cab tilting.
BS07D219 Figure 17
00-43
SECTION 00 - GENERAL INFORMATION
ROPS - LOWER
(CAB UPGRADE MACHINES ONLY)
ATTENTION: Never attempt to tilt the skid steer
Cab without proper instructions and using the proper
tool. See the service manual and/or your New
Holland dealer. Never attempt to operate or move the
skid steer without first installing and properly
tightening all Cab retaining hardware.
To return and secure the Cab and boom assembly
safely, do the following:
1. For Mechanical Control Machines, pull the
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 and throttle cable in
position to prevent damage from setting the Cab
on them.
ATTENTION: Keep the wire harness from being
damaged. A damaged wire harness could result in
damage to the skid steer electrical components.
4. Pull the wire harness through the loop.
5. Remove rubber tie straps from the hydrostatic
control handles.
2
1
BD07D178 Figure 18
00-44
SECTION 00 - GENERAL INFORMATION
BD04H092 Figure 19
10. Install the threshold.
BD07D040 Figure 20
11. Install the door frame (2), and door hinges (1).
BD07D176 Figure 21
00-45
SECTION 00 - GENERAL INFORMATION
BD07D177 Figure 22
13. Reattach the air cleaner canister with mounting
bolts, (1).
BD07D036 Figure 23
14. Remove jack and supports.
15. Reconnect the battery cables.
16. After the Cab has been installed and if the
cooling system was drained, refer to Section 00
for the correct type and quantity of coolant and
refill the cooling system.
17. If the machine is equipped with air conditioning
and the air conditioning was discharged, refer to
Air-conditioning system - Charging and
charge the air conditioning system.
18. Start machine and check for leaks.
19. Stop the engine.
20. Recheck all fluid levels.
ATTENTION: Reinstall all shields that were
removed for servicing and adjustment procedures.
00-46
SECTION 10 – ENGINE
CONTENTS
10-1
SECTION 10 - ENGINE
10-2
SECTION 10 - ENGINE
Op. 10 000
GENERAL ENGINE INFORMATION
New Holland engines, N844 used in the model
L160 skid steer and N844T turbocharger engine
used in the model L170 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 19992590
train, and flange-mounted fuel injection pump on the
engine cam, reduce frictional power loss and engine 1
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.
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
2
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.
10-3
SECTION 10 - ENGINE
PISTONS AND CONNECTING RODS machined bores in the cylinder block. The rocker
Pistons are cast from high silicon aluminum alloy and shaft is an induction hardened hollow steel tube.
are heat-treated for low weight with high strength and Valve clearances are adjusted by hardened
good thermal conductivity. The piston is fitted with ball-ended screws and locknuts.
three rings; two cast iron, chrome-faced
compression rings and one steel, chrome-faced
controlled oil ring. The fully floating gudgeon pin ROCKER COVER AND INLET MANIFOLD
(wrist pin) is made of chrome molybdenum steel alloy The cover is made of cast aluminum with an air
hardened by carburizing and retained by the intake, oil filler, and crankcase breather. It is located
conventional retaining ring method. The connecting in position by rocker pillar studs and secured by cap
rods are machined from high-strength forged steel. nuts.
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 GEAR TRAIN
tin-backed lead/bronze. 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
CAMSHAFT incorporates the governor weight cage.
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 FUEL SYSTEM
pump eccentric is machined. The camshaft is A flange-mounted, Bosch-type fuel injection pump is
supported by roller and needle bearings and mounted in the cylinder block and operated by lobes
lubricated by splash feed. The nose of the camshaft machined on the engine cam.
supports the cam gear, governor weight cage, and
governor slider assembly.
LUBRICATING SYSTEM
A trochoid lobe oil pump located in the center of the
CYLINDER HEAD idler gear sends lubricating oil to the main oil galley
The cylinder head is made of high grade copper via a relief valve through a spin-on bypass oil filter to
chrome cast iron, and incorporates replaceable the main oil gallery. The rockers are pressure fed via
heat-resistant alloy steel valve seats. Inlet and an externally mounted oil pipe from the main oil
exhaust valves are made of high grade gallery to the cylinder head.
heat-resistant alloy steel with tuftrided stems and
induction hardened heads. Each stem is fitted with a
chrome molybdenum steel cap for long life. COOLING SYSTEM
A belt-driven centrifugal water pump circulates
The valves are operated by cold drawn seamless coolant via the internal water passages. The coolant
tube push rods with hardened steel ball and forged is radiator cooled and temperature controlled by a
cup ends. Flat-based tappets are made from case conventional thermostat.
carburized chrome molybdenum steel operating in
10-4
SECTION 10 - ENGINE
TURBOCHARGER LUBRICATION
The turbocharger used on the L170 diesel engine
may not receive adequate lubrication on cool/cold
weather (below 5°C, 40°F) start-up, leading to
turbocharger bearing failure.
10-5
SECTION 10 - ENGINE
SAFETY PRECAUTIONS Do not remove the radiator cap while the engine
is hot and the coolant is under pressure, as
These safety precautions are most important: dangerous hot coolant can be discharged.
CAUTION Do not use salt water in the fresh water cooling
Do not change the specification of the engine. system or any other coolant which can cause
Do not smoke when you put fuel in the tank. corrosion.
Clean away any fuel which has spilled and move Keep sparks or fire away from batteries
material which has fuel contamination to a safe (especially while charging) or combustion can
place. occur. The battery fluid can burn and is also
dangerous to the skin and especially the eyes.
Do not put fuel in the tank during engine
operation. Disconnect the battery terminals before you
make a repair to the electrical system.
Never clean, lubricate or adjust the engine during
operation unless otherwise specified in this Only one person must be in control of the engine.
manual. Use extreme caution when working Ensure the engine is only operated from the
around moving parts to prevent injury. control panel or operator’s position.
Do not make any adjustments you do not If your skin comes into contact with high-
understand. pressure fuel, get medical assistance
Ensure the engine is not in a position to cause a immediately.
concentration of toxic emissions. Diesel fuel and used engine oils can cause skin
Persons in the area must be kept clear during damage to some persons. Use protection on the
engine and equipment or vehicle operation. hands (gloves or special skin protection
solutions).
Do not permit loose clothing or long hair near
parts which move. Do not move equipment unless the brakes are in
good condition.
Keep away from parts which turn during
operation. Note that fans cannot be seen clearly Be sure that the transmission drive control is in
while the engine is running. “Neutral” position before the engine is started.
Do not run the engine with any safety guards Do not use ether to start these engines.
removed.
10-6
SECTION 10 - ENGINE
10-7
SECTION 10 - ENGINE
10-8
SECTION 10 - ENGINE
10-9
SECTION 10 - ENGINE
10-10
SECTION 10 - ENGINE
TROUBLESHOOTING
10-11
SECTION 10 - ENGINE
FAULTY CHARGING
CAUSE CORRECTION
Loose fan belt Correct belt tension
Faulty wiring Inspect and correct
Faulty battery Repair
Worn out alternator brush Replace
10-12
SECTION 10 - ENGINE
10-13
SECTION 10 - ENGINE
Flex plate failure due to inadequate lubrication Replace flex plate (part #86521866) and input shaft,
applying Never-Seize on splines
NOTE: See L170 Oil Consumption below for more extensive troubleshooting procedures.
10-14
SECTION 10 - ENGINE
10-15
SECTION 10 - ENGINE
The maximum allowable oil consumption is Assume one quart oil is added for 50 gallons fuel.
0.8%. The following table give examples.
% Consumption = (1/4) x 100 = 0.5%
50
Fuel Consumption, Oil Consumption,
Gallons Quarts 7. The New Holland dealer must check
50 1.6 compression on all four cylinders and record.
100 3.2 The compression specifications are as follows:
200 6.4
Standard Value To Be Repaired
A log example is shown in the following table. More than 429 PSI Less than 356 PSI
The hour level is the EIC (Electronic (29.5 bar) at 200 - 250 (24.5 bar)
Instrumentation Cluster) reading when fuel is engine cranking RPM
added. Dealer must file oil consumption log with
customer file. Compression testing can be performed using a
special adaptor (see “Special Tools” in the
Fuel Oil Hour Level Additional Information Section) through the glow
plug ports. Remove all glow plugs and test each
Full Full 100 cylinder.
XX Gallons X Quart 150
This should be a “dry” compression check (do not
XX Gallons X Quart 200 put any oil in the cylinder).
6. If the oil consumption is greater than 0.8% of the If compression is low, recheck the air intake
fuel consumption, oil usage is excessive. A system for signs of dirt ingestion.
sample calculation for oil consumption follows:
% Consumption = (quarts oil/4) x 100
gallons fuel
10-16
SECTION 10 - ENGINE
SPECIFICATIONS
SERVICE STANDARDS
CYLINDER HEAD
Compression pressure of More than 426.6 Less than
cylinder PSI (30 kg/cm2) 355.5 PSI
(25 kg/cm2)
PISTON
Skirt long-diameter size 3.307″ 3.3050″ - 3.3056″ 3.295″ Oversize 0.02/.04″
(84 mm) (83.948 - 83.963 ) (83.7 mm) (0.5, 1.0 mm)
Clearance with cylinder 0.0015″ - 0.0028″ 0.01″ 68° F
(0.038 - 0.072 mm) (0.25 mm) (20° C)
Piston pin hole inside diameter 1.1024″ 1.1023″ - 1.1025″
(28 mm) (27.999 - 28.003)
Piston pin hole to pin clearance -0.00004″ ± .00028″ 0.0008″
(0.001 ± 0.007 mm) (0.02 mm)
10-17
SECTION 10 - ENGINE
PISTON PIN
Pin outside diameter 1.1024″ 1.1022″ - 1.1024″ 1.1016″
(28 mm) (27.996 - 28.0) (27.98 mm)
Rod small end bushing to pin 0.0004″-0.00098″ 0.004″ Oil clearance
clearance (0.010-0.025 mm) (0.1 mm)
PISTON RING
Piston ring groove to ring clearance
1st ring 0.0028″-0.0043″
(0.07 -0.11 mm) 0.0098″ max.
2nd ring 0.0016″-0.0031″ (0.25 mm )
(0.04-0.08 mm)
Oil ring 0.0008″-0.0024″ 0.006″max
(0.02-0.06 mm) (0.15 mm)
Ring width
1st ring 0.1378″ 0.1339″-0.1417″
(3.5 mm) (3.4-3.6 mm)
2nd ring 0.1417″ 0.1378″-0.1457″
(3.6 mm) (3.5-3.7 mm)
Oil ring 0.0984″ 0.0906″-0.1063″
(2.5 mm) (2.3-2.7 mm)
Piston ring end gap
1st ring 0.0079″-0.0138″
(0.2-0.35 mm)
2nd ring 0.0079″-0.0157″ 0.0394″
(0.2-0.4 mm) (1.0 mm)
Oil ring 0.0079″ - 0.0157″
(0.2 - 0.4 mm)
10-18
SECTION 10 - ENGINE
10-19
SECTION 10 - ENGINE
10-20
SECTION 10 - ENGINE
TORQUE SPECIFICATIONS
COMPONENT Setting/Remarks
Bearing holder bolts- hex hole type . . . . . . . . . . . . 18-22 ft. lbs. (24-30 N·m)
- hex bolt type . . . . . . . . . . . . . 36-40 ft. lbs. (49-54 N·m)
Rear plate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 ft. lbs. (14-18 N·m)
Flywheel housing bolts . . . . . . . . . . . . . . . . . . . . . . . 18-21 ft. lbs. (24-28 N·m)
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-51 ft. lbs. (58-69 N·m)
Connecting rod nuts . . . . . . . . . . . . . . . . . . . . . . . . . 36-40 ft. lbs. (49-54 N·m)
Suction filter bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 ft. lbs. (9-12 N·m)
Sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 ft. lbs. (9-12 N·m)
Crankshaft pulley nut . . . . . . . . . . . . . . . . . . . . . . . . 203-246 ft. lbs. (275-333 N·m)
Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 72-76 ft. lbs. (98-103 N·m)/oiled
Injection pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 ft. lbs. (9-12 N·m)
Injection pump nuts . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 ft. lbs. (9-12 N·m)
Rocker arm nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29 ft. lbs. (27-39 N·m)/4-cylinder engines
Head cover nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 ft. lbs. (12-16 N·m)/4-cylinder engines
Cooling fan bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 ft. lbs. (9-12 N·m)
Oil pipe banjo bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 ft. lbs. (9-12 N·m)
Oil sump drain bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 22-29 ft. lbs. (30-39 N·m)
Injection nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-51 ft. lbs. (58-69 N·m) IDI engines
Injection pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18 ft. lbs. (15-24 N·m)
Thermo switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-22 ft. lbs. (24-30 N·m)
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15 ft. lbs. (15-20 N·m)
Glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15 ft. lbs. (15-20 N·m)
Stop solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15 ft. lbs. (15-20 N·m)
Oil relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-51 ft. lbs. (60-69 N·m)
Smokeset nut (max fuel) . . . . . . . . . . . . . . . . . . . . . 15-19 ft. lbs. (20-26 N·m)
Adjusting screw nuts . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 ft. lbs. (12-16 N·m)
10-21
SECTION 10 - ENGINE
TO ENGINE GROUND
19992596
10-22
SECTION 10 - ENGINE
Op. 10 001 10
ENGINE REMOVAL
The engine can be removed from the loader by two
methods:
5
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.
6
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.
10-23
SECTION 10 - ENGINE
8
9. Remove the eight 1/2″ cap screws from the
support at 1, both sides, and remove the radiator
and oil cooler assembly.
9
The support is shown removed with the air
cleaner, radiator, oil cooler, oil filter, and fuel
pump attached.
10
10-24
SECTION 10 - ENGINE
11
Remove the hydrostatic pump to bellhousing and
pump support retaining hardware at 1 and 2.
12
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.
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.
14
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.
15
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.
16
10-26
SECTION 10 - ENGINE
17
10. Remove the neutralizer plate return spring and
hardware, 1, from the bellhousing and remove
plate, 2.
18
11. Remove the hydrostatic pump to bellhousing and
pump support retaining hardware at 1 and 2.
19
10-27
SECTION 10 - ENGINE
20
Op. 10 001 53
ENGINE DISASSEMBLY SEQUENCE
Op. 55 301 10
ALTERNATOR
Disconnect the alternator wire harness and wires, 1.
21
Op. 10 104 14
REMOVE COOLING FAN AND PULLEY
Remove the fan retaining hardware and spacers.
The L160 N844 engine fan is equipped with a cover,
1, over the center of the fan.
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. 23
Op. 10 402 10
WATER PUMP ASSEMBLY
Loosen the securing bolts and remove the water
pump assembly, 1, and set plate, 2.
24
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.
10-29
SECTION 10 - ENGINE
26
Op. 10 250 16
EXTERNAL OIL PIPE (L160)
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.
27
Op. 10 250 16/ Op. 10 250 18
EXTERNAL OIL PIPE (L170)
Loosen and remove the banjo bolts at the
turbocharger and the cylinder head assembly.
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.
29
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.
30
TAPPETS
Pull the tappets from the machined bore in the
cylinder block.
31
10-31
SECTION 10 - ENGINE
Op. 10 223 10
STOP SOLENOID
Unscrew the stop solenoid, if fitted.
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
33
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.
1
SH0233R
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.
35
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.
36
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.
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.
39
Op. 10 103 70
FLYWHEEL
Loosen the bolts and remove the flywheel.
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.
41
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.
42
Op. 10 304 38
3. Remove the relief valve assembly.
43
10-35
SECTION 10 - ENGINE
44
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.
45
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.
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.
47
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.
48
Check six positions (1 to 6 lines, as shown) for
warping. If found to be warped excessively, correct
with a surface grinder.
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)
All Engines
Standard Thickness: 0.036″ - 0 .042″ (0.925 mm
- 1.075 mm)
51
Valve to Valve Guide Clearance
Check the clearance at 1 between the valve and
valve guide. If the clearance exceeds the allowable
limit, replace.
10-38
SECTION 10 - ENGINE
Op. 10 101 55
VALVE SEAT
Intake
SH62052
Standard Width: 0.06″ - 0.08″ (1.5 mm - 2.0 mm)
53
Allowable Limit: 0.098″ max. (2.5 mm)
Exhaust
Standard Width: 0.076″ - 0.085″ (1.94 mm - 2.16
mm)
10-39
SECTION 10 - ENGINE
55
Valve Spring
Visually inspect the valve spring for damage.
Standard Value
Squareness : 0.047″ (1.2 mm)
56
Free length: 1.378″ (35 mm)
Allowable Limit
Squareness: 0.079″ (2.0 mm)
Reassembly
Reassemble the parts in the reverse order of
disassembly.
10-40
SECTION 10 - ENGINE
Op. 10 101 56
CYLINDER BLOCK
Finish stroke: 9
10-41
SECTION 10 - ENGINE
Bore Specifications
Disassembly
1. Remove piston rings, 1, using a piston ring tool.
2. Remove the retaining ring and remove the piston
pin, 2.
58
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.
59
10-42
SECTION 10 - ENGINE
Oversized Piston
When the cylinder is oversized, be sure that an
oversized piston is used.
Piston Ring
If the piston ring is worn or damaged, replace it.
#1 Ring
Standard Gap: 0.008″ - 0.014″ (0.20 mm - 0.35
mm)
#2 Ring
Standard Gap: 0.008″ - 0.016″ (0.20 mm - 0.40
mm)
10-43
SECTION 10 - ENGINE
Oil Ring
Standard Clearance: 0.008″ - 0 .016″ (0.20 mm
- 0.40 mm)
#1 Ring
Standard Clearance: 0.0028″ - 0.0043″ (0.07
mm - 0.11 mm)
#2 Ring
Standard Clearance: 0.0016″ - 0.0032″ (0.04
mm - 0.08 mm)
Oil Ring
Standard Clearance: 0.0007″ - 0.002″ (0.02 mm
- 0.06 mm)
Piston Pin
Check the outside diameter of the piston pin. If it is
less than the allowable limit, replace.
10-44
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.
1. Gauge
2. Piston pin
3. Distortion
4. Flat surface of the aligner
5. Pin
10-45
SECTION 10 - ENGINE
Oil Clearance
Using the plasti-gauge, check the oil clearance as
follows:
63
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).
10-46
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
65
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
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”).
10-47
SECTION 10 - ENGINE
Thrust Clearance
Check the thrust washer for wear, poor contact,
burning, or other defects. Defective washers must be
replaced.
Inspection
Check the bearing (bushing) for peeling, melting,
seizure, or poor contact. If found to be defective,
replace.
10-48
SECTION 10 - ENGINE
68
Crankshaft Journal (bushing)
Outside Diameter
Standard: 2.6755″ - 2.6760″ (67.957 mm -
67.970 mm)
69
Crankshaft Bushing Replacement
Bushing Removal
Remove the bushing from the housing (cylinder
block) using a bushing driving tool to prevent
damage.
10-49
SECTION 10 - ENGINE
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.
10-50
SECTION 10 - ENGINE
72
Crankshaft Pin Diameter
Standard Diameter
Standard: 2.0458″ - 2.0463″ (51.964 mm -
51.975 mm)
Allowable Limit
Standard: 2.0433″ (51.90 mm)
Allowable Limit
Standard: 2.6732″ (67.90 mm)
10-51
SECTION 10 - ENGINE
74
Op. 10 103 76
FLYWHEEL AND RING GEAR
Inspection
Check the ring gear. If it is excessively damaged or
worn, replace it.
75
Op. 10 106 40
CAMSHAFT ASSEMBLY
Inspection
Check the journals and cams for wear and damage.
Replace if the allowable limit is exceeded.
10-52
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
77
If these items have been replaced, it is essential that
the spacers, shims, etc. are assembled in the order
illustrated here.
TIMING GEAR
Inspection
Check the timing gears for wear and damage on the
contact area. Replace if any defect is found.
1 Camshaft gear
2 Idler gear
3 Crankshaft gear 78
10-53
SECTION 10 - ENGINE
Op. 10 304 41
OIL PUMP
Disassembly
Remove the snap ring.
Pull out the oil pump cover from the idler gear. 79
Remove the spring from the idler gear.
1 Snap ring
2 Collar
3 Spring
4 Shim
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.
10-54
SECTION 10 - ENGINE
Op. 10 304 10
OIL FILTER
19992602
Maintenance 81
The oil filter must be replaced every 100 hours of
operation.
Disassembly
Remove the backplate and gaskets.
1 Water pump 2
2 Gaskets 19992544
3 Set plate 82
Inspection
Op. 10 402 30
THERMOSTAT REMOVAL
Replace the thermostat if the valve opens at ambient
temperature.
10-55
SECTION 10 - ENGINE
N844 N844T
Type Wax Pellet Wax Pellet
Type Type
Temperature 176° - 183° F 156° - 163° F
when starting (80° - 84° C) (69° - 73° C)
to open
Temperature 203° F (95° C) 180° F (82° C)
when fully
open
Valve lift fully 0.315″ 0.315″
open (8.0 mm) (8.0 mm)
84
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.
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.
10-57
SECTION 10 - ENGINE
9
25
3
7
12
23 23 11
10
1
24 7
22
21
5
6 8
20
26 19
2 18
17 27
4
14
15 26
28
13 16
19992767
86
1. Timing Gear Cover 8. Washer 15. O Ring 22. Washer
2. Pin 9. Snap Pin 16. Snap Ring 23. Nut
3. Gasket 10. Governor Spring 17. Throttle Stay 24. Stop Lever
4. Oil Seal 11. Throttle Arm 18. Shutoff Arm 25. Dampener Spring
5. Arm Assembly 12. O Ring 19. Snap Ring 26. Cover
6. Spring Holder Arm 13. Throttle Lever 20. O Ring 27. Gasket
7. Snap Ring 14. Pivot Shaft 21. Return Spring 28. O Ring
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
87
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.
19993595
88
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.
19993596
89
10-59
SECTION 10 - ENGINE
19993597
90
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.
10-60
SECTION 10 - ENGINE
92
10-61
SECTION 10 - ENGINE
94
REAR OIL SEAL
This is a press-fit, retained by the backplate.
95
10-62
SECTION 10 - ENGINE
96
FLYWHEEL
Fit the flywheel. Note the location of the spring pin.
19992603
97
PISTON AND CONNECTING ROD
Coat the bearing face, piston, and piston ring with
clean engine oil.
10-63
SECTION 10 - ENGINE
Fit the end of the suction pipe to the oil strainer and
fix the oil strainer.
OIL SUMP
Tighten the bolts diagonally and evenly.
99
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)
100
IDLER GEAR AND OIL PUMP ASSEMBLY (SEE
SECTION IV OIL PUMP)
Install the thrust washer on the idler gear shaft.
1 Snap ring
2 Collar
3 Spring
4 Shim
101
5 Oil pump cover
6 Rotor
7 Spring
8 Idler gear
9 Thrust washer
10-64
SECTION 10 - ENGINE
102
Install the rotor.
Install the oil pump cover, shim, spring, and collar. Fix
them with the retaining ring.
103
NOTE: NEVER TURN the crankshaft until the timing
gear case is fitted.
104
10-65
SECTION 10 - ENGINE
105
CRANKSHAFT PULLEY
Align the keyway and key on the crankshaft pulley
and crankshaft and assemble them.
106
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.
107
10-66
SECTION 10 - ENGINE
Engine
Model Degrees Crank BTDC
Injection
X Y Z Timing
N844T 21 20 22 20 - 22
N844 22 21 23 21 - 23
Pull out the delivery valve, 1, (IN), and reinstall the
spring, 2, and delivery valve holder, 3.
109
10-67
SECTION 10 - ENGINE
N844, N844T
110
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.
10-68
SECTION 10 - ENGINE
2
3
112
6. Remove the delivery valve piston, 1, from the No.
1 delivery valve.
113
7. Reinstall the spring and holder, 1, into the
injection pump and tighten securely.
114
10-69
SECTION 10 - ENGINE
115
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.
116
12. Rotate the crankshaft clockwise. When the
timing mark on the crankshaft pulley, 1, is in line 2 1
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_. 117
10-70
SECTION 10 - ENGINE
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.
N844, N844T
Gasket Tightened
Measurement No. Thickness
0.019 - 0.023″ 111147510 t=0.047″
(0.5 - 0.6 mm) (t=1.2 mm)
0.023 - 0.031″ 111147520 t=0.051″
(0.6 - 0.8 mm) (t=1.3 mm)
10-71
SECTION 10 - ENGINE
118
Oil Pipe
Eyebolt tightening torque: 7 - 9 ft. lbs. (9 - 12 N·m)
119
L170 N844T engine - the oil pipe will be
connected to the turbocharger.
120
10-72
SECTION 10 - ENGINE
121
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.
1 Gasket
2 Plate
3 Gasket
4 Water pump
123
10-73
SECTION 10 - ENGINE
1 Thermostat housing
2 Thermostat
3 Gasket
4 Adapter
125
Return Pipe and Injection Pipe
After installing the return pipe, 1, install injection
pipes, 2.
Alternator Assembly
Install the assembly, and check the belt groove
alignment.
126
10-74
SECTION 10 - ENGINE
128
Op. 29 100 50
REINSTALLATION OF ENGINE INTO SKID
STEER FRAME
1
NOTE: Inspect the splines, 1, on the hydrostatic
pump flex plate and the splines on the input shaft. If
flex plate is damaged, replace.
129
10-75
SECTION 10 - ENGINE
4 4
132
10-76
SECTION 10 - ENGINE
19988126
133
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, 1/3-
throttle 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 1/2-
throttle 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.
10-77
SECTION 10 - ENGINE
COOLING SYSTEM
SPECIFICATIONS
Capacity - 10.8 qts. (10.3 L)
THERMOSTAT
Opening
180° F (82° C)
Fully Open
203° F (95° C)
OPERATION
The EIC (Electronic Instrument Cluster) monitors the
engine coolant temperature during operation and will
signal the operator should an overheat condition
occur.
10-78
SECTION 10 - ENGINE
DANGER 3
Allow the engine and cooling system to cool off 1
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
2
WATER PUMP ASSEMBLY AND
THERMOSTAT HOUSING
2
Disassembly
Remove the backplate and gaskets. 19992544
135
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.
Reassembly
Assemble the thermostat and spring in the housing.
Install the gasket and set plate on the water pump.
10-79
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).
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.
138
10-80
SECTION 10 - ENGINE
1
2
139
10-81
SECTION 10 - ENGINE
10-82
SECTION 10 - ENGINE
140
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.
10-83
SECTION 10 - ENGINE
2
1
142
FUEL GAUGE flashing light for about 5 seconds. When the fuel level
In the center of the EIC panel is the fuel gauge, 1, reaches three bars, 2, the segments will flash.
implemented as a vertical 10-segment green LED
bar graph. The lowest segments will flash when the When the fuel level reaches two bars, the EIC will
fuel level is low. An audible alarm will accompany the signal the operator again, with the segments flashing
and another five–second audible alarm.
10-84
SECTION 10 - ENGINE
144
10-85
SECTION 10 - ENGINE
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.
145
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.
146
Put the Service/Run switch, 1, in the SERVICE
position. Remove the fuel line, 2, Figure 148, at the
injector pump.
19984337
147
10-86
SECTION 10 - ENGINE
NOTE: Always check fuel level in tank. Always check fuel filters.
10-87
SECTION 10 - ENGINE
10-88
SECTION 10 - ENGINE
FUEL FLOW
19992606
148
1 Fuel tank 5 Filter (water trap)
2 Tank pick-up 6 Injection pump
3 In-line fuel filter 7 Fuel shut-off solenoid
4 Electric fuel pump
19992607
149
1 Key switch 4 Electric fuel pump
2 EIC board 5 Injector pump
3 Fuel level sender 6 Fuel shut-off solenoid
10-89
SECTION 10 - ENGINE
151
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.
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.
153
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.
154
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.
155
10-91
SECTION 10 - ENGINE
Op. 10 230 24
GOVERNOR
Construction/Function
A mechanical all-speed governor is used. It is
housed in the gear case.
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
157
10-92
SECTION 10 - ENGINE
19993595
158
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.
19993596
159
As the engine speed decreases, the governor
weights, 1, pivot inward allowing the slider cone, 2,
to move rearward.
19993597
160
10-93
SECTION 10 - ENGINE
Op. 10 218 34
NOZZLE AND HOLDER
Specification
Nozzle type: Throttle type
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)
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.
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 The cyclonic air cleaner houses a paper element
of the nozzle. which removes dirt or dust from air drawn in.
Adjust the pressure with adjusting shims, using
a nozzle tester so the injection starts at 150
kg/cm2 (throttle type) and 210 kg/cm2 (hole type). Inspection/Replacement
(The pressure increases or decreases about 10 1. When the EIC signals to service the air cleaner,
kg/cm2, 142 PSI, 9.7 atm with a shim of 0.1 mm take out the outer element and clean it by blowing
thick). compressed air (pressure lower than 100 PSI).
4. Spray Condition Do not remove the inner safety element.
– Fuel drops should not be mixed in the spray 2. When operating the machine in a dusty
pattern. environment, increase service frequency.
– Fuel should be sprayed in conical shape with 3. After cleaning the element, put a light inside the
respect to the nozzle axis. element and check it for cracks, holes, or wear.
– Be sure the fuel is sprayed in a circular shape If damage is found or the gasket is broken,
when tested. replace the element.
– Hold the pressure at 130 kg/cm2, lower by 20
kg/cm2, 20 atm than specified (150 kg/cm2) 4. When the inner safety element is dirty, do not
and check that no test oil drops from the clean. Replace the element.
nozzle tip. Op. 10 236 08
FUEL INJECTION TIMING
FUEL INJECTION PUMP
If trouble has been traced to this pump, disassembly, Engine
inspection, assembly, and testing/setting must only Model Degrees Crank BTDC
be carried out by fuel equipment specialists. Injection
X Y Z Timing
AIR CLEANER
N844T 21 20 22 20 - 22
N844 22 21 23 21 - 23
Construction/Function
10-96
SECTION 10 - ENGINE
164
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
166
10-97
SECTION 10 - ENGINE
2
3
168
9. Remove the delivery valve piston, 1, from the No.
1 delivery valve.
169
10-98
SECTION 10 - ENGINE
170
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.
1
171
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.
172
10-99
SECTION 10 - ENGINE
10-100
SECTION 10 - ENGINE
Specifications
ITEM DESCRIPTION SPECIFICATIONS
Turbocharger Lubrication Pressure-fed from external source
Turbine Axial-flow turbine max. continuous 180000
permissible speed (RPM)
Blower Centrifugal blower dry weight lbs. (kg) 7.0 lbs. (3.2 kg)
TROUBLESHOOTING
10-101
SECTION 10 - ENGINE
10-102
SECTION 10 - ENGINE
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.
174
10-103
SECTION 10 - ENGINE
175
3. Remove the turbocharger oil return line, 1, at the
top hose clamp, 2, and from the turbo assembly
at 3.
176
4. Remove the turbocharger assembly and adapter
from the exhaust manifold, 1, and support, 2.
177
10-104
SECTION 10 - ENGINE
Radial Movement
Standard: 0.003″ - 0.005″ (0.08 mm - 0.13 mm)
179
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.
180
10-105
SECTION 10 - ENGINE
181
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.
182
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.
183
10-106
SECTION 10 - ENGINE
184
7. Remove the thrust bearing, 1, and bushing, 2.
8. Remove the floating bearings, 3.
185
9. Remove the seal rings, 1, from the turbine shaft,
2, and oil slinger, 3.
186
10-107
SECTION 10 - ENGINE
Inspection
Before washing the disassembled parts clean,
visually inspect each part thoroughly:
187
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.
188
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).
189
10-108
SECTION 10 - ENGINE
Turbine Shaft
Standard Service
Item Value Limit
1. Journal OD 0.3146″-0.3149″ 0.3142″
(7.99-8.00 mm) (7.98 mm)
2. Groove width 0.0492″-0.0504″ 0.0508″
in turbine-side (1.25-1.28 mm) (1.29 mm)
seal ring
3. Sealing 0.0480″-0.0484″ 0.0516″
groove width, (1.22-1.23 mm) (1.31 mm)
blower side
4. Groove width 0.0402″-0.0405″ 0.0437″
in blower-side (1.02-1.03 mm) (1.11 mm) 190
seal ring
5. Shaft deflec- 0.0″-0.0004″ 0.00043″
tion (0.0-0.01 mm) (0.011
mm)
Standard Service
Item Value Limit
1. Floating 0.315″-0.316″ 0.3165″
bearing ID (8.01-8.03 mm) (8.04 mm)
2. Floating 0.485″-0.4854″ 0.4846″
bearing OD (12.32-12.33 mm) (12.31 mm)
3. Bearing cas- 0.488″-0.4886″ 0.48898″
ing boredia- (12.40-12.41 mm) (12.42 mm)
meter
191
Thrust Bearing
Standard Service
Item Value Limit
1. Thrust bear- 0.157″-0.1578″ 0.1567″
ing width (3.99-4.01 mm) (3.98 mm)
2. Groove 0.159″-0.1594″ 0.160″
width in (4.04-4.05 mm) (4.07 mm)
thrust bush-
ing
192
10-109
SECTION 10 - ENGINE
Standard Service
Item Value Limit
1. Turbine-side 0.590″-0.591″ 0.5925″
hole diame- (15.00-15.02 mm) (15.05 mm)
ter (bearing
casing)
2. Blower-side 0.488″-0.4889″ 0.4901″
hole diame- (12.40-12.42 mm) (12.45 mm)
ter (in seal
plate)
3. Blower-side 0.3937″-0.3945″ 0.3957″
hole diame- (10.00-10.02 mm) (10.05 mm) 193
ter (in seal
plate)
Turbocharger Reassembly
Oil the shaft journal, and insert the shaft into the
bearing casing.
195
10-110
SECTION 10 - ENGINE
196
Installing the Seal Plate
Insert seal rings, 1, into the oil slinger. The figure 2
shows the seal rings as seen from the front end.
197
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.
198
10-111
SECTION 10 - ENGINE
Insert the oil slinger,1, into the seal plate, 2. Fit the
3
bearing case, 3, to the seal plate and secure with the
retaining hardware. Tighten to 87 - 94 ft. lbs. (118 -
127 N·m).
2
199
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).
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.
201
10-112
SECTION 10 - ENGINE
202
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.
203
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.”
10-113
SECTION 10 - ENGINE
204
10-114
SECTION 10 - ENGINE
After Turbocharger Service, Check the Exhaust 2. Reconnect wire to the fuel stop solenoid. Move
System the hand throttle lever to the low, 1/3- throttle
1. Make sure the exhaust gas passages are position.
perfectly clean and free of foreign particles. 3. Operate the engine at no more than 1500 RPM
2. The bolts and nuts used on the joints of the for two to three minutes to insure lubrication oil is
exhaust line are of heat-resistant material; never getting to the turbo.
use ordinary bolts and nuts instead of the NOTE: Listen to the turbocharger to be sure that it is
heat-resistant hardware. Apply the antiseize running smoothly without making any abnormal
compound to the threads of bolts and nuts just noise.
before installing them.
4. Inspect the oil pipes and connections for any sign
Secure each connection good and tight, of oil leakage.
making it perfectly leak free. 5. Operate the engine normally.
6. Stopping the engine, move the engine speed
Starting the turbocharger for the first time after control lever to the low idle position. After full load
reinstallation on the engine operation, idle the engine for one minute to allow
1. Disconnect the wire to the fuel stop solenoid to components to cool.
insure that the engine will not start. Prime the CAUTION
lubrication circuit of the turbocharger by cranking
the engine with the starting motor for ten seconds Never stop the engine when it is running at high
at a time. After the first ten seconds of cranking, speed. Doing so may cause serious engine
pause for thirty seconds and then crank the damage.
engine again. Repeat the process until the oil
warning lamp goes out. The high operating speed of the turbocharger
NOTE: Cranking the engine longer than ten seconds makes it essential that adequate lubrication is
at a time is very hard on the battery and may cause ensured when the engine is started.
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.
10-115
SECTION 10 - ENGINE
Specifications: 11 V; 9.0 A
6 8
1 Heat wire 5 Nut 7
2 Sheath 6 Magnesium oxide powder
3 Asbestos 7 Insulation bushing
4 Body 8 Core 19992987
205
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.
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/cm2)
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.
206
Op. 10 223 10
1
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.
207
10-117
SECTION 10 - ENGINE
19992989
208
**
19992988
209
*Maximum current draw for oil pressure switch is **Diode capacity: Current 3 amp. Reverse voltage
0.42 amps (5-watt max. bulb). 600 volt.
10-118
SECTION 10 - ENGINE
Used to test engine compression. Screws into Removes engine oil pump port block without
the glow plug hole, allows compression testing removing oil pan.
without removing injectors. Use with FNH 02020 All of these tools are currently used on various
Diesel Compression test kit or equivalent. Compact Tractors and may already be in
– FNH 00122 - Compression Test Adapter 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.
Replace or repair pistons with new rings. OIL CONSUMPTION RECTIFICATION (7.30)
Replace or repair where necessary camshaft and Remove cylinder head, lub. oil sump and oil pump.
auxiliary drive bushings, main and big end bearings
and thrust washers. Remove all pistons and connecting rods.
Inspect and replace timing gears as necessary. Deglaze all cylinder bores using “Flexihone” or
Inspect and repair as required water pump, oil pump, similar tool (C.l. liners and bores only).
turbocharger, and any cylinder head components.
Clean and check pistons for wear, repairing as
Reassemble engine completely using new gaskets necessary and replace all piston rings.
and seals and tighten to specifications. Set valve
Strip and clean cylinder head.
clearances. Run engine and check for leaks.
Retighten head and reset valve clearances. Reseat valves and service injectors.
MINOR OVERHAUL (14.30) Check condition of oil pump and repair if necessary.
Steam clean engine, dismantle, clean and inspect
Reassemble all parts using new gaskets and seals.
parts.
Set valve clearances and tighten head to
Replace or repair pistons and check height. Hone specification.
liners, fit new main and big end bearings and thrust
Run engine and check for leaks.
washers.
Retighten head and reset valve clearances.
Check and rework/repair valves as necessary.
Additional time - turbocharged engine.
Completely reassemble and tighten to specification
using new gaskets and seals.
10-120
SECTION 10 - ENGINE
REPLACE BARE BLOCK (7.00) Additional time - replace each valve seat insert as
Steam clean complete engine, dismantle, clean and necessary. (0.10)
inspect all parts.
VALVE SPRING
Reassemble engine complete into new bare blocks
Change one-head not removed except for “B”
with same or new pistons, using new rings, main and
engines, includes C6. (0.30)
big-end bearings and thrust washers, gaskets and
Includes remove and replace cylinder head
seals, and tighten to correct specifications.
cover/camshaft cover.
Run engine and check for leaks.
Change complete set of valve springs-head not
Retighten head and reset valve clearances. removed except for “B” engines, includes C6. (1.20)
Includes remove and replace cylinder head
Additional time - turbocharged engine. cover/camshaft cover.
Additional time - cut one valve seat. (0.10) Additional time - turbocharged engine.
10-121
SECTION 10 - ENGINE
CRANKSHAFT ASSEMBLY Turn engine to “nip” push rod. Reset valve clearance.
Refit top cover.
REPLACE CRANKSHAFT (4.30) Run engine and test.
Includes replace rear main lip seal, replace damper “Pin check” only on “B” engines.
and pulley, replace thrust washers, sump and
strainer, remove, clean and reassemble with new SUMP ASSEMBLY
gaskets and replace, and remove and replace
flywheel and flywheel housing. SUMP AND STRAINER (0.30)
Remove, clean and reassemble with new gaskets
Replace damper and pulley, as a separate operation and corks and replace.
from crankshaft replacement. (0.10)
SUCTION PIPE (0.20)
THRUST WASHERS (3.50)
Remove and replace (oil pump on bench).
Replace.
Includes remove sump and strainer, remove, clean
and reassemble with new gaskets and replace.
OIL PUMP (1.10)
Remove and replace
CAMSHAFT, TIMING CASE AND GEAR Includes remove, clean and reassemble with new
gaskets and corks and replace
ASSEMBLY
(includes H3, F13 and F18 on “B” engines).
CAMSHAFT
Remove and replace. (1.10) RELIEF VALVE (0.10)
Includes remove and replace rocker shaft assembly, Strip, check, clean and reassemble.
check/adjust valve clearances, remove sump and (oil pump on bench).
strainer, remove, clean and reassemble with new
gaskets and replace. FUEL SYSTEM
Includes C24 and C5/1 on “B” engines.
INJECTION PUMP (0.40)
TAPPETS Remove and replace.
Remove and replace all. (2.40) Includes check and adjust fuel pump timing, and
(includes G1, F5 on engine types E, G, H, L, T and remove and replace high-pressure pipes.
Z).
(includes C6 on engine types C and J). INJECTION PUMP TIMING (1.10)
(includes F5 on “B” engines). Check and adjust.
10-122
SECTION 10 - ENGINE
10-123
SECTION 10 - ENGINE
10-124
SECTION 27 – REAR DRIVE AXLE (GEARBOXES)
Chapter 1 – Gearboxes
CONTENTS
27-1
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
Op. 27 000
GENERAL INFORMATION
The power is transmitted to the final drive from the 1
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
1
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
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.
27-2
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
CAUTION
Always engage the parking brake before exiting
the loader.
1 - HYDROSTATIC PUMP RH
2 - HYDROSTATIC PUMP LH
3 - HYDROSTATIC MOTOR RH
4 - HYDROSTATIC MOTOR LH
5 - GEARBOXES (2)
9 - AXLES ASSEMBLIES(4)
27-3
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
SPECIFICATIONS
Chain Case
Description Use
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
CAUTION
Never service a raised loader unless it is securely
supported with adequate jack stands or blocks.
27-5
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
One drive wheel not powered Broken drive chain Check chain and repair
Axle or drive sprocket splines worn Check axle and sprocket, replace
Chain case noise Loose drive chains Check and adjust chains
No oil in final drive Check oil level
Worn drive sprockets Check sprockets and repair
Bearing failure Check axle and gearbox bearings
and repair
Excessive axle play Bearing failure on axle shaft Check bearings and repair
Snap ring failure on axle shaft Check axle bearing pre-load,
repair
Axle outer bearing failure Prolonged operation in liquid or Decrease lubrication interval to
semi-liquid material 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.
Pre-test instructions:
* Lower boom and attachment to the ground.
* Stop engine.
* Jack loader with wheels off the ground.
* Release parking brake.
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.
27-8
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
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. 1 1
– Unhook control linkage to the auxiliary or 2
boom and bucket control at 3.
– Remove the support retaining hardware, 4,
and lift the control lever assemblies from the 4 4
loader.
3 3
19992568
11
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.
12
27-9
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
13
17. Remove center section of caliper, 1, spacers, 2,
and now remove the retaining bolts.
18. Remove inside disc, 3.
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)
16
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.
17
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.
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.
19
5. Remove the external snap ring, 1.
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.
27-12
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
22
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 23
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.
27-13
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
24
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.
25
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.
26
27-14
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
27
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.
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)
30
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.
31
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.).
32
27-16
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
4 4
3 3
19992568
34
Reassemble the Parking Brake
35
27-17
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
36
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.
37
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.).
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.
Gearbox
Remove and replace 2.0 hrs.
Rebuild 1.5 hrs.
27-19
SECTION 27 - REAR DRIVE AXLE (GEARBOXES)
27-20
SECTION 29- HYDROSTATIC TRANSMISSION
CONTENTS
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.
29-3
SECTION 29 - HYDROSTATIC TRANSMISSION
7 6
12 1
13
2 13
3
10 9 8
4
13
4
11
19997771
2
The hydrostatic system consists of the following 8. Hydrostatic transmission charge line - From the
components: charge check valve to the hydrostatic pumps
under the operator’s seat.
1. Hydraulic reservoir - Right front of engine 9. Hydrostatic pump for left drive - Under operator’s
compartment seat.
2. Suction line - From reservoir to the gear pump 10. Hydrostatic pump for right drive - Under
under the operator’s seat. operator’s seat.
3. Pressure line - From the gear pump to the control 11. Hydrostatic motor for left drive - Under operator’s
valve under the operator’s seat. seat.
