New Holland LS140 Operating instructions

LS140
LS150
87036977 1/04

87042551 1/04
© 2004 CNH America LLC
Printed In U.S.A.
LS140, LS150 REPAIR MANUAL
COMPLETE CONTENTS
SECTION 00 - GENERAL INFORMATION 2.............................
SECTION 10 - ENGINE 3..............................................
SECTION 29 - HYDROSTATIC TRANSMISSION 7........................
SECTION 33 - BRAKES AND CONTROLS 9.............................
SECTION 35 - HYDRAULIC SYSTEM 9..................................
SECTION 37 - TOWING HOOKS AND BALLASTING 11....................
SECTION 39 - FRAMES 12..............................................
SECTION 44 - AXLES AND WHEELS 12.................................
SECTION 50 - CAB CLIMATE CONTROL 13..............................
SECTION 55 - ELECTRICAL SYSTEM 13.................................
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 19.......
SECTION 88 - ACCESSORIES 20........................................
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 20.........
The following pages are the collation of the contents pages from each section and
chapter of the LS140, LS150 Repair manual. Complete Repair part # 87036977.
The sections used through out all New Holland product Repair manuals may not be
used for each product. Each Repair manual will be made up of one or several books.
Each book will be labeled as to which sections are in the overall Repair manual and
which sections are in each book.
The sections listed above are the sections utilized for the LS140, LS150 Skid Steer.
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Please cut where indicated and insert the label into the plastic pocket on the spine of
the binder.
87036977
SKID-STEER
REPAIR
LS140, LS150
Vol. 1
87036977
SKID-STEER
REPAIR
LS140, LS150
Vol. 1
87036995
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2
SECTION 00 -- GENERAL INFORMATION
BOOK 1 - 87042550
CONTENTS
Section Description Page
Introduction 2...................................................................
About Improvements 2............................................................
Company Policy 3...............................................................
Parts and Accessories 3..........................................................
Model Codes 3..................................................................
Precautionary Statements 4.......................................................
Safety Precaution Information 5....................................................
General Safety Information 7......................................................
Machine Model and Serial Number Location 9.......................................
Engine Model and Serial Number Location 9.........................................
Hardware Torque Specifications 10................................................
Installation of Adjustable Fittings in Straight Thread O Ring Bosses 12..................
Standard Torque Data for Hydraulic Tubes and Fittings 12............................
Pipe Thread Fitting Torque 13....................................................
Lubricants and Coolants 13......................................................
Sealants 13....................................................................
Properly Support a Raised Machine 14.............................................
Properly Support Boom on Boom Lock Pins 14......................................
Raising Boom Without Hydraulic Oil Flow 14........................................
Raising Boom Without Battery Voltage (12V) 15.....................................
Reattaching Cylinders After Repair with Boom Resting on Boom Lock Pins 17...........
Major Unit Overhaul 18..........................................................
Cab and Boom Tilt Procedure 19..................................................
Craning the Skid Steer 26........................................................
Special Tools 29................................................................
Specifications 30................................................................
Dimensions 33.................................................................
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3
SECTION 10 -- ENGINE
BOOK 1 - 87042550
Chapter 1 -- LS140-N843 (Before Engine S/N 93206)
LS150-N843H (Before Engine S/N 91509)
CONTENTS
Section Description Page
10 000 General Engine Information 3......................................................
General Description 3............................................................
Engine Component Descriptions 3.................................................
Engine Model and Serial Number Location 5.........................................
Safety Precautions 6.............................................................
General Engine Specifications 7...................................................
Troubleshooting 9................................................................
Specifications - Service Standards 12..............................................
Torque Specifications 17.........................................................
Engine Components Electrical Diagram 18.........................................
10 001 10 Engine Removal 19.............................................................
Engine Disassembly Sequence 25................................................
Engine Component Maintenance 33...............................................
10 101 55 Valve Seat 36..................................................................
10 101 56 Cylinder Block 39...............................................................
10 105 22 Piston and Piston Rings 40.......................................................
Connecting Rod 44..............................................................
10 103 10 Bearing Holder 48...............................................................
Front Crankshaft Bearing (Bushing) 50.............................................
10 103 30 Crankshaft 52..................................................................
10 103 76 Flywheel and Ring Gear 54.......................................................
10 106 40 Camshaft Assembly 55..........................................................
10 106 66 Camshaft Gear and Bearing Assembly 55..........................................
