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New Holland LS160 Manual

New Holland LS160 Manual

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Workshop manual (41 pages)

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SECTION 00 – GENERAL INFORMATION

Section

Description

Introduction

About Improvements

Company Policy

Parts and Accessories

Precautionary Statements

Safety Precaution Information

General Safety Information

Machine Model And Serial Number Location

Engine Model And Serial Number Location

Hardware Torque Specifications

Installation Of Adjustable Fittings In Straight Thread O Ring Bosses

Standard Torque Data For Hydraulic Tubes And Fittings

Pipe Thread Fitting Torque

Lubricants And Coolants

Properly Support A Raised Machine

Properly Support Boom On Boom Lock Pins

Raising Boom Without Hydraulic Oil Flow

Raising Boom Without Battery Voltage (12V)

Reattaching Cylinders After Repair With Boom Resting On Boom Lock Pins

Major Unit Overhaul

Cab And Boom Tilt Procedure

Craning The Skid Steer

CONTENTS

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Summary of Contents for New Holland LS160

Page 1 SECTION 00 – GENERAL INFORMATION CONTENTS Section Description Page Introduction ..............00-2 About Improvements .
Page 2 (the location of the Models LS160 and LS170 skid steers. Use it in these numbers is described later in this section). conjunction with the operator’s manual which is Record the serial numbers here.
Page 3 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”...
Page 4 SECTION 00 - GENERAL INFORMATION PRECAUTIONARY STATEMENTS DANGER The word “DANGER” denotes a forbidden practice in connection with a serious hazard. PERSONAL SAFETY Throughout this manual and on machine decals, you will find precautionary statements (“CAUTION”, Failure to follow the “CAUTION”, “WARNING”, and “WARNING”, and “DANGER”) followed by specific “DANGER”...
Page 5 SECTION 00 - GENERAL INFORMATION ground battery cable. This will shut off power SAFETY PRECAUTIONS to the eic and prevent damage to the eic CAUTION board or blowing the 5-amp fuses if the board is accidentally grounded. Unsafe operating practices and improper use of the skid steer and its attachments on the part of 16.
Page 6 Headlights, warning lights and smv signs are available through your new holland dealer. DANGER Fasten seat belt before starting engine! 39. Keep the skid steer clean. Do not allow trash, debris or other articles to accumulate in the...
Page 7 SECTION 00 - GENERAL INFORMATION If an accident occurs, see a doctor immediately. Any GENERAL SAFETY INFORMATION fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors HANDLE FLUIDS SAFELY unfamiliar with this type of injury should reference a When you work around fuel or other flammable knowledgeable medical source.
Page 8 SECTION 00 - GENERAL INFORMATION plate. If servicing requires the complete skid steer to WARNING be in the supported position, support all four wheels Engine starting with a booster battery requires off the ground using adequate jack stands or blocks. extreme care as batteries produce explosive gases.
Page 9 SECTION 00 - GENERAL INFORMATION MACHINE MODEL AND SERIAL NUMBER LOCATION The skid steer model and serial number tag is located on the right front interior of the operator’s cab at 1. 2534-05 ENGINE MODEL AND SERIAL NUMBER LOCATION The engine model and serial number is located on the left side of the block at 1.
Page 10 SECTION 00 - GENERAL INFORMATION MINIMUM HARDWARE TIGHTENING TORQUES IN FOOT POUNDS (NEWTON-METERS) FOR NORMAL ASSEMBLY APPLICATIONS INCH HARDWARE AND LOCKNUTS SAE GRADE 2 SAE GRADE 5 SAE GRADE 8 LOCKNUTS NOMINAL UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED GR.B GR.C NOMINAL SIZE W/ZnCr...
Page 11 SECTION 00 - GENERAL INFORMATION MINIMUM HARDWARE TIGHTENING TORQUES IN FOOT POUNDS (NEWTON-METERS) FOR NORMAL ASSEMBLY APPLICATIONS METRIC HARDWARE AND LOCKNUTS CLASS 5.8 CLASS 8.8 CLASS 10.9 LOCKNUT NOMINAL CL.8 SIZE UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED W/CL8.8 W/ZnCr W/ZnCr W/ZnCr BOLT 15* (1.7)
Page 12 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.
Page 13 1/2″ – 14 41 N⋅m (30 ft. lbs.) 3/4″ – 14 54 N⋅m (40 ft. lbs.) LUBRICANTS AND COOLANTS Application New Holland Part Number Specification Gearboxes 1 qt – #9613295 SAE 80W-90 2.5 gal – #9613294 4 L – #9613375 Final Drive chain case 1 qt –...
Page 14 SECTION 00 - GENERAL INFORMATION PROPERLY SUPPORT A RAISED MACHINE If servicing neutral adjustment, final drive adjustment or repairs requiring the machine to be raised, securely support the machine with adequate jack stands or blocks as shown. Support the machine at 1 to the front of the final drive cases and to the rear at 2, making sure the supports are on the flat area of the final drive cases.
Page 15 SECTION 00 - GENERAL INFORMATION 3. Attach a chain or strap, 1, to the main boom, 2, and lifting device, 3. Attach chain or strap securely to prevent unhooking during boom lifting. CAUTION Attach suitable chains or straps capable of handling the weight of the boom, 454 kg (1000 lbs).
Page 16 SECTION 00 - GENERAL INFORMATION RAISING BOOM WITHOUT BATTERY VOLTAGE (12 VOLTS) 1. Remove any attachment from the boom mounting plate. 2. Block the rear of the skid steer under the rear of the final drive cases, 1, as shown. This will prevent the front wheels from raising during boom lifting.
Page 17 SECTION 00 - GENERAL INFORMATION 5. Support the cylinders on the fenders, 1, as shown. 19995761 6. With an Operator sitting in the Operator’s seat with the seat belt buckled, slowly raise the boom above the boom lock pins, 1. 7.
Page 18 The figure shows the skid steer properly supported and the cab tilted forward. 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. 00-18...
Page 19 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.
Page 20 SECTION 00 - GENERAL INFORMATION 3. Jack up the skid steer and block it securely with all four wheels off the ground, as shown. Position the front blocks, 1, to the front of the final drive housings and the rear blocks, 2, to the rear of the flat area of the final drive housings.
Page 21 SECTION 00 - GENERAL INFORMATION 7. Remove fenders, 1, right and left sides. 8. Remove foam material, 2, from both sides. 9. Remove the rear fender supports, 3, right and left sides. 10. Raise the seat and lock in the up position, 1. Make sure the seat pan assembly is latched securely.
Page 22 2, and 1/2″ nut. 14. Install the upper cab jack support, 1. The spacer channel, 2, is used for the LS160 and LS170 models. Pivot the retaining plate, 3, up behind the boom top link and secure with 1/2″ x 1-1/4″...
Page 23 SECTION 00 - GENERAL INFORMATION 15. Install the jack assembly, 1, between the upper and lower supports using two pins and retaining clips. 16. Loosen the front cab mounting bolts, 2, only enough to allow the bolt to rotate in post. Remove the rear front cab bolts, 3.
Page 24 SECTION 00 - GENERAL INFORMATION To jack the cab and boom assembly back into position: 1. Pull the hydrostat control handles forward and hold in this position with rubber tie straps from the handle to the front cab post. 2. Jack the cab and boom back into position. 3.
Page 25 SECTION 00 - GENERAL INFORMATION CRANING THE SKID STEER If the skid steer is inoperative and located in an area where it cannot be loaded onto a truck or trailer, the unit may be craned to load the unit. To crane the skid steer, only use chain or cable with a rated capacity to handle the weight of the model skid steer being craned.
Page 26 SECTION 00 - GENERAL INFORMATION The front lifting point is in the center of the main frame, 1. The lifting chains or cables must be minimum of 3.66 m (12′). The lifting hook point must be minimum of 1.9 m (75″) above the cab, 1, to prevent the chains or cables from damaging the skid steer frame or cab.
Page 27 SECTION 00 - GENERAL INFORMATION When craning (lifting or lowering) a skid steer, observe these “CAUTIONS.” CAUTION 6. Do not attach lifting devices to the skid steer boom or attachments on the skid steer. 1. No riders (including the operator) in or on the machine while lifting or lowering.
Page 28 SECTION 00 - GENERAL INFORMATION SPECIAL TOOLS Tilting Cab LS160 LS170 Tool Number Order From Description 86590084 New Holland Cab Tilting Tool Engine LS160 LS170 Tool Number Order From Description NH00011 Oil pressure adapter NH00120 Compression test adapter NH00117 Oil pump port block installer...
Page 29 SPECIFICATIONS MODEL LS160 ENGINE MANUFACTURER ............
Page 30 SECTION 00 - GENERAL INFORMATION MODEL LS160 ENGINE OIL Oil type ..............
Page 31 SECTION 00 - GENERAL INFORMATION MODEL LS160 TIRE SIZES AND INFLATION Tire Tire Pressure 7.00 15 - CHEVRON TREAD ........... .
Page 32 ............NEW HOLLAND MODEL .
Page 33 SECTION 00 - GENERAL INFORMATION MODEL LS170 ENGINE OIL Oil type ..............API SH/CG4 SAE 10W-30 Filter part # .
Page 34 SECTION 00 - GENERAL INFORMATION MODEL LS170 TIRE SIZES AND INFLATION Tire Tire Pressure 7.00 15 - CHEVRON TREAD ........... . 414 kPa (60 PSI) 7.50 15 - HST-HOLLOW SEGMENTED TIRES...
Page 35 SECTION 00 - GENERAL INFORMATION DIMENSIONS - LS160 AND LS170 WITH 66, DIRT AND FOUNDRY BUCKET AND 10 X 16.5 TIRES - CM (IN.) 1 - OVERALL WIDTH w/BUCKET ..........
Page 36 SECTION 00 - GENERAL INFORMATION DIMENSIONS - LS160 AND LS170 WITH 66, DIRT AND FOUNDRY BUCKET AND10 X 16.5 TIRES - CM (IN.) 1 - MAXIMUM OPERATING HEIGHT ..........
Page 37 SECTION 10 – ENGINE Chapter 1 – LS160 - N844, LS170 - N844T CONTENTS Section Description Page 10 000 General Engine Information ...........
Page 38 SECTION 10 - ENGINE 10 304 38 Engine Reassembly Sequence ..........10-61 Crankshaft and Bearing Holder Assembly .
Page 39 SECTION 10 - ENGINE Op. 10 000 GENERAL ENGINE INFORMATION New Holland engines, N844 used in the model LS160 skid steer and N844T turbocharger engine used in the model LS170 skid steer. GENERAL DESCRIPTION The N844, N844T Series are four-cylinder stroke,...
Page 40 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.
Page 41 This publication is produced by New Holland North America, Inc. Every endeavor is made to ensure the information contained in this manual is correct at the...
Page 42 SECTION 10 - ENGINE Do not remove the radiator cap while the engine SAFETY PRECAUTIONS 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 system or any other coolant which can cause Do not change the specification of the engine.
Page 43 GENERAL ENGINE SPECIFICATIONS LOADER MODEL LS160 Engine Model ................
Page 44 SECTION 10 - ENGINE LOADER MODEL LS160 Recommended Engine Fluids Coolant ........
Page 45 SECTION 10 - ENGINE GENERAL ENGINE SPECIFICATIONS LOADER MODEL LS170 Engine Model ................N844T Type .
Page 46 SECTION 10 - ENGINE LOADER MODEL LS170 Recommended Engine Fluids Coolant ........Clean soft water.
Page 47 SECTION 10 - ENGINE TROUBLESHOOTING ENGINE WILL CRANK BUT DOES NOT START CAUSE CORRECTION Faulty key switch Correct the connection and/or replace switch Blown 5-amp electronic ignition fuse (cab fuse Replace fuse panel) Fuel solenoid not operating Check solenoid for battery voltage and correct Insufficient charging or complete discharging of the Charge or replace battery battery...
Page 48 SECTION 10 - ENGINE ENGINE STOPS DURING OPERATION CAUSE CORRECTION EIC (Electronic Instrument Cluster) shows fault with Check and repair hydrostatic charge pressure hydrostatic charge pressure EIC (Electronic Instrument Cluster) shows fault with Check oil level and/or repair engine crankcase oil engine crankcase oil pressure pressure Lack of fuel in the tank...
Page 49 SECTION 10 - ENGINE OIL PRESSURE LAMP NOT TURNED ON (KEY SWITCH “ON” WITH ENGINE NOT STARTED) CAUSE CORRECTION Broken lamp bulb Replace bulb Broken wire between battery to the lamp Correct it OIL PRESSURE LAMP NOT TURNED OFF CAUSE CORRECTION Lack of engine oil Fill oil to the specified level...
Page 50 SECTION 10 - ENGINE ENGINE RUNS - NO POWER TO TRANSMISSION CAUSE CORRECTION Flex plate failure due to rivets shearing Replace with new design flex plate part #86521866 Flex plate failure due to inadequate lubrication Replace flex plate (part #86521866) and input shaft, applying Never-Seize on splines LS170 TURBOCHARGER BEARING FAILURES CAUSE...
Page 51 If a customer complains about excessive engine oil – Muffler failure (cracks, misalignment). consumption on the Model LS160 or LS170 skid steer, the following steps must be taken. If a cause is Remove the hose between the turbocharger found, stop and correct the problem. If a cause is not outlet and the intake manifold.
Page 52 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% Fuel Consumption, Oil Consumption, Gallons Quarts 7.
Page 53 SECTION 10 - ENGINE SPECIFICATIONS SERVICE STANDARDS Standard Standard To Be Allowable Inspection Item Remarks Dimension Value Repaired Limit CYLINDER HEAD Compression pressure of More than 426.6 Less than cylinder PSI (30 kg/cm 355.5 PSI (25 kg/cm 72.3 - 75.9 ft. lbs. Tigtening torque of cylinder head (98 - 103 N·m) Distortion of face of cylinder...
Page 54 SECTION 10 - ENGINE Standard Standard To Be Allowable Inspection Item Remarks Dimension Value Repaired Limit 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″...
Page 55 SECTION 10 - ENGINE Standard Standard Allowable To Be Inspection Item Remarks Dimension Value Limit Repaired CRANKSHAFT Undersize Diameter of journal 2.677″ 2.6755″-2.6760″ 2.654″ 0.01″, 0.02″ (68 mm) (67.957-67.970) (67.4 mm) (0.25, 0.5) Undersize Diameter of pin 2.047″ 2.0458″-2.0463″ 2.024″ 0.01″, 0.02″...
Page 56 SECTION 10 - ENGINE Standard Standard Allowable To Be Inspection Item Remarks Dimension Value Limit Repaired PUSHROD 8.075″-8.106″ Overall length (205.1-205.9 ) 0.244″-0.252″ Outside diameter (6.2-6.4 mm) ROCKER ARM 0.5854″ Rocker arm shaft OD 0.5886″-0.5894″ (14.87 mm ) (14.95-14.97) Rocker arm to shaft clearance 0.0012″-0.0037″...
Page 57 SECTION 10 - ENGINE Standard Standard Allowable To Be Inspection Item Remarks Dimension Value Repaired Limit ALTERNATOR Type MITSUBISHI (12V-40A) 0.0028″ Rotor shaft bending (0.07 mm) Slip rings 0.871″ Diameter 0.894″ (22.1 mm) (22.7 mm) 0.002″ 0.08″ Diameter eccentric wear (0.05 mm) (0.02 mm) If dirty or...
Page 58 SECTION 10 - ENGINE ENGINE COMPONENTS ELECTRICAL DIAGRAM TO ENGINE GROUND 19992596 10-22...
Page 59 SECTION 10 - ENGINE Op. 10 001 10 ENGINE REMOVAL The engine can be removed from the loader by two methods: Method 1: Removing the rear door, radiator, oil cooler, and support as an assembly. Method 2: Tilting the cab and boom forward to gain access.
Page 60 SECTION 10 - ENGINE 8. Unhook the hydraulic oil return line, 1, from the charge check valve and cap. 9. Remove the eight 1/2″ cap screws from the support at 1, both sides, and remove the radiator and oil cooler assembly. The support is shown removed with the air cleaner, radiator, oil cooler, oil filter, and fuel pump attached.
Page 61 SECTION 10 - ENGINE 10. Raise the seat to the raised latched position, 1, to access the hydrostatic pumps and engine bellhousing. Remove the neutralizer plate return spring and hardware, 2, from the bellhousing and remove plate. Remove the hydrostatic pump to bellhousing and pump support retaining hardware at 1 and 2.
Page 62 SECTION 10 - ENGINE METHOD 2 (Tilting Cab and Boom Forward) Follow the cab tilting procedure in Section 00 of this manual for proper instructions. 1. Remove the muffler from the exhaust manifold, 2. Remove the battery. 3. Drain the cooling system, radiator and engine block, raise handles, 1, moving the radiator to the rear and drain the cooling system from drain plug, 2.
Page 63 8. Unhook the hydraulic oil return line, 1, from the charge check valve and cap. 9. Remove the fan from the water pump shaft. NOTE: The LS160 N844 engine fan is equipped with a cover over the center of the fan. 10. Remove the neutralizer plate return spring and hardware, 1, from the bellhousing and remove plate, 2.
Page 64 Remove the alternator pivot and adjusting bracket, hardware, 2. Op. 10 104 14 REMOVE COOLING FAN AND PULLEY Remove the fan retaining hardware and spacers. The LS160 N844 engine fan is equipped with a cover, 1, over the center of the fan. 10-28...
Page 65 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, Op.
Page 66 Remove the breather hose, 1. Loosen and remove four cap nuts with washers. Remove the rocker cover assembly, 2. Op. 10 250 16 EXTERNAL OIL PIPE (LS160) 1. Loosen and remove the two banjo bolts at the cylinder block main oil gallery and cylinder head assembly.
Page 67 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, Op.
Page 68 SECTION 10 - ENGINE Op. 10 223 10 STOP SOLENOID Unscrew the stop solenoid, if fitted. 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.
Page 69 SECTION 10 - ENGINE Op. 10 230 24 GEAR COVER AND GOVERNOR ASSEMBLY Remove the securing bolts and lift the cover assembly off the locating dowels. NOTE: Remove the fuel injection pump first. IDLER GEAR AND OIL PUMP ASSEMBLY Remove the retaining ring. Remove the entire assembly.
Page 70 SECTION 10 - ENGINE Op. 10 304 06 DIPSTICK ASSEMBLY Loosen the retaining bolts and remove the assembly. Op. 10 304 44 OIL SUMP Remove all bolts, lower sump, and discard the gasket. SUCTION PIPE AND STRAINER Remove two securing bolts. Rotate the suction pipe out of its bore.
Page 71 SECTION 10 - ENGINE Op. 10 103 BACKPLATE AND REAR OIL SEAL 1. Loosen the two starter retaining nuts and remove the starter. 2. Loosen the backplate retaining bolts and remove the backplate. 3. Remove the oil seal. Op. 10 103 10 CRANKSHAFT AND MAIN BEARING 1.
Page 72 SECTION 10 - ENGINE ENGINE COMPONENT MAINTENANCE Op. 10 106 20 ROCKER ASSEMBLY Disassembly 1. Loosen the M8 bolt at the rocker arm shaft end, if fitted. 2. Remove the screw located in the No. 1 cylinder rocker arm bracket, if fitted. 3.
Page 73 SECTION 10 - ENGINE Op. 10 101 21 CYLINDER HEAD ASSEMBLY 1. Using a valve spring replacer, compress the valve spring to remove the valve keepers, 1; retainer, 2; spring, 3; and valve, 4. 2. Remove the valve guide seals and glow plugs. Inspection and Correction Op.
Page 74 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.
Page 75 SECTION 10 - ENGINE Op. 10 101 55 VALVE SEAT Valve Seat Contact Width If the contact width at 1 of the valve seat is more than the allowable width, check the wear condition of the valve guide first. Using the seat cutters of 15°, 45°, and 75°, correct the seat.
Page 76 SECTION 10 - ENGINE Lapping of Contact Face of the Valve Seat Correct valve seat contact using a valve lapper and lapping compound. When using a new cylinder head, obtain correct seat contact width and seat recess using the seat cutter, and then carry out lapping.
Page 77 SECTION 10 - ENGINE Op. 10 101 56 CYLINDER BLOCK Inspection and Correction Cylinder Block Top Face Inspect the cylinder block top face for cracks, damage, and warping in the same way as for the cylinder head. If outside the limit, replace the cylinder block. Standard Value: Less than 0.002″...
Page 78 SECTION 10 - ENGINE Bore Specifications Standard Bore: 3.307″ - 3.308″ (84 mm - 84.019 Allowable Limit: 3.315″ (84.2 mm) First Re-bore: 0.02″ (0.5 mm) New Standard Bore: 3.327″ - 3.328″ (84.5 mm - 84.519 mm) Allowable Limit: 3.335″ (84.7 mm) Second Re-bore: 0.02″...
Page 79 SECTION 10 - ENGINE Oversized Piston When the cylinder is oversized, be sure that an oversized piston is used. Standard Clearance: 0.0015″ - 0.0028″ (0.038 mm - 0.072 mm) Allowable Limit: 0.010″ max. (0.25 mm) Standard Diameter (Piston): 3.3050″ - 3.3056″ (83.948 mm - 83.963 mm) Allowable Limit: 3.2953″...
Page 80 SECTION 10 - ENGINE Oil Ring Standard Clearance: 0.008″ - 0 .016″ (0.20 mm - 0.40 mm) Allowable Limit: 0.039″ (1.0 mm) Measure the clearance between the piston ring groove and ring. If the clearance exceeds the allowable limit, replace the ring. #1 Ring Standard Clearance: 0.0028″...
Page 81 SECTION 10 - ENGINE CONNECTING ROD Inspection Distortion or damage Check the connecting rod for distortion between the large and small ends of the connecting rod with a connecting rod aligner. If the result exceeds the allowable limit, replace. Distortion –3.937, (100 mm) Standard Value: Less than 0.003″...
Page 82 SECTION 10 - ENGINE Oil Clearance Using the plasti-gauge, check the oil clearance as follows: Remove oil or foreign matter from the bearing and crankshaft. Cut the plasti-gauge to the same width as the bearing. Place it on the crankshaft at 1. Avoid the oil hole.
Page 83 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.
Page 84 SECTION 10 - ENGINE Thrust Clearance Check the thrust washer for wear, poor contact, burning, or other defects. Defective washers must be replaced. Standard Thickness: 0.116″ - 0.118″ (2.95 mm - 3.0 mm) Allowable Limit: 0.11″ (2.8 mm) Reassembly Reassemble the bearing holder, center bearing, and thrust washer as follows: 1.
Page 85 SECTION 10 - ENGINE Standard Oil Clearance: 0.0017″ - 0.0046″ (0.044 mm - 0.116 mm) Allowable Limit: 0.0078″ (0.2 mm) If the oil clearance exceeds the allowable limit, replace the bearing (bushing) or grind the crankshaft journal. In this case, use an undersized bearing (bushing).
Page 86 SECTION 10 - ENGINE – Align the oil hole, 1, of the housing and bushing. – Install the bushing, confirming the mark and oil groove (hole). – Lubricate at the outer surface of the bushing. – Press in the bushing to the housing until correct depth, by using a bushing driving tool.
Page 87 SECTION 10 - ENGINE Check Crankshaft Journal, 3, and Pin, 4, for stepped wear Take four measurements (AA and BB diameters at positions 1 and 2, Figure 73). If the maximum difference between the measurements is more than the allowable limit, correction is required. Allowable Difference (stepped wear): 0.0019″...
Page 88 SECTION 10 - ENGINE NOTE: When grinding the crankshaft, work with the following specifications: 1. Radius at pin/journal: 0.118″ + 0.0078″ (3 mm + 0.2 mm) 2. Finish precision: 1.6Z 3. Radius around oil hole: 0.0787″ (2 mm) maximum 0.196″ (5 mm) minimum Use No.
Page 89 SECTION 10 - ENGINE Op. 10 106 66 CAMSHAFT GEAR AND BEARING ASSEMBLY 2 Camshaft gear 3 Camshaft 4 Tachometer gear 5 Spacer 6 Roller bearing 8 Slider If these items have been replaced, it is essential that the spacers, shims, etc. are assembled in the order illustrated here.
Page 90 SECTION 10 - ENGINE Op. 10 304 41 OIL PUMP Disassembly Remove the snap ring. Take out the collar spring and shim. Remove the idler gear vane and oil pump cover together. Pull out the rotor and thrust washer. Pull out the oil pump cover from the idler gear. Remove the spring from the idler gear.
Page 91 SECTION 10 - ENGINE Op. 10 304 10 OIL FILTER Construction and Function This engine employs a cartridge-type filter. Pressurized oil from the pump enters from 1 and is filtered by a full flow filter before discharge through 2. When the full flow filter is clogged, the safety valve, 3, opens to bypass the oil.
Page 92 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...
Page 93 SECTION 10 - ENGINE Op. 10 230 24 GOVERNOR Construction/Function A mechanical all-speed governor is used. It is housed in the gear case. A flyweight assembly is mounted on the camshaft. The movement of the flyweight is transmitted to the injection pump control rack by way of the slider, control lever, and link, 1.
Page 94 SECTION 10 - ENGINE 19992767 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.
Page 95 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.
Page 96 SECTION 10 - ENGINE As the engine speed decreases, the governor weights, 1, pivot inward allowing the slider cone, 2, to move rearward. 19993597 As the slider cone, 2, Figure 90, moves rearward, the governor linkage arm, 1, allows the fuel injection pump rack to move rearward to the full fuel position and the engine speed increases.
Page 97 SECTION 10 - ENGINE ENGINE REASSEMBLY SEQUENCE PRECAUTIONS Thoroughly wash parts before reassembly. Ensure oil galleys are clean and unobstructed. Lubricate all rotating and sliding components before assembly. Clean all gasket surfaces, using care not to scratch mating surfaces. Use special care on aluminum parts.
