Workshop Manual: Wheel Loader
Workshop Manual: Wheel Loader
W230
WHEEL LOADER
Workshop Manual
Print N° 604.13.507.00 English
II - 2005
Read and heed carefully the safety instructions listed and follow the precautions recommended to avoid
potential risks and to safeguard your health and your safety.
You will find this symbol in the text of this Manual referred to the following key words:
WARNING - Cautions directed to avoid improper repair interventions involving potential consequences
for the operator’s safety.
DANGER - These warnings qualify specifically potential dangers for the safety of the operator or other
persons directly or indirectly involved.
IMPORTANT NOTICE
All maintenance and repair interventions explained in this Manual must be performed exclusively by the Service
Organization of the Manufacturer, observing strictly the instructions explained using, whenever necessary, the
recommended specific tools.
Whoever performs the operations reported without following exactly the precautions is responsible on his own,
for the damages that may result.
Neither the Factory nor any Organizations in its Distribution Network, including but not limited to national,
regional or local distributors, are responsible for any liability arising from any damage resulting from defects
caused by parts and/or components not approved by the Factory for use in maintaining and/or repairing products
manufactured or merchandized by the Factory.
In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or
merchandized by the Factory, when failures are caused by the use of parts and/or components not approved
by the Factory.
Copyright © New Holland
AVOID ACCIDENTS
WARNING
SUMMARY
W230 0-1
SAFETY RULES
Never start or operate a FAILED machine. Before operat- According to law provisions, seat belts must be fitted with
ing the machine, always ensure that any unsafe condition Roll Over Protection Structures or cabs. Keep safety belts
has been satisfactorily corrected. fastened during operation.
Check brakes, steering and attachment controls before For your personal safety, do not climb on or off the machine
moving off. Report any malfuctioning part or system to the while it is in motion.
maintenance managers for proper action. Make sure that bystanders are clear of the machine oper-
Ensure all protective guards and panels as well as all ating range before starting the engine and operating the
safety devices provided are in place and in good operating attachment. Sound the horn. Obey all indications provided
condition. by flags, signs and signals.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
0-2 W230
SAFETY RULES
DO NOT COAST OR FREEWHEEL down hills. Engage the Operators must know thoroughly the performances of the
most suitable gear speed to keep the machine under machine they are driving. When working on slopes or near
control. sudden level drops in the terrain, avoid areas where
ground is loose or soft since overturn or loss of machine
Do not operate the machine if you are extremely tired or
control could result.
feel ill. Be especially careful towards the end of the working
shift. If noise level is high and continuosly exceeds 90 dBA over
8 hours at the operator's ear, wear approved ear protection
Do not operate a machine with misadjusted brakes.
in compliance with local regulations.
Operate the machine at low speed which can ensure
Where counterweights are provided, do not operate the
complete control at all times.
machine if they have been removed.
Travel slowly over very rough terrain, slopes or near drop-
When transporting a loaded bucket, keept it as rolled-back
offs, in congested areas or on frozen or slippery surfaces.
and low as possible for maximum visibility, stability and
When backing, always look to where the machine is to be safety of there machine. Ground speed should be ade-
moved. Be alert of the position of bystanders. Should quate to the load and ground conditions.
someone enter the work area, stop the machine.
The load must always be properly arranged in the
Maintain a safe distance from other machines or obstacles bucket; move with extreme care when transporting
to ensure required visibility conditions. Give way to loaded oversize loads.
machines.
Use only the type of bucket recommended for the machine
Maintain a clear vision of the surroundings of the travel or and the materials to be handled. Follow the recommenda-
work area at all times. Keep cab windows clean and repaired. tions concerning loading capacity, arrangement of the
When machines are operating in tandem, the pusher (rear) materials, characteristics of the ground and job to be
must be equipped with the appropriate deflectors to protect performed.
the front unit driver against the air stream coming from the Do not lift and move loads overhead where persons are
blower fan. standing or working, nor downhill when working crosswise
When pulling or towing through a cable or chain, do not on slopes. In this case, the bucket should be unloaded on
the uphill side, whenever possible.
start suddenly at full throttle. Take-up slack carefully.
Start and stop the machine carefully when the bucket is full.
Carefuly inspect the towing items for flaws or problems
Do not move off without first reducing engine speed.
before proceedig.
Overtaking manoeuvres should be performed only when
Avoid kinking or twisting chains or cables. Do not pull
absolutely necessary and unavoidable. Beware possible
through a kinked chain or cable as the high stresses
uneven terrains, poor visibility, presence of other machin-
existing in this condition may induce failures. Always wear
ery or persons out of sight.
heavy gloves when handling chains or cables.
Operate the machine at a speed adequate to the working
Chains and cables should be securely anchored. Anchor
site conditions and in any case slow enough to ensure
points should be strong enough to withstand the expected
complete control at all times.
load. Keep anyone clear of anchor points and cables or
chains. Check instruments at start-up and frequently during
operation. Stop the machine immediately should any mal-
do not pull unless the operator’S compartments of the
function be signalled.
machines involved are properly protected against possible
backlas in case of cable or chain failure or detachment. Never use the bucket as a man lift or to carry riders.
Be alert of soft ground conditions close to newly construct- Never use the machine as a work platform or scaffolding,
ed walls. The fill material and machine weight may cause nor for other improper use (such as pushing railway cars,
the wall to collapse. trucks or other machines).
In darkness, check area of operation carefully before Pay attetion to people within the machine operating range.
moving in with the machine. Use all lights provided. Do not Load trucks from the driver’s side whenever possible.
move into low visibility areas. Prior to operating the machine, check which obstacles
If the engine tends to stall for whatever reason under load and/or difficulties you will encounter, such as narrow
or at idle, immediately report this problem to the mainte- streets, overhead doors, cables, piping, as well as ground,
nance managers for proper action. Do not operate the bridges, paving and ramps bearing load limitations.
machine until this condition has been corrected. In case of road transfers, find out beforehand what
On machines fitted with suction radiator fans, regularly conditions are likely to be encountered, such as size
check the engine exhaust system for leaks, as exhaust restrictions, heavy traffic, paving type, etc. . Beware fog,
fumes expelled towards the operator are toxic. smoke or dust that obscure visibility.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
W230 0-3
SAFETY RULES
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
0-4 W230
SAFETY RULES
Do not allow unauthorized personnel to service the ma- Disconnect batteries and label all controls to warn that
chine. Do not carry out any maintenance work without prior service work is in progress. Block the machine and all
authorization. Follow all recommended maintenance and attachments to be raised.
service procedures.
Do not check or fill fuel tanks, batteries and accumulators,
Keep the operator’s compartment free of loose objects nor use the starting liquid if you are smoking or near open
that are not properly secured. flames. These fluids are flammable!
Do not wear rings, wrist watches, jewellery, loose or BRAKES ARE INOPERATIVE when manually released for
hanging garments, such as ties, torn clothing, scarves, servicing. Provisions must be made to maintain control of
unbuttoned or unzipped jackets that can get caught in the machine using suitable blocks or other means.
moving parts. Wear certified safety clothes such as: hard
The fuel filler pipe nozzle must be constantly kept in
hat, no-slip footwear, heavy gloves, ear protection, safety
contact with the filler neck. Keep this contact from the
glasses, reflector vests, respirators. Ask your employer
beginning to the end of the fuelling operation to avoid
about specific safety equipment requirements.
possible generation of sparks due to static electricity.
Never service the machine with someone sitting in the
driver's seat, unless this person is an authorized operator Tow the machine only from the attaching points provided.
assisting in the maintenance being carried out. Use care in making connections and ensure pins and/or
bolt are firmly secured before pulling. Stay clear of draw-
Keep the operator’s compartment, step plates, grab rails bars, cables or chains under load.
and handles clear of foreign objects, oil, grease, mud or
snow to minimize the danger of slipping or stumbling. To move a failed machine, use a trailer or a low platform
truck, if available. In case towing is needed, use all neces-
Clean mud or grease from your shoes before climbing on sary signals required by local regulations, and follow
the machine or driving it. directions provided in this Manual.
Never attempt to operate the machine or its attachments Load/unload the machine from transporter on firm level
from any position other than sitting in the operator’s seat. ground providing safe support to the wheels of the truck or
Never stand under the boom. trailer. Use strong access ramps, with adequate height and
angle. Keep the loading platform free of mud, oil or slippery
Should it be necessary to move the attachment through the materials.
hydraulic controls for maintenance purposes, remember
that this should be done while sitting in the operator’s seat. Tie the machine securely to the platform of the truck or
Before starting the machine or moving its attachment, trailer and opportunely wedge machine wheels or tracks as
apply the brakes, sound the horn and call that you are required.
about to manoeuvre. Raise the attachment slowly. Never align holes or slots using your fingers; always use
Always lock machine arms or any other parts that must be appropriate aligning tools.
lifted for maintenance purposes using adequate external Remove all sharp edges and burrs from re-worked parts.
means. Do not allow anyone to pass near or even below
a raised yet unlocked attachment. If you are not absolutely Use only approved and effectively grounded auxiliary
sure about your safety, do not stay under a raised attach- power sources for heaters, battery chargers, pumps and
ment, even if it is locked. similar equipment to reduce electrical shock hazard.
Do not place body, limbs, or fingers near articulated cutting Lift and handle heavy components using hoisting devices
edges of uncontrolled machine parts or deprived of the of appropriate capacity. Ensure the sling has been cor-
necessary guards, unless they are suitably and safely rectly applied. Use lifting eyes if provided. Pay attention to
locked. bystanders.
Never perform any work on the machine with the engine Never pour gasoline or diesel fuel into open, wide and low
running, except when this is specifically required. Do not containers. Never use gasoline, solvents or other flamma-
wear loose clothing, jewellery or such near moving parts. ble fluids to clean parts. Use proprietary certified non-
flammable, non-toxic solvents only.
When service or maintenance require access to areas that
cannot be reached from the ground, use a ladder or step When using compressed air to clean parts, wear safety
platform conforming to regulations in force. If such means glasses with side shields. Limit pressure to max 2 bars, in
are not available, use machine grab rails and steps. accordance with local safety regulations in force.
Always perform all service or maintenance work with the Do not run the engine in closed buildings without proper
greatest care and attention. ventilation capable to remove lethal fumes.
Shop and/or field service platforms or ladders should be Do not smoke, use open flames or produce sparks nearby
manufactured in accordance with safety regulations in while refuelling the unit or handling highly flammable
force. materials.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
W230 0-5
SAFETY RULES
Do not use any flame as a light source during mainte- Wear appropriate protective equipment such as dark
nance work or to look for leaks anywhere on the ma- safety glasses, hard hat, protective clothing, special
chine. gloves and footwear while welding. Nearby persons
should also wear dark safety glasses even if they are
Make sure that all tools provided are in good condition
not welding. DO NOT LOOK THE WELDING ARC
at all times. NEVER USE tools with mushroomed or
WITHOUT PROPER EYE PROTECTION.
damaged heads. Always wear eye protections.
Become acquainted with all your jacking equipment and
Move with extreme care when working under the ma-
its capacity. Remember that the jacking point on the
chine, its attachments, and even on or near them.
machine should be appropriate for the load applied.
Always wear protective safety equipment as required,
Also, be sure the support area of the jack at the machine
such as hard hat, goggles, safety shoes, and ear plugs.
and on the ground is appropriate and stable.
In case tests during which the engine should be kept
Any load supported by a jack represents a possible
runinng, a qualified operator must sit in the driver’s seat
hazard. Always transfer the load onto appropriate sup-
with the mechanic in sight at all times. Place the trans-
port means according to local or national safety re-
mission in neutral, apply and lock the brakes. KEEP
quirements before proceeding with service or mainte-
HANDS OFF MOVING PARTS.
nance work.
In case of field service, move machine to level ground,
Metal cables get frayed after prolonged use. Always
if possible, and block it. If work on an incline cannot be
wear appropriate protections (heavy gloves, goggles,
advised, block the machine and its attachments se-
etc.) while handling them.
curely. Move damaged to level ground as soon as
possible. Handle all parts carefully. Keep hands and fingers away
from gaps, gears, and similar. Always use and wear the
Do not trust worn and/or kinked chains and cables.
appropriate protections.
Never use them for lifting or pulling. Always wear heavy
gloves to handle chains or cables. Water can build up in pneumatic systems from conden-
sate moisture due to changes in atmospheric condi-
Be sure chains and cables are firmly fastened and that tions. If necessary, drain such deposits following in-
anchor points are strong enough to withstand the expected structions.
load. Nobody should stay near the anchor points, cables or
chains. DO NOT PULL OR TOW UNLESS THE OPERA- Before carrying out any maintenance work or service,
TOR’S COMPARTMENTS OF THE MACHINES IN- lock the machine articulated frame modules using the
VOLVED ARE FITTED WITH THE PROPER GUARDS appropriate safety device. Remember to remove and
AGAINST BACKLASH IN CASE OF CABLE OR CHAIN store it properly at the end of work.
