New Holland W50BTC User manual

www.newhollandconstruction.com
Issued 01May 08
87734623A NA
W50BTC
W60BTC
W70BTC
W80BTC
TIER 3
COMPACT WHEEL LOADER
SERVICE
MANUAL

W50BTC
W60BTC
W70BTC
W80BTC
TIER 3
COMPACT WHEEL LOADER
SERVICE MANUAL
Bur • Issued 01May 08
Printed in U.S.A. • Book/Form Number 87734623A NA
Copyright © 2008. CNH America, LLC. All Rights Reserved.
Find manuals at https://best-manuals.com

87734623A NA
W50BTC, W60BTC, W70BTC & W80BTC Tier 3 Compact Wheel Loader
01May 08
First Edition
REVISION HISTORY
RemarksIssue Issue Date Applicable Machines
This unit first became available 05-2008
CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not
necessarily show products in standard condition.For exact information about any particular product, please consult your Dealer.
Any use of editorial or pictorial content is strictly prohibited without express written permission from
CNH America LLC. Carol Stream, IL U.S.A.60188
Find manuals at https://best-manuals.com

1
TO THE READER
This manual has been printed for a skilful engineer
to supply necessary technical information to carry
out service operations on this machine.
Read carefully this manual to collect correct infor-
mation relevant to repair procedures.
For any question or remark, or in case of any error
relevant the contents of this manual, please con-
tact:
CNH ITALIA S.p.A.
Viale delle Nazioni, 55
41100 MODENA - Italy
REFERENCES
Beyond this Repair Manual, also refer to docu-
ments listed hereunder:
ZOperator’s Manual
ZParts Catalogue
COMPLETE REPAIR MANUAL
The complete Repair Manual consists of two vol-
umes:
ZW50BTC - W60BTC - W70BTC - W80BTC
Repair Manual for “Wheel loaders”
ZW50BTC - W60BTC - W70BTC - W80BTC
Repair Manual for “Engine”
The Repair Manuals for “Wheel loaders” and “En-
gine” contain the necessary technical information
to carry out service and repair on machine and on
engine, necessary tools to carry out those opera-
tions and information on service standard, on pro-
cedures for connection, disconnection,
disassembly and assembly of parts.
The complete Repair Manual which covers the
loader models W50BTC - W60BTC - W70BTC -
W80BTC consists of the following volumes, which
can be identified through their print number as
stated below:
VOLUME MACHINE TYPE PRINT NUMBER
Repair Manual - “Wheel loaders” W50BTC - W60BTC - W70BTC -
W80BTC
87734623A
Repair Manual - “Engine” W50BTC - W60BTC - W70BTC -
W80BTC
87736548A
Find manuals at https://best-manuals.com

2
TO PREVENT ACCIDENTS
The majority of accidents and injuries which occur in industry, on the farm, at home or on the
road, are caused by the failure of some individual to follow simple and fundamental safety rules
or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognizing the
real cause and taking the necessary precautions, before the accident occurs.
Regardless of the care used in design and construction of any type of equipment, there may be
conditions that cannot be completely safeguarded against, without interfering with reasonable
accessibility and efficient operation.
A careful operator and / or technician is the best insurance against accidents. The complete ob-
servance of one simple rule would prevent many thousands of serious injuries each year.
This rule is: never attempt to clean, lubricate or adjust a machine while it is in motion.
SWARNING
Before carrying out any maintenance operation, adjustment and or repair on machines equipped
with attachments, controlled hydraulically or mechanically, make sure that the attachment is low-
ered and safely set on the ground. If it is necessary to have the equipment partially or fully raised
to gain access to certain items, be sure the equipment is suitably supported by means other than
the hydraulic lift cylinders, cable and /or mechanical device used for controlling the equipment.
CNH S.p.A.
Viale delle Nazioni, 55
41100 MODENA - Italy
All rights reserved. Reproduction of text or illustrations, in whole or in part, is strictly
prohibited.
Find manuals at https://best-manuals.com

