New Holland LS180.B Skid Steer Loader Service Repair Manual

Page 1

Workshop Manual

PROVEN PERFORMANC E LS180.B LS185.B LS190.B

LS180.B

LS185.B

LS190.B

REPAIRMANUAL
13/24/2006
Contents INTRODUCTION DISTRIBUTIONSYSTEMSA PRIMARYHYDRAULICPOWERSYSTEM A.10.A SECONDARYHYDRAULICPOWERSYSTEMA.12.A HIGH-FLOWHYDRAULICPOWERSYSTEM A.16.A ELECTRICALPOWERSYSTEMA.30.A LIGHTINGSYSTEM A.40.A POWERPRODUCTIONB ENGINE B.10.A FUELANDINJECTIONSYSTEMB.20.A AIRINTAKESYSTEMB.30.A ENGINECOOLANTSYSTEMB.50.A LUBRICATIONSYSTEMB.60.A STARTINGSYSTEMB.80.A POWERTRAIN C POWERCOUPLINGFixedcouplingC.10.B TRANSMISSIONHydrostaticC.20.F TRAVELLINGD FRONTAXLE D.10.A REARAXLE D.12.A STEERINGSteeringclutch D.20.F PARKINGBRAKEHydraulicD.32.C WHEELSANDTRACKSWheelsD.50.C Finaldrive D.15.A BODYANDSTRUCTUREE USERCONTROLSANDSEATE.32.A USERPLATFORME.34.A ENVIRONMENTCONTROL HeatingsystemE.40.B 13/24/2006
ENVIRONMENTCONTROLAir-conditioningsystem E.40.C SAFETYSECURITYACCESSORIESSafetyE.50.B WORKINGARMH BOOMLift H.20.B SINGLEARMLiftH.40.B SINGLEARMTOOLATTACHMENTTiltH.50.C TOOLSANDCOUPLERS J CARRYINGUnarticulatedtoolsJ.50.B COUPLINGHydrauliccouplingJ.80.C COUPLINGMechanicalcouplingJ.80.B 13/24/2006
INTRODUCTION 604_13_552_0113/24/2006 1
Contents INTRODUCTION Basicinstructions(-A.90.A.05)3 Torque(-A.90.A.10) 7 Conversionfactors(-A.92.A.21)11 604_13_552_0113/24/2006 2

Basicinstructions(-A.90.A.05)

TechnicalInformation

Thismanualhasbeenproducedbyanewtechnicalinformationsystem.Thisnewsystemisdesignedtodeliver technicalinformationelectronicallythroughCDROMandinpapermanuals.AcodingsystemcalledICEhasbeen developedtolinkthetechnicalinformationtootherProductSupportfunctionse.g.Warranty.

Technicalinformationiswrittentosupportthemaintenanceandserviceofthefunctionsorsystemsonacustomers machine.Whenacustomerhasaconcernonhismachineitisusuallybecauseafunctionorsystemonhismachine isnotworkingatall,isnotworkingefficiently,orisnotrespondingcorrectlytohiscommands.Whenyourefertothe technicalinformationinthismanualtoresolvethatcustomersconcern,youwill findalltheinformationclassifiedusing thenewICEcoding,accordingtothefunctionsorsystemsonthatmachine.Onceyouhavelocatedthetechnical informationforthatfunctionorsystemthenyouwill findallthemechanical,electricalorhydraulicdevices,components,assembliesandsub-assembliesforthatfunctionorsystem.Youwillalso findallthetypesofinformationthat havebeenwrittenforthatfunctionorsystem,thetechnicaldata(specifications),thefunctionaldata(howitworks), thediagnosticdata(faultcodesandtroubleshooting)andtheservicedata(remove,installadjust,etc.).

ByintegratingthisnewICEcodingintotechnicalinformation,youwillbeabletosearchandretrievejusttheright pieceoftechnicalinformationyouneedtoresolvethatcustomersconcernonhismachine.Thisismadepossibleby attaching3categoriestoeachpieceoftechnicalinformationduringtheauthoringprocess.

The firstcategoryistheLocation,thesecondcategoryistheInformationTypeandthethirdcategoryistheProduct:

LOCATION-isthecomponentorfunctiononthemachine,thatthepieceoftechnicalinformationisgoingtodescribe e.g.Fueltank.