Page 98 SECTION 10 - ENGINE CRANKSHAFT AND BEARING HOLDER ASSEMBLY 1. Install the bearing holders on the crankshaft. Insert this in the bushing at the front end of the cylinder block. 2. Align the bolt hole at the lower part of the cylinder block with thread hole on the bearing holder and tighten with bolts.
Page 99 SECTION 10 - ENGINE BACK PLATE/FLYWHEEL HOUSING Coat the area around the M8 threaded holes with liquid packing solvent-based sealant and fix the backplate with bolts. Backplate tightening torque: 10 - 13 ft. lbs. (14 - 18 N·m) Housing tightening torque: 18 - 21 ft. lbs. (24 - 28 N·m) FLYWHEEL Fit the flywheel.
Page 100 SECTION 10 - ENGINE OIL INTAKE AND OIL STRAINER Fix an O ring on the suction pipe and insert the pipe into the cylinder block. Fit the end of the suction pipe to the oil strainer and fix the oil strainer. Suction filter tightening torque: 6.5 - 9.5 ft.
Page 101 SECTION 10 - ENGINE Align set marks on the idler gear, crankshaft gear, and camshaft gear, and assemble on the idler gear shaft. Install the rotor. Install the oil pump cover, shim, spring, and collar. Fix them with the retaining ring. Adjust with shim 0.1, 0.15, 0.2, 0.5 mm so the axial clearance of the oil pump, rotor, and vane is in the range of 0.004″...
Page 102 SECTION 10 - ENGINE TIMING GEAR CASE Install the start spring. Insert the link through the hole in the cylinder block. Rotate the oil pump cover to the position spring pin hole to the center position. Install the cover locating pin in the oil pump cover plate (PB094).
Page 103 SECTION 10 - ENGINE ADJUSTING THE FUEL INJECTION TIMING Normally, this procedure provides correct injection timing. However, when the new injection pump, camshaft assembly, or cylinder block is used, fuel injection timing should be adjusted as explained below. Reassemble the injection pump according to the procedures above.
Page 104 SECTION 10 - ENGINE Piston Position in Relation to the Crankshaft Angle (BTDC) N844, N844T Crankshaft Angle Position (BTDC) 0.0594″ (1.510 mm) 0.0689″ (1.749 mm) 0.0789″ (2.005 mm) 0.0897″ (2.278 mm) 0.1011″ (2.569 mm) 0.1132″ (2.875 mm) 0.1259″ (3.199 mm) 0.1393″...
Page 105 SECTION 10 - ENGINE 4. Remove the No. 1 injection line from the No. 1 injector, 1. 5. Remove the lock screw, 2, and remove the injector locking plate, 3. 6. Remove the delivery valve piston, 1, from the No. 1 delivery valve.
Page 106 SECTION 10 - ENGINE 8. Fabricate a spill tube, 1, from a discarded injection line and install the tube on the No. 1 port on the injection pump. 9. Remove the fuel shut-off solenoid from the injection pump. 10. Rotate the crankshaft counterclockwise (viewed from the front of the engine) approximately 40_.
Page 107 SECTION 10 - ENGINE Assemble the delivery valve (IN). NOTE: Delivery holder tightening torques: 29 - 33 ft. lbs. (39 - 45 N·m). Oil Filter Coat the mounting face with a thin film of oil, and then hand-tighten. Feed Pump Insert using securing bolts.
Page 108 Oil Pipe Eyebolt tightening torque: 7 - 9 ft. lbs. (9 - 12 N·m) LS160 N844 engine - the oil pipe, 1, will be connected to the block. LS170 N844T engine - the oil pipe will be connected to the turbocharger.
Page 109 SECTION 10 - ENGINE Cap, Push Rod, and Rocker Arm Assembly Install the caps, 1, on the end of the valve stem. Install the push rods, 2, and rocker arm assembly, 3. Rocker arm assembly tightening torque: 20 - 29 ft. lbs.
Page 110 SECTION 10 - ENGINE Connect the thermostat housing and hoses. 1 Thermostat housing 2 Thermostat 3 Gasket 4 Adapter Glow Plug and Connector Glow plug tightening torque: 11 - 14.5 ft. lbs. (15 - 20 N·m) Oil Pressure Switch Oil pressure switch tightening torque: 11 - 14.5 ft. lbs. (15 - 20 N·m) Nozzle/Holder Assembly Install the nozzle and holder assembly with a socket...
Page 111 SECTION 10 - ENGINE V-Belt, Fan Pulley and Cooling Fan After mounting the fan pulley, cooling fan, spacers, and cover plate on the N844 LS160 engines, install the V belt. Depress the belt at the center between the crankshaft pulley and the alternator pulley, with a force of approximately 5 kg (2.27 ft.
Page 112 SECTION 10 - ENGINE 1. Reinstall the hydrostatic pump flex plate to the engine flywheel, 1, using eight 5/16″ x 3/4″ G5 cap screws and eight M8 lock washers. Torque to 20 ft. lbs. (26 N·m). Reinstall the flex plate with the center hub of the plate away from the flywheel, 2.
Page 113 SECTION 10 - ENGINE 7. Reconnect the battery making sure the positive (+) battery cable, 1, on LS170 models routes away from the turbocharger hose, 2, and the hose clamp, 3. 8. Reverse the clamp, 3, to avoid unnecessary wear on cables and hoses. 19988126 HOW TO OPERATE THE ENGINE AFTER OVERHAUL...
Page 114 SECTION 10 - ENGINE COOLING SYSTEM SPECIFICATIONS Capacity - 10.8 qts. (10.3 L) Mixture - 50/50 antifreeze/water Radiator cap - 7 PSI (48.3 kPa) THERMOSTAT Opening 180° F (82° C) Fully Open 203° F (95° C) EIC starts reading degrees at 113° F (45° C) or 32° F (0°...
Page 115 SECTION 10 - ENGINE DANGER Allow the engine and cooling system to cool off before adding coolant to the cooling system. Always allow the engine and cooling system to cool off before draining the cooling system. Op. 10 402 28 WATER PUMP ASSEMBLY AND THERMOSTAT HOUSING Disassembly...
Page 116 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).
Page 117 SECTION 10 - ENGINE Remove the radiator support hardware and handles, 1, from both sides of the radiator. Remove the overflow hose, 2, from the radiator at the cap. 10-81...
Page 118 Otherwise, the fuel may cloud and block the fuel system. When temperatures are extremely cold, use properly mixed winter fuel. Use New Holland diesel fuel conditioner part #251202 to mix with the diesel fuel. Follow the directions for use as indicated on the container.
Page 119 SECTION 10 - ENGINE FUEL SYSTEM COMPONENTS The fuel system contains a fuel tank located in the left side of the engine compartment at 1. Fuel tank pickup tube, 2; fuel tank sending unit, 3; in-line fuel filter, 4; electric fuel pump, 5; injection pump, 6; and return fuel line, 7, from the injector bleed off to the tank.
Page 120 SECTION 10 - ENGINE 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 When the fuel level reaches two bars, the EIC will bar graph.
Page 121 SECTION 10 - ENGINE COLD START AID The EIC controls a timed preheat cold start to assist in cold weather starting. The timed period will vary from 0 to 15 seconds depending on model engine and engine temperature. STARTING A COLD ENGINE Move the engine speed control ahead to 1/3 position, maximum 1500 RPM.
Page 122 SECTION 10 - ENGINE Replace the in-line filter, 1, every 250 hours of operation. To remove the filter, remove the two hose clamps, 2, and remove the hoses from the filter. Install a new filter, hoses, clamps and tighten. WARNING All service should be performed with the engine shut down.
Page 123 SECTION 10 - ENGINE FUEL SYSTEM TESTING ELECTRIC FUEL PUMP STEP PRETEST TEST RESULT PROBABLE CAUSE AND INSTRUCTIONS CORRECTION Loader on level with Fuel level in tank Add fuel and bleed system parking brake Go to next step engaged, key “OFF” position Key “ON”...
Page 124 SECTION 10 - ENGINE FUEL TANK SENDING UNIT(Fuel level) STEP PRETEST TEST RESULT PROBABLE CAUSE AND INSTRUCTIONS CORRECTION Loader on level with EIC gauge and NO (bars light Check wires from sender to parking brake sender operation EIC board, if OK, replace engaged, key “ON”...
Page 125 SECTION 10 - ENGINE FUEL FLOW 19992606 Fuel tank Filter (water trap) Tank pick-up Injection pump In-line fuel filter Fuel shut-off solenoid Electric fuel pump FUEL SYSTEM ELECTRICAL DIAGRAM 19992607 Key switch Electric fuel pump EIC board Injector pump Fuel level sender Fuel shut-off solenoid 10-89...
Page 126 SECTION 10 - ENGINE FUEL SYSTEM COMPONENTS Op. 10 216 10 FUEL TANK Remove and Replace 1. Raise the boom, extend the boom lock pins, 1, and lower the boom down on the lock pins. 2. Stop the engine, turn the ignition key to the “ON” position and operate the boom and bucket control pedals to relieve pressure in the cylinders, turn the key “OFF.”...
Page 127 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.
Page 128 SECTION 10 - ENGINE Op. 10 230 24 GOVERNOR Construction/Function A mechanical all-speed governor is used. It is housed in the gear case. A flyweight assembly is mounted on the camshaft. The movement of the flyweight is transmitted to the injection pump control rack by way of the slider, control lever, and link, 1.
Page 129 SECTION 10 - ENGINE As the engine speed increases, the four governor weights, 1, pivot outward and push on the slider cone, 2. The weights and slider cone are located on the end of the camshaft. 19993595 The slider cone, 2, Figure 160, contacts the governor linkage arm, 1, at contact pad, C.
Page 130 SECTION 10 - ENGINE As the slider cone, 2, Figure 162, moves rearward, the governor linkage arm, 1, allows the fuel injection pump rack to move rearward to the full fuel position and the engine speed increases. Engine speed depends upon several factors: the throttle setting determined by governor spring tension;...
Page 131 SECTION 10 - ENGINE Disassembly/Inspection 1. Place the nozzle holder (body) in a vise and turn the nozzle nut to disassemble. NOTE: Care should be taken so the needle valves do not fall when the nozzle is removed. 2. Wash the nozzle body and needle valve and inspect the nozzle for seizure, sticking, and fuel leakage on the seat surface.
Page 132 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 Inspection/Replacement kg/cm (throttle type) and 210 kg/cm...
Page 133 SECTION 10 - ENGINE 1. Pull out the delivery valve, 1, (IN), and reinstall the spring, 2, and delivery valve holder, 3. NOTE: When reassembling the delivery holder, adjust the location of the delivery valve (OUT) to the correct position using a wire, 4. 2.
Page 134 SECTION 10 - ENGINE 4. Verify that the timing mark on the crankshaft pulley is in line with the “TOP” mark on the timing scale. If the mark on the crankshaft pulley is not in line with the “TOP” mark, verify piston top-dead center with a dial indicator.
Page 135 SECTION 10 - ENGINE 10. Reinstall the spring and holder, 1, into the injection pump and tighten securely. 11. Fabricate a spill tube, 1, from a discarded injection line and install the tube on the No. 1 port on the injection pump. 12.
Page 136 SECTION 10 - ENGINE 15. Rotate the crankshaft clockwise. When the timing mark on the crankshaft pulley, 1, is in line with the 21_ (N844T) or 22_ (N844) mark on the scale, 2, fuel should stop flowing from the spill tube.
Page 137 SECTION 10 - ENGINE TURBOCHARGER - LS170 N844T ENGINE The LS170 skid steer is equipped with the N844T turbocharged 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.
Page 138 SECTION 10 - ENGINE DIRTY EXHAUST SMOKE POSSIBLE CAUSE CORRECTION Not enough intake air A clogged element in the air cleaner, clean or replace element Closed air intake inlet, open inlet Air leakage from a connection, check and repair The turbocharger is not running Gum or sludge formation in the turbine-side seal, causing the turbine to resist turning, Check the oil quality and change...
Page 139 SECTION 10 - ENGINE ABNORMAL RUNNING NOISE POSSIBLE CAUSE CORRECTION Restrictions in exhaust gas passage, particularly Disassemble and clean due to the nozzle ring approaching a clogged condition Restrictions in the air outlet side of the blower, Disassemble and clean causing the air to surge at the blower wheel when the engine accelerates The casing is being rubbed by turbine wheel or...
Page 140 SECTION 10 - ENGINE 2. Remove the turbocharger oil pressure line, 1, at the block and at the turbo housing. 3. Remove the turbocharger oil return line, 1, at the top hose clamp, 2, and from the turbo assembly at 3. 4.
Page 141 SECTION 10 - ENGINE Inspection Before Disassembly Visually check the running clearances of the turbine and blower wheels for evidence of contact between the vanes and casing. Spin the rotor by hand to see if it rotates smoothly. Check for turbine fin and housing clearance, intake and exhaust.
Page 142 SECTION 10 - ENGINE 2. Separate the blower housing, 1. NOTE: Remove the housing carefully and be sure not to damage the blower vanes. 3. Remove the blower wheel, 1, by removing the shaft end nut, 2. NOTE: The shaft end nut has left-hand screw threads;...
Page 143 SECTION 10 - ENGINE 6. Remove the seal plate, 1. 7. Remove the thrust bearing, 1, and bushing, 2. 8. Remove the floating bearings, 3. 9. Remove the seal rings, 1, from the turbine shaft, 2, and oil slinger, 3. 10-107...
Page 144 SECTION 10 - ENGINE Inspection Before washing the disassembled parts clean, visually inspect each part thoroughly: 1. For carbon deposit. – Turbine shaft, turbine-side seal ring , and back of turbine wheel, 1. – Bearing casing, mating face of shield plate, and bearing casing bore, 2.
Page 145 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.
Page 146 SECTION 10 - ENGINE Holes for Admitting Seal Ring 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.
Page 147 SECTION 10 - ENGINE Installing the Thrust Bearing Run the thrust bushing onto the turbine shaft. Oil the thrust bearing, and fit it to the bearing casing, securing it by tightening its retaining bolts to 87 - 94 ft. lbs. (118 - 127 N·m) torque. Installing the Seal Plate Insert seal rings, 1, into the oil slinger.
Page 148 SECTION 10 - ENGINE Insert the oil slinger,1, into the seal plate, 2. Fit the bearing case, 3, to the seal plate and secure with the retaining hardware. Tighten to 87 - 94 ft. lbs. (118 - 127 N·m). Installing the Blower Wheel Slide the wheel onto the turbine shaft, and retain it by running the shaft-end nut down the shaft end.
Page 149 SECTION 10 - ENGINE Securing the Blower Casing to the Bearing Casing Fit the blower casing in the original angular position by aligning the marks, and secure it in place by tightening the bolts to 34.7 - 43.4 in. lbs. (3.9 - 4.9 N·m) torque.
Page 150 SECTION 10 - ENGINE Turbocharger Lubrication System Oil the lubricated parts by pouring clean engine oil into the oil inlet and by rotating the turbine shaft by hand. This will wet the journal, floating bearings, thrust bearing, and other surfaces. Thoroughly clean the oil inlet pipe and outlet pipe by flushing, making sure the pipes are absolutely free of foreign particles.
Page 151 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 position. 1. Make sure the exhaust gas passages are perfectly clean and free of foreign particles. 3.
Page 152 SECTION 10 - ENGINE MISCELLANEOUS ENGINE ELECTRICAL Op. 55 201 76 GLOW PLUG A sheathed-type glow plus is employed and provides excellent starting. Specifications: 11 V; 9.0 A 1 Heat wire 5 Nut 2 Sheath 6 Magnesium oxide powder 3 Asbestos 7 Insulation bushing 19992987 4 Body...
Page 153 SECTION 10 - ENGINE Op. 55 414 12 OIL PRESSURE SWITCH Oil Pressure Switch Operating Range: 2.8 PSI - 5.7 PSI (0.2 to 0.4 kg/cm 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.
Page 154 SECTION 10 - ENGINE MAXIMUM CIRCUIT RESISTANCE RESISTANCE OF BATTERY CABLES 1, 2, & 3 NOT TO EXCEED 0.0018 OHM 19992989 19992988 *Maximum current draw for oil pressure switch is **Diode capacity: Current 3 amp. Reverse voltage 0.42 amps (5-watt max. bulb). 600 volt.
Page 155 SECTION 10 - ENGINE Right angle quick disconnect coupling. Use with SPECIAL TOOLS FNH 00120 and FNH 02020. ENGINE – FNH 00117 - Oil Pump Port Block Installer – FNH 00011 - Fitting - 1/8 BSPT x 7/16-20 UNF Installs engine oil pump port block. Ensures part is installed straight, to the proper depth, with Used to test engine oil pressure.
Page 156 SECTION 10 - ENGINE LABOR GUIDE The following labor amounts are listed as a guide only. Working conditions and experience will vary the amount of time it actually takes to complete a job. Op. 10 001 10 Run engine and check for leaks. ENGINE REMOVAL FROM SKID STEER Retighten head and reset valve clearances.
Page 157 SECTION 10 - ENGINE Additional time - turbocharged engine. CYLINDER BLOCK REPLACE BARE BLOCK (7.00) Additional time - replace each valve seat insert as necessary. (0.10) Steam clean complete engine, dismantle, clean and inspect all parts. VALVE SPRING Reassemble engine complete into new bare blocks Change one-head not removed except for “B”...
Page 158 SECTION 10 - ENGINE Turn engine to “nip” push rod. Reset valve clearance. CRANKSHAFT ASSEMBLY Refit top cover. REPLACE CRANKSHAFT (4.30) Run engine and test. “Pin check” only on “B” engines. Includes replace rear main lip seal, replace damper and pulley, replace thrust washers, sump and strainer, remove, clean and reassemble with new SUMP ASSEMBLY gaskets and replace, and remove and replace...
Page 159 SECTION 10 - ENGINE INJECTOR FLYWHEEL AND FLYWHEEL HOUSING (0.35) Remove and replace one. (0.10) Includes remove and replace one high-pressure Remove, replace and align. pipe. Includes removal of engine from loader or hydrostatic pump removal. Remove, test and replace all. (0.40) Includes remove and replace set of high- pressure THERMOSTAT UNIT (0.20) pipes.
Page 160 SECTION 10 - ENGINE 10-124...
Page 161 SECTION 27 – REAR DRIVE AXLE (GEARBOXES) Chapter 1 – Gearboxes CONTENTS Section Description Page 27 000 General Information ............27-2 Specifications .
Page 162 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) Op. 27 000 GENERAL INFORMATION The power is transmitted to the final drive from the engine which is connected to the hydrostatic pumps, 1, with a flex plate drive coupler. The hydrostatic pumps then transmit hydraulic power to the hydrostatic motors, 2, which are connected to gearboxes, 3, located on the inside of the final drive cases.
Page 163 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) The parking brake discs are connected to the hydrostatic motor coupler shafts at 1. The parking brake is made up of two discs, actuator shaft, pads, and control linkage. The hydrostatic system is the primary braking system, and the parking brake is used when the unit is stopped.
Page 164 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) SPECIFICATIONS Chain Case Side Cover Bolt Torque ............15 N·m (11 ft.
Page 165 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) TROUBLESHOOTING FINAL DRIVE SYSTEM Before servicing or adjusting on the final drive system, the skid-steer loader should be jacked up with the wheels off the ground. Remove any attachment from the skid-steer loader boom, bucket, etc.
Page 166 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) FINAL DRIVE SYSTEM PROBLEM POSSIBLE CAUSES CORRECTION Both drive wheels on one side No hydrostatic motor shaft rotation Check for pump to motor oil flow not powered and repair No gearbox output drive Check gearbox shaft rotation and repair Broken drive chains...
Page 167 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) TESTING Pre-test instructions: * Operator in seat with seat belt buckled. * Engine running at high idle (full throttle). * Park brake disengaged position. STEP TEST RESULT PROBABLE CAUSE AND CORRECTION Push both drive controls Drive system OK.
Page 168 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) Op. 27 126 GEARBOXES Op. 27 126 40 REMOVAL AND INSPECTION The hydrostatic motor is connected to the gearbox and the gears in the gearbox transmit power to the final drive chains. The boom and cab may be tilted forward for gearbox access.
Page 169 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) 4. Slide the seat to the rearmost position, unlatch the seat pan, and raise the seat and pan assembly to the raised latched position, 1. CAUTION Before working under a raised seat make sure it is securely latched in the raised position.
Page 170 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) 12. Remove the drive chains from the double drive sprocket, 1. 13. Parking brake engaged, remove the brake disc retaining bolt and washer, 2. 14. Release the parking brake. 15. Loosen the caliper retaining hardware, 3, from the inside of the cab.
Page 171 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) 20. Remove hydrostatic motor retaining hardware, 1. NOTE: For clearance, the high pressure lines may require removal. If lines are removed, cap lines and fittings to prevent loss of oil and contamination of the hydrostatic system.
Page 172 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) Op. 27 126 48 DISASSEMBLY 1. Thoroughly clean the gearbox. 2. Remove the cover, 1. 3. Remove the shaft cover, 2, by prying it from the gearbox housing. 4. Remove the gearbox breather, 3. 5.
Page 173 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) 11. Remove the external snap ring, 1, from the shaft. With a bearing separator puller, remove the small sealed bearing, 2, from the shaft. 12. With a bearing separator puller, remove the large sealed bearing, 3, from the shaft and sprocket assembly.
Page 174 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) 6. Inspect the gearbox housing bearing areas for severe wear. NOTE: The bearings, 1, are a hand press fit into the housing, not an interference fit. 7. Examine the mounting bolt threads for damage to prevent secure gearbox retention.
Page 175 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) 5. Insert the large gear, 1, into the gearbox; note the gear will fit only one way. 6. Put a bead of medium-strength Loctite around the outer surface of the bearing at 1, between the bearing race and gearbox surface.
Page 176 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) 11. Put a bead of noncorrosive silicone sealer around the outer lip of the shaft cover, 2, and place the cover in the gearbox on the unsealed bearing side of the gearbox. Tap the cover with a hammer to seat in the gearbox.
Page 177 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) 5. Put a bead of noncorrosive silicone sealer around the flange of the hydrostatic motor. Align the motor splines with coupler splines and place motor shaft into coupler. Install the motor retaining bolts, 1, and torque to 85 N·m (63 ft. lbs.).
Page 178 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) 10. Install the inside brake disc, 1, onto splined motor coupler shaft. 11. Put a bead of silicone sealer around the caliper retaining bolts and insert in support. 12. Slide the spacers, 2, and center of caliper, 3, over bolts.
Page 179 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. Job Description Hours Gearbox Remove and replace 2.0 hrs.
Page 180 SECTION 27 - REAR DRIVE AXLE (GEARBOXES) 27-20...
Page 181 SECTION 29 - HYDROSTATIC TRANSMISSION Chapter 1 - Neutralizer, Pumps, Motors CONTENTS Section Description Page 29 100 General Information ............29-3 Operation .
Page 182 SECTION 29 - HYDROSTATIC TRANSMISSION 29 100 Steering System ............29-91 Hydrostatic System Controls .
Page 183 SECTION 29 - HYDROSTATIC TRANSMISSION Op. 29 100 GENERAL INFORMATION The hydrostatic system provides a means to transfer power from the engine to the final drive for the wheels. It provides infinitely variable speed forward and reverse and steering of the skid steer. The hydrostatic pumps receive power from the engine through a flex plate drive.
Page 184 SECTION 29 - HYDROSTATIC TRANSMISSION 19997771 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.
Page 185 SECTION 29 - HYDROSTATIC TRANSMISSION SPECIFICATIONS HYDROSTATIC PUMPS Type ............Variable Displacement Piston Pump Displacement .
Page 186 SECTION 29 - HYDROSTATIC TRANSMISSION Op. 29 100 01 WARNING TROUBLESHOOTING Gauges, gauge fittings, and hoses must have operating pressure ratings of at least 25% higher When performing tests on the hydrostatic system, than the highest pressures of the system. use the proper test procedures and test equipment.
Page 187 SECTION 29 - HYDROSTATIC TRANSMISSION PROBLEM POSSIBLE CAUSE CORRECTION Machine will not move either Machine will not move either Parking brake engaged Parking brake engaged Release parking brake Release parking brake direction direction Engine to hydrostatic drive coupler Engine to hydrostatic drive coupler Check and repair or replace Check and repair or replace Low hydraulic oil...
Page 188 SECTION 29 - HYDROSTATIC TRANSMISSION HYDROSTATIC DRIVE SYSTEM TESTING Hand controls - forward and reverse Pretest instructions: *Operator in seat *Seat belt buckled *Service/Run switch in “RUN” position *Key switch in the “OFF” position STEP TEST RESULT PROBABLE CAUSE AND CORRECTION Levers should move freely Check control linkage from levers to the pumps.
