New Holland LS180 Operating instructions

LS180
LS190
87036989 7/03

Please cut where indicated and insert the label into the plastic pocket on the spine of
the binder.
87036989
SKID-STEER
REPAIR
LS180, LS190
Vol. 1
87036989
SKID-STEER
REPAIR
LS180, LS190
Vol. 1
87036997
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87036994 7/03
2003 NEW HOLLAND NORTH AMERICA, INC.
Printed In U.S.A.
LS180, LS190 REPAIR MANUAL
COMPLETE CONTENTS
SECTION 00 - GENERAL INFORMATION 2.............................
SECTION 10 - ENGINE 3..............................................
SECTION 27 - REAR DRIVE AXLE (GEARBOXES) 7.....................
SECTION 29 - HYDROSTATIC TRANSMISSION 8........................
SECTION 33 - BRAKES AND CONTROLS 11.............................
SECTION 35 - HYDRAULIC SYSTEM 12..................................
SECTION 37 - TOWING HOOKS AND BALLASTING 14....................
SECTION 39 - FRAMES 14..............................................
SECTION 44 - AXLES AND WHEELS 15.................................
SECTION 50 - CAB CLIMATE CONTROL 15..............................
SECTION 55 - ELECTRICAL SYSTEM 16.................................
SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 21.......
SECTION 88 - ACCESSORIES 22........................................
SECTION 90 - PLATFORMS, CAB, BODYWORK, AND DECALS 23.........
The following pages are the collation of the contents pages from each section and
chapter of the LS180, LS190 Repair manual. Complete Repair part # 87036989.
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 LS180, LS190 Skid Steer.
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2
SECTION 00 -- GENERAL INFORMATION
BOOK 1 - 87036990
CONTENTS
Section Description Page
Introduction 00-2................................................................
About Improvements 00-2.........................................................
Company Policy 00-3............................................................
Parts and Accessories 00-3.......................................................
Model Codes 00-3...............................................................
Precautionary Statements 00-4....................................................
Safety Precaution Information 00-5.................................................
General Safety Information 00-7...................................................
Machine Model and Serial Number Location 00-9....................................
Engine Model and Serial Number Location 00-9......................................
Hardware Torque Specifications 00-10..............................................
Installation of Adjustable Fittings in Straight Thread O Ring Bosses 00-12................
Standard Torque Data for Hydraulic Tubes and Fittings 00-12..........................
Pipe Thread Fitting Torque 00-13..................................................
Lubricants and Coolants 00-13....................................................
Sealants 00-13..................................................................
Properly Support a Raised Machine 00-14...........................................
Properly Support Boom on Boom Lock Pins 00-14....................................
Raising Boom Without Hydraulic Oil Flow 00-14......................................
Raising Boom Without Battery Voltage (12V) 00-15...................................
Reattaching Cylinders After Repair with Boom Resting on Boom Lock Pins 00-17.........
Major Unit Overhaul 00-18........................................................
Cab and Boom Tilt Procedure 00-19................................................
Craning the Skid Steer 00-25......................................................
Special Tools 00-28..............................................................
Specifications (Model LS180) 00-29................................................
Dimensions (Model LS180) 00-32..................................................
Specifications (Model LS190) 00-34................................................
Dimensions (Model LS190) 00-37..................................................
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3
SECTION 10 -- ENGINE
BOOK 1 - 87036990
Chapter 1 -- LS180 - 332T/JF
CONTENTS
Section Description Page
10 000 Introduction 10-3................................................................
Safety Precautions 10-3..........................................................
LS 180 Engine Services 10-4......................................................
Engine Model and Serial Number Location 10-4......................................
General Engine Information 10-4...................................................
General Engine Specifications 10-8................................................
Troubleshooting 10-10............................................................
Specifications Service Standards 10-19.............................................
Hardware Torque Chart 10-26.....................................................
Torque Specifications 10-27.......................................................
Turbocharger Torque Specifications 10-28...........................................
Engine Electrical Components - LS180 10-29........................................
10 001 10 Engine Removal By Tilting Cab and Boom Forward 10-30.............................
10 001 20 Mounting the Engine for Maintenance 10-35.........................................
10 001 53 Engine Disassembly Sequence 10-35..............................................
Engine Component Maintenance 10-36.............................................
