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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9
SECTION 29 -- HYDROSTATIC TRANSMISSION
BOOK 2 - 87036991
Chapter 1 -- Neutralizer, Pumps, Motors, Two-Speed (Continued)
CONTENTS
Section Description Page
Hydrostatic Motor - Two Speed 29-79..............................................
29 100 60 Hydrostatic Motor - Two Speed Removal 29-79......................................
29 100 66 Hydrostatic Motor - Two Speed Disassembly 29-84..................................
Hydrostatic Motor - Two Speed Parts Inspection 29-88...............................
Hydrostatic Motor - Two Speed Reassembly 29-92...................................
Hydrostatic Motor - Two Speed Reinstallation 29-98..................................
29 134 Two Speed High/Low Range Components 29-101...................................
29 134 20 Two Speed High/Low Control Valve 29-103.........................................
Two Speed High/Low Control Valve Removal 29-104.................................
29 134 24 Two Speed High/Low Control Valve Disassembly 29-105.............................
Two Speed High/Low Control Valve Inspection 29-105...............................
Two Speed High/Low Control Valve Reassembly 29-106.............................
29 134 Control Valve Reinstallation 29-107................................................
29 134 30 Two Speed High/Low Slave Cylinder 29-108........................................
Two Speed High/Low Slave Cylinder Removal 29-109................................
Two Speed High/Low Slave Cylinder Disassembly 29-109............................
Two Speed High/Low Slave Cylinder Inspection 29-110...............................
Two Speed High/Low Slave Cylinder Reassembly 29-110.............................
Two Speed High/Low Slave Cylinder Reinstallation 29-110............................
29 134 40 Two Speed High/Low Motor Control Linkage 29-111..................................
Two Speed High/Low Motor Control Linkage Removal 29-112..........................
Two Speed High/Low Motor Control Linkage Inspection 29-113.........................
Two Speed High/Low Motor Control Linkage Reinstallation 29-114......................
Two Speed Control Switch 29-115..................................................
Hydraulic System Cleaning Procedure 29-116.......................................
Start-up Procedure After Rebuild (After Pump or Motor Replacement) 29-119............
29 100 Steering System 29-122.........................................................
Hydrostatic System Controls 29-122..............................................
Neutralizer Assembly 29-124.....................................................
29 130 10 Neutralizer Assembly Removal 29-124.............................................
Neutralizer Assembly Disassembly 29-124.........................................
Neutralizer Assembly Inspection 29-125............................................

10
SECTION 29 -- HYDROSTATIC TRANSMISSION
BOOK 2 - 87036991
Chapter 1 -- Neutralizer, Pumps, Motors, Two-Speed (Continued)
CONTENTS
Section Description Page
Neutralizer Assembly Reassembly 29-127..........................................
29 130 30 Control Linkage 29-129..........................................................
Control Linkage Removal 29-129..................................................
Control Linkage Disassembly 29-129..............................................
Control Linkage Inspection 29-129................................................
Control Linkage Reassembly 29-130..............................................
Left Control Handle With No Boom Control 29-131...................................
29 100 10 Left Control Handle With No Boom Control Removal 29-131..........................
Left Control Handle With No Boom Control Disassembly 29-131.......................
Left Control Handle With No Boom Control Inspection 29-132.........................
Left Control Handle With No Boom Control Reassembly 29-132.......................
Left Control Handle With No Boom Control Reinstallation 29-132......................
Left Control Handle With Boom Control 29-134......................................
29 100 11 Left Control Handle With Boom Control Removal 29-134.............................
Left Control Handle With Boom Control Disassembly 29-135..........................
Left Control Handle With Boom Control Inspection 29-136............................
Left Control Handle With Boom Control Reassembly 29-137..........................
Left Control Handle With Boom Control Reinstallation 29-138.........................
Right Control Handle With Auxiliary or Bucket Control 29-140.........................
29 100 15 Right Control Handle With Auxiliary or Bucket Control Removal 29-140.................
29 100 15 Right Control Handle With Auxiliary or Bucket Control Disassembly 29-141.............
Right Control Handle With Auxiliary or Bucket Control Inspection 29-143................
Right Control Handle With Auxiliary or Bucket Control Reassembly 29-144..............
Right Control Handle With Auxiliary or Bucket Control Reinstallation 29-147.............
Control Linkage and Neutralizer 29-149............................................
Control Linkage and Neutralizer Reinstallation 29-149................................
29 130 06 Drive Control Adjustment Procedure 29-150........................................
LS180 Links and Arms 29-151....................................................
29 130 06 LS180 Neutralizer Adjustment 29-152..............................................
Control Lever Parallel Adjustment 29-153..........................................
LS180 Linkage and Control Lever Equal Movement 29-153...........................
Left Control Linkage Adjustment 29-154............................................