4. Return line - From control valve to oil cooler. 12. Hydrostatic motor for right drive - Under
5. Oil cooler - Engine side of radiator in engine operator’s seat.
compartment. 13. Hydrostatic system case drain line - From pumps
6. Oil filter - After the oil cooler engine compartment and motors to the hydraulic reservoir.
rear door.
7. Charge check valve - In return line between oil
filter and 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
29-6
SECTION 29 - HYDROSTATIC TRANSMISSION
29-7
SECTION 29 - HYDROSTATIC TRANSMISSION
29-8
SECTION 29 - HYDROSTATIC TRANSMISSION
3
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
4. Put the “SERVICE/RUN” switch, 1, in the
“SERVICE” position.
19984337
5
29-9
SECTION 29 - HYDROSTATIC TRANSMISSION
29-10
SECTION 29 - HYDROSTATIC TRANSMISSION
5 5
4 1
2 2
3
19997776
7
HYDROSTATIC SYSTEM OIL FLOW right hydrostatic motor, 6, when the right
forward/reverse control lever is stroked in either
direction.
Hydrostatic Pumps and Motors High- Pressure
Flow The hydrostatic system is protected by four high-
The hydrostatic pumps are driven by the engine pressure relief valves, two each pump, one for
through a flex plate drive coupler. forward and one for reverse. All four high- pressure
relief valves are the same and factory set at 238 bar
The rear hydrostatic pump, 1, supplies high- (3500 PSI). Do not try changing the pressure setting
pressure oil through high-pressure lines, 2, to the left of these relief valves. If during testing the relief valves
hydrostatic motor, 3, when the left forward/reverse are found to be incorrectly set, replace the complete
control lever is stroked in either direction. valve cartridge.
The front hydrostatic pump, 4, supplies high-
pressure oil through high-pressure lines, 5, to the
29-11
SECTION 29 - HYDROSTATIC TRANSMISSION
19997777
8
Hydrostatic Pump and Motor Charge Pressure A charge check valve in the return line after the filter
Oil Flow at 1, builds backpressure in the return circuit and
During the operation of the hydrostatic pumps and forces oil through the charge line, 2, into the
motors, oil from the high-pressure system is used for hydrostatic pump back plate at 3. This charge oil
lubrication of the internal rotating parts of the pumps provides replacement oil in the high-pressure circuits
and motors. The lubrication oil drains into the pump that was used for lubrication purposes.
and motor housings.
29-12
SECTION 29 - HYDROSTATIC TRANSMISSION
19997778
9
Hydrostatic Pump and Motor Case Drain Flow drain from the pumps and motor housings (cases)
During operation of the hydrostatic pumps and through drain lines, 1.
motors, oil from the high-pressure circuit used for
lubrication oil drains into the pump and motor The front hydrostatic pump drains internally to the
housings. rear pump at 2. The oil will drain from the rear pump
and tees into the drain line from the motors. The case
The lubrication oil will fill the housings approximately drain oil returns to the hydraulic reservoir, 3.
half full. This oil then becomes cooling oil and will
29-13
SECTION 29 - HYDROSTATIC TRANSMISSION
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 11
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.
29-14
SECTION 29 - HYDROSTATIC TRANSMISSION
12
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.
29-15
SECTION 29 - HYDROSTATIC TRANSMISSION
CAUTION
Never work under a raised seat unless it is 1
securely latched in the raised position.
14
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.
CAUTION
Always stay clear of moving parts during testing
or serious injury could occur.
29-16
SECTION 29 - HYDROSTATIC TRANSMISSION
29-17
SECTION 29 - HYDROSTATIC TRANSMISSION
19
29-18
SECTION 29 - HYDROSTATIC TRANSMISSION
1 - Forward (bottom)
2 - Reverse (top)
Rear pump controls left motor:
3 - Forward (bottom)
4 - Reverse (top) 3 4
19997770
8. Start the engine and run it at full throttle (3070 - 20
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.
CAUTION
Always stay clear of moving parts during testing
or serious injury could occur.
29-19
SECTION 29 - HYDROSTATIC TRANSMISSION
19997776
21
HYDROSTATIC PUMP EFFICIENCY TEST CAUTION
This test can be used to check the operating Failure to securely support the skid steer could
efficiency of the pump. result in movement of the loader during testing
causing serious injury or damage to the
IMPORTANT: When connecting a flowmeter into the equipment.
pump circuit, make sure the meter is connected
properly and the control lever is stroked in the
5. Raise the operator’s seat and latch in the raised
direction being tested. If not, the hydrostatic system
position.
and/or flowmeter may be damaged.
6. Remove the step shield.
7. Remove the high-pressure line from the pump,
Efficiency Test Procedure for the direction to be tested.
1. Raise the boom and rest on the boom locks. 8. Connect the test hose from the fitting on the
2. Put the Service/Run switch in the “SERVICE” pump to the inlet side of the flowmeter and the
position. line from the motor to the outlet side of the
flowmeter. Turn the pressure regulator valve out
3. Disengage the parking brake. on the flowmeter to zero pressure.
4. Securely block the skid steer with all four wheels
off the ground.
29-20
SECTION 29 - HYDROSTATIC TRANSMISSION
1 - Forward (bottom)
2 - Reverse (top)
3 - Forward (bottom)
4 - Reverse (top)
3 4
IMPORTANT: Check and make sure the flowmeter is 19997770
connected properly, so when the pump is stroked the 22
flow from the pump goes to the inlet side of the
flowmeter.
23
11. Turn the pressure regulator valve, 1, in on the
flowmeter until a pressure reading of 136 bar 1
(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).
EXAMPLE:
29-21
SECTION 29 - HYDROSTATIC TRANSMISSION
29-22
SECTION 29 - HYDROSTATIC TRANSMISSION
19997776
26
HYDROSTATIC MOTOR EFFICIENCY TEST CAUTION
This test can be used to check the operating Failure to securely support the skid steer could
efficiency of the motor. result in movement of the loader during testing
causing serious injury or damage to the
IMPORTANT: When connecting a flowmeter into the equipment.
pump/motor circuit, make sure the meter is
connected properly and the control lever is stroked in
5. Raise the operator’s seat and latch in the raised
the direction being tested. If not, the hydrostatic
position.
system and/or flowmeter may be damaged.
6. Remove the step shield to access the hydrostatic
motors.
Efficiency Test Procedure 7. Remove the high-pressure line from the pump for
1. Raise the boom and rest on the boom locks. the direction to be tested.
2. Put the Service/Run switch in the “SERVICE” 8. Connect the test hose from the fitting on the
position. pump to the outlet side of the flowmeter and the
line from the motor to the inlet side of the
3. Disengage the parking brake. flowmeter. Turn the pressure regulator valve on
4. Securely block the skid steer with all four wheels the flowmeter to zero pressure.
off the ground.
29-23
SECTION 29 - HYDROSTATIC TRANSMISSION
1 - Forward (bottom)
2 - Reverse (top)
3 - Forward (bottom)
4 - Reverse (top)
3 4
IMPORTANT: Check and make sure the flowmeter is 19997770
connected properly, so when the pump is stroked the 27
flow from the pump goes to the motor and to the inlet
side of the flowmeter.
EXAMPLE:
29-24
SECTION 29 - HYDROSTATIC TRANSMISSION
CAUTION
Do not start the engine with the test tool installed,
as the hydraulic system must be able to breathe.
Test Procedure:
29
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.
29-25
SECTION 29 - HYDROSTATIC TRANSMISSION
29-26
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.
31
29-27
SECTION 29 - HYDROSTATIC TRANSMISSION
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
29-28
SECTION 29 - HYDROSTATIC TRANSMISSION
19998077
36
18. Remove the cam arm securing hardware, 1, and
remove the arms from the trunnion shafts. 3
19. Remove the plastic guides, 2, from the support 3 4
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. 2
21. Remove the pump mounting bolts, 4, and
remove the pump assembly from the unit. 3
1
1
3
4
19997770
37
29-29
SECTION 29 - HYDROSTATIC TRANSMISSION
19997815
38
23. Remove the side/top support bracket hardware,
1, and remove the bracket. 1
19998064
39
24. Remove the O ring, 1, and dust shield, 2, from
each hydrostatic pump control arm.
1
2
19998073
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 2 3 4 5
1 Left side pump (rear)
29-31
SECTION 29 - HYDROSTATIC TRANSMISSION
19997798
43
29-32
SECTION 29 - HYDROSTATIC TRANSMISSION
2 1
19997799
44
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.
1
19998066
45
13. Mark the piston, 1, and hole, 2, positions with a
soft marker (do not scratch any surface) so the 4 3
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.
2 1
19998070
46
29-33
SECTION 29 - HYDROSTATIC TRANSMISSION
19998068
47
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 2 3
remove the shaft, seal, and seal thrust washer
from the housing.
1
19998072
48
17. Remove the retaining rings, 1, to remove the
thrust washers, 2, and needle thrust bearing, 3.
1 1
2 3 2
OPS5548
49
29-34
SECTION 29 - HYDROSTATIC TRANSMISSION
3
19997800
50
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. 2
19997801
51
20. Remove the control arm side bearing cover, 1, by
removing the three capscrews, 2. Pry the cover 1
off by inserting screwdrivers in the notches on the
side of the cover.
19997802
52
29-35
SECTION 29 - HYDROSTATIC TRANSMISSION
19997803
53
22. Remove the camplate, 1, from the housing by
sliding the short end out first.
19998069
54
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.
1
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.
19998071
4. All oil seals and O rings should be replaced
during reassembly. 55
29-36
SECTION 29 - HYDROSTATIC TRANSMISSION
19997808
56
Pump Shafts
1. Check the rear pump shaft areas contacting the 6
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
57
5. Check the front pump shaft areas contacting the
needle roller bearings, 1, for wear and a rough
bearing.
1 2
6. Check for a bent or worn shaft. 2 1
7. Check the spline areas, 2, for wear or twist.
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 1
surface must be smooth with no metal flaked
away and no scoring. Circular scratches
2 2
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 19998065
roughness; replace if damaged. 59
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 OPS5561
scratches in the shoes will not cause excessive
wear. Do not lap the shoes. 60
Rotating Group
1. Check for cracks at the holes, 1, for the spherical 3 1
washer and shoes. The shoe plate is only
available as part of the rotating group. 2
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 4
spherical washer is only available as part of the
19998070
rotating group. Check the side curved area for
cracks. 61
29-38
SECTION 29 - HYDROSTATIC TRANSMISSION
OPS5563
62
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.
OPS5564
63
Replaceable Bearing Plate
2 3
1. Check the plate for overall flatness.
2. Check for scratches on the brass side of the 1
plate, extending across the area where the piston 1
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
64
29-39
SECTION 29 - HYDROSTATIC TRANSMISSION
Back Plate
1. Check the needle bearings for wear, 1. These 2
bearings are pressed into the back plate with the
bearing numbers facing out.
2. Check the backplate for flatness along 1
perpendicular lines, 2.
19997806
65
3. Two directional relief valves, 1, in each pump limit
the maximum system pressure to 238 bar (3500 1
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.
19997809
66
4. Check the relief valves for scratches in the seat
areas, 1. Check for broken springs, 2. The 3
springs should all be the same length.
3
5. Check the seat area, 3, in the backplate for
scratches that will prevent the relief valves from
sealing properly.
2 2
1
19997810
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.
19998065
68
5. Place the camplate, 1, into the housing with the
control arm, 2, toward the boss as marked at the
beginning of disassembly. 2
NOTE: The machined surface of the camplate and 3
wear plate, 3, face the open end of the housing.
19998069
69
29-41
SECTION 29 - HYDROSTATIC TRANSMISSION
1 2
19997801
70
7. Attach the trunnion bearing cover, 1, and support
bracket, 2, with the three capscrews, 3, and 2 3
washers removed during disassembly. Tighten 1
the capscrews to 40 N·m (30 ft. lbs.).
3
19997800
71
8. Install a new O ring, 1, on the control shaft side
of the housing. 1
19997811
72
29-42
SECTION 29 - HYDROSTATIC TRANSMISSION
19997803
73
10. Attach the control arm bearing cover, 1, with the
three capscrews, 2, and washers removed 1
during disassembly. Tighten the capscrews to 40
N⋅m (30 ft. lbs.).
19997802
74
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.
OPS5572
75
29-43
SECTION 29 - HYDROSTATIC TRANSMISSION
1
19998072
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.
OPS5574
77
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 3
during disassembly to place the pistons in their
previous spots.
1
2
19998070
78
29-44
SECTION 29 - HYDROSTATIC TRANSMISSION
19997809
80
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 1
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
2
shaft failure could result.
19997806
81
29-45
SECTION 29 - HYDROSTATIC TRANSMISSION
29-46
SECTION 29 - HYDROSTATIC TRANSMISSION
19997780
84
The hydraulic system gear pump consists of:
19997782
86
29-47
SECTION 29 - HYDROSTATIC TRANSMISSION
19997783
87
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.
1
19997784
88
5. Install the pump backplate, 1, and center section
together over the gear shafts. 2
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
19997796
89
29-48
SECTION 29 - HYDROSTATIC TRANSMISSION
19997790
90
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.
2
1
19997791
91
29-49
SECTION 29 - HYDROSTATIC TRANSMISSION
4 Key
5 Pump body
6
6 Pump back plate 5
3 4
Coat all parts with a thin coat of petroleum jelly or oil 19997795
to aid in reassembly.
92
The high flow pump consists of:
5 Pump body
19997782
94
29-50
SECTION 29 - HYDROSTATIC TRANSMISSION
19997783
95
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. 2
3
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.
1
19997788
96
6. Install the pump body and back plate together, 1,
over the gear shafts, taking care not to disturb the 1
seals between the pump body and backplate.
19997792
97
29-51
SECTION 29 - HYDROSTATIC TRANSMISSION
1
2
3
19997762
98
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.
19997763
99
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.
2
1
19997764
100
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 1
between the pump body and backplate. Make
sure there are no gaps between the pump bodies
and plates.
19997793
101
11. Install the housing hardware with the eight bolts,
1, and sealing washers. Tighten the bolts evenly 1
in a criss-cross pattern to 34 - 38 N⋅m (25 - 28 ft.
lbs.).
19997797
102
29-53
SECTION 29 - HYDROSTATIC TRANSMISSION
REINSTALLATION
1. Install the side/top support bracket, 1, with the 1
capscrews, 2, and washers removed during
disassembly.
19998046
103
2. Install the dust shields, 1, and new O rings, 2,
around each hydrostatic pump control arm.
2
1
19998073
104
3. Install the neutralizer cam arms, 1, over the
trunnion shafts, with the bearings facing the rear 2
of the unit. Secure the arms with the 3/8″ Grade 2
8 bolts, 3, lockwashers and nuts removed during 3
disassembly. Tighten to 65 N⋅m (48 ft. lbs.).
1
4. Fill the pump assembly with oil through the case
drain port. Install all the port fittings, but do not 3
tighten the fitting nuts at this time as aligning 1
hoses and fittings will be required. 2
Refer to the “Hydraulic System Cleaning After a
Rebuild” section of this manual before installing 2
the pump assembly in the loader.
19998075
105
29-54
SECTION 29 - HYDROSTATIC TRANSMISSION
29-55
SECTION 29 - HYDROSTATIC TRANSMISSION
2
19998081
109
12. Install the high pressure port fittings, 1, and the
high pressure lines, 2. Tighten the high pressure 3 2
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 1
bottom of the hydraulic pump.
14. Turn the suction tube fitting down and install the
suction tube, 4. TIghten all hydraulic connections
securely.
4
19998080
110
15. Turn the suction tube fitting, 1, down and install
the suction tube, 2. TIghten all hydraulic
connections securely.
1
2
19998082
111
29-56
SECTION 29 - HYDROSTATIC TRANSMISSION
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.
19984593
115
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.
116
29-58
SECTION 29 - HYDROSTATIC TRANSMISSION
117
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.
118
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.
119
29-59
SECTION 29 - HYDROSTATIC TRANSMISSION
120
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.
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.
122
29-60
SECTION 29 - HYDROSTATIC TRANSMISSION
19998078
123
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.
19998079
124
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.
125
29-61
SECTION 29 - HYDROSTATIC TRANSMISSION
126
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.
128
29-62
SECTION 29 - HYDROSTATIC TRANSMISSION
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
132
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.
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
135
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.
136
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.
137
29-65
SECTION 29 - HYDROSTATIC TRANSMISSION
138
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.
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.
142
29-67
SECTION 29 - HYDROSTATIC TRANSMISSION
144
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.
145
29-68
SECTION 29 - HYDROSTATIC TRANSMISSION
146
10. Check the connecter plate for wear in the band
area, 1, or any connecting scratches between the
kidney ports, 2.
147
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.
148
29-69
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.
29-70
SECTION 29 - HYDROSTATIC TRANSMISSION
151
5. Lubricate the thrust bearing, 1, and install it over
the bearing race at 2.
152
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.
153
29-71
SECTION 29 - HYDROSTATIC TRANSMISSION
154
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.
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.
156
29-72
SECTION 29 - HYDROSTATIC TRANSMISSION
157
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.
158
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.
159
29-73
SECTION 29 - HYDROSTATIC TRANSMISSION
160
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.
161
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.
162
29-74
SECTION 29 - HYDROSTATIC TRANSMISSION
0.075″ 1.91 mm
0.015″ 0.38 mm
29-75
SECTION 29 - HYDROSTATIC TRANSMISSION
163
29-76
SECTION 29 - HYDROSTATIC TRANSMISSION
164
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.
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.
166
29-77
SECTION 29 - HYDROSTATIC TRANSMISSION
167
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.
168
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.
169
29-78
SECTION 29 - HYDROSTATIC TRANSMISSION
170
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.
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.
172
29-79
SECTION 29 - HYDROSTATIC TRANSMISSION
RENSTALLATION
1. Clean all previously sealed surfaces, motor to
gearbox, final drive cover, brake disk retaining
bolt and washer. 1
When resealing, use a noncorrosive silicone
sealer to prevent rust and corrosion of parts after
assembled.
174
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.
175
29-80
SECTION 29 - HYDROSTATIC TRANSMISSION
19998079
177
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 19992573
wheels off the ground, or movement of the loader 178
may cause serious injury or damage to the
equipment.
29-81
SECTION 29 - HYDROSTATIC TRANSMISSION
179
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.
CAUTION
Use a floor jack to support the belly pan to
prevent serious injury.
181
29-82
SECTION 29 - HYDROSTATIC TRANSMISSION
182
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.
183
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.
184
29-83
SECTION 29 - HYDROSTATIC TRANSMISSION
185
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.
186
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.
187
29-84
SECTION 29 - HYDROSTATIC TRANSMISSION
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. 1
Re-crank the engine until the gauge moves. After
the gauge moves, stop cranking and reconnect
the fuel solenoid.
19984593
189
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.
29-85
SECTION 29 - HYDROSTATIC TRANSMISSION
191
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.
CAUTION
Use a floor jack to support the belly pan to pre-
vent serious injury.
193
29-86
SECTION 29 - HYDROSTATIC TRANSMISSION
194
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.
195
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.
196
29-87
SECTION 29 - HYDROSTATIC TRANSMISSION
197
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.
198
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.
199
29-88
SECTION 29 - HYDROSTATIC TRANSMISSION
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 sec-
onds 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 1
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
2
the fuel solenoid.
19997757
202
29-89
SECTION 29 - HYDROSTATIC TRANSMISSION
204
29-90
SECTION 29 - HYDROSTATIC TRANSMISSION
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
205
attachment. Always remove the attachment from
the loader.
19984593
206
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.
207
29-91
SECTION 29 - HYDROSTATIC TRANSMISSION
208
9. Remove the snap ring, 1. Disassemble and clean
the check valve.
10. The check valve is marked for oil flow for
installation.
209
Op. 29 100
STEERING SYSTEM
29-92
SECTION 29 - HYDROSTATIC TRANSMISSION
19984593
211
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.
212
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
4825-11r
213
29-93
SECTION 29 - HYDROSTATIC TRANSMISSION
NEUTRALIZER ASSEMBLY
2
Op. 29 130 10
Neutralizer Removal 3
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 1
1
plate from the unit.
19992569
214
Neutralizer Parts Inspection
6 6
1. Inspect the plastic guides, 1, for breaks or wear. 1 2
If worn or damaged, replace. 7 5
2. Inspect the guide pins, 2, for excessive wear. If
worn, replace.
3. Inspect the cam blocks, 3, for wear in the area the 4
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. 3
5. Inspect the spring, 5, for proper free length: 114.3
±2.4 mm (4.5″ ±3/32″). If not within specification, 19998067
replace the spring.
215
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 6
the pins, 2, to the front of the neutralizer plate.
2. Remove the centering spring retaining bolt, 3, 3
and spring from the engine bellhousing. When 5 6
removing the retaining bolt the spring will be
under slight pressure. Lift the plate from the unit.
1 4
3. Remove the control link hardware, 4, at the 1
control handles. 2
4. Note the number and position of the spacers and 2
washers for the dampener mounting hardware at 19992569
5 and 6. Remove the link and dampener 216
hardware, 5, at the pintle arms. Remove the
dampener hardware, 6, at the support brackets.
29-94
SECTION 29 - HYDROSTATIC TRANSMISSION
1
1
19997770
217
Control Linkage Parts Inspection
1. Inspect the bushings, 1, in the control links; 2
replace if worn, loose, or damaged.
2. Inspect the dampeners, 2, for unequal
pressures, leaks, or binding shafts. If damaged,
replace.
1
19997805
218
3. Inspect the rubber bushings, 1, in the cam arms;
if loose or worn, replace. Inspect the arms in the 1
clamping area, 2, for damage. Check that the 3
bearings, 3, are not damaged and can move
freely. 2
NOTE: Bearings are a press fit and replaceable
separately; however, cam arms come from parts with 2
bearings already installed. To replace bearings, use
a puller to remove the old bearing.
3 1
19998074
219
29-95
SECTION 29 - HYDROSTATIC TRANSMISSION
19998067
19997798
220
Op. 29 130 06
Control Linkage and Neutralizer Reassembly
and Adjustment
1
1. Install a new O ring, 1, around each cam plate
shaft.
19998073
221
2. Slide the cam arms, 1, onto the cam plate shafts.
The bearings, 2, should be toward the engine 1 2
2
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.).
3
1
19997770
222
29-96
SECTION 29 - HYDROSTATIC TRANSMISSION
2 1
19998067
223
4. Install the dampener hardware, 1, at the support
brackets with the bolts, washers and spacers
removed during disassembly. Install the link and
1
dampener hardware, 2, at the pintle arms.
Tighten the hardware securely.
5. Install the control link hardware, 3, at the control 4
handles. 2 1
6. Install the neutral return spring assembly with the
long bolt, 4. Slide the short spring retainer over 5 3
the shoulder bolt first. Slide the spring on the bolt, 5
and then slide the longer retainer on the bolt. 6
Install the bolt into the bellhousing cover, 6
compressing the spring by hand. Screw the bolt 19992569
into the housing until it bottoms, and then tighten 224
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.
29-97
SECTION 29 - HYDROSTATIC TRANSMISSION
4802-10
225
3. Remove the handle mounting bolts, 1, and
remove the handle assembly from the unit.
226
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 2
washers for reassembly.
3. Remove the bearings, 5, from the handle,
retaining any shim washers at 6.
5 4
4. Slide the handle sideways and remove from the 1
stub shafts.
3
227
29-98
SECTION 29 - HYDROSTATIC TRANSMISSION
INSPECTION
3
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.
2 1
228
REASSEMBLY
1. Slide the handle sideways over the stub shafts.
7
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 6
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 1
boot securing bolts.
4
3
5. Install a new hand grip, 7, if grip is worn. 3
2
229
REINSTALLATION
1. Place the handle assembly in the unit and install
the five handle mounting bolts, 1, and tighten
securely.
1
230
29-99
SECTION 29 - HYDROSTATIC TRANSMISSION
4802-10
231
29-100
SECTION 29 - HYDROSTATIC TRANSMISSION
4802-10
232
3. Remove the boom control rod, 1, from the left
control handle arm, 2.
2
1
19996848
233
4. Remove the four handle mounting bolts, 1, and
remove the handle assembly from the unit.
234
29-101
SECTION 29 - HYDROSTATIC TRANSMISSION
DISASSEMBLY
4 2 3 1 10
1. Take note of the number and position of all shim
washers for reassembly.
8
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. 9
4. Remove the groove pin, 5, from the arm, 6.
5. Loosen the set screw, 7, on the set collar. 10 11
Remove the cotter pins, 8, and shim washers, 9,
taking note of the number of shim washers for 11 7 6 5 8 9
reassembly.
6. Remove the bearings, 10, from the control 235
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.
1 2
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 3
removing the capscrew, 3, flat washer and 1
locknut. Remove the ball end, 2, and jam nut, 4,
from the rod, 5.
2 4
19996839
237
29-102
SECTION 29 - HYDROSTATIC TRANSMISSION
1 1
2
19997750
238
INSPECTION
1. Inspect the handle pivot bearings, 1; replace if 2
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.
3
1
19997747
239
4. Inspect the pivot handle linkage for looseness in
the ball joints, 1; replace if worn. 1
2
5. Inspect the pivot handle, 2, and handle support,
3, for damage or deformation. Replace as
necessary.
3
240
29-103
SECTION 29 - HYDROSTATIC TRANSMISSION
REASSEMBLY
1
1. Install a new hand grip on the top of the handle,
1, if grip is worn. 6 5
9
2. Attach the ball end, 2, and jam nut, 3, to the rod,
8
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 7
not tighten the jam nut at this time.
2
3. Attach the handle assembly to the handle
3
support, 7, with the long bolt, 8, and locknut, 9.
4. Tighten the locknut to remove any movement
4
between the handle assembly and support, but
19996839
do not overtighten. The support should be loose
enough to allow the handle to pivot without 241
binding.
5. Slide the handle tube up through the slot, 1, in the
handle support base.
7
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. 1 2
8. Install shim washers, 5, to reduce side play on 5
the stub shafts. Retain the shims on the stubs
shaft with a roll pin, 6. 6
9. Slide the rubber boot, 7, down over the end of the 4
control handle, one side at a time, and secure 3 4
with the the hardware removed during
disassembly. 242
4
1
2
19996838
243
29-104
SECTION 29 - HYDROSTATIC TRANSMISSION
244
15. Attach the ball end and jam nut, 1, onto rod, 2.
Install spacer, 12, (OD - 7/16″; length - 15/32″) 8 2 3
between the ball end and arm, 3. Secure with a
5/16″ x 1-3/4″ bolt, lock washer, and nut at 4. 1 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
10
tighten the setscrew.
10
17. Drive the groove pin, 12, in the arm completely 11
into place. 9 12 6 5 7
18. With the handle in the neutral position angle,
adjust the length of the rod, 2, so the ball stud at 245
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 1
install the handle mounting bolts, 2.
2
246
29-105
SECTION 29 - HYDROSTATIC TRANSMISSION
2
1
19996848
247
3. Connect the hydrostatic pump control link, 1.
4. Reinstall all shields removed for the repair.
4802-10
248
29-106
SECTION 29 - HYDROSTATIC TRANSMISSION
4802-10
249
3. Remove the auxiliary hydraulic control or bucket
control rod, 1, from the right control handle arm,
2.
2
1
19996848
250
4. Remove the five handle mounting bolts, 1, and
remove the handle assembly from the unit.
251
29-107
SECTION 29 - HYDROSTATIC TRANSMISSION
DISASSEMBLY
1. Take note of the number and position of all shim 4 2 3 1 10
washers for reassembly. 8
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. 9
4. Remove the groove pin, 5, from the arm, 6.
5. Loosen the set screw, 7, on the set collar. 10 11
6. Remove the cotter pins, 8, and shim washers, 9,
taking note of the number of shim washers for 11 7 6 5 8 9
reassembly.
7. Remove the bearings, 10, from the control 252
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.
2
1
4
19996890
253
9. Boom hydraulics control - Remove the roll pin, 1,
the L-pin, 2, and the spring and ball at 3.
19997746
254
29-108
SECTION 29 - HYDROSTATIC TRANSMISSION
19996889
255
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 2
4
19996838
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 3
removing the capscrew, 3, flat washer and 1
locknut. Remove the ball end, 2, and jam nut, 4,
from the rod, 5.
2 4
19996839
257
29-109
SECTION 29 - HYDROSTATIC TRANSMISSION
1 1
2
19997750
258
INSPECTION
1. Inspect the handle pivot bearings, 1; replace if 2
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.
3
1
19997747
259
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 1
handle support, 3, for damage or deformation. 2
Replace as necessary.
1
19997751
260
29-110
SECTION 29 - HYDROSTATIC TRANSMISSION
261
REASSEMBLY
1
1. Bucket control - Install a new hand grip on the top
of the handle, 1, if grip is worn. 6 5
9
2. Bucket control - Attach the ball end, 2, and jam
8
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 7
handle. Do not tighten the jam nut at this time.
2
3. Bucket control - Attach the handle assembly to
3
the handle support, 7, with the long bolt, 8, and
locknut, 9.
4
4. Bucket control - Tighten the locknut to remove
19996839
any movement between the handle assembly
and support, but should be loose enough to all 262
the handle to pivot without binding.
5. Bucket control - Slide the handle tube up through
the slot, 1, in the handle support base. 7
6. Bucket control - Slide the handle sideways over
the stub shafts.
7. Bucket control - Install the bearings, 2, on the
4
handle, install shim washers, 3, to center the
handle in the slot, 1. Fasten each bearing with 2 1
5
two 5/16″ x 3/4″ carriage bolts, lock washers, and
nuts at 4.
8. Bucket control - Install shim washers, 5, to 6 4
reduce side play on the stub shafts. Retain the
shims on the stubs shaft with a roll pin, 6. 4 3
9. Bucket control - Slide the rubber boot, 1, down
over the end of the control handle, one side at a 263
time, and secure with the the hardware, 2,
removed during disassembly.
29-111
SECTION 29 - HYDROSTATIC TRANSMISSION
4
1
2
19996838
264
12. Boom hydraulics control - Install a new hand grip
on the top of the handle, 1, if grip is worn. 1
13. Boom hydraulics control - Attach the ball end, 2, 6
and jam nut, 3, to the rod, 4, and fasten to the 5
handle, 5, with a 5/16″ x 1-1/4″ capscrew, 6, flat 8
washer and locknut. Position the flat washer 9
between the ball end and handle. Do not tighten
the jam nut at this time. 2 3
14. Boom hydraulics control - Attach the handle
assembly to the handle support, 8, with the long 7
bushing, 3/8″ x 3-1/4″ capscrew and locknut at 9.
15. Boom hydraulics control - Tighten the locknut to 4
remove any movement between the handle 19996889
assembly and support, but should be loose 265
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. 7
17. Boom hydraulics control - Slide the handle
sideways over the stub shafts.
18. Boom hydraulics control - Install the bearings, 2, 4
on the handle, install shim washers, 3, to center
the handle in the slot, 1. Fasten each bearing with 2 1
5
two 5/16″ x 3/4″ carriage bolts, lock washers, and
nuts, 4.
19. Boom hydraulics control - Install shim washers, 6 4
5, to reduce side play on the stub shafts. Retain
the shims on the stubs shaft with a roll pin, 6. 4 3
20. Boom hydraulics control - Slide the rubber boot,
7, down over the end of the control handle and 266
secure with the the hardware removed during
disassembly.
29-112
SECTION 29 - HYDROSTATIC TRANSMISSION
1
4
2
19996890
267
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
19997746
268
24. Assemble the pivot shaft, 1, shim washers, 2,
arm, 3, set collar, 4, and bearings, 5, into the 3
control arm housing. Fasten each bearing with 5
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 6
7
relation to the arm at 7. Insert groove pin, 8,
4
through arm, 3, and into shaft, 1, just far enough
to position the arm. Do not hammer into place at 5 2
this time. 8 1
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″) 8 2 3
between the ball end and arm, 3. Secure with a
5/16″ x 1-3/4″ bolt, lock washer, and nut at 4. 1 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
10
remove any side movement of the shaft and
tighten the setscrew. 10
29. Drive the groove pin, 12, in the arm completely 11
into place. 9 12 6 5 7
30. With the handle in the neutral position angle,
adjust the length of the rod, 2, so the ball stud at 270
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.
REINSTALLATION
1. Place the handle assembly in the unit, install the
handle mounting bolts, 1, and tighten securely.
271
2. Install the auxiliary hydraulic control or bucket
control rod, 1, on the right control handle arm, 2.
2
1
19996848
272
29-114
SECTION 29 - HYDROSTATIC TRANSMISSION
4802-10
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.
CAUTION
Never work under a raised seat unless it is
securely latched in the raised position.
29-116
SECTION 29 - HYDROSTATIC TRANSMISSION
Op. 29 130 06
4
NEUTRAL ADJUSTMENT 2
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 1
bell housing, 2, and on the front slides, 3. The
neutralizer plate should be against the stop on the
engine bell housing at 4.
19984593
276
To adjust the right side, loosen the block retaining
bolts, 1, slightly and move the control arm, 2, to stop 3
wheel rotation. Now move the block so it contacts
both cams on arm, 2, and tighten the retaining bolts, 4
1.
29-117
SECTION 29 - HYDROSTATIC TRANSMISSION
1 2
3
19992568
278
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.
2 2
To adjust the stops, follow these steps: 2
1. Loosen the four cap screws, 2, each lever stop.
2. Pull the control lever forward until the internal 1 1
transmission stop is felt and hold the linkage 19992573
against the internal stop.
279
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
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.
29-118
SECTION 29 - HYDROSTATIC TRANSMISSION
LABOR GUIDE
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 29- HYDROSTATIC TRANSMISSION
NOTES
29-120
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SECTION 29- HYDROSTATIC TRANSMISSION
HYDROSTATIC SYSTEM TROUBLESHOOTING
(MACHINES EQUIPPED WITH PILOT CONTROLS)
ONE TRANSMISSION (RIGHT OR LEFT) WORKS MACHINE DOES NOT HAVE ENOUGH POWER
CORRECTLY AND THE OTHER DOES NOT
1. Check full throttle and rated engine speeds.
1. Check the interlock valve power/function.
A. Is there still a problem? No: Troubleshooting
A. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 2.
complete. Yes: Go to Step 2.
2. Full throttle engine speed is OK, rated engine
2. Check the brake valve power/function. Make speed is low. Problem in engine or fuel system.
sure park brakes are released. Repair as required.
A. Is there still a problem? No: Troubleshooting A. Is there still a problem? No: Troubleshooting
complete. Yes: Go to Step 3. complete. Yes: Go to Step 3.
3. Check the DA pressure. 3. Do Check 2- Checking Charge Pressure. Also
A. Do Check 1 - Checking the DA pressure check for damaged parts. Adjust pressure
setting.
B. Is there still a problem? No: Troubleshooting
complete. Yes: Go to Step 4. A. Is there still a problem? No: Troubleshooting
complete. Yes: Go to Step 4.
4. Check the charge pressure.
4. Faulty hydrostatic pump or hydrostatic drive
A. Do Check 2 - Checking the Charge motors.
Pressure/Flow.
A. Disassemble and inspect the hydrostatic
B. Charge pressure OK? Stroke the control lever. pump and hydrostatic drive motors. Repair as
A 20 psi or greater drop indicates a leaky required.
servo.
C. Is there still a problem? No: Troubleshooting
complete. Yes: Go to Step 5.
5. Check the pressure setting of the circuit relief
valve for the transmission with the problem.
A. Do Check 3 - Checking Circuit Relief Valve
Pressure.
B. Is there still a problem? No: Troubleshooting
complete. Yes: Go to Step 6.
6. There is too much leakage in the hydrostatic
system. Disassemble and inspect the hydrostatic
pump and hydrostatic drive motors.
29-143
SECTION 29- HYDROSTATIC TRANSMISSION
HYDROSTATIC SYSTEM 5. Slow the engine to low idle. Read the pressure
gauge and record the DA Pressure reading at
TROUBLESHOOTING CHECKS low idle. Stop the engine.
(Machines Equipped with Pilot Controls) 6. For L160 (Euro) and L170 Single Speed
Machines: The pressure must be a minimum of
Check 1- Checking DA Pressure 1965 to 2861 kPa (20 to 29 bar) (285 to 415 psi)
IMPORTANT: For the following test the machine at high idle. The low idle pressure should be
MUST be raised up on supports until the tires are between 1034 ± 138 kPa (10.3 ± 1.4 bar) (150 ±
above the floor. This is a safety procedure if the 20 psi) at 1000 RPM.
parking brakes fail to hold. 7. If the pressure is correct go to Step 9. If the
pressure is not correct loosen the cap on the
NOTE: You will need two people to perform this test.
hydraulic reservoir.
The operator seat must be in the raised position to
gain access to the hydrostatic pump. 8. Remove the cap on the end of the DA control
cartridge (2). Loosen the jam nut and turn the
1. Remove the instrument cluster and disconnect threaded rod to adjust. Turning the rod out will
the 26 pin connector from the instrument cluster. increase the pressure and turning the rod in will
Install the Service Plug - Special Tool decrease the pressure. If required, remove and
(380002723) into the 26 pin connector in the replace the DA control cartridge (2) and repeat
wiring harness. This will allow the machine to be the test. If the pressure is correct go to Step 9.
started for the test procedures.
2. Install a Tee connection in the hose and connect
a 4,137 kPa (41 bar) (600 psi) pressure gauge to
test port Y (1), see next figure.
BS06M586_2
2. DA CONTROL CARTRIDGE
9. Check the pressure from the ground drive
controller to the pump.
BS06M586_1 Figure 1
1. TEST PORT Y
2. DA CONTROL CARTRIDGE
29-144
SECTION 29- HYDROSTATIC TRANSMISSION
10. Install a Tee connection in the hose and connect 13. The pressure readings should vary from 2068
a 4,137 kPa (41 bar) (600 psi) pressure gauge to kPa (20.7 bar) (300 psi) to 2758 kPa (27.8 bar)
test ports X3 (1) and test ports X4 (2), see next (400 psi) at high idle for a given angle on the
figure. drive control handle.
14. If the pressure readings are correct, the test is
complete. If the pressure readings are not
correct, repair or replace the hydrostatic pump
assembly.
BS06M608_1
1. TEST PORTS X3
2. TEST PORTS X4
11. Start the engine and run at high idle. Move the
ground drive control handle to forward drive.
Read the pressure gauges while the ground
drive control is in the forward position and record
the reading. Move the ground drive control
handle to reverse drive position. Read the
pressure gauges while the ground drive control is
in the reverse position and record the reading.
12. Stop the engine.
29-145
SECTION 29- HYDROSTATIC TRANSMISSION
BS06M582_2
2. CHARGE PRESSURE VALVE
3. SHIM(S)
BS06M582_1
1. TEST PORT G1 8. After you get the correct charge pressure in
2. CHARGE PRESSURE VALVE NEUTRAL, do the following steps:
3. SHIM(S)
IMPORTANT: For the following test the machine
3. If the hydraulic oil is not at operating temperature MUST be raised up on supports until the tires are
run the engine at full throttle and hold the bucket above the floor. This is a safety procedure if the
control lever in the ROLLBACK position for 30 parking brakes fail to hold.
seconds. Then return the bucket control lever to
A. Start and run the engine at low idle. Engage
NEUTRAL for 15 seconds. Repeat this cycle until
the parking brake.
the temperature of the oil is at least 52 ° C
(125°F). B. Increase the engine speed to full throttle.
Slowly move the ground drive control lever
4. Continue to run the engine at full throttle. Read
FORWARD to load the hydraulic piston
the pressure gauge and record the Charge
pumps without decreasing the engine speed.
Pressure reading. Stop the engine.
C. Read the pressure gauge. The pressure must
be within 138 kPa (1.5 bar) (20 psi) of the
pressure in step 3.
D. Repeat Steps B and C with the ground drive
control lever in REVERSE position.
29-146
SECTION 29- HYDROSTATIC TRANSMISSION
Check 3- Checking Circuit Relief 5. Run the engine at low idle. Move the ground
drive control lever slowly to the FORWARD
Valve Pressure position.
(Machines Equipped with Pilot Controls) 6. Increase the engine speed to full throttle. Move
IMPORTANT: For the following test the machine the ground drive control lever for the circuit being
MUST be raised up on supports until the tires are tested one half the distance of full travel and
above the floor. This is a safety procedure if the watch the pressure gauge. When the pressure
parking brakes fail to hold. gauge stops increasing, read the pressure gauge
and move the ground drive control lever to
NOTE: You will need two people to perform this test. NEUTRAL.
The operator seat must be in the raised position to
gain access to the hydrostatic pump. 7. The correct pressure is the gauge reading minus
the charge pressure. If the pressure is not
1. Remove the instrument cluster and disconnect correct, use a new circuit relief valve. You can
the 26 pin connector from the instrument cluster. temporarily repair a forward circuit by
Install the Service Plug - Special Tool interchanging a functioning reverse circuit relief
(380002723) into the 26 pin connector in the valve with the forward circuit relief valve. See the
wiring harness. This will allow the machine to be figure below.
started for the test procedures.
2. Connect a 68 947 kPa (690 bar) (10,000 psi)
pressure gauges to the test ports MA and MB.
See the figure below.
BS06M584_1
1. LEFT HAND FORWARD DRIVE CIRCUIT RELIEF
2. LEFT HAND REVERSE DRIVE CIRCUIT RELIEF
3. RIGHT HAND FORWARD DRIVE CIRCUIT RELIEF
4. RIGHT HAND REVERSE DRIVE CIRCUIT RELIEF
BS06M614_1
1. TEST PORTS MA
2. TEST PORTS MB
29-147
SECTION 29- HYDROSTATIC TRANSMISSION
29-148
SECTION 29- HYDROSTATIC TRANSMISSION
HYDROSTATIC PUMPS (MACHINES EQUIPPED WITH PILOT CONTROLS)
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.
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 attach-
ment. Always remove the attachment from the BS06B469 Figure 2
loader. 4. Securely block the skid-steer loader at, (1) and
1. Lower the boom and bucket to the lowered (2) with all four wheels off the ground, refer to
position, resting on the ground or remove any Section 00 for more detailed information on
attachments and raise the boom and rest on the properly supporting a skid-steer loader.
boom lock pins, (1).
2. Engage the parking brake CAUTION
3. Stop the engine, turn the ignition key to the run Failure to securely support the skid-steer loader
position and operate the boom and bucket could result in movement of the loader causing
control pedals to relieve pressure in the boom serious injury or damage to the equipment.
and bucket circuits. Turn off the key.
BS06J115 Figure 3
29-149
SECTION 29- HYDROSTATIC TRANSMISSION
5. Raise the operator’s seat and latch in the raised
position, (1). CAUTION
Never loosen any hydraulic lines without first
CAUTION relieving all pressure in the systems to avoid
serious injury.
Never work under a raised seat unless it is
securely latched in the raised position. Draining the hydraulic oil reservoir is not required if
the suction and return lines are capped to prevent
loss of oil. If the hydraulic system requires cleaning,
draining is required.
8. Drain the hydraulic reservoir.
❷ Loosen the return line clamp, (2).
❷ Remove the return line at, (3) and rotate the line
into a suitable drain pan.
BD06K111_1 Figure 4
6. Remove the step shield to access the hydrostatic
pump area. For more access, remove the right
and left hydrostatic control handle assemblies.
7. Relieve all pressure in the hydraulic and
hydrostatic systems.
BD06K115_1 Figure 5
BD06K127
29-150
SECTION 29- HYDROSTATIC TRANSMISSION
9. Disconnect and tag all the hoses from the 13. Disconnect and tag all the hoses from the
equipment pump. Install caps and plugs on the hydrostatic pump. Install caps and plugs on the
fittings. fittings.
BD06K132_1 Figure 7
29-151
SECTION 29- HYDROSTATIC TRANSMISSION
14. Connect acceptable lifting equipment to the
hydrostatic pump. Support the hydrostatic pump.
15. Loosen and remove the two mount bolts, (5)
from the support bracket located under the
hydrostatic pump.
16. Loosen and remove the two mount bolts, (6)
from the hydrostatic pump at the flywheel cover.
17. Move the hydrostatic pump away from the
engine as far as possible.
18. Use the lifting equipment to remove the
hydrostatic pump from the chassis.