Timing Gear 56.................................................................
10 304 41 Oil Pump 56....................................................................
Port Block 57...................................................................
10 304 10 Oil Filter 58....................................................................
10 402 28 Water Pump Assembly and Thermostat Housing 59..................................
10 402 30 Thermostat 59..................................................................
10 230 24 Governor 60...................................................................
Governor Operation 61..........................................................
10 304 38 Engine Reassembly Sequence 63.................................................
Crankshaft and Bearing Holder Assembly 64........................................
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4
SECTION 10 -- ENGINE
BOOK 1 - 87042550
Chapter 1 -- LS140-N843 (Before Engine S/N 93206)
LS150-N843H (Before Engine S/N 91509) (Continued)
CONTENTS
Section Description Page
Rear Oil Seal 65................................................................
Backplate/Flywheel Housing 65...................................................
Flywheel 65....................................................................
Piston and Connecting Rod 66....................................................
Oil Intake and Oil Strainer 66.....................................................
Oil Sump 66....................................................................
Dipstick and Tube 66............................................................
Front Plate 67..................................................................
Idler Gear and Oil Pump Assembly 67.............................................
Timing Gear Case Installation 68..................................................
Crankshaft Pulley 69............................................................
Injection Pump Installation 69.....................................................
Spill Timing Procedure 70........................................................
29 100 50 Reinstallation of Engine into Skid Steer Frame 79...................................
How to Operate the Engine After Overhaul 81.......................................
Cooling System 82..............................................................
Cooling System Operation 82.....................................................
Water Pump Assembly and Thermostat Housing 83..................................
Radiator 85....................................................................
Fuel System 86.................................................................
Fuel Specifications 86...........................................................
Diesel Fuel 86..................................................................
Diesel Fuel Storage 86..........................................................
Fuel System Components 87.....................................................
Fuel Guage 88.................................................................
Cold Start Aid 89................................................................
Fuel Filter System 89............................................................
Priming the Fuel System 90......................................................
Fuel System Testing 91..........................................................
Fuel System Components 94.....................................................
10 236 08 Fuel Injection Timing 102.........................................................
Miscellaneous Engine Electrical 105...............................................
Special Tools 107...............................................................
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5
SECTION 10 -- ENGINE
BOOK 1 - 87042550
Chapter 2 -- LS140-N843 (Tier II Engine S/N 93206 and After)
LS150-N843H (Tier II Engine S/N 91509 and After)
CONTENTS
Section Description Page
10 000 General Engine Information 3......................................................
General Description 3............................................................
Engine Component Descriptions 3.................................................
Engine Model and Serial Number Location 5.........................................
Safety Precautions 6.............................................................
General Engine Specifications 7...................................................
Troubleshooting 9................................................................
Specifications - Service Standards 12..............................................
Torque Specifications 17.........................................................
Engine Components Electrical Diagram 18.........................................
10 001 10 Engine Removal 19.............................................................
Engine Disassembly Sequence 25................................................
Engine Component Maintenance 33...............................................
10 101 55 Valve Seat 36..................................................................
10 101 56 Cylinder Block 39...............................................................
10 105 22 Piston and Piston Rings 40.......................................................
Connecting Rod 44..............................................................
10 103 10 Bearing Holder 48...............................................................
Front Crankshaft Bearing (Bushing) 50.............................................
10 103 30 Crankshaft 52..................................................................
10 103 76 Flywheel and Ring Gear 54.......................................................
10 106 40 Camshaft Assembly 55..........................................................
10 106 66 Camshaft Gear and Bearing Assembly 55..........................................
Timing Gear 56.................................................................
10 304 41 Oil Pump 56....................................................................
Port Block 57...................................................................
10 304 10 Oil Filter 58....................................................................
10 402 28 Water Pump Assembly and Thermostat Housing 59..................................
10 402 30 Thermostat 59..................................................................
10 230 24 Governor 60...................................................................
Governor Operation 61..........................................................
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6
SECTION 10 -- ENGINE
BOOK 1 - 87042550
Chapter 2 -- LS140-N843 (Tier II Engine S/N 93206 and After)
LS150-N843H (Tier II Engine S/N 91509 and After) (Continued)
CONTENTS
Section Description Page
10 304 38 Engine Reassembly Sequence 63.................................................
Crankshaft and Bearing Holder Assembly 64........................................
Rear Oil Seal 65................................................................