FAILURE OR DETACHMENT. If the machine is equipped with hydraulic brakes, make
Keep the area where maintenance is carried out CLEAN sure that the reservoir is always filled up to the correct level.
and DRY at all times. Clean immediately all water and
oil spillages. Always block all wheels, front and rear, before bleeding
the braking system or disconnecting control hoses and/
Do not pile up oily or greasy rags as they represent a major or cylinders.
fire hazard. Always store them in closed metal containers.
Before starting the machine or its attachment, check,
adjust and lock the operator’s seat. Also ensure that
nobody is within the machine operating range. Sound the STARTING
horn. Do not run the engine in closed buildings without proper
Rust inhibitors are volatile and flammable. Use them ventilation capable to remove lethal exhaust fumes.
only in well ventilated areas. Keep open flames away - Do not place head, body, limbs, feet, hands or fingers
DO NOT SMOKE - Store containers in a cool well near rotating fans or belts.
ventilatedplace where they could not be reached by
unauthorised people. Be especially careful near blower fans.
REMEMBER THAT THE STARTING FLUID IS HIGHLY
Do not carry loose objects in your pockets that might fall
FLAMMABLE. Follow recommendations provided in
unnoticed into open compartments.
this Manual and printed on the containers. Containers
Wear safety glasses with side shields, hard hat, safety must be stored in a cool, well ventilated place out of the
shoes, heavy gloves when metal particles or similar reach of unauthorised persons.
may be ejected and hit you. DO NOT PUNCTURE OR BURN CONTAINERS.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
0-6 W230
SAFETY RULES
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
W230 0-7
SAFETY RULES
Deflate the tyre before removing objects from the tyre tread. tensioner etc.)
Never inflate tyres with flammable gas: explosions and
• Heavy machine components (frames, blades,
severe bodily injuries may result.
buckets etc.)
When starting your work shift, check for loose wheel or rim
bolts and brackets and retighten to correct torque as
necessary.
WARNING
Ensure that the attachment is safely resting on to the ground before repairing,adjusting, or servicing
machines fitted with hydraulically, mechanically or cable controlled attachments (such as excavators,
loaders, dozers, scrapers, etc.). Should it be necessary to partially or fully raise the hydraulically,
mechanically, or cable controlled attachment to gain access to certain items, make sure the attachment is
adequately retained in the raised position by means other than the hydraulic lift cylinders, cable and/or
mechanical devices used for controlling it.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
0-8 W230
TRANSMISSION TYRES
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Copyright © New Holland
W230 0-9
HYDRAULIC SYSTEM
CAB
Sealed type with anti-cavitation and safety valve.
Modular, ROPS/FOPS type.
Steel gear pumps, with automatic wear take-up.
Glassed surface 4.6 sq m
A sequence valve cuts-off one pump when pressure
The ROPS/FOPS cab is complying with the following
exceeds 172 bar.
regulations:
– maximum flow ........... 146 (+208) l/min a 210 bar
ROPS - ISO34717SAE 1040
– max operating pressure ........................... 210 bar
FOPS - ISO34497SAE J 231.
Control valve ............................................... 2 spool
3 spool
– setting of pressure relief valve ................. 210 bar
– setting of raising safety valve . ................. 274 bar CAPACITIES
– bucket roll-back safety valve (A1) ........................
................................................................ 230 bar ENGINE
– bucket dumping safety valve (B1) ........................ Lube oil ............................................ 18 l (4.7 USG)
................................................................ 186 bar Antifreeze ...................................... 60 l (15.8 USG)
Fuel ................................................ 325 l (86 USG)
Control ...................................... piloted, single lever
..................................................... piloted, 2-lever TRANSMISSION
..................................................... piloted, 3-lever Torque converter/transmission oil . 40 l (10.5 USG)
Hydraulic cylinders, double stroke
boom control ...................................................... 2 HYDRAULIC SYSTEM ................ 160 l (42.2 USG)
bore and stroke .............................160 x 880 mm
bucket control .................................................... 1 AXLES
bore and stroke ............................ 190 x 550 mm Front ................................................ 36 l (9.5 USG)
Pipes and connecting flanges with O-Ring seals. Rear .............................................. 40 l (10.5 USG)
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Copyright © New Holland
0 - 10 W230
3000
40
R6670
5600 (220.5")
45
4180 (164.5")
961 (38")
3570 (140.5")
3120 (123")
1335 (52.5")
41
Dimensions in mm (in)
Operating weight: 21210 kg (46760 lb)
Note — The machine is specified with 3.6 cu m standard bucket (without teeth), tyres 26.5 R25XHA, filled and
with operator.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
TABLE OF FLUID CAPACITIES
W230
Ambra – Super Gold API CF-4/SG 15W-40 –10 to +50 °C (14 to 122 °F)
ENGINE 18 (4.8) MIL-L-2104E 10W-30 –30 to +20 °C (–22 to 68 °F)
Ambra-Super Gold HSP* API CH-4 15W-40 –10 to +50 °C (14 to 122 °F)
FUEL
TANK 325 (86) – – – –
GREASE FITTINGS – Ambra-MG-2 QFH 585 GR, NLG12 – –40 to +50 °C (–40 to 122 °F)
AIR CONDITIONER
COMPRESSOR 0.2 (0.05) L BAR 134 – – –
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Oil quantities indicated are those required for periodical changes following the draining and filling procedures indicated in detail for each group.
*In the event engine oil with "CH4" classification is used, the change interval can be prolonged to 500 hours providing that the outer temperature of operation
does not exceed 38 °C (100 °F) and that the percentage of sulphur in the fuel does not exceed 0.5 %.
In the event of really heavy duty conditions, reduce the greasing intervals.
0 - 11
Copyright © New Holland
Copyright © New Holland
0 - 12 W230
The following tables is to be used to convert units of The latter is identified by a coded eight digit number,
measure: allowing a complete description of the item.
multiply by to obtain
Example:
Force kg 9.807 daN I / a b c d e / f g
Pressure kg/cm2 0.9807 bar
I - Standard index digit
Torque kgm 9.807 daNm
It is always represented by the digit 1. This number
indicates that the item can be fabricated in a number
of versions differing for material and coating.
Note — For current service use, the following a - b - c - d - e - Standard base digits
equivalences can be considered to be valid: kg = daN;
kg/cm2 = bar; kgm = daNm. It is a number always composed of five digits identify-
ing dimensional specifications of the item.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
W230 0 - 13
0 4.8 4D - 4S - 4A 1 A 42
1 5.8 5S - 6S 3 P 56
2 8.8 8G 5 T 80
- Lubricate all hardware until 24 dia., with engine oil. If correct torque is not specifically indicated in the
Use grease for larger diameters. relevant pages, refer to the following tables.
8 replaces R50
12 " R100
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Copyright © New Holland
0 - 14 W230
Diameter Normal Low type With polyamide ring Diameter Normal Self-locking
and pitch Normal Low type and pitch ZNT ZNT
mm Nm Nm Nm Nm mm Nm Nm
M6 x 1 13 12 - - M6 x 1 13 -
M8 x 1.25 32 26 39 32 M8 x 1.25 13 35
M14 x 1.5 195 130 216 150 M14 x 1.5 200 220
M16 x 1.5 300 170 340 200 M16 x 1.5 300 330
M16 x 2 - - - - M16 x 2 - -
M18 x 1.5 450 250 500 290 M18 x 1.5 450 480
M20 x 1.5 600 305 645 350 M20 x 1.5 600 650
M24 x 3 - - - - M24 x 3 - -
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Copyright © New Holland
SECTION 1
ENGINE
TABLE OF CONTENTS
Fig. 1-1
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Fig. 1-2
Fig. 1-3
Fig. 1-4
Fig. 1-5
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Maker CUMMINS
Model 6CTAA8.3
Type 6 Cyl-in line-
turbocharge-AAC
Displacement cm3 8268
Number 6
Cylinder
Bore x Stroke mm x mm 114 x 135
Mass (water + oil) kg 617
Compression Ratio 18.0 : 1
Direction of Rotation Clockwise
(View from Front)
Gross Power @ Rated Speed kW @ rpm 179 @ 2200
Peak Power @ Speed kW @ rpm 192 @ 2000
Torque @ Low Idle Nm @ rpm 678 @ 850
SAE J1349 kW (CV) 167
Net Flywheel Power
DIN 6270 kW (CV) 167
ISO 9249 kW (CV) 167
Net Flywheel Power
CEE 80/1269 kW (CV) 167
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Copyright © New Holland
Maker Bosch
Type 3938371
Fuel Pump Model
Injection advance deg 10.5
before TDC
Injection order 153624
Fuel Filtration
Type Pushed
Lubrification
Filtration Full flow
At idle speed bar 0.69
Oil pressure (minimum allowed)
At rated speed (min.allowed) bar 2
Back pressure opening the oil filter bar 1.68
by-pass valve
Oil flow at rated speed (minus the flow lt/min 106.8
through pressure relief)
Oil temperature at rated speed °C 99 a 126
Oil temperature thermostat Fully open °C 116
(oil through heat
exchanger)
Closed (part of the oil °C 104
by-passes the heat
exchanger)
Oil sump capacity l 18
Intake mm 0.30
Valve Clearance
Exhaust mm 0.60
HC g/(kW*h) 0.21
CO g/(kW*h) 0.653
Emission (ISO 8178)
NOx g/(kW*h) 5.701
Particolate g/(kW*h) 0.174
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Copyright © New Holland
Water Pump Flow (@ Press Head 2.8 bar) l/min 344 @ 2200 rpm
Coolant flow l 258
(thermostats fully open,
engine speed 2000 rpm)
Coolant capacity l 10.9
Maker ABB - SV
Type Aluminium
Drive Ratio Hydraulic fan
Fan (Engine : Fan) (0.76 : 1 max)
Diameter mm 710
Blades (number - angle) °C 6/27
Blades Sizes mm
Maker Donaldson
Model FTG15 - 0029
Diameter mm 381
Air Cleaner Type Dry, 2 stage w/safety
element
Rated Capacity m3/min (mbar) 25.5 (25)
Max Airflow Restriction mbar 30
Maker Donaldson
Type M 120512
Dimensions mm 308
Muffler
Max Back Pressure mbar 96
Exhaust pipe inside mm 98
diameter
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Copyright © New Holland
The engine is mounted on the rear module of the fra- bolted on elastic pads and on the rear, by plates bolted
me in four points: frontally, by the transmission-torque to the engine and supported by elastic pads as well.
converter group, that in turn, is supported by brackets
1 1
4 2
6
9 1
7
10
8
11
12 1
13
14
15
1. Screw m16x2x110 - 2. Left rear support. - 3. Washer - 4. Screw M12x1.75x40 - 5. Upper pad. - 6. Lower pad. -
7. Plate - 8. Nut - 9. Screw m16x2x110 - 10. Left front support . - 11. Washer - 12. Screw M 16x2x40 - 13.Lower pad -
14. Plate- 15. Nut.
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General description
The configuration of the engine cooling system is as The oil, once it is sucked by pump 1 is forwarded to
follows: a controlling valve block 2 and through solenoid valve
A hydraulic pump 1 is installed on the engine (fuel 3, reaches two-direction hydraulic motor 4 driving the
pump side) powers by two hydraulic motors driving, main fan. Also through solenoid valve 3, oil under
respectively, the coolant radiator fan and the after- pressure reaches the second hydraulic motor 5 driving
cooler fan. A controlling valve is located between the the after-cooler fan, then it turns to the discharge.
two circuits with a dual function: modulating the oil
flow to the hydraulic motors, depending upon the speed
of the engine and invert the rotation direction of the
radiator fan, upon the command by the button located
in the cab.
DUAL DIRECTION
MOTORE MOTOR14CC/REV
BIDIREZIONALE 14CC/REV ALLATOLINEA
DISCHARGE LINE
DI SCARICO
(ENGINERADIATOR)
(RADIATORE MOTORE )
ONEDIRECTION
MOTORE MOTOR14CC/REV
UNIDIREZIONALE 14CC/REV
(AFTER-COOLER))
(AFTERCOOLER
4
5
1/2" BSP 10 1/2" BSP
220 BAR
11
220 BAR
3 T1
1/2" BSP
7
G1 T
2 3/4"BSP 3/4" BSP
9
200 BAR
8 B A
6
T P
P1 3/4" BSP
1 19CC/REV
Fig. 1-7
1. Pump - 2. Fan hydraulic control block - 3. Solenoid valve - 4. Dual direction hydraulic motor - 5. One direction hydraulic
motor - 6. Proportional valve - 7. Safety valve - 8. Orifice (2 mm) - 9. Safety valve -10. Safety valve - 11. Safety valve.