BS06K580 Figure 9
29-152
SECTION 29- HYDROSTATIC TRANSMISSION
HYDROSTATIC PUMP-INSTALL (MACHINES EQUIPPED WITH PILOT CONTROLS)
1. Connect acceptable lifting equipment to the 14. Position the equipment pump on the hydrostatic
hydrostatic pump. pump. Engage the splines of the equipment
2. Move the hydrostatic pump towards the engine pump drive coupler with the splines in the
flywheel cover. Engage the splines of the pump hydrostatic pump.
drive coupler with the splines of the flywheel. 15. Install and tighten the equipment pump mount
bolts, (4) and washers.
NOTE: Apply Loctite 243 to all pump and support
bracket mounting bolts. 16. Torque the equipment pump mount bolts to 100
Nm (74 pound-feet).
3. Install the two hydrostatic pump mount bolts, (6)
and washers into the flywheel cover. 17. Remove caps and plugs from the hydraulic
fittings and hoses for the equipment pump. Install
4. Torque the hydrostatic pump mount bolts, (6) to
the hydraulic hoses onto the equipment pump
228 Nm (169 pound-feet).
and tighten the fittings.
5. If the hydrostatic pump support bracket was
18. If the right and left hydrostatic control handle
removed, install it at this time.
assemblies were removed, install them at this
6. Install and tighten the two lower pump support time.
bracket bolts, (9) to a temporary torque of 4 Nm
(35 pound-inch).
7. Use acceptable tools to tap the pump support
bracket up until it contacts the pump mounting
surface.
8. Install the two upper pump support bracket bolts,
(8). Torque bolts to 143 Nm (105 pound-feet).
9. Torque the two lower pump support bracket
bolts, (9) to 100 Nm (74 pound-feet).
10. Install and tighten the two mount bolts, (5) and
washers in the support bracket located under the
hydrostatic pump.
11. Torque the two mount bolts, (5) to 164 Nm (121 BD06K132_1 Figure 11
pound-feet).
12. Remove the lifting equipment from the
hydrostatic pump.
13. Remove caps and plugs from the hydraulic
fittings and hoses for the hydrostatic pump.
Install the hydraulic hoses onto the hydrostatic
pump and tighten the fittings.
BS06K580_2 Figure 10
29-153
SECTION 29- HYDROSTATIC TRANSMISSION
19. Install and tighten the return line, (3). 23. Start and run the engine at low idle for two to five
20. Tighten the return line clamp, (2). minutes and check for any leaks. Stop the
engine.
24. Install the step shield, (7) onto the machine.
Install the bolts and washers and tighten.
25. Check the oil level in the hydraulic reservoir and
add hydraulic oil as needed. Refer to Section 00
for correct type and quantity.
BD06K115_1 Figure 12
21. Check the oil level in the hydraulic reservoir and
add hydraulic oil as needed. Refer to Section 00
for correct type and quantity.
22. Unlatch the operator’s seat and lower it to the
operating position.
. BD06K112_1 Figure 14
BD06K110 Figure 13
29-154
SECTION 29- HYDROSTATIC TRANSMISSION
BS06J363_1
1. CENTERING ADJUSTMENT 5. MECHANICAL STROKE LIMITER
2. CONTROL CARTRIDGE 6. TIMING ADJUSTMENT SCREW
3. LOW PRESSURE VALVE 7. INNER GEAR PUMP
4. HIGH PRESSURE VALVE 8. HYDRAULIC CONTROL
AA20 VARIABLE AXIAL PISTON PUMP
29-155
SECTION 29- HYDROSTATIC TRANSMISSION
DISASSEMBLY
STEP 2 STEP 4
29-156
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 5 STEP 8
BD06J055 Figure 20
Remove the O-ring from the rotary group housing. BD06J060 Figure 23
Remove the spline collar.
Rotary Group
STEP 10
NOTE: Disassembly, inspection, and assembly
procedures are the same for both rotary groups.
STEP 7
BD06J061 Figure 24
Remove the cradle.
BD06J056_1 Figure 21
Remove the slide ring.
29-157
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 11 Left Pump Rotary Group Housing
Bearing
STEP 13
Remove the rotary group for this procedure. See
Rotary Group in the disassembly section.
STEP 14
BD06J062 Figure 25
Remove the cradle bearings.
STEP 12
BD06J067 Figure 27
Use acceptable tools and remove the drive shaft
retaining ring.
STEP 15
BD06J064_1 Figure 26
Remove the bearing liners.
BD06J068 Figure 28
Use acceptable tools and remove the drive shaft
from the bearing.
29-158
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 16 STEP 19
STEP 17
BD06J074 Figure 33
Use acceptable tools and remove the bearing from
BD06J071 Figure 30 the housing.
Use acceptable tools and remove the shaft seal ring.
STEP 18
BD06J072 Figure 31
Remove the spacer.
29-159
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 21
BD06J006 Figure 37
Use acceptable tools and remove the rotary group
BD06J002 Figure 34 housing mount bolts.
Use acceptable tools and remove the bolts that
fasten the intermediate flange to the pump. STEP 25
STEP 22
BD06J010_1 Figure 38
Use acceptable tools and separate the rotary group
BD06J004 Figure 35 housing from the pump housing. Ensure the slide
Remove the intermediate flange. ring is not left in the pump housing.
STEP 23 STEP 26
BD06J012_1 Figure 39
BD06J005_1 Figure 36
Remove the O-ring from the IZP housing. Record or mark the position of the wear plate inside
the pump housing prior to removing the wear plate.
29-160
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 27 Internal Gear Pump
STEP 30
BD06J013 Figure 40
Remove the wear plate from the pump housing.
BD06J124_1 Figure 42
STEP 28 Apply reference mark on internal gear housing and
IZP-housing.
STEP 31
BD06J077 Figure 41
Remove the O-ring from the rotary housing.
BD06J085_1 Figure 44
Remove the O-ring from the IZP housing.
29-161
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 33 STEP 36
BD06J087 Figure 46
Remove the inner gear. BD06J090 Figure 49
Remove the wear plate.
STEP 35
STEP 38
BD06J088 Figure 47
Remove the through coupling. BD06J091 Figure 50
Use acceptable tools and remove the snap-ring from
the rotary house bearing.
29-162
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 39 STEP 41
STEP 40 STEP 42
29-163
SECTION 29- HYDROSTATIC TRANSMISSION
BS06J364_1
1. INTERMEDIATE FLANGE 8. SOCKET HEAD SCREW
2. IZP HOUSING 9. O-RING
3. BEARING BUSHING 10. O-RING
4. THROUGH DRIVE COUPLING 11. O-RING
5. GEAR SET 12. WEAR PLATE
6. SHAFT KEY (NOT SHOWN) 13. CYLINDER PIN
7. SNAP RING
INTERNAL GEAR PUMP
29-164
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 43 STEP 46
BD06J123_1 Figure 58
BD06J120 Figure 56
Inspect and replace the O-rings(1) as necessary.
Use acceptable tools and loosen counter nut while Ensure two spacers(2) are on the adjustment screw
holding the adjustment screw. behind the O-ring.
29-165
SECTION 29- HYDROSTATIC TRANSMISSION
Hydraulic Control
NOTE: Removal and installation procedures are the STEP 50
same for both hydraulic controls.
STEP 48
BD06J028 Figure 61
Use acceptable tools and remove the hydraulic
control mount bolts.
BD06J001_1 Figure 59
ATTENTION: If hydraulic control cover plate is
STEP 49 rotated, it may affect the neutral setting of the
hydraulic control piston.
STEP 51
BD06J001_2 Figure 60
NOTE: Removal of the rotary pump is required for
hydraulic control piston removal and installation.
BD06J031 Figure 62
Remove the rotary pump. See disassembly steps for
Remove the hydraulic control piston.
appropriate pump. Front (left side) pump(1) rear
(right side) pump(2).
29-166
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 52 Control Cartridge
STEP 54
BD06J034 Figure 63
Remove and inspect the O-ring. Replace O-ring as
necessary. BD06J025 Figure 65
Use acceptable tools and remove the control
STEP 53 cartridge.
STEP 55
BD06J033_1 Figure 64
Remove and inspect the guide rings (2 each).
Replace as necessary. BD06J027_1 Figure 66
Remove and inspect the O-ring. Replace O-ring as
necessary.
29-167
SECTION 29- HYDROSTATIC TRANSMISSION
BS06J145
1. CONTROL CARTRIDGE W/O ORIFICE 2. ORIFICE
CONTROL CARTRIDGE
29-168
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 57 STEP 59
BD06J0221 Figure 70
Use acceptable tools and remove the spring collar(1)
and shims(2).
Ensure the same amount of shims are used at
installation. The boost pressure is adjusted by the
use of shims.
BS06J366_1 Figure 68
29-169
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 60 Pump House Bearing
STEP 61
BD06J023_1 Figure 71
Use acceptable tools and remove the pressure
spring. BD06J048_1 Figure 73
NOTE: The removal procedures are the same for
both pump house bearings.
Use acceptable tools and remove the pump house
bearing.
STEP 62
BS06J365_1 Figure 72
STEP 63
Repeat STEP 61 for the other pump house bearing
as necessary.
29-170
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 64
BD06J0601 Figure 76
Inspect spline collar for damage and wear. Replace
BD06J059_1 Figure 75 part as necessary.
INSPECTION ITEMS
STEP 73
STEP 65
Clean all parts in cleaning solvent.
STEP 66
Inspect the face of the cylinder block(1) for wear,
scoring, and other damage. Use a new cylinder
assembly as necessary.
STEP 67
Inspect the cylinder bores for wear, scoring, and
other damage. Use new cylinder assembly as
necessary.
BD06J063 Figure 77
Inspect the cradle and bearings for damage and
STEP 68
wear. Replace parts as necessary.
Inspect the pistons(2) for damage and wear. use new
parts as necessary.
STEP 74
STEP 69
Lubricate the pistons and cylinder bores with clean
oil.
STEP 70
Check the fit of the pistons in the bores. The piston
must move freely with minimum clearance. Use a
new cylinder assembly as necessary.
STEP 71
Inspect the surface of the retainer plate(3). Use a
new retainer plate as necessary. BD06J065 Figure 78
Inspect both pump’s shaft for damage to the splines
and wear at the seal surfaces. Inspect the bearing
liners for damage and wear. Replace parts as
necessary.
29-171
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 75 STEP 77
Inspect all bearings for damage and wear. Replace
any damaged or worn bearings.
STEP 76
BD06J047_1 Figure 80
Inspect the pressure relief valve seats in the pump
housing for damage. Replace housing as necessary.
29-172
SECTION 29- HYDROSTATIC TRANSMISSION
ASSEMBLY
STEP 79
BD06J024 Figure 83
LOW (BOOST) PRESSURE RELIEF VALVE
STEP 82
BD06J125 Figure 81
Use acceptable tools and install the bearing into the
pump housing.
STEP 80
BD06J021 Figure 84
NOTE: Ensure the same amount of shims that were
installed on the pressure relief valve at the time of
removal are used for the installation procedure.The
low (boost) pressure is adjusted by these shims.
BD06J0491 Figure 82
Insert the through coupling from the other side. STEP 83
NOTE: Ensure the through coupling is installed in Replace the O-ring.
the pump housing prior to installing both pump house
bearings. STEP 84
Use acceptable tools and install the low (boost)
STEP 81 pressure relief valve. Refer to Special Torques and
If the other pump bearing was removed, install it at tighten to the correct torque.
this time.
29-173
SECTION 29- HYDROSTATIC TRANSMISSION
BD06J017 Figure 86
Use acceptable tools and install the high pressure
relief valve. Refer to Special Torques and tighten to
the correct torque.
29-174
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 88
BD06J120 Figure 90
Use acceptable tools to hold the adjustment screw
and install counter nut on adjustment screw to the
measurement noted earlier.
BD06J122_1 Figure 88
STEP 91
Use acceptable tools and hold the adjustment screw
Adjust the hydraulic control piston to the zero
while installing the cover plate by turning clockwise.
(neutral) position.
STEP 89
BD06J029 Figure 89
Use acceptable tools to install the hydraulic control
mount bolts and tighten to the proper torque.
29-175
SECTION 29- HYDROSTATIC TRANSMISSION
BD06J031 Figure 94
NOTE: Ensure the slider guide portion of the
hydraulic control piston is in the down position in the
pump to assist in the alignment of the slider ring. See
BD06J001_1 Figure 91
figure 85.
STEP 92 Install hydraulic control piston into pump housing.
STEP 95
BD06J034 Figure 92
Replace the O-ring prior to installation.
BD06J029 Figure 95
STEP 93 Use acceptable tools and install the hydraulic control
mount bolts and tighten.
STEP 96
Install rotary group housing. See applicable rotary
group housing in the assembly section.
BD06J033_1 Figure 93
Install the two guide rings if they were removed
earlier.
29-176
SECTION 29- HYDROSTATIC TRANSMISSION
BS06J140
1. POSITIONING PISTON, COMPLETE 6. GUIDE RING
2. THREADED PIN 7. ROD SEAL KIT
3. SOCKET HEAD SCREW 8. ADJUSTMENT SCREW
4. HEXAGON NUT 9. SLIDE RING GUIDE
5. SEAL, LOCK NUT
HYDRAULIC CONTROL
29-177
SECTION 29- HYDROSTATIC TRANSMISSION
BD06J070 Figure 99
Use acceptable tools and install the shaft seal ring.
BD06J070 Figure 96
STEP 101
Use acceptable tools and install the bearing into the
housing.
STEP 98
BD06J073 Figure 97
STEP 102
Use acceptable tools and install the snap-ring.
STEP 99
29-178
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 104
STEP 103
STEP 106
BD06J064_1 Figure 103
NOTE: Ensure the raised edge on the bearing liners
face away from the drive shaft.
Install the bearing liners.
29-179
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 107 Left Pump Rotary Group Housing
STEP 110
STEP 111
29-180
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 112 STEP 114
STEP 113
29-181
SECTION 29- HYDROSTATIC TRANSMISSION
BS06J146_1
1. ROTARY GROUP 7. SHAFT SEAL RING
2. CRADLE 8. IVE SHAFT
3. SLIDE RING 9. PLAIN ROLLER BEARING
4. WIRE WITH COIL 10. CRADLE BEARING ASSEMBLY
5. BEARING LINER 11. RETAINING RING
6. SNAP RING
LEFT PUMP ROTARY GROUP
29-182
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 115
29-183
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 121 STEP 124
STEP 123
29-184
SECTION 29- HYDROSTATIC TRANSMISSION
BS06J364_1
1. INTERMEDIATE FLANGE 8. SOCKET HEAD SCREW
2. IZP HOUSING 9. O-RING
3. BEARING BUSHING 10. O-RING
4. THROUGH DRIVE COUPLING 11. O-RING
5. WHEEL SET 12. WEAR PLATE
6. SHAFT KEY (NOT SHOWN) 13. CYLINDER PIN
7. SNAP RING
INTERNAL GEAR PUMP
29-185
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 126
STEP 129
BD06J078_1 Figure 126
NOTE: Ensure the cradle arm(1) is opposite of the
alignment pin(2).
Assemble and install the rotary group onto the drive
shaft.
STEP 127
29-186
SECTION 29- HYDROSTATIC TRANSMISSION
STEP 130 STEP 132
STEP 131
STEP 134
29-187
SECTION 29- HYDROSTATIC TRANSMISSION
BS06J147_1
1. ROTARY GROUP 6. BEARING LINER
2. CRADLE 7. SNAP RING
3. SLIDE RING 8. RETAINING RING
4. DRIVE SHAFT 9. PLAIN ROLLER BEARING
5. WIRE WITH COIL 10. CRADLE BEARING ASSEMBLY
RIGHT PUMP ROTARY GROUP
29-188
SECTION 29- HYDROSTATIC TRANSMISSION
BD06M010
BD06M017_1
BD06M001_1
29-189
SECTION 29- HYDROSTATIC TRANSMISSION
BD06M019 BD06M008
6. Remove the pilot control handle and set aside. 8. Use acceptable tools and remove the handle
adapter.
BD06M012
7. Remove the boot and set aside.
29-190
SECTION 29- HYDROSTATIC TRANSMISSION
BD06M009 BD06M003_1
9. Remove the handle adapter and set aside. 12. Remove all hoses from the bottom of the
controller
13. Install caps and plugs on all fittings and hoses.
BD06M013_1
10. Loosen the jam nut, (1) and remove the rod
assembly, (2).
14. Remove the hex socket head screws securing
the controller to the mount.
15. Remove the pilot controller.
BD06M005_1
11. Disconnect backup alarm electrical harness, (3)
from the pressure switch, (4) located at the
bottom of the controller.
29-191
SECTION 29- HYDROSTATIC TRANSMISSION
Left Control Lever Installation
(Machines Equipped with ISO Pattern
Pilot Controls)
BD06M003
4. Remove caps and plugs from all fittings and
hoses.
BD06M020_1
5. Install the hoses in the correct color coded
1. Install the controller into the mount. locations on the controller and tighten all hoses.
2. Install and tighten the hex socket head screws to
secure the controller to the mount.
BD06M005_@
6. Connect the backup alarm electrical harness, (1)
to the pressure switch, (2) located on the bottom
BD06M013_2
of the controller.
3. Install the rod assembly, (4) temporarily. Install
the rod with the bend facing forward. Temporarily
snug down the jam nut, (3).
NOTE: Rod height adjustment may be required to
align the screw holes between the handle adapter
and the rod assembly.
29-192
SECTION 29- HYDROSTATIC TRANSMISSION
BD06M009 BD06M017_1
7. Use acceptable tools to install the handle 12. Install the controller handle.
adapter on the rod assembly. 13. Install the screws into the sides of the handle.
8. Check alignment of the screw holes between the 14. Check the oil level in the hydraulic reservoir and
rod assembly and the handle adapter. add hydraulic oil as needed. Refer to Section 00
9. If adjustment is required, loosen the jam nut of for correct type and quantity.
the rod assembly and adjust rod to align screw 15. Unlatch the operator’s seat and lower it to the
holes. operating position.
10. Once the screw holes are aligned, tighten the 16. Turn engine over for 30 seconds to allow
jam nut. hydraulic oil from the reservoir to flow into the
hydraulic pump. Reconnect the fuel shutoff
solenoid connector.
17. Start and run the engine at low idle for two to five
minutes and check for any leaks.
18. Stop the engine.
BD06M012
11. Install the boot.
29-193
SECTION 29- HYDROSTATIC TRANSMISSION
BD06M001_1
19. Install the cover.
20. Install and tighten the bolts and washers into the
cover.
21. Check the oil level in the hydraulic reservoir and
add hydraulic oil as needed. Refer to
Specification Section for correct type and
29-194
SECTION 29- HYDROSTATIC TRANSMISSION
5
3
BS06N849_1
1. HYDROSTATIC PUMP 4. EQUIPMENT PUMP
2. RIGHT HAND DRIVE MOTOR 5. DRAIN MANIFOLD
3. LEFT HAND DRIVE MOTOR
HYDROSTATIC SYSTEM (MACHINES EQUIPPED WITH PILOT CONTROLS)
29-195
SECTION 29- HYDROSTATIC TRANSMISSION
BD07B092
BD06K132
BD07B093
29-196
SECTION 33 – BRAKES AND CONTROLS
CONTENTS
Op. 33 000
GENERAL INFORMATION
Power for the skid steer ground drive is transmitted
from the engine through a flex plate drive coupler to
the hydrostatic pumps, 1. The hydrostatic pumps
then transmit hydraulic fluid power to the hydrostatic
motors at 2, which are connected to gearboxes, 3,
located on the inside of the final drive chain cases.
The right and left hydrostatic drives are separate
from each other and operate in-dependently by use
of hand controls.
BS05J024
SPECIFICATIONS
Chain Case
Side Cover Bolt Torque .................................................................................................... 15 Nm (133 pound-inches)
Brake Caliper Mounting Bolt Torque (Center) .................................................................. 20 Nm (177 pound-inches)
Brake Caliper Mounting Bolt Torque (Outer) ..........................................................................70 Nm (52 pound-feet)
Drive Chains
Drive Chain............................................................................................................................................................#80
Front Drive Chain Length (68 pitches).................................................................................... 1727.2 mm (68 inches)
Rear Drive Chain (66 pitches) ............................................................................................... 1676.4 mm (66 inches)
Chain Tension ..................................................................................0-6 mm (0 to 0.25 inch) movement at tire tread
Lubrication .................................................7.6 Litres (2.0 U.S. gallons) each side - (10W-30 API service SG-CE oil)
Other Materials
Description
Ultra/Blue Silicone Sealer......................................................................................Motor housing and mounting bolts
........................................................................................................................................................Axle housing bolts
......................................................................................................................................... Chain case cover and bolts
....................................................................................................................................................... Brake caliper bolts
Sealing Material............................................................................................................. NH Ultra Blue silicone sealer
Hydraulic Oil ................................................ NH Ambra Auto Supreme SAE 10W-30 motor oil (API Service SG-CE)
Gear Oil ..........................................................NH Ambra Hypoide 80W-90 Gear Lube (API Service GL-5 Gear Oil)
Grease............................................................. NH Ambra GR-9 Multi Purpose Grease (High viscosity lithium base)
NOTE: Always use a noncorrosive sealer to seal where required to prevent corrosion during the silicone curing
process.
33-4
6-81710 Revised 9/05
SECTION 33 - BRAKES AND CONTROLS
TROUBLESHOOTING
FINAL DRIVE/PARKING BRAKE SYSTEM
Before servicing or adjusting the final drive/parking
brake system, the skid steer should be jacked up and
securely blocked up with all the wheels off the
ground.
Jack up the skid steer and support the skid steer with
the wheels off the ground, using adequate jack
stands or blocks to securely support the skid steer.
Support the skid steer at the front of the final drive
cases at 1, and at the rear at 2.
IMPORTANT: Never service a raised skid steer
unless it is securely supported with adequate jack
stands or blocks.
TROUBLESHOOTING
PARKING BRAKE SYSTEM
TESTING
PARKING BRAKE
Pre-test instructions:
● Operator in the seat with seat belt fastened.
● Engine running at 1500 RPM.
● Park brake in disengaged position.
Pre-test instructions:
● Operator in the seat with seat belt fastened.
● Engine running at 1500 RPM.
● Park brake in engaged position.
Op. 33 110
PARKING BRAKE
OPERATION
The parking brake system is a spring applied -
hydraulic release 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 when the engine is shut down or the
parking br ake button o n th e control pane l is
activated.
When the parking br ake is en ga ge d and the
hydrostatic control levers are stroked, the skid steer
should not move if the parking brake is adjusted
properly.
The hydrostatic system is the primary brake for the
skid steer when the skid steer is in operation. The
parking brake system is used to hold the skid steer in
place and prevent rolling or creeping when parked.
The parking brake should always be engaged before
exiting the skid steer.
IMPORTANT: Always activate the parking brake
before leaving the operator station. Never operate
the skid steer unless the parking brake is released.
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.
IMPORTANT: Never work under a raised boom
unless the boom is properly supported by the boom
lock pins.
Never work under a raised boom with an attachment
mounted. Always remove the attachment from the
skid steer.
3. Securely block the skid steer with all four wheels
off the ground. Refer to section 1 for more
detailed information on properly supporting the
skid steer.
Support the skid steer at the front of the drive
cases at 1, and at the rear at 2.
ATTENTION: Failure to securely support the skid
steer could result in movement of the skid steer
causing serious injury or damage to the equipment.
33-9
6-81710 Revised 9/05
SECTION 33 - BRAKES AND CONTROLS
5. Remove the tires and wheels from the final drive and
brake being serviced.
6. Clean the 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.
9. Remove the final drive case center cover, 3.
Op. 33 110 14
Brake Control Linkage and Cylinder Removal 1 2
1. Connect a vacuum pump to the hydraulic
5
reservoir. Start the vacuum pump. 7
2. Loosen and remove the hydraulic hose, 7, from 3
the cylinder, 1. Install plugs in the hoses. Stop
the vacuum pump.
3. Connect a hand hydraulic pump to the cylinder.
Apply pressure to the cylinder with the hand
pump to extend the cylinder and release the 4 6
pressure on the arm.
4. Remove the cotter key, 3 from the chassis
mount, 2.
5. Remove the cotter key, 4, from the cylinder
swivel mount, 5.
6. Remove the cylinder, 1, from the chassis mount,
2, and the brake arm, 6. BS05J054
BS05J054
6-81710 Revised 9/05
33-10
SECTION 33 - BRAKES AND CONTROLS
Op. 33 110 48
Brake Caliper and Disc Removal
The skid steer must be properly supported with all
four wheels off the ground.
1. Remove the rear axle assembly and slide to the
front to loosen the drive chain.
2. Remove the rear drive chain from the drive
sprocket and push the chain to the rear.
3. Engage the parking brake.
4. Remove the center brake disc retaining bolt and
washer at, 1.
5. Disengage the parking brake.
6. Loosen the caliper retaining hardware, 2, from
inside the cab. Thread the two bolts from the
out-side caliper assembly, 3. DO NOT remove
the bolts from the caliper support at this time.
7. Remove the outside brake disc, 4.
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
33-15
6-81710 Revised 9/05
SECTION 33 - BRAKES AND CONTROLS
Op. 33 110 .
Caliper Adjustment
Place the parking brake in the disengaged position.
1. Remove the cotter key, 1, and disconnect the 3
swivel from the control arm, 2, at, 3.
2. Push the arm, 2, down to turn the shaft into the
caliper support to remove any play in the caliper 4
and disc.
3. Loosen the setscrew, 4, in the arm, 2, and slide
the arm, 2, off of the shaft, 5.
1 2 5
4. Rotate the arm, 2, up so that the swivel can be
re-hooked and slide the arm, 2, back onto the
shaft, 5, splines.
5. Position the control arm, 2, on the shaft, 5, for
clearance between the arm, 2, and the other
components when the brake is engaged or
disengaged.
6. Tighten the setscrew, 4, in the control arm, 2. BS05J054
Reconnect the swivel to the control arm, 2, at, 3,
and install the cotter key, 1. If required, repeat
the above procedure for the other side.
33-17
6-81710 Revised 9/05
SECTION 33 - BRAKES AND CONTROLS
NOTES
35-2
SECTION 35 - HYDRAULIC SYSTEM
12
10 9
1
11
2
6 5
3
4
14
14
8
13
7
14
13
11
12
19997771
1
Op. 35 000 1. Hydraulic reservoir - Right front of engine
compartment
GENERAL INFORMATION
2. Suction line - From reservoir to the gear pump
The hydraulic system provides hydraulic oil to the under operator’s seat
boom and bucket, and the return oil provides charge
oil for the hydrostatic drive system. On skid steers 3. Gear pump - Under the operator’s seat
equipped with the auxiliary boom hydraulic kit, sys- 4. Pressure line - From gear pump to control valve
tem oil will be provided to quick couplers at the front 5. Control valve (three spool) - Under operator’s
of the boom to operate hydraulic attachments. The step shield
hydraulic system is an open center type system. The 6. Main system relief valve - In control valve
gear pump provides continuous oil flow through the
system to the boom, bucket circuits, auxiliary boom 7. Return line - From control valve to oil cooler
circuit, if equipped, and the hydrostatic drive charge 8. Oil cooler - Engine side of radiator in engine
circuit. compartment
A open center system means the first control valve 9. Filter - Right rear of engine compartment through
function has priority over the next function in line. rear door
NOTE: The return oil must follow the normal return 10. Charge check valve - After filter and before the
path from the control valve to the oil cooler/filter and reservoir
back to the hydrostatic charge pressure inlet on the 11. Bucket cylinders
transmissions or severe damage to the hydrostatic 12. Boom cylinders
system may occur.
13. Auxiliary boom hydraulics
Figure 1 shows the hydraulic circuit and components 14. Optional high flow kit - Dealer installed kit - Refer
for the L160 and L170 skid steers. to Section 88 - “Accessories” for more informa-
tion.
The hydraulic system is built with the following com-
ponents and their location.
35-3
SECTION 35 - HYDRAULIC SYSTEM
L160 15.5 GPM (58.7 l/min.) @2900 RPM 24.0 GPM (90.8 l/min.) @2900 RPM
@1000 PSI (68 bar) @1000 PSI (68 bar)
L170 17.7 GPM (67.0 l/min.) @2900 RPM 26.2 GPM (99.2 l/min.) @2900 RPM
@1000 PSI (68 bar) @1000 PSI (68 bar)
NOTE: When using the High-Flow system, 3/4, quick 5. Will the attachment accept hydraulic system
couplers must be used or high system backpressure backpressure?
may result. If “YES”, nothing is required.
If “NO”, the attachment will not function properly
3. Will the attachment accept oil flow in both direc- on a New Holland skid-steer loader. Normal
tions? backpressure for New Holland skid-steer skid
If “YES”, nothing is required. steers is between 200 - 250 PSI.
If “NO”, install a check valve or cross into the at- Examples: Post drivers, some breakers, and
tachment return line to prevent reverse oil flow to some hand held hydraulic tools do not accept
the attachment. system backpressure.
Examples: Backhoes and trees spades with a If all the skid-steer loader oil flow is not required
separate control valve do not accept oil flow in to operate an attachment (e.g., shaver post driv-
both directions. er), a flow divider can be installed into the hydrau-
4. Must the attachment “Free Wheel” to a STOP? lic oil circuit on the attachment. The flow divider
If “YES”, a crossover relief connection must be sends the required oil flow to the attachment and
installed on the attachment side to allow the at- the remainder back to the normal skid-steer load-
tachment to free wheel to a stop after the skid- er hydraulic circuits.
steer loader hydraulics is turned off. Model L160 and L170 skid steers must have
If “NO”, nothing is required. a minimum of 22.7 l/min. (6 GPM) returning
Example: Snow blowers must free wheel to a through the main hydraulic system at all times,
stop. required to charge the hydrostatic system.
35-4
SECTION 35 - HYDRAULIC SYSTEM
6. Does the attachment have a separate case drain NOTE: Skid steers equipped with High Flow
oil line? Hydraulics have a separate case drain coupler and
If “NO”, nothing is required. return line attached to the right boom arm.
If “YES”, install a separate case drain line to re-
turn the attachment case drain oil directly to the 7. Does the attachment require circuit relief in the
hydraulic oil reservoir. bucket circuit?
Example: Cold planners have a separate case If “NO”, nothing is required.
drain oil line. If “YES”, install a bucket circuit relief valve on
NOTE: Most attachment case drains will not accept front of the control valve.
backpressure and must drain directly into the Example: Some mini-backhoes attach like a
reservoir. bucket, and require a bucket circuit relief.
35-5
SECTION 35 - HYDRAULIC SYSTEM
35-6
SECTION 35 - HYDRAULIC SYSTEM
1
19987103
4
To use the power-beyond port for a second oil supply
to additional attachments, remove the factory power-
beyond 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
5
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 power-
beyond 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. 2
A tee fitting can be inserted in the return line at 2, for 1
attachment oil return.
19987105
6
35-7
SECTION 35 - HYDRAULIC SYSTEM
SPECIFICATIONS
SKID STEER MODEL L160
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
BOOM CYLINDERS
BUCKET CYLINDERS
RESERVOIR
35-8
SECTION 35 - HYDRAULIC SYSTEM
TORQUE SPECIFICATIONS
SKID STEER MODEL L160
Control Valve
Boom Cylinders
Bucket Cylinders
Gear Pump
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
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 L170
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
BOOM CYLINDERS
BUCKET CYLINDERS
RESERVOIR
35-10
SECTION 35 - HYDRAULIC SYSTEM
TORQUE SPECIFICATIONS
SKID STEER MODEL L170
Control Valve
Boom Cylinders
Bucket Cylinders
Gear Pump
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
NOTE: Always use a noncorrosive silicone sealer to prevent damage to the components being sealed
during the silicone curing process.
35-11
SECTION 35 - HYDRAULIC SYSTEM
TROUBLESHOOTING WARNING
When performing a test on the hydraulic system, use Gauges, gauge fittings, and hoses must have
the proper test procedures and test equipment. operating pressure ratings of at least 25% higher
Before testing, lower the attachment to the ground or than the highest pressures of the system.
remove the attachment from the loader. Never adjust or replace the relief valves to get
If testing is to be performed with a raised boom, make higher pressures than those specified by the
sure the boom is raised above and resting on the equipment manufacturer.
boom lock pins. Fluid under pressure can have sufficient force to
Before opening the hydraulic system, clean the area penetrate the skin, causing serious personal
thoroughly to prevent contaminating the system. injury. Always protect the skin and eyes from
Before opening the hydraulic system, relieve all pres- escaping fluid under pressure.
sure from the system. Before disconnecting lines or fittings, be sure to
Before testing the hydraulic system, check the hy- turn off the skid steer engine and relieve all
draulic oil level. pressure. Before applying pressure to the
system, be sure all connections are tight and that
Before testing the hydraulic system, the oil must be lines, pipes, and hoses are not damaged.
at normal operating temperature.
If injured by escaping fluid, obtain medical
If testing requires the skid-steer loader to be raised, assistance at once. Serious infection or reaction
use adequate blocking and/or jack stands to securely can develop if medical treatment is not
support the loader. administered immediately.
CAUTION Remove any attachment from the mounting plate
When connecting test equipment into the before loosening or disconnecting any hydraulic
hydraulic system, relieve the pressure in the lines.
system. stop the engine, turn the ignition switch
to the “ON” Position and operate all hydraulic
control valve circuits to relieve pressure. Turn CAUTION
the ignition switch to the “OFF” Position. Use adequate blocking and/or jack stands to
insure that the loader is safely supported with all
four wheels off the ground.
35-12
SECTION 35 - HYDRAULIC SYSTEM
35-13
SECTION 35 - HYDRAULIC SYSTEM
35-14
SECTION 35 - HYDRAULIC SYSTEM
35-15
SECTION 35 - HYDRAULIC SYSTEM
Control valve plugs leaking oil to re- Check O ring and back-up washer
turn on plugs
Hydraulic system overheats Control handle shifted slightly Return control to neutral and lock
when auxiliary hydraulics is not
in use Control linkage not adjusted proper- Adjust linkage
ly
35-16
SECTION 35 - HYDRAULIC SYSTEM
35-17
SECTION 35 - HYDRAULIC SYSTEM
35-18
SECTION 35 - HYDRAULIC SYSTEM
35-19
SECTION 35 - HYDRAULIC SYSTEM
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
35-20
SECTION 35 - HYDRAULIC SYSTEM
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
35-22
SECTION 35 - HYDRAULIC SYSTEM
Pretest instructions:
* Operator in seat
* Service/Run switch in “RUN” position
* Seat belt fastened
* Ignition switch in the “ON” position
35-23
SECTION 35 - HYDRAULIC SYSTEM
10 9
2 1
6 5
3
4
11
8
7
19997772
8
HYDRAULIC SYSTEM OIL FLOW 5. With the control valve spools in neutral position,
the oil flows through center of control valve, 5, to
Control Valve - Spools in Neutral Position return line, 7.
1. Hydraulic oil reservoir, 1, storage for system oil. 6. The oil flows through return line, 7, to oil cooler,
8.
2. Oil flows through suction line, 2, from reservoir,
1, to gear pump, 3. 7. Oil passes through the oil cooler, 8, being cooled
with the air blast from engine fan through the
3. Oil flows from gear pump, 3, through pressure cooler.
line, 4, to control valve, 5.
8. Oil flows from the oil cooler, 8, through filter, 9,
4. Control valve, 5, is equipped with a system relief and check valve, 10, to return line, 11, and reser-
valve, 6. voir, 1.
35-24
SECTION 35 - HYDRAULIC SYSTEM
3
6 5 1
2
19997773
9
CONTROL VALVE - BUCKET SPOOL 1. Oil flows from the gear pump, 1, through pres-
SHIFTED sure line, 2, to control valve, 3.
2. When the bucket valve spool, 4, is pulled out, the
Bucket Control Operation oil flows from the rear work port, 5, to the shaft
side of the bucket cylinder to curl the bucket
Foot Controls back.
When the toe of the control pedal is pushed down, it 3. When the bucket valve spool, 4, is pushed in, the
will shift the control valve spool in, dumping the buck- oil flows from the front work port, 6, to the base
et. When the heel of the control pedal is pushed (piston) end of bucket cylinder to dump the buck-
down, it will shift the control valve spool out curling et.
the bucket back. 4. When the bucket circuit is operated to maximum
pressure or cylinders are bottomed, the main
Hand Controls system relief valve will relieve the high pressure
oil into the return oil galley in the control valve, re-
When the right control handle is pivoted up it will shift turning the oil to the reservoir.
the control valve spool in, dumping the bucket. When
the right control handle is pivoted down it will shift the 5. The return oil from the opposite side of the cylin-
control valve spool out, curling the bucket back. der being pressured will return through the con-
trol valve to the reservoir.
35-25
SECTION 35 - HYDRAULIC SYSTEM
7
3
1
2
6 5
19997774
10
CONTROL VALVE - BOOM SPOOL 3. When the boom valve spool, 4, is pushed in, the
SHIFTED oil flows from the front port, 6, to the shaft end of
boom cylinders, to lower the boom.
Boom Control Operation 4. When the boom circuit is operated to maximum
pressure or cylinders are bottomed, the main
Foot Controls system relief valve will relieve the high pressure
oil into the return oil valley in the control valve, re-
When the toe of the control pedal is pushed down, it turning the oil to the reservoir.
will shift the control valve spool in, lowering the boom.
When the heel of the control pedal is pushed down 5. The return oil from the opposite side of cylinders
it will shift the control valve spool out, raising the being pressured will return through the control
boom. valve to the reservoir.
6. When the boom cylinders are extended, the
Hand Controls boom control valve spool is in neutral, and a load
is put on the boom cylinders causing them to re-
When the left control handle is pivoted down, it will tract the circuit. Relief valve, 7, will relieve the
shift the control valve spool in, lowering the boom. pressure in the base (piston) side of cylinders
When the left control handle is pivoted up, it will shift protecting the cylinder and lines. The oil relieved
the control valve spool out, raising the boom. from the circuit relief valve enters the return oil
1. Oil flows from the gear pump, 1, through pres- galley in the control valve and returns to the res-
sure line, 2, to control valve, 3. ervoir.
2. When the boom valve spool, 4, is pulled out, the 7. When the boom valve spool, 4, is pushed in all
oil flows from the rear work port, 5, to the base the way, it will put the spool into detent position,
(piston) end of the boom cylinder raising the holding the spool, opening both work ports 5 and
boom. 6 to the return allowing the boom to float.
35-26
SECTION 35 - HYDRAULIC SYSTEM
3
2 1
6
9
7 5
9
8
19997775
11
CONTROL VALVE - AUXILIARY SPOOL 3. When the auxiliary valve spool, 4, is pushed in,
SHIFTED the oil flows from the front work port, 7, and sup-
plies oil to the male quick coupler, 8, at the front
Auxiliary Control Operation of the boom.
4. When the auxiliary circuit is operated to maxi-
Hand Controls mum pressure, the main system relief valve will
relieve the high pressure oil into the return oil gal-
When the right control handle is pivoted down, it will ley in the control valve, returning the oil to the res-
shift the control valve spool in, supplying oil to the ervoir.
male quick coupler. When the right control handle is
pivoted up, it will shift the control valve spool out, sup- 5. The return oil from the opposite quick coupler be-
plying oil to the female quick coupler. ing pressured will return through the control valve
to the reservoir.
Foot Control NOTE: The return oil from the quick couplers must be
returned through the normal return line, 9, to
When the toe of the control pedal is pushed down, it replenish the hydrostatic system; hydrostatic charge
will shift the control valve spool in, supplying oil to the oil is required for lubrication of the hydrostatic pumps
male quick coupler. When the heel of the control ped- and motors.
al is pushed down, it will shift the control valve spool
out, supplying oil to the female quick coupler.
6. When the auxiliary valve spool, 4, is pushed in all
1. Oil flows from the gear pump, 1, through pres- the way, it will put the spool into detent position,
sure line, 2, to control valve, 3. holding the spool for continuous oil flow to the
2. When the auxiliary valve spool, 4, is pulled out, male quick coupler.
the oil flows from the rear work port, 5, and sup-
plies oil to the female quick coupler, 6, at the front
of the boom.
35-27
SECTION 35 - HYDRAULIC SYSTEM
Op. 35 710 02
1
MAIN SYSTEM PRESSURE TESTS
Check the main system pressure to insure the main
relief valve is within specifications to provide ade-
quate working pressure to the hydraulic system.
The main system pressure can be checked at the
base end of the boom cylinders at 1.
12
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.
13
To check main system pressure at the boom cylin-
ders, the boom must be up and resting on the boom
lockpins, 1.
14
35-28
SECTION 35 - HYDRAULIC SYSTEM
15
Raise the seat and seat pan to the raised latched
position, 1. Be sure the seat support rod is latched se-
curely at 2, before working under a raised seat.
CAUTION
Do not work under raised seat unless securely
latched in the raised position.
16
35-29
SECTION 35 - HYDRAULIC SYSTEM
Test Procedure
18
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 con-
trol pedals to relieve pressure in the cylinders.
Turn off the key.
35-30
SECTION 35 - HYDRAULIC SYSTEM
19997742
20
CHECKING MAIN SYSTEM PRESSURE AT
BUCKET CYLINDERS, 1
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 con-
trol pedals to relieve pressure in the cylinders.
Turn off the key. 21
35-31
SECTION 35 - HYDRAULIC SYSTEM
22
7. The relief valve is a cartridge type and is not ad-
justable. Replace the relief valve cartridge, 1, if
the pressure is not within specifications.
CAUTION 1
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.
19997742
23
CHECKING MAIN SYSTEM PRESSURE AT
AUXILIARY BOOM HYDRAULIC QUICK
COUPLERS, 1
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 aux-
iliary controls to relieve pressure in the systems. 24
Turn off the key.
35-32
SECTION 35 - HYDRAULIC SYSTEM
19997742
26
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.
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.
28
4. Boom control valve spool in the neutral (cen-
tered) 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 29
replace the valve.
30
35-34
SECTION 35 - HYDRAULIC SYSTEM
Test Procedure
Gear pump flow test with units equipped with auxilia-
ry boom hydraulics.
1. Lower the boom and bucket to the lowered posi-
tion, 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 test-
er 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 31
of the test circuit, and pump over pressure may
cause a pump failure by splitting the center
section or twisting off the input shaft.
35-35
SECTION 35 - HYDRAULIC SYSTEM
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 posi-
tion, resting on the ground.
2. Stop the engine, turn the ignition key to the run
position and operate the boom and bucket con-
trol 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
33
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 hy-
draulic system and the pressure reading at this
point is force required to pump the oil through the
system. The pressure is called back pressure.
34
35-37
SECTION 35 - HYDRAULIC SYSTEM
35-38
SECTION 35 - HYDRAULIC SYSTEM
35
35-39
SECTION 35 - HYDRAULIC SYSTEM
36
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 1
must be in the seat with the seat belt buckled and 1
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.
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.
35-40
SECTION 35 - HYDRAULIC SYSTEM
Test Procedure:
1. Remove the filler/breather cap.
2. Remove the self-tapping screws around the cap 38
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.
35-41
SECTION 35 - HYDRAULIC SYSTEM
The following checks should then be performed to – It may be necessary in some instances (where
trace the source of the air ingress. leakage is occurring on shaft seals into
– Examine the suction tubes and fittings to the gearboxes or bell housing) to pressurize the
hydraulic gear pump and the return tubes from reservoir for 2 - 4 hours and monitor the oil level
the filter to the reservoir. in the gearboxes.
– Examine the transmission case drain – If the prior checks do not locate the source of the
tubes/hoses and fittings from the hydraulic leak, it may be necessary to pressurize each
motors and pumps to the suction side of the hydrostatic component individually. To do this it
hydraulic pump. Also check the cam plate shaft will be necessary to disconnect each case drain
seals and the pump and motor casing gaskets. line in turn and pressurize using an air line to a
maximum pressure of 10 PSI.
– Potential leakage areas could also be input shaft
seals in the engine bell housing, gearbox or NOTE: A check valve can be installed in the case
output shaft seals in motors and gearboxes and drain tube which maintains a 5 PSI pressure in the
the chain case. 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
Torque Specifications
Control Valve Retaining Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N·m (18 ft. lbs.)