11
SECTION 29 -- HYDROSTATIC TRANSMISSION
BOOK 2 - 87036991
Chapter 1 -- Neutralizer, Pumps, Motors, Two-Speed (Continued)
CONTENTS
Section Description Page
LS180 Straight Travel and Forward/Reverse Stop Adjustment 29-154..................
LS190 Links and Arms 29-157....................................................
29 130 06 LS190 Neutralizer Adjustment 29-157..............................................
LS190 Hydrostatic Control Lever 29-158...........................................
LS190 Linkage and Control Lever Equal Movement 29-158...........................
Left Control Linkage Adjustment 29-159............................................
LS190 Straight Travel and Forward/Reverse Stop Adjustment 29-159..................
LS190 and LS190 High/Low Range Adjustment (Optional on LS180) 29-162............
SECTION 33 -- BRAKES AND CONTROLS
BOOK 2 - 87036991
Chapter 1 -- Parking Brake
CONTENTS
Section Description Page
33 000 General Information 33-2.........................................................
Specifications 33-3...............................................................
Troubleshooting 33-4.............................................................
Tes ting 33-6....................................................................
33 110 Parking Brake 33-7..............................................................
Parking Brake Removal and Inspection 33-8.........................................
33 110 Parking Brake Adjustment 33-13...................................................

12
SECTION 35 -- HYDRAULIC SYSTEM
BOOK 3 - 87036992
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 35-11............................................................
Auxiliary Boom Hydraulics Troubleshooting 35-15....................................
Hydraulic System Testing 35-17....................................................
Hydraulic System Oil Flow (Neutral Position) 35-23...................................
Control Valve - Bucket Spool Shifted 35-24..........................................
Control Valve - Boom Spool Shifted 35-25...........................................
Control Valve - Auxiliary Spool Shifted 35-26.........................................
Hydraulic System Oil Flow 35-27...................................................
35 710 02 Main System Pressure Tests 35-29.................................................
Checking Main System Pressure at Boom Cylinders 35-32............................
Checking Main System Pressure at Bucket Cylinders 35-33...........................
Checking Main System Pressure at Auxiliary Boom Hydraulic Quick Couplers 35-34......
Boom Circuit Relief Valve Test 35-35...............................................
Gear Pump Flow Efficiency Test 35-37..............................................
Boom and Bucket Spool Lock Solenoid Test 35-40...................................
Hydraulic, Hydrostatic System Air Ingress Test 35-42.................................
Control Valve Specifications 35-44.................................................
35 724 50 Control Valve Removal 35-45......................................................
35 724 54 Control Valve Disassembly and Inspection 35-47.....................................
Control Valve Parts Inspection 35-51...............................................
Control Valve Reassembly 35-52...................................................
Control Valve Reinstallation 35-56..................................................
Hydraulic Pump Specifications 35-57...............................................
35 710 10 Hydraulic Pump Removal 35-58...................................................
35 710 20 Hydraulic Pump Disassembly 35-61................................................
Hydraulic Pump Parts Inspection 35-62.............................................
Hydraulic Pump Reassembly 35-65................................................