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INLET OUTLET
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SUCTION DELIVERY
Fig. 1-10
TYPE: gear
DISPLACEMENT: 19 cu cm/rev
REVOLUTION: clockwise
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1 - 10 ENGINE W230
1 9
7
8
POS. DESIGNATION
1 Drilled block 5
2 Safety valve
3 Proportional valve
4 Safety valve
5 Solenoid valve
6 Anti cavitation valve 2
7 Safety valve
8 Safety valve
9 Dowel Fig. 1-12
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SECTION 2
TRANSMISSION
TABLE OF CONTENTS
The transmission power train is made of a drive group The power driven to each axle reaches, through the
(torque converter and transmission), prop shafts, front wheels, the tires, thus driving the loader.
and rear axles and tires. Here below a diagram of the transmission power train
The engine power is driven to the converter-transmis- is provided.
sion group, where the r.p.m. are reduced and the torque
is increased.
: Prop shaft
Torque converter
Rear axle
Prop shaft
Transmission
Front axle
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TORQUE CONVERTER
TRANSMISSION PUMP
TRANSMISSION
CLUTCHES (TRANSMISSION)
GENERAL DESCRIPTION
The control group of the transmission is made of a The engine power is driven to the transmission unit
combination of the torque converter and the trans- by the flywheel and the converter.
mission, in a single body. The engine and the torque converter - transmission
The power train system is connected to the engine group are connected by means of a splined flange.
and is installed on the rear frame.
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Transmission - Torque converter Besides for the removal of the parking brake, it is
necessary to compress the engagement springs by
Countershaft power-shift type with 6 clutch packs for means of a screw placed on it.
4 forward and 4 reverse speeds. The torque converter This operation must be carried out each time the
is mounted are the transmission housing and is a 3 machine must be moved with a dead engine.
element type, single stage, single phase.
The hydraulic circuit has:
- The lubrication fo the shaft with the directional Transmission control
clutches assured by a section of the feed pump.
The gear shifting is completely electric and there are
- The second speed clutch engagement modulation
various gearshifting modes:
is assured by an accumulator and a no-return val-
ve with an orifice.
- Normal working phase in automatic and manual
The hydraulic circuit is feed by a two-section gear
modes.
type pump. The first section feeds the clutch
- Kick-down function.
engagement circuit, the torque converter and assure
- Shift-down function (only for automatic mode).
the lubrication of the shafts with the speed clutch
- Transmission disengagement when braking.
packs.
The second section assures the lubrication of the
All the components are located inside the cab. the
directional clutch packs.
gear selector located on the steering column, a switch
On the second speed shaft is installed the multiple
located under the throttle pedal and a switch located
disc parking brake. It is disengaged by hydraulic
at the base of the bucket control for "Kick-down"
pressure and engaged by spiral type springs. The
function, a series of relays and fuses located in the
control is assured by means of a steel cable actuated
main electric board and the transmission electronic
by a control lever located on side of the operators
unit located behind the seat the main difference
seat and operating an hydraulic control valve.
between a machine with automatic transmission and
The selection of the various speeds is obtained through
one with manual transmission is given by the fact
a control valve incorporating all the valves, such as,
that all functions described above are in an automatic
the spools, the main pressure regulating valve and
transmission controlled by the electronic unit, while
the modulating valves.
in the manual transmission the sames are controlled
Totally there are 4 solenoids that are controlled by a
speeds selector installed on steering wheel support. by the relays and fuses console.
The only valves placed outside the control valve are
the torque converter inlet safety valve and the Advantages of automatic transmission:
modulating valve with accumulator for the engagement - Comfort.
of the second speed. - Modulation.
To avoid traction losses during shifting operations from - Less gearshifting requirements.
second to first speed, a non-return valve with orifice - Less noise (two to medium low no-load engine
and accumulator is fitted or the second speed supply speeds during gearshifting).
retarding the disengagement of the clutch pack. - No loads on transmission.
As a result there will be a temporary pressure - Optimized use of power-train components (engine,
overload in the first and second clutch packs (also of transmission, axles).
the third clutch pack as a result of the system - No possibility of incorrect operation.
arrangement) with partial engagement of the two - Performance and production.
clutch packs. - Maximum use of engine output.
In this way the machine is not moving backward during - Overall efficiency of torque converter.
shifting from second to first speed in uphill operations. - Less fuel consumption.
The emergency pump is connected to the output shaft - Reduction in travel times.
through on idler gear placed on 3rd and 4th gear shaft. - Increased production.
The transmission disassembly does not reguire - Easy and safe driving.
particular cautions, there are no adjustment either for - More operator concentration on production.
clutch packs or shafts.
All shafts are rotating on ball bearings. The only caution
to be observed regards the removal of the torque
converter that must be removed together with thee
transmission front cover to which it is connected with
screws mounted on the inside.
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2 3
2
3
4
3
6
7
8
2 51 Nm
3 225 Nm
4 90 Nm
1. Engine - 2. Gasket - 3. Cover - 4. Torque converter-transmission group - 5. Support bracket - 6. Upper rubber support pad
- 7. Lower rubber support pad - 8. Plate.
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Section G-G
View from F
1
3
Note:
1 Threaded part: LOCTITE 572
4th FWD.
• •
TORQUE CONVERTER GROUP
1. From heat exchanger - 2. Oil filler hole - 3. Parking brake disengagement pressure - 4. To heat exchanger - 5. From filter - 11. Reverse
3rd FWD.
•
clutch 21 - 24 bar pressure port - 12. Forward clutch 21 - 24 bar pressure port - 13. 1st speed clutch 21 - 24 bar pressure port - 14. 2nd speed 2nd FWD.
• • •
clutch 21 - 24 bar pressure port - 15. 3rd speed clutch 21 - 24 bar pressure port - 16. 4th speed clutch 21 - 24 bar pressure port - 17.
Pressure switch mounting port - 18. Temperature sensor mounting port - 19. Converter output pressure port - 20. Converter input pressure
1st FWD.
N
• •
port - 31. Transmission pump - 32. Suction pipe - 33. Strainer- 35. Control valve - 36. Hose - 37. Breather - 38. Spring - 39. Plunger (safety
valve) - 40. Mounting for emergency steering pump. st
1 REV.
• •
2nd REV.
• • •
Note — For sections D-D, E-E, J-J, please refer to the page to follow. 3rd REV.
•
4th REV.
• •
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Copyright © New Holland
5 Setting of gap E: after bringing the sensor against the gear, move it away, by
loosening it, 1.5 turn.
Green Black
35 34
3 1 38
5 3
39
2 40
41
36
37
Section J-J Section E-E Section D-D Detail area Z
Fig. 2-4 Torque converter group (2)
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The torque converter consists of a torque converter The hydraulic pumps drive actuates the transmission
group, an hydraulic pumps drive gear and a turbine power pump, the equipment pump and the steering
shaft. pump, through the drive gear, mounted on the pumps
The torque converter group is composed of a pump drive hub.
wheel and a turbine wheel, positioned one in front of
the other, with an intermediate stator, located inside
the torque converter housing, filled with oil.
1 9
2
10
3
11
4 2
5
12 3
1
13
6
3 7
8
14
15
1. Taper plug - 2. Pump wheel cover - 3. Coupling gear - 4. Turbine - 5. Pump hub - 6. Input guide - 7. Stator hub - 8. Stator -
9. Impeller cover- 10. Pump wheel - 11. Pump drive gear - 12. Stator retainer - 13. Turbine shaft - 14. Seal - 15. Seal.
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Power train
The engine power is transmitted through the engine
flywheel, the disc joint or the coupling gear, the front
cover, the pump wheel, the turbine and the transmis-
sion.
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The pump is mounted on the torque converter cover. and speed clutches, it provides lubrication to the inner com-
It powers, through the control valve, the forward-reverse ponents of the transmission, feeds the torque converter.
1. Transmission - torque converter group - 2. transmission - Torque converter pump - 3. Sleeve - 4.Pump securing screw -
5. Transmission control valve.
5 13 7
11-12 8
11-12
10
13
6 14
Z 3 15
2
17 16
18
1
9
View from Z
16
16
4
16
1. Front cover. - 2. Pump body - 3. Gear - 4. Gear - 5. Side plate. - 6. Plate - 7. Body - 8. Gear - 9. Gear - 10. Top cover. -
11. Support - 12. Seal - 13. Seal - 14. Screw - 15. Washer - 16. Bushings - 17. Seal - 18. Snap ring.
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2 - 10 TRANSMISSION W230
2.5 TRANSMISSION
The transmission changes the speeds and the travel DIRECTION CLUTCHES SHAFT
direction.
The direction clutches allow the engagement or
The transmission includes three clutch shaft groups, discugagement of power, under load, no matter what
one inverter gear, one output shaft, a parking brake speed is engaged.
and a control valve.
16
1 2 3 4 5 6 1 8 9 11 12 13
7 10 1
FORWARD REVERSE
14 15
Detail A Detail B
1. Shaft and drum - 2. Gear - 3. Inner toothed disc - 4. Return spring - 5. Outer toothed disc. - 6. Spacer - 7. Discharge valve -
8. Sealing ring (outer) - 9. O-ring - 10. Sealing ring (inner) - 11. Piston - 12. End disc - 13. Gear - 14. Sealing ring - 15. Plug -
16. Spring.
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W230 TRANSMISSION 2 - 11
(Forward/reverse shaft)
FORW. REV.
2a 1a
4a 3a
Discs
(outer toothed) 13 - 13 17 - 10 17 - 10
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2 - 12 TRANSMISSION W230
OPERATION
The clutch is engaged by the oil under pressure flow- Then the clutch piston compresses the outer and in-
ing from the transmission control valve. ner disc fully, thus holding the clutch shaft with the
Pressurized oil flows through the distribution cover clutch hub, allowing the driving of the power through
and the ducts in the clutch shaft reaching the rear the output shaft of the transmission.
side of the clutch piston, moving it.
1 2 3 4 5
Pressurized oil
From transmission
control valve
1. Clutch shaft - 2. Clutch piston - 3. Clutch inner disc - 4. Clutch outer disc. - 5. Clutch hub.
When pressurized oil from the control valve is cut-off, the clutch shaft and the clutch hub to rotate inde-
the return spring moves the clutch piston backward, pendently, thus avoiding the transmission of power to
freeing the clutch inner and outer disc pack, allowing the output shaft of the transmission.
1 2 3 4 5 6
To transmission
control valve
1. Clutch shaft - 2. Clutch piston - 3. Clutch inner disc. - 4. Return spring - 5. Clutch outer disc - 6. Clutch hub.
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W230 TRANSMISSION 2 - 13
7 8 9
3 2nd speed
clutch
4
5
6 To reservoir
1. Plug - 2. Adapter - 3. Spring- 4. Ball - 5. 1.0 mm (0.039 in) orifice - 6. Cover - 7. Plug - 8. Spool - 9. Spring.
The accumulator comes into action when a sudden In graph of fig. 2.12, it is possible to note how the
pressure drop accours in the actuating clutch packs pressure changes with and without accumulator.
as it happens for example when passing from 2nd to The engagement time of 1st speed t2 is distinctly lower
1st speed with a full bucket on step gradient. The ac- then time t1 without accumulator. This translates into
cumulator therefore releases pressure to prevent the an almost constant availability of the power during
rolling backward of the machine when using that is gearshifting, preventing unwanted backing of the ma-
the automatic selection of lower speeds (KICK-DOWN). chine, under the operating conditions described above.
The accumulator operates, also, in the same manner
during normal gearshifting (from 2nd to 1st, from 2nd to
3rd).
Clutch
pressure
t1 1
t2
Clutch
2 engagement oil
pressure
2
Time Operation
1 1st speed engagement pressure 1. When the 2nd gear is engaged, pressurised oil
flowing out the control valve flows through the
2 2nd speed engagement pressure check valve, to the 2nd speed clutch pack and
(without accumulator)
into the accumulator.
2 2nd speed engagement pressure 2. When from the 2nd gear the operator shifts to
(with accumulator) another speed, pressurised oil is discharged
through an orifice, so that the oil pressure in the
Fig. 2-13 Graph of accumulator operation 2nd speed clutch decreases gradually.
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2 - 14 TRANSMISSION W230
When both the forward and reverse clutches are dis- When both the forward and reverse clutches are
engaged, the power driven from the torque converter disengaged, the power driven from the torque converter
rotates the forward-reverse clutches shaft, without rotates the forward-reverse clutches shaft, without
driving the speed clutches. driving the speed clutches.
FWD. REV.
A
C
C A
4a 3a
D
B
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W230 TRANSMISSION 2 - 15
When the gearshift lever is in any of the four reverse reach the transmission output shaft through the for-
gears, the power driven from the torque converter can ward clutch and the clutch of the speed selected.
FWD. REV.
A
C
C A
4a 3a
D
B
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2 - 16 TRANSMISSION W230
The transmission control valve allows the selection The control valve is equipped, also, with a modulation
of the clutches receiving oil at the engagement pres- device operating distinctly, depending upon the speed
sure to shift direction and speed of the loader. engaged. If the electrical system fails, it is possible
to operate manually the control valve.
The control valve includes a body and 4 solenoid
valves that are energised and de-energized by the
transmission gearshift selector (control lever), to move
the distribution spools regulating the oil under pressure.