Labor Required
Remove and Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 hours
35-43
SECTION 35 - HYDRAULIC SYSTEM
CONTROL VALVE
Op. 35 724 50
REMOVAL
1. Lower the boom and bucket to the lowered posi-
tion (resting on the ground), or remove any at-
tachment 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 con-
trol pedals to relieve pressure in the boom and
bucket circuits. Turn off the key.
39
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. 40
Never loosen any hydraulic lines without first
relieving all pressure in the system.
41
35-44
SECTION 35 - HYDRAULIC SYSTEM
42
7. Unplug the spool lock solenoids, 1.
8. Remove the pressure line, 2, and return line, 3;
7
cap both lines to prevent loss of oil and contami-
nation from entering the hydraulic system.
9. Remove the hydraulic lines connected to the 2
work ports of the control valve, 4, four or six lines, 3
if unit is equipped with auxiliary boom hydraulics
and cap. 5
4
10. Remove the line from the power beyond port, 5,
if equipped with auxiliary hydraulics and cap. 1
11. Unhook the control linkage from the control valve
spools at 6. 6
19984464
12. Remove the control valve retaining hardware, 7.
43
Lift the control valve assembly from the loader.
Op. 35 724 54
DISASSEMBLY AND INSPECTION
35-45
SECTION 35 - HYDRAULIC SYSTEM
19984466
45
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
1
19984467
46
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.
35-46
SECTION 35 - HYDRAULIC SYSTEM
2 4
19984469
48
Spools, Caps, and O Rings
Oil is directed through the housing to the different 4
ports by way of the spools: the bucket spool, 1, the 1
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 2
5
disconnecting the control linkage and removing the 3
spool caps.
CAUTION 19984470
1
19984471
50
35-47
SECTION 35 - HYDRAULIC SYSTEM
19984472 1
51
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.
19984473
52
5. The complete control valve components include:
1 5
1. Main system relief valve 6
2. Boom circuit relief valve
3. Plugs 3 7
4. Caps
11
5. Plain control spool cap
6. Detent control spool caps
13
7. Centering springs and hardware 3
8. Bucket control spool
9. Boom control spool 2 10
12 3 4 8 9
10. Auxiliary control spool 19984474
11. Lift check, springs, and caps 53
12. Bucket and boom solenoids
13. Boom lower circuit orifice plate
35-48
SECTION 35 - HYDRAULIC SYSTEM
PARTS INSPECTION
Inspect the control valve components thoroughly for 2
scratches or nicks, weak centering springs, weak lift 1
check springs, and scored lift checks or valve seats. 3
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
19984475
-- Check the spool lands for scratches.
-- Check spool straightness. 54
IMPORTANT: The spools are matched to the control
valve body. If excessively worn or damaged, replace
the control valve assembly.
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 con-
trol spool ports.
19984473
56
2. Install the O ring seals, 1, on the boom circuit re-
lief valve, 2, and all the plugs, 3.
3. Install small O rings, 4, and backup rings, 5, on
the relief valve and plugs.
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.
2 2
1
19984468
58
35-50
SECTION 35 - HYDRAULIC SYSTEM
2 4
3
19984469
59
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.
60
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.
61
35-51
SECTION 35 - HYDRAULIC SYSTEM
1 2 3
19984472
62
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
1
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.
1
19984467
64
35-52
SECTION 35 - HYDRAULIC SYSTEM
2 1
3
19984466
65
16. Install an O ring on the main system relief valve,
1, and install into the valve body.
19984465
66
REINSTALLATION
1. Place the rubber isolation mount, 1, in place un-
der 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 har- 1
ness 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. 19984464
6. With the unit supported off the ground, start the 67
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 re-
quired.
35-53
SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC PUMP
Specifications 26000 Series
Type Gear Pump
L160
Output @2900 RPM - 69 bar (1000 PSI) 58.7 L/min (15.5 GPM)
L170
Output @2900 RPM - 69 bar (1000 PSI) 67.0 L/min (17.7 GPM)
Rotation (Viewed from shaft end) Clockwise
Gear teeth 13 per gear
Wear plate Black, powdered metal with Teflon coating
Bushings Teflon coated
Internal lubrication system Inlet (suction) side
Labor Required
R&R Pump 1.5 hrs.
Disassembly, Inspection and Reassembly 0.5 hrs.
35-54
SECTION 35 - HYDRAULIC SYSTEM
Op. 35 710 10
PUMP REMOVAL
1. Lower the boom and bucket to the lowered posi-
tion (resting on the ground), or remove any at-
tachment 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 con-
trol 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 68
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.
35-55
SECTION 35 - HYDRAULIC SYSTEM
Op. 35 710 20
HYDRAULIC SYSTEM PUMP REMOVAL/ 5
DISASSEMBLY (WITHOUT HIGH FLOW) 2 4
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 fit- 6
ting from the housing.
3. Clean the pump thoroughly and mark the pump
assembly, 5, to ensure proper reassembly.
1 3
4. Remove the pump housing hardware, 6, and 19998082
separate the end plate and body sections. 69
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 2
4. Pump body
5. Pump back plate 5
1 4
Separate the hydraulic system pump end plate and
body sections.
3
19997794
70
Op. 35 710 20
HYDRAULIC SYSTEM PUMP AND HIGH
FLOW PUMP REMOVAL/DISASSEMBLY
1
1. On units equipped with high flow, loosen and re-
move the boom circuit hydraulic lines, 1 and 2,
and the high flow supply line, 3.
2
19998077
71
35-56
SECTION 35 - HYDRAULIC SYSTEM
3 4 5
19997759
73
The hydraulic system pump consists of:
1. Wear plate assembly
2. Idler gear assembly
2
3. Drive gear assembly
4. Key
1
5. Pump body
6. Pump back plate
35-57
SECTION 35 - HYDRAULIC SYSTEM
76
4. Inspect the pump gear teeth, 1, for excessive
wear. Inspect the drive gear key, 2, to ensure it is 2
not sheared.
The idler gear shaft should measure greater than 1
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.
3
19997760
77
35-58
SECTION 35 - HYDRAULIC SYSTEM
35-59
SECTION 35 - HYDRAULIC SYSTEM
19997761
81
6. The wear plate, 1, seal, 2, and backup gasket, 3,
should be replaced when the pump is rebuilt. In-
spect for damage, such as nicks and tears, to de-
termine 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.
82
7. With High Flow - Inspect the pump gear teeth, 1,
for excessive wear. 2
The gear shaft assemblies should measure
greater than or equal to 0.7485″ (19.0 mm) in the 1
bushing area, 2. L160 gears should be at least 2
22.56 mm (0.888″) wide. L170 gears should be 2
at least 22.76 mm (1.014″) wide. Replace the
gears if they do not meet specifications.
2
NOTE: If replacement of the gear assemblies is 2
necessary, the gear assemblies should be replaced
in pairs.
19997787
83
35-60
SECTION 35 - HYDRAULIC SYSTEM
19997814
84
HYDRAULIC SYSTEM PUMP
REASSEMBLY/ INSTALLATION (WITHOUT 1
HIGH FLOW)
NOTE: If installing a new pump, refer to “New
Hydraulic System Pump Installation (Without High
Flow)” below.
86
35-61
SECTION 35 - HYDRAULIC SYSTEM
NOTE: The gasket AND seal must align and lay flat
when installed in the wear plate.
87
4. Install the wear plate assembly, 1, with the gas-
ket/seal side towards the pump mounting plate
with the mid section cut away on the suction side, 1
2, of the pump.
19997783
88
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. Ro-
tate 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
1
19997784
89
35-62
SECTION 35 - HYDRAULIC SYSTEM
1
19997785
90
7. Install a new O ring, 1, in the back plate.
19997761
91
8. Install the pump back plate, 1, over the gear
shafts. Check that the reference marks made 1
during disassembly align correctly. 5
9. Install the housing hardware with the eight bolts, 3
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 2
line connections securely.
11. Install the suction tube port fitting, 5, and turn the 4
fitting up. Add SH/CG4 10W-30 oil to fill the bot-
tom of the hydraulic pump. 19998081
92
35-63
SECTION 35 - HYDRAULIC SYSTEM
2
19998082
93
HYDRAULIC SYSTEM PUMP AND HIGH
FLOW PUMP REASSEMBLY/ INSTALLATION 1
NOTE: If installing a new pump assembly, refer to
“New Hydraulic System Pump / High Flow Pump
Installation” below.
19997782
94
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.
95
35-64
SECTION 35 - HYDRAULIC SYSTEM
NOTE: The gasket AND seal must align and lay flat
when installed in the wear plate.
96
4. Install the wear plate assembly, 1, with the gas-
ket/seal side towards the pump mounting plate
with the mid section cut away on the suction side, 1
2, of the pump.
19997783
97
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. Ro-
tate the gears to help slide the idler gear into
place. 2
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. 3
Position the keyway, 3, up.
1
19997788
98
35-65
SECTION 35 - HYDRAULIC SYSTEM
19997789
99
7. Install a new O ring, 1, in the back plate.
1
19997761
100
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
1
the drive shaft.
2
3
19997762
101
35-66
SECTION 35 - HYDRAULIC SYSTEM
102
NOTE: The gasket AND seal must align and lay flat
when installed in the wear plate.
103
11. Install the wear plate assembly, 1, with the gas-
ket/seal side towards the pump mounting plate
with the mid section cut away on the suction side,
2, of the pump.
19997763
104
35-67
SECTION 35 - HYDRAULIC SYSTEM
2
1
19997764
105
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 dur-
ing disassembly align correctly. 1
NOTE: The small half-moon cavity, 3, must be on the
pressure side of the pump. 2
19997765
106
14. Install a new O ring, 1, in the back plate.
1
19997761
107
35-68
SECTION 35 - HYDRAULIC SYSTEM
2
19997758
109
20. Reinstall the boom circuit hydraulic lines, 1, and
high flow line, 2, and tighten securely.
2
1
19998077
110
35-69
SECTION 35 - HYDRAULIC SYSTEM
19997780
111
The hydraulic system gear pump consists of:
1 Wear plate assembly
2 Idler gear assembly
3 Drive gear assembly 2
4 Pump body
5 Pump back plate 1
Coat all parts with a thin coat of petroleum jelly or oil
to aid in reassembly.
3 4 5
19997794
112
2. Clean the mounting plate surface thoroughly and
install a new O ring, 1. 1
19997782
113
35-70
SECTION 35 - HYDRAULIC SYSTEM
19997783
114
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. Ro-
tate 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
1
19997784
115
5. Install the pump backplate, 1, and body together
over the gear shafts. 1
6. Install the housing hardware with the eight bolts, 5
2, and sealing washers. Tighten the bolts evenly 3
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. 2
8. Install the suction tube port fitting, 5, and turn the
fitting up. Add SH/CG4 10W-30 oil to fill the bot- 4
tom of the hydraulic pump.
19998081
116
35-71
SECTION 35 - HYDRAULIC SYSTEM
2
19998082
117
NEW HYDRAULIC SYSTEM PUMP / HIGH
2 1
FLOW PUMP INSTALLATION
1. Remove the through bolts, 1, and washers.
2. Separate the pumps at 2, taking care not to dis-
turb the seals between the pump bodies and
backplates.
19997790
118
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.
2
1
19997791
119
35-72
SECTION 35 - HYDRAULIC SYSTEM
19997782
122
35-73
SECTION 35 - HYDRAULIC SYSTEM
19997783
123
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. Ro-
tate the gears to help slide the idler gear into
place. 2
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.
1 3
19997788
124
6. Install the pump body and back plate together, 1,
over the gear shafts, taking care not to disturb the 1
seals between the pump body and backplate.
19997792
125
35-74
SECTION 35 - HYDRAULIC SYSTEM
1
2
3
19997762
126
8. Install the wear plate assembly, 1, with the gas-
ket/seal side towards the pump mounting plate
with the mid section cut away on the suction side,
2, of the pump.
19997763
127
9. Install the drive gear, 1, on the drive shaft, slip-
ping 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
2
1
19997764
128
35-75
SECTION 35 - HYDRAULIC SYSTEM
10. Install the high flow pump body and end plate to-
gether, 1, taking care not to disturb the seals be- 1
tween the pump body and backplate. Make sure
there are no gaps between the pump bodies and
plates.
19997793
129
11. Install the housing hardware with the eight bolts,
1, and sealing washers. Tighten the bolts evenly 4 3
in a criss-cross pattern to 34 - 38 N·m (25 - 28 ft.
lbs.).
12. Install the high pressure port fittings, 2, and the 2
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 bot-
tom of the hydraulic pump. 1
19998080
130
14. Turn the suction tube fitting, 1, down and install
the suction tube, 2. Tighten all hydraulic connec- 1
tions securely.
2
19997758
131
35-76
SECTION 35 - HYDRAULIC SYSTEM
19998077
132
35-77
SECTION 35 - HYDRAULIC SYSTEM
35-78
SECTION 35 - HYDRAULIC SYSTEM
Torque
Labor Required
Torque
Labor Required
35-79
SECTION 35 - HYDRAULIC SYSTEM
Torque
Labor Required
Torque
Labor Required
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.
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 hard-
ware.
NOTE: DO NOT remove the retaining hardware at
this time.
136
35-81
SECTION 35 - HYDRAULIC SYSTEM
137
10. Remove the UPPER boom pin retaining bolt, 1,
and boom pin, 2.
11. Remove the cylinder.
138
12. Shown here is the boom cylinder, 1, lower ta-
pered pivot pin and hardware, 2, and the upper
pivot pin and retaining hardware, 3.
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 2 1
unscrew the cylinder head. Flattening of the barrel
will cause damage to the piston and piston seals.
140
4. Remove the piston rod assembly, 1, from the bar-
rel, 2.
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
143
7. Remove the wear ring, 1, and seal, 2, from the
piston, 3.
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 ex-
cessive 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
146
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.
147
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.
35-85
SECTION 35 - HYDRAULIC SYSTEM
19987106
149
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.
151
35-86
SECTION 35 - HYDRAULIC SYSTEM
REINSTALLATION
1. Lubricate the boom pivot pins, 1, with an anti-
1
seize-type lubricant.
2. Install the cylinder onto the loader.
NOTE: Refer to Service Bulletins 5/96 - I6 and 7/96 2
- I6 for updated pivot pin support information and
proper pin, spacer, and bolt part numbers.
153
BUCKET CYLINDER
Op. 35 710 10
REMOVAL
1
CAUTION
Never loosen any hydraulic lines without first
relieving all pressure in the system.
35-87
SECTION 35 - HYDRAULIC SYSTEM
155
11. Shown here is the bucket cylinder,1, with the up-
per tapered pivot pin, 2, and hardware. 1
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
158
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.
159
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 exces-
sive 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 seal-
ing properly.
160
35-89
SECTION 35 - HYDRAULIC SYSTEM
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. 1
2. Examine the piston assembly prior to installation. 3
Replace the wear ring, 1, and T-seal, 2, making 3
sure they are firmly in their groove and snug 2
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 T-
seal as shown.
19987106
163
35-90
SECTION 35 - HYDRAULIC SYSTEM
164
5. Install O ring, 1, and backup washer, 2, on the
cylinder gland.
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.
4
NOTE: Seals, 3, should be clamped with a ring
compressor and chilled before being installed in the
barrel.
35-91
SECTION 35 - HYDRAULIC SYSTEM
167
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 hard-
wood to protect the pin, hit the pivot pin and re-
taining hardware at 1, to properly seat the ta-
pered 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 168
from the system and check the cylinder for leaks.
7. Check the hydraulic oil level and add 10W-30 oil
as required.
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.
169
3. Remove the bolts, 1, connecting the two bracket
halves.
1
4. Disconnect the control valve links, 2, at the con-
trol valve.
170
PEDAL INSPECTION
2
With Boom and Bucket Pedal Controls
1. Remove the control valve links, 1, from the hub 1 1
control arms, 2.
19996895
171
35-93
SECTION 35 - HYDRAULIC SYSTEM
19996894
172
3. Inspect the auxiliary hydraulic hub arm, 1, the
boom hub arm, 2, and the bucket hub arm, 3, for 1
any deformation or cracks. 4
2 4
3
4. To disassemble hub arms, remove the roll pins,
4, from the hub arms and control shaft.
5
5
19996893
173
6. To remove control shafts, remove bolt, 1, secur-
ing shaft arm to pedal. Take note of the position 2
and number of any spacer washers or shims. Re-
move the nuts, 2, holding the bearings on the
pedal support. Separate the shaft from the pedal
and bearing.
2
1
19996891
174
35-94
SECTION 35 - HYDRAULIC SYSTEM
19996826
175
8. Inspect the pedals, 1, and pedal supports, 2, for
any excessive wear or deformation.
19996827
176
PEDAL REINSTALLATION
With Boom and Bucket Pedal Controls
1 1
1. Reinstall the bearings, 1, shafts, 2, brackets, 3, 3
and control arms, 4, using the same number and
position of washers or shims.
2 4 4 2
19996896
177
35-95
SECTION 35 - HYDRAULIC SYSTEM
178
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.
179
5. Install the right pedal, 1, adding shim washers as
necessary so pedal mounting holes line up cor-
rectly. Check that the inside edge of the bucket 1
hub arm aligns with the slot in the control valve 3
spool as described above. Install the pedal with
hardware, 2, previously removed, and tighten se-
curely. Connect the two-piece bracket with the
two bolts, 3, washers and nuts.
2
6. Check for free operation of the foot pedals and
hub control arm assemblies. If any components
are binding, adjust or reshim the pedal assem-
blies.
180
35-96
SECTION 35 - HYDRAULIC SYSTEM
181
9. Connect the auxiliary hydraulic control rod, 1, to
the pedal hub arm, 2, with the bolt, washer, lock
washer, and nut.
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
2. Remove the bolts, 1, washers, lock washers, and
nuts, that connect the control rods, 2, to the pedal
hub arms.
1
19997768
183
3. Disconnect the control valve links, 1, from the
control valve spools by removing the cotter pins,
2, and clevis pins, 3. 3
19996833
184
5. Remove the right pedal mounting bolts, 1, and re-
move the right pedal, 2.
4 2
19996832
185
35-98
SECTION 35 - HYDRAULIC SYSTEM
PEDAL INSPECTION
With Boom and Bucket Hand Controls
1. Remove the bucket hub arm assembly, 1, and 3
4
the boom hub arm assembly, 2. Inspect the hub
arm assemblies for any deformation or cracks.
19996825
187
4. Inspect the shaft bearings, 1, for excessive wear.
If bearings do not move freely, replace.
1
19996826
188
35-99
SECTION 35 - HYDRAULIC SYSTEM
19996827
189
6. Inspect the control valve spool links, 1, for bends
or excessive wear. 1
19996829
190
PEDAL REINSTALLATION
With Boom and Bucket Hand Controls 3
1. Insert the control shaft, 1, through the left pedal, 1
6
2, and left pedal support, 3, fitting three washers,
4, between the pedal and support. 5
2. Slide the auxiliary boom hydraulic hub assembly,
5, onto the control shaft and secure with allen
screws, 6.
2 4
19996824
191
35-100
SECTION 35 - HYDRAULIC SYSTEM
19996831
192
5. Slide the pedal assembly to align the auxiliary hy-
draulic 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 mount-
ing hardware.
193
8. Install the right pedal, 1, adding shim washers as
necessary at 2, fitting inside the bearing, 3, so 3
pedal mounting holes line up correctly. Install the
pedal with hardware, 4, previously removed, and 2
tighten securely.
4
9. Check for free operation of the foot pedals and
hub assemblies. If any components are binding,
adjust or reshim the right pedal assembly.
1
19996832
194
35-101
SECTION 35 - HYDRAULIC SYSTEM
19997768
196
35-102
SECTION 35 - HYDRAULIC SYSTEM
Labor Required
35-103
SECTION 35 - HYDRAULIC SYSTEM
Op. 35 705
FILTER SYSTEM
The skid-steer loader is equipped with a single spin-
on 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.
197
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.
198
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.
199
35-104
SECTION 35 - HYDRAULIC SYSTEM
REASSEMBLY
1. Reinstall the filter base with the hardware pre-
viously 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 con-
tacts the base, and then tighten another half to
three-quarter turn.
200
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.
201
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 202
assembly from the loader frame.
35-105
SECTION 35 - HYDRAULIC SYSTEM
203
REASSEMBLY
1. Reattach the oil cooler to the support with the
previously removed hardware.
2. Reinstall the support with the oil cooler and radia-
tor 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.
204
6. Reconnect the filter hydraulic lines. Tighten the
lines to seat to fittings, then loosen lines and re-
torque.
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 hydrau-
lic 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
205
washers, 2, and lift the screen assembly from the
reservoir neck.
35-106
SECTION 35 - HYDRAULIC SYSTEM
206
The hydraulic reservoir is equipped with a tempera-
ture sender, 1, which allows the EIC (Electronic In-
strument Cluster) to monitor the hydraulic oil temper-
ature and signal the operator of an oil overheat
condition. 1
IMPORTANT: Do not over tighten the sender or
damage to the reservoir may occur.
19997779
207
Op. 35 300 10
OIL RESERVOIR REMOVAL
To access the reservoir, open the rear door and re-
move 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.
208
35-107
SECTION 35 - HYDRAULIC SYSTEM
35-108
SECTION 35 - HYDRAULIC SYSTEM
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
35-110
SECTION 35- HYDRAULIC SYSTEM
SPECIFICATIONS
Machines Equipped With ISO Pattern Pilot Controls
Relief Valve - General Specification
Loader Control Valve Main Relief Pressure at 16 GPM at 2900 rpm................... 19,000 kPa (190 bar) (2755 psi)
Hydraulic Pump
Type ................................................................................................................................................................Gear
Displacement (Per Revolution) ...................................................................................................22.5 cc (137 CID)
Flow at Rated Engine Speed at 100% Volumetric Efficiency .........................................65.1 L/min (17.2 US gpm)
Pump to Engine Speed ............................................................................................................................ Ratio 1:1
Oil Filter Bypass
Return Filter Bypass Pressure ..................................................................................................345 kPad (50 psid)
High-Flow Hydraulic Power System
Type ................................................................................................................................................................Gear
Displacement .............................................................................................................................. 12.6 cc (0.77 cid)
Pump Flow at Rated Engine Speed at 100% Volumetric Efficiency.................................36.6 L/min (9.7 US gpm)
Pump to Engine Speed ............................................................................................................................ Ratio 1:1
System Combined Flow
Loader Pump Flow ...........................................................................................................65.1 L/min (9.7 US gpm)
High-Flow Pump Flow ......................................................................................................36.6 L/min (9.7 US gpm)
Total Flow.....................................................................................................................101.7 L/min (26.9 US gpm)
System Relief Valve Pressure....................................................................................... 19,000 kPa (190 bar) (psi)
35-111
SECTION 35- HYDRAULIC SYSTEM
35-112
SECTION 35- HYDRAULIC SYSTEM
BS06M040_5
1. IMPLEMENT CONTROLLER 5. Move the implement controller lever (1) to raise
2. INTERLOCK VALVE the loader control arms. Read the pressure
3. LOADER CONTROL VALVE gauge and record the pilot pressure reading.
4. TEST GUAGE LOCATIONS
5. HYDROSTATIC PUMP 6. Move the implement controller lever (1) to lower
6. GROUND DRIVE CONTROLLER the loader control arms. Read the pressure
gauge and record the pilot pressure reading.
1. If the hydraulic oil is not at operating temperature
run the engine at full throttle and hold the bucket 7. Move the implement controller lever (1) to tilt the
control lever in the ROLLBACK position for 30 loader bucket. Read the pressure gauge and
seconds. Then return the bucket control lever to record the pilot pressure reading.
NEUTRAL for 15 seconds. Repeat this cycle until 8. Move the implement controller lever (1) to dump
the temperature of the oil is at least 52 ° C the loader bucket. Read the pressure gauge and
(125°F). record the pilot pressure reading.
2. Disconnect the hydraulic lines from the 9. The pressure readings should vary from 0 kPa (0
implement controller where they connect to the bar) (0 psi) to 2482 kPa (24.8 bar) (360 psi) at
loader control valve. high idle for a given angle on the implement
3. Connect a 4,137 kPa (41 bar) (600 psi) pressure control handle.
gauges to test locations (4) as shown. 10. If the pressure readings are correct, the test is
4. Start the engine and run at high idle. Read the complete. If the pressure readings are not
pressure gauge and record the Pilot Pressure correct, repair or replace the charge/hydrostatic
reading at high idle. pump assembly or the loader control valve.
35-113
SECTION 35- HYDRAULIC SYSTEM
10
4 9
5
6
7
8
BS06N848_1
1. INTERLOCK SUPPLY 6. JOYSTICK DRAIN
2. PUMP CONTROL 7. LOADER CONTROL VALVE
3. INTERLOCK SUPPLY 8. IMPLEMENT CONTROL
4. LOADER CONTROLLER 9. GROUND DRIVE CONTROLLER
5. IMPLEMENT CONTROLLER 10. INTERLOCK SUPPLY
LOADER CONTROL (MACHINES EQUIPPED WITH ISO PATTERN PILOT CONTROLS)
35-114
SECTION 35- HYDRAULIC SYSTEM
(MACHINES EQUIPPED WITH ISO PATTERN
PILOT CONTROLS)
REMOVAL
BD06M034_1
5. Remove screws and washers from the sides of
the pilot control handle.
BD06K111_1
1. Securely latch the seat in the raised and latched
position to gain more access to the pilot control
area.
2. Relieve all pressure in the hydraulic and
hydrostatic systems.
BD06M035
BD06M015_1
3. Remove the bolts and washers securing the pilot
control cover.
BD06M033
35-115
SECTION 35- HYDRAULIC SYSTEM
BD06M036 BD06M038_1
7. Remove the boot. 10. Loosen the jam nut, (5) and remove the rod, (6)
assembly.
BD06M016
BD06M037
35-116
SECTION 35- HYDRAULIC SYSTEM
BD06K112 BD06M039_2
11. Remove the step shield to gain access to the 15. Remove the hex socket head screws securing
magnetic detent electrical connector. the controller to the mount.
12. Disconnect the magnetic detent electrical 16. Remove controller.
harness from the main electrical harness
connector located under the step shield.
BD06M039_3
13. Remove the step shield to gain access to the
magnetic detent electrical connector.
14. Disconnect the magnetic detent electrical
harness from the main electrical harness
connector located under the step shield.
35-117
SECTION 35- HYDRAULIC SYSTEM
(MACHINES EQUIPPED WITH ISO PATTERN
PILOT CONTROLS)
INSTALLATION
BD06M038_1
6. Install the rod assembly, (6) temporarily. Place
the bend in the rod forward. Temporarily snug
down the jam nut, (5).
NOTE: Rod height adjustment may be required to
align the screw holes between the handle adapter
BD06M039_2
1. Install pilot controller into the mount. and the rod assembly.
BD06M037
7. Use acceptable tools to install the handle
adapter on the rod assembly
BD06M039_3
8. Check alignment of the screw holes between the
3. Remove caps and plugs from all fittings.
rod assembly and the handle adapter.
4. Install and tighten all hoses on the bottom of the 9. If adjustment is required, loosen the jam nut of
controller. the rod assembly and adjust rod to align screw
holes.
10. Once the screw holes are aligned, tighten the
jam nut.
BD06K104
BD06M015_1
BD06M034_1
35-119
SECTION 35- HYDRAULIC SYSTEM
BS06N069-03A
1. LEFT PISTON PUMP 12. RIGHT BRAKE CYLINDER
2. RIGHT PISTON PUMP 13. NOT USED
3. OIL FILTER 14. BRAKE SOLENOID VALVE
4. HYDROSTATIC PUMP 15. CHARGE PRESSURE SWITCH
5. CIRCUIT RELEIF VALVE 16. NOT USED
6. OIL FILTER BY-PASS SWITCH 17. HYDRAULIC RESERVOIR
7. CHECK VALVE 18. ATTACHMENT CASE DRAIN
8. HYDRAULIC PUMP 19. OIL COOLER
9. LEFT DRIVE MOTOR 20. MAIN RELEIF VALVE
10. RIGHT DRIVE MOTOR 28. HIGH FLOW PUMP (IF EQUIPPED)
11. LEFT BRAKE CYLINDER 29. HIGH FLOW CONTROL VALVE (IF EQUIPPED)
35-120
SECTION 35- HYDRAULIC SYSTEM
BS06N069-04A
5. CIRCUIT RELEIF VALVE 25. LIFT SPOOL
7. CHECK VALVE 26. AUXILIARY SPOOL
21. TILT CYLINDERS 27. AUXILIARY OUTLETS
22. LIFT CYLINDERS 30. FLOW RESTRICTOR
23. LOADER CONTROL VALVE 31. SECONDARY AUXILIARY CONTROL VALVE (IF
24. TILT SPOOL EQUIPPED)
32. SECONDARY AUXILIARY OUTLETS (IF EQUIPPED)
35-121
SECTION 35- HYDRAULIC SYSTEM
BS06N069-05A
1. LEFT PISTON PUMP 13. LEFT BRAKE CYLINDER
2. RIGHT PISTON PUMP 14. RIGHT BRAKE CYLINDER
3. CHARGE PUMP 15. CHECK VALVE
4. HYDROSTATIC PUMP 16. BRAKE SOLENOID VALVE
5. CIRCUIT RELEIF VALVE 17. CHARGE PRESSURE SWITCH
6. HIGH PRESSURE RELEIF VALVE 18. ATTACHMENT CASE DRAIN
7. BOOST VALVE 19. HYDRAULIC RESERVOIR
8. CONTROL CARTRIDGE 20. DRAIN MANIFOLD
9. SERVO PISTON 21. OIL COOLER
10. HYDRAULIC PUMP 22. OIL FILTER BY-PASS SWITCH
11. LEFT DRIVE MOTOR 23. OIL FILTER
12. RIGHT DRIVE MOTOR 24. HIGH FLOW PUMP (IF EQUIPPED)
35-122
SECTION 35- HYDRAULIC SYSTEM
BS06N069-06A
25. HIGH FLOW CONTROL VALVE (IF EQUIPPED)
35-123
SECTION 35- HYDRAULIC SYSTEM
BS06N069-07A
26. BACKUP ALARM PORT 29. GROUND DRIVE CONTROLLER SPOOL
27. GROUND DRIVE CONTROLLER 30. RESOLVER BLOCK SHUTTLE VALVE
28. CONTROL INTERLOCK VALVE
35-124
SECTION 35- HYDRAULIC SYSTEM
BS06N069-8A
31. IMPLEMENT CONTROLLER 33. IMPLEMENT CONTROLLER SPOOL
32. CONTROL INTERLOCK VALVE 34. IMPLEMENT CONTROLLER SPOOL WITH MAGNETIC
DETENT
35-125
SECTION 35- HYDRAULIC SYSTEM
BS06N069-09A
5. CIRCUIT RELEIF VALVE 40. LIFT CYLINDERS
35. LOADER CONTROL VAL;VE 41. AUXILIARY OUTLETS
36. TILT SPOOL 42. EMERGENCY BOOM LOWER SAFETY VALVE (PILOT
37. LIFT SPOOL CONTROL MODELS ONLY)
38. AUXILIARY SPOOL 43. SECOND AUXILIARY VALVE (IF EQUIPPED)
39. TILT CYLINDERS 44. SECOND AUXILIARY OUTLETS (IF EQUIPPED)
35-126
SECTION 37 – TOWING HOOKS AND BALLASTING
CONTENTS
37-1
SECTION 37 - TOWING HOOKS AND BALLASTING
Op. 37 140 10
REAR COUNTERWEIGHTS 2 3
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.
Weight Removal
1. To remove weights, remove cotter pin at 2, and
remove pin, 3, from the weights and support
bracket.
Op. 37 140 12
REAR COUNTERWEIGHT SUPPORT
REMOVAL
37-2
ROPS Removal (Cab Upgrade Machines Only).............................................................39-12
ROPS Reinstallation (Cab Upgrade Machines Only).....................................................39-24
39-1
SECTION 39 - FRAMES
GENERAL INFORMATION
ROPS
The ROPS is a welded frame structure to provide rol-
lover protection for the operator and pivot point loca-
tions for the boom assembly.
1
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 re-
moved.
39-2
SECTION 39 - FRAMES
5
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 se-
curely latched in the raised position.
39-3
SECTION 39 - FRAMES
19992572
7
9. Remove the engine side panels, 1, and top en-
gine screen, 2.
10. Disconnect the (-) negative ground battery cable.
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.
39-4
SECTION 39 - FRAMES
10
16. Remove the ground strap, 1, from the cab inner
shell and lower main frame.
11
17. Remove the engine fuse/relay panel support
hardware, 1, and raise and tie the panel assem-
bly to the back of the cab assembly.
12
39-5
SECTION 39 - FRAMES
13
19. With the boom in the lowered position and the hy-
draulic pressure relieved in the boom and bucket
circuits, disconnect the boom, bucket, and auxil-
1 1
iary boom hydraulics hose connections, 1, and
cap all connections.
CAUTION
Never loosen any hydraulic lines without first re-
lieving all pressure in the system.
14
20. Rotate the boom lock pin control lever, 1, to ex-
tend (engage) the boom lock pins.
15
39-6
SECTION 39 - FRAMES
16
22. With a suitable lifting device support the boom at
the rear.
17
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.
18
39-7
SECTION 39 - FRAMES
19
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.).
20
3. Torque the rear hardware, 1, to 108 N·m (80 ft.
lbs.). Replace any washers used for proper spac-
ing.
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.
21
39-8
SECTION 39 - FRAMES
22
7. Reconnect the ground wires to the bell housing
at 1. Place the largest wire next to the ground sur-
face, stacking the remaining wire by size, largest 1
to smallest, to ensure proper grounding. Recon-
nect the main wiring harness connector, 2.
23
8. Reconnect all hydraulic lines, 1, and position for
clearances between other components. Install
any hose clamps removed.
24
39-9
SECTION 39 - FRAMES
25
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
19992572
26
12. After all wires and hydraulic hoses are con-
nected, 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.
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.
Remove and replace ROPS frame (Includes seat, boom lock linkage, boom removal, inner shell) 18.5 hrs.
39-11
SECTION 39 - FRAMES
ROPS - REMOVE
(CAB UPGRADE MACHINES ONLY)
TO REMOVE THE CAB 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.
ATTENTION: 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.
BS07D179 Figure 1
2. Disconnect the door wiring harness (1), and
wiper fluid supply hose at disconnects under the
threshold.
3. Connect the diode to the Cab main wiring
harness.
1
BD07D177 Figure 2
BD07D176 Figure 3
39-12
SECTION 39 - FRAMES
BD07D176 Figure 4
6. Remove the threshold.
BD07D040 Figure 5
BD04E111 Figure 6
39-13
SECTION 39 - FRAMES
OPS8766 Figure 7
11. Relieve the hydraulic pressure from the boom
and bucket circuits.
12. Turn the ignition (key) switch to the “ON”
position.
13. Operate the boom and bucket controls relieving
all pressure in the system.
14. Turn the ignition switch “OFF” and exit the unit.
BD04E120 Figure 8
39-14
SECTION 39 - FRAMES
OPS8772 Figure 9
22. Remove the engine fuse/relay panel support
hardware, and raise and tie the panel assembly
to the back of the Cab.
BD07D035 Figure 10
39-15
SECTION 39 - FRAMES
BD07D038 Figure 11
24. Remove the throttle control cable, (1), from the
control lever.
25. Loosen and remove the nut (2), on the throttle 1
cable and remove the cable from the Cab.
2
BD07D037 Figure 12
ATTENTION: Never loosen any hydraulic lines
without first relieving all pressure in the system.
26. Connect a vacuum pump to the reservoir. Start
the vacuum pump. With the boom in the lower
position and the hydraulic pressure relieved in
the boom and bucket circuits, disconnect the
boom, bucket, and auxiliary boom by hydraulic
hose connections, and cap and plug all
connections.
27. Stop the vacuum pump.
39-16
SECTION 39 - FRAMES
BD07D036 Figure 13
29. Loosen and remove the mounting hardware (3)
from the rear hood (2). Remove the hood prop
rod (4). Allow the rear hood to rest on top of the
engine.
2
BD04E111 Figure 14
BD04E090 Figure 15
39-17
SECTION 39 - FRAMES
BD04E124 Figure 16
32. Rotate the boom lock pin control lever to extend
(engage) the boom lock pins (1) above the top of
the lower link, (2) as shown.
1
BS07D181 Figure 17
BS07D182 Figure 18
39-18
SECTION 39 - FRAMES
BS07D183 Figure 19
35. Remove the left and right rear attaching
hardware, (1).
BD04H092 Figure 20
1
1
BD07D178 Figure 21
37. Use acceptable lifting equipment to lift the Cab
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.
39-19
SECTION 39 - FRAMES
14 13
15
12
1
11
16 10
11 9
17
18
00
8
19 5
20 6
21 22 14
12
23
25
26 24
27
4
28
31 29 3
30
32 2
33 34 1
BS07C758 Figure 22
CAB ASSEMBLY
39-20
SECTION 39 - FRAMES
1. WASHER 10. WEAR STRIP 19. PLUG TYPE 4 27. STRIKER PLATE
2. FOAM 11. BOLT 20. NUT 28. BOLT
3. SEALING STRIP 12. ISOLATOR MOUNT 21. WASHER 29. SPRING WASHER
4. SHEET, LH SIDE 13. SUPPORT WA GRAY 22. BOLT 30. NUT
5. WEAR STRIP 14. SEALING SCREW 23. WINDOW A 31. SCREW
6. CAB WA 15. NUT 24. SEALING STRIP 32. LOCK WASHER
7. BOLT 16. WASHER 25. SIDE SCREEN TIE 33. BOLT
8. WASHER 17. SPACER 26. SIDE SHEET RH WA 34. FOAM-CLOSED CELL
9. SCREW 18. RIVET
CAB ASSEMBLY
39-21
SECTION 39 - FRAMES
12
7
14
11
10
13
9 4
2 8
1 3
5
6 7
4
16
5
15
BS07C760 Figure 23
1. WASHER 6. FOAM CLOSED CELL 11. DOOR
2. BOLT 7. BOLT 12. SILL, THRESHOLD, NA
3. CLAMP COATED 8. STRAP, THRESHOLD 13. CAP, THRESHOLD
4. WASHER 9. BOLT 14. SCREW, HEX
5. SEALING SCREW 10. PUMP, WASHER 15. WINDSHIELD WASHER TUBING
16. DOOR FRAME HARNESS
39-22
SECTION 39 - FRAMES
3
7
5 7
6
BS07C759 Figure 24
1. BOLT 5. CAP, RH
2. FASTNER 6. CAP, LH
3. HEADLINER 7. U NUT
4. TOP WINDOW
OPEN CAB
39-23
SECTION 39 - FRAMES
ROPS - INSTALL
(CAB UPGRADE MACHINES ONLY)
1. Lift the Cab and Boom assembly onto the lower
frame resting the rear Cab post on the lower
frame pads. Install the front retaining hardware,
align the rear Cab posts and install the rear
hardware.
BS07D183 Figure 25
1
1
BD07D178 Figure 26
BD04H092 Figure 27
39-24
SECTION 39 - FRAMES
2
BD07D037 Figure 28
9. Install the throttle control bracket hardware
(1).Tighten hardware to a torque of 2.8 Nm (25
pound inches).
BD07D038 Figure 29
10. Connect the heater hoses to the heater. Connect
the clamps which attach the hoses to the Cab.
11. After the Cab has been installed and if the
cooling system was drained, refer to Section 00
ENGINE COOLANT SYSTEM - General
specification for the correct type and quantity of
coolant and refill the cooling system.
12. If the machine is equipped with air conditioning
and the air conditioning was discharged, refer to
Air-conditioning system - Charging and
charge the air conditioning system.
13. Check the oil level in the hydraulic reservoir and
add hydraulic oil as needed. Refer to Section 00
for correct type and quantity.
14. Start machine and check for leaks.
15. Stop the engine.
16. Recheck all fluid levels.
39-25
SECTION 39 - FRAMES
39-26
SECTION 44 – AXLES AND WHEELS
Chapter 1 – Axles
CONTENTS
44-1
SECTION 44 - AXLES AND WHEELS
Op. 44 100
GENERAL INFORMATION
The power is transmitted to the final drive from the 1
engine which is connected to the hydrostatic pumps,
1, with a flex plate drive coupler. The hydrostatic
pumps then transmit hydraulic power to the hydro-
static 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
1
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
The axle sprocket, 1, is splined to the axle shaft and
hub assembly, 2. A large O ring, 3, seals the assem-
bly to the frame.
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)
9 - AXLES ASSEMBLIES(4)
44-3
SECTION 44 - AXLES AND WHEELS
SPECIFICATIONS
Drive Axles
Description Use
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
CAUTION
Never service a raised loader unless it is securely
supported with adequate jack stands or blocks.
44-5
SECTION 44 - AXLES AND WHEELS
One drive wheel not powered Broken drive chain Check chain and repair
Axle or drive sprocket splines worn Check axle and sprocket, replace
Chain case noise Loose drive chains Check and adjust chains
No oil in final drive Check oil level
Worn drive sprockets Check sprockets and repair
Bearing failure Check axle and gearbox bearings
and repair
Excessive axle play Bearing failure on axle shaft Check bearings and repair
Snap ring failure on axle shaft Check axle bearing pre-load,
repair
Axle outer bearing failure Prolonged operation in liquid or Decrease lubrication interval to
semi-liquid material 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.
Pre-test instructions:
* Lower boom and attachment to the ground.
* Stop engine.
* Jack loader with wheels off the ground.
* Release parking brake.
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.
44-8
SECTION 44 - AXLES AND WHEELS
10
Op. 44 106 16
DISASSEMBLY
NOTE: A press is required to remove the axle shaft
and hub assembly from the housing.
44-9
SECTION 44 - AXLES AND WHEELS
12
7. Remove the inner bearing race, 1, by driving it
from the housing with a suitable hammer and
driver.
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 remov-
al, as the replacement seal should be located in
the same position.
14
44-10
SECTION 44 - AXLES AND WHEELS
15
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
16
PARTS INSPECTION
Thoroughly clean all parts before inspection.
17
44-11
SECTION 44 - AXLES AND WHEELS
18
REASSEMBLY
1. Install the outer seal, 1, as shown, on the axle-
hub 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.
19
4. Install inner seal, 1, in housing as shown with the
flat side of seal to the center of housing and re-
tainer and lip of seal to the outside.
5. Install bearing race, 2.
6. Install replaceable seal sleeve, 3, in housing.
20
44-12
SECTION 44 - AXLES AND WHEELS
21
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.).
44-13
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 straight-
edge 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.
24
– Wipe the new stud with a wicking-type seal-
ant. 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. In-
spect for damage.
25
5. Position the drive sprocket, 1, in the axle open-
ing. 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 sprock-
et and slide together. Lifting the axle housing as-
sembly 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.
26
44-14
SECTION 44 - AXLES AND WHEELS
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.
28
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.
44-15
SECTION 44 - AXLES AND WHEELS
CAUTION
Failure to securely support the skid-steer loader
could result in movement of the loader causing
serious injury or damage to the equipment.
30
4. Remove the tires and wheels from the final drive
being serviced.
5. Clean the axle and final drive area to prevent de-
bris 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 bot-
tom of the case.
32
44-16
SECTION 44 - AXLES AND WHEELS
33
Rear Drive Sprocket and Chain
11. To remove the rear chain and sprocket, the park-
ing brake disc and caliper will need to be re-
moved first.
35
44-17
SECTION 44 - AXLES AND WHEELS
36
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).
37
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).
38
44-18
SECTION 44 - AXLES AND WHEELS
39
PARTS INSPECTION
Thoroughly clean all parts before inspection.
40
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).
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.
42
4. Install the front drive chain, 1.
NOTE: The front drive chain is longer than the rear
drive chain.
43
6. Install the rear drive sprocket, with the long cen-
ter 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 re-
positioning.
44
44-20
SECTION 44 - AXLES AND WHEELS
45
– 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.
46
– Install outer section of caliper, 1, and attach
with hardware previously installed and tight-
en to 70 N·m (52 ft. lbs.).
– Put a bead of sealer around the end of the
motor coupler and install the brake disc re-
taining bolt and flat washer, 2, and tighten.