13
SECTION 35 -- HYDRAULIC SYSTEM
BOOK 3 - 87036992
Chapter 1 -- Valves, Gear Pump, Cylinders, and Pedal Controls
(Continued)
CONTENTS
Section Description Page
Hydraulic Pump Installation 35-68..................................................
Cylinders, Boom and Bucket 35-72.................................................
35 710 10 Boom Cylinder Removal 35-74....................................................
35 730 18 Boom Cylinder Disassembly 35-75.................................................
Boom Cylinder Parts Inspection 35-77..............................................
Boom Cylinder Reassembly 35-78.................................................
Boom Cylinder Reinstallation 35-80................................................
35 730 10 Bucket Cylinder Removal 35-81....................................................
35 730 13 Bucket Cylinder Disassembly 35-81................................................
Bucket Cylinder Parts Inspection 35-82.............................................
Bucket Cylinder Reassembly 35-84................................................
Bucket Cylinder Reinstallation 35-86................................................
Pedal Controls 35-87.............................................................
35 724 16 Pedal Removal (With Boom and Bucket Pedal Controls) 35-87.........................
Pedal Inspection (With Boom and Bucket Pedal Controls) 35-87........................
Pedal Reinstallation (With Boom and Bucket Pedal Controls) 35-89.....................
35 724 16 Pedal Removal (With Boom and Bucket Hand Controls) 35-92.........................
Pedal Inspection (With Boom and Bucket Hand Controls) 35-93........................
Pedal Reinstallation (With Boom and Bucket Hand Controls) 35-94.....................
35 300 Hydraulic Cooling, Filter, Reservoir System 35-97....................................
35 705 Filter System 35-98..............................................................
35 705 04 Filter Removal 35-98.............................................................
35 705 05 Base Removal 35-98.............................................................
Reassembly 35-99...............................................................
Oil Cooler 35-100...............................................................
35 300 10 Oil Cooler Removal 35-100.......................................................
Oil Cooler Reassembly 35-100....................................................
35 300 Oil Reservoir 35-101............................................................
35 300 10 Oil Reservoir Removal 35-102....................................................
Oil Reservoir Inspection 35-103...................................................
Oil Reservoir Reinstallation 35-104................................................
Adapting Attachments 35-105....................................................

14
SECTION 37 -- TOWING HOOKS AND BALLASTING
BOOK 3 - 87036992
Chapter 1 -- Rear Counter Weights
CONTENTS
Section Description Page
37 140 10 Rear Counterweights 37-2........................................................
37 140 12 Rear Counterweight Support Removal 37-2.........................................
SECTION 39 -- FRAMES
BOOK 3 - 87036992
Chapter 1 -- Lower Main, ROPS
CONTENTS
Section Description Page
General Information 39-2.........................................................
ROPS 39-2.....................................................................
ROPS Frame 39-2...............................................................
90 152 46 ROPS Removal 39-2.............................................................
ROPS Reinstallation 39-9.........................................................

15
SECTION 44 -- AXLES AND WHEELS
BOOK 3 - 87036992
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 Drive Chain and Sprocket Removal 44-16...........................................
Final Drive Parts Inspection 44-18..................................................
Final Drive Reassembly 44-19.....................................................
44 511 Tires/Wheels 44-22..............................................................
Tire and Track Installation 44-23...................................................
SECTION 50 -- CAB CLIMATE CONTROL
BOOK 3 - 87036992
Chapter 1 -- Heater/Defroster
CONTENTS
Section Description Page
50 100 Heater/Defroster (Cab) 50-2.......................................................
Evaluation Procedure 50-8........................................................
Heater/Defroster System Troubleshooting 50-9......................................
Heater/Defroster Schematic/Wiring Diagram 50-18...................................