Cylinder Block, Pistons, Rings, Rods and Bearings 10-45..............................
Crankshaft, Main Bearings, and Flywheel 10-53......................................
Camshaft and Timing Gear Train 10-59.............................................
Timing Gear 10-62...............................................................
Engine Timing 10-66.............................................................
10 400 Cooling System 10-70............................................................
10 402 30 Thermostat Removal 10-71.......................................................
10 402 10 Water Pump Removal 10-72.......................................................
10 304 Lubrication System 10-77.........................................................
10 102 10 Oil Pan Removal 10-77...........................................................
10 304 34 Oil Pump Removal 10-78.........................................................
10 304 06 Oil Level Dipstick 10-81...........................................................
Fuel System 10-82...............................................................
10 210 21 Electric Lift Pump 10-82..........................................................
10 218 34 Injectors 10-90..................................................................
10 218 34 Fuel Injector Overhaul 10-92......................................................
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4
SECTION 10 -- ENGINE
BOOK 1 - 87036990
Chapter 1 -- LS180 - 332T/JF (Continued)
CONTENTS
Section Description Page
10 210 21 Electric Lift Pump 10-95..........................................................
10 216 10 Fuel Tank 10-97.................................................................
Air Intake and Exhaust System 10-100.............................................
Exhaust Muffler 10-102..........................................................
Turbocharger 10-103............................................................
Starting a Turbocharged Engine After Installation of a Turbocharger 10-112..............
Engine Installation 10-113.........................................................
Operating the Engine After Overhaul 10-116.........................................
Electrical Component Maintenance 10-117..........................................
Adjust Belt Tension 10-118........................................................
SECTION 10 -- ENGINE
BOOK 1 - 87036990
Chapter 2 -- LS190 - 450/NC
CONTENTS
Section Description Page
10 000 Introduction 10-125.............................................................
Safety Precautions 10-125.......................................................
LS 180 Engine Services 10-126...................................................
General Engine Information 10-126................................................
General Engine Specifications 10-130.............................................
Troubleshooting 10-131..........................................................
Specifications Service Standards 10-141...........................................
Hardware Torque Chart 10-147...................................................
Torque Specifications 10-148.....................................................
Engine Electrical Components - LS190 10-149......................................
10 001 10 Engine Removal By Tilting Cab and Boom Forward 10-150...........................
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5
SECTION 10 -- ENGINE
BOOK 1 - 87036990
Chapter 2 -- LS190 - 450/NC (Continued)
CONTENTS
Section Description Page
10 001 20 Mounting the Engine for Maintenance 10-157.......................................
10 001 53 Engine Disassembly Sequence 10-157............................................
Engine Component Maintenance 10-158...........................................
Cylinder Head Reassembly 10-166................................................
Cylinder Head Installation 10-166.................................................
Engine Front Cover and TIming Gear Removal 10-167...............................
Camshaft Drive Gear 10-168.....................................................
Engine Timing 10-171...........................................................
10 102 10 Oil Pan Removal 10-175.........................................................
10 105 10 Connecting Rods, Bearings, Pistons, and Rings Removal 10-175......................
10 304 06 Connecting Rod Bushing 10-178..................................................
Cylinder Block Overhaul 10-180...................................................
Cylinder Bore 10-181............................................................
Sleeve - Boring and Honing 10-182................................................
Balancer/Vibration Damper 10-187................................................
Main Bearing Removal 10-188....................................................
Flywheel Removal 10-189........................................................
Rear Cover Plate Removal 10-190................................................
Oil Pump Removal 10-192.......................................................
Crankshaft Removal 10-194......................................................
Crankshaft Reassembly 10-196...................................................
Camshaft Removal 10-197.......................................................
Camshaft Bearings 10-198.......................................................
Engine Compression Test 10-199.................................................
10 400 Cooling System 10-200..........................................................
Radiator 10-200................................................................
10 402 30 Thermostat Removal 10-200.....................................................
Fan Belt Tensioner Removal 10-202...............................................
Idler Pulley 10-203..............................................................
10 402 10 Water Pump Removal 10-203.....................................................
10 304 Lubrication System 10-208.......................................................
10 304 06 Oil Level Dipstick 10-208.........................................................
