New Holland W110 Wheel Loader Service Repair Manual by fengfanfen14

W110 and W130 Wheel Loader Service Manual 6-81160

Table of Contents Description

Section No.

General

Form No.

Tab 1

Section Index - General

6-81180

Standard Torque Specifications

1001

6-80470

Fluids and Lubricants

1002

6-81190

Metric Conversion Chart

1003

6-80690

Engines

Tab 2

Section Index - Engines

6-81200

Engine and Radiator Removal and Installation

2000

Stall Tests

2002

For Engine Repair, See the Engine Service Manual

6-81210 6-81220 6-80940

Fuel System

Tab 3

Section Index - Fuel System

6-81230

For Fuel System Repair, See the Engine Service Manual

6-80940

Electrical

Tab 4

Section Index - Electrical

6-81240

Removal and Installation of Starter and Alternator

4001

6-81250

Electrical Specifications and Troubleshooting

4002

6-81260

Batteries

4003

6-81270

Instrument Cluster and Digital Display

4005

6-81280

CNH America LLC. 245 E NORTH AVENUE CAROL STREAM, IL 60188 U.S.A.

Bur 6-81170

W110 and W130 Wheel Loader Service Manual 6-81160

Table of Contents Description Steering

Section No.

Form No.

Tab 5

Section Index - Steering

6-81290

Removal and Installation of Steering Components

5001

6-81300

Steering Specifications, Pressure Checks, and Troubleshooting

5002

6-81310

Steering Control Valve

5003

6-81320

Auxiliary Steering Priority Valve

5004

6-81330

Steering Cylinders

5005

6-81340

Center Pivot

5006

6-81350

Auxiliary Steering Motor and Pump

5007

6-81360

Power Train

Tab 6

Section Index - Power Train Removal and Installation of Power Train Components

6-81370 6001

6-81380

Transmission Specifications, Pressure Checks, and Troubleshooting

6002

6-81390

Transmission

6003

6-81400

Front Axle

6004

6-81410

Rear Axle

6004

6-81420

Drive Shafts, Center Bearing, and Universal Joints

6005

6-81430

Wheels and Tires

6006

6-81440

Transmission Control Valve

6007

6-81450

Brakes

Tab 7

Section Index - Brakes

6-81460

Removal and Installation of Brake Components

7001

6-81470

Hydraulic Brake Troubleshooting

7002

6-81480

Brake Accumulators

7004

6-81490

Parking Brake

7008

6-81500

Hydraulics

Tab 8

Section Index - Hydraulics

6-81510

Removal and Installation of Hydraulic Components

8001

6-81520

Hydraulic Specifications, Troubleshooting, and Pressure Checks

8002

6-81530

Cleaning the Hydraulic System

8003

6-81540

Loader Control Valve

8005

6-81550

Cylinders

8006

6-81560

Coupler Solenoid Locking Valve

8007

6-81570

Pilot Pressure Accumulator and Ride Control Accumulator

8013

6-81580

Ride Control Valve

8014

6-81590

Bur 6-81170

Issued 3-06

Printed in U.S.A.

W110 and W130 Wheel Loader Service Manual 6-81160

Table of Contents Description

Section No.

Mounted Equipment

Form No.

Tab 9

Section Index - Mounted Equipment

6-81600

Pedal and Levers

9001

6-81610

Air Conditioning Troubleshooting and System Checks For Systems with HFC-134a Refrigerant

9002

6-81620

Air Conditioner System Service

9003

6-81630

Removal and Installation of Air Conditioning and Heater Components

9004

6-81640

Loader

9006

6-81650

ROPS Cab and ROPS Canopy

9007

6-81660

Cab Glass Installation

9010

6-81670

In Rear Pocket

6-81680

Electrical Schematic Foldouts and Hydraulic Schematic Foldouts

NOTE: CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

CNH America LLC. 245 E NORTH AVENUE CAROL STREAM, IL 60188 U.S.A.