A A
B B
C C 3 4
D 2
1. Plate (for manual operation) - 2. Cover - 3. Cover - 4. Cover - 5. Solenoid valve - 6. Connection block - 7. Control valve
body (lower) - 8. Forw./rev. selector spool. - 9. Adapter - 10. Spring - 11. SpooL (A) - 12. Selector spool spring - 13. Spool (B) -
14. Selector spool spring - 15. Orifice 0.8 mm (0.031 in) diam. (for solenoid valve) - 16. Orifice [W] ACCESS plug - 17. orifice
[z] ACCESS plug See Note - 18. Orifice [Y] ACCESS plug - 19. Orifice [x] ACCESS plug - 20. Control valve body (upper) -
21. Spring - 22. Flow valve. 23. Spring - 24. Pin - 25. Rod - 26. Inner spring - 27. Intermediate spring - 28. Outer spring - 29.
Load plunger (H) - 30. Pressure regulating valve - 31. Plunger. Asta
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W230 TRANSMISSION 2 - 17
7
15
sol 8
IND.
9
sol 10
AV. (W)
11
12
A sol (Z) (X)
13
14
B sol (Y)
Section A-A
6 16 17 18 19
View from B-B
20
30
21
31
22
39
32
23
24 33
25 34
26 35
27 36
Section D-D
28 29 38 37
Section C-C
32. Outer spring - 33. Inner spring - 34. Modulating spool - 35. Inner spring - 36. Intermediate spring - 37. Outer spring -
38. Load piston L - 39. manual spool (for emergency movements).
.
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2 - 18 TRANSMISSION W230
Accumulator
One way 1 2
FOR./REV restriction
selector spool FWD. REV.
4
sol. REV.
sol. B
sol. FWD.
To torque Spool B
converter
Manual
spool
sol. A
Spool A
Pressure (Y)
regulating
valve (W) (Z)
(X)
Flow valve
Modulating valve
from Pump
Accumulator
(load plunger)
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W230 TRANSMISSION 2 - 19
OPERATION
The modulating valve of this control valve changes The intervention of the modulating valve is represen-
the time required to increase the oil pressure up to ted in the diagram by points A - E. The intervention of
the clutch engagement value, modifying the pressure the solenoid valves and the manual spool (emergen-
increment curve, in accordance with the transmission cy travel spool) is explained in the pages to follow.
speed, allowing a smother gearshifting.
Speed
A D
2nd
Oil pressure
speed
3rd/4th
speed E
C
1st
speed
0 Time
1. The oil delivered by the transmission pump to the chamber of the 3rd speed clutch. The other clutches
pressure regulating valve through duct (1) of the are connected with the discharge.
control valve, flows through a small calibrated hole
“a”: filling chamber (2) behind the spool, moving it 4. The oil in circuit (8) flows through the axial hole of
leftward, as in the figure. spool A, reaching circuit (19). Then, the oil goes
The oil, which pressure is regulated at the value of through orifice [Z] and joins chamber (20) of the
engagement of the clutch, travels circuit (3) to reach accumulator.
the circuit of modulation valve (5). Oil in excess is In this chamber there are two load plungers, one
discharged into the torque converter, through circuit for low pressure, the other for high pressure. After
(4). the movement of the low pressure plunger moves
to contact the rod, the high pressure plunger starts
2. The oil in circuit (5) flows through the gap left open moving.
by the chamfer of the modulating valve plunger,
reaching circuit (6), communicating, through ori- 5. The oil in circuit (12) is stopped by the FORW./
fice [W] with the circuits of the gear shift spool (8), REV. selector spool. Both the forward and reverse
of flow valve (9) and forward/reverse selector spool clutches are disengaged (neutral).
(12).
6. All solenoid valves are in “OFF” (not energized)
3. The oil sent into circuit (8) reaches, through condition, thus the oil reaching them through the
passages (8) → (16) → (17) → (18) to the piston relevant orifices is discharged.
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2 - 20
Fig. 2-20
4 1
REV.
3 2
TRANSMISSION CONTROL VALVE
“OFF” 18
sol. “OFF”
REV. sol. B
“OFF”
sol.
To TRANSMISSION
8 19
5 MODULATOR
(LUBRICATION)
TORQUE
CONVERTER
TRANSMISSION
HEAT EXCHANGER 3 Z X Y
9
SAFETY VALVE
FLOW
4 a VALVE
FILTER
ACCUMULATOR
PUMP
1 2
PRESSURE RELIEF HIGH PRESSURE 20 BLOW PRESSURE
VALVE
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SUCTION AND PRESSURE OIL CONVERTER
DRAIN OIL LUBRICATION OIL
W230
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Copyright © New Holland
W230 TRANSMISSION 2 - 21
1. Solenoid valves F and A are energized. 5. The pressure difference between circuits (9) and
(22) moves the flow valve plunger rightward, as
2. With solenoid valve F energized, the oil discharge indicated in the figure, discharging the oil of
is closed, so the oil flow coming from the pressure accumulator (20).
relief valve is forced to move toward circuit (26)
where the FORW./REV. selector spool is located. 6. The modulating valve plunger moves rightward, as
The pressure created by this oil flow moves the shown in the figure, as a consequence of the
FORW./REV. selector spool rightward, as shown pressure drop in circuit (25), letting only the quantity
in the figure. of oil due to circuits (5, 6) go through.
Speed
A D
2nd
Oil pressure
speed
3rd/4th
speed E
C
1a
speed
0 Time
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2 - 22
FWD. CLUTCH CLUTCH
4 1
Fig. 2-21
REV.
3 2
TRANSMISSION CONTROL VALVE
“OFF” 26 21 18
sol. FF “OFF”
REV. sol. B
“ON”
sol. FORW./REV. 12
FWD. SELECTION
“ON” SPOOL B 17
w sol. A
FORW. N REV. 6 16
To TRANSMISSION 5 8
MODULATOR
(LUBRICATION)
TORQUE
CONVERTER
TRANSMISSION
HEAT EXCHANGER
Z X Y
9
SAFETY
VALVE
FLOW VALVE
22
FILTER
ACCUMULATOR
PUMP PRESSURE RELIEF
VALVE
1
HIGH PRESSURE 20 LOW PRESSURE
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SUCTION AND PRESSURE OIL CONVERTER VARIABLE
DRAIN OIL LUBRICATION OIL PRESSURE OIL
W230
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Copyright © New Holland
W230 TRANSMISSION 2 - 23
Speed
A D
2nd
Oil pressure
speed
3rd/4th
speed E
C
1st
speed
0 Time
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FWD. CLUTCH CLUTCH
2 - 24
4 1
Fig. 2-22
REV.
3 2
TRANSMISSION CONTROL VALVE
“OFF”
sol. F “OFF”
REV. sol. B
“ON”
sol.
FWD. FORW./REV.
SELECTION
w “ON” SPOOL B
sol. A
FORW. N REV. 6
MANUAL SPOOL
25
7 SPOOL A
24
23
TORQUE
CONVERTER
TRANSMISSION
HEAT EXCHANGER
Z X Y
SAFETY
VALVE
FLOW VALVE
FILTER
ACCUMULATOR
PUMP PRESSURE RELIEF
VALVE
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HIGH PRESSURE 20 LOW PRESSURE
W230 TRANSMISSION 2 - 25
Speed
A D
2nd
Oil pressure
speed
3rd/4th
speed E
C
1st
speed
0 Time
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FWD. CLUTCH CLUTCH
4
2 - 26
1
Fig. 2-23
REV.
3 2
TRANSMISSION CONTROL VALVE
“OFF”
sol. “OFF”
REV. sol. B
“ON”
sol. FORW./REV.
FWD. SELECTION
“ON” SPOOL B
W
FORW. N REV. sol. A
25
MANUAL SPOOL
SPOOL A
7
To TRANSMISSION
MODULATOR
(LUBRICATION)
TORQUE
CONVERTER
HEAT EXCHANGER Z X Y
FLOW VALVE
SAFETY
VALVE
FILTER
ACCUMULATOR
PUMP PRESSURE RELIEF
VALVE
HIGH LOW
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
PRESSURE 20 PRESSURE
W230 TRANSMISSION 2 - 27
Speed
A D
2nd
Oil pressure
speed
3rd/4th
speed E
C
1st
speed
0 Time
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
FWD. CLUTCH CLUTCH
4
2 - 28
1
Fig. 2-24
REV.
3 2
TRANSMISSION CONTROL VALVE
“OFF”
sol. “ON”
REV. sol. B 28
“ON”
sol. FORW./REV.
FWD.
SELECTION
“ON” SPOOL B 8
W sol. A 27
FORW. N REV.
MANUAL SPPOL
SPOOL A
23 24
To TRANSMISSION MODULATOR
(LUBRICATION)
29
TORQUE
CONVERTER
Z X Y
HEAT EXCHANGER
SAFETY
VALVE
FLOW VALVE
FILTER
HIGH LOW
PRESSURE PRESSURE
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
20
W230 TRANSMISSION 2 - 29
Four solenoid valves are mounted on the control valve. Oil at the pressure controlled by the pressure relief
When selecting speeds, an electric signal is trans- valve, flows constantly through the calibrated orifice
mitted to the solenoid valves of the control valve. For and enters the solenoid valve. When the solenoid is
each speed selected, a combination of solenoid valves not energized, the oil flows through it and discharges
are energized (see tables here below) which have the to tank.
purpose of controlling the selecting spools “FOR and The oil pressure in point P is 0 bar (0 psi).
REV “A and B”.
4a
• •
FOR
3a
•
2a
• • • NOT ENERGIZED
"OFF"
P
1a
• • CALIBRATED
ORIFICE
1a
• •
REV.
2a
• • • FROM PRESSURE RELIEF VALVE
3a
• Fig. 2-26
4a
• • Solenoid valve energized
ENERGIZED "ON"
Fig. 2-25
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2 - 30 TRANSMISSION W230
WARNING
Ensure that the engine is not running prior to ope- Fig. 2-28 Transmission control valve
rate the manual spool. Should the spool actuated
when the engine is running, the loader could move 1.Control valve - 2. Solenoid valves - 3. Screw - 4. Spools
suddenly, causing accidents. retainer plate - 5. Manual spools
REV.
“OFF”
Sol. 26
FOR.
FOR. N REV.
FORW./REV.
MANUAL SPOOL SELECTOR SPOOL
32 31
33
Drain oil
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W230 TRANSMISSION 2 - 31
To shift into 3rd reverse, push-in the manual spool about Note - The connection of the wires on the ATC with
10 mm (0.39 in). the system energised could result in damaging the
The operation principle is the same as in the case of electronic components of the unit with the subsequent
3rd forward. zeroing of all the ATC functions.
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2 - 32 TRANSMISSION W230
Operation
Rotating the starting key on the ON position: The switch AT/MAN in automatic mode:
1)Are under control: the warning lamps, the solenoid 1) The logic of gear shifting is controlled by the electro-
circuits, the solenoids A and B of the speeds, the nic unit according to the following table.
rev sensors and the L.T.S. circuit. 2) The gear shifting depends on the speed and is ac-
2) The solenoids F and R (forward and reverse) are tuated accroding to three different logics: same di-
controlled when actuated. rection of travel, inversion of direction, use of Kick-
3) If during the check a malfunction is noticed the down button.
situation is indicated by the flashing of one of the 3) The gear up shifting it is possible only with the throt-
warning lamps. tle pedal pressed down. The hold function is possi-
ble only when the foot releases the accelerator.
AT/MAN switch in manual mode: 4) The Kick-down function is automatically released
1) The logic of gear shifting depends on the position when the travel speed reaches a certain value.
of the selector. 5) The electronic unit reads the signal in HZ sent by
2) With the Kick-down button it is possible to shift two sensors located in transmission.
down from 2nd to 1st speed both in forward or rever- 6) The two sensors read the same signal on the same
se without limitation values. gear. A malfunction of a sensor is indicated as er-
3) The disengagement of the Kick-down is obtained ror.
by moving the selector either in neutral position or
in another speed. The L.T.S. (Load Travelling System) operates in all spe-
4) The L.T.S. operates in all speeds, it engages at 7 eds. It engages at 7 km/h (4.3 mph) and disengages at
km/h (4.3 mph) and disengages at 5 km/h (3.1 mph). 5 km/h (3.1 mph).