INDEX
SECTION 00 - INTRODUCTION
1. SAFETY INSTRUCTIONS ............................................................................................................................ 1
2. GENERAL SAFETY INSTRUCTIONS .......................................................................................................... 2
3. TECHNICAL SPECIFICATIONS................................................................................................................. 12
SECTION 10 - ENGINE
1. DIESEL ENGINE .......................................................................................................................................... 1
2. FUEL SYSTEM ............................................................................................................................................. 2
SECTION 25 - FRONT AXLES
1. REMOVAL AND INSTALLATION ................................................................................................................. 1
2. DIMENSIONS ............................................................................................................................................... 3
3. TECHNICAL SPECIFICATIONS................................................................................................................... 5
4. OIL CHANGE................................................................................................................................................ 9
5. DISASSEMBLY AND ASSEMBLY.............................................................................................................. 12
5.1 DISC BRAKE ASSY............................................................................................................................. 12
5.2 BRAKE CALIPER ................................................................................................................................ 19
5.3 REDUCTION GEAR (W50BTC) .......................................................................................................... 27
5.4 REDUCTION UNIT (W60BTC, W70BTC, W80BTC) ........................................................................... 30
5.5 WHEEL HUB (W50BTC)...................................................................................................................... 33
5.6 WHEEL HUB (W60BTC, W70BTC, W80BTC) .................................................................................... 42
5.7 WHEEL SHAFT (W60BTC, W70BTC, W80BTC) ................................................................................ 48
5.8 BRAKE AND WHEEL SHAFT (W60BTC, W70BTC, W80BTC “HIGH SPEED”)................................. 52
5.9 DIFFERENTIAL SUPPORT................................................................................................................. 60
5.10 DIFFERENTIAL ASSY....................................................................................................................... 68
5.11 PINION............................................................................................................................................... 75
6. TROUBLESHOOTING................................................................................................................................ 81
7. SPECIAL TOOLS........................................................................................................................................ 84
SECTION 27 - REAR AXLES
1. REMOVAL AND INSTALLATION ................................................................................................................. 1
2. DIMENSIONS ............................................................................................................................................... 3
3. TECHNICAL SPECIFICATIONS................................................................................................................... 7
4. OIL CHANGE.............................................................................................................................................. 14
5. DISASSEMBLY AND ASSEMBLY.............................................................................................................. 18
5.1 MOTOR TB150.................................................................................................................................... 18
5.2 MOTOR TB138.5 “HIGH SPEED” ....................................................................................................... 21
5.3 TRANSMISSION BOX TB150 ............................................................................................................. 25
5.4 TRANSMISSION TB138.5 “HIGH SPEED” ......................................................................................... 34
5.5 REDUCTION GEAR (W50BTC) .......................................................................................................... 54
5.6 REDUCTION UNIT (W60BTC, W70BTC, W80BTC) ........................................................................... 57
5.7 WHEEL HUB (W50BTC)...................................................................................................................... 61
5.8 WHEEL HUB (W60BTC, W70BTC, W80BTC) .................................................................................... 70
Find manuals at https://best-manuals.com

INDEX
5.9 WHEEL SHAFT (W60BTC, W70BTC, W80BTC) ................................................................................ 76
5.10 DIFFERENTIAL SUPPORT ............................................................................................................... 80
5.11 DIFFERENTIAL ASSY....................................................................................................................... 88
5.12 LIMITED SLIP DIFFERENTIAL ASSY ............................................................................................... 94
5.13 PINION............................................................................................................................................. 101
6. TROUBLESHOOTING .............................................................................................................................. 107
7. SPECIAL TOOLS...................................................................................................................................... 110
SECTION 33 - BRAKE SYSTEM
1. BRAKE SYSTEM DIAGRAM ........................................................................................................................ 1
1.1 STANDARD DIAGRAM.......................................................................................................................... 1
1.2 “HIGH SPEED” DIAGRAM..................................................................................................................... 2
2. TECHNICAL SPECIFICATIONS................................................................................................................... 3
2.1 BRAKE PEDAL VALVE.......................................................................................................................... 3
2.2 PRESSURE SWITCHES ....................................................................................................................... 3
3. OPERATION ................................................................................................................................................. 4
3.1 SERVICE BRAKE OPERATION ............................................................................................................ 6
3.2 PARKING BRAKE OPERATION............................................................................................................ 8
4. BRAKE PEDAL VALVE................................................................................................................................. 9
5. PRESSURE SWITCHES ............................................................................................................................ 11
6. BRAKE ACCUMULATOR ........................................................................................................................... 12
6.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 12
7. CHECKS AND ADJUSTMENTS ................................................................................................................. 13
7.1 SERVICE BRAKE SYSTEM PRESSURE CHECK .............................................................................. 13
7.2 ACCUMULATOR PRESSURE CHECK ............................................................................................... 14
7.3 PEDAL ANGLE ADJUSTMENT........................................................................................................... 15
7.4 “INCHING” VALVE ADJUSTMENT...................................................................................................... 16
8. TROUBLESHOOTING ................................................................................................................................ 17
SECTION 35 - HYDRAULIC SYSTEM
1. HYDRAULIC DIAGRAMS ............................................................................................................................. 1
1.1 HYDRAULIC DIAGRAM FOR W50BTC ................................................................................................1
1.2 HYDRAULIC DIAGRAM FOR W50BTC WITH OPTIONAL OUTFITS................................................... 3
1.3 HYDRAULIC DIAGRAM FOR W60BTC ................................................................................................5
1.4 HYDRAULIC DIAGRAM FOR W60BTC WITH OPTIONAL OUTFITS................................................... 7
1.5 HYDRAULIC DIAGRAM FOR W70BTC ................................................................................................9
1.6 HYDRAULIC DIAGRAM FOR W70BTC WITH OPTIONAL OUTFITS................................................. 11
1.7 HYDRAULIC DIAGRAM FOR W80BTC .............................................................................................. 13
1.8 HYDRAULIC DIAGRAM FOR W80BTC WITH OPTIONAL OUTFITS................................................. 15
2. TRANSMISSION......................................................................................................................................... 17
2.1 HYDRAULIC DIAGRAM....................................................................................................................... 17
2.2 OPERATION ........................................................................................................................................ 18
2.3 ADJUSTMENTS................................................................................................................................... 20
3. VARIABLE-DISPLACEMENT PISTON PUMP............................................................................................22
3.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 23
3.2 MAIN VALVES ..................................................................................................................................... 24
3.3 DISASSEMBLY.................................................................................................................................... 32
3.4 ASSEMBLY.......................................................................................................................................... 51
Find manuals at https://best-manuals.com