Backplate/Flywheel Housing 65...................................................
Flywheel 65....................................................................
Piston and Connecting Rod 66....................................................
Oil Intake and Oil Strainer 66.....................................................
Oil Sump 66....................................................................
Dipstick and Tube 66............................................................
Front Plate 67..................................................................
Idler Gear and Oil Pump Assembly 67.............................................
Timing Gear Case Installation 68..................................................
Crankshaft Pulley 69............................................................
Injection Pump Installation 69.....................................................
29 100 50 Reinstallation of Engine into Skid Steer Frame 76...................................
How to Operate the Engine After Overhaul 78.......................................
Cooling System 79..............................................................
Cooling System Operation 79.....................................................
Water Pump Assembly and Thermostat Housing 80..................................
Radiator 82....................................................................
Fuel System 83.................................................................
Fuel Specifications 83...........................................................
Diesel Fuel 83..................................................................
Diesel Fuel Storage 83..........................................................
Fuel System Components 84.....................................................
Fuel Guage 85.................................................................
Cold Start Aid 86................................................................
Fuel Filter System 86............................................................
Priming the Fuel System 87......................................................
Fuel System Testing 88..........................................................
Fuel System Components 91.....................................................
Miscellaneous Engine Electrical 99................................................
Special Tools 101...............................................................
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7
SECTION 29 -- HYDROSTATIC TRANSMISSION
BOOK 2 - 87036979
Chapter 1 -- Neutralizer, Pumps, Motors
CONTENTS
Section Description Page
29 100 General Information 29-3.........................................................
Operation 29-3..................................................................
Specifications 29-5...............................................................
29 100 01 Troubleshooting 29-6.............................................................
Hydrostatic Drive System Testing 29-8..............................................
Hydrostatic System Oil Flow 29-11.................................................
Hydrostatic Charge System Pressure Test 29-14.....................................
Hydrostatic Pump Case Drain Test 29-16............................................
Hydrostatic Pump High Pressure Test 29-19.........................................
Hydrostatic Pump Efficiency Test 29-21.............................................
Hydrostatic Motor Case Drain Test 29-23............................................
Hydrostatic Motor Efficiency Test 29-24.............................................
Hydraulic, Hydrostatic System Air Ingress Test 29-26.................................
Hydrostatic Pumps 29-27.........................................................
29 100 40 Hydrostatic Pump Removal 29-27..................................................
29 100 46 Hydrostatic Pump Disassembly 29-31..............................................
Hydrostatic Pump Parts Inspection 29-37...........................................
Hydrostatic Pump Reassembly 29-40...............................................
Hydrostatic Pump Reinstallation 29-46..............................................
Hydrostatic Motor 29-48..........................................................
29 100 60 Hydrostatic Motor Removal 29-48.................................................
29 100 66 Hydrostatic Motor Disassembly 29-52..............................................
Hydrostatic Motor Parts Inspection 29-55...........................................
Hydrostatic Motor Reassembly 29-59..............................................
Hydrostatic Motor Reinstallation 29-63.............................................
Hydraulic System Cleaning Procedure 29-66........................................
Start-up Procedure After Rebuild (After Pump or Motor Replacement) 29-69.............
Charge Check Valve 29-71........................................................
29 100 36 Charge Check Valve Removal and Replacement 29-71...............................
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8
SECTION 29 -- HYDROSTATIC TRANSMISSION
BOOK 2 - 87036979
Chapter 1 -- Neutralizer, Pumps, Motors (Continued)
CONTENTS
Section Description Page
29 100 Steering System 29-73...........................................................
Hydrostatic System Controls 29-73................................................
Neutralizer Assembly 29-75.......................................................
Left Control Handle With No Boom Control 29-81.....................................
29 100 10 Left Control Handle With No Boom Control Removal 29-81............................
Left Control Handle With No Boom Control Disassembly 29-81.........................
Left Control Handle With No Boom Control Inspection 29-82...........................
Left Control Handle With No Boom Control Reassembly 29-82.........................
Left Control Handle With No Boom Control Reinstallation 29-82........................
29 100 11 Left Control Handle With Boom Control 29-84........................................
Left Control Handle With Boom Control Removal 29-84...............................
Left Control Handle With Boom Control Disassembly 29-85............................
Left Control Handle With Boom Control Inspection 29-86..............................
Left Control Handle With Boom Control Reassembly 29-87............................
Left Control Handle With Boom Control Reinstallation 29-88...........................
Right Control Handle With Auxiliary or Bucket Control 29-90...........................
29 100 15 Right Control Handle With Auxiliary or Bucket Control Removal 29-90...................
Right Control Handle With Auxiliary or Bucket Control Disassembly 29-91...............
Right Control Handle With Auxiliary or Bucket Control Inspection 29-93..................
Right Control Handle With Auxiliary or Bucket Control Reassembly 29-94................
Right Control Handle With Auxiliary or Bucket Control Reinstallation 29-97...............
29 130 06 Drive Control Adjustment Procedure 29-99..........................................
29 130 06 Neutral Adjustment 29-100.......................................................
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9
SECTION 33 -- BRAKES AND CONTROLS
BOOK 2 - 87036979
Chapter 1 -- Parking Brake
CONTENTS
Section Description Page
33 000 General Information 33-2.........................................................
Specifications 33-4...............................................................
Troubleshooting 33-5.............................................................
Tes ting 33-7....................................................................
33 110 Parking Brake 33-8..............................................................
Parking Brake Removal and Inspection 33-9.........................................
SECTION 35 -- HYDRAULIC SYSTEM
BOOK 3 - 87036980
Chapter 1 - Valves, Gear Pump, Cylinders, and Pedal Controls
CONTENTS
Section Description Page
35 000 General Information 35-3.........................................................
Hydraulic System Compatibility 35-4................................................
Boom Cylinder Pivot Pins 35-6....................................................
Boom Cylinder Pivot Pin Location and Machine Usage 35-6...........................
Control Valve Power Beyond 35-7..................................................
Specifications 35-8...............................................................
Troubleshooting 35-10............................................................
Auxiliary Boom Hydraulics Troubleshooting 35-14....................................
Hydraulic System Testing 35-16....................................................
Hydraulic System Oil Flow (Neutral Position) 35-22...................................
Control Valve - Bucket Spool Shifted 35-23..........................................
Control Valve - Boom Spool Shifted 35-24...........................................
Control Valve - Auxiliary Spool Shifted 35-25.........................................
35 710 02 Main System Pressure Tests 35-26.................................................
Checking Main System Pressure at Boom Cylinders 35-29............................

10
SECTION 35 -- HYDRAULIC SYSTEM
BOOK 3 - 87036980
Chapter 1 - Valves, Gear Pump, Cylinders, and Pedal Controls (Continued)
CONTENTS
Section Description Page
Checking Main System Pressure at Bucket Cylinders 35-30...........................
Checking Main System Pressure at Auxiliary Boom Hydraulic Quick Couplers 35-31......
Boom Circuit Relief Valve Test 35-32...............................................
Gear Pump Flow Efficiency Test 35-34..............................................
Boom and Bucket Spool Lock Solenoid Test 35-37...................................
Hydraulic, Hydrostatic System Air Ingress Test 35-40.................................
Control Valve Specifications 35-41.................................................
35 724 50 Control Valve Removal 35-42......................................................
35 724 54 Control Valve Disassembly and Inspection 35-44.....................................
Control Valve Parts Inspection 35-48...............................................
Control Valve Reassembly 35-49...................................................
Control Valve Reinstallation 35-53..................................................
Hydraulic Pump Specifications 35-54...............................................
35 710 10 Hydraulic Pump Removal 35-55...................................................
35 710 20 Hydraulic Pump Disassembly 35-57................................................
Hydraulic Pump Parts Inspection 35-58.............................................
Hydraulic Pump Reassembly 35-60................................................
Hydraulic Pump Installation 35-63..................................................
Cylinders, Boom and Bucket 35-64.................................................
35 710 10 Boom Cylinder Removal 35-65....................................................
35 730 18 Boom Cylinder Disassembly 35-67.................................................
Boom Cylinder Parts Inspection 35-68..............................................
Boom Cylinder Reassembly 35-70.................................................
Boom Cylinder Reinstallation 35-71................................................
35 730 10 Bucket Cylinder Removal 35-72....................................................
35 730 13 Bucket Cylinder Disassembly 35-73................................................
Bucket Cylinder Parts Inspection 35-74.............................................
Bucket Cylinder Reassembly 35-74................................................
Bucket Cylinder Reinstallation 35-75................................................
Pedal Controls 35-76.............................................................
35 724 16 Pedal Removal (With Boom and Bucket Pedal Controls) 35-76.........................