– Engage the parking brake and torque the re-
taining bolt to 35 N·m (26 ft. lbs.).
47
44-21
SECTION 44 - AXLES AND WHEELS
48
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
49
Tire Pressures
Tire Pressure
7.00 x 15 Chevron tread 60 PSI (414 kPa)
7.50 x 15 HST-Hollow segmented N/A
10.00 x 16.5 R4-Cleat tread 50 PSI (345 kPa)
10.00 x 16.5 PHD- Premium heavy-duty 50 PSI (345 kPa)
10.00 x 16.5 HST-Hollow segmented N/A
31.0 x 15.5-15 G1 Flotation 40 PSI (276 kPa)
44-22
SECTION 44 - AXLES AND WHEELS
50
Op. 44 511 28
When replacing the sections of the hollow seg-
mented tires, torque the section hardware to 13.6
N·m (10 ft. lbs.).
51
Track Installation on Loader
Correct tire/track combinations are important to pre-
vent damage to the tracks, tires/wheels, and loader
main frame.
44-23
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.
Axle
Remove and replace 0.5 hr.
Rebuild 1.0 hr.
Final Drive
Drive chain, sprocket (front) - replace 1.5 hrs.
Drive chain, sprocket (rear) - replace 3.0 hrs.
44-24
SECTION 50 - CAB CLIMATE CONTROL
CHAPTER 1 - HEATER/DEFROSTER/AIR CONDITIONER
CONTENTS
50-1
SECTION 50 - CAB CLIMATE CONTROL
Op. 50 100
HEATER/DEFROSTER (CAB)
Switch and Control Panel
1. Disconnect the negative (–) battery cable to pre-
vent possible shorting of the electrical system.
1 2
2. Remove the retaining hardware, 1, and pull the
panel from the rear support, 2.
3. Disconnect the switch wires and control cable.
19990481
1
Switch Wiring
The heater switch, 1, has four terminals marked, L,
M, H, and B, that the wire harness must be connected
to.
2
Relay and Fuse Block
1 - Fuse block - 20 amp
2 - Relay
50-2
SECTION 50 - CAB CLIMATE CONTROL
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.
50-3
SECTION 50 - CAB CLIMATE CONTROL
6
Op. 50 104 24
Heater Core Replacement 1 2
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.
19997753
7
Op. 50 104 23
2 3 2
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. 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 hard- 3
ware, 3, and remove the valve.
19997755
8
50-4
SECTION 50 - CAB CLIMATE CONTROL
Op. 50 104 20
2 2
Heater Fan Assembly Replacement 1
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.
19997754
9
Op. 50 100 10
Heater Hose to Engine Connections
1. Heater hose from the heater core to the front
plug, 1.
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 L170 turbo-
charged 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.
12
Op. 50 104 10
Filter
Replacement filter #86504784
13
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 ele-
ment 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.
14
50-6
SECTION 50 - CAB CLIMATE CONTROL
To completely bleed air from the heater lines and 4. Start and run the engine. When the system is
heater core: completely bled, remove the “pinch off” device.
5. Finish system filling, per the installation instruc-
1. After component installation is completed, refill tions.
the coolant system, per the installation instruc-
NOTE: Do not install a shut-off valve or orifice in the
tions.
oil cooler supply hose. Restricting coolant flow to the
2. Leave the radiator cap off and run the loader en- engine oil cooler may result in overheating and en-
gine, circulating coolant. Stop the engine and re- gine failure. Should this type of overheating cause a
fill the radiator. failure, it is NOT covered by warranty.
3. Temporarily “pinch off” the oil cooler supply hose
at the new tee to force coolant through the heater
hoses and heater core.
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.
Heater/Defroster
Remove and replace electrical switch 0.25 hrs.
Remove and replace water shutoff switch 1.5 hrs.
Remove and replace heater core 1.5 hrs.
Remove and replace heater fan assembly 1.5 hrs.
Remove and replace heater hoses (1) 0.5 hrs.
50-8
SECTION 50 - CAB CLIMATE CONTROL
299L7C Figure 1
OEM1415 REFRIGERANT RECOVERY,
RECYCLING AND CHARGING STATION
A22094 Figure 2
A22090 Figure 3
SAFETY GOGGLES - OBTAIN LOCALLY
299L7A Figure 4
50-9
SECTION 50 - CAB CLIMATE CONTROL
T81574 Figure 5
50-10
SECTION 50 - CAB CLIMATE CONTROL
GENERAL SPECIFICATIONS
Compressor - General Specifications
Compressor Lubricant - PAG Oil - Capacity............................................................................ 236.6 ml (8 ounces)
Compressor Belt Tension..........................................................................................200-245 N (45 to 55 pounds)
Front Plate Air Gap ................................................................................ 0.41 to 0.79 mm (O.016 to 0.031 inches)
Compressor - Capacity
Refrigerant Charge................................................................................................................ 828.5 ml (28 ounces)
Compressor - Torque
Compressor - Rotor Shaft Nut...........................................................................15 to 20 Nm (11 to 15 pound-feet)
Oil Filler Plug .....................................................................................................15 to 24 Nm (11 to 18 pound-feet)
Dust Cover Screws .................................................................................................7 to 11 Nm (5 to 8 pound-feet)
50-11
SECTION 50 - CAB CLIMATE CONTROL
5
4
208L95 Figure 1
1. EXPANSION VALVE
2. EVAPORATOR
3. COMPRESSOR
4. CONDENSER
5. RECEIVER/DRIER
50-12
SECTION 50 - CAB CLIMATE CONTROL
BD07F071 Figure 6
A22114 Figure 7
50-13
SECTION 50 - CAB CLIMATE CONTROL
A22107 Figure 8
7. Connect the main power plug to a 115 volt AC
outlet. Move the main power switch to the ON
position and depress the recovery start switch.
The compressor will shut OFF automatically
when recovery is complete. Wait for 5 minutes
and observe the manifold pressure gauges for a
pressure rise. If the pressure rises above 0 PSI,
depress the hold/continue. switch then wait for
the compressor to automatically shut OFF.
A22112 Figure 9
A22108 Figure 10
50-14
SECTION 50 - CAB CLIMATE CONTROL
9. Slowly open the oil drain valve and drain the oil
into the reservoir. When the oil stops draining,
close the oil drain valve completely.
A22110 Figure 11
10. Fill the A/C compressor with fresh oil equal to the
amount in the reservoir.
A22111 Figure 12
BD07F071 Figure 13
50-15
SECTION 50 - CAB CLIMATE CONTROL
BD07F071 Figure 14
50-16
SECTION 50 - CAB CLIMATE CONTROL
A22113 Figure 15
A22115 Figure 16
A22113 Figure 17
50-17
SECTION 50 - CAB CLIMATE CONTROL
A22114 Figure 18
A22107
50-18
SECTION 50 - CAB CLIMATE CONTROL
A22113 Figure 20
A22114 Figure 21
50-19
SECTION 50 - CAB CLIMATE CONTROL
BD07F071 Figure 23
50-20
SECTION 50 - CAB CLIMATE CONTROL
COMPRESSOR
REMOVAL
1. Park the machine on a level surface and lower
the loader lift arm to the floor. Apply the parking 2
brake. Stop the engine.
2. Make sure the compressor and engine are clean
before connecting the refrigerant recovery
system or disconnecting any lines. 1
3. Connect the OEM1415 Refrigerant Recovery,
Recycling and Charging Station to the Low (1)
and High (2) charge ports in the hose fittings
connected to the compressor. Evacuate the
system to remove all the refrigerant. BD07F071 Figure 24
4. Disconnect the compressor clutch wire
connector (1) from the engine harness assembly.
BD07F072 Figure 25
BD07F072 Figure 26
50-21
SECTION 50 - CAB CLIMATE CONTROL
1 2
BD07F072 Figure 27
BD07F072 Figure 28
50-22
SECTION 50 - CAB CLIMATE CONTROL
COMPRESSOR
INSTALLATION
3
1. Install the compressor on the mounting bracket.
Install the pivot bolt (3) and washer into the rear
of the compressor. Install the lock washer and
nut on the pivot bolt.
BD07F072 Figure 29
BD07F072 Figure 30
BD07F072 Figure 31
50-23
SECTION 50 - CAB CLIMATE CONTROL
BD07F072 Figure 32
BD07F072 Figure 33
50-24
SECTION 50 - CAB CLIMATE CONTROL
COMPRESSOR
COMPRESSOR OIL LEVEL CHECK
Check the oil level in the compressor when any of the
following has occurred:
A. Broken refrigerant hose.
B. Large refrigerant leak.
C. Compressor leak.
D. Damage to system components.
E. New compressor installed.
Use the following procedure to check the compressor
oil level.
1. Start the engine and run at 1500 RPM maximum.
Operate the air conditioner for 10 to 15 minutes
at maximum cooling and high blower speed.
2. Stop the engine. Connect the OEM1415
Refrigerant Recovery, Recycling and Charging
Station to the compressor. Follow the procedure
to discharge the system.
7791288 Figure 35
50-25
SECTION 50 - CAB CLIMATE CONTROL
BD07F071 Figure 36
103L7 Figure 37
85010 Figure 38
50-26
SECTION 50 - CAB CLIMATE CONTROL
BS04D060 Figure 39
BD07F071 Figure 40
50-27
SECTION 50 - CAB CLIMATE CONTROL
COMPRESSOR BELT
MEASURE TENSION AND ADJUSTMENT
Check interval . . . . . . Every 250 hours of operation
NOTE: Check the belt tension after the first 50 hours
of operation and then use the regular check interval.
1. Measure the compressor belt for correct tension
using a belt tension gage. Check the belt to the
following specifications.
Belt Tension. . . . . . . 200 to 245 N (45 to 55 pounds)
1 1
BD07F072 Figure 42
BD07F072 Figure 43
50-28
SECTION 50 - CAB CLIMATE CONTROL
A21250 Figure 44
A21251 Figure 45
A21252 Figure 46
50-29
SECTION 50 - CAB CLIMATE CONTROL
A21253 Figure 47
A21254 Figure 48
A21255 Figure 49
50-30
SECTION 50 - CAB CLIMATE CONTROL
A21256 Figure 50
A21257 Figure 51
A21258 Figure 52
50-31
SECTION 50 - CAB CLIMATE CONTROL
A21260 Figure 53
A21261 Figure 54
A21262 Figure 55
50-32
SECTION 50 - CAB CLIMATE CONTROL
A21263 Figure 56
A21265 Figure 57
A21264 Figure 58
50-33
SECTION 50 - CAB CLIMATE CONTROL
A21266 Figure 59
A21267 Figure 60
50-34
SECTION 50 - CAB CLIMATE CONTROL
2
7 8
3
4
1016L93 Figure 61
1. COMPRESSOR
2. COIL ASSEMBLY
3. PULLEY
4. BEARING
5. BEARING DUST COVER
6. FRONT PLATE
7. SHIM(S)
8. DUST COVER
MAGNETIC CLUTCH ASSEMBLY
50-35
SECTION 50 - CAB CLIMATE CONTROL
102L7 Figure 62
50-36
SECTION 50 - CAB CLIMATE CONTROL
A21266 Figure 63
A21264 Figure 64
A21265 Figure 65
50-37
SECTION 50 - CAB CLIMATE CONTROL
A21267 Figure 66
A21268 Figure 67
A21268 Figure 68
50-38
SECTION 50 - CAB CLIMATE CONTROL
A21260 Figure 69
A21259 Figure 70
A21269 Figure 71
50-39
SECTION 50 - CAB CLIMATE CONTROL
A21270 Figure 72
A21256 Figure 73
A21271 Figure 74
50-40
SECTION 50 - CAB CLIMATE CONTROL
A21272 Figure 75
14. Install the nut on the rotor shaft. Use the spanner
wrench and a torque wrench to tighten the nut to
a torque of 15 to 20 Nm (11 to 15 pound-feet).
A21253 Figure 76
T97256 Figure 77
50-41
SECTION 50 - CAB CLIMATE CONTROL
A21252 Figure 78
17. Install the six bolts that hold the dust cover to the
compressor. Tighten to 7 to 11 Nm (5 to 8
pound-feet).
A21251 Figure 79
50-42
SECTION 50 - CAB CLIMATE CONTROL
SH88084 Figure 80
50-43
SECTION 50 - CAB CLIMATE CONTROL
BS04E122_2 Figure 81
AIR CONDITIONING SYSTEM
1. CASE 9. RECEIVER DRYER
2. SCREWS 10. THERMOSTAT
3. AIR CONDITIONING LINE 11. WATER VALVE
4. AIR CONDITIONING LINE 12. AIR FILTER COVER
5. BLOWER 13. AIR FILTER
6. HEATER EVAPORATOR COIL 14. DRAIN PAN
7. SUCTION LINE 15. PRESSURE SWITCH
8. WIRE HARNESS 16. SCREWS
50-44
SECTION 50 - CAB CLIMATE CONTROL
50-45
SECTION 50 - CAB CLIMATE CONTROL
BD07F074 Figure 83
50-46
SECTION 50 - CAB CLIMATE CONTROL
BD07F074 Figure 84
BD07F073 Figure 85
50-47
SECTION 50 - CAB CLIMATE CONTROL
SH88084 Figure 86
19997753 Figure 87
50-48
SECTION 50 - CAB CLIMATE CONTROL
50-49
SECTION 50 - CAB CLIMATE CONTROL
NOTES
50-50
SECTION 50 - CAB CLIMATE CONTROL
INSTALLATION
1. Install the receiver/drier (9) and retaining bracket
into the case (1).
2. Remove the caps and plugs from the tubes and
fittings.
50-51
SECTION 50 - CAB CLIMATE CONTROL
BS04E122_1 Figure 88
AIR CONDITIONING SYSTEM
1. CASE 9. RECEIVER DRYER
2. SCREWS 10. THERMOSTAT
3. AIR CONDITIONING LINE 11. WATER VALVE
4. AIR CONDITIONING LINE 12. AIR FILTER COVER
5. BLOWER 13. AIR FILTER
6. HEATER EVAPORATOR COIL 14. DRAIN PAN
7. SUCTION LINE 15. PRESSURE SWITCH
8. WIRE HARNESS
50-52
SECTION 50 - CAB CLIMATE CONTROL
50-53
SECTION 50 - CAB CLIMATE CONTROL
BC04D002 Figure 89
Air Temperature (F) Entering the A/C Unit Inlet - Outlet Temperature (F) Differential Inlet - Outlet Temperature (F) Differential
(Fresh or Recirculated) (Low Humidity) (High Humidity)
50 10 10
60 15 10
70 20 15
80 25 20
90 30 25
100 30 25
110 35 30
50-54
SECTION 50 - CAB CLIMATE CONTROL
Ambient Air Temperature (F) Entering Suction Pressure (PSIG) at Discharge Pressure (PSIG) at
Condenser Evaporator Outlet Compressor Outlet
50 5-15 75-125
60 5-15 100-150
70 10-20 125-175
80 10-20 150-225
90 15-25 175-250
100 15-25 200-275
110 15-30 225-350
WARNING
When refrigerant comes in contact with an open
flame, it forms phosgene gas. Never breath these
fumes.
SM109A
50-55
SECTION 50 - CAB CLIMATE CONTROL
Operation Troubleshooting
Compressor clutch does not engage If there is power to the Compressor Clutch, replace the clutch
High and Low Pressure and Temperature The combination High and Low Pressure switch is located at the evapo-
Switch rator and the and Temperature switch is located at the receiver/drier
Blower Fuse Check for damaged blower fuse
Check switch operation. Switch must give four different blower speeds:
OFF, Low, Medium, and High
Blower Fan Switch Check for loose connections or broken wires.
Repair or replace as required.
Check resistor board.
Check wiring to the blower motor.
Repair or replace as required.
Blower Motor Check motor ground wire.
Make sure motor ground wire is making good contact with mounting
bracket.
Turn the switch to the A/C position.
Compressor clutch must engage.
Air Conditioning Switch Blower must be operating, since electrical power to temperature control
switch is received from the blower switch.
50-56
SECTION 50 - CAB CLIMATE CONTROL
Operation Troubleshooting
Loose or broken drive belt. Replace as required.
Adjust the tension on a new belt at 200 to 245 N (45 to 55 pounds)
Compressor Belt Too much belt wear. Replace worn belt. Worn belt will cause too much
slippage.
Loose mounting bracket bolts.
Tighten mounting bolts to the correct torque.
Mounting Brackets Bracket is broken or cracked.
Replace the bracket
Compressor will slip on the compressor pulley if there is compressor sie-
Compressor Belt Slips zure. Repair or replace the compressor.
Remove the dust cover and check the air gap on the compressor clutch.
The gap between the front plate and the pulley assembly must be 0.41
Compressor Clutch does not Engage to 0.79 mm (0.016 to 0.031 inches).
Use a socket wrench to rotate the compressor. Compressor rotation
should be smooth and not require much effort.
50-57
SECTION 50 - CAB CLIMATE CONTROL
NOTES
50-58
SECTION 55 - ELECTRICAL SYSTEM
Contents
Section Description Page
55 000 General Electrical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55- 4
Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-5
Adapting Attachments Requiring 12V Electrical Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-8
Wire Identification and Circuit Diagram Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-12
Electrical Diagram - Starting System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-13
Electrical Diagram - Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-14
Electrical Diagram -Safety Interlock and Fuel Supply System . . . . . . . . . . . . . . . . . . . . . 55-15
Electrical Diagram - Instrument Cluster Monitoring System . . . . . . . . . . . . . . . . . . . . . . . 55-16
Electrical Diagram - Standard Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-17
Electrical Diagram - Loader Arm Auxiliary Electrical Control Box (Optional). . . . . . . . . . . 55-18
Electrical Diagram - Loader Arm Auxiliary Electric Power Controls (Optional) . . . . . . . . . 55-19
Electrical Diagram - Flasher and Turn Signals North America Electrical . . . . . . . . . . . . . 55-20
Electrical Diagram - Main Electrical European On-Road Regulations. . . . . . . . . . . . . . . . 55-21
Electrical Diagram - Boom/Rear Electrical European On-Road Regulations . . . . . . . . . . 55-22
Electrical Diagram - Right-Hand Handle (Option) Electrical Multifunction Adaptation. . . . 55-23
Electrical Diagram - Left-Hand Handle (Options) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-24
Electrical Diagram - Right-Hand Handle (Options) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-25
Electrical Diagram - Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-26
Electrical Diagram - Rotating Beacon (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-27
Electrical Diagram - Two Speed (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-28
Electrical Diagram - Horn (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-29
Electrical Diagram - Accessory Outlet (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-30
Electrical Diagram - Back-up Alarm (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-31
Electrical Diagram - Wiper/Washer (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-32
Electrical Diagram - Auxiliary Hydraulics (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-33
Electrical Diagram - High Flow (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-34
Electrical Diagram - Hydraulic Coupler (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-35
Electrical Diagram - Heating and Air Conditioning (Optional) . . . . . . . . . . . . . . . . . . . . . . 55-36
Electrical Diagram - Pilot Hydraulic Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-37
Electrical Diagram - Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-38
Electrical Diagram - Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-39
Wire Identification and Circuit Diagram Legend (Cab Upgrade Machines) . . . . . . . . . . . . 55-40
Electrical Diagram - Starting System (Cab Upgrade Machines) . . . . . . . . . . . . . . . . . . . . 55-41
Electrical Diagram - Power Distribution (Cab Upgrade Machines) . . . . . . . . . . . . . . . . . . 55-42
Electrical Diagram -Safety Interlock and Fuel Supply System (Cab Upgrade Machines) . 55-43
Electrical Diagram - Instrument Cluster Monitoring System (Cab Upgrade Machines) . . . 55-44
Electrical Diagram - Standard Lamps (Cab Upgrade Machines). . . . . . . . . . . . . . . . . . . . 55-45
Electrical Diagram - Loader Arm Auxiliary Electrical Control Box (Optional)
(Cab Upgrade Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-46
Electrical Diagram - Loader Arm Auxiliary Electric Power Controls (Optional)
(Cab Upgrade Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-47
55-1
SECTION 55 - ELECTRICAL SYSTEM
Electrical Diagram - Flasher and Turn Signals North America Electrical
(Cab Upgrade Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-48
Electrical Diagram - Main Electrical European On-Road Regulations
(Cab Upgrade Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-49
Electrical Diagram - Boom/Rear Electrical European On-Road Regulations
(Cab Upgrade Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-50
Electrical Diagram - Work Lamps (Cab Upgrade Machines). . . . . . . . . . . . . . . . . . . . . . . 55-51
Electrical Diagram - Control Lever Interface (Cab Upgrade Machines) . . . . . . . . . . . . . . 55-52
Electrical Diagram - Left-Hand Handle (Options) (Cab Upgrade Machines) . . . . . . . . . . . 55-53
Electrical Diagram - Right-Hand Handle (Options) (Cab Upgrade Machines). . . . . . . . . . 55-54
Electrical Diagram - Grid Heater System (Cab Upgrade Machines) . . . . . . . . . . . . . . . . . 55-55
Electrical Diagram - Rotating Beacon (Optional) (Cab Upgrade Machines) . . . . . . . . . . . 55-56
Electrical Diagram - Two Speed (Optional) (Cab Upgrade Machines) . . . . . . . . . . . . . . . 55-57
Electrical Diagram - Horn (Optional) (Cab Upgrade Machines) . . . . . . . . . . . . . . . . . . . . 55-58
Electrical Diagram - Accessory Outlet (Optional) (Cab Upgrade Machines) . . . . . . . . . . . 55-59
Electrical Diagram - Back-up Alarm (Optional) (Cab Upgrade Machines). . . . . . . . . . . . . 55-60
Electrical Diagram - Wiper/Washer/Door Switch (Optional) (Cab Upgrade Machines) . . . 55-61
Electrical Diagram - Auxiliary Hydraulics (Optional) (Cab Upgrade Machines) . . . . . . . . . 55-62
Electrical Diagram - High Flow (Optional) (Cab Upgrade Machines) . . . . . . . . . . . . . . . . 55-63
Electrical Diagram - Hydraulic Mount Plate (Optional) (Cab Upgrade Machines) . . . . . . . 55-64
Electrical Diagram - Heating and Air Conditioning (Optional) (Cab Upgrade Machines) . 55-65
Electrical Diagram - Pilot Hydraulic Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-66
Electrical Diagram - Ground Connections (Cab Upgrade Machines) . . . . . . . . . . . . . . . . 55-67
Electronic Instrument Cluster (EIC) Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-68
Electronic Instrument Cluster (EIC) Panel (Cab Upgrade Machines) . . . . . . . . . . . . . . . . 55-69
Electronic Instrument Cluster Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-70
Electronic Instrument Cluster Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-73
Advanced Instrument Cluster (AIC) Panel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-77
Advanced Instrument Cluster (AIC) Panel (Optional) (Cab Upgrade Machines). . . . . . . . 55-78
Advanced Instrument Cluster Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-79
Advanced Instrument Cluster Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-86
55 100 Removal, Installation and Wiring of Electrical Components . . . . . . . . . . . . . . . . . . . . . . . 55-90
55 301 40 Battery Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-91
Cab Fuse Block and Panel Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-92
55 201 15 Seat Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-93
Seat Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-94
55 201 14 Seat Belt Buckle and Switch Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . 55-94
55 404 20 Road Light and Work Light Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 55-95
Engine Fuse and Relay Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-96
55 100 34 Start Interlock Relay Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-97
Engine Fuse Block Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-98
55 100 34 Preheat Relay Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-99
55 201 76 Preheat Glow Plug Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-100
Fuel System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-101
Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-102
10 210 21 Electric Fuel Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-104
55-2
SECTION 55 - ELECTRICAL SYSTEM
10 223 Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-104
Fuel Shutoff Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-104
10 223 10 Replacement of Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-105
55 414 14 Air Filter Restriction Indicator Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . 55-106
55 414 10 Engine Coolant Temperature Sender Removal and Installation . . . . . . . . . . . . . . . . . . . 55-106
55 414 12 Engine Oil Pressure Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-107
55 414 28 Hydrostatic Charge Pressure Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . 55-107
55 414 24 Hydraulic Oil Filter Restriction Switch Removal and Installation . . . . . . . . . . . . . . . . . . . 55-108
55 414 20 Hydraulic Oil Temperature Sender Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-108
Hydraulic Oil Temperature Sender Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-109
35 724 90 Boom/Bucket Control Valve Spool Lock Solenoid Removal and Installation . . . . . . . . . . 55-110
55 404 Road/Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-111
55 301 Alternator (55 Amp Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-114
Alternator Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-116
Alternator - System Testing and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-117
Initial Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-120
55 301 10 Alternator Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-125
55 301 12 Alternator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-126
Alternator Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-132
55 201 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-133
Starter Motor Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-134
55 201 50 Starter Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-135
Starter Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-140
Starter Motor Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-144
Starter Motor Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-150
Starter Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-153
Miscellaneous Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-154
Glow Plugs and Glow Plug Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-154
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-155
Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-155
Labor Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-156
55-3
SECTION 55 - ELECTRICAL SYSTEM
Op. 55 000
GENERAL ELECTRICAL INFORMATION
The electrical system is a 12-volt negative (–) ground 6. Fuse blocks/ fuses/ circuit breakers, cab and
system that provides battery voltage to the Electronic engine - Used to protect the electrical circuits and
Instrument Cluster (EIC), starting circuit, and other manifold heater circuit.
electrical components.
7. Manifold Heater (Thermo-Start) - Used to
The electrical system is made up of the following provide aid in cold engine starting.
components (with their functions):
8. Fuel solenoid - Controls fuel flow and is
controlled by the EIC.
1. Battery - Power supply and storage.
9. Switches - Used to control other electrical
2. Alternator/Regulator - Power supply and source
circuits, lights, etc.
to maintain fully charged system.
IMPORTANT: Do not connect any electrical circuits
3. Starter motor - To crank engine for starting.
at the ignition key switch or cab fuse block(s) unless
4. Ignition switch - Used to control electrical circuits there are written instructions telling you to do so or
and direction of battery voltage. damage to the EIC board may occur.
* Controls engine fuel system (fuel shut off). IMPORTANT: If the EIC requires removal from the
dash area or the skid steer, disconnect the negative
* Provides engine shutdown if fault occurs in (–) ground battery cable. This will shut off power to
engine oil pressure or hydrostatic charge the EIC and prevent damage to the EIC board, or
pressure circuits. prevent blowing the 5-amp fuses, if the board is
accidentally grounded.
* Provides safety interlock for the boom and
bucket control valve spools.
55-4
SECTION 55 - ELECTRICAL SYSTEM
DEFINITION OF TERMS
ALTERNATING CURRENT (A.C.) - A flow of OHM - The standard unit for measuring resistance to
electrons which reverses its direction of flow at flow of an electrical current.
regular intervals in a conductor.
OHMMETER - An instrument for measuring the
AMMETER - Measures the flow of electrical current resistance in ohms of an electrical circuit.
in amperes. Ammeters are connected in series with
the circuit to be tested. OPEN CIRCUIT - An open circuit occurs when a
circuit is broken which interrupts the flow of current
AMPERE - A unit of measure for the flow of current through the circuit.
in a circuit. The ampere is used to measure electricity
such as “gallons per minute” is used to measure RELAY - An electrical switch which opens and closes
liquid flow. a circuit automatically when activated.
CIRCUIT - A continuous, unbroken path along a RESISTANCE - The opposing force offered by a
conductor through which electrical current can flow circuit. Resistance is measured in ohms.
from a source, through various components, and
back to the source. SHORT CIRCUIT - A part of a circuit that comes in
contact with part of the same circuit or unintentionally
CIRCUIT BREAKER - A device to protect an touches a metallic object.
electrical circuit from overloads and can be reset, or
will automatically reset. SOLENOID - A circular coil used for producing a
magnetic field.
COLD CRANK RATING (CCA) - The cranking load
capacity of a battery at low temperatures (cold SWITCHES - A device used to control and direct
cranking amperes at 0° F). current to circuits and will remain in this position until
changed.
CONTINUITY - Unbroken path along a conductor
through which electrical current can flow. SWITCHES (MOMENTARY) - Momentary switches
are used to direct current to circuits and these
CURRENT - Movement of electricity along a switches will return to the neutral position when
conductor. Current is measured in amperes. released.
DIODE - An electrical device that will allow current to VOLT - A unit of electrical pressure which caused
pass through itself in one direction only. current to flow in a circuit.
DIODE (RESISTOR TYPE) - An electrical device that VOLTAGE - The force which is generated to cause
will allow current to pass through itself in one current to flow in an electrical circuit. Voltage is
direction only and will cause resistance as the measured in volts.
electricity passes through. The electricity coming
from this type diode will be less than what is going in. VOLTMETER - An instrument for measuring the
force in volts of electrical current. Voltmeters are
DIRECT CURRENT (D.C.) - A flow of electrons connected in parallel to the points where voltage is to
moving in the same direction along a conductor from be measured.
a point of high potential to one of lower potential.
55-5
SECTION 55 - ELECTRICAL SYSTEM
The following are common terms used in electrical The following chart shows the abbreviations for the
diagnostics and how they may affect the circuit and various wire colors used to identify the electrical
electrical components. circuits.
55-6
SECTION 55 - ELECTRICAL SYSTEM
55-7
SECTION 55 - ELECTRICAL SYSTEM
SPECIFICATIONS
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 amp
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BCI PC31 - 12 volt - 625 amps @ –18 C (0° F) Top stud
Engine coolant temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.
55-8
SECTION 55 - ELECTRICAL SYSTEM
Hydraulic oil temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EIC will read “COLD” until 0° C (32° F)
EIC will fault at 99° C (210° F)
Hydraulic oil filter sensor (differential between in/out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch normally closed
EIC will fault at 2.7 ± 0.3 bar (40 ± 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)
55-9
SECTION 55 - ELECTRICAL SYSTEM
55-10
SECTION 55 - ELECTRICAL SYSTEM
ELECTRICAL DIAGRAM
55-11
SECTION 55 - ELECTRICAL SYSTEM
BS05E048
BS05E049
55-12
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-01A
1. BATTERY 5. STARTER RELAY
2. ALTERNATOR 6. RESISTOR
3. STARTER AND SOLENOID 7. IGNITION SWITCH
4. REVERSE POLARITY DIODE 8. RUN RELAY
55-13
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-02A
9. CAB FUSE BLOCK 11. REAR FUSE BLOCK NO. 2
10. REAR FUSE BLOCK NO. 1
55-14
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-03A
12. JUMPER WIRE 17. NOT USED
13. SEAT SWITCH 18. NOT USED
14. SEAT BELT SWITCH 19. NOT USED
15. NOT USED 20. NOT USED
16. INTERLOCK START RELAY 21. FUEL HOLD-IN SOLENOID
55-15
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-04A
22. FUEL PUMP (ISM ENGINE ONLY) 28. CHARGE PRESSURE SWITCH
23. FUEL SENDER 29. HYDRAULIC OIL TEMPERATURE SWITCH
24. ENGINE COOLANT TEMPERATURE SENDER 30. BRAKE RELEASE/TANDEM PUMP
25. ENGINE OIL PRESSURE SWITCH NEUTRAL OVERRIDE SWITCH
26. AIR FILTER RESTRICTION SWITCH 31. LOADER VALVE SOLENOID
27. HYDRAULIC FILTER PRESSURE SWITCH 32. LOADER VALVE SOLENOID
55-16
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-05A
33. LIGHT RELAY NO. 1 37. RIGHT FRONT WORK LIGHT
34. LIGHT RELAY NO. 2 38. REAR WORK LAMP
35. DIODE 39. LEFT REAR INDICATOR LIGHT
36. LEFT FRONT WORK LIGHT 40. RIGHT REAR INDICATOR LIGHT
55-17
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-06A
41. MOTOR CONTROL LEFT RELAY 43. WIPER MOTOR RELAY
42. MOTOR CONTROL RIGHT RELAY 44. FUSE (10 AMP)
55-18
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-07A
45. ATTACHMENT RELAY
55-19
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-08A
46. HAZARD / TURN RELAY 53. LEFT FRONT FLASHING LAMP
47. FLASHER MODULE 54. LEFT REAR FLASHING LAMP
48. DIODE (6 AMP) 55. TURN INDICATOR LAMP (LEFT)
49. TURN SIGNAL CONVERTER MODULE 56. TURN INDICATOR LAMP (RIGHT)
50. BEACON 57. RIGHT FRONT FLASHING LAMP
51. FUSE 58. RIGHT REAR FLASHING LAMP
52. HAZARD / BEACON SWITCH
55-20
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-09A
59. ROAD LIGHT SWITCH (EURO) 64. BEACON (EURO)
60. FLASHER MODULE (EURO) 65. BRAKE LAMP SWITCH (EURO)
61. CAB FUSE BLOCK (EURO) 66. BRAKE LAMP SWITCH (EURO)
62. DIODE (6 AMP) 67. TURN INDICATOR LAMP (LEFT) (EURO)
63. HAZARD / BEACON SWITCH (EURO) 68. TURN INDICATOR LAMP (RIGHT) (EURO)
55-21
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-10A
69. OPTIONAL RIGHT TURN L;AMP (EURO) 77. RIGHT REAR TURN LAMP (EURO)
70. OPTIONAL LEFT TURN L;AMP (EURO) 78. RIGHT REAR BRAKE LAMP (EURO)
71. RIGHT FRONT TURN LAMP (EURO) 79. RIGHT REAR POSITION LAMP (EURO)
72. RIGHT FRONT POSITION LAMP (EURO) 80. LICENSE PLATE LIGHT
73. RIGHT FRONT ROAD LAMP (EURO) 81. LEFT REAR POSITION LAMP (EURO)
74. LEFT FRONT POSITION LAMP (EURO) 82. LEFT REAR BRAKE LAMP (EURO)
75. LEFT TURN LAMP (EURO) 83. LEFT REAR TURN LAMP (EURO)
76. LEFT FRONT ROAD LAMP (EURO)
55-22
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-11A
55-23
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-12A
84. HORN SWITCH 88. FRONT ELECTRIC CONTROL SWITCH NO. 2
85. TURN SIGNAL SWITCH 89. FRONT ELECTRIC CONTROL SWITCH NO. 3
86. AUXILIARY HYDRAULIC SWITCH 90. FRONT ELECTRIC CONTROL SWITCH NO. 4
87. FRONT ELECTRIC CONTROL SWITCH NO. 1
55-24
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-13A
84. HORN SWITCH 86. AUXILIARY HYDRAULIC SWITCH
85. TURN SIGNAL SWITCH 91. TWO- SPEED SWITCH
55-25
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-14A
92. PRE-HEATER RELAY 93. GLOW PLUGS
(3 CYLINDER ENGINE = 3)
(4 CYLINDER ENGINE = 4
55-26
SECTION 55 - ELECTRICAL SYSTEM
)
BC06M392-15A
94. FUSE (7.5 AMP) 50. BEACON
95. BEACON SWITCH
55-27
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-16A
96. TWO-SPEED SOLENOID
55-28
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-17A
97. HORN (OPTIONAL)
55-29
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-18A
55-30
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-19A
98. BACK-UP ALARM SWITCH (LEFT) (OPTIONAL) 100.BACK-UP ALARM (OPTIONAL)
99. BACK-UP ALARM SWITCH (RIGHT) (OPTIONAL)
55-31
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-20A
101.WIPER/WASHER SWITCH (OPTIONAL) 103.WIPER MOTOR
102.WASHER PUMP
55-32
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-21A
104.SECOND AUXILIARY HYDRAULIC SOLENOID NO. 1 105.SECOND AUXILIARY HYDRAULIC SOLENOID NO. 2
55-33
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-22A
106.HIGH FLOW SWITCH (OPTIONAL) 107.HIGH FLOW SOLENOID (OPTIONAL)
55-34
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-23A
108.FUSE 110.HYDRAULIC COUPLER RELEASE SOLENOID (OPTIONAL)
109.HYDRAULIC COUPLER SWITCH (OPTIONAL) 111.HYDRAULIC COUPLER ENGAGE SOLENOID (OPTIONAL)
55-35
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-24A
112.HEATER/AIR CONDITIONER RELAY (OPTIONAL) 116.COMPRESSOR CLUTCH
113.BLOWER SWITCH (OPTIONAL) 117.PRESSURE SWITCH
114.AIR CONDITIONER SWITCH (OPTIONAL) 118.THERMOSTAT
115.HEATER CONTROL SWITCH (OPTIONAL) 119.BLOWER MOTOR
55-36
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-25A
120.LOADER CONTROL PRESSURE SOLENOID 122.GROUND DRIVE CONTROL PRESSURE SOLENOID
121.MAGNETIC DETENT SOLENOID 123.BRAKE VALVE SOLENOID
55-37
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-26A
55-38
SECTION 55 - ELECTRICAL SYSTEM
BC06M392-27A
55-39
SECTION 55 - ELECTRICAL SYSTEM
BC07E519-00A
55-40
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-01A
1. BATTERY 5. STARTER RELAY
2. ALTERNATOR 6. RESISTOR
3. STARTER AND SOLENOID 7. IGNITION SWITCH
4. REVERSE POLARITY DIODE
55-41
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-02A
8. ELECTRICAL ACCESSORY (RUN RELAY) 11. LAMP RELAY NO. 1
9. HVAC RELAY 11. LAMP RELAY NO. 2
10. STARTER RELAY
55-42
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-03A
12. AUXILIARY OVERRIDE SWITCH 17. NOT USED
13. SEAT SWITCH 18. NOT USED
14. SEAT BELT SWITCH 19. COLD START ADVANCE TEMPERATURE SENDER
15. NOT USED 20. COLD START ADVANCE SOLENOID
16. NOT USED 21. FUEL HOLD-IN SOLENOID
55-43
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-04A
22. FUEL PUMP (ISM ENGINE ONLY) 28. CHARGE PRESSURE SWITCH
23. FUEL SENDER 29. HYDRAULIC OIL TEMPERATURE SENDER
24. ENGINE COOLANT TEMPERATURE SENDER 30. BRAKE RELEASE/TANDEM PUMP
25. ENGINE OIL PRESSURE SWITCH NEUTRAL OVERRIDE SWITCH
26. AIR FILTER RESTRICTION SWITCH 31. LOADER VALVE SOLENOID
27. HYDRAULIC FILTER PRESSURE SWITCH 32. LOADER VALVE SOLENOID
55-44
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-05A
33. NOT USED 37. RIGHT FRONT WORK LIGHT
34. NOT USED 38. REAR WORK LAMP
35. DIODE 39. LEFT REAR INDICATOR LIGHT
36. LEFT FRONT WORK LIGHT 40. RIGHT REAR INDICATOR LIGHT
55-45
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-06A
41. MOTOR CONTROL LEFT RELAY 43. WIPER MOTOR RELAY
42. MOTOR CONTROL RIGHT RELAY 44. FUSE (10 AMP)
55-46
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-07A
45. ATTACHMENT RELAY
55-47
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-08A
46. HAZARD / TURN RELAY 53. LEFT FRONT FLASHING LAMP
47. FLASHER MODULE 54. LEFT REAR FLASHING LAMP
48. DIODE (6 AMP) 55. TURN INDICATOR LAMP (LEFT)
49. TURN SIGNAL CONVERTER MODULE 56. TURN INDICATOR LAMP (RIGHT)
50. BEACON 57. RIGHT FRONT FLASHING LAMP
51. FUSE 58. RIGHT REAR FLASHING LAMP
52. HAZARD / BEACON SWITCH
55-48
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-09A
59. ROAD LIGHT SWITCH (EURO) 65. BRAKE LAMP SWITCH (EURO)
60. FLASHER MODULE (EURO) 66. BRAKE LAMP SWITCH (EURO)
61. CAB FUSE BLOCK (EURO) 67. TURN INDICATOR LAMP (LEFT) (EURO)
62. DIODE (6 AMP) 68. TURN INDICATOR LAMP (RIGHT) (EURO)
63. HAZARD / BEACON SWITCH (EURO) 69. NOT USED
64. BEACON (EURO) 70. NOT USED
55-49
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-10A
71. RIGHT TURN LAMP (EURO) 78. RIGHT REAR BRAKE LAMP (EURO)
72. RIGHT FRONT POSITION LAMP (EURO) 79. RIGHT REAR TURN LAMP (EURO)
73. RIGHT FRONT ROAD LAMP (EURO) 80. LICENSE PLATE LIGHT
74. LEFT FRONT POSITION LAMP (EURO) 81. LEFT REAR POSITION LAMP (EURO)
75. LEFT TURN LAMP (EURO) 82. LEFT REAR BRAKE LAMP (EURO)
76. LEFT FRONT ROAD LAMP (EURO) 83. LEFT REAR TURN LAMP (EURO)
77. RIGHT REAR POSITION LAMP (EURO)
55-50
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-11A
36. OPTIONAL RIGHT REAR WORK LAMP 39. STANDARD FRONT WORK LAMP
37. STANDARD RIGHT REAR WORK LAMP 40. OPTIONAL FRONT WORK LAMP
38. OPTIONAL LEFT REAR WORK LAMP
55-51
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-12A
55-52
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-13A
84. HORN SWITCH 86. TURN SIGNAL SWITCH
85. TWO- SPEED SWITCH 87. AUXILIARY HYDRAULIC SWITCH
55-53
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-14A
88. FRONT ELECTRIC SWITCH NO. 1 90. FRONT ELECTRIC SWITCH NO. 3
89. FRONT ELECTRIC SWITCH NO. 2 91. FRONT ELECTRIC SWITCH NO. 4
55-54
SECTION 55 - ELECTRICAL SYSTEM
)
BC07E492-15A
92. GRID HEATER RELAY 93. GRID HEATER
55-55
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-16A
50. BEACON 95. BEACON SWITCH
94. FUSE (7.5 AMP)
55-56
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-17A
96. 2 SPEED SOLENOID
55-57
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-18A
97. HORN
55-58
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-19A
55-59
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-20A
98. BACK-UP ALARM SWITCH 100.BACK-UP ALARM
99. BACK-UP ALARM SWITCH
55-60
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-21A
101.WASHER PUMP
55-61
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-22A
102.SECOND AUXILIARY HYDRAULICS-SOLENOID NO. 1 103.SECOND AUXILIARY HYDRAULICS-SOLENOID NO. 2
55-62
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-23A
104.HIGH FLOW SWITCH (OPTIONAL) 105.HIGH FLOW SWITCH SOLENOID (OPTIONAL)
55-63
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-24A
106.HYDRAULIC MOUNT PLATE SWITCH (OPTIONAL) 108.HYDRAULIC MOUNT PLATE ENGAGE SOLENOID
107.HYDRAULIC MOUNT PLATE RELEASE SOLENOID (OPTIONAL)
(OPTIONAL)
55-64
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-25A
109.BLOWER SWITCH (OPTIONAL) 113.PRESSURE SWITCH
110.AIR CONDITIONER SWITCH (OPTIONAL) 114.THERMOSTAT
111.HEATER CONTROL SWITCH (OPTIONAL) 115.BLOWER MOTOR
112.COMPRESSOR CLUTCH
55-65
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-26A
116.LOADER CONTROL PRESSURE SOLENOID 118.GROUND DRIVE CONTROL PRESSURE SOLENOID
117.MAGNETIC DETENT SOLENOID 119.BRAKE VALVE SOLENOID
55-66
SECTION 55 - ELECTRICAL SYSTEM
BC07E492-27A
55-67
SECTION 55 - ELECTRICAL SYSTEM
BD04H059
1. SWITCH PANEL 2. KEY SWITCH
INSTRUMENT CONSOLE
BD04E088
ELECTRONIC INSTRUMENT CLUSTER
1. SEAT BELT INDICATOR LAMP 9. PARK BRAKE ON/OFF SWITCH
2. ENGINE OIL PRESSURE INDICATOR LAMP 10. HYDRAULIC OIL FILTER WARNING LAMP
3. PARK BRAKE INDICATOR LAMP 11. COOLANT TEMPERATURE WARNING LAMP AND ALARM
4. HOURMETER 12. ENGINE AIR FILTER WARNING LAMP
5. FUEL GUAGE 13. ENGINE GRID HEATER LAMP (IF EQUIPPED)
6. WORK LAMP SWITCH 14. CHARGE PRESSURE WARNING LAMP
7. AUXILIARY HYDRAULIC INTERLOCK OVERRIDE SWITCH 15. HYDRAULIC OIL TEMPERATURE WARNING LAMP
8. ROAD LAMP SWITCH
55-68
SECTION 55 - ELECTRICAL SYSTEM
1
14
2
15
11
10
12
3
13
4 5
6
8
9
7
BD07C137
ELECTRONIC INSTRUMENT CLUSTER
1. SEAT BELT INDICATOR LAMP 9. PARK BRAKE / SYSTEM ENABLE ON/OFF SWITCH
2. ENGINE OIL PRESSURE INDICATOR LAMP 10. HYDRAULIC OIL FILTER WARNING LAMP
3. PARK BRAKE INDICATOR LAMP 11. COOLANT TEMPERATURE WARNING LAMP AND ALARM
4. HOURMETER 12. ENGINE AIR FILTER WARNING LAMP
5. FUEL GUAGE 13. ENGINE PRE-HEATING LAMP (IF EQUIPPED)
6. WORK LAMP SWITCH 14. CHARGE PRESSURE WARNING LAMP
7. AUXILIARY HYDRAULIC INTERLOCK OVERRIDE SWITCH 15. HYDRAULIC OIL TEMPERATURE WARNING LAMP
8. ROAD LAMP SWITCH
55-69
SECTION 55 - ELECTRICAL SYSTEM
55-70
SECTION 55 - ELECTRICAL SYSTEM
Auxiliary hydraulic override – if pressed, the light next to the switch will turn on for thirty seconds. Within that
period of time, an operator may leave the seat without interruption to attachment hydraulic flow. This feature is
turned off or reset while the operator is in the seat and (1) the operator again pushes the button during the thirty
seconds (2) automatically after thirty seconds or (3) leaves to operate the attachment and then sits back down in
the seat at some later time. When the operator returns to the seat after using an implement for an extended period
of time, the brake button must be pushed again to enable the loader hydraulic system and turn off the brake. The
override feature is primarily used to support attachments such as a backhoe or other out-of-cab operated
implements.
Restraint System: The New Holland version of the EIC contain logic to ensure operator safety. The EIC
continually monitors the seat switch, seat belt switch (NH). If, during operation, any of these restraint devices
indicates to the EIC that the operator has left the seat or is about to leave the seat, the EIC will inhibit hydraulic flow
to the boom and bucket and will set the brake. Additionally, if the operator has not pressed the auxiliary hydraulic
override push button, flow will be halted to attachments via hydraulic solenoid interlock or automatic engine shut
down provided that the auxiliary control is displaced from neutral.
To prevent annoying attachment flow interruption and hydraulic brake activation due to operator-induced seat
switch bounce, the NH brand implements a short seat switch time delay prior to halting auxiliary flow.
The New Holland brand logic requires that the seat belt must be unfastened prior to operation at power on. The
New Holland brand also requires that the seat belt be unbuckled then buckled if the operator is out of the seat for
more than two seconds.
The EIC will power up when an operator sits in the seat. This enables viewing of fuel level and engine hours
without use of the ignition key. If the operator is in the seat for more than thirty seconds and the ignition key is not
turned on, the EIC will turn itself off.
EIC Special Functions (Setup Menu):
Special machine setup features are available via the operator push button selector area. The EIC will display the
word “SETUP” as a first menu item visual “anchor” message.
The choices available are (1) select engine type (for correct cold engine preheat profile) (2) select brake type:
hydraulic, none or manual (NH only) (3) display EIC software revision level and (5) modify engine hours (coded
entry required).
Push Button Definitions:
Any button: Any button may be depressed and held for six seconds to enter the setup mode. The seat must be
unoccupied and the ignition key off during this time, but the operator may sit in the seat after the setup mode is
entered.
Parking brake: Provides for editing the values that a setup menu item (engine type, brake type, engine hours) can
have. When a value has been changed, this button is also used to save the value in memory. Verification of the
saved value is automatic. The display will blank and go dark. Then, after a short delay time, the value will be
retrieved from memory and shown again in the display. After this visual verification, the word “SETUP” will again
appear in the display.
Road light: Used to view in succession all of the values that an item can have. When changing engine hours, this
button increments a flashing digit value in a circular manner from 0 – 9.
Work light: Used to navigate to the next menu item. When changing engine hours, this button causes the flashing
emphasis to move to the next digit to the right.
Auxiliary override: This button functions as an unconditional setup exit without save from any location in the
menu. When this button is pushed, the EIC will turn off. If the operator is in the seat, the EIC will immediately power
up normally. None of any changed information will be saved unless that information was first saved using the
parking brake button and then verified.
To Exit the Setup Menu: (1) Leave the loader. After three seconds the EIC will automatically power down, (2)
place the ignition key in either the ACC or the ON position or (3) push and release the auxiliary override button.
55-71
SECTION 55 - ELECTRICAL SYSTEM
Special Feature Choices: (1) display/select engine type, (2) display/change brake type and (3) display/change
engine hours are the only values that may be modified
NOTE: For the following three descriptions, it is assumed that the operator has already placed the instrument
cluster in the SETUP mode and is sitting in the seat. The word “SETUP” appears in the text display.
Detailed Description of Setup Items:
Selecting an Engine Preheat Profile: To select an engine preheat profile (item 1), press and release the work
light push button one time. The word “ENGIN” will be displayed. Then, push and release the park brake push
button. The engine type “NH” (for NH brand) or “ISM” will be displayed depending on the profile currently stored in
the EIC. Push and release the road light push button to switch between the engine types. When the desired engine
type is displayed, push and release the park brake push button to store the new selection. After visual verification,
the word “SETUP” will again appear in the display.
Changing Brake Type: To select a brake type (item 2), press and release the work light push button two times.
The word “BRAKE” will be displayed. Then, push and release the park brake push button. The brake type “HYDRL”
(for hydraulic) “NOBRK” (for no brake – to adjust drive neutral) or “MANUL” (for manual) will be displayed
depending on the type currently stored in the EIC. Push and release the road light push button to switch between
the brake types. When the desired type is displayed, push and release the park brake push button to store the new
selection. After visual verification, the word “SETUP” will again appear in the display.
NOTE: You must contact your CNH Technical Services Advisor to obtain the UNLOCK CODE before the
Engine Hourmeter can be changed.
Changing Engine Hours: To change engine hours (item 4), press and release the work light push button four
times until the word “HOUR” is displayed. Then, push and release the park brake push button. The word
“UNLOCK” will be displayed for two seconds to prompt that an unlocking code must be entered to change engine
hours. After the two second delay, the display will prompt for the entry of a four-digit code. The leftmost digit after
the prompt “>” will flash, indicating a digit that can be changed. Using the road light push button to change the digit
value and the work light push button to select the next digit, enter the unlocking code. Push and release the park
brake push button to accept this unlocking code. Currently stored engine hour value will be retrieved and displayed
and the leftmost digit will flash. Using the same technique outlined above, enter the desired engine hour value.
Push and release the park brake push button to store the new engine hour value. After visual verification, the word
“SETUP” will again appear in the display.
Exit the Setup Menu using one of the three methods described above.
55-72
SECTION 55 - ELECTRICAL SYSTEM
TROUBLESHOOTING
55-73
SECTION 55 - ELECTRICAL SYSTEM
55-74
SECTION 55 - ELECTRICAL SYSTEM
55-75
SECTION 55 - ELECTRICAL SYSTEM
Replace EIC.
EIC will not read monitored circuits. Incorrect engine configuration. Correct engine configuration.
Open or short in wire from sensor Repair open/short.
to EIC.
Faulty sender or sensor. Repair/replace sender or sensor.
55-76
SECTION 55 - ELECTRICAL SYSTEM
5 6 7 8 10
15 16 17 18 19
20 20
11
1 2 3 4 12 13 14 9
BD05M014
ADVANCED INSTRUMENT CLUSTER (AIC) (OPTIONAL)
1. SEAT BELT INDICATOR LAMP 13. ENGINE COOLANT TEMPERATURE BAR GRAPH DISPLAY
2. ENGINE OIL PRESSURE WARNING LAMP 14. FUEL GUAGE BAR GRAPH DISPLAY
3. ENGINE AIR FILTER WARNING LAMP 15. TEXT DISPLAY
4. ENGINE GRID HEATER LAMP (IF EQUIPPED) (DISPLAYS THE FOLLOWING PARAMETERS) -
5. CHARGE PRESSURE WARNING LAMP 16. ENGINE HOURMETER -
6. HYDRAULIC OIL FILTER WARNING LAMP 17. ENGINE RPM -
7. PARKING BRAKE INDICATOR LAMP 18. ENGINE COOLANT TEMPERATURE
8. WORK LAMP SWITCH (DISPLAYS TEMPERATURE IN DEGREES CELSIUS OR
9. ROAD LAMP SWITCH DEGREES FAHRENHEIT) -
10. SYSTEM ENABLE SWITCH 19. HYDRAULIC OIL TEMPERATURE
(DISPLAYS TEMPERATURE IN DEGREES CELSIUS OR
11. AUXILIARY HYDRAULIC OVERRIDE SWITCH
DEGREES FAHRENHEIT)
12. HYDRAULIC OIL TEMPERATURE BAR GRAPH DISPLAY
20. LED INDICATOR LAMP
1 2
BD05M014
ADVANCED INSTRUMENT CLUSTER (AIC) (OPTIONAL)
1. DISPLAY AREA 2. SWITCH PANEL AREA
55-77
SECTION 55 - ELECTRICAL SYSTEM
1
2 5
6
3
4 7
15 16 17 18 19
14
12
8
13
10
9
11
BD07C016
ADVANCED INSTRUMENT CLUSTER (AIC) (OPTIONAL)
1. SEAT BELT INDICATOR LAMP 13. ENGINE COOLANT TEMPERATURE BAR GRAPH DISPLAY
2. ENGINE OIL PRESSURE WARNING LAMP 14. FUEL GUAGE BAR GRAPH DISPLAY
3. ENGINE AIR FILTER WARNING LAMP 15. TEXT DISPLAY
4. ENGINE PRE-HEATER LAMP (IF EQUIPPED) (DISPLAYS THE FOLLOWING PARAMETERS) -
5. CHARGE PRESSURE WARNING LAMP 16. ENGINE HOURMETER -
6. HYDRAULIC OIL FILTER WARNING LAMP 17. ENGINE RPM -
7. PARKING BRAKE INDICATOR LAMP 18. ENGINE COOLANT TEMPERATURE
8. WORK LAMP SWITCH (DISPLAYS TEMPERATURE IN DEGREES CELSIUS OR
9. ROAD LAMP SWITCH DEGREES FAHRENHEIT) -
10. PARK BRAKE / SYSTEM ENABLE SWITCH 19. HYDRAULIC OIL TEMPERATURE
11. AUXILIARY HYDRAULIC OVERRIDE SWITCH (DISPLAYS TEMPERATURE IN DEGREES CELSIUS OR
DEGREES FAHRENHEIT)
12. HYDRAULIC OIL TEMPERATURE BAR GRAPH DISPLAY
55-78
SECTION 55 - ELECTRICAL SYSTEM
55-79
SECTION 55 - ELECTRICAL SYSTEM
2. Engine Oil Pressure:
This switched input is driven by a sensor which is normally open. This switch will close if during normal
operation the engine oil pressure drops. The AIC response to this fault is debounced to prevent erroneous
occurrences; the fault must appear for 2.5 seconds before a warning is triggered. The operator is warned of
low engine oil pressure by a flashing red backlit visual indicator and a beeping audible. Low engine oil pressure
will also cause the AIC to shut down the engine. If engine oil pressure is lost, power will be removed from the
fuel solenoid after thirty seconds. During that time a 30 second countdown will appear in the LCD text display.
After the AIC shuts down the engine the operator my restart the unit any number of times. As long as the
engine oil pressure is low, each time the engine is started the thirty second timer will countdown until the
instrument cluster automatically shuts the engine off again. The ability to restart the engine for short periods of
time will allow an operator to move a unit to a location more suitable for service. Each occurrence will
increment the tally for this fault in the fault history in the SETUP menu.
3. Engine Air Filter:
This switched input is driven by a sensor which is normally open. The switch will close during normal operation
if the pressure differential across the air filter is too high, indicating the filter is clogged. The AIC response to
this fault is delayed by a debounce time of 1.5 seconds to prevent erroneous warnings. The operator is warned
of a clogged engine air filter by a flashing yellow backlit indicator and a beeping audible alarm. Each
occurrence will increment the tally for this fault in the fault history in the SETUP menu.
4. Engine Preheat:
When active (output voltage high), this output applies power to a grid heat relay to help start the loader in cold
weather. This feature heats the engine for a time inversely proportional to the temperature of the engine
coolant. Preheat is activated when the ignition key is turned from OFF to RUN. If preheat is needed the yellow
backlit indicator will light continuously until preheat is finished. In addition, a countdown will be displayed in the
LCD text window to indicate the amount of preheat remaining. If at any time the ignition key is turned to START
preheat will be cancelled. The amount of preheat depends not only on the temperature but also the type of
engine in the machine. The correct profile is selected manually in the SETUP menu during machine
production. Preheat thresholds are included at the end of this overview.
5. Hydraulic Charge Pressure:
This switched input is driven by a sensor which is normally open. The AIC response to this fault is debounced
to prevent erroneous occurrences; the fault must appear for 2.5 seconds before a warning is triggered. The
operator is warned of low hydraulic oil pressure by a flashing red backlit visual indicator and a beeping audible
alarm. Since low hydraulic charge pressure is likely to cause an independent application of the hydraulic brake,
then if the unit is equipped with a SAHR brake the red LED backlit ISO Park Brake symbol will also flash. Each
occurrence will increment the tally for this fault in the fault history in the SETUP menu.
6. Hydraulic Oil Filter:
This switched input is driven by a sensor which is normally open. The switch will close during normal operation
if the pressure differential across it is too high, indicating the filter is clogged. The AIC response to this fault is
delayed by a debounce time of 5 seconds to prevent erroneous warnings. The operator is warned of a clogged
hydraulic filter by a flashing yellow backlit indicator and a beeping audible alarm. Each occurrence will
increment the tally for this fault in the fault history in the SETUP menu.
7. Parking Brake:
When not active (output voltage low), this output by default logic in the SAHR (Spring Applied Hydraulic
Release) brake causes the brake to be set (brake ON). This output must be active high in order to release the
brake. The brake may set independent of the instrument cluster in the even of low hydraulic charge pressure.
8. Hydraulic Oil Temperature:
This proportional analog input is driven by a thermistor-type sensor. The operator is warned of high hydraulic
oil temperature when the sensor reads above 99° C (210° F). When this fault occurs the hydraulic oil
temperature LCD graph will display all 8 segments, the backlighting for the LCD will flash and the audible
alarm will sound. The AIC will also replace the parameter being shown in the text display with a digital display
of the current hydraulic oil temperature. Each occurrence will increment the tally for this fault in the fault history
in the SETUP menu.
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9. Engine Coolant Temperature:
This proportional analog input is driven by a thermistor-type sensor. The operator is warned of high engine
coolant temperature when the sensor reads above 109° C (228° F). When this fault occurs the engine coolant
temperature LCD graph will display all 8 segments, the backlighting for the LCD will flash and the audible
alarm will sound. The AIC will also replace the parameter being shown in the text display with a digital display
of the current engine coolant temperature to the nearest degree. Each occurrence will increment the tally for
this fault in the fault history in the SETUP menu.
10. Voltage:
The AIC will warn the operator if the system voltage is out of limits. If the system voltage goes above 16.5 volts
or falls below 11.5 volts, the operator will be warned. The cluster will replace the parameter being shown in the
text display with a digital display of the current system voltage to the nearest tenth volt. The text window will
display “VOLTS” and the actual voltage value alternately every half second. This will be accompanied by an
audible alarm.
11. Low Fuel:
This proportional analog input is driven by a rheostat-type sensor floating in the fuel tank. The cluster will warn
the operator of low fuel level by displaying the single bottom element in the fuel level bar graph and blinking the
LCD backlighting accompanied by an audible alarm. The audible alarm will sound for five beeps every ten
minutes until the fuel level rises. The cluster may receive erroneous readings of higher fuel level due to fuel
sloshing in the tank. To prevent the AIC from canceling the low fuel level warning the fuel level must rise above
two bars on the LCD display before the warning is canceled and the LCD backlighting quits flashing. This
means that once the AIC has registered a low fuel level the bar graph will blink with either one or two bars
displayed. If the fuel level has dropped to two bars, but not yet to one bar, the graph will not blink.
NOTE: A fuel level display of one bar does not indicate one-eighth the fuel remains in the unit. The sensor cannot
reach to the bottom of the fuel tank, so the AIC cannot give a linear display from full to empty.
12. Accessory:
If the AIC is turned off and the ignition key is inadvertently switched to ACCESSORY, the instrument cluster
will display the backlit message “ACC” for several seconds in the text window. Subsequently, the backlight will
turn off, but the “ACC” message will remain indefinitely.
13. Hydraulic Solenoid:
When active (output voltage high), this output enables the hydraulic circuit which provides fluid flow to the
boom and bucket.
14. Fuel Solenoid:
When active (output voltage high), this output provides current to the fuel flow solenoid. The cluster will remove
power from this output after a 30 second countdown to stop the engine when the engine oil pressure drops
below a critical value.
Switch Panel:
Push Button Functional Description:
System Enable- Pushing initially will enable hydraulic loader functions (boom and bucket) and, if the unit is
equipped with hydraulic brakes, will disengage the SAHR brake. Any subsequent push of the system enable button
will toggle a SAHR brake on and off, but will have no effect on the hydraulic loader functions. A flashing yellow LED
to the right of the button prompts the user to push the button at startup to enable the hydraulic system.
Work lights- Pushing turns on a unit’s work lights. A green LED indicates when work lights are activated.
Activating the work lights will dim the lights on the display panel. Pushing and holding for two (2) seconds will
silence a beeping audible alarm. Any subsequent fault alarm will not be muted.
Road lights - Pushing turns on a unit’s road lights. A green LED indicates when road lights are activated.
Activating the road lights will dim the lights on the display panel. Pushing and holding for two (2) seconds
will silence a beeping audible alarm. Any subsequent fault alarm will not be muted.
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Auxiliary Hydraulic Override:
A. Pushing allows operator to exit loader without the engine shutting off automatically. Boom and bucket
functions are disengaged and a SAHR brake is activated, but the auxiliary hydraulics are still operational to
allow for use of certain attachments. After pushing this button the operator is given thirty (30) seconds to exit
the loader. At the end of thirty seconds, if the operator has not left the seat, the override will be cancelled.
The override will also be cancelled if the operator pushes the button a second time before leaving the seat,
or when, after leaving the seat, the operator sits back down in the seat.
B. Pushing and holding for approximately two (2) seconds allows the operator to change the parameter shown
in the text display without entering the SETUP menu. A text description of the parameter currently displayed
will appear in the display when this button is pushed and held for at least two seconds. Then within three
seconds, if the button is released and pushed repeatedly, all of the viewing options will be shown in a
circular manner. A three second period of inactivity on the push button will cause the AIC to save the last
item shown as the parameter to be displayed during normal operation.
C. Pushing and holding while turning the ignition key to the OFF position will activate the security lockout
feature if a code has been established in the SETUP menu. The security feature will be explained in more
detail later.
NOTE: The functions detailed above for the push buttons apply during normal operating conditions. The buttons
will have different functions when used within the SETUP menu; these will be described later.
AIC Special Functions (Setup Menu):
The Advanced Electronic Instrument Cluster stores settings and machine information for the user to view and/or
modify. By entering the setup menu, a user can change machine and user interface parameters and use
information and tools to aid in troubleshooting the electrical system. The following information will help the user
navigate the setup menu, and describes in detail what information and options are available for the user to view
and change.
To Enter the Setup Menu:
A. With the key off, remove all weight from the seat (the cluster should display nothing)
B. Push and hold any cluster push button for 5 seconds until “SETUP” appears in the text display
C. Sit in the seat
The push buttons in the switch panel of the Advanced Electronic Instrument Cluster are used to navigate through
and make selections in the SETUP menu. These buttons have functions in the SETUP menu different from their
normal operating functions.
System Enable Switch:
When at the top-level menu, pushing the System Enable button will select the top-level item currently displayed in
the text window and enter into the sub-menu options.
For sub-menu options that can be changed the System Enable button is used to save the option to memory and
return to the SETUP prompt.
Work Light Switch:
When at the top-level menu, pushing the Work Light button will increment to the next top-level item.
When in a sub-menu, pushing and holding this button will exit the user from the sub-menu and increment to the
next top-level menu item. Any changes made in the sub-menu will not be saved if this button is used to exit and
move on.
Certain menus will prompt the user to enter an access code or allow the user to change a numerical value. Pushing
the Work Light button at such a prompt will increment to the next digit.
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Road Light Switch:
Certain menus will prompt the user to enter an access code or allow the user to change a numerical value. Pushing
the Road Light button at such a prompt will increment the digit.
Certain menus contain multiple settings or parameters a user my view or select. Push the Road Light button to
cycle through these sub-menu options.
Auxiliary Override Switch:
Pushing and holding for about three (3) seconds at any time anywhere in the SETUP menu will exit the user
completely out of SETUP and return the AIC to normal operation. The cluster and machine will behave as if an
operator just sat down in the seat.
After entering the Setup Menu the following items may be displayed:
SETUP:
SETUP is the first term displayed in the setup menu. This item tells the user when he/she has entered the menu
and is used as a reference as the operator navigates through other menu items. No information or parameters are
maintained by this item. The user is returned to this menu anchor after selecting and saving parameters in other
menus.
LOCK:
The advanced instrument cluster allows the user to lock the machine so the engine cannot be started without first
entering a four-digit pass-code. The LOCK category in the setup menu is where a user may set or modify the
four-digit code. The code is itself pass-code protected to prevent unauthorized altering of the lockout code. When a
user enters the lock menu the prompt “UNLOC” will appear in the text display for a few seconds to remind him/her
to enter the lockout menu code, “2430”, in order to reset the machine lockout code. “>0000” then appears in the
text display. Use the work light and road light buttons to enter the code “2430”. Press the system enable button to
enter the code and proceed to the saved machine lockout code. Use the work and road light buttons to enter the
desired machine lockout code. Press the system enable button to save the new lockout code in memory. The
instrument cluster text display will go dark as it saves the new value to memory. It will then retrieve the machine
lockout code and display it in the text display to confirm the correct value has been saved. The user will then return
automatically to the SETUP anchor.
REVLV:
This menu displays the software revision installed on the instrument cluster.
FAULT:
The fault menu allows an operator to view the accumulated history of the faulted parameters since the last time the
fault history was cleared or until the fault buffer is full. Viewing fault history will highlight the appropriate icon or
graph and display the number of accumulated faults in the text display. As the work light switch is exercised, each
fault icon is backlighted and accompanied by the fault count in the display. When a fault history is being displayed,
pressing and holding the road light button will set the accumulated fault total being displayed to zero. When
“CLEAR” is displayed in the text display, pressing the system enable button will set all accumulated fault totals to
zero. The maximum number of faults the instrument cluster can record is 256.
The Fault Items in Order Are:
● Hydraulic Charge Pressure (LED backlighted symbol)
● Engine Oil Pressure (LED backlighted symbol)
● Hydraulic Oil Filter (LED backlighted symbol)
● Engine Air Filter (LED backlighted symbol)
● Hydraulic Oil Temperature (bar graph highlighted)
● Engine Coolant Temperature (bar graph highlighted)
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dIAGI:
The input diagnostic menu allows a user to verify the function of the wiring harness and instrument cluster from the
connection of input switches and sensors to the display on the instrument cluster. To verify continuity in the wire
harness and correct processing by the cluster, the text screen will display the name of the switch or sensor when a
transition is seen by the cluster.
Input Diagnostics:
“PUSHB” – Instrument cluster push buttons pushed.
“KEYAC” – Ignition key transition from OFF to ACCESSORY, or back.
“KEYON” – Ignition key transition from OFF to ON, or back.
“EOILP” – Engine oil pressure switch.
“CPrES” – Hydraulic charge pressure switch.
“AIrFL” – Engine air filter switch.
“OILFL” – Engine oil filter switch.
“SEATb” – Seat belt switch.
“SEATS” – Seat switch.
“KEYST” – Ignition key transition from ON to START, or back.
“FULST” – Fuel solenoid status.
“00000” – Engine coolant temperature sensor resistance.
“00000” – Hydraulic oil temperature sensor resistance.
“00000” – Fuel level sender resistance.
dIAGO:
The output diagnostic menu allows a user to confirm the function of the wiring harness and instrument cluster from
the cluster to various devices in the skid steer loader. To verify continuity in the wire harness and correct
processing by the cluster, the text screen will display the name of the output device while sending a signal to the
device. Press the road light button to toggle through the output diagnostic functions. Confirm 12 volts is seen at the
correct output pin of the instrument cluster and at the connector to the electrical device.
Output Diagnostics:
”HYdEN” – Hydraulic enable of loader valve solenoids.
“PHEAT” – Output to preheat relay.
“bRAKE” – Hydraulic brake solenoid.
“WLITE” – Output to work light relay.
“RLITE” – Output to road light relay.
“AUXOV” – Output of auxiliary hydraulic override to the fuel solenoid..
UNITS:
The units menu allows the user to choose to display temperatures in the Fahrenheit or Celsius scale. When in the
units menu, press the road light button to toggle between “FAHR” and “CELC”. Press the system enable button to
save the selection. This will return the user to the SETUP placeholder.
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dSPLY:
The display menu allows the user to select the parameter shown in the text display during normal operation. When
in the display menu, press the road light button to select the desired display parameter and press the system
enable button to save the choice. This will return the user to the SETUP anchor.
Parameter to Display During Normal Operation:
“ENHRS” – Engine hours.
“ENRPM” – Engine RPMs.
“COOLT” – Engine coolant temperature.
“HOILT” – Hydraulic oil temperature.
“CYCLE” – Cycles continuously through all four of the above options.
JTIMR:
The job timer menu allows a user to view and clear a timer independent of the engine hour timer. When entering
the job timer menu the text screen will display the current count of the job timer to the nearest one-tenth of an hour.
Pressing the road light button will toggle to “ERASE”. Pressing the system enable button at “ERASE” will clear the
job timer count to zero.
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TROUBLESHOOTING
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Replace AIC.
AIC will not read monitored circuits. Incorrect engine configuration. Correct engine configuration.
Open or short in wire from sensor Repair open/short.
to AIC.
Faulty sender or sensor. Repair/replace sender or sensor.
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Op. 55 100
REMOVAL, INSTALLATION AND WIRING
OF ELECTRICAL COMPONENTS
This section will show and explain the correct wiring IMPORTANT: If any servicing or adjustments require
of switches and relays, and when and where battery the battery to be disconnected, or welding is required
voltage should be with the key switch (ignition) “ON” on the skid-steer loader, disconnect the negative (–)
or “OFF” for the electrical components. ground cable. Failure to disconnect the battery may
result in damage to the EIC (Electronic Instrument
This section will also explain the removal and Cluster) monitoring system and other electrical
installation of the switches, relays, EIC board, and components.
main wire harness.
IMPORTANT: If the EIC requires removal from the
Before servicing, changing or adding any electrical dash area of the skid-steer loader, disconnect the
components, read the following precautionary negative (–) ground battery cable. This will shut off
statements. power to the EIC and prevent damage to the EIC
board or blowing the 5-amp fuses if the board is
IMPORTANT: Do not connect any power or ground accidentally grounded.
electrical circuits at the ignition key switch, the cab
electrical fuse panel, or the cab ground terminal in IMPORTANT: Do not service the EIC board with
the fuse panel area unless there are written magnetized tools (wrenches, screwdriver, etc.) or
instructions from New Holland telling you to do so or magnets. Severe damage to the EIC board may
damage and false readings with the EIC board may occur.
occur.
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SECTION 55 - ELECTRICAL SYSTEM
BATTERY 4
Op. 55 301 40
REMOVAL
1. Raise the boom and rest it on the boom lock pins,
1.
CAUTION
Never work under a raised boom unless it is
properly supported by the boom lock pins.
INSTALLATION
1. Orient the battery with the positive post, 2, 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.
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89
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SECTION 55 - ELECTRICAL SYSTEM
Battery
Ref Color Destination Voltage
1 LTGN To EIC Board Pin Seat Belt
#11 (large Buckled
connector)
2 T From Seat Sit in
Switch(es) Seat
3 T To Seat Belt switch Sit in
Seat
4 LTGN/R From Electronics 5A All Times
Fuse (engine panel)
5 T To Service/Run Sit in
Switch Seat
94
Op. 55 201 15
SEAT SWITCH REMOVAL
1. Disconnect the negative (–) battery cable.
CAUTION
Never work under a raised seat unless it is
securely latched in the raised position.
96
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Op. 55 201 14
SEAT BELT BUCKLE AND SWITCH
ASSEMBLY REMOVAL
1. Disconnect the negative (–) battery cable.
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Op. 55 404 20
ROAD LIGHT AND WORK LIGHT SWITCH
REMOVAL
1. Disconnect the negative (–) battery cable.
101
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SECTION 55 - ELECTRICAL SYSTEM
1. Accessory 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.
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SECTION 55 - ELECTRICAL SYSTEM
Op. 55 100 34
START INTERLOCK RELAY REMOVAL
1. Disconnect the negative (–) battery cable.
1
START INTERLOCK RELAY INSTALLATION
1. Reinstall the retaining hardware. 19984973
108
2. Reconnect the wires to the proper terminals as
shown in the “START INTERLOCK RELAY
WIRING” figure above.
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SECTION 55 - ELECTRICAL SYSTEM
111
2. Attach the wires to the proper side of the fuses as
shown in the “ENGINE FUSE PANEL WIRING”
figure above.
2
19984973
112
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SECTION 55 - ELECTRICAL SYSTEM
Op. 55 100 34
PREHEAT RELAY REMOVAL
1. Disconnect the negative (–) battery cable.
120
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Op. 55 201 76
PREHEAT GLOW PLUG REMOVAL
1. Disconnect the negative (–) battery cable.
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122
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.
FUEL TANK SENDING UNIT (Fuel level)
PROBABLE CAUSE AND
STEP PRETEST INSTRUCTIONS TEST RESULT CORRECTION
1 Loader on level with parking EIC gauge and NO bars light up Check wires from sender to
brake engaged, key “ON” sender operation EIC board, if OK, replace
position EIC board
Jumper wire from
Symptom: No bars lit one terminal to YES (bars light up) Replace sender
other at sender
2 Symptom: Fuel level does not Disconnect Bars stay lit Check for PU/W wire
read lower on gauge (too many PU/W wire shorted to ground. If OK,
bars lit) replace EIC board.
PU/W
PU/O
LTBL/O
123
1. Key switch 4. Electric fuel pump
2. EIC board 5. Injector pump
3. Fuel level sender 6. Fuel shutoff solenoid
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SECTION 55 - ELECTRICAL SYSTEM
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.
124
Op. 55 410 80
REMOVAL OF FUEL LEVEL SENDER
1. Support the boom on the boom lock pins.
125
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.
126
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SECTION 55 - ELECTRICAL SYSTEM
127
ELECTRIC FUEL PUMP TESTING
PRETEST PROBABLE CAUSE AND
STEP INSTRUCTIONS TEST RESULT CORRECTION
1 Loader on level with Fuel level in tank NO Add fuel and bleed system
parking brake engaged,
key “OFF” position YES Go to next step
2 Key “ON” position Fuel pump NO Check power supply (5-amp
operating fuse in cab panel). If OK, check
ground; if OK, replace pump
NOTE: Always check fuel level in tank. Always check fuel filters.
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Op. 10 210 21
ELECTRIC FUEL PUMP REMOVAL
1. Support the boom on the boom lock pins.
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.
129
FUEL SHUTOFF SOLENOID TESTING
PRETEST PROBABLE CAUSE AND
STEP INSTRUCTIONS TEST RESULT CORRECTION
1 Loader on level with Battery voltage to NO Check power wire from EIC to
parking brake engaged, solenoid solenoid for open; if OK, go to
key “ON” position, next step
service “RUN” switch in
“RUN” position YES Replace solenoid
2 Key “ON” position, Battery voltage to NO Check power wire from
service “RUN” switch in solenoid service/run switch to fuel
“SERVICE” position solenoid; if OK, go to next step
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SECTION 55 - ELECTRICAL SYSTEM
Op. 10 223 10
REPLACEMENT OF FUEL SHUTOFF
SOLENOID
1. Support the boom on the boom lock pins.
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2. Open the rear door and raise and remove the top
engine shield; remove the right engine shield to
access the sender.
INSTALLATION
1. Remove and clean the engine block thread area.
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SECTION 55 - ELECTRICAL SYSTEM
INSTALLATION
133
1. Install the switch.
INSTALLATION 134
1. Install the charge pressure switch into the hose.
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SECTION 55 - ELECTRICAL SYSTEM
INSTALLATION
1. Install the switch into the filter base.
CAUTION
Never work under a raised boom unless it is
properly supported by the boom lock pins.
CAUTION
Never work under a raised seat unless it is
securely latched in the raised position.
CAUTION
Use a floor jack to support the belly pan and
prevent serious injury.
136
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SECTION 55 - ELECTRICAL SYSTEM
137
7. Remove the PU/LTBL wire and B wire from the
sender, 1.
19992572
138
INSTALLATION
1. Install grounding ring, 1, and washer, 2, over
threads of sender, 3.
IMPORTANT: The grounding ring and washer must
be threaded all the way onto the sender before
installing the sender into the reservoir.
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SECTION 55 - ELECTRICAL SYSTEM
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.
CAUTION
Never work under a raised seat unless it is
securely latched in the raised position.
INSTALLATION
1. Thoroughly clean the control valve block.
19997742
2. Install the solenoid coil into block, and tighten the
coils to 15 N·m (11 ft. lbs.). 140
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.
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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.
168
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.
169
Disconnect wires from the switch, squeeze the
switch retaining tabs in, and remove the switch from
the panel.
170
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SECTION 55 - ELECTRICAL SYSTEM
Bulb Replacement
Clear lens with bulb #86533429
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.
173
2. Unplug the wire harness from the bulb,
unlatching the connector at 1, and sliding the 1
harness from the bulb.
174
3. Facing the back of the assembly, rotate the bulb
holder, 1, counterclockwise and remove the bulb
3
from the support.
2
175
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SECTION 55 - ELECTRICAL SYSTEM
Op. 55 404 10
Rear Work and Taillight
1. Remove the center work light, 1, by pushing the 3 3
lens assembly to the left and lift the right side of
the assembly from the support.
2
177
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SECTION 55 - ELECTRICAL SYSTEM
178
Op. 55 301 Principle of the Integrated Circuit Regulator
ALTERNATOR (55 AMP VERSION) The basic circuit of the IC regulator is shown here.
The portion enclosed by the dashed line represents
CHARGING CIRCUIT the regulator.
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SECTION 55 - ELECTRICAL SYSTEM
The basic operating principles are explained as 3. When the generated voltage is low, no current
follows: flows in the Zener diode (DZ) since the voltage at
point A is lower than the Zener voltage.
1. When the key switch is closed, current from the
battery flows through the field excitation resistor 4. As the speed and voltage increases, the voltage
and resistor R6, which are in parallel, to the field at point A also increases until it reaches the
coil. limiting value set by the factory. As the Zener
diode (DZ) breaks down, current flows through
The current continues to flow on through the field R1, DZ, and the base-emitter circuit of Tr1 to
coil to ground, completing the circuit back to the ground. This renders Tr1 conductive, so that
battery. much of the current flows through the
collector-emitter circuit of Tr1. This reduces the
Field Excitation base current of Tr2 thereby reducing the field
Resistor current. This means that Tr1 turns on and Tr2
Battery Key Switch turns off.
Terminal R-
Resistor R6
Regulator
R1 DZ
Terminal L
Alternator Field Coil Tr2 Ground Tr1 Ground
terminal L Regulator R6 R5
Terminal R
2. When the alternator begins to rotate, A.C. 5. When the generated voltage decreases, the
voltage is generated in the stator coil. The diodes Zener diode (DZ) again turns off and Tr1 also
in the rectifier assembly change the stator A.C. turns off.
voltage to a D.C. voltage which appears between
the ground and terminal, B. This cycle then repeats many times per second
and the alternator output voltage is, therefore,
The stator also supplies D.C. field current regulated within a narrow limit.
through the diode trio, the field coil, Tr2, and then
ground. 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
Diode trio Field Coil Tr2 Ground voltage, but in place of the voltage coil and spring
system, there is a potential divider (R1 and R2)
and a Zener diode.
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NO CHARGING
FAULT LOCATION POSSIBLE CAUSE CORRECTION
Wiring Loose connection, short circuit Repair
Alternator Loose connection, no ground, short Repair or replace
circuit
Defective rectifier Replace
Loose connection of RF resistor Replace
Regulator Defective regulator Replace
Loose connection of alternator or Repair or replace
regulator
INSUFFICIENT CHARGING
FAULT LOCATION POSSIBLE CAUSE CORRECTION
Wiring Loose connection or short circuit Repair
Alternator Loose drive belt Repair
Short in rotor coil Replace
Short in stator coil Replace
Defective rectifier Replace
Insufficient brush contact Repair or replace
Regulator Defective regulator Replace
Loose connection of alternator and Repair
regulator
Battery Defective battery Replace
OVERCHARGE
FAULT LOCATION POSSIBLE CAUSE CORRECTION
Battery Internal short Replace
Regulator Defective regulator Replace
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Alternator Construction
The principal components of the IC alternator are the
IC voltage regulator, 1, the rotor, 2, the pulley, 3, the
rectifier assembly, 4, the rear support bracket, 5, the
stator, 6, and the front support bracket, 7.
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SECTION 55 - ELECTRICAL SYSTEM
55-121
SECTION 55 - ELECTRICAL SYSTEM
55-122
SECTION 55 - ELECTRICAL SYSTEM
55-123
SECTION 55 - ELECTRICAL SYSTEM
55-124
SECTION 55 - ELECTRICAL SYSTEM
ALTERNATOR
4
Op. 55 301 10
REMOVAL
1. Raise the boom and rest it on the boom lock pins,
1. Open the rear door, 2; raise the top engine
shield, 3; and remove the right engine side
shield, 4, to access the alternator.
CAUTION
185
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.
186
55-125
SECTION 55 - ELECTRICAL SYSTEM
Op. 55 301 12
DISASSEMBLY
1. Mark both brackets and the stator with a scribe
mark for reassembly.
187
3. Place the rotor in a vise with soft jaws and
remove the pulley nut, washer, pulley, spacer,
and rear bracket from the rotor.
SM463-170
188
Unsolder three stator leads, 1, and remove the
stator. Lead Wire
SM463-171
189
55-126
SECTION 55 - ELECTRICAL SYSTEM
190
Op. 55 301 14
Alternator Component Tests
Rotor
1. Inspection of slip ring surface, 1.
SM463-173
191
2. Check for continuity between both slip rings. If
there is no continuity, the field coil is defective.
Replace the rotor assembly.
192
55-127
SECTION 55 - ELECTRICAL SYSTEM
SM463-175
193
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.
SM463-176
194
2. Check for continuity between any stator lead and
stator core. If there is continuity, it means the coil
is shorted. Replace the stator assembly.
SM463-177
195
55-128
SECTION 55 - ELECTRICAL SYSTEM
Rectifier Assembly
196
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.
197
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.
198
55-129
SECTION 55 - ELECTRICAL SYSTEM
SM463-181
199
Reassembly
Reverse the disassembly, observing the following:
Installing Rotor 1
1. Push brushes, 1, into the brush holder and insert 2
a wire, 2, to hold them in the raised position.
Install the rotor and remove the wire.
55-130
SECTION 55 - ELECTRICAL SYSTEM
Bench Check
To check the alternator on a test bench, proceed as
follows:
IMPORTANT:
55-131
SECTION 55 - ELECTRICAL SYSTEM
ALTERNATOR REINSTALLATION
1. Attach the alternator to the lower pivot, 1, and the
upper support strap, 2.
202
55-132
SECTION 55 - ELECTRICAL SYSTEM
Op. 55 201
STARTER
STARTER MOTOR TROUBLESHOOTING
Starter Motor Specifications
Rated voltage 12 volts
Output 2 kw
Motor type Four-pole series wound motor
Engaging system Magnetic shift
Rotation Clockwise (viewed from pinion side)
Weight Approximate 5 kg (11 lbs)
55-133
SECTION 55 - ELECTRICAL SYSTEM
Do not disconnect or short any lead wire while the Starter cranks engine very slowly.
starter is operating.
1. Check battery condition, should be a minimum of
12.5 volts.
With key switch in “start” position: 2. Check starting system circuit.
Starter does not crank engine, solenoid switch Voltage drop between battery positive post and
clicks. starter terminal should not exceed 0.2 volts.
1. Disconnect the three cables from the solenoid. Voltage drop between battery negative post and
starter ground should not exceed 0.2 volts.
2. Using an ohmmeter, touch one probe to the
solenoid spade terminal and the other to the If voltage drop exceeds 0.2 volts, clean
starter case. There should be continuity. connections or replace the cable.
If none, the hold-in winding is open-circuited. 3. If battery is charged and voltage is within
Replace the solenoid. specification, repair or replace starter.
If continuity, the fault is in the starter motor. Refer
to repair procedures. Engine starts but pinion does not disengage.
1. Check voltage at spade terminal of solenoid. If 12
Starter does not crank engine, solenoid does volts with key switch “off”, fault is in the key switch
not click. or start circuit.
1. Disconnect battery cable from starter. 2. If 0 volts with key switch “off” but starter turns,
fault is in the solenoid or overrunning clutch
2. Connect a jumper wire to the battery positive assembly.
post. Ensure the negative cable is attached to
battery and starter ground.
55-134
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.
CAUTION
Never work under a raised boom unless it is
properly supported by the boom lock pins.
CAUTION
Never work under a raised seat unless it is
properly latched in the raised position.
55-135
SECTION 55 - ELECTRICAL SYSTEM
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, 205
reduction type starter consisting of the motor,
reduction gearset, overrunning clutch and electric
solenoid.
55-136
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.
206
The overrunning clutch assembly consists of the
pinion, 1, pinion shaft, 2, ball bearings and
4
overrunning clutch which is a conventional design 2
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.
3
1
SM463-189
207
55-137
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 SM463-190
208
11 Starter Switch
12 Clutch Gear
13 Overrunning Clutch
55-138
SECTION 55 - ELECTRICAL SYSTEM
SM463-192 5 4
210
55-139
SECTION 55 - ELECTRICAL SYSTEM
STARTER DISASSEMBLY
1. Disconnect the lead wire from the electric
solenoid.
SM463-193
211
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.
SM463-194
212
SM463-195
213
55-140
SECTION 55 - ELECTRICAL SYSTEM
1
3
SM463-196
214
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 3
the armature from the housing, griping behind
the front bearing, 4. 4
1 2
SM463-197
215
5. Remove the screws securing the drive end frame
to the solenoid.
SM463-198
216
55-141
SECTION 55 - ELECTRICAL SYSTEM
SM463-199
217
7. Remove the overrunning clutch from the drive
end frame.
SM463-200
218
8. Remove the steel ball from the center of the
overrunning clutch.
SM463-201
219
55-142
SECTION 55 - ELECTRICAL SYSTEM
SM463-202
220
10. Remove the idler gear bearing rollers and
retainer.
SM463-203
221
11. Remove the return spring from the electric
solenoid.
SM463-204
222
55-143
SECTION 55 - ELECTRICAL SYSTEM
Armature
Inspect the armature for internal short circuits with a
growler.
SM463-205
223
Inspect the armature for a short to ground using a
continuity tester.
2 3
SM463-206
224
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 0.5 to
(0.02″ and 0.03″). 0.8mm
SM463-207
225
55-144
SECTION 55 - ELECTRICAL SYSTEM
SM463-208
226
55-145
SECTION 55 - ELECTRICAL SYSTEM
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.
227
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.
228
55-146
SECTION 55 - ELECTRICAL SYSTEM
Brushes
Clean brushes and adjacent parts, removing carbon
particles by wiping with a clean cloth.
230
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.
231
55-147
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.
SM463-214
232
Reduction Gears
Inspect the pinion gear, 1, the idler gear, 2, and the
overrunning clutch gear for wear or damage.
2
3 1
SM463-215
233
55-148
SECTION 55 - ELECTRICAL SYSTEM
Electric Solenoid
The following tests should be performed with the
motor removed from the starter assembly.
SM463-217
235
55-149
SECTION 55 - ELECTRICAL SYSTEM
REASSEMBLY
Reassemble the starter in the reverse order of
disassembly. Observe the following cautions and
procedures.
Overrunning clutch.
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.
SM463-219
237
3. Install the idler gear bearing rollers and retainer.
SM463-220
238
55-150
SECTION 55 - ELECTRICAL SYSTEM
SM463-221
239
5. Position the pinion gear, 1,over the armature hole
shaft then install the drive end frame, 2. Install the 2
1
retaining screws and torque to 7 - 12 N·m (5 - 9
ft. lbs.).
SM463-222
240
6. Install the armature into the motor housing.
Gently tap the armature into place with a soft
hammer to seat the rear bearing. 3
4
1 2
SM463-223
241
55-151
SECTION 55 - ELECTRICAL SYSTEM
SM463-224
242
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.).
SM463-225
243
9. Reconnect the lead wire from the electric
solenoid.
SM463-226
244
55-152
SECTION 55 - ELECTRICAL SYSTEM
Performance Test
After reassembly, a no-load test should be
2
conducted. 1
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.
246
55-153
SECTION 55 - ELECTRICAL SYSTEM
1. Heat wire
2. Sheath
3. Insulation
4. Body
5. Nut SM463-229
6. Magnesium oxide powder 247
7. Insulating bushing
8. Center electrode
Open Circuit
The glow plug system operates even if a glow plug is
disconnected or if it open-circuits internally because
the glow plugs are connected in parallel. An open
circuit in one glow plug will result in a greatly
extended heating cycle.
55-154
SECTION 55 - ELECTRICAL SYSTEM
Short Circuit
Glow plugs seldom short-circuit internally. If,
however, the glow plug should short, the external
wiring will be damaged at start-up.
248
FUEL SHUT-OFF SOLENOID
The fuel shut off solenoid is a normally extended
solenoid. In this state the plunger rests against the
injection pump rack, holding it in the shut-off position.
Applying current to the terminal causes the plunger
to withdraw into the solenoid body allowing the fuel
control rack to move to the operating position.
249
55-155
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.
55-156
SECTION 82 – FRONT LOADER (BOOM AND MOUNTING PLATE)
Chapter 1 – Buckets
CONTENTS
82-1
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
1
Op. 82 100 pacity. Handle dense materials with a relatively small
GENERAL INFORMATION bucket. Handle lighter materials with higher capacity
buckets. Refer to the following bucket capacity chart
BUCKETS and the material weight chart in the operator’s manu-
al when choosing the bucket for a job.
Bucket Types
1. LP - Low profile
The low-profile bucket has a shorter back and is Bucket Capacity Cubic Feet
longer from bucket heel to cutting edge for opti-
Bucket Bucket
mum cutting edge visibility. This is important for Capacity Capacity
finish grading and accurate cut and fill jobs. Heaped Struck
Width (cu ft) (cu ft)
2. D & F - Dirt and foundry
66″ Utility fork N/A N/A
The dirt and foundry bucket is shorter from buck-
et heel to cutting edge to provide maximum 60″ Low profile 11.5 8.9
breakout force for tough digging conditions. 60″ Dirt and foundry 11.5 8.7
66″ Low profile 13.2 9.7
3. M & F - Manure and fertilizer (slurry)
The manure and slurry bucket is for handling 66″ Dirt and foundry 15.2 11.6
loose or fluid materials with more rollback to mini- 72″ Low profile 14.5 10.6
mize spillage. 72″ Dirt and foundry 16.7 12.7
4. LM - Light material 72″ Manure and fertilizer 15.5 15.5
The light-material bucket is for light, high- volume 72″ Light material 23.7 19.0
materials for more productivity handling light ma- 84″ Light material 27.9 22.3
terial.
Select bucket styles and sizes to provide both ade-
quate breakout force and reasonable carrying ca-
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.
2
To engage the boom lock pins:
CAUTION 3
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 attach-
ment, 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
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 re-
moved 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 attach-
ment. The control levers and pins are shown in the
latched position.
5
BOOM AND CYLINDER PIVOT PINS
When the boom, upper and lower boom links and cyl-
inders 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, loca-
tion, and size for identification and locations.
82-4
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
7
PART NUMBER A B C
9614349 95 mm (3-3/4I) 38 mm (1-1/2I)
86501420 49 mm (1-15/64I) 60.3 mm (2-3/8I) 113 mm (4-29/64I)
86501422 77 mm (3-1/32I) 60.3 mm (2-3/8I) 141 mm (5-9/16I)
86501430 72.3 mm (2-7/8I) 38.10 mm (1-1/2I) 112.5 mm (4-7/16I)
86501434 57.8 mm (2-9/32I) 38.1 mm (1-1/2I) 92 mm (3-5/8I)
86504316 40.0 mm (1-5/32I) 60.3 mm (2-3/8I) 113 mm (4-7/16I)
86521982 117 mm (4-39/64I) 38.1 mm (1-1/2I)
82-5
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
Op. 82 100 30
PALLET FORK 1
The pallet fork (shown) has a frame and guard as-
sembly, 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.
19990486
8
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.
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.
10
The standard tine spacing, center to center, is 21.8
cm (8-1/2″). The fork frame is equipped with addition-
al holes for additional tines, reducing the tine spacing
to 10.9 cm (4-1/4″).
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 back-
plate.
2. Position the spacer, 3, as shown with the angle
end of the spacer next to the floor of the back-
plate. 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.
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 weld-
ing to prevent damage to the loader electrical
system.
Material to be welded is low carbon, grade 50
steel; use welding rods marked 6011 or compa-
rable.
CAUTION
Good quality welds are necessary for new plates
to be properly retained. Use a professional weld- 15
er if required.
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)
18
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 cor-
ner 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.
19
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.
20
82-10
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
21
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 con-
tact the loader quick-attach plate and engage the
latch handles and pins, making sure the latch
pins engage the bucket plates properly.
22
Op. 82 100
DIRT TOOTH KIT INSTALLATION
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” de-
sign and can be obtained from Parts.
Place the new point over the shank and insert the re-
taining 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.
24
NOTE: If the punch or driver is too small and just con-
tacts 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 plac-
ing and welding the teeth.
IMPORTANT: Remove the bucket from the loader
while welding teeth to prevent damage to the loader
electrical system.
82-12
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
25
2. Locate the teeth on the bucket edge as indicated.
BUCKET TOOTH SPACING
Bucket
Width From End 2nd Tooth 3rd Tooth 4th Tooth 5th Tooth 6th Tooth
1 2 3 4 5 6 7
52″ 1-13/16″ 9-1/2″ 18-15/16″ 28-3/8″ 37-13/16″ 47-5/16″
54″ 1-13/16″ 9-3/4″ 19-1/2″ 29-3/16″ 38-15/16″ 48-5/8″
58″ 1-13/16″ 10-11/16″ 21-5/16″ 32″ 42-5/8″ 53-5/16″
60″ 1-13/16″ 10-15/16″ 21-7/8″ 32-3/4″ 43-3/4″ 54-5/8″
62″ 1-13/16″ 11-3/8″ 22-3/4″ 34-1/8″ 45-1/2″ 56-7/8″
66″ 1-13/16″ 12-3/16″ 24-5/16″ 36-1/2″ 48-11/16″ 60-7/8″
70″ 1-13/16″ 13″ 26″ 38-15/16″ 51-7/8″ 64-7/8″
76″ 1-13/16″ 14-3/16″ 28-5/16″ 42-1/2″ 56-11/16″ 70-7/8″
82″ 1-13/16″ 15-3/8″ 30-3/4″ 46-1/8″ 61-1/2″ 76-13/16″
NOTE: Position the teeth at these spacings, then re-center if necessary for equal spacing.
82-13
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
26
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
5 mm
sides of the tooth, 2, high carbon steel to high car- (3/16″)
bon steel.
5 mm
(3/16″)
13 mm
(1/2″)
27
82-14
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
3
1
19985917
28
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.
29
8. Remove the plastic handle grip, 1, from the con-
trol lever.
30
82-15
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
7. Spring
31
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.
32
82-16
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
33
7. Install the control rod, 4, in the handle assembly
and the left boom lock pin, 1. Slide new push re-
taining nuts onto rod at 6, Figures 33 and 34.
34
8. Slide the plastic handle grip, 1, onto the handle.
9. Operate the control handle to insure proper op-
eration.
a. Pivot the handle towards the outside of the op-
erator’s cab. The lock pins should extend from
the cab post.
82-17
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
REMOVAL
1. Remove any attachment (bucket, fork, etc.) from
the boom mounting plate and lower the boom to
the lowered position.
36
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.
37
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.
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.
39
3. With the boom properly supported and all hy-
draulic 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 hy-
draulic pressure is removed from the boom and
bucket hydraulic circuits.
40
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 ta-
pered end of pin or the link and pin may fall.
41
82-19
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
42
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 re-
moved as described.
43
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 cir-
cuits.
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 44
the tapered pivot pin is broken loose at the ta-
pered end of pin or the link and pin may fall.
82-20
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
45
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.
46
3. With the boom properly supported and all hy-
draulic 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 hy-
draulic pressure is removed from the boom and
bucket hydraulic circuits.
47
82-21
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
48
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.
49
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 ta-
pered end of pin or the link and pin may fall.
82-22
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
51
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.
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 hard-
ware and pin from the mounting plate and cylin-
der.
4. Remove the mounting plate from the main boom.
a. Loosen the mounting plate pivot
hardware. DO NOT remove the hardware. 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 re-
move 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″)
82-24
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
56
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 in-
serted into the ROPS post straight.
4. Position the main boom assembly over the load-
er positioning the boom against the boom stops
(front of the final drive case).
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)
59
7. With the main boom, upper and lower links at-
tached, the pivot pins and hardware must be 2
properly seated.
2
Torque the pin retaining hardware to the following
torques: 1
61
82-26
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
62
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, position-
ing the hoses and tubes for clearance at the fend-
er when the boom is raised and lowered.
63
16. When all boom links and pivot pins are properly
seated and torqued and all hydraulic connec-
tions are tightened, operate the boom up and
down. Check the clearance between the tube
and ROPS (cab) at 1.
64
82-27
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
65
18. Remove any slack between the top clamp, 1, and
second clamp, 2, and then tighten the second
clamp.
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 cir-
cuit.
67
82-28
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
1 1
68
ATTACHMENT MOUNTING PLATE
Op. 82 100 70
4
REMOVAL
1. Remove any attachment from the loader attach- 2
ment mounting plate.
2. Lower the boom to the fully lowered position.
3. Tilt the attachment mounting plate forward until 3
the face is level with the ground. 3 1
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 19984476
cylinders.
69
CAUTION
Support the mounting plate during removal to
prevent dropping the plate when pins are re-
moved.
82-29
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
1
2
19984478
71
7. Remove the cylinder attachment mounting plate
pivot pins to allow access to the latch handle piv-
ot pin snap ring clips.
CAUTION
Support the mounting plate during removal of
the mounting plate pivot pins to prevent drop-
ping the plate down when pins are removed.
1 1
8. Remove the pin retaining bolts, 1, and slide the
pins from the mounting plate and cylinders.
19984476
72
82-30
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
2
19984479
73
10. Remove the retaining ring, 1, from the latch han-
dle 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 han-
dle retaining pin, 2, downward and out through
the front of the attachment mounting plate on 2
both sides. If there is insufficient ground clear-
ance to fully remove the latch handle pivot pins,
lift the attachment mounting plate up as neces- 1
sary to clear the pins.
19984480
74
12. Remove the handle/spring assembly, 1, from the
attachment mounting plate on the LEFT and
RIGHT sides of the attachment mounting plate.
1
19984481
75
82-31
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
PARTS INSPECTION
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 bush-
ings 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.
77
82-32
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
Op. 82 100 74
2
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. 1
3
CAUTION
When removing the step bolt, the spring will
have some compression pressure. Remove the
bolt while applying downward pressure on the
bolt.
19984483
78
2. Remove the upper spring guide, 1, pivot block, 2,
and step bolt, 3, from handle, 4.
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.
1 3 4 5
NOTE: Apply slight pressure to the lower spring
guide to compress the spring slightly and start 6
threading the lower guide onto the step bolt.
19984485
2
80
82-33
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
1
19984481
81
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 reinstalla-
tion in the attachment plate. If the snap ring retaining
clip is not present, install the clip prior to pin installa-
tion. 1
2
19984486
82
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 at-
tachment.
6. With a hammer and punch, drive the grooved pin,
2, through the lower spring guide and latch pin.
1
2
19984478
83
82-34
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
19984477
84
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 hard-
ware must be hammer seated by striking the head of 3
the bolt and pin, and then re-tightening. This step
must be repeated until the torque remains constant.
2 2
10. Reinstall hub caps, 3, into the plate pivots. 1
11. Extend the attachment mounting plate cylinders
until they align with their mounting holes on the
attachment mounting plate. 19984476
82-35
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
Inspection
The L160 and L170 loader latching system re-
quires that the faceplate wedge into the attachment.
The faceplate must contact the attachment at 1, 2,
and 3, and must have clearance between the attach-
ment and faceplate at 4, when the attachment is
latched properly.
87
82-36
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
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.
82-38
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
15-5/8I
91
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 re-
quire straightening or replacement.
92
82-39
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
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.
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.
Remove and replace boom lock pins and linkage 2.5 hrs.
Remove and replace main boom 4.5 hrs.
Removal and replace one upper link 1.0 hrs.
Removal and replace one lower link 2.0 hrs.
Remove and replace attachment mounting plate 1.0 hrs.
Rebuild attachment mounting plate 1.5 hrs.
82-41
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)
82-42
SECTION 88 – ACCESSORIES
CONTENTS
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 elec-
trical connections to locations other than recom-
mended may allow electric current to feed back
through the EIC board, creating false EIC board
readings and warnings, or causing EIC board dam-
age or failure.
1
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 spe-
cified attachments.
88-2
SECTION 88 - ACCESSORIES
2
3
4
5 6
10 11
13
12
88-3
SECTION 88 - ACCESSORIES
4
The Figure 5 shows the circuit for intermittent high
current loads up to 30 amps.
CAUTION
Always disconnect the battery before installing 5
any electrical attachment to prevent accidental
shorting of system.
88-4
SECTION 88 - ACCESSORIES
L160 58.7 l/min. (15.5 GPM) @2900 RPM 90.8 l/min. (24.0 GPM) @2900 RPM
@68 bar (1000 PSI) @156 bar (2300 PSI)
L170 67.0 l/min. (17.7 GPM) @2900 RPM 99.2 l/min. (26.6 GPM) @2900 RPM
@68 bar (1000 PSI) @156 bar (2300 PSI)
NOTE: When using the High-Flow system, 3/4 quick 5. Will the attachment accept hydraulic system
couplers must be used or high system backpressure backpressure?
may result.
If “YES”, nothing is required.
3. Will the attachment accept oil flow in both di-
rections? If “NO”, the attachment will not function properly
on a New Holland skid-steer loader. Normal
If “YES”, nothing is required. backpressure for New Holland skid-steer loaders
is between 14 - 17 bar (200 - 250 PSI).
If “NO”, install a check valve or cross into the at-
tachment return line to prevent reverse oil flow to Examples: Post drivers, some breakers, and
the attachment. some hand held hydraulic tools do not accept
Examples: Backhoes and trees spades with a system backpressure.
separate control valve do not accept oil flow in
NOTE: L160 and L170 model loaders must have
both directions.
a minimum of 22.7 l/min. (6 GPM) returning through
4. Must the attachment “Free Wheel” to a the main hydraulic system at all times to charge the
STOP? hydrostatic system.
If “YES”, a crossover relief connection must be If all the skid-steer loader oil flow is not required
installed on the attachment side to allow the at- to operate an attachment (e.g., shaver post driv-
tachment to free wheel to a stop after the skid- er), a flow divider can be installed into the hydrau-
steer loader hydraulics is turned off. lic oil circuit on the attachment. The flow divider
If “NO”, nothing is required. sends the required oil flow to the attachment and
the remainder back to the normal skid-steer load-
Example: Snow blowers must free wheel to a er hydraulic circuits.
stop.
88-5
SECTION 88 - ACCESSORIES
6. Does the attachment have a separate case 7. Does the attachment require a circuit relief in
drain oil line? the bucket circuit?
If “YES”, install a separate case drain line to re- If “YES”, install a bucket circuit relief valve on
turn the attachment case drain oil directly to the front of the control valve in the bucket circuit.
hydraulic oil reservoir.
Example: Some mini-backhoes attach like a
Example: Cold planners have a separate case bucket, and require a bucket circuit relief.
drain oil line.
88-6
SECTION 88 - ACCESSORIES
Op. 90 000
ARM PADS FOR CAB SIDE PANELS
The cab arm pads provide additional operator com-
fort and may be used separately or in combination
with the seat armrest.
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 com-
fort.
Armrest Adjustment
The armrest can be adjusted up or down for operator
comfort by turning adjusting screws, 1.
88-7
SECTION 88 - ACCESSORIES
Op. 90 000
FOREARM RESTS
The forearm rests are attached to the side of the op-
erator’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 con-
trols. 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 10
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 L160 and L170 armrests mount with the
bracket, 1, over the cab side panel, 2. 2
1
Pivot the armrest up and down and adjust the two
clamp bolts, 3, if binding occurs, or to retain the arm-
rest in the raised position.
19990509
11
The right and left armrests are shown installed and
pivoted down in the operating position.
19990510
12
88-8
SECTION 88 - ACCESSORIES
Op. 55 000
BACK-UP ALARM
The back-up alarm serves as an audible warning de-
vice 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.
Alarm Location 13
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 hard-
ware.
19984978
14
Back-up Alarm Wiring
The alarm is a negative (–) ground system.
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 dam-
age to the engine, heater element, and/or person-
al injury could occur.
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 en-
ergized, the element sheath could burst and
cause personal injury.
CAUTION
This is a 115-volt heater. Use caution when instal-
ling and using the heater. Properly grounded elec-
trical 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.
CAUTION
Disconnect the extension cord from the grounded
electrical outlet first and then from the heater be-
fore 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
SECTION 88 - ACCESSORIES
Op. 55 000
17
Electric Power Wiring
18
88-11
SECTION 88 - ACCESSORIES
Op. 10 254
EXHAUST (ENGINE)
CATALYTIC MUFFLER
The catalytic muffler kit can be installed on diesel en-
gines being operated in applications where cleaner
exhaust emissions are required.
Op. 10 254
ASPIRATOR PRECLEANER MUFFLER
The precleaner aspirator muffler kit can be installed
on diesel engines being operated in dusty applica-
tions to prolong air cleaner element life.
21
88-12
SECTION 88 - ACCESSORIES
88-13
SECTION 88 - ACCESSORIES
Op. 35 000
HIGH FLOW HYDRAULICS
When the high flow hydraulics circuit is used, it will al-
low the operator to utilize more available engine
horsepower through the auxiliary hydraulic circuit.
L160
From 15.5 GPM, 1000 PSI at 2900 RPM to 24.0
GPM, 1000 PSI at 2900 RPM (= 32.2 HP).
L170
From 17.7 GPM, 1000 PSI at 2900 RPM to 26.6
GPM, 1000 PSI at 2900 RPM (= 35.7 HP).
19987112
24
When the high-flow is being used, 3/4″ quick cou-
plers, 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 attach-
ments that do not require the added oil flow.
25
88-14
SECTION 88 - ACCESSORIES
26
88-15
SECTION 88 - ACCESSORIES
No selector valve spool movement Check valve spool for binding and
sticking
Hydraulic oil overheats Using 1/2″ quick couplers Must use 3/4″ quick couplers
Control valve and boom steel lines Change lines and hoses to 3/4″
and hoses were not changed from
5/8″ to 3/4″
Operating high flow when not Turn high flow switch to the “OFF”
required position
Operating attachment when high oil Turn high flow switch to the “OFF”
flows are not required position
Oil cooler restricted not allowing Clean oil cooler and radiator
cooling air to flow properly
88-16
SECTION 88 - ACCESSORIES
Selector valve spool binding Check for spool binding and repair
Low main system relief valve Check and replace relief valve
setting
88-17
SECTION 88 - ACCESSORIES
27
Rebuild the selector valve with new O rings on the
spool and fittings at 1, and on both ends of the coil at
2.
28
88-18
SECTION 88 - ACCESSORIES
Op. 35 710
High Flow Pump Removal / Disassembly
1. Clean the pump thoroughly and mark the pump 1 2
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 4
be easily damaged. BE CAREFUL not to damage
3
machined surfaces. DO NOT use a screwdriver or 19997758
other hard, sharp objects to pry the pump from the 29
plate.
The high flow gear pump consists of:
5
4
3
19997759
30
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 1
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 2
the plate if the I.D. of the idler gear bushing ex-
ceeds 19.2 mm (0.755″).
19997762
2. Check the seal areas, 2, for scratches or damage 31
that could prevent a good seal.
88-19
SECTION 88 - ACCESSORIES
19984487
33
6. Inspect the pump gear teeth, 1, for excessive
wear. Inspect the drive gear key, 2, to ensure it is 2
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 diam-
eter, replace the gear assembly.
88-20
SECTION 88 - ACCESSORIES
2
19997762
35
3. Install the seal, 1, and backup gasket 2, on the
wear plate, 3. BE SURE that the flat area, 4, on 3
1 2
the gasket AND seal, 5, are properly aligned and
lay flat when installed in the wear plate.
5 4
19984487
36
NOTE: The gasket AND seal must align and lay flat
when installed in the wear plate.
19997767
37
88-21
SECTION 88 - ACCESSORIES
19997763
38
5. Install the drive gear, 1, on the drive shaft, slip-
ping 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
1
2
19997764
39
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 dur-
ing disassembly align correctly.
NOTE: The small half-moon cavity, 2, must be on the 1
pressure side of the pump. 2
1
19997765
40
88-22
SECTION 88 - ACCESSORIES
19997761
41
8. Install the pump back plate, 1, over the gear
shafts. Check that the reference marks made
during disassembly align correctly. 4
9. Install the housing hardware with the eight bolts,
2, and sealing washers. Tighten the bolts evenly
1
in a criss-cross pattern to 34 - 38 N⋅m (25 - 28 ft.
lbs.).
10. Install the pump port fitting, 3, and the high pres-
sure tube, 4, and tighten securely.
2
3
19997758
42
88-23
SECTION 88 - ACCESSORIES
43
High Flow Hydraulic Oil Flow Diagram
19997766
44
88-24
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 hy-
drostatic control lever. 1
19984626
45
Horn Wiring Diagram
46
88-25
SECTION 88 - ACCESSORIES
Op. 90 000
SHOULDER BELT (SEAT)
The shoulder belt can be installed with the lap seat
belt.
47
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 retrac-
tor 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 un-
lock and pull out in any other position.
48
The shoulder belt support pivot bolt, 1, must be loose
enough to allow the belt to pivot. If the belt will not piv-
ot properly, it will not adjust to fit the operator.
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.
50
1. Attach the angle, 1, with one 5/16″ x 1-1/4″ car-
riage 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, us-
ing two #10 x 1/2″ machine screws and flange
nuts at 6.
4. Mount the SMV sign assembly in the spade sock-
et as shown at 7.
51
88-27
SECTION 88 - ACCESSORIES
Op. 55 000
WARNING LIGHT (ROTARY BEACON)
The beacon light is a visual alerting device for by-
standers and other machine operators. The beacon
light’s magnetic base mounts the light securely to any
part of the roof or frame.
52
The beacon light switch, 1, is located in the ignition
key switch panel in the upper right corner of the over-
head dash.
53
Disconnect wires from the switch, squeeze the
switch retaining tabs in, and remove the switch from
the panel.
54
88-28
SECTION 88 - ACCESSORIES
55
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.
56
88-29
SECTION 88 - ACCESSORIES
57
Squeeze the bulb retaining tabs to separate the bulb
from the holder.
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 bystand-
ers and other machine operators.
59
The warning light switch, 1, is located in the ignition
key switch panel in the upper right corner of the over-
head dash.
60
Disconnect the wires from the switch. Squeeze the
switch retaining tabs in and remove the switch from
the panel.
61
88-31
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
Op. 55 404 10
Rear Light
1. Remove the bezel, 1, retaining hardware and re-
move the lens from the light bar.
NOTE: The remaining light lens will be loose in the
light bar.
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
88-35
SECTION 88 - ACCESSORIES
88-36
SECTION 90 – PLATFORM, CAB, BODYWORK, AND DECALS
CONTENTS
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.
1
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.
2
The seat/pan support assembly support rod, 1, is
shown in the raised latched position at 2.
90-2
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
19984338
4
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.
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.
6
2. Disconnect the seat and seat belt wire harness
connector, 1.
90-3
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
19984338
7
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
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.
90-4
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
10
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.
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.
12
90-5
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
13
4. Reinstall the seat and seat pan support assembly
into the loader and attach with hardware at 1. 2
If the seat pan latch rod, 2, or latch plates, 3, were 3 1 3
removed, they may require adjustment to ensure
proper seat latching.
19992567
14
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.
15
90-6
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
16
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.
90-7
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
19984336
19
7. Remove the ignition switch panel hardware, 1,
and lower the switch panel.
DO NOT remove any wires from any switches.
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
A5371-9
22
13. Remove the front cross support, 1, by removing
hardware, 2, separating the cross member from
the right and left side panels.
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
19984338
25
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.
26
19. Remove the retaining hardware, 1, of the right
and left fenders to access the front isolator mount 1 1
bolts and wire harness.
27
90-10
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
28
21. Remove any wire harness clamps and cut wire
ties along the rear of the seat support and side
panels, 1.
1 1
1 1
29
22. Remove the upper rear support retaining
hardware, 1, right and left side and remove
support.
30
90-11
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
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.
1
19992568
32
25. Remove the left and right side shield isolator and
hardware at 1 (right side shown).
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.
1
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. 2
19992572
36
90-13
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
37
The loader ROPS with the seat and inner shell
removed.
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
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.
41
5. Install the upper rear support, 1, and hardware,
2. Do not tighten at this time.
42
90-15
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
43
9. Tighten the hardware, 1, for the upper rear
support, 2.
2
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
46
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.
47
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.
48
90-17
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
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
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
19992572
55
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.
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 1
information.
19992568
57
90-20
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
58
90-21
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
Op. 90 108 around your machine and note the content and
SAFETY DECALS location of these warning signs. Review these decals
with your machine operators.
The following safety decals have been placed on
your machine in the areas indicated. They are Keep the decals legible. If they are not, obtain
intended for the personal safety of you, and those replacements from your New Holland dealer. The
working with you. Please take this manual, walk decal part numbers are listed with each decal.
90-22
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
Part #86521717
L170 - 770 kg/1700 lbs. (Mfg. Rating)
90-23
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS
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
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.
90-26
STARTING SYSTEM POWER DISTRIBUTION SAFETY INTERLOCK AND FUEL SUPPLY SYSTEM INSTRUMENT CLUSTER MONITORING SYSTEM STANDARD LAMPS LOADER ARM LOADER ARM FLASHER AND TURN SIGNALS
AUXILIARY ELECTRIC CONTROL BOX (OPTIONAL) AUXILIARY ELECTRIC POWER CONTROLS (OPTIONAL) NORTH AMERICAN ELECTRICAL
623A W-0.8 623A W-0.8 623A W-0.8 623A W-0.8
42D 42B
622C W-1.0 622C W-1.0
121C DG-1.0 B 178FB B-0.8 B 178EE B-0.8
623A W-0.8 623A W-0.8
26 24 8 24 A 136F DG-0.8 7 24 A 136D DG-0.8
21 314C W-0.8 314C W-0.8 900C O-2.0
623B W-1.0 623B W-1.0 2
53 42A 752A O-2.0
312C T-1.0 312C T-1.0 1 B 178FA B-1.0
136B DG-0.8 15A 900D O-2.0 752B O-1.0
310B R-0.8 310B R-0.8 36 920D R-1.0 10A 1 8 24 A
1 7 24
B 178DE B-1.0
6 136A DG-0.8 190A R-3.0 190A R-3.0 32 920C R-2.0 58A 58 42C 136E DG-1.0 A 170 86 30
783D P-2.0 783F P-1.0 1 1 44 1 2 136C DG-1.0
121D DG-1.0
920B R-2.0
920A R-1.0
920E R-1.0
20A 65 4
20
4 45 47
783G P-1.0
42 7 65 2 753C R-2.0 171 4
23 300A R-1.0
A 2 27 1 171
BATTERY V+ 3 GRAY 120F R-2.0
1 46
121B Y-1.0
8 B 8
IGN 0N (IN) 23 300C R-0.8
SPL15
37 2
59 59A
125A 125
131 0-1.0
5A 907B K-0.8 4 4 907A K-0.8 907A K-0.8 903A O-1.0 3 B A 173
7 9 8 10 8A 138A O-3.0 138A O-3.0 1 2
895A O-1.0 19 12 NOT USED
SPARE (IN)
4 781A P-0.8 5 901B B/W-1.0 5 5 901A B/W-1.0 901A B/W-1.0 904A O-0.8 4 52 OFF
755B Y-1.0 754D Y-1.0
6
178B B-0.8
178E B-0.8 15A 623A W-0.8 9 9 9 BEACON 754C Y-1.0 1
905B R-0.8 6 6 905A R-1.0 905A R-1.0 5
131E R-1.0