INFORMATIONTYPE-isthepieceoftechnicalinformationthathasbeenwrittenforaparticularcomponentorfunctiononthemachinee.g.CapacitywouldbeatypeofTechnicalDatathatwoulddescribetheamountoffuelheldby theFueltank.

PRODUCT-isthemodelthatthepieceoftechnicalinformationiswrittenfor.

Everypieceoftechnicalinformationwillhavethose3categoriesattachedtoit.Youwillbeabletouseanycombination ofthosecategoriesto findtherightpieceoftechnicalinformationyouneedtoresolvethatcustomersconcernonhis machine.

Thatinformationcouldbe:

thedescriptionofhowtoremovethecylinderhead

atableofspecificationsforahydraulicpump

afaultcode

atroubleshootingtable

aspecialtool

HowtoUsethisManual

ThismanualisdividedintoSections.EachSectionisthendividedintoChapters.Contentspagesareincludedatthe beginningofthemanual,theninsideeverySectionandinsideeveryChapter.AnalphabeticalIndexisincludedatthe endofaChapter.PagenumberreferencesareincludedforeverypieceoftechnicalinformationlistedintheChapter ContentsorChapterIndex.

EachChapterisdividedintofourInformationtypes:

(D) TechnicalData(specifications)forallthemechanical,electricalorhydraulicdevices,componentsand,assemblies.

(C) FunctionalData(howitworks)forallthemechanical,electricalorhydraulicdevices,componentsandassemblies.

604_13_552_0113/24/2006

INTRODUCTION
3

(G) DiagnosticData(faultcodes,electricalandhydraulictroubleshooting)forallthemechanical,electricalorhydraulic devices,componentsandassemblies.

(F) Servicedata(removedisassembly,assemble,install)forallthemechanical,electricalorhydraulicdevices,componentsandassemblies.

Sections

Sectionsaregroupedaccordingtothemainfunctionsorasystemsonthemachine.EachSectionisidentifiedby aletterA,B,Cetc.TheamountofSectionsincludedinthemanualwilldependonthetypeandfunctionofthe machinethatthemanualiswrittenfor.EachSectionhasaContentspagelistedinalphabetic/numericorder.This tableillustrateswhichSectionscouldbeincludedinamanualforaparticularproduct.

SECTION A-DistributionSystems

B-PowerProduction

C-PowerTrain

D-Travelling

E-BodyandStructure

F-FramePositioning

G-ToolPositioning

H-WorkingArm

J-ToolsandCouplers

K-CropProcessing

L-FieldProcessing

Chapters

EachChapterisidentifiedbyaletterandnumbercombinatione.g.EngineB.10.AThe firstletterisidenticaltothe Sectionletteri.e.ChapterB.10isinsideSectionB,PowerProduction.

CONTENTS

TheChapterContentslistsallthe (D) technicaldata(specifications), (C) functionaldata(howitworks), (F) service data(remove,installadjust,etc..)and (G) diagnosticdata(faultcodesandtroubleshooting)thathavebeenwrittenin thatChapterforthatfunctionorsystemonthemachine.

INTRODUCTION
PRODUCT TractorsXXXXXXXX Vehicleswithworkingarms:backhoes, excavators,skidsteers,..... XXXXXXXXX Combines,forageharvesters,balers,.... XXXXXXXXXX Seeding,planting, floating,spraying equipment,.... XXXXXXXXX Mountedequipmentandtools,.....XXXX
Contents POWERPRODUCTION ENGINE_10.A TECHNICALDATA ENGINE-Generalspecification(B.10.A-D.40.A.10) 3 FUNCTIONALDATA ENGINE-Dynamicdescription(B.10.A-C.30.A.10) 4 SERVICE ENGINE-Remove(B.10.A-F.10.A.10) 5 DIAGNOSTIC ENGINE-Troubleshooting(B.10.A-G.40.A.10) 6 INDEX 604_13_552_0113/24/2006 4