1st ----------
1st only 1st
2nd loading 2nd only 1st
3rd loading and travel 2nd →3rd aut. 2nd - 1st
4th travel 2nd - 3rd - 4th aut. 3rd - 2nd - 1st
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
W230 TRANSMISSION 2 - 33
"ACC"
14 15
Wiring diagram of the automatic transmission D10
ATC
+30
E4 N11
E14 N9 N7 N8 S3
CN2-2
D29
Connectors SW1-1
E13
CN2-11 CN1-2
B-G-M-D-E-P-C-N-S RELE'
SW1-2 CN2-17 SERVICES
SERVIZI
E15 RELAY
CN2-16
Connectors C-D-B
CN2-10
1 CN2-15
S2 VC2
1 G17 E9
G1 CN2-4 CN2-14
M-B
2 G18 E8
Transmission selector CN2-3
M-N
wire Connectors
9 3 G15 E7
CN1-13
+VC2
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Copyright © New Holland
2 - 34 TRANSMISSION W230
CN2-11 CN1-2 B1
CN2-17 M
CN2-16
CN2-10
1 CN2-15 F4A
F4B
CN2-4 CN2-14
R5
CN2-3
07
CN1-13
CN1-7 CN1-5 CN1-11 CN2-7 CN2-8 CN2-9 CN2-6
937
033 R4
022
N1
N2 N6 N3
D37 033
R-N
A-R
S-G
C-H
C-V
C3
A-V
C-B
D27
M14
B11
L-B B2 L-B
B-R
R-G B3 G-R
A-V B4 A-B
R-V B5 R-V
C-N B7 C-N
R-N B6 R-N
3 1 2 3 2
2 3
N
1 4 2 R F
5
ACC
D10
F11A
R-G
2
S-G
C-B
G/V
G/R
A-B
A-V
A-V
H-L
L-B
G1
N
R
B
7 11 1 4 3 5 8 10 9 12 13 2 6
R
1 9 1 3
0 1 3 G1 G3 G5 G2 G4 G6
4 5 10
D
R R
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Copyright © New Holland
W230 TRANSMISSION 2 - 35
F 8
A
6 1
2
F
3
4
N
R
9
F/R
C H C H
COOLANT OIL TRAM
1 2 3 4
E\G OIL BRAKE PRESS
1\10h PARKING
GENERAL
FUEL 50 HOUR METER WARNING
13 km\h
10
5
CN1
4 3 11
ATC
1
CN2
14
1. Electronic unit - 2. Logic board - 3. L.T.S. solenoid valve - 4. Sensor under the throttle pedal (for function hold) - 5. Button for "KICK DOWN" function - 6. L.T.S. engagement switch - 7. Automatic Transmission mode engagement switch - 8. Transmission pilot valve - 9. Speed
engaged inticators - 10. Tachometer - 11. Engagement solenoid valves on trasmission control valve - 12. Direction reverser auxiliary switch control button (option) - 13. "Forward/reverse" function switch - 14. "Forward/reverse" control unit.
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Copyright © New Holland
2 - 36 TRANSMISSION W230
ND
X1 4
3
2
1
X2 1
1
2
3
4
X3
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Copyright © New Holland
W230 TRANSMISSION 2 - 37
AUTOMATIC GEARSHIFTING
The speeds and the inversion of directions are choo- Forward ("F")
sen by a transmission control selector located on the Push the button of the transmission automatic sy-
left side of the steering column, under the steering stem (on the right panel) to engage the automatic
wheel (see figure). mode, rotate the knob to position 3 or 4 and move the
The knob of the selector incorporates a horn button; gearshift lever to forward (“F”).
In this position the transmission ratios are changed
the speeds which can be selected are eight (four automatically as a function of the speed of the ma-
forward and four reverse). chine, from second to third respectively or from se-
A particular feature distinguishing machines equip- cond to forth. The display indicating the transmission,
ped with “Automatic Power-shift” is to have available shows the ratio being used.
both gearshifting modes, in automatic and manual. When the gearshift lever is in this position and the
machine is at a standstill, the second gear is auto-
matically engaged (the first being not enabled).
The following gears (third and fourth) will be engaged
as you accelerate.
MANUAL GEARSHIFTING Dowhshifting from fourth to third to second occurs
automatically as the loader ground speed decreases.
Forward ("F")
However, when moving on steep slopes, the machi-
When the lever is moved to the forward position (“F”)
ne does not change the gear ratio even if the throttle
the machine moves forward.
is fully released. This is due to the action of a sensor
Rotate the knob to positions 1, 2, 3, and 4 to select
located under the throttle pedal, which will be descri-
the first, second, third, and fourth gear ratios, respec-
bed in detail further on.
tively. The gear ratio selected will be displayed on the
Transition from the automatic to the manual mode is
dashboard display (automatic gearshift option only).
always possible, while it is necessary to reduce engi-
Neutral ("N") ne rpm and machine ground speed adequately to chan-
When the gearshift lever is in the middle position (“N”), ge the direction of travel.
the trasmission is in neutral.
Neutral ("N")
Reverse ("R") When the gearshift lever is moved to the middle po-
When the gearshift lever is in this position, the ma- sition (“N”), the transmission is in neutral.
chine can move only rearwards, with the possibility to The second gear, however, remains engaged as it is
select the first, sescond, third or fou rth gears. the basic ratio.
Change of direction is always possible independently
of the gear selected. Reverse ("R")
For example, if you are working using the second When the gearshift lever is in this position, the ma-
forward and reverse the direction of travel by moving chine can move only rearwards and the gears change
the gearshift lever to the “R” position, the transmis- automatically according to the the ground speed.
sion will automatically switch from second forward to Operation modes and gear selection are same as for
second reverse. forward travel.
Reduce the engine rpm when reversing the direc- “HOLD” function
tion. When operating on steep ramps or downhill, it is easy
overheating the brakes while slowing down continuo-
usly the machine, to prevent a galloping speed under
the effect of the automatic shifting to higher speeds.
The HOLD function provides that, when the foot rele-
ases the accelerator, the transmission keeps the speed
engaged, without allowing the shifting into higher spe-
eds.
In the event the speed of the machine results to be
too high, it is possible to slow-down further, without
using the brakes, with the function described below.
Automatic
transmission
switch
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Copyright © New Holland
2 - 38 TRANSMISSION W230
2.7.1 SHIFT-DOWN DEVICE In the event, during the use of the function, the ge-
arshifting lever is moved, the device is cut-off. To
The Shift-Down device is actuated by the automatic re-engage it, return the gearshifting lever into neu-
transmission button engaged, on the right console. This tral and press the neutraliser button again.
function allows, under steep gradient situations, the
down-shifting by simply pressing button A located betwe-
en the equipment control levers. The device is compo-
FORWARD
sed of a down-shifting button and two relays.
REVERSE
NEUTRAL
Operation
1. When the key is moved into START with the se-
lector lever in neutral, the neutral relay is closed,
allowing electric power to go through the safety
relay, thus powering the starter motor of the engi-
ne.
Fig. 2-35 2. When the starter key is moved to START with the
pilot valve not in neutral, the neutral relay stays
To activate this direction reversing auxiliary function, open, preventing the power from crossing the sa-
it is necessary that the gearshifting lever is in neutral fety relay. The engine cannot be started.
and the reverser auxiliary switch neutraliser button is
engaged.
Switch pressed forward: forward speed
Switch pressed backward: reverse speed
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Copyright © New Holland
W230 TRANSMISSION 2 - 39
1. When the gearshift lever is moved into 2nd speed, 1. When the KICK-DOWN device is actuated, relay
solenoid valve AV is energized by power “a”, whe- 2 is activated by power “e”, that in turn, cuts-off
reas relay 1 is actuated by power “b”. power “d” to solenoid valve B, de-energizing sole-
noid valve B. Thus, the transmission shifts to 1st
2. Solenoid valve A is energized by power “c” where- speed.
as solenoid valve B is energized by power “d”.
Consequently, the transmission engages the 2nd
forward.
–– ––
–– ––
Relay 1 Relay 1 e
b 13
b 13
Kick-down Kick-down
Relay 2 e
button Relay 2 button “ON”
14 14
d
Transmission e
Transmission
Solenoid d selector Solenoid selector
valve A d
1a 2a 3a 4a valve A 1a 2a 3a 4a
14 14
c e
d
Solenoid Solenoid
valve B valve B
d
d
Solenoid valve 13 Solenoid valve
FOR b FOR.F. REV. 13 FOR. F. REV.
FOR
11 a
Solenoid valve REV 11
Solenoid valve REV
9
9
15
15
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Copyright © New Holland
2 - 40 TRANSMISSION W230
2. At the same time, power “f” appears, allowing re- Transmission in reverse direction
lay 2 to remain self energized, thus it stays acti-
vated also after the KICK-DOWN button device is 1. When the gearshift lever is moved to reverse, power
released. “b” is zeroed, thus relay 1 is de-activated. This
Consequently, the transmission stays in 1st speed causes the cut-off of power “f” at relay 2 causing
after the KICK-DOWN device is de-activated. also the opening of relay 2.
14
f
Transmission
Solenoid selector ––
––
valve A 1a 2a 3a 4a
Relay 1
b
14
b
13
Kick-down
Solenoid f
Relay 2 button “OFF”
valve B
14
f
13 FOR. F. REV. d Transmission
Solenoid valve FOR
Solenoid d selector
11 valve A 1a 2a 3a 4a
Solenoid valve REV
14
9
d
Solenoid
15 valve B
d
13 b
Solenoid valve FOR FOR. F. REV.
11 g
Fig. 2-39 Solenoid valve REV
g
9
15
Fig. 2-40
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Copyright © New Holland
W230 TRANSMISSION 2 - 41
GENERAL DESCRIPTION
The oil used to engage the clutches is taken from the The oil drain by the rear pump passes, with the oil lea-
transmission housing. ving the converter, into the heat excharger to be coo-
As soon as the engine starts, the dual power pump led. After leaving the heat exchanger, the oil lubricates
sucks the oil from the sump of the transmission hou- and cools all the speed clutch packs, prior to returning
sing, through the mesh filter. The oil sucked by the into the sump of the transmission housing.
front pump flows through the delivery filter, to the tran-
smission control valve. The control valve divides the Note - The heat exchanger is located inside the lower
oil flow into two parts: one for the operation of the tor- tank of the engine coolant radiator.
que converter and the other for the actuation of the
transmission clutches.
2 3 4
7 8
6
9 10
1. Feeding double pump - 2. Torque converter - 3. Heat exchanger - 4. Oil distribution cover (3rd / 4th speed shaft) - 5. Oil
distribution cover (1st / 2nd speed shaft) - 6. Oil distribution cover (forw./rev. shaft) - 7. Delivery filter - 8. Transmission control
valve - 9. Strainer - 10. Transmission housing.
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Copyright © New Holland
2 - 42 TRANSMISSION W230
Delivery filter
The delivery filter is located in the transmission clu- When the filtering element is clogged, the pressure at
tch engagement control oil delivery circuit. the filter inlet port increases so that the by-pass val-
The oil flows through the filtering element from the ve opens, letting the oil flow directly to the outlet port
outside to the inside and filtered oil is sent to the tran- of the filter.
smission control valve.
A A
3
1
Section A-A
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Copyright © New Holland
W230 TRANSMISSION 2 - 43
Note:
• Use a working bench, hoist, bearing puller and
hangers for easy and safe disassembly.
• Put the disassembled parts to insure speedy parts
in order, and efficient reassembly of them.
• You are reminded that the real configuration of the
machine can differ from the illustrations.
• Unit weight: 838 kg (1847.5 lb)
Fig. 2-43
Fig. 2-44
Fig. 2-45
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Copyright © New Holland
2 - 44 TRANSMISSION W230
Fig. 2-46
Fig. 2-47
Fig. 2-48
Fig. 2-49
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Copyright © New Holland
W230 TRANSMISSION 2 - 45
Fig. 2-50
Fig. 2-51
2
1
Fig. 2-52
Fig. 2-53
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Copyright © New Holland
2 - 46 TRANSMISSION W230
Fig. 2-54
Fig. 2-55
Fig. 2-56
Fig. 2-57
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Copyright © New Holland
W230 TRANSMISSION 2 - 47
Fig. 2-58
Fig. 2-59
Fig. 2-60
Fig. 2-61
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Copyright © New Holland
2 - 48 TRANSMISSION W230
Fig. 2-62
Fig. 2-63
Fig. 2-64
Fig. 2-65
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Copyright © New Holland
W230 TRANSMISSION 2 - 49
Fig. 2-66
Fig. 2-67
Fig. 2-68
Fig. 2-69
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Copyright © New Holland
2 - 50 TRANSMISSION W230
Fig. 2-70
Fig. 2-71
Fig. 2-72
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Copyright © New Holland
W230 TRANSMISSION 2 - 51
Fig. 2-73
2. Remove the snap ring from the groove at the outer
diameter of the bearing.
Fig. 2-74
Fig. 2-75
Fig. 2-76
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Copyright © New Holland
2 - 52 TRANSMISSION W230
Fig. 2-77
Fig. 2-78
Fig. 2-79
Fig. 2-80
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Copyright © New Holland
W230 TRANSMISSION 2 - 53
Fig. 2-81
Fig. 2-82
Fig. 2-83
Fig. 2-84
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Copyright © New Holland
2 - 54 TRANSMISSION W230
Fig. 2-85
Fig. 2-86
WARNING
Use caution when loosening the bolts since strong
springs are incorporated inside the cover. Loosen
the bolts in turns little by little until you come to
feel no spring force.