INDEX
4. GEAR PUMP .............................................................................................................................................. 58
4.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 58
4.2 COMPONENTS ................................................................................................................................... 59
4.3 DISASSEMBLY AND ASSEMBLY....................................................................................................... 60
5. PRIORITY VALVE ...................................................................................................................................... 63
5.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 63
6. TRAVEL MOTOR........................................................................................................................................ 64
6.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 64
6.2 MAIN COMPONENTS ......................................................................................................................... 65
6.3 OPERATION........................................................................................................................................ 66
6.4 REMOVAL ........................................................................................................................................... 69
7. DISASSEMBLY AND ASSEMBLY.............................................................................................................. 70
8. ONE-WAY DISTRIBUTOR VALVE............................................................................................................. 84
9. HYDRAULIC OIL TANK.............................................................................................................................. 85
9.1 OIL FILTER.......................................................................................................................................... 86
10. TROUBLESHOOTING .............................................................................................................................. 87
SECTION 39 - FRAME
1. ARTICULATED JOINT.................................................................................................................................. 1
1.1 COMPONENTS ..................................................................................................................................... 1
1.2 DISASSEMBLY AND ASSEMBLY......................................................................................................... 2
SECTION 41 - STEERING SYSTEM
1. OPERATION................................................................................................................................................. 1
1.1 EMERGENCY STEERING .................................................................................................................... 3
1.2 PRESSURE ADJUSTMENT.................................................................................................................. 4
2. POWER STEERING ..................................................................................................................................... 5
2.1 TECHNICAL SPECIFICATIONS............................................................................................................ 6
2.2 COMPONENTS ..................................................................................................................................... 7
2.3 DISASSEMBLY AND ASSEMBLY......................................................................................................... 8
2.4 TROUBLESHOOTING......................................................................................................................... 24
2.5 SPECIAL TOOLS................................................................................................................................. 25
3. STEERING CYLINDER .............................................................................................................................. 26
3.1 REMOVAL AND INSTALLATION ........................................................................................................ 27
3.2 DISASSEMBLY.................................................................................................................................... 29
4. TROUBLESHOOTING................................................................................................................................ 34
SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM
1. HEATING ...................................................................................................................................................... 1
2. AIR CONDITIONING .................................................................................................................................... 3
3. TROUBLESHOOTING................................................................................................................................ 29
SECTION 55 - ELECTRICAL SYSTEM
1. ELECTRICAL DIAGRAMS............................................................................................................................ 1
2. FUSES AND RELAYS ................................................................................................................................ 17
Find manuals at https://best-manuals.com

INDEX
3. VOLTAGE AND CONTINUITY CHECK ...................................................................................................... 20
4. BATTERY.................................................................................................................................................... 21
4.1 REPLACEMENT .................................................................................................................................. 23
5. BULBS ........................................................................................................................................................ 24
6. TROUBLESHOOTING ................................................................................................................................ 28
SECTION 82 - WORKING EQUIPMENT
1. HYDRAULIC DIAGRAM................................................................................................................................ 2
2. OPERATION ................................................................................................................................................. 3
3. REMOVAL AND INSTALLATION ................................................................................................................. 4
4. QUICK TOOL COUPLER.............................................................................................................................. 6
4.1 COMPONENTS ..................................................................................................................................... 7
4.2 QUICK TOOL COUPLER CYLINDERS ................................................................................................. 8
5. BUCKET........................................................................................................................................................ 9
5.1 ASSEMBLY............................................................................................................................................ 9
5.2 DISASSEMBLY.................................................................................................................................... 10
5.3 BUCKET TEETH - REPLACEMENT.................................................................................................... 11
6. FORKS........................................................................................................................................................ 13
6.1 DISASSEMBLY AND ASSEMBLY....................................................................................................... 14
6.2 CHECKS .............................................................................................................................................. 15
7. CYLINDERS................................................................................................................................................ 17
7.1 BOOM CYLINDER ............................................................................................................................... 17
7.2 DUMPING CYLINDER ......................................................................................................................... 21
8. CONTROL VALVE ...................................................................................................................................... 25
9. LOAD HOLDING VALVE ............................................................................................................................ 28
9.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 28
10. TROUBLESHOOTING .............................................................................................................................. 29
Find manuals at https://best-manuals.com

1. SAFETY INSTRUCTIONS ............................................................................................................................ 1
2. GENERAL SAFETY INSTRUCTIONS .......................................................................................................... 2
3. TECHNICAL SPECIFICATIONS................................................................................................................. 12
SECTION 00 - INTRODUCTION
Find manuals at https://best-manuals.com