REPAIRMANUAL DISTRIBUTIONSYSTEMS

LS180.B

LS185.B

LS190.B

13/24/2006 A
Contents
PRIMARYHYDRAULICPOWERSYSTEM LS180.B,LS185.B,LS190.B A.10.A SECONDARYHYDRAULICPOWERSYSTEM LS180.B,LS185.B,LS190.B A.12.A HIGH-FLOWHYDRAULICPOWERSYSTEM LS180.B,LS185.B,LS190.B A.16.A ELECTRICALPOWERSYSTEM LS180.B,LS185.B,LS190.B A.30.A LIGHTINGSYSTEM LS180.B,LS185.B,LS190.B A.40.A 13/24/2006 A
DISTRIBUTIONSYSTEMS-A

DISTRIBUTION SYSTEMS-A

PRIMARYHYDRAULICPOWERSYSTEM-10.A
13/24/2006 A.10.A/1
LS180.B LS185.B LS190.B

DISTRIBUTIONSYSTEMS-A

Contents
PRIMARYHYDRAULICPOWERSYSTEM-10.A TECHNICALDATA PRIMARYHYDRAULICPOWERSYSTEM Capacity(A.10.A-D.40.A.20) 4 Specialtools(A.10.A-D.20.A.40) 4 Generalspecification(A.10.A-D.40.A.10) 5 Reliefvalve Generalspecification(A.10.A.16-D.40.A.10) 6 Hydraulicpump Generalspecification(A.10.A.20-D.40.A.10) 7 Oil filterby-pass Generalspecification(A.10.A.25-D.40.A.10) 8 FUNCTIONALDATA PRIMARYHYDRAULICPOWERSYSTEM Identification(A.10.A-C.40.C.01) 9 Hydraulicschematicframe01(A.10.A-C.20.H.01) 10 Hydraulicschematicframe02(A.10.A-C.20.H.02) 11 Hydraulicschematicframe03(A.10.A-C.20.H.03) 13 Hydraulicschematicframe04(A.10.A-C.20.H.04) 15 Hydraulicschematicframe05(A.10.A-C.20.H.05) 17 Hydraulicschematicframe06(A.10.A-C.20.H.06) 18 Hydraulicpump Sectionalview(A.10.A.20-C.10.A.30) 19 SERVICE PRIMARYHYDRAULICPOWERSYSTEM Cleaning(A.10.A-F.30.A.10) 20 Decontaminating(A.10.A-F.30.A.60) 24 Reliefvalve Flowtest(A.10.A.16-F.40.A.45) 26 Pressuretest(A.10.A.16-F.40.A.30) 28 Hydraulicpump Flowtest(A.10.A.20-F.40.A.45) 29 Disassemble(A.10.A.20-F.10.A.25) 31 Visualinspection(A.10.A.20-F.40.A.10) 36 Assemble(A.10.A.20-F.10.A.20) 38 Remove(A.10.A.20-F.10.A.10) 43 13/24/2006 A.10.A/2
Install(A.10.A.20-F.10.A.15) 45 Chargepump Pressuretest(A.10.A.21-F.40.A.30) 47 Reservoir Applyvacuum(A.10.A.22-F.35.A.50) 51 Filling(A.10.A.22-F.60.A.10) 52 Remove(A.10.A.22-F.10.A.10) 53 Install(A.10.A.22-F.10.A.15) 56 Visualinspection(A.10.A.22-F.40.A.10) 58 Oil filter Remove(A.10.A.24 -F.10.A.10) 59 Install(A.10.A.24-F.10.A.15) 60 Oilcooler Remove(A.10.A.32-F.10.A.10) 61 Install(A.10.A.32-F.10.A.15) 62 DIAGNOSTIC Sensingsystem Temperaturesensor-Testing(A.10.A.95.90-G.40.A.20) 63 Filterrestrictionsensor-Testing(A.10.A.95.94-G.40.A.20) 63 13/24/2006 A.10.A/3

DISTRIBUTIONSYSTEMS-PRIMARYHYDRAULICPOWERSYSTEM

Hydraulicpump-Disassemble(A.10.A.20-F.10.A.25)

1.Drawalignmentmarksonthehousingwithawhite marker.Thesemarkswillbereferencedduringassembly.
1
GD98J801 2.Loosenandremovethesocketboltsandwashers.
2
GD98J802 3.Removethecover.
3 13/24/2006 A.10.A/31
GD98J803

DISTRIBUTIONSYSTEMS-PRIMARYHYDRAULICPOWERSYSTEM

4.Removethegearplate.