Fig. 2-87
Fig. 2-88
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Copyright © New Holland
W230 TRANSMISSION 2 - 55
Fig. 2-89
Fig. 2-90
Fig. 2-91
Fig. 2-92
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Copyright © New Holland
2 - 56 TRANSMISSION W230
Fig. 2-93
Fig. 2-94
6. Remove the O-ring and oil seal from the seal re-
tainer.
Fig. 2-95
Fig. 2-96
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Copyright © New Holland
W230 TRANSMISSION 2 - 57
Fig. 2-97
Fig. 2-98
Fig. 2-99
Fig. 2-100
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
2 - 58 TRANSMISSION W230
Fig. 2-101
Fig. 2-102
Fig. 2-103
Fig. 2-104
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Copyright © New Holland
W230 TRANSMISSION 2 - 59
Fig. 2-105
Fig. 2-106
Fig. 2-107
9. Remove the 2 bolts securing the seal retainer
from the front side of the transmission case.
Remove the seal retainer.
Remove the oil seal from the seal retainer.
Fig. 2-108
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Copyright © New Holland
2 - 60 TRANSMISSION W230
Fig. 2-109
Fig. 2-110
12. Remove the snap ring from the 1st/2nd speed shaft
hole in the transmission case. Press the outer
diameter of the roller bearing outer race little by
little to remove.
Using the same manner, remove the bearing ou-
ter race from the 3rd/4th speed shaft hole.
Fig. 2-111
13. Remove the snap ring from the back gear shaft.
Fig. 2-112
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Copyright © New Holland
W230 TRANSMISSION 2 - 61
Fig. 2-113
15. Remove the back gear and spacer.
Fig. 2-114
Fig. 2-115
Fig. 2-116
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Copyright © New Holland
2 - 62 TRANSMISSION W230
Fig. 2-117
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Copyright © New Holland
W230 TRANSMISSION 2 - 63
Fig. 2-118
Fig. 2-119
Fig. 2-120
Fig. 2-121
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Copyright © New Holland
2 - 64 TRANSMISSION W230
WARNING
Return springs are installed inside the clutch. Be
sure to press the belleville spring using a press.
Fig. 2-122
Fig. 2-123
Fig. 2-124
Fig. 2-125
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Copyright © New Holland
W230 TRANSMISSION 2 - 65
Fig. 2-126
Fig. 2-127
Fig. 2-128
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Copyright © New Holland
2 - 66 TRANSMISSION W230
Fig. 2-129
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Copyright © New Holland
W230 TRANSMISSION 2 - 67
WARNING
Pay your utmost attention when loosening the
screws, since springs are incorporated in the cover.
Loosen the screws alternatively, a little bit at a time,
until the pressure of the springs is no further felt.
Remember that the two central springs are longer
than the other ones. Fig. 2-130
Fig. 2-131
WARNING
Use caution when loosening the bolts since strong
springs are incorporated inside the cover. Loosen
the bolts in turns little by little until you come to
feel no spring force.
Fig. 2-132
8
6
11 10
7
Fig. 2-133
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Copyright © New Holland
2 - 68 TRANSMISSION W230
Fig. 2-134
Fig. 2-135
Fig. 2-136
Fig. 2-137
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Copyright © New Holland
W230 TRANSMISSION 2 - 69
3
2
1
2
3
Fig. 2-138
Fig. 2-139
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Copyright © New Holland
2 - 70 TRANSMISSION W230
Fig.2- 140
Fig. 2-141
Fig. 2-142
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Copyright © New Holland
W230 TRANSMISSION 2 - 71
Fig. 2-143
Fig. 2-144
Fig. 2-145
Fig. 2-146
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Copyright © New Holland
2 - 72 TRANSMISSION W230
Fig. 2-147
Fig. 2-148
Fig. 2-149
Fig. 2-150
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Copyright © New Holland
W230 TRANSMISSION 2 - 73
Fig. 2-151
Fig. 2-152
Fig. 2-153
10. Press the bearing into the cover wheel and install
the input guide to it with 6 bolts.
Fig. 2-154
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2 - 74 TRANSMISSION W230
11. Lift the cover wheel with a hoist and put it onto
the wheel assembly to align bolt holes.
Fig. 2-155
Fig. 2-156
Fig. 2-157
Fig. 2-158
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Copyright © New Holland
W230 TRANSMISSION 2 - 75
Fig. 2-159
Fig. 2-160
Fig. 2-161
Fig. 2-162
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Copyright © New Holland
2 - 76 TRANSMISSION W230
Fig. 2-163
8. Remove all the rod jigs and attach the snap ring
into the groove in the drum.
Fig. 2-164
9. Fit the hub gear ball bearing (inner) onto the clutch
shaft.
Fig. 2-165
10. Make sure the 2 snap rings are installed inside
the hub gear.
11. Install the hub gear inside the clutch drum, turn-
ing it to the right and left by hand to align the gear
teeth with the disk splines.
Fit the hub gear onto the shaft with a soft ham-
mer until it comes in contact with the bearing on
the shaft.
Fig. 2-166
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W230 TRANSMISSION 2 - 77
12. Install the shield bearing into the hub gear with
the shield side pointed outside.
Install the snap ring into the shaft groove.
Fig. 2-167
Fig. 2-168
Fig. 2-169
f) Reassembling 3rd/4th speed clutch shaft
1. Using the same procedure for the forward clutch
pack reassemble the 3rd speed clutch pack (spline
shaft side) till the hub gear shield bearing.
Refer to (1) Reassembling forward/reverse clutch
shaft, step (2) to (12).
Remember that a spacer is not used between the
drum and piston. A belleville spring is not used
either.
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2 - 78 TRANSMISSION W230
Fig. 2-170
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Copyright © New Holland
W230 TRANSMISSION 2 - 79
Fig. 2-171
2
3
Fig. 2-172
Fig. 2-173
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Copyright © New Holland
2 - 80 TRANSMISSION W230
Fig. 2-174
Fig. 2-175
Fig. 2-176
Fig. 2-177
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Copyright © New Holland
W230 TRANSMISSION 2 - 81
Fig. 2-178
Fig. 2-179
Fig. 2-180
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2 - 82 TRANSMISSION W230
Fig. 2-181
3. Install the snap ring into the back gear fit the ball
bearings from both sides.
Fig. 2-182
Fig. 2-183
Fig. 2-184
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Copyright © New Holland
W230 TRANSMISSION 2 - 83
Fig. 2-185
Fig. 2-186
Fig. 2-187
Fig. 2-188
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2 - 84 TRANSMISSION W230
2. Install the snap ring and 51T gear onto the oppo-
site end of the shaft. Press the roller bearing and
secure it with a snap ring.
Fig. 2-189
Fig. 2-190
Fig. 2-191
Fig. 2-192
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Copyright © New Holland
W230 TRANSMISSION 2 - 85
Fig. 2-193
7. Press the oil seal into the seal retainer and in-
stall the "O"-ring into it.
Fig. 2-194
Fig. 2-195
Fig. 2-196
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2 - 86 TRANSMISSION W230
10. Install the snap ring into the groove at the outer
diameter of the bearing on the idler shaft.
Fig. 2-197
Fig. 2-198
Fig. 2-199
14. Press the roller bearing into the high gear and
secure it with a snap ring.
15. Install the assembled high gear into the spline
on the 3rd/4th speed shaft, engaging it with the
output gear.
Fig. 2-200
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W230 TRANSMISSION 2 - 87
16. Install the 51T gear into the output shaft. Install
the snap ring.
Fig. 2-201
17. Press the roller bearing inner race onto the low
gear. Install it into the 1st/2nd speed shaft engag-
ing with the output gear.
Fig. 2-202
18. Install the oil baffle and two two tubes on the
transmission case and tighten the two mounting
bolts.
Fig. 2-203
Fig. 2-204
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Copyright © New Holland
2 - 88 TRANSMISSION W230
Fig. 2-205
Fig. 2-206
Fig. 2-207
Fig. 2-208
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W230 TRANSMISSION 2 - 89
6. Press the oil seal into the seal reatiner and in-
stall the O-ring.
Fig. 2-209
Fig. 2-210
Fig. 2-211
Fig. 2-212
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2 - 90 TRANSMISSION W230
Fig. 2-213
11. Press the roller bearing outer race into the 1st/2nd
speed shaft low gear. At this step, install the spa-
cer for the bearing shaft into it.
Fig. 2-214
12. Install the snap ring into the groove of the case
at the outer diameter of the bearing.
Fig. 2-215
Fig. 2-216
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W230 TRANSMISSION 2 - 91
Fig. 2-217
Fig. 2-218
6. Install the brake disk hub onto the low gear spli-
nes of the 1st/2nd speed shaft and secure with the
snap ring.
Fig. 2-219
Fig. 2-220
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2 - 92 TRANSMISSION W230
Fig. 2-221
Fig. 2-222
Fig. 2-223
Fig. 2-224
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W230 TRANSMISSION 2 - 93
Fig. 2-225
Fig. 2-226
Fig. 2-227
Fig. 2-228
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2 - 94 TRANSMISSION W230
1. Install the spring (3) and spool (2) from the top of 1
the cap (the 1st/2nd distributor cap) and tighten
the hex. plug (with a O-ring) (1).
2
Fig. 2-229
2
1
Fig. 2-230
Fig. 2-231
Fig. 2-232
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W230 TRANSMISSION 2 - 95
Fig. 2-233
Fig. 2-234
Fig. 2-235
Fig. 2-236
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2 - 96 TRANSMISSION W230
Fig. 2-237
Fig. 2-238
Fig. 2-239
Fig. 2-240
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W230 TRANSMISSION 2 - 97
Low discharge from charging Measure oil pressure at inlet port Replace pump
pump of torque converter
Defective oil baffle oil Check for oil leak to flywheel Replace parts
Oil leak (from seal
flywheel)
Defective O-ring of oil baffle Check for oil leak to flywheel Replace parts
Improper oil used Check oil type Change for the speci-
fied oil
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2 - 98 TRANSMISSION W230
2.11.2 TRANSMISSION
Low oil level Check oil level with oil level gauge Add oil to the speci-
fied level
Improper oil used Check oil type Change for the speci-
fied oil
Check oil level with oil level gauge Add oil to the speci-
Low oil level
fied level
Machine won't Measure oil pressure of Replace charging
travel forward/ Malfunction of changing pump transmission clutch (lowered in pump
reverse all ranges)
Measure oil pressure of Disassemble and
Regulator valve stayed open transmission clutch (lowered in replace parts
all ranges)
Broken bolts securing torque Check the operation of load Replace parts
Machine won't
converter input plate handling system
travel forward/
reverse Parking brake won't release
(stuck or dragged) Refer to "2.11.3 PARKING BRAKE"
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W230 TRANSMISSION 2 - 99
Manual spool (emergency Check manual spool position at Raise the spool to
travel spool) is pressed in the the control valve locate it in the normal
position for reverse travel condition
Machine won't
travel forward Slipping forward clutch (F Measure oil pressure of forward Disassemble and
(can travel solenoid valve is not operated clutch replace parts
reverse)
Seizing reverse clutch Check if machine travels reverse Disassemble and
with clutch in neutral replace parts
Manual spool (emergency Check manual spool position at Lower the spool to
travel spool) is pulled in the the control valve locate it in the normal
position for forward travel) condition
Machine won't
travel reverse
Slipping reverse clutch (R so- Measure manual spool position Disassemble and
(can travel
lenoid valve is not operated) at the control valve replace parts
forward)
Check if machine travels forward Disassemble and
Seizing forward clutch with clutch in neutral replace parts
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I.D. of stator holder in turbine shaft seal ring sliding area 50 50.05
(1.97") (1.99")
I.D. of Pump drive gear in stator holder seal ring sliding area 84 84.05
(3.307") (3.309")
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2.12.3 TRANSMISSION
Unit: mm (in)
Item Standard value Useful limit
I.D. of distributor cap in clutch shaft seal ring sliding area 55 to 55.02 55.07
(fwd/rev 1st/2nd, 3rd/4th) (2.165 to 2.166") (2.192")
Width 1.95 to 2.05 1.7
Clutch shaft seal ring (axial) (0.076 to 0.080") (0.066")
Thickness 1.95 to 2.05 1.9
(radial) (0.076 to 0.080") (0.074")
O.D. of companion flange in oil seal sliding area 89.9 to 90.0 89.863
(3.539 to 3.543") (3.537")
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Note — The accumulator is incorporated in the distributor cap of the 1st/2nd speed shaft.
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2.13.2 TRANSMISSION
Item Tightening torque kg-m Remarks
Distributor cap fitting bolt 35
Output shaft bearing cap fitting bolt 24
Output shaft companion flange retainer plate fitting bolt 90 Apply LOCTITE 262
Brake housing fitting socket bolt 53
Parking brake assembly hex. bolt 93
Parking brake fitting socket bolt 93
Converter housing fitting bolt 35
Control valve fitting bolt 53
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4 1 7 2
2 2 2 1 3 6
1. Front prop shaft - 2. Intermediate prop shaft - 3. Rear prop shaft - 4. Front axle - 5. Transmission - 6. Rear axle - 7. Rigid
support.