Bur 6-81170

SECTION INDEX

GENERAL Section Title

Section Number

Standard Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001 Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002 Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003

CNH America LLC. 245 E NORTH AVENUE CAROL STREAM, IL 60188 U.S.A.

Bur 6-81180

1001 Section 1001 GENERAL TORQUE SPECIFICATIONS

CNH America LLC. 245 E NORTH AVENUE CAROL STREAM, IL 60188 U.S.A.

Bur 6-80470

1001-3

TORQUE SPECIFICATIONS - DECIMAL HARDWARE Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphities, Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 5 Bolts, Nuts, and Studs

Grade 8 Bolts, Nuts, and Studs

PoundInches

Newton metres

1/4 inch

144 to 180

16 to 20

5/16 inch

288 to 348

33 to 39

3/8 inch

540 to 648

61 to 73

Size

PoundInches

Newton metres

Size

PoundFeet

Newton metres

1/4 inch

108 to 132

12 to 15

7/16 inch

70 to 84

95 to 114

5/16 inch

204 to 252

23 to 28

1/2 inch

110 to 132

149 to 179

3/8 inch

420 to 504

48 to 57

9/16 inch

160 to 192

217 to 260

5/8 inch

220 to 264

298 to 358

Newton metres

3/4 inch

380 to 456

515 to 618

Size

PoundFeet

7/8 inch

600 to 720

814 to 976

7/16 inch

54 to 64

73 to 87

1.0 inch

900 to 1080

1220 to 1465

1/2 inch

80 to 96

109 to 130

1-1/8 inch

1280 to 1440

1736 to 1953

9/16 inch

110 to 132

149 to 179

1-1/4 inch

1820 to 2000

2468 to 2712

5/8 inch

150 to 180

203 to 244

1-3/8 inch

2380 to 2720

3227 to 3688

3/4 inch

270 to 324

366 to 439

1-1/2 inch

3160 to 3560

4285 to 4827

7/8 inch

400 to 480

542 to 651

1.0 inch

580 to 696

787 to 944

1-1/8 inch

800 to 880

1085 to 1193

1-1/4 inch

1120 to 1240

1519 to 1681

1-3/8 inch

1460 to 1680

1980 to 2278

1-1/2 inch

1940 to 2200

2631 to 2983

Size

Bur 6-80470

NOTE: Use thick nuts with Grade 8 bolts.

Issued 1-06

Printed in U.S.A.

1001-4

TORQUE SPECIFICATIONS - METRIC HARDWARE Use the following torques when specifications are not given. These values apply to fasteners with coarse threads as received from supplier, plated or unplated, or when lubricated with engine oil. These values do not apply if graphite or Molydisulfide grease or oil is used.

Grade 8.8 Bolts, Nuts, and Studs 8.8

Size

PoundInches

Grade 10.9 Bolts, Nuts, and Studs 10.9

Size

PoundInches

Newton metres

36 to 48

4 to 5

84 to 96

9 to 11

132 to 156

15 to 18

324 to 384

37 to 43

PoundFeet

Newton metres

24 to 36

3 to 4

Size

60 to 72

7 to 8

M10

54 to 64

73 to 87

96 to 108

11 to 12

M12

93 to 112

125 to 150

228 to 276

26 to 31

M14

149 to 179

200 to 245

M10

456 to 540

52 to 61

M16

230 to 280

310 to 380

M20

450 to 540

610 to 730

Newton metres

M24

780 to 940

1050 to 1275

Size

PoundFeet

M30

1470 to 1770

2000 to 2400

M12

66 to 79

90 to 107

M36

2580 to 3090

3500 to 4200

M14

106 to 127

144 to 172

M16

160 to 200

217 to 271

M20

320 to 380

434 to 515

M24

500 to 600

675 to 815

M30

920 to 1100

1250 to 1500

M36

1600 to 1950

2175 to 2600

Bur 6-80470

Grade 12.9 Bolts, Nuts, and Studs 12.9

Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.

Issued 1-06

Printed in U.S.A.

1001-5

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS 37 Degree Flare Fitting

Straight Threads with O-ring

Tube OD Hose ID

Thread Size

PoundInches

Newton metres

Tube OD Hose ID

Thread Size

PoundInches

Newton metres

1/4 inch 6.4 mm

7/16-20

72 to 144

8 to 16

1/4 inch 6.4 mm

7/16-20

144 to 228

16 to 26

5/16 inch 7.9 mm

1/2-20

96 to 192

11 to 22

5/16 inch 7.9 mm

1/2-20

192 to 300

22 to 34

3/8 inch 9.5 mm

9/16-18

120 to 300

14 to 34

3/8 inch 9.5 mm

9/16-18

300 to 480

34 to 54

1/2 inch 12.7 mm

3/4-16

180 to 504

20 to 57

1/2 inch 12.7 mm

3/4-16

540 to 804

57 to 91

5/8 inch 15.9 mm

7/8-14

300 to 696

34 to 79 Tube OD Hose ID

Thread Size

PoundFeet

Newton metres

Tube OD Hose ID

Thread Size

PoundFeet

Newton metres

5/8 inch 15.9 mm

7/8-14

58 to 92

79 to 124

3/4 inch 19.0 mm

1-1/16-12

40 to 80

54 to 108

3/4 inch 19.0 mm

1-1/16-12

80 to 128

108 to 174

7/8 inch 22.2 mm

1-3/16-12

60 to 100

81 to 135

7/8 inch 22.2 mm

1-3/16-12

100 to 160

136 to 216

1.0 inch 25.4 mm

1-5/16-12

75 to 117

102 to 158

1.0 inch 25.4 mm

1-5/16-12

117 to 187

159 to 253

1-1/4 inch 31.8 mm

1-5/8-12

125 to 165

169 to 223

1-1/4 inch 31.8 mm

1-5/8-12

165 to 264

224 to 357

1-1/2 inch 38.1 mm

1-7/8-12

210 to 250

285 to 338

1-1/2 inch 38.1 mm

1-7/8-12

250 to 400

339 to 542

Split Flange Mounting Bolts PoundInches

Newton metres

5/16-18

180 to 240

20 to 27

3/8-16

240 to 300

27 to 34

7/16-14

420 to 540

47 to 61

Size

PoundFeet

Newton metres

1/2-13

55 to 65

74 to 88

5/8-11

140 to 150

190 to 203

Size

Bur 6-80470

Issued 1-06

Printed in U.S.A.

Section 2000

CNH America LLC. 245 E NORTH AVENUE CAROL STREAM, IL 60188 U.S.A.

Bur 6-81210

2000

ENGINE AND RADIATOR REMOVAL AND INSTALLATION

2000-3

ENGINE Removal

STEP 7

STEP 1 Park machine on a level surface and lower bucket to floor. Stop engine. Actuate brake pedal several times to discharge brake accumulators. Move loader control lever back and forth at least 30 times to release any pressure from hydraulic circuit.

STEP 2

BD03J111

Open the engine compartment side panel, attach a lifting eye to the hole in the lower portion of the panel.

STEP 8

BD00M030

Put articulation lock in LOCKED position.

STEP 3 Slowly loosen the filler cap for hydraulic reservoir to release air pressure in hydraulic reservoir.

STEP 4 Put master disconnect switch in OFF position.

BD03J110

STEP 5

Attach lifting straps to the hinge side of the hood, attach suitable lifting equipment to the straps and take up slack in the straps.

Disconnect battery cable from LH battery negative post. Put a plastic cap over the negative post.

STEP 9

STEP 6 Disconnect battery cable from RH battery positive post. Put a plastic cap over the positive post.

BD03J112

Disconnect the gas cylinders from the side panel and hood. Remove hinge pins, remove panel from machine.

Bur 6-81210

Issued 3-06

Printed in U.S.A.

2000-4

STEP 10

STEP 16

Repeat steps 7 through 9 for the other side panel.

STEP 11 Attach lifting straps to the center hood section.

STEP 12 Connect lifting equipment to the lifting straps. Take up all slack in strap connected to hood.

STEP 13

BC03J056

Remove the four rear grill mounting bolts, remove the grill. Remove the six rear grill frame mounting bolts and nuts, remove the frame.

STEP 17

BD03J115

Remove two nuts and bolts and four washers securing the rear of the hood.

STEP 14

BD03J103

Tag and disconnect engine wiring harness connector from air filter restriction switch.

BD03J116

Remove the two front bolts and washers securing the front of the hood.

STEP 15 Carefully raise and remove hood from loader. Lower hood onto suitable platform and disconnect lifting equipment.

Bur 6-81210

Issued 3-06

Printed in U.S.A.

2000-5

STEP 18

STEP 21 2

19 3

1 3

1 12

5 2

8 BC03J132

9 10

Remove four bolts (1) and washers (2) securing drive belt guard (3) to the frame.

1. BOLT 2. WASHER 3. DRIVE BELT GUARD

BS02J036

1. 2. 3. 4. 5. 6.

CLAMP INTAKE HOSE CLAMP HOSE CLAMP HOSE

7. 8. 9. 10. 11. 12.

TUBE HOSE LOCK NUT WASHER BOLT AIR CLEANER

Loosen clamp (1) on air cleaner intake hose (2) and remove intake hose.

STEP 19 Loosen clamps (3 and 5) on crankcase hose (6) and turbocharger intake hose (8). Disconnect hose (6) from breather pipe. Disconnect hose (8) with tube (7) attached from turbocharger.

STEP 20 Support air cleaner assembly (12) and remove two lock nuts (9), bolts (11), four washers (10). Remove air cleaner (12) and associated par ts as an assembly.

Bur 6-81210

Issued 3-06

Printed in U.S.A.

2000-6

STEP 22

STEP 26

5 1

1 6 2

9 4 8

6 3

1 5

4 8 7

BS02J048

BC03J131

1. 2. 3. 4. 5.

CLAMP BOLT WASHER BOLT WASHER

6. 7. 8. 9. 10.

FRONT BRACKET REAR BRACKET MUFFLER CLAMP EXHAUST TUBE ELBOW

Remove clamp (1) securing exhaust tube elbow (10) to muffler (8).

1. 2. 3. 4.

CLAMP TUBE HOSE CLAMP

5. 6. 7. 8.

CLAMP TUBE HOSE CLAMP

Loosen two clamps (1). Remove tube (2) and hose (3) as an assembly.

STEP 27 Loosen two clamps (5). Remove tube (6) and hose (7) as an assembly.

STEP 28 STEP 23 At front of engine, remove two bolts (2) and washers (3) securing muffler front mounting bracket (6).

STEP 24 Suppor t muffler (8) and brackets (6 and 7) and remove two bolts (4) and washers (5) at rear of e n g i n e. R e m ove mu f f l e r a n d b ra cke t s a s a n assembly from engine.

STEP 25 Loosen clamp (9) and remove exhaust tube elbow (10) from turbocharger.

Bur 6-81210

BD03J096

Disconnect grounding strap from left side of engine.

Issued 3-06

Printed in U.S.A.

2000-7

STEP 29

STEP 32 5

BD03J098

Identify, tag, and disconnect engine harness from alternator.

BS02J056

1. ACORN NUT 2. NUT 3. WASHER

4. COVER 5. B+ STUD

STEP 33

Remove acorn nut (1), nut (2), and washer (3) securing cover (4) to starter. Remove cover.

STEP 30 Remove nut and washer securing cables to starter B+ stud (5). Identify, tag, and disconnect both cables.

STEP 31 Identify, tag, and disconnect connector from engine coolant temperature sender. Remove bolt and washer securing cable clamp to engine.

STEP 34

BS02J055

Identify and tag rear chassis harness wire connected to starter solenoid terminal. Disconnect rear chassis harness wire from terminal.

Bur 6-81210

If wheel loader is equipped with air conditioning, identify, tag, and disconnect connector from air conditioner compressor clutch. Identify. tag, and disconnect connector from air conditioning high pressure switch.

STEP 35 Support air conditioning compressor and remove bolts securing compressor. Remove compressor and place on battery cover.

Issued 3-06

Printed in U.S.A.

2000-8

STEP 36

STEP 41

BD03J144

BD03J089

Remove bolts and bracket securing fuel line to rear of engine.

Disconnect injection pump fuel solenoid and oil pressure sending unit.

STEP 37

STEP 42

BD03J145

Remove bolts, nuts and clamps securing wiring harness to rear of engine.

STEP 38 If equipped, identify, tag, and disconnect wire from grid heater.

STEP 39

BD03J090

STEP 43 Connect a vacuum pump to hydraulic reservoir. If a vacuum pump is not available, drain the hydraulic oil (hydraulic reservoir holds 68.5 liters (18 gallons) of oil). Tur n on vacuum pump (if available). Tag, disconnect, and plug hoses connected to brake pump. Plug hoses securely and cap fittings. Turn off vacuum pump.

If equipped, identify, tag, and disconnect connector from fuel filter heater.

STEP 40 If equipped, identify, tag, and disconnect connector from fuel filter temperature switch.

Bur 6-81210

Issued 3-06

Printed in U.S.A.

2000-9

STEP 44

STEP 46

BD03J142

Remove bracket mounting hydraulic brake pump lines and fuel line from bell housing.

STEP 45 BS02J069

Loosen two clamps. Disconnect and remove bottom hose.

STEP 47 1 3 8

6 BD00M031

Put a 37.8 liter (10 gallon) container below radiator drain. Remove cap and drain coolant into container. Install cap after coolant has drained.

5 4

2 4 1

BS02J068

1. 2. 3. 4.

CLAMP BLEED LINE HOSE CLAMP CLAMP

5. 6. 7. 8.

HOSE PIPE TIE STRAP HOSE

Loosen two clamps (1) securing bleed line hose (2). Disconnect bleed line hose (2) from fittings.

Bur 6-81210

Issued 3-06

Printed in U.S.A.

2000-10

STEP 48

STEP 51

Loosen clamps (3 and 4). Disconnect and remove hose (5) from engine and pipe (6). Disconnect and remove pipe (6) with bleed line hose (2) attached from hose (8). If necessary, cut, remove, and discard tie straps (7) to separate bleed line hose (2) from pipe (6).

4 STEP 49

10 3 7 9

2 1

6 5 BS02J070 BD00M031

Put a 18.9 liter (5 gallon) container below engine oil drain . R em ove cap and drain e ng in e o il into container. Install cap after oil has drained.

1. 2. 3. 4. 5.

NUT WASHER BALL JOINT THROTTLE LEVER NUT

6. 7. 8. 9. 10.

WASHER U-BOLT CLAMP THROTTLE CABLE SUPPORT BRACKET

Remove nut (1) and washer (2) securing ball joint (3) to throttle lever (4).

STEP 50

STEP 52 Remove two nuts (5) and washers (6), U-bolt (7), and clamp (8) securing throttle cable (9) to suppor t bracket (10). Position throttle cable away from engine.

STEP 53

BS02J065

Disconnect hose from elbow installed in engine oil pan. Put a plug in hose and a cap on fitting.

4 3 1 2

BS02J072

1. BOLT 2. CLAMP

Bur 6-81210

3. FUEL SUPPLY HOSE 4. FUEL RETURN HOSE

Issued 3-06

Printed in U.S.A.

2000-11 Remove bolt (1) and washer securing clamp (2) holding in-line fuel filter to engine block. Tag and disconnect fuel supply hose (3) from priming pump. Plug hose and cap fitting. Tag and disconnect fuel return hose (4) from fuel injection pump. Plug hose and cap fitting.

STEP 56 3 4 6

STEP 54

9 8

6 7 5 BD01D200

At front of engine, remove six bolts securing drive shaft to engine coupling. Use a pry bar to move drive shaft away from engine coupling.

STEP 55 Connect lifting equipment to engine lifting brackets. Take up all slack in lifting equipment.

BS02J073

1. 2. 3. 4. 5.

NUT WASHER BOLT WASHER WASHER

6. 7. 8. 9.

ENGINE MOUNT BOLT WASHER MOUNTING BRACKET

Remove nut (1), washer (2), bolt (3), and washer (4) securing engine and mounting brackets to chassis.

STEP 57 Slowly raise engine from rear chassis. Check and be sure all harness connections, hoses, and throttle cable have been disconnected and are positioned out of the way. Remove engine from machine.

Bur 6-81210

Issued 3-06

Printed in U.S.A.

2000-12

Installation

STEP 61

STEP 58

Disconnect lifting equipment from engine lifting brackets.

STEP 62

3 4 6

140

141

9 8

6 7

BD01D200

At front of engine, position drive shaft on engine coupling. Put Loctite 242 on threads of six bolts. Install six bolts and tighten to a torque of 53 to 62 Nm (39 to 46 pound-feet).

STEP 63

BS02J073

1. 2. 3. 4. 5.

NUT WASHER BOLT WASHER WASHER

6. 7. 8. 9.

ENGINE MOUNT BOLT WASHER MOUNTING BRACKET

If engine mounting brackets (9) were removed, position bracket on engine and secure using bolts (7) and washers (8). Torque bolts to 118 to 130 Nm (87 to 98 pound-feet). If necessary, install new engine mount (6) in mounting bracket. Repeat this step to install remaining engine mounting brackets and engine mounts as necessary.

STEP 59 Connect suitable lifting equipment to engine lifting brackets. Slowly raise engine and move into position over rear chassis. Be sure all harness connections and hoses are out of the way then lower engine. Put washer (5) between front engine mount (6) and chassis. Install washers (4 and 5), bolt (3), washer (2), and nut (1) in engine front mounts. Lower engine into position.

BD03J142

Install bracket mounting hydraulic brake pump lines and fuel line to bell housing.

STEP 64 Tur n on vacuum pump connected to hydraulic reservoir. Remove caps from brake pump fittings and plugs from brake pump hoses. Connect hoses to brake pump following tags installed during removal. Remove and discard tags. Turn off and disconnect vacuum pump from hydraulic reservoir.

STEP 60 Torque bolts (3) to a torque of 244 to 298 Nm (180 to 220 pound-feet).

Bur 6-81210

Issued 3-06

Printed in U.S.A.

2000-13

STEP 65

STEP 67 Install ball joint (3) on throttle lever (4) and secure using washer (2) and nut (1).

STEP 68 4 3 1 2

BS02J072

1. BOLT 2. CLAMP

3. FUEL SUPPLY HOSE 4. FUEL RETURN HOSE

BS02J065

Remove plug from fuel return hose (4) and cap from fuel injection pump fitting. Connect fuel return hose to fuel injection pump. Remove plug from fuel supply hose (3) and cap from priming pump fitting. Connect fuel supply hose to priming pump. Position clamp (2) holding in-line fuel filter and secure to engine block using washer and bolt (1).

Remove plug from oil drain hose and cap from fitting installed in engine oil pan. Connect hose to fitting and tighten.

STEP 66

4 10 3 7 9

2 1

6 5 BS02J070

1. 2. 3. 4. 5.

NUT WASHER BALL JOINT THROTTLE LEVER NUT

6. 7. 8. 9. 10.

WASHER U-BOLT CLAMP THROTTLE CABLE SUPPORT BRACKET

Route throttle cable (9) up and over towards fuel injection pump. Put clamp (8), throttle cable (9), and U-bolt (7) on support bracket (10) and secure using two washers (6) and nuts (5). Bur 6-81210

Issued 3-06

Printed in U.S.A.

Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING

NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.

2000-14

STEP 69

STEP 71 1 3 8

105 7

7 106

105

4 1

BS02J069

BS02J068

1. 2. 3. 4.

CLAMP BLEED LINE HOSE CLAMP CLAMP

5. 6. 7. 8.

HOSE PIPE TIE STRAP HOSE

Put clamp (3) on hose (8). Connect pipe (6) to hose (8). Position clamp (3) and tighten to a torque of 10.1 to 11.3 Nm (90 to 100 lb-inch). Put clamps (4) on hose (5). Connect hose (5) to pipe (6) and engine coolant outlet. Position clamps (4) and tighten to a torque of 10.1 to 11.3 Nm (90 to 100 lb-inch).

STEP 70 Put hose clamps (1) on bleed line hose (2) and connect hose to fittings. Position clamps (1) and tighten to a torque of 10.1 to 11.3 Nm (90 to 100 lb-inch). Install three tie straps (7) to secure bleed line hose (2) to pipe (6).

Bur 6-81210

Put clamps on hose. Connect hose between bottom pipe and engine coolant inlet. Position clamps and tighten to a torque of 10.1 to 11.3 Nm (90 to 100 lb-inch).

STEP 72 If equipped, position and support air conditioning compressor on mounting bracket. Secure using bolts washers.

STEP 73 If wheel loader is equipped with air conditioning, connect connector to air conditioning compressor clutch following tag installed during removal. Connect connector to air conditioning high pressure switch following tag installed during removal. Remove and discard tags.

STEP 74 Install drive belt, take up slack in drive belt and tighten bolts.

Issued 3-06

Printed in U.S.A.

2000-15

STEP 75

STEP 81

BD03J089

Connect injection pump fuel solenoid and oil pressure sending unit.

Connect wires to alternator.

STEP 76

STEP 82

BD03J098

If equipped, connect connector to fuel filter temperature switch following tag installed during removal. Remove and discard tag.

STEP 77 If equipped, connect connector to fuel filter heater following tag installed during removal. Remove and discard tag.

STEP 78 If equipped, connect wire to grid heater following tag installed during removal. Remove and discard tag.

STEP 79 Connect connector to engine coolant temperature sender following tag installed during removal. Remove and discard tag.

BS02J055

Connect harness wire to starter solenoid terminal following tag installed during removal. Remove and discard tag.

STEP 80

BD03J145

Position clamp holding engine harness on flywheel housing cover.

Bur 6-81210

Issued 3-06

Printed in U.S.A.

2000-16

STEP 83

STEP 86 5 5 1 4

2 4 3 2

BS02J056

1. ACORN NUT 2. NUT 3. WASHER

6 3

4. COVER 5. B+ STUD

Connect cables to starter B+ stud (5) following tags installed during removal. Install nut and washer to secure cables. Remove and discard tags from cables.

STEP 84 Put cover (4) on starter. Install washer (3), nut (2), and acorn nut (1) to secure cover (4).

STEP 85

8 7 BS02J048

1. 2. 3. 4.

CLAMP TUBE HOSE CLAMP

5. 6. 7. 8.

CLAMP TUBE HOSE CLAMP

Install tube (6) and hose (7) as an assembly. Tighten two clamps (5) to a torque of 10.1 to 11.3 Nm (90 to 100 lbs-inch).

STEP 87 Install tube (2) and hose (3) as an assembly. Tighten two clamps (1) to a torque of 10.1 to 11.3 Nm (90 to 100 lbs-inch).

BD03J096

Connect grounding strap from left side of engine.

Bur 6-81210

Issued 3-06

Printed in U.S.A.

2000-17

STEP 88

STEP 90

10 1

At front of engine, install two washers (3) and bolts (2) to secure muffler front mounting bracket (6). Tighten bolts (2) to a torque of 118 to 133 Nm (87 to 98 pound-feet). Tighten bolts (4) to a torque of 68 to 77 Nm (50 to 56 pound-feet).

STEP 91

Install clamp (1). Tighten clamp (1) to a torque of 20 to 25 Nm (15 to 18 pound-feet). Tighten clamp (9) to a torque of 4.8 to 5.2 Nm (42.5 to 46 pound-feet).

STEP 92 8

1 3

4 5 2

BC03J131

1. 2. 3. 4. 5.

CLAMP BOLT WASHER BOLT WASHER

6. 7. 8. 9. 10.

FRONT BRACKET REAR BRACKET MUFFLER CLAMP EXHAUST TUBE ELBOW

Put clamp (9) on exhaust tube elbow (10). Install exhaust tube elbow and clamp on turbocharger. Do not tighten clamp at this time.

BC03J132

1. BOLT 2. WASHER 3. DRIVE BELT GUARD

Position drive belt guard (3) and secure using four washers (2) and bolts (1) to the frame.

STEP 89 Install and support muffler (8) and brackets (6 and 7) on engine while connecting muffler to exhaust tube elbow (10). Install two washers (5) and bolts (4) finger tight.

Bur 6-81210

Issued 3-06

Printed in U.S.A.

2000-18

STEP 93

STEP 97 1

Remove plastic cap installed over the negative post during removal. Connect battery cable to LH battery negative post.

4 3

STEP 98

1 12

8 BD03J103

9 10

Connect engine wiring harness connector to air filter restriction switch following tag installed during removal. Remove and discard tag.

STEP 99 10

BS02J036

1. 2. 3. 4. 5. 6.

CLAMP INTAKE HOSE CLAMP HOSE CLAMP HOSE

7. 8. 9. 10. 11. 12.

TUBE HOSE LOCK NUT WASHER BOLT AIR CLEANER

Position air cleaner assembly (12) and support as an assembly. Secure using two washers (10), bolts (11) and lock nuts (9).

STEP 94 Connect turbocharger intake hose (8) attached to tube (7) to turbocharger and crankcase hose (6) to breather pipe. Position clamps (3 and 5) and tighten. Tighten clamps (3) to a torque of 10.1 to 11.3 Nm (90 to 100 lb-inch).

BC03J056

Install the frame and secure with six mounting bolts and nuts. Install the grill and secure with four mounting bolts.

STEP 100 Carefully raise and position hood onto loader.

STEP 95 Connect air cleaner intake hose (2) between cooling frame and air cleaner inlet. Position clamp (1) and tighten to a torque of 3.6 to 4.5 Nm (32.4 to 39.6 lb-inch).

STEP 96 Remove plastic cap installed over the positive post during removal. Connect battery cable to RH battery positive post. Bur 6-81210

Issued 3-06

Printed in U.S.A.

2000-19

STEP 101

STEP 106

BD03J116

Install the two front bolts and washers securing the front of the hood.

BD00M031

Check and make sure that drain caps are tight.

STEP 107

STEP 102

Install a new oil filter on engine. Fill engine with 10.5 liters (11 quarts) of New Holland AMBRA engine oil (SAE 15W-40).

STEP 108 If hydraulic reservoir was drained, fill reservoir with 68.5 liters (18 gallons) of New Holland AMBRA Hydrosystem 46 fluid.

STEP 109

BD03J115

Install two nuts and bolts and four washers securing the rear of the hood.

Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 34.1 liters (9 gallons). Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir.

STEP 110

STEP 103 Place engine compartment side panel into position.

Put master disconnect switch in ON position. WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: Let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap.

STEP 104

STEP 111 Start engine and run the engine at low idle. Run the engine at operating temperature for approximately five minutes to completely mix the Ethylene Glycol an d wat er. Wh en the coo lan t is at o pe ra tin g temperature, stop the engine. When engine has cooled, check the coolant level at the reservoir. BD03J112

Install hinge pins, connect the gas cylinders to the side panel and hood.

STEP 105

STEP 112 Lower and close hood side panels.

STEP 113 Put articulation lock in OPERATING position.

Repeat steps 103 and 104 for the other side panel. Bur 6-81210

Issued 3-06

Printed in U.S.A.