11
SECTION 35 -- HYDRAULIC SYSTEM
BOOK 3 - 87036980
Chapter 1 - Valves, Gear Pump, Cylinders, and Pedal Controls (Continued)
CONTENTS
Section Description Page
Pedal Inspection (With Boom and Bucket Pedal Controls) 35-76........................
Pedal Reinstallation (With Boom and Bucket Pedal Controls) 35-78.....................
35 724 16 Pedal Removal (With Boom and Bucket Hand Controls) 35-81.........................
Pedal Inspection (With Boom and Bucket Hand Controls) 35-82........................
Pedal Reinstallation (With Boom and Bucket Hand Controls) 35-83.....................
35 300 Hydraulic Cooling, Filter, Reservoir System 35-86....................................
35 705 Filter System 35-87..............................................................
35 705 04 Filter Removal 35-87.............................................................
35 705 05 Base Removal 35-87.............................................................
Reassembly 35-88...............................................................
Oil Cooler 35-88.................................................................
35 300 10 Oil Cooler Removal 35-88.........................................................
Oil Cooler Reassembly 35-89......................................................
35 300 Oil Reservoir 35-90..............................................................
35 300 10 Oil Reservoir Removal 35-91......................................................
Oil Reservoir Reinstallation 35-92..................................................
SECTION 37 -- TOWING HOOKS AND BALLASTING
BOOK 3 - 87036980
Chapter 1 -- Rear Counterweights
CONTENTS
Section Description Page
37 140 10 Rear Counterweights 37-2........................................................
37 140 12 Rear Counterweight Support Removal 37-2.........................................

12
SECTION 39 -- FRAMES
BOOK 3 - 87036980
Chapter 1 -- Lower Main, ROPS
CONTENTS
Section Description Page
General Information 39-2.........................................................
Cab and ROPS 39-3.............................................................
90 152 46 Cab and ROPS Removal 39-3.....................................................
Cab and ROPS Reinstallation 39-10................................................
SECTION 44 -- AXLES AND WHEELS
BOOK 3 - 87036980
Chapter 1 -- Axles
CONTENTS
Section Description Page
44 100 General Information 44-2.........................................................
Specifications 44-4...............................................................
Troubleshooting 44-5.............................................................
Tes ting 44-7....................................................................
44 106 Axles 44-8......................................................................
44 106 10 Axle Housing Assembly Removal 44-8..............................................
44 106 16 Axle Disassembly 44-9...........................................................
Axle Parts Inspection 44-11.......................................................
Axle Reassembly 44-12..........................................................
Axle Housing Reinstallation 44-14..................................................
Final Drive 44-16................................................................
44 106 48 Final Drive Removal 44-16........................................................
Final Drive Parts Inspection 44-23..................................................
Final Drive Reassembly 44-24.....................................................
44 511 Tires/Wheels 44-30..............................................................
Tire and Track Installation 44-31...................................................
Loader Boom Stop Adjustment 44-32...............................................

13
SECTION 50 -- CAB CLIMATE CONTROL
BOOK 3 - 87036980
Chapter 1 -- Heater/Defroster
CONTENTS
Section Description Page
50 100 Heater/Defroster (Cab) 50-2.......................................................
Evaluation Procedure 50-8........................................................
Estimated Performance Guidelines 50-8............................................
Heater/Defroster System Troubleshooting 50-9......................................
Cab Heater/Defroster Wire Schematic 50-18.........................................
Heater Control Wire Diagram 50-18................................................
SECTION 55 -- ELECTRICAL SYSTEM
BOOK 4 - 87036981
Chapter 1 -- Advanced Warning System, Circuits, Alternator, and Starter
CONTENTS
Section Description Page
55 000 General Electrical Information 55-6.................................................
Definition of Terms 55-7..........................................................
Adapting Attachments Requiring 12V Electrical Power 55-9............................
Specifications 55-12..............................................................
Electrical Diagram 55-15..........................................................
55 418 Advanced Warning System 55-19..................................................
Electronic Instrument Cluster (EIC) 55-19...........................................
(EIC) Electronic Instrument Cluster Front Panel 55-20................................
EIC Functional Groups 55-21......................................................
Engine Preheat 55-26............................................................
Automatic Shutdown 55-26........................................................
Operating Mode 55-27............................................................
Broken Alternator/Water Pump Belt Warning 55-29...................................
Fuel Level 55-30.................................................................

14
SECTION 55 -- ELECTRICAL SYSTEM
BOOK 4 - 87036981
Chapter 1 -- Advanced Warning System, Circuits, Alternator,
and Starter (Continued)
CONTENTS
Section Description Page
EIC Interlocks 55-30.............................................................
EIC Lock Mode 55-31............................................................
EIC Engine Preheat 55-32........................................................
Troubleshooting 55-33............................................................
Advanced Warning System (AWS) 55-36............................................
EIC Board Self Test 55-37.........................................................
Diagnostic and Setup Modes 55-38.................................................
Arrow, Open Book, and Audible Alarm Test 55-40....................................
Diagnostic Mode EIC Circuit Tests 55-40............................................
EIC Setup Mode 55-44...........................................................
Electronic Instrument Cluster (EIC) and Starter Circuits 55-52..........................
Blown Fuse Symptom and Testing 55-52............................................
Testing Other EIC Functions 55-54.................................................
EIC Board Reading Accuracy 55-57................................................
EIC Board Claims Warranty 55-59..................................................
Electrical Circuits 55-60...........................................................
Seat Switch Circuit to EIC Board 55-61.............................................
Seat Belt Switch Circuit to EIC Board 55-62.........................................
Ignition Switch Circuit to EIC Board 55-63...........................................
Cranking Circuit (Starter Motor) 55-64..............................................
“Service/Run” Switch in the “Run” Position 55-65.....................................
Cranking Circuit Ground 55-66.....................................................
Operating Conditions “Service/Run” Switch in the “Service” position 55-66...............
Service/Run” Switch in the “Service” position 55-67...................................
Cranking Circuit Ground 55-68.....................................................
Start Relay Operation 55-68.......................................................
Start Relay Circuit 55-69..........................................................
Start Relay Ground Circuit 55-70...................................................
Start Interlock Relay Operation 55-70..............................................
Start Interlock Circuit 55-71.......................................................

15
SECTION 55 -- ELECTRICAL SYSTEM
BOOK 4 - 87036981
Chapter 1 -- Advanced Warning System, Circuits, Alternator,
and Starter (Continued)
CONTENTS
Section Description Page
Start Interlock Ground Circuit 55-72................................................
Start Circuit 55-72...............................................................
55 100 Removal, Installation and Wiring of Electrical Components 55-73.......................
Battery 55-74...................................................................
55 301 40 Battery Removal 55-74...........................................................
Battery Installation 55-74..........................................................
55 418 10 EIC (Electronic Instrument Cluster) Board Removal 55-75.............................
EIC (Electronic Instrument Cluster) Wiring 55-76.....................................
EIC (Electronic Instrument Cluster) Board Installation 55-76...........................
Ignition (Key) Switch Wiring 55-78..................................................
55 201 10 Ignition (Key) Switch Removal 55-78...............................................
Ignition (Key) Switch Installation 55-78..............................................
Cab Fuse Panel Wiring 55-79.....................................................
Cab Fuse Block and Panel Removal 55-80..........................................
Cab Fuse Block and Panel Installation 55-80........................................
Service/Run Switch Wiring 55-81..................................................
Service/Run Switch - Service Position 55-81.........................................
Service/Run Switch - Run Position 55-81............................................
55 418 30 Service/Run Switch Removal 55-82................................................
Service/Run Switch Installation 55-82...............................................
Seat and Seat Belt Switch Wiring 55-83.............................................
55 201 15 Seat Switch Removal 55-83.......................................................
Seat Switch Installation 55-84.....................................................
Seat Belt Buckle and Switch Assembly Removal 55-84................................
Seat Belt Buckle Installation 55-84.................................................
Road Light and Work Light Switch Wiring 55-85......................................
55 404 20 Road Light and Work Light Switch Removal 55-86....................................
Road Light and Work Light Switch Installation 55-86..................................
Engine Fuse and Relay Panel 55-87................................................
Accessory Relay Wiring 55-88.....................................................

16
SECTION 55 -- ELECTRICAL SYSTEM
BOOK 4 - 87036981
Chapter 1 -- Advanced Warning System, Circuits, Alternator,
and Starter (Continued)
CONTENTS
Section Description Page
Accessory Relay Removal 55-88...................................................
Accessory Relay Installation 55-88.................................................
Preheat Circuit Breaker Wiring 55-89...............................................