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3 4 1 1 2 3 7 5 8
1. Shaft - 2. Bearing support - 3. Bearing - 4. Spider - 5. Flange - 6. Grease fitting - 7. Washer - 8. Nut.
4 3 6 5 4 2 2
3
3 1
1. Spider - 2. Spider - 3. Shaft - 4. Screw 3/8" - 24 - 5. Spider grease fitting - 6. Shaft grease fitting.
1 2 2
2 2
4
3
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Drive: 4 wheel
Final reduction
Model: TCM 678-30
Type: Planetary
Weight
Front: 1216 Kg (2680 lbs)
Rear: 1184 Kg (2610 lbs)
The axle is composed of a differential, final reduction The front axle is mounted directly on the front axle by
units, oil-bath disc brakes and axle shafts connected screws.
to the wheels.
The power output from the transmission is driven by The rear axle is mounted with a pivot pin, using
the prop shafts to the front and rear axles. Thus, the supports on both sides of the axle, secured by screws
power is driven to the differential that splits it to the to the rear frame. Consequently, the rear axle can pivot
axle right and left shafts driving the final drives, around the axle of the differential with an amplitude
reaching the wheels. depending upon the ground conditions travelled by the
The oil bath disc brake is mounted in front of the final loader. The drive axle mounted with a pivoting pin
drive and operates as service brake. As for the improves the driving conditions of the loader when
operation of the service brakes, please refer to section travelling on rough terrain, since the loader jumps at a
"3 - BRAKES SYSTEM". lesser extent than a loader with axle supported by a
traditional oscillating cradle system.
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1 2
2 1
3 4
5 6
1. Front pivoting support - 2. Rear pivoting support - 3. Tyre - 4. Rim - 5. Front axle -6. Rear axle.
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1 3 2 1 3 3 4 3 5 6 7
1
8 4 5 4 9 2 10
1. Dust seal - 2. Front pivoting support - 3. Rear axle - 4. Dust seal - 5. Rear pivoting support - 6. Thrust plate - 7. Cover -
8. Bushing - 9. Bushing - 10. Spacer discs.
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4 1 2 3 4 5 8
6 7
1
9 10 3 3 11 12 3 13 5 A
5
A 3 14 2
A Brake piping connection
ports, 2 points
4 Lip: Grease
1. Oil seal - 2. Axle shaft - 3. Final drive - 4. Differential housing - 5. Differential - 6. Crown gear hub - 7. Pin - 8. Pin - 9. Axle
shaft housing - 10. Dipstick - 11. Bleeding screw - 12. Bleeding screw - 13. Cover - 14. Draining plug.
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4 1 2 3 4 5 8
1
6 7
9 3 10 11 3 12 5 A 3 15
4 Lip: Grease
5
Mating surfaces: LOCTITE 509
1. Oil seal - 2. Axle shaft - 3. Final drive - 4. Houding differential - 5. Differential - 6. Pin - 7. Crown wheel - 8. Dowel -
9. Axle housing - 10. Bleeding screw - 11. Bleeding screw - 12. Cover - 13. Plug (level check) -14. Draining plug -
15. Dipstick.
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The differential forms a single body with the reduction When the loader is moving straight, the bevel ring
unit. gear, the differential gear cage and the differential side
The power is driven from the prop shafts to the gears rotating together; the idle pinions inside the gear
differential gear housing through the pinion/bevel gear cage do not rotate. Thus the right and left side gears
group. Thus, it is driven through the right and left gears, drive the power to the wheels. When the loader turns,
to the final drives. The reduction of r.p.m. is obtained the right and left wheels turn at different speeds, the
by the pinion/bevel gear ratio. idle pinions in the gear cage rotate around their pin,
proportionally with the speed difference between the
right and left side gears.
High Low
speed speed
4 5
6 7
1. Idle gear - 2. Side gear - 3. Axle shaft - 4. Differential gear cage - 5. Idle pinion spider - 6. Bevel drive pinion - 7. Bevel drive
ring gear.
Wheel loaders often operate under severe terrain A proportional torque differential design is almost
conditions, such as sandy or muddy grounds. Under identical to a normal differential, with the exception of
such unfavourable terrain conditions, a loader the idle pinions, having an odd number of teeth with a
equipped with a standard differential could experience special profile. When the tyres start spinning on soft
a spinning of the wheels, thus making difficult to ground, the idle pinions continue to drive both side
exploit fully its potential performance. Also, the tyres gears, without turning on their pins, until the difference
could wear quickly. To avoid this, some models are of the adhesive force of the right and left tyres on the
equipped with a proportional torque type differential, ground reach a certain value. In this manner, the
limiting its function. spinning of the tyres is prevented.
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1 2 3 2 4 5 3 1
7 12
8 13
9 14
6 10 15
11 5 20 19 18 4 17 7 16
Notes -
1 90 Nm Threaded part: LOCTITE 262
7 After reassembling the differential, set the spacer so that the rolling torque is 0.15 ÷ 0.26 Nm, without seal.
1. Adjusting nut - 2. Bearing retainer - 3. Half-housing (B) - 4. Bevel crown gear - 5. Half-housing (A) - 6. Locking plate - 7.
Thrust washer - 8. Thrust washer - 9. Spider - 10. Drive pinion - 11. Bearing holder housing -12. Idle gear - 13. Pin - 14.
Planet gear - 15. Shim - 16. Spacer - 17. Spacer - 18. Nut - 19. Flange - 20. Oil seal.
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The final drive units are of a planetary type and crea- shaft rotates the three planet gears inside the toothed
te the final rpm reduction in the power train. drum, thus driving the axle shaft through the planet
The power driven by the differential to the sun gear gear carrier.
8 7 6 5 4 3 2
1 A
1. Pinion - 2. Differential - 3. Sun gear shaft - 4. Planet gear pin - 5. Planet gear - 6. Toothed drum - 7. Planet carrier -
8. Axle shaft.
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1 2 2 3 4 5 6 7 8 9 10 11 12 1
13 14 15 16 17 18 19 20
1) Tighten screw (1) to a torque of 50 Nm (36 ft-lbs) and set inward the taper bearing, by rotating the axle
shaft.
2) Loosen screw (1) without turning the shaft
3) Measure the gap between thrust ring (3) and axle shaft. Value measured = Y.
4) Select adjusting shims forming a pack with a total thickness exceeding 0.03 to 0.10 mm the value of
Y.
5) Install the shim pack, the retaining ring and the screw.
The rolling torque of the bearing must be included between 20 and 40 Nm (4.4 ÷ 8.8 ft-lbs).
1. Screw - 2. Spacer - 3. Retaining plate - 4. Thrust ring - 5. Lock pin - 6. Brake disc (outer toothed) -
7. Brake disc (inner toothed) - 8. Adapter - 9. O-ring - 10. Spring - 11. O-ring - 12. Piston - 13. Planet carrier - 14. Pin -
15. Ball - 16. Thrust ring - 17. Needle bearing - 18. Planet gear - 19. Disc hub - 20. Sun gear.
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• When disassembling and reassembling the drive axle, it is good practice to place it on a unit table and use
disassembly and reassembly jigs.
• Unit weight: front: 1216 kg rear: 1184 kg
(2680 lbs) (2610 lbs)
Fig. 2-253
Fig. 2-254
Fig. 2-255
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Copyright © New Holland
Fig. 2-256
Fig. 2-257
6. Remove the snap ring and disk hub from the spli-
nes. Then, remove the snap ring.
7. Remove the axle tube and shaft at the opposite
side, using the same procedure as above.
Fig. 2-258
2) Disassembling axle tube
Fig. 2-259
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Copyright © New Holland
Fig. 2-260
Fig. 2-261
Fig. 2-262
Fig. 2-263
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Copyright © New Holland
Fig. 2-264
Fig. 2-265
Portal jig
Plate
Ring gear
Fig. 2-266
Fig. 2-267
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Copyright © New Holland
Fig. 2-268
Fig. 2-269
Fig. 2-270
Fig. 2-271
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Copyright © New Holland
Fig. 2-272
Fig. 2-273
Fig. 2-274
Fig. 2-275
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Copyright © New Holland
Fig. 2-276
2. Check the ring gear for tooth surface contact pat-
tern and backlash. Refer to steps (5) and (6) in
2.17 Reassembly".
3. Remove the bolts securing the bearing cage.
Number of bolts: 8 for front axle
10 for rear axle
Fig. 2-277
Fig. 2-278
Fig. 2-279
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Copyright © New Holland
Fig. 2-280
Fig. 2-281
Fig. 2-282
Fig. 2-283
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Copyright © New Holland
Fig. 2-284
Fig. 2-285
Fig. 2-286
Fig. 2-287
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Copyright © New Holland
Fig. 2-288
Fig. 2-289
Fig. 2-290
Fig. 2-291
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Copyright © New Holland
Fig. 2-292
Fig. 2-293
Fig. 2-294
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Copyright © New Holland
Fig. 2-295
Fig. 2-296
Fig. 2-297
Fig. 2-298
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Copyright © New Holland
• Wash disassembled parts with a clean washing oil and dry by blowing air.
• Handle the washed parts, with care not to damage or contaminate them.
• Check the disassembled parts for wear or damage and replace any worn or damaged part with a new one.
Refer to "2.19 STANDARD VALUES FOR MAINTENANCE".
• Replace all the seals with new ones.
Fig. 2-299
2. Make sure the two dowel pins in the differential
case. Align the two holes in the thrust washer
with the dowel pins and install the thrust washer
into the case.
Fig. 2-300
3. Install the side gear.
Fig. 2-301
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Copyright © New Holland
Fig. 2-302
Fig. 2-303
Fig. 2-304
Fig. 2-305
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Copyright © New Holland
Fig. 2-306
Fig. 2-307
Fig. 2-308
Fig. 2-309
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Copyright © New Holland
Fig. 2-311
C
A
Fig. 2-312
D C
Fig. 2-313
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Copyright © New Holland
Fig. 2-314
Fig. 2-315
Fig. 2-316
Fig. 2-317
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Copyright © New Holland
Fig. 2-318
Fig. 2-319
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Copyright © New Holland
Fig. 2-320
Fig. 2-321
Fig. 2-322
Fig. 2-323
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Copyright © New Holland
Fig. 2-324
Fig. 2-325
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Copyright © New Holland
Fig. 2-326
10. Using a jig, press the oil seal into the cage.
Fig. 2-327
Fig. 2-328
Fig. 2-329
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Copyright © New Holland
13. Then put the O-ring into the groove between the
flange and pinion, and put the washer on it.
Fig. 2-330
Fig. 2-331
Fig. 2-332
Fig. 2-333
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Copyright © New Holland
Fig. 2-334
Fig. 2-335
4) Installing drive pinion (bearing cage)
Fig. 2-336
Fig. 2-337
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Copyright © New Holland
Fig. 2-338
4. Carry out steps "(5) Adjusting backlash of ring
gear" and "(6) Adjusting the tooth surface con-
tact pattern of ring gear". After that, install the
lock plate and lock the adjusting nut.
Fig. 2-339
Fig. 2-340
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Copyright © New Holland
Fig. 2-341
Face
Frank
Fig. 2-342
Fig. 2-343
Fig. 2-344
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Copyright © New Holland
Fig. 2-345
Fig. 2-346
Fig. 2-347
7) Installing brake unit
Fig. 2-348
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Block
Brake piston
Fig. 2-349
Fig. 2-350
4. Install the snap ring, disk hub and snap ring onto
the sun gear and shaft.
Fig. 2-351
5. Install the sun gear and shaft which has the disk
hub, onto the side gear splines installed in the
differential case.
6. Install the 2 lock pins into the lower part of the
differential body. Install the brake ring aligning
them.
Fig. 2-352
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Copyright © New Holland
Fig. 2-353
8. Install the second brake disk, aligning with the
first disk.
9. Then, install the brake ring and end plate in this
order.
Fig. 2-354
10. Install the other six lock pins using a soft mallet.
11. Install the brake unit at the opposite side, using
the same procedure as above.
Fig. 2-355
Fig. 2-356
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Copyright © New Holland
Fig. 2-357
Fig. 2-358
Fig. 2-359
5. Put the tube jig (item (1) in Fig. 360) onto the
axle shaft and press the oil seal and bearing of
the wheel onto the shaft.
Fig. 2-360
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Copyright © New Holland
Fig. 2-361
Fig. 2-362
Fig. 2-363
Fig. 2-364
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Copyright © New Holland
Fig. 2-365
Fig. 2-366
Fig. 2-367
Fig. 2-368
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Copyright © New Holland
Fig. 2-369
Fig. 2-370
Fig. 2-371
Fig. 2-372
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Copyright © New Holland
Fig. 2-373
Fig. 2-374
Fig. 2-375
Fig. 2-376
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Copyright © New Holland
Fig. 2-377
Fig. 2-378
Fig. 2-379
Fig. 2-380
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Copyright © New Holland
Fig. 2-381
Fig. 2-382
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2.18 TROUBLESHOOTING
Oil leakage from Oil seal worn or damaged. Replace oil seal.
axle shaft.