Page 189 SECTION 29 - HYDROSTATIC TRANSMISSION Before performing any hydraulic test, operate the skid steer to get the hydraulic oil to operating temperature (about 38°C or 100° F above ambient temperature). For access to hydrostatic testing, remove any attachment from the loader attaching face plate and support the boom on the lockpins.
Page 190 SECTION 29 - HYDROSTATIC TRANSMISSION 5. Raise the operator’s seat and latch in the raised position, 1. CAUTION Never work under a raised seat unless it is securely latched in the raised position. 6. Check the hydraulic oil level and add, if required, to proper level.
Page 191 SECTION 29 - HYDROSTATIC TRANSMISSION 19997776 right hydrostatic motor, when right HYDROSTATIC SYSTEM OIL FLOW 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.
Page 192 SECTION 29 - HYDROSTATIC TRANSMISSION 19997777 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.
Page 193 SECTION 29 - HYDROSTATIC TRANSMISSION 19997778 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 The front hydrostatic pump drains internally to the lubrication oil drains into the pump and motor rear pump at 2.
Page 194 SECTION 29 - HYDROSTATIC TRANSMISSION HYDROSTATIC CHARGE SYSTEM PRESSURE TEST Hydrostatic charge pressure oil is the return oil from the boom, bucket, and auxiliary hydraulic circuits from the return side of the control valve. This oil is required for replenishing oil to the hydrostatic system for lubrication and cooling of the hydrostatic pumps and motors.
Page 195 SECTION 29 - HYDROSTATIC TRANSMISSION 5. Remove the right engine side shield to access the charge check valve and test port. 6. Install the pressure test gauge in the test port at IMPORTANT: Check the hydraulic oil level and add if required to insure sufficient oil for the test.
Page 196 SECTION 29 - HYDROSTATIC TRANSMISSION 5. Raise the operator’s seat and latch in the raised position, 1. CAUTION Never work under a raised seat unless it is securely latched in the raised position. 6. Remove the step shield to access the hydrostatic pumps and motors.
Page 197 SECTION 29 - HYDROSTATIC TRANSMISSION Pump Case Drain (Oil Flow) Test Procedure 1. Raise the boom and rest on the boom locks. 2. Put the Service/Run switch in the “SERVICE” position. 3. Engage the parking brake. 4. Securely block the skid steer with all four wheels off the ground.
Page 198 SECTION 29 - HYDROSTATIC TRANSMISSION HYDROSTATIC PUMP HIGH-PRESSURE TEST The hydrostatic drive system has a high-pressure relief valve for forward and reverse, two relief valves per pump or side. The relief valves, 1, for both pumps and for forward and reverse are the same and the same setting, 238 bar (3500 PSI).
Page 199 SECTION 29 - HYDROSTATIC TRANSMISSION The following pump relief valves protect the direction of motor (tire) rotation forward or reverse. Front pump controls right motor: 1 - Forward (bottom) 2 - Reverse (top) Rear pump controls left motor: 3 - Forward (bottom) 4 - Reverse (top) 19997770 8.
Page 200 SECTION 29 - HYDROSTATIC TRANSMISSION 19997776 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 equipment.
Page 201 SECTION 29 - HYDROSTATIC TRANSMISSION The following pump ports control direction of motor (tire) rotation forward or reverse. Front pump controls right motor: 1 - Forward (bottom) 2 - Reverse (top) Rear pump controls left motor: 3 - Forward (bottom) 4 - Reverse (top) IMPORTANT: Check and make sure the flowmeter is 19997770...
Page 202 SECTION 29 - HYDROSTATIC TRANSMISSION HYDROSTATIC MOTOR CASE DRAIN TEST The motors can be checked for excessive internal leakage which will cause a unit to be weak in the ground drive. The excessive leakage is caused by damage to the motor rotating group or camp plate to allow high-pressure oil to leak into the case.
Page 203 SECTION 29 - HYDROSTATIC TRANSMISSION 19997776 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 equipment.
Page 204 SECTION 29 - HYDROSTATIC TRANSMISSION The following pump ports control direction of motor (tire) rotation forward or reverse. Front pump controls right motor: 1 - Forward (bottom) 2 - Reverse (top) Rear pump controls left motor: 3 - Forward (bottom) 4 - Reverse (top) IMPORTANT: Check and make sure the flowmeter is 19997770...
Page 205 SECTION 29 - HYDROSTATIC TRANSMISSION HYDRAULIC, HYDROSTATIC SYSTEM AIR INGRESS TEST Hydraulic system air ingress, causing oil aeration, can affect performance of the hydraulic oil. This may be evident on a machine by jerky or uneven movement of the loader boom or bucket. To assist in testing and finding leaks, a tool has been developed (part...
Page 206 SECTION 29 - HYDROSTATIC TRANSMISSION The following checks should then be performed to trace the source of the air ingress. – Examine the suction tubes and fittings to the hydraulic gear pump and the return tubes from the filter to the reservoir. –...
Page 207 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.
Page 208 SECTION 29 - HYDROSTATIC TRANSMISSION 6. Raise the operator’s seat and latch in the raised position, 1. CAUTION Never work under a raised seat unless it is securely latched in the raised position. 7. Remove the step shield to access the hydrostatic pump area.
Page 209 SECTION 29 - HYDROSTATIC TRANSMISSION 12. Remove the two pin retaining nuts, 1, securing the pins, 2, to the front of the neutralizer plate. 13. Remove the centering spring retaining bolt, 3, and spring from the engine bellhousing. When removing the retaining bolt the spring will be under slight pressure.
Page 210 SECTION 29 - HYDROSTATIC TRANSMISSION 22. Note the model and serial number markings, 1, on the rear pump housing. The model number for pump assemblies without high flow 78364–RAV; with high flow it is 78364–RAW. NOTE: Dealer warranty requests for any hydrostatic component repair must include the machine model, serial numbers, transmission model number, and date codes.
Page 211 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.
Page 212 SECTION 29 - HYDROSTATIC TRANSMISSION High Flow - The complete high flow pump assembly consists of: 1 Left side pump (rear) 2 Dual back plate 3 Right side pump (front) 4 Hydraulic gear pump 5 High flow pump The back plate carries high pressure oil from the pumps to the motors through the high pressure 19997797 hoses.
Page 213 SECTION 29 - HYDROSTATIC TRANSMISSION 10. Discard the gasket, 1, and note the two alignment dowel pins, 2, on each side of the backplate. 11. Remove the replaceable bearing plate, 3, from the backplate. The two bearing plates in this assembly are not identical;...
Page 214 SECTION 29 - HYDROSTATIC TRANSMISSION 15. Remove the front pump drive shaft, 1, by pulling it out of the pump housing bearings. 19998068 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.
Page 215 SECTION 29 - HYDROSTATIC TRANSMISSION 18. Remove the trunnion bearing cover, 1, and support bracket, 2, by removing the three capscrews, 3. Pry the cover off by inserting screwdrivers in the notches on the side of the cover. 19997800 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.
Page 216 SECTION 29 - HYDROSTATIC TRANSMISSION 21. Remove the bearing race, 1, and crush ring, 2, from the bearing cover. Discard the crush ring. Remove and discard the control arm seal, 3. 19997803 22. Remove the camplate, 1, from the housing by sliding the short end out first.
Page 217 SECTION 29 - HYDROSTATIC TRANSMISSION 5. Inspect the rear pump housing for any obvious damage. Inspect the shaft needle bearing, 1, for a loose fit, and for missing or loose needles. 6. The shaft needle bearing is a tight fit in the housing.
Page 218 SECTION 29 - HYDROSTATIC TRANSMISSION Cam Plates 1. Shoes of the pump pistons rotate at high speeds against the camplate wear plate surface, 1. The surface must be smooth with no metal flaked away and no scoring. Circular scratches centered on this machined surface are due to contamination.
Page 219 SECTION 29 - HYDROSTATIC TRANSMISSION Piston Block - replace the rotating group if: 1. The cylinders, 1, are worn or scored so the pistons do not move freely. The pistons do have side play in the piston block. 2. The surface, 2, is worn or grooved or shows metal buildup.
Page 220 SECTION 29 - HYDROSTATIC TRANSMISSION Back Plate 1. Check the needle bearings for wear, 1. These bearings are pressed into the back plate with the bearing numbers facing out. 2. Check backplate flatness along perpendicular lines, 2. 19997806 3. Two directional relief valves, 1, in each pump limit the maximum system pressure to 238 bar (3500 PSI).
Page 221 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.
Page 222 SECTION 29 - HYDROSTATIC TRANSMISSION 6. Install a new O ring, 1, and place the trunnion bearing cover, 2, on the pump housing. 19997801 7. Attach the trunnion bearing cover, 1, and support bracket, 2, with the three capscrews, 3, and washers removed during disassembly.
Page 223 SECTION 29 - HYDROSTATIC TRANSMISSION 9. Install a new camplate arm seal, 1, in the bearing cover, 2. Install a new crush ring, 3, into the bearing cover, 2. Place the bearing race, 4, over the crush ring in the bearing cover. NOTE: A new crush ring, 3, must be used for proper camplate bearing pre-load.
Page 224 SECTION 29 - HYDROSTATIC TRANSMISSION 12. Install the shaft and bearing assembly, 1, into the housing. Install the seal thrust washer and new shaft seal, 2. Tap the seal to seat the washer and seal in the pump housing. Secure the seal with the retaining ring, 3.
Page 225 SECTION 29 - HYDROSTATIC TRANSMISSION 15. Invert the housing and insert the rotating group assembly, 1, into the housing. In the front pump, it may be easier to install the drive shaft, 2, and rotating group together. NOTE: Piston shoes must contact the camplate. Make sure all parts are in their proper position before proceeding.
Page 226 SECTION 29 - HYDROSTATIC TRANSMISSION 18. Lubricate the replaceable valve plate, 1, and place the steel side to the back plate, aligning the small groove with pin, 2. The metering slots, 3, must face out. NOTE: The two bearing plates in this assembly are not identical;...
Page 227 SECTION 29 - HYDROSTATIC TRANSMISSION HYDRAULIC SYSTEM PUMP INSTALLATION (WITHOUT HIGH FLOW) 1. Remove the through bolts and separate the gear assemblies and wear plate from the pump body by removing the drive gear, 1, and idler gear, 2. Do not disturb the seal between the pump body and the backplate.
Page 228 SECTION 29 - HYDROSTATIC TRANSMISSION 3. Install the wear plate assembly, 1, with the gasket/seal side towards the pump mounting plate with the mid section cut away on the suction side, 2, of the pump. 19997783 4. Install the drive shaft, 1, making sure to engage the splines inside the hydrostatic pump.
Page 229 SECTION 29 - HYDROSTATIC TRANSMISSION HYDRAULIC SYSTEM PUMP / HIGH FLOW PUMP INSTALLATION 1. Remove the through bolts, 1, and washers. 2. Separate the pumps at 2, taking care not to disturb the seals between the pump bodies and backplates. 19997790 3.
Page 230 SECTION 29 - HYDROSTATIC TRANSMISSION The hydraulic system pump consists of: 1 Wear plate assembly 2 Idler gear assembly 3 Drive gear assembly 4 Key 5 Pump body 6 Pump back plate Coat all parts with a thin coat of petroleum jelly or oil 19997795 to aid in reassembly.
Page 231 SECTION 29 - HYDROSTATIC TRANSMISSION Install the wear plate assembly, 1, with the gasket/seal side towards the pump mounting plate with the mid section cut away on the suction side, 2, of the pump. 19997783 5. Install the drive shaft, 1, making sure to engage the splines inside the hydrostatic pump.
Page 232 SECTION 29 - HYDROSTATIC TRANSMISSION 7. Clean the mounting plate surface thoroughly and install a new O ring, 2. Install the shaft key, 3, in the drive shaft. 19997762 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.
Page 233 SECTION 29 - HYDROSTATIC TRANSMISSION 10. Install the high flow pump body and end plate together, 1, taking care not to disturb the seals between the pump body and backplate. Make sure there are no gaps between the pump bodies and plates.
Page 234 SECTION 29 - HYDROSTATIC TRANSMISSION REINSTALLATION 1. Install the side/top support bracket, 1, with the capscrews, 2, and washers removed during disassembly. 19998046 2. Install the dust shields, 1, and new O rings, 2, around each hydrostatic pump control arm. 19998073 3.
Page 235 SECTION 29 - HYDROSTATIC TRANSMISSION 5. Lubricate the engine flex plate splines and pump shaft splines with MOLY COATE GN PASTE or NEVER SEIZE. Lower the pump assembly into the unit and align the pump shaft with the drive coupler. Do not force the shaft into the drive coupler.
Page 236 SECTION 29 - HYDROSTATIC TRANSMISSION 10. Install the high pressure port fitting, 1, and the high pressure line, 2. Tighten the high pressure line connections securely. 11. Install the suction tube port fitting, 3, and turn the fitting up. Add SH/CG4 10W-30 oil to fill the bottom of the hydraulic pump.
Page 237 SECTION 29 - HYDROSTATIC TRANSMISSION 16. Install the left dampener hardware, 1, at the support bracket. 17. Install the link and dampener hardware, 2, at the pintle arms. 18. Install the control link hardware, 3, at the control handles. 19. Install the centering spring retaining bolt, 4, and spring into the engine bellhousing.
Page 238 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.
Page 239 SECTION 29 - HYDROSTATIC TRANSMISSION 6. Raise the operator’s seat and latch in the raised position, 1. CAUTION Never work under a raised seat unless it is securely latched in the raised position. 7. Remove the step shield, 1, to access the hydrostatic pump and motor area.
Page 240 SECTION 29 - HYDROSTATIC TRANSMISSION 10. Drain the hydraulic reservoir. – Loosen the return line clamp, 1. – Remove the return line at 2, and rotate the line into a suitable drain pan. 11. Remove the fender, 1, on the side the motor is being removed from.
Page 241 SECTION 29 - HYDROSTATIC TRANSMISSION 14. Right Motor – Remove the high-pressure and case drain lines from the motor and cap to prevent loss of oil. Remove the two motor retaining bolts, 1. NOTE: The large fittings may need to be removed for clearance.
Page 242 SECTION 29 - HYDROSTATIC TRANSMISSION 17. Remove the motor from the loader. Thoroughly clean the motor before disassembly. Op. 29 100 66 DISASSEMBLY This section describes 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.
Page 243 SECTION 29 - HYDROSTATIC TRANSMISSION 3. Mark the motor housing, as indicated at 1, for proper reassembly of the motor. Clamp the motor in a vise, as shown, on the housing flange. 4. Remove the cap screws, 2, from the back plate assembly, and lift the plate straight from the housing to prevent damage to the shaft and bearings.
Page 244 SECTION 29 - HYDROSTATIC TRANSMISSION 7. Remove two pistons noting the holes they are from, then remove the spider and remaining piston assembly. Be sure to lay all parts being removed from the motor on clean cardboard to prevent contamination. Do not drop any parts on removal or reassembly, as the parts may be damaged.
Page 245 SECTION 29 - HYDROSTATIC TRANSMISSION 13. Pull the case straight up and remove it from the shaft. The heavy thrust bearing, 1, and piston race, 2, can now be removed. 14. A replaceable bearing race, 1, is installed in the housing assembly and will normally remain in the housing when other parts are removed.
Page 246 SECTION 29 - HYDROSTATIC TRANSMISSION IMPORTANT: There is a burr around the holes in the piston block at 1; this is normal, do not remove. DO NOT place the piston block on the ends or the burr around the holes may be damaged, causing a piston to stick during operation.
Page 247 SECTION 29 - HYDROSTATIC TRANSMISSION PARTS INSPECTION Clean all parts in a suitable solvent and air dry prior to inspection. IMPORTANT: Due to close tolerances and finish of motor internal surfaces, it is important to maintain absolute cleanliness during inspection reassembly or damage to the components may occur.
Page 248 SECTION 29 - HYDROSTATIC TRANSMISSION 4. Inspect the piston block for any wear in the key or shaft area, 1. 5. The hollow pistons with slippers must be installed into the piston block holes on the side of the block with the tapered shaft opening, 2.
Page 249 SECTION 29 - HYDROSTATIC TRANSMISSION 9. The solid piston assemblies should individually checked in the block bores to be sure they move freely when lubricated. The solid pistons go in the end of the block with the shoulder, 1. Install the solid pistons from the tapered end of the block, 2, with the tapered end of the piston, 3, towards the shoulder end of block, 1.
Page 250 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 reassembly or damage to the components may occur. Be sure all parts are clean and air-dried before reassembly.
Page 251 SECTION 29 - HYDROSTATIC TRANSMISSION 4. Lubricate the piston race assembly, 1, and place it on the pivot, as shown, with the bearing locating ring, 2, up. 5. Lubricate the thrust bearing, 1, and install it over the bearing race at 2. 6.
Page 252 SECTION 29 - HYDROSTATIC TRANSMISSION Slide the housing down over the complete shaft assembly. Be sure the shaft extends through the housing approximately 38 mm (1-1/2″). If the shaft does not protrude through the housing the distance shown, the spacer and/or pivot is installed incorrectly.
Page 253 SECTION 29 - HYDROSTATIC TRANSMISSION Install spring, 1, over the shaft. Lubricate pivot, 2, with STP, and make sure it slides easily over the shoulder on the shaft, 3. Install pilot, 4, over the pivot assembly. 2. Lubricate the pistons with SAE SH/CG4 10W-30 oil and install the pistons and spider assembly, 1, making sure the spider plate is properly positioned over the pivot support, 2.
Page 254 SECTION 29 - HYDROSTATIC TRANSMISSION 5. Lubricate the small thrust bearing and races with a thin coating of STP and stack race, 2; bearing, 3; race, 4; and thin shim washer, 5, on the end of the shaft at 1. NOTE: Reinstall the thin shim washer at 5, if one was previously removed.
Page 255 SECTION 29 - HYDROSTATIC TRANSMISSION 8. With a feeler gauge, measure the gap between 0.015″ 0.38 mm the two opposite pads, 1. If either gap is over 5 0.015″ 0.38 mm mm (0.200″), the motor has been incorrectly 0.015″ 0.38 mm assembled and must be disassembled before 0.135″...
Page 256 SECTION 29 - HYDROSTATIC TRANSMISSION 29-76...
Page 257 SECTION 29 - HYDROSTATIC TRANSMISSION 10. Disassemble and replace the shim gauge block, 1, with the required number of shims from the seal kit. When two 1.91 mm (0.075″) shims are used, the 0.38 mm (0.015″) shims must be placed between them. When only one 1.91 mm (0.075″) shim is used, place the 1.91 mm (0.075″) shim against the spring, as shown.
Page 258 SECTION 29 - HYDROSTATIC TRANSMISSION 14. Install the connector plate, 1, and lubricate both sides with a thin coating of STP. Install it as shown with the flat side next to the pistons and the raised side up. Check the connector plate and make sure it is seated over the locating tabs, 2, on the spider plate.
Page 259 SECTION 29 - HYDROSTATIC TRANSMISSION 18. Install a bolt in the drive end of the motor shaft and use an inch pound torque wrench to check the rolling torque of the motor shaft. If the rolling torque exceeds 6.8 N·m (5 ft. lbs.) or 10.5 N·m (60 in.
Page 260 When resealing, use a noncorrosive silicone sealer to prevent rust and corrosion of parts after assembled. 2. Place a bead of New Holland Ultra-Blue silicone sealer around the face of the motor housing. 3. Align the motor assembly tapered splines with the coupler splines in the gearbox and slide the motor shaft into the coupler.
Page 261 SECTION 29 - HYDROSTATIC TRANSMISSION 11. Right Motor – Reinstall the motor high-pressure hoses and case drain line. The hoses connect the pump and motor parts top-to-top and bottom-to-bottom. The top motor hose, 1, from the top pump port, 2, routes under the motor. The bottom motor hose, 3, routes over the motor.
Page 262 SECTION 29 - HYDROSTATIC TRANSMISSION 17. Return the cab and boom to the operating position if the cab was tilted. 18. Install the step shield and fender. 19. Check and refill the hydraulic system to the proper oil level. Hydraulic System Cleaning Procedure After a Hydraulic System or Transmission Overhaul The hydraulic/hydrostatic system must be cleaned if during repair the cause was from contamination and...
Page 263 SECTION 29 - HYDROSTATIC TRANSMISSION Loosen the return line clamp, 1. Remove the return line at 1, and rotate the line into a suitable drain pan. Thoroughly flush the reservoir with a suitable clean solvent or clean 10W-30 oil. 4. Remove the charge check valve, 2, and thoroughly flush the oil cooler with solvent by forcing the solvent through the cooler.
Page 264 SECTION 29 - HYDROSTATIC TRANSMISSION 6. Remove the filter and base, clean the base, and check the bypass valve, 1, for operation. 7. Clean and flush all hydraulic lines. If the failure was hydrostatic, be sure to flush and clean the high-pressure hoses from the pumps to the motors.
Page 265 SECTION 29 - HYDROSTATIC TRANSMISSION 3. Remove the fuel solenoid power wire, 1, to prevent the engine from starting. CAUTION Never crank the starter for more than 30 seconds or damage to the starter may occur. Crank the starter for 30 seconds and cool 1 minute. 4.
Page 266 SECTION 29 - HYDROSTATIC TRANSMISSION 12. Adjust the neutral system if required; refer to the operator’s manual for procedures. 13. Run the engine at 1500 RPM for an additional 30 minutes to filter the oil. Stop the engine and change the oil filter. 14.
Page 267 SECTION 29 - HYDROSTATIC TRANSMISSION b. Loosen the return line clamp, 1. c. Remove the return line at 1, and rotate the line into a suitable drain pan. Thoroughly flush the reservoir with a suitable clean solvent or clean 10W-30 oil. 4.
Page 268 SECTION 29 - HYDROSTATIC TRANSMISSION 6. Remove the filter and base, clean the base, and check the bypass valve, 1, for operation. 7. Remove tube, 1, between the top of the oil cooler and the inlet to the hydraulic filter base. Also disconnect the tube at the inlet to the oil cooler.
Page 269 SECTION 29 - HYDROSTATIC TRANSMISSION START-UP PROCEDURE AFTER REBUILD (AFTER PUMP OR MOTOR REPLACEMENT) 1. Fill the reservoir with SAE 10W-30 oil to the proper level. 2. Install a 21 bar (300 PSI) gauge in charge pressure test port, 1. 3.
Page 270 SECTION 29 - HYDROSTATIC TRANSMISSION 7. Start the engine and monitor the charge pressure gauge to ensure charge oil for the hydrostatic system; the pressure reading should be 6.8 - 8.2 bar (100 - 120 PSI). IMPORTANT: If charge pressure remains below 3.4 bar (50 PSI) for more than 10 seconds, stop the en- gine and locate the cause.
Page 271 SECTION 29 - HYDROSTATIC TRANSMISSION CHARGE CHECK VALVE Op. 29 100 36 REMOVAL AND REPLACEMENT 1. Lower the boom and bucket to the lowered position, resting on the ground, or remove any attachment and raise the boom and rest on the boom lock pins, 1.
Page 272 SECTION 29 - HYDROSTATIC TRANSMISSION 6. Remove the right engine side shield to access the check valve, 1. 7. Remove the return line at 2, and cap to prevent the loss of oil. 8. Remove the check valve from the oil filter base at 3.
Page 273 SECTION 29 - HYDROSTATIC TRANSMISSION 3. Put the Service/Run switch, 1, in the “SERVICE” position. 4. Engage the parking brake. 19984593 5. Securely block the skid steer at 1 and 2 with all four wheels off the ground. Refer to Section 1 for more information on properly supporting a skid steer.
Page 274 SECTION 29 - HYDROSTATIC TRANSMISSION NEUTRALIZER ASSEMBLY Op. 29 130 10 Neutralizer Removal 1. Remove the two retaining nuts, 1, securing the pins to the front of the neutralizer plate. 2. Remove the centering spring, 2, from the engine bellhousing. When removing the retaining bolt, 3, the spring will be under slight pressure.
Page 275 SECTION 29 - HYDROSTATIC TRANSMISSION 5. Remove the cam arm securing hardware, 1, and remove the arms. 19997770 Control Linkage Parts Inspection 1. Inspect the bushings, 1, in the control links; replace if worn, loose, or damaged. 2. Inspect dampeners, unequal pressures, leaks, or binding shafts.