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6
SECTION 10 -- ENGINE
BOOK 1 - 87036990
Chapter 2 -- LS190 - 450/NC (Continued)
CONTENTS
Section Description Page
Fuel System 10-213.............................................................
Sediment Separator 10-214......................................................
Thermostat 10-214..............................................................
Fuel Filter 10-214...............................................................
Injectors 10-215................................................................
Verifying Pup Timing 10-218......................................................
Installing the Injection Pump 10-219...............................................
10 210 21 Electric Lift Pump 10-223........................................................
10 218 34 Injectors 10-225................................................................
10 218 34 Fuel Injector Overhaul 10-225....................................................
10 216 10 Fuel Tank 10-232...............................................................
Air Intake and Exhaust System 10-234.............................................
Manifolds 10-237...............................................................
Engine Installation 10-239........................................................
Operating the Engine After Overhaul 10-245........................................
Electrical Component Maintenance 10-246.........................................
Charging Circuit 10-247..........................................................
Adjust Belt Tension 10-247.......................................................
Special Tools 10-248............................................................
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7
SECTION 27 -- REAR DRIVE AXLE (GEARBOXES)
BOOK 2 - 87036991
Chapter 1 -- Gearboxes
CONTENTS
Section Description Page
27 000 General Information 27-2.........................................................
Specifications 27-4...............................................................
Troubleshooting 27-5.............................................................
Tes ting 27-7....................................................................
27 126 Gearboxes 27-8.................................................................
Final Drive and Gearbox Fill/Check Plug (2) 27-8.....................................
27 126 40 Gearbox Removal 27-9...........................................................
27 126 48 Gearbox Disassembly 27-10......................................................
Gearbox Parts Inspection 27-14...................................................
Gearbox Reassembly 27-15.......................................................
27 126 40 Gearbox Reinstallation 27-18......................................................
Engine-to-Transmission Gearbox 27-23............................................
Engine-to-Transmission Gearbox Removal - Disassembly 27-23.......................
Engine-to-Transmission Gearbox Parts Inspection 27-28..............................
Engine-to-Transmission Gearbox Reassembly - Installation 27-29......................
Start-Up Procedure 27-32.........................................................
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8
SECTION 29 -- HYDROSTATIC TRANSMISSION
BOOK 2 - 87036991
Chapter 1 -- Neutralizer, Pumps, Motors, Two-Speed
CONTENTS
Section Description Page
29 100 General Information 29-4.........................................................
Operation 29-4..................................................................
Specifications 29-6...............................................................
29 100 01 Troubleshooting 29-8.............................................................
Low Power Through the Engine/Transmission System 29-10...........................
Hydrostatic Drive System Testing 29-13.............................................
Hydrostatic System Oil Flow 29-16.................................................
Hydrostatic Charge System Pressure Test 29-19.....................................
Hydrostatic Pump Case Drain Test 29-21............................................
Hydrostatic Pump High Pressure Test 29-23.........................................
Hydrostatic Motor Case Drain Test 29-25............................................
Hydraulic, Hydrostatic System Air Ingress Test 29-27.................................
Hydrostatic and Charge Pumps 29-29..............................................
Hydrostatic Pumps 29-29.........................................................
29 100 40 Hydrostatic Pump Removal 29-29..................................................
29 100 46 Hydrostatic and Charge Pump Disassembly 29-35....................................
Hydrostatic Charge Pump 29-36...................................................
Hydrostatic Charge Pump Disassembly 29-36.......................................
Hydrostatic Charge Pump Parts Inspection 29-37....................................
Hydrostatic Charge Pump Reassembly 29-38........................................
Hydrostatic Pump 29-39..........................................................
Hydrostatic Pump Disassembly 29-39..............................................
Hydrostatic Pump Parts Inspection 29-44...........................................
Hydrostatic Pump Reassembly 29-50...............................................
Hydrostatic Pump Reinstallation 29-58..............................................
Motors 29-62...................................................................
Hydrostatic Motor - Single Speed 29-62............................................
29 100 60 Hydrostatic Motor - Single Speed Removal 29-62....................................
29 100 66 Hydrostatic Motor - Single Speed Disassembly 29-66................................
Hydrostatic Motor - Single Speed Parts Inspection 29-69..............................
Hydrostatic Motor - Single Speed Reassembly 29-73.................................
Hydrostatic Motor - Single Speed Reinstallation 29-77................................
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