101
121A Y-1.0
890A O-2.0 17 310A R-1.0 310A R-1.0 314B W-1.0 SEAT BELT (IN) 13 314C W-0.8
625B W-5.0 3 4
782A P-0.8 906B Y-0.8 7 7 906A Y-1.0 906A Y-1.0 6
FUEL SOLENOID (OUT) 5 132A O-1.0 5 101A 771G Y-1.0 2
26
602A W-1.0
10A 22 3 4 2 1 781A P-0.8 101B 102 902B DB-0.8 8 8 902A DB-1.0 902A DB-1.0 7 12
753A O-2.0 NOT USED 11 622D W-1.0 4
5 6 8 908B T-0.8 9 9 908A T-0.8 908A T-0.8 8 752C O-1.0 12
178B B-0.8 41 ROAD LIGHTS (OUT) 21 781A P-0.8 791G DG-1.0 3
20A 22A 3 4 2 1 8 8A 99 A B 10 10 909A O-0.8 9
820A O-3.0 WORK LIGHTS (OUT) 22 782A P-0.8 29
7 8 24
SPARE (IN) 9 5 5 2 38 41 42 43 911B W-0.8 11 11 911A W-1.0 911A W-1.0 910A O-1.0 10 1 701A G-1.0 4
V 178KB B-2.0 12 12 178KK B-2.0 178KK B-2.0 11
310C R-1.0
TACHOMETER (IN) 35 3
312B T-1.0
314A T-1.0
19 124B R-0.8 4 4 124A R-1.0
L R 43
11 19 1 3 16 1 33 47 86 30 49 86 30 51 1 3 163
784B P-1.0
12
925A DG-2.0
B A
782B P- 0.8
COOLANT TEMP (IN) 5 4 702A Y-0.8
706D P-3.0
120E R-5.0 120E R-5.0 25 257B Y-0.8 3 3 257A Y-1.0 783C P-2.0 784A P-1.0 A 52 52 68 2
120D R-5.0 120D R-5.0 OIL PRESSURE SW (IN) 18 255B Y-0.8 2 2 255A Y-1.0 6
178F B-1.0
2 13 AIR FILTER SW (IN) 16 266B Y-0.8 1 1 266A Y-1.0
B
906B Y-0.8
1 9 7 9
180 30 85 87a 181 86 30
780A O-3.0
5 85 HYD OIL FILTER SW (IN) 15 261A Y-0.8 261A Y-0.8 2 781C P-0.8 906C Y-0.8
2 10 8
2 HYD CHARGE PR (IN) 17 262B Y-0.8 3
P B+
178DB B-1.0
902B DB-0.8 174 174
721B O-1.0
4 3 1 HYD OIL TEMP (IN) 2 264A Y-0.8 782A P-0.8 783B P-2.0 4
15A 4 902C DB-0.8
120A R-13.0
124A R-1.0
178DA B-1.0
3 BRAKE SOLENOID (OUT) 8 258B T-0.8 5
G
131C O-0.8
1 2
HYD INTERLOCK (OUT) 14 311F T-0.8 35 39 905B R-0.8 6 49
5A 19 2 5 4
FUEL LEVEL SENDER (IN) 1 SPL14 27 96 1 3 93 1 3
706B P-1.0
47 85 87 87A 49 85 87 87A 51 2 5 4 905C R-0.8 7 51
3 4 901B B/W-1.0
311G T-1.0
311H T-1.0
AUX OVERRIDE (OUT) 26 8
178AE B-0.8 25A 901C B/W-1.0 66 66X 1 2
623B W-1.0 623B W-1.0 GROUND 20 P 36 137E O-1.0
5 6 1 180 86 87 181 87 85 87a
120B R-13.0 927C LG- 1.0 A A
33 34
234A Y-0.8
178KC B-2.0
312A T-1.0
SPL22 602B W-0.8 602B W-0.8 25 25 178KL B- 1.0 B B 179
120F R-3.0 7 8
706C P-1.0
7 103 B A 178KD B-0.8 178KJ B-0.8 761B Y-1.0
138B O-3.0
2 1 57 B A 62 178DC B-1.0
703B G-1.0
704B Y-1.0
178W B-1.0
8 8A 001X B A 001Z B A 178KE B-2.0
131D O-1.0 44
23 622C W-1.0 622C W-1.0 10 178KF B-0.8
107 704A Y-1.0 703A G-1.0
178XA B-0.8
178ZA B-0.8
311X T-0.8
96 93
311Z T-0.8
602D W-1.0 6 6 2 5 4 2 5 4 L
BLACK 704C Y-1.0 703C G-1.0
137D O-2.0 131A 0-1.0 131A 0-1.0 B A 84 2 751B O-1.0 25 178KG B-0.8 61 61A
9
602C W-1.0
A
TO FRAME 2[3A]
137E O-1.0 9 80
30 B A 40 920F R-1.0 1 1 920G R-1.0 920G R-1.0 N
183 184 176 175 185 186
POS_CBL
8 37 2 2 P
001X 002Z
2 1 63 29 30A B A 3 3 178KH B-2.0 B 2
LEFT RIGHT
15 137F O-1.0 780A O-3.0 5 14 45 B A B A
783A P-3.0 784A P-1.0
923A DBR-2.0 4 4 923B DBR-2.0 923B DBR-2.0 D
3
262 Y-0.8
15A 178AU B-0.8 706A P-3.0 38 901C B/W-1.0 5 5 901D B/W-1.0 901D B/W-1.0 E LIFT ARM 1
830A O-1.0
1 2 20
M 905C R-0.8 6 6 905D R-1.0 905D R-1.0 G CONNECTOR 53 54 57 58
15A 22 23 178
17V B-0.8
9 9
124A R-1.0 4 ACC
7 5 6 920A R-1.0 10 10 920H R-2.0 920H R-2.0 K 178DH B-1.0
7.5A
751A O-0.8 22 21 30 11 11 M 178DD B-1.0
7 8
32 31 P
178CC B-0.8
START
178HH B-1.0 927A LG-1.0 12 12 927B LG-1.0 927B LG-1.0 927D LG-1.0 J
178CK B-0.8
178AE B-0.8
178DG B-1.0
178CJ B-1.0
178DC B-1.0
178DK B-1.0
178DF B-0.8
178DJ B-1.0
178H B-0.8
178U B-0.8
178R B-1.0
200D B-0.8
178V B-0.8
178Y B-1.0
178X B-1.0
178B B-0.8
178B B-0.8
178T B-0.8
178L B-1.0
BAT
178K B-1.0
178D B1.0
751B O-1.0
178KH B-2.0
178KK B-2.0
178KL B-1.0
NEG_CBL 15 4
50 60
MAIN ELECTRICAL BOOM/REAR ELECTRICAL RIGHT-HAND HANDLE (OPTION) LEFT-HAND HANDLE (OPTIONS) RIGHT-HAND HANDLE (OPTIONS) GLOW PLUGS ROTATING BEACON 2 SPEED HORN ACCESSORY OUTLET BACK-UP ALARM
EUROPEAN ON-ROAD REGULATIONS EUROPEAN ON-ROAD REGULATIONS ELECTRICAL MULTIFUNCTION ADAPTION (OPTIONAL) (OPTIONAL) (OPTIONAL) (OPTIONAL) (OPTIONAL)
OPTION F OPTION A
1 5 2 753B O-1.0
163A
102B 41A 150 86 30
1
69
2
84
OFF
137D O-2.0
706E P-2.0
706F P-0.8
BK
GN
POSITION LIGHTS 60 3
12
BK
4 4 178EB B-2.0
ROAD LIGHTS 164F 165F 2 895A O-1.0
4
71 3 3 234 82F
SLOW
67 67A
GN
890B O-1.0 890A O-2.0 890B O-1.0 890A O-2.0
771B P-1.0
FAST
150 87 85 87a 77 A 890AF W-1.0 2 2
72 RD 2 2 235 17 B 565AF B-1.0 76A 182A 91
25A 25 25A 25
TO FRAME
754A Y-1.0 754B Y-1.0 2[3C]
78 890AA W-1.0 192A 641A W-0.8 94
791B P-1.0
RD/ 1 1 A 4
178ER B-1.0 236
1
3 707A P-2.0 73
BL
227A 227 OPTION G
16 B 565AA B-1.0 50A
721D O-0.8
82 82 98
237 LEFT 1 2 B B
142A
5
2
4
6 791E P-1.0 1 1 791F P-0.8 79 890K W-1.0 79F
721C O-1.0
137F O-1.0 1
890D O-1.0
A 12 11 A 12 11
3 3 A A 1 7.5A 130 B B 895B O-1.0
791C P-1.0 791C P-1.0 791D P-1.0 890L W-1.0 RIGHT
7 9 61 771C P-1.0 771C P-1.0 4 4 771D P-1.0 2 2 771F P-0.8 565B LB-1.0 B B 16 84 85 168G 25B 25C
A A
709A P-1.0
10 8
707B P-2.0 707B P-2.0 5 5 707D P-2.0 771E P-1.0 142
79X
178C B-0.8
162 162 5A 707C P-2.0 707C P-2.0 6 6 707E P-1.0 711C P-1.0 4 4 711D P-0.8
178CC B-0.8
1 754AG Y-0.8
711A P-1.0 711A P-1.0 2 2 711B P-1.0 238 83 9
120C R-8.0
166G 167G
160A R-8.0
1 2 2 771AG Y-0.8 172G
713A P-1.0 713A P-1.0 1 1 713B P-1.0 3 3 713F P-0.8 4 4 ON
59 5A
731B P-1.0 731B P-1.0 7 7 731C P-1.0 731C P-1.0 231 231A 713D P-0.8 239
80 82X 82A 890G W-1.0 3 3
82G 8
3 791AG DG-0.8 169G
3
7.5A
4
8 8 B B 892B B-1.0 898A W-1.0 2 2 12 A 890AG W-1.0 4
OFF
79 140 99
17 B 565AG B-1.0 163G 890E O-1.0 B 892A O-1.0
230A 230 17 A A 890K W-1.0 899A W-1.0 1 1 144A
178EG B-1.0
5 6
55 565A LB-1.0 A 13 178M B-1.0
137D O-2.0
7.5A
155B
RIGHT 68 B B
731D P-0.8 890F W-1.0 83X 141 B B 896A O-1.0
7 8 731E P-0.8
1 1 754E Y-1.0
OPTION H STOP
OPTION B A A
157B A A 178ED B-1.0 1 5 132 97 144
62 152 9 2 2 771H Y-1.0
6 AMP 156B
232 232A 178EF B-1.0 240
74 84 86 GO 92 2 3
81
721A O-2.0
10 8 A B 148
761C Y-1.0
8 168H
241 3 3 791H LG-1.0 1 7 9
643A R-32
B A 151
791H LG-1.0 2 1
755A Y-1.0 754A Y-1.0 LEFT 67 242 82 4 4 754E Y-1.0 3 166H 167H
1
2
754AH Y-0.8
771AH Y-0.8 172H 1 001R B/W-0.8
132
6 134
163X 163B 890H 0-1.0 4 82H 8 3 791AH DG-0.8 2 002R DB-0.8 4 96 71 71
HAZARD 62 243 898A W-1.0 5 A 890AH W-1.0
169H
95 897A O-1.0
OFF 76 RD/
83 899A W-1.0 6 17 B 565AH B-1.0
4 3
4
003R P-0.8
004R O-0.8
890C O-1.0 B
TO ACCESSORY
POWER OUTLET
890C O-1.0 B
TO ACCESSORY
POWER OUTLET
BEACON A BL
4 4 565B LB-1.0 7 13 83H 178AD B-1.0 A (NORTH AMERICA) 178AD B-1.0 A (NORTH AMERICA)
5 005R R-0.8
8
6 006R Y-0.8
B 74 RD 3 3 890L W-1.0 9
OPTION J 11 7 007R K-0.8 50
6 AMP 153 890J O-1.0 10
8
GN 2 2 892B B-1.0 11 1 001L B/W-0.8
75 12 2 002L DB-0.8
9 009R O-0.8 93 CONNECT B 817D R-1.0
BK 10 010R O-0.8
1 1 3 003L O-0.8
550A DG-1.0
11 011R K-0.8
GN
4 004L O-0.8
BK
63 65 66 12
ON
1 68A RETRACT RETRACT RETRACT
158 OFF (DOWN) (DOWN) (DOWN) 84 91 86 85
178EM B-1.0
178BM B-1.0
178EP B-1.0
178CH B-1.0
178EU B-0.8
178ER B-1.0
178EC B-2.0
178ES B-0.8
178EA B-2.0
178EB B-2.0
178AD B-1.0
178AD B-1.0
178AD B-1.0
178BL B-0.8
64
178M B-1.0
87 88 89 90
FRAME 9 FRAME 10 FRAME 11 FRAME 12 FRAME 13 FRAME 14 FRAME 15 FRAME 16 FRAME 17 FRAME 18 FRAME 19
BC06M392-09A BC06M392-10A BC06M392-11A BC06M392-12A BC06M392-13A BC06M392-14A BC06M392-15A BC06M392-16A BC06M392-17A BC06M392-18A BC06M392-19A
WIPER/WASHER AUXILIARY HYDRAULICS HIGH FLOW HYDRAULIC COUPLER HEATING AND AIR CONDITIONING (OPTIONAL) PILOT HYDRAULIC GROUND CONNECTIONS GROUND CONNECTIONS COMPONENTS - MECHANICAL AND PILOT CONTROL MACHINES
(OPTIONAL) (OPTIONAL) (OPTIONAL) (OPTIONAL) CONTROLS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS
42F
B 178FD B-0.8
108 1 7 A 136H DG-0.8 FRAME 1 COMPONENTS FRAME 5 COMPONENTS FRAME 10 COMPONENTS FRAME 19 COMPONENTS FRAME 24 COMPONENTS
2 830A O-1.0
2 1 42E
1- 1. Battery 5 - 33. Light Relay #1 10- 69. Optional Right Turn Lamp (Europe) 19- 98. Back-Up Alarm Switch (Left) (Optional) 24- 112. Heater / Air Conditioner Relay
17 17A 540A O-1.0 131D O-1.0 1 B 178FE B-1.0 1- 2. Alternator 5 - 34. Light Relay #2 10- 70. Optional Left Turn Lamp (Europe) 19- 99. Back-Up Alarm Switch (Right) (Optional)
113 1 7 A
250 250
GROUND 23 - CAB 1- 3. Starter And Solenoid 5 - 35. Diode 10- 71. Right Front Turn Lamp (Europe) (Optional) 24- 113. Blower Switch (Optional)
ON
136G DG-1.0 1 2 178FE B-1.0 251A 1- 4. Reverse Polarity Diode 5 - 36. Left Front Work Lamp 10- 72. Right Front Position Lamp (Europe) 19- 100. Back-Up Alarm (Optional) 24- 114. Air Conditioner Switch (Optional)
OFF
830B O-1.0 2 820A O-3.0 820B O-2.0 3 5 821A R-2.0 ET001A R-2.0 GROUND 22 - AIR CONDITIONING / HEATING 1- 5. Starter Relay 5 - 37. Right Front Work Light 10- 73. Right Front Road Lamp (Europe) FRAME 20 COMPONENTS 24- 115. Heater Control Switch (Optional)
ON 4
751A O-0.8 2 31 31A 251 1- 6. Resistor 5 - 38. Rear Work Lamp 10- 74. Left Front Position Lamp (Europe) 20- 101. Wiper / Washer Switch (Optional) 24- 116. Compressor Clutch
112 120 GROUND 9 - BELL HOUSING
1- 7. Ignition Switch 5 - 39. Left Rear Indicator Light 10- 75. Left Front Turn Lamp (Europe) 24- 117. Pressure Switch
890M DG-1.0 109 20- 102. Washer Pump
OFF GROUND 21 - AIR CONDITIONING / HEATING 1- 8. Run Relay 5 - 40. Right Rear Indicator Light 10- 76. Left Front Road Lamp (Europe) 20- 103. Wiper Motor 24- 118. Thermostat
25E 25D 113 ON 114
4
10- 77. Right Rear Brake Lamp (Europe) 24- 119. Blower Motor
OFF 270
GROUND 8 - BELL HOUSING
FRAME 2 COMPONENTS FRAME 6 COMPONENTS FRAME 21 COMPONENTS
101 16 ON 1 549A W-1.0 L
2- 9. Cab Fuse Block 6 - 41. Motor Control Left Relay 10- 78. Right Rear Position Lamp (Europe)
ET001B R-0.8 268 GROUND 20 - BELL HOUSING OR ENGINE 21- 104. Second Auxiliary Hydraulics - FRAME 25 COMPONENTS
106 3 547A W-1.0 B M 271 274
2 - 10. Rear Fuse Block #1 6 - 42. Motor Control Right Relay 10- 79. Left Rear Position Lamp (Europe)
5 4 ET008A Y-0.8 Solenoid #1 25- 120. Loader Control Pressure Solenoid
C H
2 - 11. Rear Fuse Block #2 6 - 43. Wiper Motor Relay 10- 80. License Plate Light
281 282 2 6 273
21- 105. Second Auxiliary Hydraulics - 25- 121. Magnetic Detent Solenoid
2 7 9 3 2 252 269 272 GROUND 19 - CAB 1 GROUND 7 - CAB 2
6 - 44. Fuse (10 amp) 10- 81. Left Rear Position Lamp (Europe)
830C O-1.0 833A W-1.0 3 535A DB-1.0 10 8 FRAME 3 COMPONENTS Solenoid #2 25- 122. Ground Drive Control Pressure
72 275 121 10- 82. Left Rear Brake Lamp (Europe)
RD
BL
163C 9
114 114 ET006A R-2.0 57B 3 - 12. Auxiliary Override Switch FRAME 7 COMPONENTS Solenoid
57A 10- 83. Left Rear Turn Lamp (Europe) FRAME 22 COMPONENTS
557A W-1.0 1 72 81
115 1 311M B-1.0 A GROUND 18 - CAB 1 GROUND 6 - CAB 1 3 - 13. Seat Switch 7 - 45. Attachment Relay 25- 123. Brake Valve Solenoid
81A 4 2 178KM B-1.0 B FRAME 12 COMPONENTS 22- 106. High Flow Switch (Optional)
559A W-1.0 2
12 3 - 14. Seat Belt Switch FRAME 8 COMPONENTS 22- 107. High Flow Solenoid (Optional)
BK
178S B-0.8 245A 8 - 48. Diode (6 amp) 12- 87. Front Electric Control Switch #1 23- 109. Hydraulic Coupler Switch (Optional)
102 104 256A 122 GROUND 16 - UNDER LEFT-HAND ROPS 3 - 18. Not Used
91 80B GROUND 4 - CAB 1
8 - 49. Turn Signal Converter Module 12- 88. Front Electric Control Switch #2 23- 110. Hydraulic Coupler Release Solenoid
A
ET003A P-2.0 E E ET003C P-2.0
258E T-0.8 A
3 - 19. Not Used 8 - 50. Beacon
178FH B-1.0 B
ET004A Y-2.0 B B ET004C Y-2.0
178WB B-1.0 B 3 - 20. Not Used 12- 89. Front Electric Control Switch #3 (Optional)
178P B-1.0
110 ET005A O-2.0 C C ET005C O-2.0 GROUND 15 - CAB 2 8 - 51. Fuse 12- 90. Front Electric Control Switch #4 23- 111. Hydraulic Coupler Engage Solenoid
76 ET001E R-2.0 D D ET001A R-2.0
GROUND 3 - ENGINE STARTER 3 - 21. Fuel Hold-in Solenoid 8 - 52. Hazard/beacon Switch
280 105 XX1 R-1.0 A
ET006B LB-1.0 A A ET001D R-0.8
123 FRAME 13 COMPONENTS (Optional)
B B 830D W-1.0 92
B A 120 XX3 G-1.0 B
ET000A B-1.0 F F ET007A LB-2.0 80C FRAME 4 COMPONENTS 8 - 53. Left Front Flashing Lamp
A A 178EJ B-1.0 A ET000C B-0.8 256 ET000D B-1.0
258F T-0.8 A
GROUND 14 - CAB 1
4 - 22. Fuel Pump (ISM Engine Only) 8 - 54. Left Rear Flashing Lamp 13- 84. Horn Switch
280A 283
178FG B-1.0 B 178WA B-1.0 B
GROUND 2 - CAB MOUNT 4 - 23. Fuel Sender 8 - 55. Turn Indicator Lamp (Left) 13- 85. Turn Signal Switch
111 265 13- 86. Auxiliary Hydraulic Switch
73 264 266 4 - 24. Engine Coolant Temperature Sender 8 - 56. Turn Indicator Lamp (Right)
107 GROUND 13 - UNDER 13- 91. 2 Speed Switch
178WC B-1.0
XX2 W-1.0 A
4 - 25. Engine Oil Pressure Switch 8 - 57. Right Front Flashing Lamp
258D T-0.8
LEFT-HAND ROPS
103 XX4 B-1.0 B
119 GROUND 1 - CAB MOUNT 4 - 26. Air Filer Restriction Switch 8 - 58. Right Rear Flashing Lamp FRAME 14 COMPONENTS
ET018A LB-2.0 GROUND 12
4 - 27. Hydraulic Filter Pressure Switch FRAME 9 COMPONENTS 14- 92. Glow Plug Relay
UNDER RIGHT-HAND ROPS 4 - 28. Charge Pressure Switch 9 - 59. Road Light Switch (Europe) 14- 93. Glow Plugs
PHRT_GND -
ET018 R-2.0 259 262 267 1 2 80A GROUND TOP OF
4 - 29. Hydraulic Oil Temperature Sender 9 - 60. Flasher Module (Europe) FRAME 15 COMPONENTS
BELL HOUSING 4 - 30. Brake Release / Tandem Pump Neutral 9 - 61. Cab Fuse Block (Europe) 15- 50. Beacon
257 4
F E D C B A
261 118 GROUND 11 - UNDER Override Switch 9 - 62. Diode (6 amp) 15- 94. Fuse (7.5 amp)
LEFT-HAND ROPS
STARTER 1
4 - 31. Loader Valve Solenoid 9 - 63. Hazard/beacon Switch (Europe) 15- 95. Beacon Switch
ENGINE STARTER 4 - 32. Loader Valve Solenoid
NEGATIVE CABLE
263
117 9 - 64. Beacon (Europe) FRAME 16 COMPONENTS
260
ET000D B-1.0
ET000E B-0.8
ET000F B-2.0
178FG B-1.0
178FH B-1.0
178CC B-1.0
GROUND 10
178BD B-1.0
178CK B-0.8
178BM B-1.0
178CH B-1.0
178DG B-1.0
178DC B-1.0
178FG B-1.0
178KH B-2.0
178ER B-1.0
178EU B-0.8
178AD B-1.0
178DK B-1.0
178EM B-1.0
178FH B-1.0
178EK B-1.0
178ES B-0.8
178DF B-0.8
178EC B-2.0
178BL B-0.8
178KL B-1.0
178DJ B-1.0
178CJ B-1.0
178KK B-2.0
178EP B-1.0
178EA B-2.0
178EB B-2.0
178S B-0.8
178P B-1.0
178EL B-0.8
178R B-1.0
178U B-0.8
178H B-0.8
XX4 B-1.0
178P B-1.0
178S B-0.8
178X B-1.0
178Y B-1.0
178L B-1.0
178J B-0.8
XX3 G-1.0
XX4 B-1.0
200D B-0.8
178K B-1.0
178V B-0.8
178N B-1.0
178T B-0.8
640C B-32
116 CAB MOUNT 9 - 66. Right Brake Lamp Switch (Europe)
9 - 67. Turn Indicator Lamp (Left) (Europe) FRAME 17 Components
9 - 68. Turn Indicator Lamp (Right) (Europe) 17- 97. Horn (Optional)
121C DG-0.8
21 B A 20 A
138B O-3.0 234A Y-TXL-0.8 1 1 234B Y-0.8 32
300C R-TXL-0.8
AA1 900C O-2.0
136G DG-0.8 136G DG-0.8 178E B-1.0 A
121E DG-0.8
137B DG-TXL-0.8
266B Y-TXL-0.8 266C Y-0.8
300D R-TXL-0.8
895C O-3.0 A1 2 2 783FA P-1.0 A 53
131C O-0.8
B
136A DG-0.8 136H DG-0.8 136H DG-0.8 138A O-3.0 B1 310B R-TXL-0.8 310B R-TXL-0.8 623A W-TXL-0.8 4 4 623C W-0.8 623C W-0.8 178XA B-1.0 B 900D O-2.0
1 2 120F R-3.0
65
46 771P Y-1.0
312C T-TXL-0.8
C
20A 27W
6 136B DG-0.8 C1 641A W-TXL-0.8 5 5 641B W-0.8 641B W-0.8 10A
314C W-TXL-0.8
101A 101 15A 220A R-2.0 3 171
136K DG-0.8 751B O-0.8 9 9 751C O-0.8
D1 BATTERY V+ (IN) 3 783D P-2.0 44 900A O-2.0 5 753F R-1.0
314C W-TXL-0.8
30
54
310B R-TXL-0.8
10 A 261A Y-TXL-0.8 12 12 261B Y-0.8 198
120H R-1.0 AA2 IGN 0N (IN) 23 920D R-1.0
783C P-2.0
20
753C O-1.0 A2 IGN 0N (IN) 24 178DH B-0.8 37 920A R-1.0
125A 125
A 136E DG-1.0
4
1
45 87
87A
752A O-2.0 178F B-1.0 A
136G DG-0.8 B2 132C O-0.8 KEY SWITCH ACC (IN) 10 130B R-0.8 34 1 2 58A C2 F1-C14 B
C2
8 132A O-TXL-0.8 2 2
452A 452B SEAT SWITCH (IN) 12
178DG B-0.8
783GA P-1.0 A 920C R-2.0 1 2 58 58B 1 2
B 178FA B-1.0 2 86 136J DG-1.0 771R Y-1.0 C 27W
124D R-0.8 1
178G B-1.0 178GA B-1.0 B 920B R-2.0 42C 85 178DF B-1.0
121B Y-0.8 190A R-3.0 D2 SEAT BELT (IN) 13 GRAY
121CC DG-0.8 6 6 121C DG-0.8 20 A 602A W-1.0 178DG B-0.8 2
120G R-3.0 AA3 FUEL SOLENOID (OUT) 5 132A-O-TXL-0.8
136B DG-0.8 7 7 136BB DG-0.8 130B R-0.8 3 59 59A 195 57
920E R-1.0
920F R-1.0
820A O-3.0 A3 108 B A SPARE (IN) 11 622D W-TXL-0.8
625A W-TXL-5.0 623B W-1.0 8 8 623BB W-1.0 178DH B-0.8 4 900C O-2.0 1 1 900B O-2.0 900B O-2.0 1 1 136J DG-1.0 178BF B-1.0 A
821A R-3.0 B3 FUEL LEVEL SENDER (IN) 1 234A Y-TXL-0.8 GBLTRCS
783A P-3.0
783B P-2.0
451A 451B 264B Y-0.8 5 913B O-1.0 2 2 913A O-2.0 913A O-2.0 1 2 2 753F R-1.0 B
C3 108A AIR FILTER SW (IN) 16 266B Y-TXL-0.8
314B W-0.8
257C Y-0.8 6 3 3 2 3 3 178DF B-1.0 791J DG-1.0 C
SPARE (IN) 27W
124E R-0.8
310A R-0.8
7
312C T-TXL-0.8
5 8 9 6 7 8A 120J R-2.0 AA4 B 641A W-TXL-0.8
130A R-2.0 A4 HYD OIL FILTER SW (IN) 15 261A Y-TXL-0.8
262D Y-0.8 8
47
901B B/W-1.0 5 5 901A B/W-1.0 901A B/W-1.0 904A O-0.8 4 5 5 771G Y-1.0 196 58
314D W-0.8
38
310D R-0.8
905B R-0.8 6 6 905A R-1.0 905A R-1.0 5 6 6 791G DG-1.0 178BC B-1.0 A
136H DG-0.8 B4 Auxiliary Switch Adapter BRAKE SOLENOID (OUT) 8 258B T-TXL-0.8 258B T-TXL-0.8 1 1 258C T-0.8 101B 30 925A DG-2.0
625B W-5.0
623C W-0.8 42 C4 9 TACHOMETER (IN) 19 124B R-TXL-0.8 124C R-0.8 3 3 124E R-0.8 124E R-0.8 784B P-2.0 33 87 920B R-2.0
906B Y-0.8 7 7 906A Y-1.0 906A Y-1.0 6
F14-C1 C3
302 303 B
820A O-3.0 D4 12 COOLANT TEMP (IN) 25 257B Y-TXL-0.8 257D Y-0.8 4 4 257E Y-0.8 784A P-1.0 A 41 87A 178KE B-2.0
902B DB-0.8 8 8 902A DB-1.0 902A DB-1.0 7 791L DG-1.0 C 27W
178BA B-1.0
623BB W-1.0 A
F7-C2 C14 5A OIL PRESSURE SW (IN) 18 255B Y-TXL-0.8 255D Y-0.8 784C P-2.0 178LA B-1.0 908B T-0.8 9 9 908A T-0.8 908A T-0.8 8
178D B-0.8 B 120L R-0.8 AA5 5 5 255E Y-0.8 B 86 907B K-0.8
121A Y-0.8
602A W-1.0
10 10 909A O-0.8 9
310A R-0.8 A5 22 3 4 2 1 HYD CHARGE PR (IN) 17 262B Y-TXL-0.8 262C Y-0.8 6 6 262E Y-0.8 85 178KF B-0.8
124A R-1.0 623B W-1.0 B5 HYD OIL TEMP (IN) 2 264A Y-TXL-0.8 264C Y-0.8 7 7 264E Y-0.8 178KG B-0.8
911B W-0.8 11 11 911A W-1.0 911A W-1.0 910A O-1.0 10 48 306
C5 22A 3 4 2 1 NOT USED 4 311K T-1.0 8 8 311KK T-1.0
178KB B-2.0 12 12 178KK B-2.0 178KK B-2.0 11 30 47
4 A B C D 106 A D5 SPARE (IN) 9 452A 452B 39
37 49
30 923A DBR-2.0
12
B A 173
752B O-1.0 87
86
106A A AA6 25 A HYD INTERLOCK (OUT) 14 311F T-TXL-0.8 311K T-1.0 36 52 68
120K R-3.0 SPL 22
310C R-0.8
312B T-0.8
314A T-0.8
2 P
L I S
190A R-3.0 A6 ROAD LIGHTS (OUT) 21 781A P-TXL-0.8 311F T-TXL-0.8 178L B-1.0 178LB B-0.8 A
42
87
87A
920C R-2.0
178KC B-2.0 906B Y-0.8
1 754G Y-1.0
755B Y-1.0
754D Y-1.0
178BB B-1.0
87A
85
WORK LIGHTS (OUT) 22 782A P-TXL-0.8 781A P-TXL-0.8 706B P-0.8 2
752D O-1.0
B
5
791M DG-1.0
B6
625C W-5.0
314B W-0.8
10 602B W-TXL-0.8 86 908B T-0.8 906C Y-0.8
178CB B-1.0
3 3 602E W-0.8 AUX OVERRIDE (OUT) 26 3
B+ C6
D6
13 451A 451B GROUND 20 8A 8
782A P-TXL-0.8 C
85 178KF B-0.8 902B DB-0.8 4 HAZARD
622E W-1.0 622E W-1.0 622E W-1.0 85 102 902C DB-0.8
52
781A P-TXL-0.8
178KD B-0.8 OFF
782A P-TXL-0.8
25 A 5
120M R-3.0 AA7 2 602B W-TXL-0.8 602B W-TXL-0.8 266A Y-1.0 3 3 266C Y-0.8 706D P-2.0 905B R-0.8 RIGHT
780A R-3.0 A7 257A Y-1.0 2 2 257E Y-0.8 40 51 6 BEACON
175 56
771R Y-1.0
1 905C R-0.8
771P Y-1.0
130A R-2.0 130A R-2.0 B7 255A Y-1.0 4 4 255E Y-0.8 706A P-2.0 35 3 920E R-1.0 7
791P G-1.0
120A R-13.0 120B R-13.0 783A P-3.0 3 901B B/W-1.0
602D W-1.0
5 927A LG-1.0 8
C7 178LC B-0.8 A
29 24 P 706C P-0.8 43 4
901C B/W-1.0
9 66 66X
622C W-1.0
138D O-2.0
D7
AA8 15 A 1 26 B
C 1 911B W-0.8
178KJ B-0.8 927C LG-1.0 A A WATER PUMP 174
178CA B-1.0
V 178KL B-1.0 B B MOTOR
A8 2 2 178KG B-0.8 1 791N G-1.0 771S Y-1.0
131A 0-2.0 300B O-2.0
782C P-0.8 B8
11 25 3 721B O-1.0 176 55
178Y B-1.0
771GA Y-1.0
312A T-0.8
4 771N Y-1.0 LEFT
131A 0-2.0
45
830E O-2.0 A9 311KK T-1.0 782B P-0.8 9 87a
SPL14
7 782C P-0.8 920F R-1.0 1 1 920G R-1.0 920G R-1.0 N
A B
8 178DJ B-1.0 791GA B-1.0
234B Y-0.8
B9 258C T-0.8 87
311G T-1.0
311H T-1.0
C9 B A 84 1 IVC2 B-0.8 781A P-TXL-0.8 2 2 P 10 178DL B-1.0 85
2
M 264E Y-0.8 781D P-0.8 3 3 178KH B-2.0 B 2 755B Y-1.0
OFF IGN C14 F19-C1 890C O-1.0 D9 781C P-0.8 791N G-1.0 30
IVC3 B-0.8
AA10 64 923A DBR-2.0 4 4 923B DBR-2.0 923B DBR-2.0 D 5 791G DG-1.0 86
C13 F12-C3 890A O-2.0 62 261B Y-0.8
29
IVC4 B-0.8
ACC A10 80 1 2 901C B/W-1.0 5 5 901D B/W-1.0 901D B/W-1.0 E LIFT ARM
C12 F20-C1 895A O-0.8 183
450A 450B 14 57 B A 103 B A 905C R-0.8 6 6 905D R-1.0 905D R-1.0 G CONNECTOR
178HH B-0.8
C11 F12-C1 753C O-1.0 B10 262E Y-0.8
1 1 120EE R-5.0
2 2 120DD R-5.0 BAT
START
C10 F1-C4 120E R-5.0 C10 11 19 C10 F21-C1 311F T-TXL-0.8
906C Y-0.8 7 7 906D Y-1.0 906D Y-1.0 H
1 178DK B-1.0
752D O-1.0 87a
D10
902C DB-0.8 8 8 902D DB-1.0 902D DB-1.0 F
771G Y-1.0 85
C9 F25-C1 821A R-3.0 30 C9 F21-C3 311K T-1.0
P 925A DG-2.0 9 9 925B DG-2.0 925B DG-2.0 C
1 130B R-0.8 F4-C7 C13 C8 F1-C3 120D R-5.0 B
P
C8 F1-C1 124E R-0.8 920A R-1.0 10 10 920H R-2.0 920H R-2.0 K 2 761B Y-1.0
771N Y-1.0
771GA Y-1.0
30
200D BK-TXL-0.8
C7 F3-C1 310A R-0.8 783B P-2.0 F5-C2 C21 63 C7 F1-C13 130B R-0.8 87
622D W-TXL-0.8 F4-C3 C12 A 11 11 M 178
137B DG-TXL-0.8 F4-C2 C11 C6 F1-C8 623B W-1.0 781C P-0.8 F5-C6 C20 23 27 C6 F15-C1 641B W-0.8 781C P-0.8 F2-C20 C6 927A LG-1.0 927B LG-1.0 927B LG-1.0 927D LG-1.0
1 86
178CJ B-1.0
12 12 J
178CK B-0.8
178DG B-0.8
178DH B-0.8
178DC B-1.0
178CD B-1.0
20 21 50
178H B-0.8
178B DB1.0
178C B-0.8
178D B-0.8
178Y B-1.0
201A B-3.0
178K B-1.0
178T B-0.8
178L B-1.0
178G B-1.0
C5 F3-C2 314B W-0.8 784C P-2.0 F5-C3 C19 C5 F1-C7 623C W-0.8 782C P-0.8 F2-C1 C5 179 184
178V B-0.8
NEG_CBL
178B B-1.0
30 51
178KH B-2.0
178KK B-2.0
178KL B-1.0
120E R-5.0 F2-C10 C4 137E O-1.0 F8-C1 C9 C4 F5-C1 783A P-3.0 706A P-2.0 F5-C4 C18 C4 F2-C2 751B O-0.8 706A P-2.0 F2-C18 C4
120D R-5.0 F2-C8 C3 623B W-1.0 F2-C6 C8 C3 F4-C1 300A R-1.0 830A O-2.0 F21-C2 C17 32 31 28 C3 F1-C12 622D W-TXL-0.8 784C P-2.0 F2-C19 C3 2 49
120C R-32 F15-C2 C2 623C W-0.8 F4-C5 C7 C2 F4-C4 751B O-0.8 751A O-0.8 F23-C1 C16 314B W-0.8 F2-C5 C2 C2 F1-C11 137B DG-TXL-0.8 783B P-2.0 F2-C21 C2
124E R-0.8 F4-C8 C1 136K DG-0.8 F12-C2 C6 C1 F5-C5 782C P-0.8 540A O-0.8 F24-C1 C15 310A R-0.8 F2-C7 C1 C1 F2-C3 300A R-1.0 783A P-3.0 F2-C4 C1 C1 F1-C5 120F R-3.0 C1 F1-C9 137E O-1.0
MAIN ELECTRICAL BOOM/REAR ELECTRICAL WORK LAMPS CONTROL LEVER INTERFACE LEFT-HAND CONTROL LEVER (OPTIONS) RIGHT-HAND CONTROL LEVER GRID HEATER SYSTEM ROTATING BEACON 2 SPEED HORN ACCESSORY OUTLET BACK-UP ALARM
EUROPEAN ON-ROAD REGULATIONS EUROPEAN ON-ROAD REGULATIONS CAB UPGRADE MACHINES CAB UPGRADE MACHINES CAB UPGRADE MACHINES (OPTIONAL) CAB UPGRADE MACHINES (OPTIONAL) (OPTIONAL) CAB UPGRADE MACHINES CAB UPGRADE MACHINES CAB UPGRADE MACHINES
CAB UPGRADE MACHINES CAB UPGRADE MACHINES CAB UPGRADE MACHINES CAB UPGRADE MACHINES CAB UPGRADE MACHINES
178EB B-2.0
HORN HORN SWITCH, TURN SIGNALS,
1 150
1 AND 2-SPEED FRONT AUXILIARY ELECTRICAL
2 753B O-1.0 753B O-1.0 30
POSITION LIGHTS 3 178DD B-1.0 754H Y-1.0 87 RHEU 73 178DE B-1.0
3
2
LEFT (RIGHT-HAND CONTROL LEVER) 147
OFF 4 754H Y-1.0 86 178EB B-2.0 1
753C O-1.0
4 84 86 RIGHT 100 178N B-1.0
ROAD LIGHTS 5 771KA Y-1.0 87A 707D P-1.0 2 LB 73 136K DG-0.8
5
6 791KA DG-1.0 178DD B-1.0 85 3 HB OFF
136K DG-0.8 1 6 146
59 303A 711C P-1.0 4 POS 72 753C O-1.0 2
C3 F12-C6 7 ON 1 001RA B/W-0.8
60 791E P-0.8 5 TS 178DE B-1.0 3 8 2 002RA DB-0.8 EXT
1
6 CL
71 37 36 754F Y-1.0 4 9 010RD O-1.0 3 003RA P-0.8 (UP)
178LE B-1.0 A 771K Y-1.0 5 10 4
SLOW RET
3
4
707A P-2.0 B 791K DG-1.0 6 11 011RD K-1.0 5 85 FAST (DN)
784E P-1.0 C 302X 12 6
6 709A P-1.0 27W C4 F12-C6 7
178EA B-2.0 74C-C6 007RA K-0.8
7 8 88 Back-up Alarm Adapter
9 178ES B-0.8 791C P-1.0 791C P-1.0 3 3 791D P-1.0
33A 38 37 HORN AND 2-SPEED 9 009RA O-0.8
8
771C P-1.0 771C P-1.0 4 4 771D P-1.0 LHEU 76 F5
A 784D P-1.0 784F P-1.0 A 202D B-1.0 10 010RA O-1.0 143
178LD B-1.0 178LF B-1.0
10
2 706E P-0.8
61 707B P-1.0 707B P-1.0 5 5 707D P-1.0 178EA B-2.0 1
B B
4
SLOW
11 011RA K-1.0 641B W-0.8 A 897B O-0.8
5 707C P-1.0 707C P-1.0 6 6 707E P-1.0 707E P-1.0 2 LB 76 50W 202D B-1.0 3
F22-C1 C7 FAST
12 OFF B 896C O-0.8
P
711A P-1.0 711A P-1.0 2 2 711B P-1.0 3 HB 31 38 557B W-1.0 2 85 74C-C3 120C R-32
709A P-1.0
1 ON 190A 142
162 713A P-1.0 713A P-1.0 1
7
1
7
713B P-1.0 713C P-1.0 4 POS 74 178LG B-1.0 A 559B W-1.0 1 2 EXT 55 ON
5A 550A DG-1.0 731B P-1.0 731B P-1.0 731C P-1.0 771E P-0.8 5 TS B 310B 3 (UP)
1 2 B A 159
8 8 6 CL
75 784G P-1.0 C
27W 4 84 RET
OFF
62 5A
B A 159A
230A 230 5
1
2
001L B/W-0.8
002L DB-0.8 (DN) 92 565A LB-0.8
3 4 6
7.5A C2 F12-C6 OFF 3 003L O-0.8
B A 151 7 007RC K-0.8 190
74 4 004L O-0.8 89 892A O-1.0
731A P-1.0
643A R-32
178CC B-1.0
755a Y-1.0 8 791KK DG-1.0 2 2-SPEED, AND SECOND AUXILIARY 6 006L Y-0.8 2 3
7 10 010RC O-1.0 C1 F7-C3
754K Y-1.0 3 11 011RC K-1.0
7 007L K-0.8 10 8 A B 148
761C Y-1.0
137D O-2.0
721A O-1.0
LEFT 8
EUT 890H 0-1.0 008L T-0.8
62 152 161A
77
4
F13-C5 C6 12 7 9 140 890C O-1.0
160A 66 178ED B-1.0 1 33B 41 39 559B W-1.0 5
F13-C4 C6 74C-C5 86 RIGHT 9 009L O-0.8
132
1
892A O-1.0
B A 153 65 711D P-0.8 2 POS
A 783F P-1.0 783FB P-1.0 A
557B W-1.0 6
F13-C3 C6 84 10 010L O-0.8 6 134 178M B-1.0 97
721A O-1.0
731D P-0.8 3 BRK 78 F5
B 178R B-1.0 178RA B-1.0 B
565A LB-0.8 7
F13-C2 C6
11
12
011L W-0.8
EXT 4 96 141 71
791F P-0.8 8 190B
741A O-1.0
4 TS
50W 890G O-0.8 9
F13-C1 C6
68A-C0
(UP) 95 890C O-1.0 B
TO ACCESSORY
POWER OUTLET 897C O-0.8
79 43 HORN AND TURN SIGNALS
RET 178AD B-1.0 A
A 145A
HAZARD
791H B-0.8 1 1 791F P-0.8
178RB B-1.0 A
890F O-1.0
892B O-1.0
10
11
87 (DN)
(NORTH AMERICA) B
771H B-0.8 2 2 771F P-0.8 STOP P
OFF
160B
161B
711G P-0.8 3 3 711D P-0.8 238 B 12 50 A
90
791KK DG-1.0
LEFT 1 001R B/W-0.8 GO
771B P-1.0
771KK Y-1.0
713G P-1.0 4 4 713H B-1.0 713F P-0.8 27W 895E O-0.8 144A
892B O-1.0
791B P-1.0
754K Y-1.0
2 002R DB-0.8
63 551A DG-1.0 731C P-1.0 5 5 731H B-1.0 239
80 RIGHT
3 003R P-0.8 191B
178EC B-1.0 6 6 178EN B-1.0 178EG B-0.8 1 001RB B/W-0.8
4 004R O-0.8 CONNECT B 817D R-1.0 Back-up Alarm Adapter
RIGHT RLB1 RLB2 2 002RB DB-0.8 OFF TO 71 A 178BZ B-1.0
154 5 005R R-0.8
155B 68 3 003RB P-0.8
890AA O-2.0
6 006R Y-0.8 ON 71A
1 791BH P-1.0 791BG P-1.0 9 10 11 12 452B 4 C5 F12-C6 7 007R K-0.8
3 741A O-1.0 EUT2 9 10 11 12 452A 5 SLOW TO ACCESSORY POWER OUTLET (EUROPE)
4 771A P-1.0 178EM B-1.0 178TE B-1.0 1 81 6 86 8
FAST
91 93
721D O-0.8
721C 0-1.0
C1 F12-C6 OFF 9 009R O-0.8
754F Y-1.0
771K Y-1.0
791K DG-1.0
892A O-1.0
6 761A P-1.0 157B 713D P-0.8 2 POS 7 191
450A 450B
10 010R O-1.0
7 706F P-0.8 771AB B-1.0 731E P-0.8 3 BRK 82 8 ON 11 011R K-1.0 A 896A O-0.8
3 3
9 178EU B-0.8
156B 67 771F P-0.8 4 TS 9
12
99 B 895D O-0.8
LEFT
8
10
83 10
11
010RB O-1.0
011RB K-1.0 74B-CO 94
890A O-2.0
2 755A Y-1.0 12
OFF
5 761A P-1.0 2
74C-C4 85 1 2 451B 10
178CH B-0.8
178CC B-1.0
178BM B-1.0
178DE B-1.0
178EC B-1.0
178EV B-1.0
178EA B-2.0
178EB B-2.0
178AD B-1.0
178BL B-0.8
84 ON 451A 10
178M B-1.0
178N B-1.0
C5 F18-C1 892A O-1.0
202D B-1.0
640C B-32
102B 178EP B-1.0 1
C4 F17-C1 565A LB-0.8 7.5A 130
706G P-2.0 158 C3 F2-C13 890A O-2.0
178ER B-1.0 64 C2 F1-C6 136K DG-0.8 84 C2 F1-C2 120C R-32
137D O-2.0 F1-C10 C1 C1 F2-C11 753C O-1.0 C1 F4-C6 641B W-0.8 C1 F8-C1 137F O-1.0 C1 F12-C4 565A LB-0.8 C1 F12-C5 892A O-1.0 C1 F2-C14 890C O-1.0 C1 F2-C12 895A O-0.8
FRAME 9 FRAME 10 FRAME 11 FRAME 12 FRAME 13 FRAME 14 FRAME 15 FRAME 16 FRAME 17 FRAME 18 FRAME 19 FRAME 20
BC07E492-09A BC07E492-10A BC07E492-11A BC07E492-12A BC07E492-13A BC07E492-14A BC07E492-15A BC07E492-16A BC07E492-17A BC07E492-18A BC07E492-19A BC07E492-20A
WIPER/WASHER AUXILIARY HYDRAULICS HIGH FLOW HYDRAULIC HEATING AND AIR CONDITIONING PILOT HYDRAULIC CONTROLS GROUND CONNECTIONS - CAB UPGRADE MACHINES COMPONENTS - MECHANICAL AND PILOT CONTROL MACHINES
AND DOOR SWITCH (OPTIONAL) (OPTIONAL) MOUNT PLATE (OPTIONAL) (OPTIONAL) FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS
ET000F B-3.0
(OPTIONAL) CAB UPGRADE MACHINES CAB UPGRADE MACHINES (OPTIONAL) CAB UPGRADE MACHINES CAB UPGRADE MACHINES GRD 22 - HVAC
CAB UPGRADE MACHINES CAB UPGRADE MACHINES FRAME 1 COMPONENTS FRAME 5 COMPONENTS FRAME 10 COMPONENTS FRAME 17 COMPONENTS FRAME 25 COMPONENTS
GRD 21 - HVAC
ET000E B-0.8 1- 1. Battery 5 - 33. Not Used 10- 71. Right Front Turn Lamp (Europe) 17- 96. 2 Speed Solenoid 25- 109. Blower Switch (Optional)
1- 2. Alternator 5 - 34. Not Used 10- 72. Right Front Position Lamp (Europe) FRAME 18 Components 25- 110. Air Conditioner Switch (Optional)
178EX B-1.0
821B R-3.0 B
B 114 178EK B-2.0
1- 3. Starter and Solenoid 5 - 35. Diode 10- 73. Right Front Road Lamp (Europe 18- 97. Horn (Optional) 25- 111. Heater Control Switch (Optional)
GRD 19 - CAB 1
821E R-1.0 C
C
1- 4. Reverse Polarity Diode 5 - 36. Left Front Work Lamp 10- 74. Left Front Position Lamp (Europe) 25- 112. Compressor Clutch
ET005A R-3.0 H
H
M
109 178KK B-2.0 1- 5. Starter Relay 5 - 37. Right Front Work Lamp 10- 75. Left Front Turn Lamp (Europe) FRAME 19 COMPONENTS 25- 113. Pressure Switch
ET004A Y-3.0 M GRD 17 - UNDER LEFT-HAND ROP
ET003A P-3.0 L
L 1- 6. Resistor 5 - 38. Rear Work Lamp 10- 76. Left Front Road Lamp (Europe) No Components 25- 114. Thermostat
A 311M T-1.0
B 311L T-1.0 108 270A
262 263
116 178KL B-1.0 1- 7. Ignition Switch 5 - 39. Left Rear Indicator Lamp 10- 77. Right Rear Position Lamp (Europe) FRAME 20 COMPONENTS 25- 115. Blower Motor
C 73 178KH B-2.0 5 - 40. Right Rear Indicator Lamp 10- 78. Right Rear Brake Lamp (Europe)
549B W-0.8
GRD 16 - UNDER LEFT-HAND ROP FRAME 2 COMPONENTS 20- 100. Back-Up Alarm FRAME 26 COMPONENTS
A OFF F4
504 10- 79. Right Rear Turn Lamp (Europe)
ET007A LB-1.0
ET018A LB-1.0
B 178AC B-0.8 ON 178EV B-1.0 2- 8. Electrical Accessory (Run) Relay FRAME 6 COMPONENTS 20- 98. Back-Up Alarm Switch 26- 116. Loader Control Pressure Solenoid
2- 9. HVAC Relay 6 - 41. Motor Control Left Relay 10- 80. License Plate Lamp 20- 99. Back-Up Alarm Switch
1 225C P-1.0 76
178ER B-1.0 26- 117. Magnetic Detent Solenoid
229A B-1.0
GRD 14 - CAB 1
2 - 10. Starter Relay 6 - 42. Motor Control Right Relay 10- 81. Left Rear Position Lamp (Europe)
2
A 178A G-0.8 178EC B-1.0 FRAME 21 COMPONENTS 26- 118. Ground Drive Control Pressure
3 134A P-1.0 178EA B-2.0 2 - 11. Lamp Relay #1 6 - 43. Wiper Motor Relay 10- 82. Left Rear Brake Lamp (Europe)
B 547B R-0.8 821E R-1.0 1 110 21- 101. Washer Pump Solenoid
502
821F R-1.0 2 GRD 13 - UNDER LEFT-HAND ROP
178EB B-2.0
2 - 11. Lamp Relay #2 6 - 44. Fuse (10 amp) 10- 83. Left Rear Turn Lamp (Europe)
OFF 107 26- 119. Brake Valve Solenoid
1 559A W-1.0 178ET B-1.0 3
259 117 178CD B-1.0 FRAME 11 COMPONENTS FRAME 22 COMPONENTS
C1 F12-C7
2 557A W-1.0 ON 275A 57A 57B 178DC B-1.0 FRAME 3 COMPONENTS FRAME 7 COMPONENTS 22- 102. Second Auxiliary Hydraulics -
3 202C B-1.0
104 113 1 311M B-1.0 A 178B B-1.0 3 - 12. Auxiliary Override Switch 7 - 45. Attachment Relay 11- 36. Optional Right Rear Work Lamp
4 F4 Solenoid #1
178AC B-0.8
1 134A P-1.0 BK 2 178KM B-1.0 GRD 7 - CAB 2 - FL/TS 11- 37. Standard Rear Work Lamp
549B W-0.8
B
178A G-0.8
547B R-0.8
4
3
7 225A P-1.0 ON 178M B-1.0 8 - 48. Diode (6 amp) 23- 104. High Flow Switch (Optional)
1
102
2
3
4
72
8 229B B-1.0 OFF 118 200M B-2.0
178L B-1.0 3.- 17. Not Used 8 - 49. Turn Signal Converter Module FRAME 12 COMPONENTS
91 80B 23- 105. High Flow Solenoid (Optional)
451B 451A
549A W-0.8
547A R-0.8
178AK B-0.8
178AE B-0.8
9
559A W-1.0
ON
821F R-1.0 1 1 ET007A LB-1.0 A 200D BK-TXL-0.8 3.- 18. Not Used 8 - 50. Beacon No Components
11 11
A 258E T-0.8 A
10 200N B-2.0 178AD B-1.0
503
B 202A B-1.0 ET008A Y-0.8 2 2 ET008B Y-0.8 B 178WB B-1.0 B GRD4 - CAB 1
178AF B-1.0
3 - 19. Cold Start Advance Temperature 8 - 51. Fuse FRAME 24 COMPONENTS
821D R-0.8 3 3 ET001D R-0.8 C
Sender FRAME 13 COMPONENTS 24- 106. Hydraulic Coupler Switch (Optional)
103 114
ET003A P-3.0 4 4 ET003C P-3.0 D
178Y B-1.0 8 - 52. Hazard/Beacon Switch 13- 84. Horn Switch
105 ET004A Y-3.0 5 5 ET004C Y-3.0 E 119 GRD3 - ENGINE STARTER 3 - 20. Cold Start Advance Solenoid 8 - 53. Left Front Flashing Lamp 24- 107. Hydraulic Coupler Release Solenoid
101 92 120 1 ET005A O-3.0 6 6 ET005C O-3.0 F 80C 178N B-1.0
3 - 21. Fuel Hold-In Solenoid 13- 85. 2-Speed Switch (Optional)
A 557A W-1.0 A 535C DB-0.8 3 821G R-1.0 7 7 ET018 R-1.0 258F T-0.8 A 200H B-2.0 178C B-0.8 8 - 54. Left Rear Flashing Lamp
257
B 202B B-1.0 B 178P B-0.8 4 8 8 178WA B-1.0 B 178H B-0.8 13- 86. Turn Signal Switch 24- 108. Hydraulic Coupler Engage Solenoid
6 178BD B-1.0 FRAME 4 COMPONENTS 8 - 55. Turn Indicator Lamp (Left) 13- 87. Auxiliary Hydraulic Switch
2 229CC B-1.0
7
HVAC1 HVAC2 265
200K B-2.0 178K B-1.0 4 - 22. Fuel Pump (ISM Engine Only) 8 - 56. Turn Indicator Lamp (Right) (Optional)
450B 450A
264 266
178WC B-1.0
9
266AA P-1.0 4 - 23. Fuel Sender 8 - 57. Right Front Flashing Lamp
258D T-0.8
1
8 178AG B-0.8 178CK B-0.8
501
4 - 24. Engine Coolant Temperature Sender 8 - 58. Right Rear Flashing Lamp 14- 88. Front Electric Control Switch #1
1 1 229C B-1.0 10 115 200L B-2.0
178CC B-1.0
14- 89. Front Electric Control Switch #2
821K R-1.0
510A 510B 2 2 266A P-1.0 120B 120C 2 540A O-0.8 4 - 25. Engine Oil Pressure Switch
178V B-0.8 FRAME 9 COMPONENTS
535BD B-0.8 5
A A 311MM T-1.0 3 3 311M T-1.0 A A
80A 200G B-2.0 178T B-0.8 4 - 26. Air Filer Restriction Switch 14- 90. Front Electric Control Switch #3
B B 206AA R-2.0 4 4 206A R-2.0 B 178PA B-0.8 B GRD1 - CAB MOUNT 178CJ B-1.0 9 - 59. Road Lamp Switch (Europe) 14- 91. Front Electric Control Switch #4
C C 229DD B-2.0 5 5 229D B-2.0 267 F4
1
2
4 - 27. Hydraulic Filter Pressure Switch 9 - 60. Flasher Module (Europe)
311L T-1.0 High Flow Adapter 202D B-1.0
D D 311LL T-1.0 6 6
261 200P B-2.0 178HCHB-0.8
4 - 28. Charge Pressure Switch 9 - 61. Cab Fuse Block (Europe) FRAME 15 COMPONENTS
610A 610B
GRD1A
178D B-0.8 4 - 29. Hydraulic Oil Temperature Sender 9 - 62. Diode (6 amp) 15- 92. Grid Heater Relay
112 4 - 30. Brake Release / Tandem Pump Neutral 15- 93. Grid Heater
201A B-3.0 9 - 63. Hazard/Beacon Switch (Europe)
BUSSMANN GND Override Switch 9 - 64. Beacon (Europe)
4 - 31. Loader Valve Solenoid FRAME 16 COMPONENTS
ET000E B-0.8
ET000F B-3.0
178EX B-1.0
178AF B-1.0
P A
32
19 19 T B
6 6
15 15
18 18
30 30
OPENS AT 50 PSI OPENS AT 50 PSI
20 17 23 B D F OUT
20 17 23 B D F OUT
160 ±10 PSI 160 ±10 PSI R2
7 5 21 7 5 21
7 5 R2
7 1 2
7 5 7
9 IN 9 4 IN
BYD
5 5 BYD
1
R2
2
R2
8 22 R2 22
2.48 CID R1 R1 5.04 CID R1 R2 R1
R1 R1
29
R1 R1 P
A C AUX E 8 28 A C AUX E
R2 R2 R2 R2
R1 R1 IN 27 IN 27
4 4 5 5
11 11
12 12
PILOT CONTROL MACHINES (OPTION) HIGH FLOW (OPTION) GROUND DRIVE CONTROLLER IMPLEMENT CONTROLLER CONTROL VALVE
ZG ZG ZG ZG ZG ZG
ZF ZF ZF ZF ZF ZF ZF ZF
ZE ZE ZE ZE ZE ZE
50 PSID
23 39 40
5 44
13 14
18 A B
21
43
16 19 22 ZD ZD ZD ZD ZD ZD ZD ZD
ZC ZC ZC ZC ZC ZC ZC ZC
15
P T
ZB ZB ZB ZB ZB ZB
42 FC MC
41
20 28
F9 F9 F9 F9 G7 G6 G5 G4 F5 F4
17 5 5 5
A B A B A B
32 35
25
11 P
12
F9 SV1
H11 J8 P T
H13 8 27 31 P T
CV1 1
RV1
R T MB B Y G B MB R G2 (Fe) 29 29
4 R4 29
2
ZA ZA AUX T 5
1 2 3 4