Page 276 SECTION 29 - HYDROSTATIC TRANSMISSION 4. Inspect the blocks, 1, that the bearings ride on. If worn, turn the blocks around for a new surface. 19998067 19997798 Op. 29 130 06 Control Linkage and Neutralizer Reassembly and Adjustment 1. Install a new O ring, 1, around each cam plate shaft.
Page 277 SECTION 29 - HYDROSTATIC TRANSMISSION 3. Loosely install the blocks, 1, to the neutralizer plate with 1/2″ x 3/4″ capscrews, 2, and large 1/12″ flat washers. 19998067 4. Install the dampener hardware, 1, at the support brackets with the bolts, washers and spacers removed during disassembly.
Page 278 SECTION 29 - HYDROSTATIC TRANSMISSION LEFT CONTROL HANDLE WITH NO BOOM HAND CONTROL Op. 29 100 10 REMOVAL 1. Securely latch the seat in the raised and latched position. Remove the step shield and front step cover to access the control handle, linkage and valve area.
Page 279 SECTION 29 - HYDROSTATIC TRANSMISSION INSPECTION 1. Inspect the handle pivot bearings, 1; replace if worn or damaged. 2. Inspect the control handle for excessive wear or bends in the bearing mounting plates, 2, and pivot stub shafts, 3. REASSEMBLY 1.
Page 280 SECTION 29 - HYDROSTATIC TRANSMISSION 2. Connect the hydrostatic pump control link, 1. 3. Reinstall all shields removed for the repair. 4802-10 29-100...
Page 281 SECTION 29 - HYDROSTATIC TRANSMISSION LEFT CONTROL HANDLE WITH BOOM HAND CONTROL Op. 29 100 11 REMOVAL 1. Securely latch the seat in the raised and latched position. Remove the step shield and front step cover to access the control handle, linkage and valve area.
Page 282 SECTION 29 - HYDROSTATIC TRANSMISSION DISASSEMBLY 1. Take note of the number and position of all shim washers for reassembly. 2. Remove the bolt, 1, securing the ball end to the control arm. 3. Remove the jam nut, 2, and ball end, 3, from the rod, 4.
Page 283 SECTION 29 - HYDROSTATIC TRANSMISSION 10. Loosen the boot securing bolts, 1, and slide the boot, 2, off the handle. 19997750 INSPECTION 1. Inspect the handle pivot bearings, 1; replace if worn or damaged. 2. Inspect the pivot stub shafts, 2, for any obvious bends or deformation.
Page 284 SECTION 29 - HYDROSTATIC TRANSMISSION REASSEMBLY 1. Install a new hand grip on the top of the handle, 1, if grip is worn. 2. Attach the ball end, 2, and jam nut, 3, to the rod, 4. Fasten the ball end to the handle, 5, with the capscrew, 6, flat washer and locknut.
Page 285 SECTION 29 - HYDROSTATIC TRANSMISSION 12. Assemble the pivot shaft, 1, shim washers, 2, arm, 3, set collar, 4, and bearings, 5, into the control arm housing. Fasten each bearing with two 5/16″ x 3/4″ carriage bolts, lock washers, and nuts at 6.
Page 286 SECTION 29 - HYDROSTATIC TRANSMISSION 2. Install the boom control rod, 1, on the left control handle arm, 2. 19996848 3. Connect the hydrostatic pump control link, 1. 4. Reinstall all shields removed for the repair. 4802-10 29-106...
Page 287 SECTION 29 - HYDROSTATIC TRANSMISSION RIGHT CONTROL HANDLE WITH AUXILIARY OR BUCKET CONTROL Op. 29 100 15 REMOVAL 1. Securely latch the seat in the raised and latched position. Remove the step shield and front step cover to access the control handle, linkage and valve area.
Page 288 SECTION 29 - HYDROSTATIC TRANSMISSION DISASSEMBLY 1. Take note of the number and position of all shim washers for reassembly. 2. Remove the bolt, 1, securing the ball end to the control arm. 3. Remove the jam nut, 2, and ball end, 3, from the rod, 4.
Page 289 SECTION 29 - HYDROSTATIC TRANSMISSION 10. Boom hydraulics control - Remove the locknut, 1, and bolt, 2, to separate the handle, 3, from the handle support, 4. Retain the bushing and capscrew. Remove the ball end, 5, from the handle by removing the capscrew, 6, flat washer and locknut.
Page 290 SECTION 29 - HYDROSTATIC TRANSMISSION 13. Loosen the boot securing bolts, 1, and slide the boot, 2, off the handle. 19997750 INSPECTION 1. Inspect the handle pivot bearings, 1; replace if worn or damaged. 2. Inspect the pivot stub shafts, 2, for any obvious bends or deformation.
Page 291 SECTION 29 - HYDROSTATIC TRANSMISSION 6. Boom Hydraulics Control - Inspect the pivot handle linkage for looseness in the ball joints, 1; replace if worn. 7. Boom Hydraulics Control - Inspect the pivot handle, 2, and handle support, 3, for damage or deformation.
Page 292 SECTION 29 - HYDROSTATIC TRANSMISSION 10. Bucket control - Attach the handle and rod assembly, 1, to the control handle by first sliding the rod down through the control handle tube, 2. 11. Bucket control - Attach the handle assembly to the handle tube arms, 3, with the short carriage bolts, 4, lock washers, 5, and nuts, 6.
Page 293 SECTION 29 - HYDROSTATIC TRANSMISSION 21. Boom hydraulics control - Attach the handle and rod assembly, 1, to the control handle, 2, by first sliding the rod, 3, down through the control handle tube. 22. Boom hydraulics control - Position the handle support on the tube by aligning the setscrew, 4, with the drilled hole in the tube.
Page 294 SECTION 29 - HYDROSTATIC TRANSMISSION 27. Attach the ball end and jam nut, 1, onto rod, 2. Install spacer, 12, (OD - 7/16″; length - 15/32″) between the ball end and arm, 3. Secure with a 5/16″ x 1-3/4″ bolt, lock washer, and nut at 4. 28.
Page 295 SECTION 29 - HYDROSTATIC TRANSMISSION 3. Connect the hydrostatic pump control link, 1. 4. Reinstall all shields removed for the repair. 4802-10 29-115...
Page 296 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...
Page 297 SECTION 29 - HYDROSTATIC TRANSMISSION Op. 29 130 06 NEUTRAL ADJUSTMENT Before making any adjustments, make sure there is no binding in the control linkage, shock absorbers or neutralizer plate. The neutralizer plate, 1, should be free to move on the spring retaining bolt at the engine bell housing, 2, and on the front slides, 3.
Page 298 SECTION 29 - HYDROSTATIC TRANSMISSION Control Lever Parallel Adjustment The control levers, 1 and 2, are set at the factory at 9 degrees to the front. The levers can be adjusted so the two levers are parallel. To adjust the levers, loosen bolts, 3, and move the levers to the desired position and retighten the hardware.
Page 299 SECTION 29 - HYDROSTATIC TRANSMISSION LABOR GUIDE HYDROSTATIC SYSTEM AND STEERING SYSTEM The following labor amounts are listed as a guide only. Working conditions and experience will vary the time it actually takes to complete each job. Hours Hydrostatic pump - RH & LH assembly - remove/replace .
Page 300 SECTION 33 – BRAKES AND CONTROLS Chapter 1 – Parking Brake CONTENTS Section Description Page 33 000 General Information ............33-2 Specifications .
Page 301 SECTION 33 - BRAKES AND CONTROLS Op. 33 000 GENERAL INFORMATION The power is transmitted to the final drive from the engine which is connected to the hydrostatic pumps, 1, with a flex plate drive coupler. The hydrostatic pumps then transmit hydraulic power to the hydro- static motors, 2, which are connected to gearboxes, 3, located on the inside of the final drive cases.
Page 302 SECTION 33 - BRAKES AND CONTROLS The parking brake discs are connected to the hydro- static motor coupler shafts at 1. The parking brake is made up of two discs, actuator shaft, pads, and con- trol linkage. The hydrostatic system is the primary braking system, and the parking brake is used when the unit is stopped.
Page 303 SECTION 33 - BRAKES AND CONTROLS SPECIFICATIONS Chain Case Side Cover Bolt Torque ............15 N·m (11 ft.
Page 304 SECTION 33 - BRAKES AND CONTROLS TROUBLESHOOTING FINAL DRIVE/PARKING BRAKE SYSTEM Before servicing or adjusting on the final drive/park- ing brake system, the skid-steer loader should be jacked up with the wheels off the ground. Remove any attachment from the skid-steer loader boom, bucket, etc.
Page 305 SECTION 33 - BRAKES AND CONTROLS TROUBLESHOOTING PARKING BRAKE SYSTEM PROBLEM POSSIBLE CAUSES CORRECTION Parking brake will not hold Park brake not engaged Engage parking brake loader Brake not adjusted properly Adjust parking brake Handle not operating or latching Check handle components repair or replace Loose brake linkage Inspect and repair linkage...
Page 306 SECTION 33 - BRAKES AND CONTROLS TESTING PARKING BRAKE Pre-test instructions: * Operator in seat with seat belt buckled. * Engine running at 1500 RPM. * Park brake disengaged position. STEP TEST RESULT PROBABLE CAUSE AND CORRECTION Push both drive controls forward Brake system OK.
Page 307 SECTION 33 - BRAKES AND CONTROLS Op. 33 110 PARKING BRAKE OPERATION The parking brake system is a mechanically acti- vated double disc brake system. The brake discs are attached to the hydrostatic motor shafts, 1, with a separate system located in each final drive case. Both brake systems are activated by a single control lever.
Page 308 SECTION 33 - BRAKES AND CONTROLS REMOVAL AND INSPECTION To access and remove the parking brake control link- age, the seat can be raised and latched in the raised position. To access the brake disc and caliper as- sembly, the final drive inspection cover will need to be removed.
Page 309 SECTION 33 - BRAKES AND CONTROLS 4. Slide the seat to the most rear position and un- latch the seat pan and raise the seat and pan as- sembly to the raised latched position. CAUTION Before working under a raised seat make sure it is securely latched at 1, in the raised position.
Page 310 SECTION 33 - BRAKES AND CONTROLS Op. 33 110 30 2. To remove the control rod assembly, 1, remove the cotter pins from the spring links, 2. 3. Remove the left support bracket and hardware, 3, then pivot the rod assembly down and slide the control rod from the right support bracket.
Page 311 SECTION 33 - BRAKES AND CONTROLS Spring Brake Assembly Parts 1. Shaft Weld Assembly 2. Roll Pin 3. Spring Plate 4. Threaded Rod 5. Spring 19995773 Inspection of Control Linkage Parts 1. Examine the latch plate, 1, and tab, 2, for bends or damage.
Page 312 SECTION 33 - BRAKES AND CONTROLS Installation of Brake Control Linkage 1. Install the control rod assembly, 1, friction pad, 2, on right end of rod. Insert pivot bushing, 3, into supports, and slide the right end into support and pivot link, 3, up and install the left support, 4.
Page 313 SECTION 33 - BRAKES AND CONTROLS 5. Adjust the spring assembly length by threading rod, 1, in or out to obtain an overall length of 8-5/8″ at 2. 19980499 Op. 33 110 48 Brake Caliper and Disc Removal The loader must be properly supported with all four wheels off the ground.
Page 314 SECTION 33 - BRAKES AND CONTROLS 10. Remove brake friction puck, 1, and spacer plate, NOTE: The spacer plate is thinner than the friction puck and must be inserted into brake caliper first upon reassembly. 11. Remove the caliper support retaining bolt, 1, and remove the support from the loader.
Page 315 SECTION 33 - BRAKES AND CONTROLS 1. Inspect the brake disc for wear in the clamp area, 1, and splines, 2. The disc should also be flat. If worn severely or bent, replace. 2. Inspect the brake friction puck, 1. If worn severe- ly, replace.
Page 316 SECTION 33 - BRAKES AND CONTROLS Inspect the caliper outer plate for wear. Replace if worn. Inspect the thread area, 2, and if damaged, re- place outer plate. 5. Inspect the caliper support, 1, and shaft thread area, 2. If damaged and shaft rotates hard in sup- port, replace the damaged part.
Page 317 SECTION 33 - BRAKES AND CONTROLS 2. Install the correct, right or left, caliper support, 1, in the final drive case. Position and install retain- ing bolt, 2, and tighten to 12 N·m (9 ft. lbs.). 3. Install the spacer plate, 2, next to the end of shaft, then the brake friction puck, 1.
Page 318 SECTION 33 - BRAKES AND CONTROLS 7. Install outer brake disc, 1, on motor shaft. 8. Thread caliper retaining bolts into outer section of caliper, 2, and tighten to 70 N·m (52 ft. lbs.). Check the center section of the caliper, 3, to make sure it is free to move.
Page 319 SECTION 33 - BRAKES AND CONTROLS 12. Reinstall the drive chain over the drive sprocket at 1. 13. Install the rear axle assembly. Slide the axle as- sembly to the rear and tighten the drive chain to obtain a movement of 0 - 6 mm (0 - 1/4″) move- ment at the outer tire tread.
Page 320 SECTION 33 - BRAKES AND CONTROLS Caliper Adjustment Parking brake in the disengaged position. 1. Unhook the lower pin of the spring assembly, 1, from the control arm at 3. 2. Push the arm, 2, down to turn the shaft into the caliper support to remove any play in caliper and disc.
Page 321 SECTION 33 - BRAKES AND CONTROLS LABOR GUIDE The following labor amounts are listed as a guide only. Working conditions and experience will vary the time the job actually takes to complete each job. Job Description Hours Brake Handle - remove, rebuild, replace 1.0 hr.
Page 322 SECTION 35 - HYDRAULIC SYSTEM Chapter 1 - Valves, Gear Pump, Cylinders, and Pedal Controls CONTENTS Section Description Page 35 000 General Information ............35-3 Hydraulic System Compatibility .
Page 323 SECTION 35 - HYDRAULIC SYSTEM Hydraulic System Pump Parts Inspection ........35-59 Hydraulic System Pump Reassembly/Installation (Without High Flow) .
Page 324 14. Optional high flow kit - Dealer installed kit - Refer Figure 1 shows the hydraulic circuit and components to Section 88 - “Accessories” for more informa- for the LS160 and LS170 skid steers. tion. The hydraulic system is built with the following com- ponents and their location.
Page 325 Model LS160 and LS170 skid steers must have steer loader hydraulics is turned off. a minimum of 22.7 l/min. (6 GPM) returning If “NO”, nothing is required.
Page 326 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 return line attached to the right boom arm. If “NO”, nothing is required. If “YES”, install a separate case drain line to re- 7.
Page 327 SECTION 35 - HYDRAULIC SYSTEM BOOM CYLINDER PIVOT PINS When the main boom, upper and lower boom links and cylinders are removed, the figure and chart here may be used for proper pin placement. The figure and chart show the boom and cylinder ta- pered and straight pivot pins, location/description, quantity used, and part number.
Page 328 Control valve, used on all skid-steer skid steers, has a plugged power-beyond port, 1. This port is not nor- mally used with New Holland-supplied attachments, as these can be operated through the auxiliary boom hydraulics (the third control valve spool), 2.
Page 329 SECTION 35 - HYDRAULIC SYSTEM SPECIFICATIONS SKID STEER MODEL LS160 MAIN CONTROL VALVE Type ............... . .
Page 330 SECTION 35 - HYDRAULIC SYSTEM TORQUE SPECIFICATIONS SKID STEER MODEL LS160 Control Valve Control Valve Retaining Hardware ..........
Page 331 SECTION 35 - HYDRAULIC SYSTEM SPECIFICATIONS SKID STEER MODEL LS170 MAIN CONTROL VALVE Type ............... . . 3-spool open center Relief Valve .
Page 332 SECTION 35 - HYDRAULIC SYSTEM TORQUE SPECIFICATIONS SKID STEER MODEL LS170 Control Valve Control Valve Retaining Hardware ..........24 N·m (18 ft.
Page 333 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 than the highest pressures of the system. Before testing, lower the attachment to the ground or remove the attachment from the loader.
Page 334 SECTION 35 - HYDRAULIC SYSTEM PROBLEM POSSIBLE CAUSE CORRECTION Noisy system pump Oil level too low Add proper oil and amount Oil of incorrect viscosity Oil of incorrect viscosity Replace oil and filter Replace oil and filter Suction line plugged Clean or replace line Reservoir air vent plugged Clean reservoir cap...
Page 335 SECTION 35 - HYDRAULIC SYSTEM PROBLEM POSSIBLE CAUSE CORRECTION Boom arms will not raise or raise Low oil flow from pump Plugged inlet line or worn pump slowly slowly Low relief valve pressure Low relief valve pressure Check pressure, replace valve if Check pressure, replace valve if pressure is not correct pressure is not correct...
Page 336 SECTION 35 - HYDRAULIC SYSTEM PROBLEM POSSIBLE CAUSE CORRECTION Hydraulic system hot Low oil flow pump Plugged inlet line, clean or replace line Main control valve linkage or spool Check and correct linkage binding or damaged binding or damaged Auxiliary boom hydraulic control Lock handle in neutral when not in not in neutral not in neutral...
Page 337 SECTION 35 - HYDRAULIC SYSTEM AUXILIARY BOOM HYDRAULICS TROUBLESHOOTING PROBLEM POSSIBLE CAUSES CORRECTION No oil flow to quick couplers Broken control linkage Check and repair linkage Inoperative quick coupler Repair or replace Plugged supply line Clean or replace Control valve plugs leaking oil to re- Check O ring and back-up washer turn on plugs...
Page 338 SECTION 35 - HYDRAULIC SYSTEM Adjustments Control Handle Locked, 1, In Neutral Adjust the length of rod, 2, by threading the ball joints, 3, on or off, at both ends of the rod to set the link, 4, vertical. Check adjustment by shifting the hydrostatic control lever forward and reverse.
Page 339 SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC SYSTEM TESTING Foot or hand controls and control valve spool locks: Pretest instructions: * Hydraulic oil reservoir oil at proper oil level * Operator in seat * Service/Run switch in “RUN” position * Seat belt fastened * Ignition switch in the “OFF”...
Page 340 SECTION 35 - HYDRAULIC SYSTEM Foot or hand control and control valve spool lock solenoids: Pretest instructions: * Hydraulic oil reservoir oil at proper oil level * Operator in seat * Service/Run switch in “RUN” position * Seat belt fastened * Ignition switch in the “ON”...
Page 341 SECTION 35 - HYDRAULIC SYSTEM Electronic instrument cluster (EIC) hydraulic oil filter light: Pretest instructions: * Hydraulic oil reservoir oil at proper oil level * Operator in seat * Service/Run switch in “RUN” position * Seat belt fastened * Ignition switch in the “ON” position * Engine running half throttle, 1500 RPM STEP TEST...
Page 342 SECTION 35 - HYDRAULIC SYSTEM Boom lift check test: Pretest instructions: * Operator in seat * Service/Run switch in “RUN” position * Seat belt fastened * Ignition switch in the “ON” position * Engine running half throttle, 1500 RPM STEP TEST RESULT PROBABLE CAUSE AND CORRECTION...
Page 343 SECTION 35 - HYDRAULIC SYSTEM Bucket operation: Pretest instructions: * Operator in seat * Service/Run switch in “RUN” position * Seat belt fastened * Ignition switch in the “ON” position * Engine running half throttle, 1500 RPM STEP TEST RESULT PROBABLE CAUSE AND CORRECTION Bucket movement System OK...
Page 344 SECTION 35 - HYDRAULIC SYSTEM Bucket drift down test: Pretest instructions: * Operator in seat * Service/Run switch in “RUN” position * Seat belt fastened * Ignition switch in the “ON” position * Engine running half throttle, 1500 RPM STEP TEST RESULT PROBABLE CAUSE AND CORRECTION...
Page 345 SECTION 35 - HYDRAULIC SYSTEM 19997772 5. With the control valve spools in neutral position, HYDRAULIC SYSTEM OIL FLOW the oil flows through center of control valve, 5, to return line, 7. Control Valve - Spools in Neutral Position 6. The oil flows through return line, 7, to oil cooler, 1.
Page 346 SECTION 35 - HYDRAULIC SYSTEM 19997773 1. Oil flows from the gear pump, 1, through pres- CONTROL VALVE - BUCKET SPOOL sure line, 2, to control valve, 3. SHIFTED 2. When the bucket valve spool, 4, is pulled out, the oil flows from the rear work port, 5, to the shaft Bucket Control Operation side of the bucket cylinder to curl the bucket...
Page 347 SECTION 35 - HYDRAULIC SYSTEM 19997774 3. When the boom valve spool, 4, is pushed in, the CONTROL VALVE - BOOM SPOOL oil flows from the front port, 6, to the shaft end of SHIFTED boom cylinders, to lower the boom. 4.
Page 348 SECTION 35 - HYDRAULIC SYSTEM 19997775 3. When the auxiliary valve spool, 4, is pushed in, CONTROL VALVE - AUXILIARY SPOOL the oil flows from the front work port, 7, and sup- SHIFTED plies oil to the male quick coupler, 8, at the front of the boom.
Page 349 SECTION 35 - HYDRAULIC SYSTEM Op. 35 710 02 MAIN SYSTEM PRESSURE TESTS Check the main system pressure to insure the main relief valve is within specifications to provide 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.
Page 350 SECTION 35 - HYDRAULIC SYSTEM The hydraulic system pressures are factory set. Changes to the settings should not be necessary. To access the control and relief valve area, remove the step shield, 1. Raise the seat and seat pan to the raised latched position, 1.
Page 351 SECTION 35 - HYDRAULIC SYSTEM The main system relief valve, 1, is located in the con- trol valve. If there is some reason to suspect incorrect pressure, check the pressures as follows: WARNING Gauges, gauge fittings, and hoses must have operating pressure ratings of at least 25% higher than the highest pressures of the system.
Page 352 SECTION 35 - HYDRAULIC SYSTEM 3. Install the pressure test gauge in the boom cylin- der at 1. 4. Start the engine and run it at full throttle (3070 - 3150 RPM) to bring the hydraulic oil to operating temperature. 5.
Page 353 SECTION 35 - HYDRAULIC SYSTEM 3. Install the pressure test gauge in the left bucket cylinder at 1. 4. Start the engine and run it at full throttle (3070 - 3150 RPM). 5. Operate the bucket control to dump the bucket to the fully dumped position until the system by- passes and take a pressure reading.
Page 354 SECTION 35 - HYDRAULIC SYSTEM 3. Install the pressure test gauge in one of the quick couplers at 2. 4. Start the engine and run it at full throttle (3070 - 3150 RPM). 5. Operate the auxiliary control to pressurize the auxiliary circuit until the system bypasses and take a pressure reading.
Page 355 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.
Page 356 SECTION 35 - HYDRAULIC SYSTEM GEAR PUMP FLOW EFFICIENCY TEST Fittings and gauges required: 1. Hydraulic flow tester (30 GPM capacity). 2. Male and female 1/2″ quick couplers for units equipped with auxiliary boom hydraulics. 3. Two male 3/4″ UNF 37 flare-to-tester fittings for units without auxiliary boom hydraulics.
Page 357 9. Turn the resistance valve, 1, on the tester to ap- ply resistance in the hydraulic system to obtain the following specifications: LS160 - 2900 RPM (engine) 68 bar (1000 PSI) - 15.5 GPM (58.7 LPM) Maximum without high flow L170 - 2900 RPM (engine) 68 bar (1000 PSI) - 17.7 GPM (67.0 LPM) Maximum without high...
Page 358 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.
Page 359 16 GPM free flow Step 10. following specifications: 12.5 GPM flow Step 11. LS160 - 2900 RPM (engine) 68 bar (1000 PSI) - 80% of 16 GPM = 12.5 GPM 15.5 GPM (58.7 LPM) Maximum without high The pump is not at least 80% of free flow. Repair or flow replace pump.
Page 360 SECTION 35 - HYDRAULIC SYSTEM BOOM AND BUCKET SPOOL LOCK SOLENOID TEST The boom and bucket control valve solenoid spool locks are controlled by the EIC (Electronic Instru- ment Cluster). The operator must be in the operator’s seat with the seat belt buckled for the EIC to unlock the control valve spool lock solenoids.
Page 361 SECTION 35 - HYDRAULIC SYSTEM 2. Raise the seat and latch securely in the raised latch position, 1. Remove the step shield, 2, from over the control valve to access the solenoid locks. 3. Unplug one solenoid, 1, at a time and check for battery voltage at the main wire harness plugs, pink/light-blue and black wires.
Page 362 SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC, HYDROSTATIC SYSTEM AIR INGRESS TEST Hydraulic system air ingress, causing oil aeration, can affect performance of the hydraulic oil. This may be evident on a machine by jerky or uneven move- ment of the loader boom or bucket. To assist in testing and finding leaks, a tool has been developed (part #FNH22ESS95).
Page 363 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 gearboxes or bell housing) to pressurize the –...
Page 364 SECTION 35 - HYDRAULIC SYSTEM CONTROL VALVE SPECIFICATIONS Type ............... . . 3-spool open center Relief Valve .
Page 365 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.
Page 366 SECTION 35 - HYDRAULIC SYSTEM 6. Drain the hydraulic reservoir by disconnecting the return line, 1, at tee, 2, and drain the oil into a suitable container. 7. Unplug the spool lock solenoids, 1. 8. Remove the pressure line, 2, and return line, 3; cap both lines to prevent loss of oil and contami- nation from entering the hydraulic system.
Page 367 SECTION 35 - HYDRAULIC SYSTEM Lift Check Valves There is a check valve in each circuit - bucket, boom, and auxiliary. The only time the check valves serve a function is af- ter the control spools have been shifted. If the valves are operating properly, they prevent any movement of either the boom or bucket until pressure opens the lift checks.
Page 368 SECTION 35 - HYDRAULIC SYSTEM Remove the plug, 1, from the port, 2, over the main relief valve port. Remove the plug, 3, from the port, 4, over the auxiliary control spool. 19984469 Spools, Caps, and O Rings Oil is directed through the housing to the different ports by way of the spools: the bucket spool, 1, the boom spool, 2, and the auxiliary spool, 3.
Page 369 SECTION 35 - HYDRAULIC SYSTEM NOTE: Before removing the spools, make sure the exposed portion of the spool is free from any paint or corrosion which could damage the internal porting of the valve. 3. Remove the spools, 1, from the valve body. NOTE: Each spool is different.
Page 370 SECTION 35 - HYDRAULIC SYSTEM PARTS INSPECTION Inspect the control valve components thoroughly for scratches or nicks, weak centering springs, weak lift check springs, and scored lift checks or valve seats. Valve Body, 1 Check for cracks in casting that allow an oil leak.
Page 371 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 2. Install the O ring seals, 1, on the boom circuit re- lief valve, 2, and all the plugs, 3.
Page 372 SECTION 35 - HYDRAULIC SYSTEM 6. Install the plug, 1, into the port, 2, over the main relief valve port. Install the plug, 3, into the port, 4, over the auxiliary control spool. 19984469 7. Install new O rings, 1, on the spools. 8.
Page 373 SECTION 35 - HYDRAULIC SYSTEM 10. Install the control spools into the valve body - bucket, 1, boom, 2, auxiliary, 3. 11. Reinstall the boom lower orifice plate, 4, with the slot towards the fitting in port, 5. NOTE: The three spools are different. Do not mix spools and return spring assemblies during reassembly.
Page 374 SECTION 35 - HYDRAULIC SYSTEM 14. Add O rings to the lift check valve caps, 1. Install the lift checks, 2, springs, 3, and caps. 15. Install the two caps, 4, with O rings into the valve body. 19984466 16. Install an O ring on the main system relief valve, 1, and install into the valve body.
Page 375 SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC PUMP Specifications 26000 Series Type Gear Pump LS160 Output @2900 RPM - 69 bar (1000 PSI) 58.7 L/min (15.5 GPM) LS170 Output @2900 RPM - 69 bar (1000 PSI) 67.0 L/min (17.7 GPM) Rotation (Viewed from shaft end)
Page 376 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.
Page 377 SECTION 35 - HYDRAULIC SYSTEM Op. 35 710 20 HYDRAULIC SYSTEM PUMP REMOVAL/ DISASSEMBLY (WITHOUT HIGH FLOW) 1. Remove the suction tube, 1, from the gear pump port fitting, 2, and cap the tube to prevent oil loss. Remove the fitting from the housing. 2.
Page 378 SECTION 35 - HYDRAULIC SYSTEM 2. Remove the suction tube, 1, from the gear pump port fitting, 2, and cap the tube to prevent oil loss. Remove the fitting from the housing. 3. Remove the high pressure hoses, 3, from the pump fittings, 4, and cap the tubes.
Page 379 SECTION 35 - HYDRAULIC SYSTEM HIGH FLOW PUMP PARTS INSPECTION 1. Inspect the pump back plate for excessive wear. The oil grooves in the back plate bushings, 1, should be at approximately 37° to the pressure side. If the bushing oil grooves are not positioned as noted, the bushings have turned in the plate.
Page 380 SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC SYSTEM PUMP PARTS INSPECTION 1. Inspect the pump mounting plate for excessive wear. The oil grooves in the bushings, 1, should be line up with the dowel pin holes and be approximately 180° apart. If the bushing oil grooves are not positioned as noted, the bush- ings have turned in the plate - the plate should be replaced.
Page 381 The gear shaft assemblies should measure greater than or equal to 0.7485″ (19.0 mm) in the bushing area, 2. LS160 gears should be at least 22.56 mm (0.888″) wide. LS170 gears should be at least 22.76 mm (1.014″) wide. Replace the gears if they do not meet specifications.
Page 382 The gear shaft assemblies should measure greater than or equal to 0.748″ (19.0 mm) in the bushing area, 2. LS160 gear should be at least 22.56 mm (0.888″) wide. LS170 gears should be at least 22.76 mm (1.014″) wide. Replace the gears if they do not meet specifications.
Page 383 SECTION 35 - HYDRAULIC SYSTEM NOTE: The gasket AND seal must align and lay flat when installed in the wear plate. 4. Install the wear plate assembly, 1, with the gas- ket/seal side towards the pump mounting plate with the mid section cut away on the suction side, 2, of the pump.
Page 384 SECTION 35 - HYDRAULIC SYSTEM 6. Make sure the dowel pins, 1, are in place and install the body on the plate with the half-moon cavities, 2, in the body facing out away from the plate. Check that the reference marks made dur- ing disassembly align correctly.
Page 385 SECTION 35 - HYDRAULIC SYSTEM 12. Turn the suction tube fitting, 1, down and install the suction tube, 2. Tighten all hydraulic connec- tions securely. 19998082 HYDRAULIC SYSTEM PUMP AND HIGH FLOW PUMP REASSEMBLY/ INSTALLATION NOTE: If installing a new pump assembly, refer to “New Hydraulic System Pump / High Flow Pump Installation”...
Page 386 SECTION 35 - HYDRAULIC SYSTEM NOTE: The gasket AND seal must align and lay flat when installed in the wear plate. 4. Install the wear plate assembly, 1, with the gas- ket/seal side towards the pump mounting plate with the mid section cut away on the suction side, 2, of the pump.
Page 387 SECTION 35 - HYDRAULIC SYSTEM 6. Make sure the dowel pins, 1, are in place and install the body, 2, on the plate with the half-moon cavities, 3, in the body facing out away from the plate. Check that the reference marks made dur- ing disassembly align correctly.
Page 388 SECTION 35 - HYDRAULIC SYSTEM 10. Install the seal, 1, and backup gasket 2, on the wear plate, 3. BE SURE that the flat area, 4, on the gasket AND seal, 5, are properly aligned and lay flat when installed in the wear plate. NOTE: The gasket AND seal must align and lay flat when installed in the wear plate.
Page 389 SECTION 35 - HYDRAULIC SYSTEM 12. 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 the shaft, be careful not to knock the round key, 2, from the shaft.
Page 390 SECTION 35 - HYDRAULIC SYSTEM 15. Install the pump backplate, 1, over the gear shafts. Check that the reference marks made during disassembly align correctly. 16. Install the housing hardware with the eight bolts, 2, and sealing washers. Tighten the bolts evenly in a criss-cross pattern to 34 - 38 N·m (25 - 28 ft.
Page 391 SECTION 35 - HYDRAULIC SYSTEM NEW HYDRAULIC SYSTEM PUMP INSTALLATION (WITHOUT HIGH FLOW) 1. Remove the through bolts and separate the gear assemblies and wear plate from the pump body by removing the drive gear, 1, and idler gear, 2. Do not disturb the seal between the pump body and the backplate.
Page 392 SECTION 35 - HYDRAULIC SYSTEM 3. 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. 19997783 4. Install the drive shaft, 1, making sure to engage the splines inside the hydrostatic pump.
Page 393 SECTION 35 - HYDRAULIC SYSTEM 9. Turn the suction tube fitting, 1, down and install the suction tube, 2. Tighten all hydraulic connec- tions securely. 19998082 NEW HYDRAULIC SYSTEM PUMP / HIGH FLOW PUMP INSTALLATION 1. Remove the through bolts, 1, and washers. 2.
Page 394 SECTION 35 - HYDRAULIC SYSTEM The hydraulic system pump consists of: 1 Wear plate assembly 2 Idler gear assembly 3 Drive gear assembly 4 Key 5 Pump body 6 Pump back plate Coat all parts with a thin coat of petroleum jelly or oil to aid in reassembly.
Page 395 SECTION 35 - HYDRAULIC SYSTEM 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. 19997783 5. Install the drive shaft, 1, making sure to engage the splines inside the hydrostatic pump.
Page 396 SECTION 35 - HYDRAULIC SYSTEM 7. Clean the mounting plate surface thoroughly and install a new O ring, 2. Install the shaft key, 3, in the drive shaft. 19997762 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.
Page 397 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- tween the pump body and backplate. Make sure there are no gaps between the pump bodies and plates.
Page 398 SECTION 35 - HYDRAULIC SYSTEM 15. Reinstall the boom circuit hydraulic lines, 1, and high flow line, 2, and tighten securely. 19998077 35-77...
Page 399 SECTION 35 - HYDRAULIC SYSTEM GEAR PUMP START-UP PROCEDURE This procedure must be performed if the gear pump has been removed for repair purposes or any gear pump hydraulic lines have been removed. 1. Fill the reservoir with SAE SH/CG4 10W-30 oil to the proper level.
Page 400 SECTION 35 - HYDRAULIC SYSTEM CYLINDERS, BOOM AND BUCKET BOOM CYLINDERS - LS160 Specifications Bore Diameter ..............
Page 401 SECTION 35 - HYDRAULIC SYSTEM BOOM CYLINDERS - LS170 Specifications Bore Diameter ..............63.5 mm (2.5″) Stroke .
Page 402 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.
Page 403 SECTION 35 - HYDRAULIC SYSTEM 9. Support the cylinder and with a hammer strike the cylinder at the base area, 1, to loosen the ta- pered pivot pin from the loader main frame. 10. Remove the UPPER boom pin retaining bolt, 1, and boom pin, 2.
Page 404 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.
Page 405 SECTION 35 - HYDRAULIC SYSTEM 6. Remove the wiper seal, 1; O ring and backup washer, 2; and inner seal and wear ring, 3, from the cylinder head (gland), 4. 7. Remove the wear ring, 1, and seal, 2, from the piston, 3.
Page 406 SECTION 35 - HYDRAULIC SYSTEM 5. Inspect the outer diameter of the piston, 1, for ex- cessive wear or scoring. If the piston is damaged, the inner surface of the barrel will also most likely be damaged. Inspect the barrel thoroughly. If the piston is not damaged, do not replace.
Page 407 SECTION 35 - HYDRAULIC SYSTEM 4. Examine the piston assembly prior to installation. Replace the wear ring, 1, and T-seal, 2, making sure they are firmly in their groove and snug against the piston. Insert the L shaped back-up rings, 3, on both sides of the T-seal with the short leg of the L shaped back-up rings towards the T- seal as shown.
Page 408 SECTION 35 - HYDRAULIC SYSTEM REINSTALLATION 1. Lubricate the boom pivot pins, 1, with an anti- seize-type lubricant. 2. Install the cylinder onto the loader. NOTE: Refer to Service Bulletins 5/96 - I6 and 7/96 - I6 for updated pivot pin support information and proper pin, spacer, and bolt part numbers.
Page 409 SECTION 35 - HYDRAULIC SYSTEM 6. Remove the hydraulic hoses from both ends of the cylinder, 1, and cap the lines to prevent loss of oil. 7. Remove the retaining bolt and pin, 2, from the lower end of the cylinder. 8.
Page 410 SECTION 35 - HYDRAULIC SYSTEM 4. Remove piston retaining stud, 1, from the cylin- der rod, piston, 2, and gland, 3, from the piston rod. 5. Remove seals from the gland, the outer O ring seal and backup ring, 1, the inner shaft seal, 2, and the wiper seal, 3.
Page 411 SECTION 35 - HYDRAULIC SYSTEM 5. Inspect the outer diameter of the piston, 1, for ex- cessive wear or scoring. If the piston is damaged, the inner surface of the barrel will also most likely be damaged. Inspect the barrel thoroughly. If the piston is not damaged, do not replace.
Page 412 SECTION 35 - HYDRAULIC SYSTEM 3. Install a new shaft seal, 1. 4. Install a wiper seal, 2. NOTE: Install shaft wiper seal, 1, with the lip of the seal facing the piston. 5. Install O ring, 1, and backup washer, 2, on the cylinder gland.
Page 413 SECTION 35 - HYDRAULIC SYSTEM 8. Liberally oil the piston and place it inside the bar- rel, being careful not to damage the seals. 9. Thread the cylinder gland into the barrel, 1, and torque to 285 N·m (210 ft. lbs.). REINSTALLATION 1.
Page 414 SECTION 35 - HYDRAULIC SYSTEM PEDAL CONTROLS Op. 35 724 16 REMOVAL With Boom and Bucket Pedal Controls 1. Remove the step shield hardware and step shield. 2. Remove the bolt, 1, washer, lock washer, and nut, that connects the control rod, 2, to the pedal hub arm.
Page 415 SECTION 35 - HYDRAULIC SYSTEM 2. Inspect the control valve links for any obvious damage, bends or twisting. 19996894 3. Inspect the auxiliary hydraulic hub arm, 1, the boom hub arm, 2, and the bucket hub arm, 3, for any deformation or cracks. 4.
Page 416 SECTION 35 - HYDRAULIC SYSTEM 7. Inspect the shaft bearings, 1, for excessive wear. If bearings do not move easily, replace. 19996826 8. Inspect the pedals, 1, and pedal supports, 2, for any excessive wear or deformation. 19996827 PEDAL REINSTALLATION With Boom and Bucket Pedal Controls 1.
Page 417 SECTION 35 - HYDRAULIC SYSTEM 2. Install the left pedal assembly, 1, and attach the front plate with hardware, 2, previously removed. Do not tighten the hardware at this time. 3. Slide the pedal assembly to align the auxiliary boom hydraulic hub arm and boom hub arm as shown.
Page 418 SECTION 35 - HYDRAULIC SYSTEM 7. Install the control spool links, 1, with clevis pins, 2, and cotter pins, 3. 8. Attach each link to each hub arm with 3/8″ hex head bolts, 4, flat washer, 5, two link washers, 6, lock washer, 7, and nut, 8.
Page 419 SECTION 35 - HYDRAULIC SYSTEM Op. 35 724 16 PEDAL REMOVAL With Boom and Bucket Hand Controls 1. Remove the step shield hardware and step shield. 2. Remove the bolts, 1, washers, lock washers, and nuts, that connect the control rods, 2, to the pedal hub arms.
Page 420 SECTION 35 - HYDRAULIC SYSTEM PEDAL INSPECTION With Boom and Bucket Hand Controls 1. Remove the bucket hub arm assembly, 1, and the boom hub arm assembly, 2. Inspect the hub arm assemblies for any deformation or cracks. 2. Inspect the control shaft, 3, for any obvious dam- age or bends.
Page 421 SECTION 35 - HYDRAULIC SYSTEM 5. Inspect the pedals, 1, and pedal supports, 2, for any excessive wear or deformation. 19996827 6. Inspect the control valve spool links, 1, for bends or excessive wear. 19996829 PEDAL REINSTALLATION With Boom and Bucket Hand Controls 1.
Page 422 SECTION 35 - HYDRAULIC SYSTEM 3. Install the left pedal assembly, 1, and attach the front plate with hardware, 2, previously removed. Do not tighten the hardware at this time. 4. Install the boom hub assembly, 3, and bucket hub assembly, 4, onto the pivot shaft, 5.
Page 423 SECTION 35 - HYDRAULIC SYSTEM 10. Install the control spool links, 1, with clevis pins, 2, and cotter pins, 3. 11. Link the boom valve link and the bucket valve link to the hub arms with 3/8″ hex head bolts, 4, flat washer, 5, thick link washer, 6, lock washer, 7, and nut, 8.
Page 424 SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC COOLING, FILTER, RESERVOIR SYSTEM Specifications Filter (spin-on canister) ..............10 micron Reservoir (filter screen at fill cap) capacity .
Page 425 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.
Page 426 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.
Page 427 SECTION 35 - HYDRAULIC SYSTEM 8. Remove the fan shroud retaining hardware, 1, to access the oil cooler. 9. Remove the oil cooler, 2, retaining hardware to separate the cooler from the radiator. REASSEMBLY 1. Reattach the oil cooler to the support with the previously removed hardware.
Page 428 SECTION 35 - HYDRAULIC SYSTEM Back flush the screen, 1, with a clean solvent and blow dry with low-pressure air. Reinstall the screen assembly making sure the screen is sealed between the screen and reservoir neck with gaskets, 2. Use a silicone sealer with gas- kets to seal between the screen and reservoir is rec- ommended.
Page 429 SECTION 35 - HYDRAULIC SYSTEM With the cab tilted forward: 1. Drain the reservoir by lowering the engine belly pan, removing the return line from the charge check valve and rotating the line into a container. Allow the oil to drain. 2.
Page 430 SECTION 35 - HYDRAULIC SYSTEM ADAPTING ATTACHMENTS WITH PREVIOUS-STYLE NH-SUPPLIED BALL/PIN COUPLERS TO FLAT-FACED COUPLERS If the attachment to be used has the 1/2I ball/pin- type couplers, adaptors, 1 and 2, can be used to at- tach to the loader flat-faced couplers. Part Description Item#...
Page 431 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. Hours Remove and replace control valve .
Page 432 SECTION 37 – TOWING HOOKS AND BALLASTING Chapter 1 – Rear Counterweights CONTENTS Section Description Page 37 140 10 Rear Counterweights ............37-2 37 140 12 Rear Counterweight Support Removal...
Page 433 SECTION 37 - TOWING HOOKS AND BALLASTING Op. 37 140 10 REAR COUNTERWEIGHTS Counterweights can be installed to improve the stability of the loader when handling heavy loads or when operating the skid-steer loader with a heavy front-mounted attachment. Four 27.2 kg (60.0 lbs.) weights, 1, (two per side) may be added to the rear of the loader as shown.
Page 434 SECTION 39 – FRAMES Chapter 1 – Lower Main, ROPS CONTENTS Section Description Page General Information ............39-2 ROPS .
Page 435 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. Shown here is the loader and ROPS with the inner shell removed.
Page 436 SECTION 39 - FRAMES To remove the ROPS with the cab inner shell and boom attached: 1. Remove any attachment from the loader mount- ing plate, raise the boom and rest on the boom lock pins. CAUTION Never work under a raised boom unless it is properly supported by the boom lock pins.
Page 437 SECTION 39 - FRAMES 7. Disconnect the parking brake linkage at 1. 8. Raise the parking brake control lever to the raised engaged position. 19992572 9. Remove the engine side panels, 1, and top en- gine screen, 2. 10. Disconnect the (-) negative ground battery cable. 11.
Page 438 SECTION 39 - FRAMES 15. Remove the wire harness clamps and plastic ties along the left side of the lower frame at 1, 2, and 16. Remove the ground strap, 1, from the cab inner shell and lower main frame. 17.
Page 439 SECTION 39 - FRAMES 18. Remove the throttle control cable, 1, from the control lever at 2. Remove the cable retaining nut, 3, and slide the cable down through the right side shield at 4. 19. With the boom in the lowered position and the hy- draulic pressure relieved in the boom and bucket circuits, disconnect the boom, bucket, and auxil- iary boom hydraulics hose connections, 1, and...
Page 440 SECTION 39 - FRAMES 21. Remove the left and right rear attaching hard- ware, 1. If there are washer spacers under the bolt heads, make sure to replace them on instal- lation for proper torquing. 22. With a suitable lifting device support the boom at the rear.
Page 441 SECTION 39 - FRAMES 24. Remove the right and left front retaining bolts, 1. 25. Lift the ROPS and boom assembly from the lower main frame and move to a level area. Rest the as- sembly on the floor, lowering the boom to the floor.
Page 442 SECTION 39 - FRAMES 5. Reinstall the wire harness along the main frame and attach the engine fuse/relay panel. 6. Reconnect the main harness to the engine har- ness, re-route the wire harness along the fuel tank and the right side of the engine installing all clamps and ties previously removed at 1, 2, and 7.
Page 443 SECTION 39 - FRAMES 9. Slide the throttle cable up through the hole in the left cab panel and secure with retaining nut at 1. Attach the control lever, 2, to the cab panel at 3, with 3/8″ x 1-1/2″ cap screw; friction disc, 4; spring, 5;...
Page 444 SECTION 39 - FRAMES LABOR GUIDE The following labor amounts are listed as a guide only. Working conditions and experience will vary the time it actually takes to complete each job. Job Description Hours Remove and replace ROPS frame (Includes seat, boom lock linkage, boom removal, inner shell) 18.5 hrs.
Page 445 SECTION 39 - FRAMES 39-12...
Page 446 SECTION 44 – AXLES AND WHEELS Chapter 1 – Axles CONTENTS Section Description Page 44 100 General Information ............44-2 Specifications .
Page 447 SECTION 44 - AXLES AND WHEELS Op. 44 100 GENERAL INFORMATION The power is transmitted to the final drive from the engine which is connected to the hydrostatic pumps, 1, with a flex plate drive coupler. The hydrostatic pumps then transmit hydraulic power to the hydro- static motors, 2, which are connected to gearboxes, 3, located on the inside of the final drive cases.
Page 448 SECTION 44 - AXLES AND WHEELS 1 - HYDROSTATIC PUMP RH 2 - HYDROSTATIC PUMP LH 3 - HYDROSTATIC MOTOR RH 4 - HYDROSTATIC MOTOR LH 5 - GEARBOXES (2) 6 - FINAL DRIVE SPROCKET ASSEMBLIES (2) 7 - DRIVE CHAINS(FRONT AND REAR)(4) 8 - AXLE DRIVE SPROCKETS(4) 9 - AXLES ASSEMBLIES(4) 44-3...
Page 449 SECTION 44 - AXLES AND WHEELS SPECIFICATIONS Drive Axles Wheel Nut Torque ............170 N·m (125 ft.
Page 450 SECTION 44 - AXLES AND WHEELS TROUBLESHOOTING FINAL DRIVE SYSTEM Before servicing or adjusting on the final drive sys- tem, the skid-steer loader should be jacked up with the wheels off the ground. Remove any attachment from the skid-steer loader boom, bucket, etc.
Page 451 SECTION 44 - AXLES AND WHEELS PROBLEM POSSIBLE CAUSES CORRECTION Both drive wheels on one side No hydrostatic motor shaft rotation Check for pump to motor oil flow not powered and repair No gearbox output drive Check gearbox shaft rotation and repair Broken drive chains Check chains and repair...
Page 452 SECTION 44 - AXLES AND WHEELS TESTING FINAL DRIVE Pre-test instructions: * Operator in seat with seat belt buckled. * Engine running at high idle (full throttle). * Park brake disengaged position. STEP TEST RESULT PROBABLE CAUSE AND CORRECTION Push both drive controls...
Page 453 SECTION 44 - AXLES AND WHEELS Op. 44 106 AXLES Op. 44 106 10 AXLE HOUSING ASSEMBLY REMOVAL The axle housings must be removed to service axle seals, axle bearings, drive chains, drive sprockets, and axle housing mounting bolts. NOTE: The axle housings may be removed without removing the final drive side cover or draining the case oil.
Page 454 SECTION 44 - AXLES AND WHEELS 4. Remove the tire and wheel from the axle being serviced. 5. Clean the axle and final drive area to prevent de- bris from entering the final drive case. 6. Remove the eight axle housing retaining nuts and washers, 1.
Page 455 SECTION 44 - AXLES AND WHEELS 5. The outer axle seal, 1, may be replaced at this time without further disassembly. The seal can be replaced without removing the bearing, 2. 6. Install a bearing separator/puller and remove the outer axle bearing, 2. 7.
Page 456 SECTION 44 - AXLES AND WHEELS 10. The axle hub wheel studs, 1, can be removed from the hub, by pressing them from the hub. 11. Shown here are the related parts used in the axle assembly. Ref. Description Housing Axle and hub assembly Outer seal Outer bearing assembly...
Page 457 SECTION 44 - AXLES AND WHEELS 2. Inspect the axle shaft and hub assembly. – Inspect the bearing areas, 1, for wear. – Inspect the splines, 2, and retaining groove, 3, for wear. – Inspect the seal area. – Inspect the wheel lug studs for damaged threads or looseness in the hub, replace studs if required.
Page 458 SECTION 44 - AXLES AND WHEELS 7. Place the housing over the axle and hub assem- bly making sure the outer bearing is seated in race properly. 8. Remove tape from axle shaft. 9. Install the inner bearing race, 1, into housing. 10.
Page 459 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.
Page 460 SECTION 44 - AXLES AND WHEELS 7. With the axle housing, 1, tight against the case, install the retaining nuts and flat washers, 2, to hold the housing against the case. 8. Slide the axle housing assembly to tighten the drive chains.
Page 461 SECTION 44 - AXLES AND WHEELS 3. Securely block the skid-steer loader with all four wheels off the ground. Refer to Section 00 for more detail information on properly supporting a skid-steer loader. Support the loader at the front of the final drive cases at 1, and at the rear at 2.
Page 462 SECTION 44 - AXLES AND WHEELS Drive Chain And Sprocket Removal 10. Remove the drive chains from the drive sprocket, 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.
Page 463 SECTION 44 - AXLES AND WHEELS – Remove brake friction puck, 1, and spacer plate, 2. 12. Slide the rear chain and sprocket to the case opening and remove the chain from the sprocket and the case. 13. Remove the drive sprocket and note the position of the center hub, 1 (long or short shoulder in or out).
Page 464 SECTION 44 - AXLES AND WHEELS 17. Shown here are the final drive components. Ref. Description Drive sprockets (2 each side) Front drive chain Rear drive chain NOTE: The front drive chain is 68 links and the rear chain is 66 links. PARTS INSPECTION Thoroughly clean all parts before inspection.
Page 465 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.
Page 466 SECTION 44 - AXLES AND WHEELS 9. Reassemble the parking brake: – Clean the old sealant from the brake hard- ware. – Install the spacer plate, 2, and brake friction puck, 1, into caliper at 3. NOTE: The spacer plate is thinner than the brake friction puck and must be inserted into the caliper first.
Page 467 40 PSI (276 kPa) MAINTAIN PROPER TIRE INFLATION! NOTE: Iatco “Air Boss” segmented tires are ap- proved for all new generation New Holland loader models. These tires must be mounted with the wheel dish “in” to the frame (narrowest wheel tread posi- tion).
Page 468 A pneumatic tire will absorb this type of stress and, in severe cases, may deflate before damage to the loader or track oc- curs. New Holland only recommends pneumatic tires be installed with tracks. 44-23...
Page 469 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. Job Description Hours Axle Remove and replace 0.5 hr.
Page 470 SECTION 50 – CAB CLIMATE CONTROL Chapter 1 – Heater/Defroster CONTENTS Section Description Page 50 100 Heater/Defroster (Cab) ............50-2 Labor Guide .
Page 471 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. 2. Remove the retaining hardware, 1, and pull the panel from the rear support, 2.
Page 472 SECTION 50 - CAB CLIMATE CONTROL Heater Wiring Diagram Louver Replacement 1. To remove the louver, use a small flat screwdriver and pry the louver from the support base at 1. 2. Remove the two #6 self-tapping screws from the base and remove the base from the headliner.
Page 473 SECTION 50 - CAB CLIMATE CONTROL Heater Core, Shutoff Valve and Fan Assembly Access To access the heater core and/or fan assembly, the rear light bar, 1, (if equipped with lights) and top heat- er cover, 2, must be removed. Remove the heater cover mounting screws, 3, to remove the cover and light bar together.
Page 474 SECTION 50 - CAB CLIMATE CONTROL Op. 50 104 20 Heater Fan Assembly Replacement 1. Remove the heater core retaining hardware and pivot the core away from the fan support. 2. Disconnect the fan power wire, 1. 3. Remove the retaining hardware for the fan and motor assembly, 2.
Page 475 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.
Page 476 SECTION 50 - CAB CLIMATE CONTROL Bleeding Air from Heater (LS170) CAUTION The LS170 utilizes an engine crankcase oil cooler Stop the engine while working around these which is teed into the water pump supply side of the hoses. cab heater. To completely bleed air from the heater lines and 4.
Page 477 SECTION 50 - CAB CLIMATE CONTROL LABOR GUIDE The following labor amounts are listed as a guide only. Working conditions and experience will vary the time it actually takes to complete each job. Job Description Hours Heater/Defroster Remove and replace electrical switch 0.25 hrs.
Page 478 SECTION 55 – ELECTRICAL SYSTEM Chapter 1 – Advanced Warning System, Circuits, Alternator, and Starter CONTENTS Section Description Page 55 000 General Electrical Information ..........55-6 Definition of Terms .
Page 479 SECTION 55 - ELECTRICAL SYSTEM Ignition Switch Circuit to EIC Board ......... . 55-63 Cranking Circuit (Starter Motor) .
Page 480 SECTION 55 - ELECTRICAL SYSTEM Road Light and Work Light Switch Installation ....... . . 55-86 Engine Fuse and Relay Panel .
Page 481 SECTION 55 - ELECTRICAL SYSTEM 55 414 24 Hydraulic Oil Filter Restriction Switch Removal ....... 55-106 Hydraulic Oil Filter Restriction Switch Installation .
Page 482 SECTION 55 - ELECTRICAL SYSTEM 55-5...
Page 483 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 glow plug circuit.
Page 484 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.
Page 485 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.
Page 486 SECTION 55 - ELECTRICAL SYSTEM ADAPTING ATTACHMENTS REQUIRING 12V ELECTRICAL POWER There are important rules that must be followed when adapting attachments that require 12 volt electrical power. Proper wiring of electrical devices and power and ground connections is very important to prevent other electrical component damage.
Page 487 SECTION 55 - ELECTRICAL SYSTEM Engine Fuse Panel Wires and connections are available providing electrical attachments were not previously installed. Ref. Color Destination Fuse Battery Voltage Status To turn signal relay 10-amp All times Available R/GY To accessory relay 25-amp All times Available R/LTGN...
Page 488 15 amps. The Figure 6 shows the circuit for intermittent high current loads up to 30 amps. New Holland sealed circuit breakers that can be purchased from parts. Part Number Capacity 9827329...
Page 489 SECTION 55 - ELECTRICAL SYSTEM SPECIFICATIONS Alternator ................40 amp Tachometer output (“P”...
Page 490 SECTION 55 - ELECTRICAL SYSTEM Hydraulic oil temperature sensor ......EIC will read “COLD” until 45° C (113° F) EIC will fault at 99°...
Page 491 SECTION 55 - ELECTRICAL SYSTEM ALTERNATOR SERVICE SPECIFICATIONS (40 amp) Item How Rated Standard Or Service Limit Normal Output (V - A) 12 V - 40 A Polarity Negative ground Weight (kg, lbs) 3.7 kg (8.2 lbs) Rotational direction (viewed from Clockwise the pulley) Load characteristics (cold)
Page 492 SECTION 55 - ELECTRICAL SYSTEM ELECTRICAL DIAGRAM 55-15...
Page 493 SECTION 55 - ELECTRICAL SYSTEM 55-16...
Page 494 SECTION 55 - ELECTRICAL SYSTEM 55-17...
Page 495 SECTION 55 - ELECTRICAL SYSTEM 55-18...
Page 496 SECTION 55 - ELECTRICAL SYSTEM Op. 55 418 ADVANCED WARNING SYSTEM ELECTRONIC INSTRUMENT CLUSTER (EIC) The Skid-Steer Loader advanced warning system, 1, monitors engine functions and operator controls and reports conditions to the operator and provides safety interlocks to the hydraulic control valve spools to the boom and bucket.
Page 497 SECTION 55 - ELECTRICAL SYSTEM (EIC) ELECTRONIC INSTRUMENT 3. RIGHT ARROW DISPLAY SELECTOR SWITCH CLUSTER FRONT PANEL The display selector switch, covered with an 1. AUDIBLE ALARM “ARROW” symbol, will cause an audible “chirp” The audible alarm will sound if there is an when pressed if the ignition key is in the “RUN”...
Page 498 SECTION 55 - ELECTRICAL SYSTEM EIC FUNCTIONAL GROUPS The EIC display panel is divided into four functional groups, 1 through 4. 5. Engine hours, displayed to 0.1 hours (no light). FUNCTIONAL GROUP 1 Those symbols in display group 1, backlighted white are: 6.
Page 499 SECTION 55 - ELECTRICAL SYSTEM FUNCTIONAL GROUP 2 Those symbols in display group 2, backlighted yellow are: 4. Parking brake. Used to remind operator to engage the parking brake when exiting the loader. An audible alarm will sound when the operator begins to exit the 1.
Page 500 SECTION 55 - ELECTRICAL SYSTEM FUNCTIONAL GROUP 3 The symbol in display group 3 is: 1. Fuel gauge. The fuel gauge, 1, is a vertical 10-segment green LED bar graph. When the fuel level reaches three bars, 2, the segments will flash accompanied by an audible alarm for about 5 seconds.
Page 501 SECTION 55 - ELECTRICAL SYSTEM FUNCTIONAL GROUP 4 Symbols in display group 4 are backlighted red. When a fault occurs, the flashing lamp is 5. Coolant temperature. accompanied by the audible alarm. When the engine coolant temperature is above operating temperature of 102°C (216°F) the lamp will flash with a 5-second alarm.
Page 502 SECTION 55 - ELECTRICAL SYSTEM CONTINUOUSLY MONITORED ELEMENTS The following machine elements are continuously monitored by the EIC: 5. Hydrostatic charge pressure. When the pressure drops below normal operating pressure the lamp will flash with a continuous alarm. 1. Engine air filter. Monitors the condition of the air cleaner element and will signal when the element is dirty and requires replacement.
Page 503 AUTOMATIC SHUTDOWN speeds. Damage to the engine and/or transmissions If either the engine oil pressure, or hydrostatic charge may occur. Contact your New Holland dealer for pressure fall below certain limits, the EIC will remove assistance. power from the fuel solenoid after 30 seconds, stopping the engine.
Page 504 SECTION 55 - ELECTRICAL SYSTEM OPERATING MODE If a fault occurs in the following monitored functions, the EIC will automatically show that function’s By pressing and releasing the “ARROW” switch, 1, reading in the character display, accompanied by a during normal skid-steer loader operation, the flashing light and a five second audible alarm.
Page 505 SECTION 55 - ELECTRICAL SYSTEM If a fault occurs in the following monitored functions FAULT CODE a fault code will appear in the EIC character display, Hydraulic Boom/Bucket Solenoid (F0A) 1, accompanied by a five second audible alarm. By Engine Preheat Relay Coil (F03) turning the ignition key switch to the “OFF”...
Page 506 LUBRICATING OILS for the engine and/or the hydrostatic transmissions. DO NOT restart the loader more than once or operate the engine at high engine speeds. Damage to the engine and/or transmission may occur. Contact your New Holland dealer for assistance. 55-29...
Page 507 SECTION 55 - ELECTRICAL SYSTEM FUEL LEVEL Fuel level is shown to the operator by the fuel gauge bar lights located in the center of the EIC display at 1. The operator will be signaled when the level is at three bars and again at two bars.
Page 508 8. Press and release the “OPEN BOOK” switch and unlocked by using a (MASTER CODE). Contact your enter any number from “0” to “9” for the left digit. NEW HOLLAND dealer for assistance. 9. Press and release the “ARROW” switch, 1, the right zero will start to flash.
Page 509 SECTION 55 - ELECTRICAL SYSTEM EIC ENGINE PREHEAT The engine preheat is governed automatically by the EIC based on coolant temperature and engine code. Preheat is initiated when the ignition key is turned to the “RUN” position and the cycle time will vary from 0 to 20 seconds.
Page 510 SECTION 55 - ELECTRICAL SYSTEM TROUBLESHOOTING ELECTRONIC INSTRUMENT CLUSTER (EIC) PROBLEM POSSIBLE CAUSE CORRECTION EIC board will not light up when Service/run switch in service Push switch to run position operator sits in seat position Faulty seat switch Replace switch No battery voltage to seat switch Blown 5-amp fuse electronic battery in engine panel, replace fuse...
Page 511 SECTION 55 - ELECTRICAL SYSTEM PROBLEM POSSIBLE CAUSE CORRECTION EIC will not read correct engine Incorrect engine configuration Correct configuration RPMs, varies more than ± 50 RPMs No AC voltage at tachometer Repair alternator terminal at alternator Loose or corroded connection at Repair connection tachometer terminal at alternator No AC voltage at EIC board from...
Page 512 SECTION 55 - ELECTRICAL SYSTEM PROBLEM POSSIBLE CAUSE CORRECTION Engine will not start and/or run Seat belt unbuckled Buckle seat belt Incorrect engine configuration Correct configuration (EIC) No battery voltage to start relay Open in power wire from key switch “start”...
Page 513 SECTION 55 - ELECTRICAL SYSTEM The AWS provides the following features for dealer ADVANCED WARNING SYSTEM (AWS) technician use in diagnostics and troubleshooting of This skid-steer loader is equipped with an Advanced the monitored function circuits: Warning System (AWS) that provides information to the operator about the operation of the skid-steer Diagnostics loader.
Page 514 SECTION 55 - ELECTRICAL SYSTEM EIC BOARD SELF TEST 3. The EIC will enter the normal start up mode. When first sitting in the operator’s seat and/or before 4. Turning the ignition key to the “ON” position will entering Diagnostics, allow the EIC board to self test. start the automatic engine preheat system (if (Service/Run switch in the “RUN”...
Page 515 SECTION 55 - ELECTRICAL SYSTEM DIAGNOSTIC AND SETUP MODES 5. Display, 3, will show the program level of the EIC When in the Diagnostic Mode, the technician can test board (example - r0100); at this time, release the the individual monitored circuit wiring. When in the “OPEN BOOK”...
Page 516 SECTION 55 - ELECTRICAL SYSTEM EIC Diagnostics and Setup Items 1. Press and release the “ARROW” switch, 1; “dIAg” will appear in the character display, 2. Diagnostics Mode With display showing “LOC_ _” for lock. _______________________________________________________________________________________________ 2. Press and hold the “OPEN BOOK” switch, 1, until 1.
Page 517 SECTION 55 - ELECTRICAL SYSTEM ARROW, OPEN BOOK, AND AUDIBLE ALARM TEST In this mode, by pressing the “ARROW,” 1, or “OPEN BOOK,” 2, switches, all of the display segments are turned on for verification and at the same time with an audible beep.
Page 518 SECTION 55 - ELECTRICAL SYSTEM 2. Air Cleaner Switch Remove one wire at a time from the sensor switch, 1, on the air cleaner canister. Remove the B wire, and the EIC board will light and beep when the wire is removed from the switch. Remove the B/Y wire, and the EIC board will light and beep.
Page 519 SECTION 55 - ELECTRICAL SYSTEM 5. Coolant Temperature Sensor Remove the PU/LTGN wire, 1, from the sensor and short the wire to ground. The EIC board will light and beep when the wire is removed from the sender and grounded. If the EIC board lights and beeps, the EIC and circuit wire to the sensor is OK.
Page 520 SECTION 55 - ELECTRICAL SYSTEM 8. Seat Switch and Circuit Raise your weight off the center of the seat and then sit back on the seat. The EIC board will light and beep. If the board lights and beeps, the switch and circuit are OK.
Page 521 SECTION 55 - ELECTRICAL SYSTEM r-CAL - Adjust Engine RPM EIC SETUP MODE The EIC Setup Mode is made up of several items: • Calibrate EIC display to external RPM tach reading. FAULt - Fault/Warning history • Fault occurrence with hour level of last CLr F - Clear Faults occurrence.
Page 522 SECTION 55 - ELECTRICAL SYSTEM FAULt - Fault/Warning history With display showing “LOC_ _” for lock. 1. Press and release the “ARROW” switch, 1; “dIAg” will appear in the character display. Then press and release the “ARROW” switch again; “SEtUP” will appear in the display, 2. _______________________________________________________________________________________________ 2.
Page 523 SECTION 55 - ELECTRICAL SYSTEM Press and hold the “OPEN BOOK” switch, 1, until “F0-XX” appears in the display. The “F0” is the fault and the “XX” is the number of occurrences of that fault since the fault memory was last cleared. The fault code display will be accompanied by an illuminated front panel symbol identifying the fault.
Page 524 SECTION 55 - ELECTRICAL SYSTEM Pressing and releasing the “ARROW” switch again will forward to the next fault “F1-00” and pressing and releasing the “OPEN BOOK” switch again will display the hour of the last occurrence if any fault occurrences were shown. Use this procedure to go through all the fault codes: FAULT SYMBOL...
Page 525 SECTION 55 - ELECTRICAL SYSTEM Once all faults have been identified, the fault history can be cleared to zero. To return to “FAULt” and clear the faults, press and hold the “ARROW” switch, 1, until the original “FAULt” item is displayed in the character display. Press and release the “ARROW”...
Page 526 7. Press and release the “OPEN BOOK” switch to enter the right number of the engine code (Example “Eng 01” for the LS160 and LS170 skid steers is shown in display 1). The engine code is as follows: 01 - LS160, LS170 To exit this item, press and hold the “ARROW”...
Page 527 SECTION 55 - ELECTRICAL SYSTEM Unit F or Unit C (EIC Reading Fahrenheit or Celsius) With display showing “LOC_ _” for lock. 1. Press and release the “ARROW” switch; “dIAg” will appear in the character display. Then press and release the “ARROW” switch again; “SEtUP” will appear in the display.
Page 528 SECTION 55 - ELECTRICAL SYSTEM 4. Press and hold the “OPEN BOOK” switch until all zeros are displayed in the character display. Upon releasing of the switch only the right zero will be showing in display, 1. 5. Buckle the seat belt and start the engine. Using a hand held photo-tach or other accurate measuring device, check the engine RPM at high idle (full throttle).
Page 529 SECTION 55 - ELECTRICAL SYSTEM ELECTRONIC INSTRUMENT CLUSTER (EIC) AND STARTER CIRCUITS: BLOWN FUSE SYMPTOMS AND TESTING Electronic Ignition Fuse, 1 (Cab Fuse Panel - 5A) Service/Run Switch “Run” Position 1. Board shows self test (with operator in seat). 2. Board shows 5.2 volts. 3.
Page 530 SECTION 55 - ELECTRICAL SYSTEM IMPORTANT: If any servicing or adjustments require the battery to be disconnected, or welding is required on the skid-steer loader, disconnect the negative (–) ground cable. Failure to disconnect the battery may result in damage to the EIC (Electronic Instrument Cluster) monitoring system and other electrical components.
Page 531 SECTION 55 - ELECTRICAL SYSTEM TESTING OTHER EIC FUNCTIONS NOTE: These tests are performed with the EIC in the normal operating mode and the “SERVICE/RUN” switch in the “RUN” position. 1. Parking Brake Light Sit in the seat with the seat belt buckled. After the EIC board self test, the parking brake light, 1, should flash.
Page 532 SECTION 55 - ELECTRICAL SYSTEM 3. Boom and Bucket Spool Locks, 1 (Control valve spools in neutral and boom and bucket resting on the ground) a. Sit in the seat. After the EIC board self tests, turn the ignition switch to the “ON” position. The boom and bucket controls should not move.
Page 533 SECTION 55 - ELECTRICAL SYSTEM 4. Boom and Bucket Spool Lock Solenoid Test (Voltage Test) To perform the following test, the operator must be sitting in the seat, seat belt buckled, and the ignition “key” switch in the “RUN” position. a.
Page 534 SECTION 55 - ELECTRICAL SYSTEM EIC BOARD READING ACCURACY EIC board readings for the digital display, including RPM, Battery Voltage, Hourmeter, Engine Coolant Temperature, or Hydraulic Oil Temperature may not be accurate or may have no reading when selected. Complaints usually follow installation of an optional kit or customer-installed option, or complaints can arise after a machine repair such as engine overhaul or cab tilting.
Page 535 SECTION 55 - ELECTRICAL SYSTEM All grounding locations should be checked for tight hardware and absence of paint between parts for good connecting, as follows: 1. Check the grounding strap from the engine to main frame, 1. 2. Check the wiring harness from the EIC to the bell housing.
Page 536 SECTION 55 - ELECTRICAL SYSTEM EIC BOARD CLAIMS WARRANTY When filing a warranty claim for a defective EIC (Electronic Instrument Cluster) board, include the part number and serial number on the white tag of the defective board. The EIC board part number, 1, and this number must be used as the causal part number.
Page 537 SECTION 55 - ELECTRICAL SYSTEM ELECTRICAL CIRCUITS EIC (ELECTRONIC INSTRUMENT MAIN POWER CIRCUIT TO EIC BOARD CLUSTER) The EIC board receives power from five different Battery voltage points. The power originates at the battery and proceeds through the (R) battery cable to the starter solenoid. 1.
Page 538 SECTION 55 - ELECTRICAL SYSTEM SEAT SWITCH CIRCUIT TO EIC BOARD The power continues through the (LTGN/R) wire to the seat switch. When one seat switch (only 1 switch needs to be closed as switches are in parallel wiring) Battery voltage is pressed closed, the power then continues through The power originates at the battery and proceeds the (T) wire to the Service/Run switch.
Page 539 SECTION 55 - ELECTRICAL SYSTEM SEAT BELT SWITCH CIRCUIT TO EIC When the seat belt is buckled, the power proceeds through the (LTGN) wire to the EIC board terminal 11 BOARD of connector P2. Battery voltage When the seat belt is buckled, power is sent through The power originates from the seat switch(es) the (W/O) wire to the start interlock relay.
Page 540 SECTION 55 - ELECTRICAL SYSTEM IGNITION SWITCH CIRCUIT TO EIC BOARD When the ignition key switch is turned to the “ON” position, power continues through the (O/PU-2) wire to the Electronics 5-amp fuse in the cab fuse panel. Battery voltage The power originates at the battery and proceeds The power continues through the (O) wire to terminal through the (R) battery cable to the starter solenoid.
Page 541 SECTION 55 - ELECTRICAL SYSTEM CRANKING CIRCUIT (STARTER MOTOR) Operating conditions with “SERVICE/RUN” switch in the “RUN” position: To start the engine with the “SERVICE/RUN” switch in the “RUN” position, 1, the operator must be in the seat with the seat belt buckled. Then turn the key switch to the “START”...
Page 542 SECTION 55 - ELECTRICAL SYSTEM “SERVICE/RUN” SWITCH IN THE “RUN” Power then flows from the service/run switch through the (W/LTGN) wire to the start interlock relay coil POSITION terminal. The power originates at the battery and flows through the (R) positive battery cable to the starter solenoid. With the interlock energized, the power from the From here the power flows through the (R) wire to the seat/seat belt circuit (W/O) wire flows through the...
Page 543 SECTION 55 - ELECTRICAL SYSTEM CRANKING CIRCUIT GROUND The start interlock relay is grounded through the (B-4) wire to the ground terminal on the start relay. The system ground (B-6) wire then goes to the ground terminal of the preheat relay. The system ground (B-8) wire then goes to the engine ground at the bell housing.
Page 544 SECTION 55 - ELECTRICAL SYSTEM SERVICE/RUN SWITCH IN THE “SERVICE” With the service/run switch in the “SERVICE” position, power goes through the (W/DKBL) wire POSITION from the service/run switch to the start relay to The power originates at the battery and flows through activate the relay.
Page 545 SECTION 55 - ELECTRICAL SYSTEM CRANKING CIRCUIT GROUND The start interlock relay is grounded through the (B-4) wire to the ground terminal on the start relay. The system ground (B-6) wire then goes to the ground terminal of the preheat relay. The system ground (B-8) wire then goes to the engine ground at the bell housing.
Page 546 SECTION 55 - ELECTRICAL SYSTEM START RELAY CIRCUIT and the start interlock relay is energized by the W/LTGN wire from the service/run switch, the start The power originates at the battery and flows through relay receives energizing power from the seat/seat the (R) positive battery cable to the starter solenoid.
Page 547 SECTION 55 - ELECTRICAL SYSTEM START RELAY GROUND CIRCUIT The start relay is grounded through the (B-6) wire to the ground terminal on the preheat relay and then through the (B-8) wire to the engine bell housing. START INTERLOCK RELAY OPERATION The start interlock relay, 1, controls the starting circuit when the “SERVICE/RUN”...
Page 548 SECTION 55 - ELECTRICAL SYSTEM START INTERLOCK CIRCUIT When the interlock is “satisfied” that the service/run switch is in the “RUN” position and the operator is “SERVICE/RUN” switch in the “RUN” position. sitting in the seat with the seat belt buckled, power will travel through the W/DKBL wire to the start relay The start interlock relay coil receives power from the and through the LTBL/O wire to the fuel solenoid,...
Page 549 SECTION 55 - ELECTRICAL SYSTEM START INTERLOCK GROUND CIRCUIT the switch in the “SERVICE” position, power flows from the key switch “START” terminal via the W wire The interlock is grounded through the B-4 wire to the to the service/run switch, then through the LTBL/O start relay, through B-6 wire to the preheat relay, wires to the fuel solenoid, allowing the engine to start through B-8 wire to the engine bell housing ground.
Page 550 SECTION 55 - ELECTRICAL SYSTEM Op. 55 100 REMOVAL, INSTALLATION AND WIRING OF ELECTRICAL COMPONENTS This section will show and explain the correct wiring on the skid-steer loader, disconnect the negative (–) of switches and relays, and when and where battery ground cable.
Page 551 SECTION 55 - ELECTRICAL SYSTEM BATTERY Op. 55 301 40 REMOVAL 1. Raise the boom and rest on the boom lock pins. CAUTION Never work under a raised boom unless it is properly supported by the boom lock pins. 2. Open the rear door and remove the right engine side shield to access the battery.
Page 552 SECTION 55 - ELECTRICAL SYSTEM Op. 55 418 10 EIC (ELECTRONIC INSTRUMENT CLUSTER) BOARD REMOVAL 1. Disconnect the negative (–) battery cable. 2. Remove the retaining hardware, 1, and remove the EIC board from the overhead dash area. 3. Unplug the two wire harness connectors, 1, from the EIC, taking care to not stress or bend the plastic locking ramps on the connectors.
Page 553 SECTION 55 - ELECTRICAL SYSTEM EIC (Electronic Instrument Cluster) WIRING NOTE: There are two different style EIC board connectors as shown here. Board Harness Connector #1 Connector #1 (J1) (P1) Pin Number Wire Color Pin Number NOT USED NOT USED NOT USED PU/W PU/LTGN...
Page 554 SECTION 55 - ELECTRICAL SYSTEM EIC (Electronic Instrument Cluster) BOARD INSTALLATION 1. Connect the wire harness connectors P1 to J1 and P2 to J2 on the EIC board, making sure the connectors are properly aligned and fully seated. IMPORTANT: If the connector is not connected correctly, damage to the EIC may occur: •...
Page 555 SECTION 55 - ELECTRICAL SYSTEM IGNITION (KEY) SWITCH WIRING Battery Color Destination Voltage O/LTBL To Four-Way Flashing Key “ON” lights 10A Fuse (cab position panel) To Beacon Light 7.5A Fuse (cab panel) LTGN/B To EIC Board Pin #11 Key “ON” (small connector) position LTGN/B To Accessory Relay...
Page 556 SECTION 55 - ELECTRICAL SYSTEM CAB FUSE PANEL WIRING STANDARD FUSE BLOCK Battery Color Destination Voltage O/LTGN (15A Fuse) From Key “ON” Accessory Relay position (engine panel) (If equipped with lights or other acces- sories). (15A Fuse) To Road/ Key “ON” Work Light Switch position O/GY...
Page 557 SECTION 55 - ELECTRICAL SYSTEM CAB FUSE BLOCK AND PANEL REMOVAL 1. Disconnect the negative (–) battery cable. 2. Remove panel, 1; retaining hardware, 2; and lower panel from the support. Removal of panel, 3, may be required for easier access. 3.
Page 558 SECTION 55 - ELECTRICAL SYSTEM SERVICE/RUN SWITCH WIRING SERVICE POSITION RUN POSITION SERVICE/RUN SWITCH - SERVICE SERVICE/RUN SWITCH - RUN POSITION POSITION Battery Color Destination Voltage Battery Color Destination Voltage W/DKBL To Start Relay (engine panel) “START” W/DKBL To Start Relay position (engine panel) “START”...
Page 559 SECTION 55 - ELECTRICAL SYSTEM SERVICE/RUN SWITCH Op. 55 418 30 REMOVAL 1. Disconnect the negative (–) battery cable. 2. Remove panel, 1; retaining hardware, 2; and lower panel from the support. Removal of panel, 3, may be required for easier access. 3.
Page 560 SECTION 55 - ELECTRICAL SYSTEM SEAT AND SEAT BELT SWITCH WIRING Battery Color Destination Voltage LTGN To EIC Board Pin Seat Belt #11 (large connector) Buckled From Seat Sit in Switch(es) Seat To Seat Belt switch Sit in Seat LTGN/R From Electronics 5A All Times Fuse (engine panel) To Service/Run...
Page 561 SECTION 55 - ELECTRICAL SYSTEM SEAT SWITCH INSTALLATION 1. Install the switch(es) into the seat pan, making sure the switch is seated into the hole in the seat pan, 1. IMPORTANT: If the switch is not seated properly when the retaining hardware is tightened, the switch flange will be broken.
Page 562 SECTION 55 - ELECTRICAL SYSTEM ROAD LIGHT AND WORK LIGHT SWITCH WIRING Switch Pushed in at Top Battery Color Destination Voltage PK/B To Taillights DKBL/W To Front Road/Work Light DKBL/W To Front Road/Work Light DKBL To Rear Work Light From 15A Fuse (cab Key “ON”...
Page 563 SECTION 55 - ELECTRICAL SYSTEM ROAD LIGHT AND WORK LIGHT SWITCH Op. 55 404 20 REMOVAL 1. Disconnect the negative (–) battery cable. 2. Remove the switch panel retaining hardware, 1, and lower the panel. 3. Remove the wires and connector from the switch terminals.
Page 564 SECTION 55 - ELECTRICAL SYSTEM ENGINE FUSE AND RELAY PANEL The engine panel electrical components are shown here: 1. Accessory relay 2. Heater power relay (if equipped) 3. Preheat circuit breaker 4. Start interlock relay 5. Optional equipment fuse block 6.
Page 565 SECTION 55 - ELECTRICAL SYSTEM ACCESSORY RELAY WIRING Battery Color Destination Voltage O/LTGN To Attachment/Horn Key “ON” 15A Fuse position LTGN/ To Turn Signal Relay Key “ON” or Heater Power position Relay LTGN/B From Key Switch Key “ON” (accessory terminal) position To Turn Signal Relay Ground...
Page 566 SECTION 55 - ELECTRICAL SYSTEM PREHEAT CIRCUIT BREAKER WIRING Battery Color Destination Voltage R/LTBL To Preheat Relay All Times To Start Relay All Times From 15A Key Main All Times Fuse Engine Fuse Block PREHEAT CIRCUIT BREAKER Op. 55 100 24 REMOVAL 1.
Page 567 SECTION 55 - ELECTRICAL SYSTEM START INTERLOCK RELAY WIRING Service/Run Switch - Run Position Battery Color Destination Voltage W/LTGN From Key “START” Service/Run position Switch From Cab Fuse Key “ON” Panel position Electronic Ignition Fuse LTBL/O To Fuel Solenoid Key “ON” position * LTBL/O From EIC Board...
Page 568 SECTION 55 - ELECTRICAL SYSTEM Op. 55 100 34 START INTERLOCK RELAY REMOVAL 1. Disconnect the negative (–) battery cable. 2. Disconnect the wires from the terminals, 1. 3. Remove the interlock relay retaining hardware. START INTERLOCK RELAY INSTALLATION 1. Reinstall the retaining hardware. 2.
Page 569 SECTION 55 - ELECTRICAL SYSTEM ENGINE FUSE PANEL WIRING Battery STANDARD FUSE BLOCK Color Destination Voltage (10A Fuse) To Turn All Times Signal Relay R/GY (25A Fuse) To All Times Accessory Relay R/LTGN (5A Fuse) To EIC All Times board Pin #14 P2 connector.
Page 570 SECTION 55 - ELECTRICAL SYSTEM ENGINE FUSE BLOCK REMOVAL 1. Disconnect the negative (–) battery cable. 2. Remove the fuse block retaining hardware. NOTE: The standard fuse block, 1, is part of the main harness and cannot be completely removed. 3.
Page 571 SECTION 55 - ELECTRICAL SYSTEM ALTERNATOR EXCITE RESISTOR WIRING Color Destination Y/DKBL To Alternator LTGN/B-1 From Accessory Relay LTGN/B-3 To Alternator Op. 55 301 16 ALTERNATOR EXCITE RESISTOR REMOVAL 1. Disconnect the negative (–) battery cable. 2. Unplug the wires from the resistor terminals. 3.
Page 572 SECTION 55 - ELECTRICAL SYSTEM START RELAY WIRING Battery Color Destination Voltage To 20A Heater Fuse All Times (optional fuse block) To Preheat Circuit All Times Breaker From Starter All Times Solenoid To Starter Solenoid “START” position W/DKBL From Start Interlock Relay “START”...
Page 573 SECTION 55 - ELECTRICAL SYSTEM PREHEAT RELAY WIRING Service/Run Switch - Service Position Battery Color Destination Voltage R/LTBL From Preheat Circuit All Times Breaker LTBL/B To Glow Plugs Push But- LTBL/Y From Manual Push But- Preheat Button To Start Relay Ground Circuit To Engine...
Page 574 SECTION 55 - ELECTRICAL SYSTEM Op. 55 100 34 PREHEAT RELAY REMOVAL 1. Disconnect the negative (–) battery cable. 2. Remove the relay cover, 1, attaching hardware and cover. 3. Remove the wires from the relay terminals. 4. Remove the relay retaining hardware. 5.
Page 575 SECTION 55 - ELECTRICAL SYSTEM Op. 55 201 76 PREHEAT GLOW PLUG REMOVAL 1. Disconnect the negative (–) battery cable. 2. Disconnect the LTBL/B wire, 1, from the glow plug bus bar. 3. Remove the bus bar retaining nuts, 2, and remove the bus bar from the glow plugs.
Page 576 SECTION 55 - ELECTRICAL SYSTEM FUEL SYSTEM COMPONENTS The fuel system consists of a fuel tank located in the left side of the engine compartment at 1; fuel tank pickup tube, 2; fuel tank sending unit, 3; in-line fuel filter, 4; electric fuel pump, 5; injection pump, 6; and return fuel line, 7, from the injector bleed off to the tank.
Page 577 SECTION 55 - ELECTRICAL SYSTEM TESTING FUEL GAUGE IN DIAGNOSTIC MODE Use a jumper wire and connect sender terminals, 1, and the EIC board will light and beep. If the EIC board lights and beeps, the EIC and circuit wires to the sender are OK.
Page 578 SECTION 55 - ELECTRICAL SYSTEM ELECTRIC FUEL PUMP The electric fuel pump, 1, is located in the left side of the engine compartment. ELECTRIC FUEL PUMP TESTING PRETEST PROBABLE CAUSE AND STEP TEST RESULT INSTRUCTIONS CORRECTION Loader on level with Fuel level in tank Add fuel and bleed system parking brake engaged,...
Page 579 SECTION 55 - ELECTRICAL SYSTEM Op. 10 210 21 ELECTRIC FUEL PUMP REMOVAL 1. Support the boom on the boom lock pins. 2. Open the rear door and remove the left engine side shield. 3. Remove the hose clamps, 1, from the pump and hoses.
Page 580 SECTION 55 - ELECTRICAL SYSTEM Op. 10 223 10 REPLACEMENT OF FUEL SHUTOFF SOLENOID 1. Support the boom on the boom lock pins. 2. Open the rear door and remove the left engine side shield. 3. Remove the power wire from the solenoid, 1. 4.
Page 581 SECTION 55 - ELECTRICAL SYSTEM AIR FILTER RESTRICTION INDICATOR SWITCH Op. 55 414 14 REMOVAL 1. Support the boom on the boom lock pins. 2. Open the rear door and remove the left engine side shield to access the sender. 3.
Page 582 SECTION 55 - ELECTRICAL SYSTEM ENGINE OIL PRESSURE SWITCH Op. 55 414 12 REMOVAL 1. Support the boom on the boom lock pins. 2. Open the rear door and raise the top engine shield to access the switch. 3. Remove the Y/B wire, 1, from the switch terminal. 4.
Page 583 SECTION 55 - ELECTRICAL SYSTEM HYDRAULIC OIL FILTER RESTRICTION SWITCH Op. 55 414 24 REMOVAL 1. Support the boom on the boom lock pins. 2. Open the rear door, raise the top engine shield and remove the right engine side shield to access the switch.
Page 584 SECTION 55 - ELECTRICAL SYSTEM 4. Loosen the return line clamp at 1. 5. Remove the return line at 2, and rotate the line so the oil drains into a clean suitable pan for reuse. 6. After the reservoir is drained, reconnect the return lines and tighten all fittings and connections.
Page 585 SECTION 55 - ELECTRICAL SYSTEM BOOM/BUCKET CONTROL VALVE SPOOL LOCK SOLENOIDS Op. 35 724 90 REMOVAL 1. Remove any attachment from the loader attaching plate. 2. Raise the boom and support on the boom lock pins. 3. Stop the engine, turn the ignition key to the “RUN”...
Page 586 SECTION 55 - ELECTRICAL SYSTEM INSTALLATION 1. Thoroughly clean the control valve block. 2. Install the solenoid coil into block and tighten the coils to 15 N·m (11 ft. lbs.). 3. Reconnect the coil wires to the main wire harness. 4.
Page 587 SECTION 55 - ELECTRICAL SYSTEM WIRE HARNESS Op. 55 100 74 MAIN WIRE HARNESS REMOVAL 1. Remove any attachment from the loader attaching plate. 2. Raise the boom and support on the boom lock pins. 3. Stop the engine, turn the ignition key to the “RUN”...
Page 588 SECTION 55 - ELECTRICAL SYSTEM 7. Remove the right side plate, 1, and headliner, 2, if equipped. Unhook all wire connections at the service/run switch, preheat button, and fuse block(s) at this time. Removal of fuse block/switch panel, 3, may be required for easier switch access.
Page 589 SECTION 55 - ELECTRICAL SYSTEM 10. Unplug the seat wire harness from the main harness. 11. Remove the seat and seat pan assembly retaining hardware, 1, unlatch the seat assembly at 2, and remove the assembly from the loader. 19984338 12.
Page 590 SECTION 55 - ELECTRICAL SYSTEM 14. Remove the right hydrostatic control handle assembly, 1, retaining hardware. Unhook the hydrostatic control linkage and auxiliary boom hydraulic linkage (if equipped). Lift the control assembly from the loader. 19992568 15. Remove the right fender to access and loosen the right front isolator mount bolt, 1.
Page 591 SECTION 55 - ELECTRICAL SYSTEM 18. Remove harness from left rear of engine area after disconnecting wires from fuel sender, 1, and fuel pump, 2. Remove tubing from the harness that is located in fuel tank groove, 3. 19. Thoroughly clean the connector between the main and engine harness.
Page 592 SECTION 55 - ELECTRICAL SYSTEM 23. Now the right side panel, 1, can be pivoted into the center of the cab area at the rear and the wire harness can be removed from the corner of the side panel. MAIN WIRE HARNESS INSTALLATION 1.
Page 593 SECTION 55 - ELECTRICAL SYSTEM 3. Route the wire harness to the front of the loader on the left side, 1 and 2, and install wire clamps where previously installed. Place the harness into the loop (keeper) and secure with a wire tie at 1, and then along the top of the lower frame to the rear of the loader to the engine fuse/relay panel area.
Page 594 SECTION 55 - ELECTRICAL SYSTEM 9. Reattach the wires to the service/run switch, 1; fuse block(s), 2; preheat switch, 3; and any ground wires if removed at 4. NOTE: When attaching ground wires, always place the heaviest ground wire next to the ground surface and then stack the remaining ground wires according to wire size on top of the heaviest wire.
Page 595 SECTION 55 - ELECTRICAL SYSTEM 16. Route the wire harness to the front of the cab to the ignition switch and EIC board area. Attach the wires to the ignition switch and position the wire harness to prevent damage. Reinstall the switch panel, 1.
Page 596 SECTION 55 - ELECTRICAL SYSTEM Op. 55 404 ROAD/WORK LIGHTS The road and work lights provide illumination for road travel and work operations. The rear work lights are not recommended for road travel. Road/work light switch, 1, is located in the ignition key switch panel in the upper right corner of the overhead dash.
Page 597 SECTION 55 - ELECTRICAL SYSTEM Road/Work Light Switch Wiring Road/Work Light Wiring Diagram NOTE: When attaching ground wires, always place the heaviest ground wire next to the ground surface and then stack the remaining ground wires according to size on top of the heaviest wire. 55-120...
Page 598 SECTION 55 - ELECTRICAL SYSTEM Bulb Replacement Clear lens with bulb #86533429 Bulb only (clear) #86533428 Red lens with bulb #9829515 Bulb only (red) #C6AB13465A 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.
Page 599 SECTION 55 - ELECTRICAL SYSTEM Op. 55 404 10 Rear Work and Taillight 1. Remove the center work light, 1, by pushing the lens assembly to the left and lift the right side of the assembly from the support. 2. Remove the red taillight lamps, 2, by unscrewing the bezel self-tapping screws, and removing the bezels, 3.
Page 600 SECTION 55 - ELECTRICAL SYSTEM Indicator lamp Op. 55 301 Principle of Integrated Circuit Regulator The basic circuit of the IC regulator is shown here. ALTERNATOR (40-AMP VERSION) The part enclosed by a dotted line represents the IC CHARGING CIRCUIT regulator.
Page 601 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.
Page 602 SECTION 55 - ELECTRICAL SYSTEM ALTERNATOR SERVICE SPECIFICATIONS Item How Rated Standard Or Service Limit Normal Output (V - A) 12 V - 40 A Polarity Negative ground Weight (kg, lbs) 3.7 kg (8.2 lbs) Rotational direction (viewed from Clockwise the pulley) Load characteristics (cold) Terminal voltage (V)
Page 603 SECTION 55 - ELECTRICAL SYSTEM ALTERNATOR - SYSTEM TESTING AND TROUBLESHOOTING 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...
Page 604 SECTION 55 - ELECTRICAL SYSTEM UNSTABLE CHARGING CIRCUIT FAULT LOCATION POSSIBLE CAUSE CORRECTION Wiring Loose connection or open wire Repair or replace Alternator Loose drive belt Repair Short in rotor coil Replace Short in stator coil Replace Insufficient brush contact Repair or replace Broken brush or spring Replace...
Page 605 SECTION 55 - ELECTRICAL SYSTEM Alternator Construction Sectional view of the IC alternator The principal components of the IC alternator are the stator, the rotor, the rectifier assembly, the IC voltage regulator, the front bracket, the rear bracket, and the pulley.
Page 606 SECTION 55 - ELECTRICAL SYSTEM 3. With the test ammeter terminals short-circuited, start the engine. CAUTION In the case of where the test ammeter is connected at the position shown in Figure 181, make sure no starting current is applied to the ammeter when the engine is started.
Page 607 SECTION 55 - ELECTRICAL SYSTEM ALTERNATOR Op. 55 301 10 ALTERNATOR REMOVAL 1. Open the rear door, 1, raise the top engine shield, 2, and remove the right engine side shield, 3, to access the alternator. 2. For easier access, remove any attachment from the loader boom face plate and raise the boom and rest it on the boom lock pins.
Page 608 SECTION 55 - ELECTRICAL SYSTEM Op. 55 301 12 DISASSEMBLY 1. Mark both brackets and the stator with a scribe mark for assembly. 2. Remove the four through bolts. Pry between the stator and front bracket with the blade of a screwdriver.
Page 609 SECTION 55 - ELECTRICAL SYSTEM Unsolder three stator leads, 1, and remove the Stator Lead wire stator. 4. Remove the voltage regulator assembly, 1, and rectifier assembly, 2. 55-132...
Page 610 SECTION 55 - ELECTRICAL SYSTEM Op. 55 301 14 ALTERNATOR COMPONENT TEST Rotor 1. Inspection of slip ring surface, 1. Correct stain or scratches on the slip ring surface with a sandpaper of about 400# - 600#. A badly roughened slip ring or slip ring worn down beyond service...
Page 611 SECTION 55 - ELECTRICAL SYSTEM Stator 1. Check for continuity between the leads of the stator coil. If there is no continuity, the stator coil is defective. Replace the stator assembly. 2. Check for continuity between any stator lead and stator core.
Page 612 SECTION 55 - ELECTRICAL SYSTEM Rectifier Assembly Positive Heat Sink Check for continuity between the positive (+) heat sink and stator coil lead connection terminal with a circuit tester. If there is continuity in both directions, the diode is short-circuited. Replace the rectifier assembly.
Page 613 SECTION 55 - ELECTRICAL SYSTEM Brush and Brush Spring Check the length of the brush. A brush worn down to the wear limit line should be replaced. Check the brush spring pressure and make sure the brush moves smoothly in the brush holder. Reassembly Reverse the disassembly, except for the following: Installing Rotor...
Page 614 SECTION 55 - ELECTRICAL SYSTEM Bench Check To check the alternator on a test bench, proceed as follows: 1. Make the connection as shown, except leave the load resistor disconnected. 2. Slowly increase the alternator speed and observe the voltage. 3.
Page 615 SECTION 55 - ELECTRICAL SYSTEM ALTERNATOR REINSTALLATION 1. Attach the alternator to the lower pivot, 1, and the upper support strap, 2. 2. Reattach the wires to the alternator terminals. 3. Pivot the alternator to tighten the belt to obtain proper belt tension.
Page 616 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) Starter Motor Service Specifications ITEM HOW RATED...
Page 617 SECTION 55 - ELECTRICAL SYSTEM STARTER MOTOR TROUBLESHOOTING Use the diagnostic charts as a guide when repairing 3. Briefly touch the jumper wire to the spade the starting system. Before diagnosis, be certain the terminal on the solenoid. battery is fully charged and inspect the starter and If the solenoid clicks, the probable cause is in the battery cables for clean and tight connections.
Page 618 SECTION 55 - ELECTRICAL SYSTEM STARTER MOTOR Op. 55 201 50 REMOVAL 1. The starter can be accessed through the right engine side shield with the boom up or down or from the operator’s area with the seat raised. 2. To access the starter, 1, through the right engine side shield, open the rear door, raise the top engine side shield and remove the right engine side shield.
Page 619 SECTION 55 - ELECTRICAL SYSTEM Starter Motor Description 1. Drive Gear 2. Housing 3. Field Coil 4. Armature 5. Brush Spring 6. Brush 7. Plunger 8. Electric Solenoid 9. Overrunning Clutch 10. Pinion 11. Idler Gear The starter assembly is a positive pinion shift, reduction type starter consisting of the motor, reduction gearset, overrunning clutch and electric solenoid.
Page 620 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.
Page 621 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 SM463-190 10. Battery 11. Starter Switch 12.
Page 622 SECTION 55 - ELECTRICAL SYSTEM Electric Solenoid Operation The electric solenoid consists of the pull-in coil, 1, hold-in coil, 2, main contacts, 3, plunger, 4 and return spring, 5. The mechanism is sealed against entry of dirt and moisture. When the starting switch is closed, battery current flows through both the pull-in coil and the hold-in coil.
Page 623 SECTION 55 - ELECTRICAL SYSTEM STARTER DISASSEMBLY 1. Disconnect the lead wire from the electric solenoid. SM463-193 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.
Page 624 SECTION 55 - ELECTRICAL SYSTEM 3. Extract the insulated brushes, 1, from the brush holders. Hold the springs away and remove the brushes. Slide the brush plate, 2, from the commutator, 3. SM463-196 4. Remove the armature, 1, from the motor housing, 2.
Page 625 SECTION 55 - ELECTRICAL SYSTEM 6. Remove the drive end frame, 1, from the solenoid, 2. The idler gear with bearings, 3, and the pinion gear, 4, will be free to fall out. Work over a clean bench, using care to avoid losing these pieces.
Page 626 SECTION 55 - ELECTRICAL SYSTEM 9. Remove the idler gear and small pinion from the drive end frame if they were not dislodged when the housing was separated. SM463-202 10. Remove the idler gear bearing rollers and retainer. SM463-203 11. Remove the return spring from the electric solenoid.
Page 627 SECTION 55 - ELECTRICAL SYSTEM INSPECTION AND REPAIR Inspect following components, using conventional test methods, and repair or replace as necessary. Armature Inspect the armature for internal short circuits with a growler. Replace the armature if a short circuit is indicated. SM463-205 Inspect the armature for a short to ground using a continuity tester.
Page 628 SECTION 55 - ELECTRICAL SYSTEM Check the spline teeth for wear or damage, and replace the armature as necessary. Check the bearings for signs of roughness or dryness. Lubricate or replace as necessary. SM463-208 Field Coil Inspect the field coil for an open circuit with a continuity tester.
Page 629 SECTION 55 - ELECTRICAL SYSTEM Brushes Clean brushes and adjacent parts, removing carbon particles by wiping with a clean cloth. Check each brush for wear. Replace brushes if they are worn to the service limit. The positive brushes are welded to the field windings.
Page 630 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.
Page 631 SECTION 55 - ELECTRICAL SYSTEM Electric Solenoid The following tests should be performed with the motor removed from the starter assembly. Each test should not last more than 3 - 5 seconds to avoid overheating the solenoid. Tests should be performed with a fully charged 12 volt battery.
Page 632 SECTION 55 - ELECTRICAL SYSTEM REASSEMBLY Reassemble the starter in the reverse order of disassembly. Observe the following cautions and procedures. 1. Lubricate the following components with a light coating of White Lithium Grease (Part Number RL 666). Idler gear retainer and rollers. Overrunning clutch.
Page 633 SECTION 55 - ELECTRICAL SYSTEM 4. Install the overrunning clutch assembly part way into the housing. Mesh the idler gear with the driven gear, then fully install both pieces together. SM463-221 5. Position the pinion gear, 1,over the armature hole shaft then install the drive end frame, 2.
Page 634 SECTION 55 - ELECTRICAL SYSTEM 7. Install the brush plate onto the motor housing. Install the insulated brushes into the holder. Ensure the insulated brush leads are not grounded. Avoid getting oil or grease on the brushes or commutator. SM463-224 8.
Page 635 SECTION 55 - ELECTRICAL SYSTEM Performance Test After reassembly, a no-load test should be conducted. Clamp the starter securely in a vise. Connect a heavy wire (jumper cable) from a 12 volt battery positive terminal, through a suitable ammeter, to the battery cable post of the starter, 1.
Page 636 SECTION 55 - ELECTRICAL SYSTEM Maximum current draw for oil pressure switch is 0.42 amps (5-watt max. bulb). ** Diode capacity: Current 3 amp. Reverse voltage 600 volt. STARTER REINSTALLATION 1. Attach the starter to the bellhousing and tighten the hardware, 1. When installing the starter into the bellhousing, make sure it is properly seated before installing and tightening the hardware.
Page 637 SECTION 55 - ELECTRICAL SYSTEM LABOR GUIDE The following labor amounts are listed as a guide only. Working conditions and experience will vary the time it actually takes to complete each job. Job Description Hours Air filter sensor, remove and replace 0.5 hr.
Page 638 SECTION 82 – FRONT LOADER (BOOM AND MOUNTING PLATE) Chapter 1 – Buckets CONTENTS Section Description Page 82 100 General Information ............82-2 Buckets .
Page 639 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) Op. 82 100 pacity. Handle dense materials with a relatively small bucket. Handle lighter materials with higher capacity GENERAL INFORMATION buckets. Refer to the following bucket capacity chart and the material weight chart in the operator’s manu- BUCKETS al when choosing the bucket for a job.
Page 640 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.
Page 641 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.
Page 642 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) BOOM/CYLINDER PIVOT PINS SIZE PART NUMBER 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)
Page 643 (2510 lbs.) (1255 lbs.) (1255 lbs.) Capacities listed are LS160/LS170 with 10 x 16.5 tires at 3.5 bar (50 PSI), full fluids, 79 kg (175 lb.) op- erator, 48″ pallet forks w/back guard, weight kit two 27 kg (60 lbs.) per side, per SAE rating specification J1197.
Page 644 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) Op. 82 100 20 UTILITY FORK The utility fork is for handling matted, stringy material which is difficult to load into a standard bucket. The standard tine spacing, center to center, is 21.8 cm (8-1/2″).
Page 645 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) BUCKETS Op. 82 100 12 CUTTING EDGE (REPLACEMENT) Cut or grind the old cutting edge from the bucket floor and sides. Remove all old weld and foreign material from the welding area. 1.
Page 646 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;...
Page 647 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 6. Position the first plates against the back of the bucket at 1, and rest on the quick-attach plate, 2. Locate the center of the latch plate notches, 4, and center the outer half of the notch over the latch pin, 3.
Page 648 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 10. Weld the plates to the bucket at 2; also weld the two plates at 3. 11. Reinstall the bucket quick-attach plate to the loader boom with the pins previously removed. 12.
Page 649 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. To replace the “pin-on” points, use a punch that just fits into the pin hole, 1, and drive the old retaining pin from the shank.
Page 650 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 2. Locate the teeth on the bucket edge as indicated. BUCKET TOOTH SPACING Bucket Width From End 2nd Tooth 3rd Tooth 4th Tooth 5th Tooth 6th Tooth 52″ 1-13/16″ 9-1/2″ 18-15/16″ 28-3/8″...
Page 651 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 3. Weld, 1, is high carbon steel (tooth) to high car- bon steel (bucket). Use welding rods marked 7018 or comparable rods. Weld on both sides of the tooth from the back of the tooth towards the replaceable point.
Page 652 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) BOOM LOCK PIN LINKAGE Op. 82 100 77 REMOVAL 1. Lower the boom to the lowered position. 2. Open the rear door, 1, and the top engine, 2, ac- cess cover. 3.
Page 653 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 9. Remove the control rod, 2, from the lever at 5, and slide the handle from the rear of the cab. 10. Slide the boom pins, 1, right and left, from the loader ROPS post.
Page 654 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 3. Position the control handle over the lock pin, 1, and install the support hardware at 2. 4. Install the handle and lock pin through bolt at 3. 5. With the handle properly positioned tighten the support hardware at 2, and the through bolt lock nut, 3.
Page 655 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) BOOM, UPPER AND LOWER LINK REMOVAL 1. Remove any attachment (bucket, fork, etc.) from the boom mounting plate and lower the boom to the lowered position. 2. Attach a chain or strap suitable for handling the weight of the boom (approximately 800 lbs.) to the boom grab handles as shown at 1.
Page 656 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.
Page 657 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 6. Loosen the front lower link pivot pin retaining hardware, 1, and strike the link at 2, to break the tapered pivot pin loose in the ROPS frame. 7. Remove the retaining pin hardware from the front and rear pins.
Page 658 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 3. Loosen the front link pivot hardware, 1, and with a soft-faced sledge hammer, strike the link at 1, to loosen the tapered pin in the ROPS post. 4. Remove the front and rear pivot pin retaining bolts and tapered pins and lift the link from the loader.
Page 659 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 4. Remove the hoses from the rear hose support, 1, remove the tube clamps, 2, and disconnect the tubes at the Z-bracket and quick couplers, 3. 5. Remove the right and left upper boom cylinder pivot pin retaining hardware, 1, and pin, 2, from cylinders and boom.
Page 660 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 8. Remove the pin retaining hardware and pin from the link and main boom. Lower the link and rest it on the loader frame. 9. Loosen the right and left upper link rear retaining bolts, 1;...
Page 661 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.
Page 662 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) BOOM, UPPER AND LOWER LINK REIN- STALLATION 1. If the upper and lower boom links and boom cylin- ders were removed, attach the upper and lower links to the ROPS before installing the main boom assembly.
Page 663 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 6. Attach the lower link rear with tapered pivot pins and retaining hardware. Tighten the hardware, making sure the pin is straight in the main boom. 7. With the main boom, upper and lower links at- tached, the pivot pins and hardware must be properly seated.
Page 664 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 12. Route the tubes and hoses to the rear of the boom through the rear hose supports, 1, and on the top side of the lower link at 2. 13. Position the hoses with one on each side of the lower link retaining clips, 1, and through the hose retainer at 2.
Page 665 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 17. Check the hoses, 1, around the rear supports with the boom in the fully raised position. The hoses should be routed as shown. Remove any slack from the hoses to the boom tubes and tight- en the hose clamp, 2.
Page 666 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 20. Reinstall the boom mounting plate if removed. Torque the pivot bolts, 1, to 108 N·m (80 ft. lbs.). The tapered pivot pins and retaining hardware must be hammer seated by striking the head of the bolt and pin and retorquing the bolt.
Page 667 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) REPAIR/REBUILD MOUNTING PLATE Op. 82 100 74 LATCH LEVER AND PIN REMOVAL/REPAIR 1. Remove any attachment from the loader attach- ment mounting plate. 2. Lower the boom to the lowered position. 3.
Page 668 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 9. Enter the skid-steer loader. Sitting in the opera- tor’s seat with the seat belt buckled, start the loader and retract the attachment mounting plate actuating cylinders, 1, fully to clear the attach- ment mounting plate, 2.
Page 669 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) PARTS INSPECTION Mounting Plate Assembly 1. Inspect the plate, 1, for straightness. If the mounting plate pods are not straight with each other it may be difficult to hook up to attachments. Refer to the “Checking Procedure for Buckets and Attachments”...
Page 670 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) Op. 82 100 74 Latch Lever and Spring Repair/Rebuild 1. Clamp the lower spring guide, 1, in a vise. Turn the step bolt, 2, to remove the lower spring guide from the step bolt and remove spring, 3. CAUTION hen removing the step bolt, the spring will have some compression pressure.
Page 671 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 3. Slide the latch handle/spring assembly, 1, into the mounting plate, pointing the spring down. 19984481 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.
Page 672 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 7. Reinstall the setscrew, 1. 19984477 19984477 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 the bolt and pin, and then re-tightening.
Page 673 Inspection The LS160 and LS170 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.
Page 674 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) The following are some quick visual checks of the loader faceplate and attachment. 1. The attachment must have a 850.1 mm ± 0.8 mm (33-15/32″ ± 1/32″) center to center latch point, 1, to be compatible with the latch system.
Page 675 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) CHECKING PROCEDURE The following are the procedures used to measure the skid-steer loader faceplate and how to measure the attachment. Checking the Attachment 1. Check the placement of the lower latch plates at 1.
Page 676 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) CHECKING THE LOADER FACEPLATE 1. Check the height of the loader faceplate from the top of the plate at 1, to the bottom of the plate at 2: 396.9 mm ± 0.8 mm (15-5/8″ ± 1/32″). To check the faceplate, place a 24″...
Page 677 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 3. Check the center dimension between the face- plate pods and the overall outside dimension. Inside Dimension 1: 647.7 mm (25-1/2″) Outside Dimension 2: 1122.4 mm (44-3/16″) Latch Pin Dimension 3: 850.1 mm ± 0.8 mm (33-15/32″...
Page 678 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) LABOR GUIDE The following labor amounts are listed as a guide only. Working conditions and experience will vary the time it actually takes to complete each job. Job Description Hours Remove and replace boom lock pins and linkage 2.5 hrs.
Page 679 SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 82-42...
Page 680 SECTION 88 – ACCESSORIES Chapter 1 – Dealer Installed Options CONTENTS Section Description Page 88 100 General Information ............88-2 Adapting Attachments Requiring 12V Electrical Power .
Page 681 This includes any terminals of the ignition switch, fuse panel, or ground terminal. 3. NEVER INSTALL an electrical device, music ra- dio, two-way radio, or unapproved New Holland attachment into the cab area. 4. ONLY USE the 12-volt accessory power outlet for attachments requiring less than 10 amps.
Page 682 SECTION 88 - ACCESSORIES Wire connections available if electrical attachments were not previously installed. Engine Fuse Panel Ref. Color Destination Fuse Battery Voltage Status To turn signal relay 10-amp All times Available R/GY To accessory relay 25-amp All times Available R/LTGN To EIC board pin #14 P2 connector 5-amp...
Page 683 Figure 4 shows circuits for intermittent high current loads up to 15 amps. The Figure 5 shows the circuit for intermittent high current loads up to 30 amps. New Holland sealed circuit breakers that can be pur- chased from parts. Part Number Capacity...
Page 684 Examples: Backhoes and trees spades with a separate control valve do not accept oil flow in NOTE: LS160 and LS170 model loaders must have both directions. a minimum of 22.7 l/min. (6 GPM) returning through the main hydraulic system at all times to charge the 4.
Page 685 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 “NO”, nothing is required. If “NO”, nothing is required. 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.
Page 686 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. The arm pads, 1, require gluing in place to the cab ...
Page 687 The LS160 and LS170 armrests mount with the bracket, 1, over the cab side panel, 2. Pivot the armrest up and down and adjust the two clamp bolts, 3, if binding occurs, or to retain the arm- rest in the raised position.
Page 688 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.
Page 689 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-...
Page 690 SECTION 88 - ACCESSORIES Op. 55 000 ELECTRIC POWER SUPPLY (12 VOLT, 15 AMP) The electric power outlet can be installed on the load- er to provide an auxiliary 12-volt power outlet rated at 15 amp. If the horn kit is installed, the power kit wire harness is incorporated in the horn harness.
Page 691 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. The catalytic muffler, 1, is a direct replacement for the standard muffler without adding other parts.
Page 692 SECTION 88 - ACCESSORIES Aspirator or Spark Arrester Muffler Cleaning Clean the muffler every 250 hours of use to ensure proper operation and prolong muffler life. 1. To clean the muffler, first move the loader to an area clear of any flammable material. 2.
Page 693 The high flow increases the hydraulic flow: LS160 From 15.5 GPM, 1000 PSI at 2900 RPM to 24.0 GPM, 1000 PSI at 2900 RPM (= 32.2 HP).
Page 694 SECTION 88 - ACCESSORIES Attachment Case Drain When the high flow kit is installed, there is a separate case drain return line, 1, for the attachment case (housing) to drain oil. The case drain line drains into the hydrostatic pump/motor case drain system with 0.0 - 1.7 bar (0 - 25 PSI) system back pressure.
Page 695 SECTION 88 - ACCESSORIES HIGH FLOW HYDRAULICS TROUBLESHOOTING PROBLEM POSSIBLE CAUSE CORRECTION No switch operation No battery voltage to switch Check power supply at 15-amp fuse (attachment) engine fuse panel Check DKGN/R (Dark Green/Red) wire from fuse to switch Inoperative switch Replace switch No selector valve operation No battery voltage to selector valve...
Page 696 SECTION 88 - ACCESSORIES PROBLEM POSSIBLE CAUSE CORRECTION No increase in hydraulic oil flow No switch operation Check power supply circuit when switch is in the “ON” position No selector valve operation Check power supply from switch Selector valve spool binding Check for spool binding and repair Drive belt slipping or broken Check drive belt adjustment or...
Page 697 SECTION 88 - ACCESSORIES HIGH FLOW HYDRAULICS COMPONENT REPLACEMENT Op. 35 724 High Flow Selector Valve Replacement To access the selector valve, 1, the seat must be raised and latched in the raised position. The left hydrostatic control lever assembly must be removed.
Page 698 SECTION 88 - ACCESSORIES Op. 35 710 High Flow Pump Removal / Disassembly 1. Clean the pump thoroughly and mark the pump assembly, 1, to ensure proper reassembly. 2. Remove the high pressure tube, 2, from the pump fitting, 3. Remove the fitting, 3, from the pump.
Page 699 SECTION 88 - ACCESSORIES 3. Inspect the pump back plate for excessive wear. The oil grooves in the back plate bushings, 1, should be at approximately 37° to the pressure side. If the bushing oil grooves are not positioned as noted, the bushings have turned in the plate. The plate should be replaced under this condi- tion.
Page 700 SECTION 88 - ACCESSORIES High Flow Pump Reassembly / Installation 1. Coat all parts with a thin coat of petroleum jelly or oil to aid in reassembly. 2. Clean the mounting plate surface thoroughly and install a new O ring, 1. Install the shaft key, 2, in the drive shaft.
Page 701 SECTION 88 - ACCESSORIES 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, 2, of the pump. 19997763 5. Install the drive gear, 1, on the drive shaft, slip- ping the groove over the shaft key, 2.
Page 702 SECTION 88 - ACCESSORIES 7. Install a new O ring, 1, in the back plate. 19997761 8. Install the pump back plate, 1, over the gear shafts. Check that the reference marks made during disassembly align correctly. 9. Install the housing hardware with the eight bolts, 2, and sealing washers.
Page 703 SECTION 88 - ACCESSORIES High Flow Electrical Wiring Diagram High Flow Hydraulic Oil Flow Diagram 19997766 88-24...
Page 704 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. 19984626 Horn Wiring Diagram 88-25...
Page 705 SECTION 88 - ACCESSORIES Op. 90 000 SHOULDER BELT (SEAT) The shoulder belt can be installed with the lap seat belt. The shoulder belt is recommended anytime a front cab door is installed. If the shoulder belt becomes completely retracted or the belt becomes locked, the web must move back into the retractor approximately 1/2″...
Page 706 SECTION 88 - ACCESSORIES Op. 88 000 SLOW-MOVING VEHICLE (SMV) SIGN KIT The Slow-Moving Vehicle (SMV) kit mounts to the rear door of the skid-steer loader when the loader is operated on roadways. On the louvered rear door, a bracket, 1, must be installed to hold the SMV sign in place on top of the door.
Page 707 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. The beacon light switch, 1, is located in the ignition key switch panel in the upper right corner of the over- head dash.
Page 708 SECTION 88 - ACCESSORIES Beacon Switch Wiring 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. 88-29...
Page 709 SECTION 88 - ACCESSORIES Beacon Bulb Replacement Bulb only #69AG13009AA (H1 12V 55W) To replace the bulb, remove the three screws attach- ing the lens to the base and lift the lens from the base. Squeeze the bulb retaining tabs to separate the bulb from the holder.
Page 710 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. The warning light switch, 1, is located in the ignition key switch panel in the upper right corner of the over- head dash.
Page 711 SECTION 88 - ACCESSORIES Warning Light Switch Wiring 88-32...
Page 712 SECTION 88 - ACCESSORIES 19985531 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...
Page 713 SECTION 88 - ACCESSORIES Warning Light Bulb Replacement Amber lens with bulb #9841566 Bulb only #529068 Op. 55 404 10 Front Light 1. Remove the bezel, 1, retaining screws and re- move lens from support. 2. Disconnect the wire harness from the bulb hold- 3.
Page 714 SECTION 88 - ACCESSORIES LABOR GUIDE The following labor amounts are listed as a guide only. Working conditions and experience will vary the time it actually takes to complete each job. Job Description Hours Arm pads (cab) Remove and replace (2) Armrest (seat) Remove and replace (1) 0.25...
Page 715 SECTION 88 - ACCESSORIES 88-36...
Page 716 SECTION 90 – PLATFORM, CAB, BODYWORK, AND DECALS Chapter 1 – Cab and Seat CONTENTS Section Description Page General Information ............90-2 Seat and Seat Pan Support .
Page 717 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS GENERAL INFORMATION Op. 90 108 SAFETY DECALS The safety decals located on the skid steer are intended for the personal safety of you and those working with you. Keep the decals legible. If they are not legible, replace as necessary.
Page 718 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS When the operator’s seat is returned to the operating position, make sure it is securely latched at 1. CAUTION Do not operate the skid steer unless the operator’s seat is securely latched in the operating position.
Page 719 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 3. Remove retaining pin from latch rod at 1 and remove rod. 4. Remove the seat pan support hardware at 2. 5. Unlatch the seat pan support at 3, and lift the seat and pan support assembly from the loader.
Page 720 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 10. To remove the seat tracks from the seat assembly remove the track retaining hardware, Op. 55 201 15 11. Remove the switch(es) from the seat pan, 2. Note the standard seat uses one switch and the deluxe seat uses two switches as shown.
Page 721 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 3. Reattach the seat to the seat pan support with retaining hardware at 1. NOTE: If the seat/seat belt wire harness was removed, reinstall the wire grommet in seat pan at 2, and wire clamp on back of seat, 3, to retain the wire harness.
Page 722 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 6. Reconnect the seat/seat belt wire harness connector to the main wire harness behind the seat at 1. NOTE: Position the seat/seat belt and main wire harness to the front of the boom lock linkage, 2, to prevent interference.
Page 723 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 5. Remove the right and left headliner supports retaining hardware, 1, right side shown, and remove both supports and headliner. 6. Remove the fuse panel retaining hardware, 2, and lower the fuse panel. DO NOT remove any wires from any switches or fuse blocks.
Page 724 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 11. Remove the light assembly, 1, from the pod by pushing the light assembly to the left, unlatching it from the pod. 12. Remove light pod retaining hardware, 2, and remove the pod assembly. A5371-9 13.
Page 725 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 15. Remove the retaining pin from latch rod at 1, and remove the rod. 16. Disconnect the seat/seat belt wire harness from the main harness, unless previously unplugged. Remove the seat pan support hardware at 2. 17.
Page 726 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 20. Remove all wire harness retaining clamps and ties, 1, from the side panels. Cut wire tie at keeper bar at left front to rear of cab pivot. 21. Remove any wire harness clamps and cut wire ties along the rear of the seat support and side panels, 1.
Page 727 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 23. Remove the rear seat support, 1, hardware at 2, and the isolator mount hardware, 3. 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).
Page 728 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.
Page 729 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS Cab inner shell removed from the loader ROPS. 1. Right side shield 2. Left side shield 3. Headliner supports 4. Upper rear support 5. Lower seat support 6. Front support (dash) not shown The loader ROPS with the seat and inner shell removed.
Page 730 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 3. Lay the main cab wire harness along the inside of the right side shield, 1, at the top and right rear corner. 4. Position the side shields and install the rear lower support hardware, 1, isolators and retaining hardware, 2.
Page 731 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 6. Install the front cross member, 1, and retaining hardware. Do not tighten at this time. 7. Position the inner shell assembly squarely with the ROPS frame. Make sure the wire harness, 2, is positioned to prevent damage to the harness when the inner shell isolators and support hardware are tightened.
Page 732 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 11. Reinstall all wire harness retaining clamps and plastic ties to secure the harness, 1, in the upper right rear corner of the operator’s cab. 12. Reinstall the wire harness clamps and ties along the rear of the operator’s seat.
Page 733 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 16. Reinstall the light pods, light wire harness and lights. 17. Reconnect the wire harness to all switches and EIC (Electronic Instrument Cluster) previously removed. NOTE: Plug the two wire harness connectors into the EIC, noting the correct positioning of the connectors.
Page 734 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 21. Reinstall the parking brake control rod and pivot bearings. Install the right bearing into the right support, 1. Slide control rod, 2, into right bearing, place the left bearing and support over rod at 3, and rotate control rod link into cab at 4.
Page 735 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 24. Reconnect the spring links, 1, to the control rod at 2 and install the cotter pins. 19992572 25. Reinstall the seat/seat pan support assembly and connect the seat/seat belt wire harness to the main wire harness, 1.
Page 736 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 29. Slide the throttle cable up through the hole in the left cab panel and secure with retaining nut at 1. Attach the control lever, 2, to the cab panel at 3, with 3/8″...
Page 737 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.
Page 738 Never transport a loaded bucket at full height. Operate the skid steer with the load as low as possible. Part #86521716 LS160 - 682 kg/1500 lbs. (Mfg. Rating) Part #86521717 LS170 - 770 kg/1700 lbs. (Mfg. Rating) 5. Warning: Never operate the skid steer without the seat belt securely fastened.
Page 739 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 6. Warning: Keep clear of moving parts. Keep bystanders clear of the skid steer at all times unless the boom is down on the ground or the boom is resting on the boom lock pins and engine is off.
Page 740 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.
Page 741 SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS LABOR GUIDE The following labor amounts are listed as a guide only. Working conditions and experience will vary the time it actually takes to complete each job. Job Description Hours Remove and replace seat, seat support 1.5 hrs.

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Ls170

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