16
SECTION 55 -- ELECTRICAL SYSTEM
BOOK 4 - 87036993
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.................................................................
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 55-60..................................................
Electrical Circuits 55-61...........................................................
Seat Switch Circuit to EIC Board 55-62.............................................
Seat Belt Switch Circuit to EIC Board 55-63.........................................

17
SECTION 55 -- ELECTRICAL SYSTEM
BOOK 4 - 87036993
Chapter 1 -- Advanced Warning System, Circuits, Alternator, and Starter
(Continued)
CONTENTS
Section Description Page
Ignition Switch Circuit to EIC Board 55-64...........................................
Cranking Circuit (Starter Motor) 55-65..............................................
“Service/Run” Switch in the “Run” Position 55-66.....................................
Cranking Circuit Ground 55-67.....................................................
Service/Run” Switch in the “Service” position 55-68...................................
Cranking Circuit Ground 55-69.....................................................
Start Relay Operation 55-69.......................................................
Start Relay Circuit 55-70..........................................................
Start Relay Ground Circuit 55-71...................................................
Start Interlock Relay Operation 55-71..............................................
Start Interlock Circuit 55-72.......................................................
Start Interlock Ground Circuit 55-73................................................
Start Circuit 55-73...............................................................
55 100 Removal, Installation and Wiring of Electrical Components 55-74.......................
Battery - LS180 55-75............................................................
55 301 40 Battery Removal - LS180 55-75...................................................
Battery Installation - LS180 55-75..................................................
Battery Removal - LS190 55-76...................................................
55 418 10 EIC (Electronic Instrument Cluster) Board Removal 55-77.............................
EIC (Electronic Instrument Cluster) Wiring 55-78.....................................
EIC (Electronic Instrument Cluster) Board Installation 55-79...........................
Ignition (Key) Switch Wiring 55-79..................................................
55 201 10 Ignition (Key) Switch Removal 55-80...............................................
Ignition (Key) Switch Installation 55-80..............................................
Cab Fuse Panel Wiring 55-81.....................................................
Cab Fuse Block and Panel Removal 55-82..........................................
Cab Fuse Block and Panel Installation 55-82........................................
Service/Run Switch Wiring 55-83..................................................
Service/Run Switch - Service Position 55-83.........................................
Service/Run Switch - Run Position 55-83............................................
55 418 30 Service/Run Switch Removal 55-84................................................

18
SECTION 55 -- ELECTRICAL SYSTEM
BOOK 4 - 87036993
Chapter 1 -- Advanced Warning System, Circuits, Alternator, and Starter
(Continued)
CONTENTS
Section Description Page
Service/Run Switch Installation 55-84...............................................
Seat and Seat Belt Switch Wiring 55-84.............................................
55 201 15 Seat Switch Removal 55-85.......................................................
Seat Switch Installation 55-85.....................................................
Seat Belt Buckle and Switch Assembly Removal 55-86................................
Seat Belt Buckle Installation 55-86.................................................
Road Light and Work Light Switch Wiring 55-86......................................
55 404 20 Road Light and Work Light Switch Removal 55-87....................................
Road Light and Work Light Switch Installation 55-87..................................
Engine Fuse and Relay Panel 55-88................................................
Accessory Relay Wiring 55-89.....................................................
Accessory Relay Removal 55-89...................................................
Accessory Relay Installation 55-89.................................................
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 55-91...................................................
Engine Fuse Block Removal 55-92.................................................
Engine Fuse Block Installation 55-92...............................................
Alternator Excite Resistor Wiring 55-93.............................................
55 301 16 Alternator Excite Resistor Removal 55-93...........................................
Alternator Excite Resistor Installation 55-93.........................................
Start Relay Wiring 55-94..........................................................
55 100 34 Start Relay Removal 55-94........................................................
Start Relay Installation 55-95......................................................
Preheat Relay Wiring 55-95.......................................................
55 100 34 Preheat Relay Removal 55-96.....................................................
Preheat Relay Installation 55-96...................................................