5.Removethedowelpins.

6.Rotatethegearteethuntilonegeartoothiscenteredinsidetwogearteeth.Drawamarkwithawhite marker.Thismarkwillbereferencedduringassembly.

GD98J804 4 GD98J805_2 5
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GD98J806 6

DISTRIBUTIONSYSTEMS-PRIMARYHYDRAULICPOWERSYSTEM

7.Removethedriveshaft. GD98J807 7 8.Removetheidlershaft. GD98J808
8
9.Removethewearplatefromthecover.
9 13/24/2006 A.10.A/33
GD98J809

DISTRIBUTIONSYSTEMS-PRIMARYHYDRAULICPOWERSYSTEM

10.Removethewearplatefromthebody.

11.Removeanddiscardthesealringfromthecover.

12.Removeanddiscardthesealringfromthebody.

10
GD98J810
11
GD98J811_2
12 13/24/2006 A.10.A/34
GD98J812_2

DISTRIBUTIONSYSTEMS-PRIMARYHYDRAULICPOWERSYSTEM

13.Removeanddiscardthetopsealfromthebody.

14.Removeanddiscardthebottomsealfromthebody.

13
GD98J813
14 13/24/2006 A.10.A/35
GD98J814

DISTRIBUTIONSYSTEMS-PRIMARYHYDRAULICPOWERSYSTEM

Hydraulicpump-Visualinspection(A.10.A.20-F.40.A.10)

1.Inspectthebrasssurfacesofthewearplatesfor wear.Replaceasrequired. GD98J815 1 2.Inspectthedriveandidlershaftsforwearordamage. Replaceasrequired. GD98J816 2 3.Inspectthebearingsleevesofthedriveandidler shaftsinthebodyandcoverforwearordamage. Replaceasrequired.
13/24/2006 A.10.A/36
GD98J817_2
3

DISTRIBUTIONSYSTEMS-PRIMARYHYDRAULICPOWERSYSTEM

4.Inspectthebodyandcoversurfacesforwearordamage.Replaceasrequired.

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GD98J818_2 4

DISTRIBUTIONSYSTEMS-PRIMARYHYDRAULICPOWERSYSTEM

Hydraulicpump-Assemble(A.10.A.20-F.10.A.20)

1.Lubricatethebottomsealwithcleanhydraulicoiland insertthebottomsealintothegrooveofthebody.

2.Lubricatethetopsealwithcleanhydraulicoiland insertthetopsealintothegrooveofthebody.

NOTE: Thetopsealwillbeplacedontopofthebottom seal.

3.Lubricatethenewsealringwithcleanhydraulicoil andinsertthenewsealringintothegrooveofthe body.

GD98J814
1
GD98J813 2
3 13/24/2006 A.10.A/38
GD98J812_2

DISTRIBUTIONSYSTEMS-PRIMARYHYDRAULICPOWERSYSTEM

4.Lubricatethenewsealringwithcleanhydraulicoil andinsertthenewsealringintothegrooveofthe cover. GD98J811_2 4 5.Placethewearplateontopofthenewsealsonthe body. GD98J810 5 6.Placethewearplateontopofthenewsealonthe cover.
6 13/24/2006 A.10.A/39
GD98J809

DISTRIBUTIONSYSTEMS-PRIMARYHYDRAULICPOWERSYSTEM

7.Inserttheidlershaftthroughthewearplate,andinto thehousing.

8.Insertthedriveshaftthroughthewearplate,andinto thehousing.

9.Duringthegearpumpdisassembly,thegearteeth werealignedandthenmarked.Pleasereferto Hydraulicpump-Disassemble(A.10.A.20F.10.A.25).Ensurethatthemeshedteethmarks, onthedriveshaftandtheidlershaft,areproperly aligned.

13/24/2006

A.10.A/40

GD98J808 7 GD98J807 8 GD98J806 9

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DISTRIBUTIONSYSTEMS-PRIMARYHYDRAULICPOWERSYSTEM

10.Inserttheguidedowelsintothehousing.

11.Alignandslidethegearplatedowntheshaftsand guidedowels untilitissnugagainstthebody.

12.Duringthegearpumpdisassembly,alignmentmarks wereplacedonthehousingforthebodyandcover. Pleasereferto Hydraulicpump-Disassemble (A.10.A.20-F.10.A.25).Alignandplacethecover ontopofthebody

10
GD98J805_2
11
GD98J804
12
GD98J803
13/24/2006 A.10.A/41

DISTRIBUTIONSYSTEMS-PRIMARYHYDRAULICPOWERSYSTEM

13.Securethecoverontopofthebodywithwashers andsocketbolts.Tightenthesocketboltsinacross patternsequencetoatorqueof 34Nm (300lbin) Donotovertightenthesocketbolts.

GD98J802 13 13/24/2006 A.10.A/42

DISTRIBUTIONSYSTEMS-PRIMARYHYDRAULICPOWERSYSTEM

Hydraulicpump-Remove(A.10.A.20-F.10.A.10)

1.Raisetheoperatorsseatandlockintheupposition. Loosenandremovethemountingboltsandwashers forthecoverplate.Removethecoverplatetogain accesstothehydraulicpump.

3.Removethecapfromthehydraulicreservoir.

4.Connectavacuumpumptothehydraulicreservoir. CAS10192

5. Reservoir-Applyvacuum(A.10.A.22-F.35.A.50) Startthevacuumpump.

6.Taganddisconnectthehosefromthe fittingatthe suctionport (2) ofthegearpump.

7.Installapluginthehoseandacaponthe fitting.

8.Taganddisconnectthehosefromthe fittingatthe pressureport (3) ofthegearpump.Ifmachineis equippedwithHigh-Flow,taganddisconnectthe High-Flowpressurehoseatthe fittingonthepump.

13/24/2006 A.10.A/43

1
bd04h165 2.Placeashop towelunderthegearpump (1)
2
bd05f004_1 bd05f004_2
3

DISTRIBUTIONSYSTEMS-PRIMARYHYDRAULICPOWERSYSTEM

9.Installaplug(s)inthehose(s)andacap(s)onthe fitting(s).

10.Stopthevacuumpump.

11.Loosenandremovethepumpmountingboltsand washers (4)

12.Removethe gearpumpfromthehydrostaticpump mountinglocation.

4
bd05f004_3
13/24/2006 A.10.A/44

Hydraulicpump-Install(A.10.A.20-F.10.A.15)

Prioroperation:

Beforepumpinstallation,applyMolykoteG-4700(P/N86983138)tothepumpandthecouplingsplines.Pre-fillthe pumpwithcleanhydraulicoil.InspectO-ringonthepumppilotandreplaceifnecessary.LubricatetheO-ringwith cleanhydraulicoil.

1.Holdthepumpinthemountinglocation.Rotate thegearpumpshaftuntilitalignswiththecoupling splinesattherearofthehydrostaticpump.Afterthe splinesarealigned,movethepumpinwarduntilthe mounting flangeis flushwiththemountingsurface ofthehydrostaticpump.

2.ApplyLoctite243tothepumpmountingbolts (4). Installwashersontheboltsandinstallthebolts (4) intothepumpmounting flange.Tightenthemounting bolts (4).

3. Reservoir-Applyvacuum(A.10.A.22-F.35.A.50) Startthevacuumpump.

4.Removethecapfromthe fittingandtheplugfrom thepressurehose.Ifthemachineisequippedwith High-Flowremovethecapfromthe fittingandthe plugfromtheHigh-Flowhose.

5.Connectthehosetothepressureport fitting (3) and High-Flowport fitting(ifequipped)ofthepumpand tightenthe fitting(s).

6.Removethecapfromthe fittingandtheplugfromthe suctionhose

7.Connectthehosetothesuctionport fitting (2) ofthe pumpandtightenthehoseclamp.

8.Stopthevacuumpump.Disconnectthevacuum pumpfromthehydraulicreservoirandinstallthe reservoircaponthereservoir fillerneck.

13/24/2006

A.10.A/45

DISTRIBUTIONSYSTEMS-PRIMARYHYDRAULICPOWERSYSTEM
bd05f004_3 1
2
bd05f004_2

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