Oil seal installed improperly. Repair or replace.
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Adjustment by
Backlash between drive pinion and ring gear From 0.25 to 0.36 kgm - adjusting nut
Rotational resistance torque of axle shaft bearing From 2.0 to 4.0 kgm - Shim
(tube fitting bolt pitch circle) adjustment
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Unit: 1 mm = (0.03937")
Item Standard Size Useful limit Remarks
Settings load.
Brake piston reaction spring 20.8 kg 18.8 kg
Settings
heigt 20
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The wheel is composed of rim and disc. In a standard configuration, the loader is equipped
The wheel disc is bolted to the axle shaft. The tyre is with radial type tyres with tread type L3, having high
mounted on the rim forming a single body with it. Con- traction characteristics. It is recommended that the
sequently, it is of the utmost importance that the cor- most appropriate tyres are selected, since a large
rect rim is used, based upon the type of tyre to be variety of types is available, based upon the type of
mounted. The use of a inappropriate rim could shor- operation and working requirements.
ten the life of the tyre and, in the worst cases, cause
serious accidents. Example: 23.5 R 25 XHA TL
Also, the dimension of the rim is provided in inches.
The first number indicates the width of the rim and 23.5 = Width of the tyre (~ 600 mm)
the second indicates the diameter. R = Radial
25 = Diameter of rim (~ 635 mm)
XHA = Type of tread
TL = Tubeless
F
A
26.5R25 GP-2B 4 (58 psi) 3 (43.51 psi) 3 (43.51 psi) 3 (43.51 psi)
26.5R25 XHA 4 (58 psi) 2 (29 psi) 2 (29 psi) 2 (29 psi)
26.5R25 XLDD2 4 (58 psi) 2 (29 psi) 2 (29 psi) 2 (29 psi)
26.5R25 RL-5K 4 (58 psi) 3 (43.51 psi) 3 (43.51 psi) 3 (43.51 psi)
26.5R25 XLDD1 4 (58 psi) 2 (29 psi) 2 (29 psi) 2 (29 psi)
750/65 R25 XLD 4.5 (65.26 psi) 2 (29 psi) 2 (29 psi) 2 (29 psi)
(*) The pressure can be increased 0.5 bar (7.2 psi) under work conditions not requiring particular floating conditions.
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SECTION 3
BRAKES SYSTEM
TABLE OF CONTENTS
The brake system consists of (refer to Fig. 3-1): The parking brake consists in:
- a two stage feeding gear pump (11), flanged to the - a recharge pump, gear type;
torque converter cover;
- a three-way diverter valve (14) which controls
- a filter (10) on pump outlet; engagement and disengagement of the parking
brake (16);
- a brake pedal valve (5) controlling simultaneously
front and rear brakes (1 and 2, respectively), which - a hydraulic ram (16) composed of springs and a
are located inside the drive axles; hydraulic cylinder to counter-act them. Spring force
is used to lock the parking brake discs when
- two accumulators (8 and 9) which during normal pressure oil in the cylinder is dumped by means of
operation stabilise system pressure and, in case of the diverter/control valve. When fed with pressure
emergency, with the engine stopped, allow to oil (by means of the diverter/control valve), the
positively apply the brakes for several times; cylinder overcomes spring action and consequently
the brake is released;
- the oil used in the brakes system is the same of the
equipment hydraulic system and it is taken from - an accumulator (not illustrated) mounted on the
hydraulic reservoir (S) through a filter. pressure relief valve, that during normal operation
stabilises the pressure inside the circuit, and, with
engine inoperative, allows the disengagement of the
parking brake, for a certain number of times.
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1 1
6
7
9
5
4
8
12
3
V
M
10
13
T 11
14 S
15
16 2 2
S. Reservoir - M. To pressure regulating valve - V. To pressure regulating valve - T. Discharging (hydraulic reservoir) - 1. Front
brakes - 2. Rear brakes- 3 and 4. Quick release pressure pick-up points - 5. Brake pedal valve - 6. Stop light pressure switch
- 7. Transmission cut-off pressure switch - 8 and 9. Brakes system accumulators - 10. Oil delivery filter - 11. Brakes oil pump
- 12. Check valve - 13. Parking brake control three way diverter - 14. Parking brake pressure switch - 15. Hydraulic cylinder
(included in the parking brake) - 16. Parking brake.
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Copyright © New Holland
3.2 OPERATION
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Copyright © New Holland
P. Brake pedal - S. Reservoir - M. To equipment pilot system - 1. Rear brakes - 2. Front brakes - 3. Transmission
disengagement pressure switch - 4. Brake lights pressure switch - 5. Brake pedal valve - 6. Accumulator control pressure
switch - 7 and 8. Brake system accumulators - 9. Pressure oil filter - 10. Brakes oil pump - 11. Check valve - 12. Three
ways diverter valve for parking brake actuation - 13. Parking brake pressure switch - 14. Hydraulic ram - 15. Parking brake
- 16. Accumulators recharge valve - 17 and 18. Check valves - 19 . Primary check valve - 20. Front axle brake control valve
- 21. Rear axle brake control valve - 22. Trasmission disengagement device - 23. Hydraulic ram springs - 24. Flow
regulating valve - 25. Pilot system pressure regulation valve - 26. Heat exchanger - 27. Pilot controls safety valve - 28.
Equipment pilot valve.
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Copyright © New Holland
22 1 1
17
7
13 12
3
18 21
20
8
14
2 2
4
23
6
15
19 28
9
16
STEERING
POMPA
PUMP
STERZO
M 26
24
27
25
10
S
Hydraulic circuit shown with engine running, P 11
accumulators being recharged, brakes
disengaged, parking brake applied.
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Copyright © New Holland
The disc brake is composed of two oil-bath, discs The inner circumference of the discs is splined
and it is mounted inside the axle housing. On this and it is keyed to the axle shaft. The outer
loader, four brake groups are mounted in the axles, circumferences of the pressure plate and reaction
one on each axle shaft. plate are secured to the axle housing by dowels,
The structure of the disc brake is described in the so that, the locking of the brake discs causes the
“TRANSMISSION” section. stopping of the axle, thus braking.
4 5 6 7 8 11 9 10
Brake pressure
Drive line oil
1 2 3
12
13
14
1. Axle shaft - 2. Planetary carrier - 3. Solar shaft - 4. Disc hub - 5. Reaction plate - 6. Pin - 7. Disc brake -
8. Disc pressure plate- 9. Piston - 10 and 11. Sealing ring - 12. Spring - 13. Piston guide - 14. Screw.
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Copyright © New Holland
To dump
To other users
or dump
T1
Rear brake feed
port (45 bar)
T2
Accumulator pressure Front brake feed port
adjustment (80 - 110 bar) (45 bar)
Primary check
valve
Accumulator minimum recharge Accumulator recharge pressure
pressure adjust screw regulating valve
Fig. 3-5 Accumulator recharge pressure and flow regulating valve section view
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Copyright © New Holland
3°
the brakes
Max working angle 16°
Backlash
take-up screw Brake oil delivery
spools
To accumulator no. 1
4
2
3
To accumulator no. 2
5
Fig. 3-7 Section view of circuit separation valve and accumulator recharge one-way valves
1. One-way valve - 2. One-way valve - 3. Circuit separation valve - 4. Tapered piston - 5. Spring - 6. Piston seal seat.
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5 4 3 2 1
10 9 8 7 6
Item "C"
1. Driven gear - 2. Mounting flange - 3. Gear plate - 4. Centering dowel - 5. Closing plate - 6. Oil seal - 7. Driving gear - 8.
Side plate - 9. Side plate - 10. O-Ring - 11. Sealing device- 12. Gasket B - 13. Gasket A.
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The parking brake valve controls the delivery of pres- The parking brake is equipped with detent devices to
surised oil to the disc brake. hold the spool, in each position.
The movement of the parking brake valve is control-
led by the appropriate knob actuating the discs brake.
A
T
11 12
A T
2 1
A T
7 6 5 4 3
8 9 10
B
1. Rod - 2. Valve body - 3. Gland ring - 4. Ring - 5. O-Ring seal - 6. Cover - 7. Spool - 8. Detent spring -
9. Sleeve - 10. Detent ball - 11. Dust ring- 12. Oil seal.
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Copyright © New Holland
Parking brake manual disengagement (in case of 3. Insert the bolt (1) into the plug hole and screw it
emergency) into the threaded hole at the centre of the brake
piston (3), as shown in Fig. 3-11.
WARNING
If it is not possible to release the parking brake WARNING
by means of the control knob following pump
failure or for any other reason, disengage it Disengage the parking brake manually only if it is
manually through the parking brake release screw. absolutely necessary. Namely, this should be done
only when towing a failed loader to traffic-free
areas. If the loader is on an incline, check that the
wheels are securely blocked with wedges or
stones prior to releasing the parking brake.
2 3
1
1
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Copyright © New Holland
1. When pressure oil acting on the piston brake is 2. The inner toothing of the rotating brake discs is
dumped, this is pushed by the spring force and keyed to the transmission shaft by the brake discs
packs the brake discs (rotating) against the fixed hub. The outer toothing of the fixed brake discs is
plates. keyed to the brake seat. As the rotating brake discs
are locked with the fixed brake discs, they stop
rotating. This causes the stopping of the rotation
of the transmission shaft, by the disc carrier hub,
thus braking the loader.
Brake pressure
oil dump
8 6 1
7 5 4 3
1. Brake piston - 2. Spring - 3. Support plat e - 4. Brake housing - 5. Brake discs - 6. Disc hub - 7. Bearing - 8. Transmission.
1. When pressure oil is sent to the rear surface of 2. A clearance is established between each brake
the brake piston, this overcomes the spring action disc and fixed plate, the brake discs are released
and moves. and the brake is disengaged.
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The membrane accumulator is used to store pressure Oil from the charge pump is diverted by the check
oil to release the parking brake. valve to the accumulator which maintains the pressure
at a certain value.
. . . . .
B A
. . . . .
B A
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N M
T1
F R1 R2
T2
T2
TI2
P
T1
P
M
R1
F
N
R2
TI1
F. Accumulator control pressure switch - M. Other users or to dump - N. Dump - P. Inlet - R 1-2. Accumulator -
T1-2. To the brakes- TI1-2. Brake control pressure switch.
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2
1
6
5
7
T1
T2
4
Diagnostic and testing
10
N
9
3
To steering
valve
14
8
12
19
P
T
20
PV
11
oil reservoir
To hydraulic
13
valve locking
15
To pilot
18
17
16
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Copyright © New Holland
T1. Front brakes delivery port. (P Max. 45 bar) 14. Pressure relief valve (setting 30 bar)
T2. Rear brakes delivery port. (P Max 45 bar) 15. Three way diverter, parking brake engagement/
disengagement control
1. Rear axle brakes
16. Parking brake pressure switch (setting of
2. Front axle brakes pressure switch: OFF = 15 bar; ON = 10 bar)
9. Brake accumulator
(capacity = 1.4 litres - precharge = 45 bar)
WARNING - DANGER
Always disconnect and connect all fittings with
10. Brake accumulator the engine stopped and braking system disabled.
(capacity = 1.4 litres - precharge = 45 bar) Accumulators keep some branches of the circuit
under pressure even if the engine is stopped.
11. Powering pump (for brake system) Pressure oil escaping from loose fittings may cau-
se personal injury and damages to things.
12. Delivery oil filter Wear safety glasses with side shields.
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Copyright © New Holland
Rear axle
pressure port
Front axle
pressure port
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Copyright © New Holland
Connect two pressure gauges (end of scale 200 bar) release the lock-nut (5) and turn the screw (4) with
to the quick coupling pressure ports (7 and 8, Fig. micrometric variations until obtaining correct value.
3-18) on the accumulators. Check pressure again before tightening the lock-nut
Start machine engine and bring oil temperature to (5).
approximately 40 to 50°C by means of the attachment
control lever. Cycle the brake pedal several times to Maximum recharge value
make oil temperature even. With the engine idling and the parking brake applied,
observe maximum recharge pressure on pressure
Minimum recharge value gauges M1 and M2.
With the engine idling and machine at a standstill, Pressure should be 110 ± 5 bar (1595 ± 72 psi).
brake slowly 4 or 5 times. If maximum recharge pressure is different from the
Observe minimum pressure values on pressure rated value, remove the plug (1), release the lock-nut
gauges M1 and M2 before recharge starts. (3) and turn the screw (2) out to increase the
The pressure gauges should momentarily read accumulator maximum recharge pressure.
80 ± 5 bar (1160 ± 72 psi). If minimum recharge pressure
is different from the rated value, remove the plug (1),
M1
M2
7
8
1 2 34
6
M1 & M2. