SR220 / SR250 / SV250 / SV300 Tier 4A
Alpha Series Skid Steer Loader
SR220 PIN NDM457559 and above; SR250 PIN NCM442784 and above; SV250 PIN NDM460776 and above; SV300 PIN NCM445399 and above
TR320 / TV380 Tier 4A
Alpha Series Compact Track Loader
TR320 PIN NCM440597 and above; TV380 PIN NCM450857 and above
SERVICE MANUAL
Part number 47540695 English April 2014
Replaces part number 47465734
Product MarketProduct Engine
NorthAmerica F5HFL413L*A001 NorthAmerica F5HFL413L*A001
SR220TIER4[NDM457559-]NorthAmerica F5HFL413H*A001
SR250TIER4[NCM442784-]NorthAmerica F5HFL413L*A001 NorthAmerica F5HFL413H*A001 NorthAmerica F5HFL413L*A001
LinkProduct/Engine
4754069528/04/2014
Contents INTRODUCTION Engine.......................................................................................10 [10.001]Engineandcrankcase.............................................................10.1 [10.216]Fueltanks..........................................................................10.2 [10.310]Aftercooler..........................................................................10.3 [10.400]Enginecoolingsystem.............................................................10.4 [10.414]Fananddrive......................................................................10.5 treatment....................................................................................10.6 [25.450]Chaindrivesystem.................................................................25.1 Rearaxlesystem........................................................................27 Hydrostaticdrive.........................................................................29 [29.202]Hydrostatictransmission...........................................................29.1 [29.200]Mechanicalcontrol.................................................................29.3 Brakesandcontrols....................................................................33 Hydraulicsystems.......................................................................35 [35.300]Reservoir,cooler,andfilters........................................................35.4 [35.350]Safetyandmainreliefvalves......................................................35.5 4754069528/04/2014
Framesandballasting.................................................................39 [39.140]Ballastsandsupports..............................................................39.1 Wheels......................................................................................44 [44.520]Rearwheels........................................................................44.2 Tracksandtracksuspension........................................................48 [48.138]Trackrollers........................................................................48.4 Cabclimatecontrol.....................................................................50 Electricalsystems.......................................................................55 [55.000]Electricalsystem...................................................................55.1 [55.010]Fuelinjectionsystem...............................................................55.2 [55.011]Fueltanksystem...................................................................55.3 [55.012]Enginecoolingsystem.............................................................55.4 [55.014]Engineintakeandexhaustsystem.................................................55.5 [55.015]Enginecontrolsystem..............................................................55.6 [55.019]Hydrostaticdrivecontrolsystem...................................................55.7 [55.031]Parkingbrakeelectricalsystem....................................................55.8 4754069528/04/2014
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Frontloaderandbucket...............................................................82 [82.100]Arm.................................................................................82.1 [82.300]Bucket..............................................................................82.2 Platform,cab,bodywork,anddecals.............................................90 4754069528/04/2014
4754069528/04/2014
INTRODUCTION
4754069528/04/2014 1
Contents
INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing(*)................................3
Safetyrules(*)..................................................................................4
Safetyrules-Personalsafety(*)...............................................................5
Safetyrules-Ecologyandtheenvironment(*).................................................6
Safetyrules(*)..................................................................................7
Torque-Minimumtighteningtorquesfornormalassembly(*).................................8
Torque-Standardtorquedataforhydraulics(*)..............................................13
Basicinstructions-Shopandassembly(*)...................................................15
Hydrauliccontamination–Contamination(*).................................................17
Generalspecification-Left-handinstrumentcluster(*)......................................18
Generalspecification-ElectronicInstrumentCluster(EIC)(*)...............................20
Generalspecification-AdvancedInstrumentCluster(AIC)(*)...............................25
Generalspecification-Biodieselfuels(*).....................................................30
Productidentification(*)......................................................................36
4754069528/04/2014 2
INTRODUCTION Foreword-Importantnoticeregardingequipmentservicing SR220 SR250 SV250 SV300 TR320 TV380 strictlycomplyingwiththeinstructionsgiven,andusing,wheneverpossible,thespecialtools. Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein shallberesponsibleforanysubsequentdamages. localdealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedbythemanuofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer. Theinformationinthismanualisup-to-dateatthedateofthepublication.Itisthepolicyofthemanufacturerfor continuousimprovement.Someinformationcouldnotbeupdatedduetomodificationsofatechnicalorcommercial Incaseofquestions,refertoyourCASECONSTRUCTIONSalesandServiceNetworks. 4754069528/04/2014 3
Safetyrules
Personalsafety
INTRODUCTION
SR220 SR250 SV250 SV300 TR320 TV380
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury. FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY. Machinesafety NOTICE: ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor Information NOTE: Noteindicatesadditionalinformationthatclarifiessteps,procedures,orotherinformationinthismanual. otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage. 4754069528/04/2014 4
INTRODUCTION Safetyrules-Personalsafety SR220 SR250 SV250 SV300 TR320 TV380 Carefullystudytheseprecautions,andthoseincludedintheexternalattachmentoperators manual,andinsistthattheybefollowedbythoseworkingwithandforyou. 1.ThoroughlyreadandunderstandthismanualandtheattachmentOperator’sManualbeforeoperatingthisorany otherequipment. purposes.PassengersmustnotbeallowedtousetheInstructorsSeat. thatmightcatchonmovingparts. • Disengageallclutchingleversorswitches. • • • • thekeyandwaitforallmachinemovementtostopbeforeleavingtheoperatorsplatform. loweredtothegroundorthesafetylock(s)isintheengagedposition. machineorattachmentmotiontocometoastop,beforeleavingtheoperatorsplatformtoservicethemachine 18.Remember:Acarefuloperatoristhebestinsuranceagainstanaccident. 4754069528/04/2014 5
SR220
SR250
SV250
TR320
TV380
Thefollowingarerecommendationsthatmaybeofassistance:
INTRODUCTION Safetyrules-Ecologyandtheenvironment
SV300
NOTE:
• • substances. • Helpfulhints • Avoidfillingtanksusingcansorinappropriatepressurizedfueldeliverysystemsthatmaycauseconsiderable spillage. • • • • Moderncoolantmixtures,i.e.antifreezeandotheradditives,shouldbereplacedeverytwoyears.Theyshouldnot • Donotopentheair-conditioningsystemyourself.Itcontainsgasesthatshouldnotbereleasedintotheatmosphere. YourCASECONSTRUCTIONdealerorairconditioningspecialisthasaspecialextractorforthispurposeandwill • • • 4754069528/04/2014 6
SR220 SR250
SV250
SV300
TR320
TV380
Safetyrules
INTRODUCTION
BT09A213 1 4754069528/04/2014 7
M10
INTRODUCTION Torque-Minimumtighteningtorquesfornormalassembly SR220 SR250 SV250 SV300 TR320 TV380 METRICNON-FLANGEDHARDWARE NOM. SIZE CLASS8.8BOLTand CLASS8NUT CLASS10.9BOLTand CLASS10NUT LOCKNUT CL.8 W/CL8.8 BOLT LOCKNUT CL.10 W/CL10.9 BOLT UNPLATED PLATED W/ZnCr UNPLATED PLATED W/ZnCr ( 19lb ) ( 26lb ) ( 28lb ) ( 37lb ) 2N·m ( 18lbin ) ( 26lb ) ( 40lb ) ( 52lb ) ( 57lb ) ( 75lb ) ( 36lbin ) ( 51lb ) ( 66lb ) 10N·m ( 89lb ) 11N·m ( 96lb ) 15N·m ( 128lb ) ( 60lb ) 10N·m ( 89lb ) ( 163lb ) ( 217lb ) ( 234lb ) ( 311lb ) ( 151lb ) ( 212lb )
37N·m ( 27lbft ) ( 36lb ) 52N·m ( 38lbft ) ( 51lb ) ( 25lb ) ( 35lb ) M12 64N·m ( 47lbft ) 85N·m ( 63lb ) 91N·m ( 67lbft ) 121N·m ( 90lb ) 58N·m ( 43lb ) 83N·m ( 61lb ) M16 158N·m ( 116lb ) 210N·m ( 155lbft ) 225N·m ( 166lb ) 301N·m ( 222lb ) 143N·m ( 106lb ) 205N·m ( 151lb ) M20 319N·m ( 235lb ) 425N·m ( 313lbft ) 440N·m ( 325lb ) 587N·m ( 433lb ) 290N·m ( 214lb ) 400N·m ( 295lb ) M24 551N·m ( 410lb ) 735N·m ( 500lbft ) 762N·m ( 560lb ) 1016N·m ( 750lbft ) 501N·m ( 370lb ) 693N·m ( 510lb ) NOTE: specificationsareshowninpound-feet. 4754069528/04/2014 8
INTRODUCTION METRICFLANGEDHARDWARE NOM. SIZE CLASS8.8BOLTand CLASS8NUT CLASS10.9BOLTand CLASS10NUT LOCKNUT CL.8 W/CL8.8 BOLT LOCKNUT CL.10 W/CL10.9 BOLT UNPLATED PLATED W/ZnCr UNPLATED PLATED W/ZnCr ( 21lb ) ( 28lb ) ( 31lb ) ( 41lb ) ( 19lb ) ( 27lb ) ( 43lb ) ( 58lb ) ( 62lb ) ( 83lb ) ( 39lb ) ( 57lb ) 8.3N·m ( 73lb ) ( 96lb ) ( 105lb ) ( 141lb ) 7.5N·m ( 66lb ) ( 96lb ) ( 179lb ) ( 240lb ) ( 257lb ) ( 343lb ) ( 163lb ) ( 240lb ) M10 40N·m ( 30lbft ) 54N·m ( 40lb ) 57N·m ( 42lbft ) 77N·m ( 56lb ) 37N·m ( 27lbft ) 53N·m ( 39lbft ) M12 70N·m ( 52lbft ) 93N·m ( 69lb ) 100N·m ( 74lb ) 134N·m ( 98lb ) 63N·m ( 47lbft ) 91N·m ( 67lbft ) M16 174N·m ( 128lb ) 231N·m ( 171lb ) 248N·m ( 183lb ) 331N·m ( 244lb ) 158N·m ( 116lb ) 226N·m ( 167lb ) M20 350N·m ( 259lb ) 467N·m ( 345lb ) 484N·m ( 357lb ) 645N·m ( 476lb ) 318N·m ( 235lb ) 440N·m ( 325lb ) M24 607N·m ( 447lb ) 809N·m ( 597lb ) 838N·m ( 618lb ) 1118N·m ( 824lbft ) 552N·m ( 407lb ) IDENTIFICATION MetricHexheadandcarriagebolts,classes5.6andup 20083680 1 1.Manufacturer'sIdentification MetricHexnutsandlocknuts,classes05andup 20083681 2 4754069528/04/2014 9
) 98N·m ( 73lbft ) 104N·m ( 77lbft ) 139N·m ( 103lbft ) 76N·m ( 56lbft ) 108N·m ( 80lb )
9/16 107N·m ( 79lbft ) 142N·m ( 105lbft ) 150N·m ( 111lbft ) 201N·m ( 148lbft ) 111N·m ( 82lbft ) 156N·m ( 115lb )
5/8 147N·m ( 108lbft ) 196N·m ( 145lbft ) 208N·m
193lbft
310lbft
465lbft
257lbft
413lbft
620lbft
153lbft
272lbft
438lbft
656lbft
204lbft
362lbft
584lbft
875lbft
113lb
200lb
323lb )
483lb
159lb
282lb
455lb )
681lb
INTRODUCTION 1.Manufacturer'sIdentification 3.ClockMarkingofPropertyClassandManufacturer'sIdentification(Optional),i.e.marks 60° apartindicateClass 120° INCHNON-FLANGEDHARDWARE NOMINAL SIZE SAEGRADE5BOLT andNUT SAEGRADE8BOLT andNUT LOCKNUT GrBW/Gr5 BOLT LOCKNUT GrCW/Gr8 BOLT UNPLATED PLATED SILVER PLATED W/ZnCr GOLD UNPLATED orPLATED SILVER PLATED W/ZnCr GOLD 1/4 8N·m ( 71lb ) 11N·m ( 97lb ) ( 106lbin ) ( 142lbin ) 8.5N·m ( 75lbin ) ( 109lb ) 5/16 ( 150lbin ) ( 204lbin ) ( 212lbin ) ( 283lbin ) 17.5N·m ( 155lb ) ( 220lb ) 3/8 ( 22lb ) ( 30lbft ) ( 31lb ) ( 42lb ) 31N·m ( 23lbft ) 44N·m ( 33lbft ) 7/16 48N·m ( 36lb ) 65N·m ( 48lbft ) 68N·m ( 50lb ) 91N·m ( 67lb ) 50N·m ( 37lbft ) 71N·m ( 53lbft ) 1/2 74N·m ( 54lb
(
) 277N·m (
) 153N·m (
) 215N·m (
) 3/4 261N·m (
) 348N·m (
) 369N·m (
) 491N·m (
) 271N·m (
) 383N·m (
) 7/8 (
) (
) (
) (
) 437N·m (
617N·m (
1 (
) (
) (
) (
) (
) (
) NOTE: 1/4inand 5/16in hardwaretorquespecificationsareshowninpound-inches. 3/8in through1in 4754069528/04/2014
1/4
1/2
55lbft
113lbft
INTRODUCTION INCHFLANGEDHARDWARE NOMINAL SIZE SAEGRADE5BOLTand NUT SAEGRADE8BOLTand NUT LOCKNUT GrFW/Gr5 BOLT LOCKNUT GrGW/Gr8 BOLT UNPLATED orPLATED SILVER PLATED W/ZnCr GOLD UNPLATED orPLATED SILVER PLATED W/ZnCr GOLD
( 80lbin ) 12N·m ( 106lb ) 13N·m ( 115lb ) 17N·m ( 150lb ) ( 71lbin ) 12N·m ( 106lb ) 5/16 19N·m ( 168lb ) 25N·m ( 221lb ) 26N·m ( 230lb ) 35N·m ( 310lb ) 17N·m ( 150lb ) 24N·m ( 212lb ) 3/8 ( 25lb ) ( 33lb ) ( 35lb ) ( 46lb ) ( 22lbft ) ( 32lbft ) 7/16 ( 39lb ) ( 52lb ) ( 55lb ) ( 74lb ) 48N·m ( 35lbft ) 68N·m ( 50lbft )
81N·m ( 60lb ) 108N·m ( 80lb ) 115N·m ( 85lb ) 153N·m (
) 74N·m (
) 104N·m ( 77lb ) 9/16 117N·m ( 86lb ) 156N·m ( 115lbft ) 165N·m ( 122lbft ) 221N·m ( 163lbft ) 106N·m ( 78lbft ) 157N·m ( 116lb ) 5/8 162N·m ( 119lb ) 216N·m ( 159lbft ) 228N·m ( 168lbft ) 304N·m ( 225lbft ) 147N·m ( 108lb ) 207N·m ( 153lb ) 3/4 287N·m ( 212lb ) 383N·m ( 282lbft ) 405N·m ( 299lbft ) 541N·m ( 399lbft ) 261N·m ( 193lb ) 369N·m ( 272lb ) 7/8 462N·m ( 341lb ) 617N·m ( 455lbft ) 653N·m ( 482lbft ) 871N·m ( 642lbft ) 421N·m ( 311lb ) 594N·m ( 438lb ) 1 693N·m ( 512lb ) ( 682lbft ) ( 722lbft ) ( 963lbft ) 631N·m ( 465lb ) 890N·m ( 656lb ) IDENTIFICATION InchBoltsandfree-spinningnuts 20083682 3 GradeMarkingExamples SAEGradeIdentification 1 4 2 5 120° Apart 3 6 60° Apart 4754069528/04/2014 11
INTRODUCTION InchLockNuts,AllMetal(Threeoptionalmethods) 20090268 4 GradeIdentification GradeCornerMarkingMethod(1)FlatsMarkingMethod(2)ClockMarkingMethod(3) GradeA NoNotches NoMark NoMarks GradeBOneCircumferentialNotch LetterB ThreeMarks GradeCTwoCircumferentialNotchesLetterC SixMarks 4754069528/04/2014
INTRODUCTION Torque-Standardtorquedataforhydraulics SR220 SR250 SV250 SV300 TR320 TV380 INSTALLATIONOFADJUSTABLEFITTINGS INSTRAIGHTTHREADORINGBOSSES petroleum.InstalltheO-ringinthegrooveadjacent tothemetalbackupwasherwhichisassembledatthe extremeendofthegroove (4) 2.InstallthefittingintotheSAEstraightthreadbossuntil themetalbackupwashercontactsthefaceoftheboss (5) NOTE: Donotovertightenanddistortthemetal againstthefaceoftheboss (6) 23085659 1 STANDARDTORQUEDATAFORHYDRAULICTUBESANDFITTINGS TUBENUTSFOR37°FLAREDFITTINGS O-RINGBOSSPLUGS ADJUSTABLEFITTING LOCKNUTS,SWIVEL SIZETUBINGOD THREAD SIZE TORQUE TORQUE 4 6.4mm ( 1/4in )7/16-20 ( 9-12lbft ) ( 6-10lbft ) 5 ( 5/16in ( 12-15lbft ) ( 10-15lbft ) 6 9.5mm ( 3/8in ( ) ( ) 8 12.7mm ( 1/2in ( 35-40lbft ) ( 25-30lbft ) ( 5/8in ( 53-58lbft ) ( 35-40lbft ) ( 3/4in ( 77-82lbft ) ( 60-70lbft ) 22.2mm ( 7/8in ( ) ( ) 25.4mm ( 1in ( 110-120lbft ) ( 80-90lbft ) ( 1-1/4in ( 140-150lbft ) ( 95-115lbft ) ( ( ) ( ) 50.8mm ( 2in ( ) ( ) Thesetorquesarenotrecommendedfortubesof ( 1/2in )ODandlargerwithwallthicknessof ( 0.035in 0.889mm ( 0.035in Beforeinstallingandtorquing 37° cleanerandapplyhydraulicsealant L OCTITE®569 tothe37° 4754069528/04/2014
PIPETHREADFITTINGTORQUE
FACED)FITTINGS
INTRODUCTION
threadswithacleansolventorLoctitecleanerandapply sealant L OCTITE ®567PSTP IPE S EALANT forallfittings includingstainlesssteelor L OCTITE ®565PSTformost temsuse L OCTITE®545 PIPETHREADFITTING ThreadSize Torque(Maximum) 1/8-27 13N·m ( 10lbft ) 16N·m ( 12lbft ) ( 16lbft ) 41N·m ( 30lbft ) 54N·m ( 40lbft ) INSTALLATIONOFORFS(O-RINGFLAT
WheninstallingORFSfittingsthoroughlycleanbothflat surfacesofthefittings (1) (2) with Torquethefittingtospecifiedtorquelistedthroughoutthe repairmanual. NOTICE: Ifthefittingsurfacesarenotproperlycleaned, NOTICE: Alwaysusegenuinefactoryreplacementoils gineandhydraulicsystemoils. systemcleanwillextendmachineandcomponentlife. 50011183 2 4754069528/04/2014
INTRODUCTION Basicinstructions-Shopandassembly SR220 SR250 SV250 SV300 TR320 TV380 Shimming Foreachadjustmentoperation,selectadjustingshimsandmeasuretheadjustingshimsindividuallyusingamicromRotatingshaftseals 3.Positionthesealinglipfacingthefluid. NOTE: 4.Coatthesealinglipwithathinlayeroflubricant(useoilratherthangrease).Fillthegapbetweenthesealinglip 5.Insertthesealinitsseatandpressdownusingaflatpunchorsealinstallationtool.Donottapthesealwitha O-ringseals LubricatetheO-ringsealsbeforeyouinsertthemintheseats.ThiswillpreventtheO-ringsealsfromoverturningand twisting,whichwouldjeopardizesealingefficiency. Sealingcompounds Applyasealingcompoundonthematingsurfaceswhenspecifiedbytheprocedure.Beforeyouapplythesealing Spareparts Onlygenuinesparepartsguaranteethesamequality,duration,andsafetyasoriginalparts,astheyarethesame • Machinemodel(commercialname)andProductIdentificationNumber(PIN) • 4754069528/04/2014