55 100 24 Preheat Circuit Breaker Removal 55-89.............................................
Preheat Circuit Breaker Installation 55-89...........................................
Start Interlock Relay Wiring 55-90..................................................
55 100 34 Start Interlock Relay Removal 55-91................................................
Start Interlock Relay Installation 55-91..............................................
Engine Fuse Panel Wiring 55-92...................................................
Engine Fuse Block Removal 55-93.................................................
Engine Fuse Block Installation 55-93...............................................
Alternator Excite Resistor Wiring 55-94.............................................
55 301 16 Alternator Excite Resistor Removal 55-94...........................................
Alternator Excite Resistor Installation 55-94.........................................
Start Relay Wiring 55-95..........................................................
55 100 34 Start Relay Removal 55-95........................................................
Start Relay Installation 55-95......................................................
Preheat Relay Wiring 55-96.......................................................
55 100 34 Preheat Relay Removal 55-97.....................................................
Preheat Relay Installation 55-97...................................................
Preheat Glow Plug Removal 55-98.................................................
Preheat Glow Plug Installation 55-98...............................................
Fuel System Components 55-99...................................................
Electric Fuel Pump 55-101.......................................................
10 210 21 Electric Fuel Pump Removal 55-102...............................................
10 223 Fuel Shutoff Solenoid 55-102.....................................................
Fuel Shutoff Solenoid Testing 55-102..............................................
10 223 10 Replacement of Fuel Shutoff Solenoid 55-103.......................................
55 414 14 Air Filter Restriction Indicator Switch Removal 55-104................................
Air Filter Restriction Indicator Switch Installation 55-104..............................

17
SECTION 55 -- ELECTRICAL SYSTEM
BOOK 4 - 87036981
Chapter 1 -- Advanced Warning System, Circuits, Alternator,
and Starter (Continued)
CONTENTS
Section Description Page
55 414 10 Engine Coolant Temperature Sender Removal 55-104...............................
Engine Coolant Temperature Sender Installation 55-104..............................
55 414 12 Engine Oil Pressure Switch Removal 55-105.......................................
Engine Oil Pressure Switch Installation 55-105......................................
55 414 28 Hydrostatic Charge Pressure Switch Removal 55-105................................
Hydrostatic Charge Pressure Switch Installation 55-105..............................
55 414 24 Hydraulic Oil Filter Restriction Switch Removal 55-106...............................
Hydraulic Oil Filter Restriction Switch Installation 55-106.............................
55 414 20 Hydraulic Oil Temperature Sender Removal 55-106..................................
Hydraulic Oil Temperature Sender Installation 55-107................................
Boom/Bucket Control Valve Spool Lock Solenoids 55-108............................
35 724 90 Boom/Bucket Control Valve Spool Lock Solenoids Removal 55-108....................
Boom/Bucket Control Valve Spool Lock Solenoids Installation 55-108..................
Wire Harness 55-109............................................................
55 100 74 Main Wire Harness Removal 55-109...............................................
Main Wire Harness Installation 55-114..............................................
55 404 Road/Work Lights 55-118.........................................................
55 301 Alternator (40 Amp Version) 55-122...............................................
Charging Circuit 55-122..........................................................
Alternator Service Specifications 55-124...........................................
Alternator System Testing and Troubleshooting 55-125...............................
Service Precautions 55-128......................................................
Initial Tests 55-128..............................................................
55 301 10 Alternator Removal 55-133.......................................................
55 301 12 Alternator Disassembly 55-134...................................................
Alternator Reinstallation 55-140...................................................
55 201 Starter 55-141..................................................................
Starter Motor Troubleshooting 55-141..............................................
55 201 50 Starter Motor Removal 55-143....................................................
Starter Motor Disassembly 55-148................................................

18
SECTION 55 -- ELECTRICAL SYSTEM
BOOK 4 - 87036981
Chapter 1 -- Advanced Warning System, Circuits, Alternator,
and Starter (Continued)
CONTENTS
Section Description Page
Starter Inspection and Repair 55-152..............................................
Starter Reassembly 55-158......................................................
Starter Reinstallation 55-161.....................................................
Miscellaneous Engine Components 55-162.........................................
Glow Plug 55-162...............................................................
Glow Plug Troubleshooting 55-162................................................
Oil Pressure Switch 55-163......................................................
Fuel Shut-off Solenoid 55-163....................................................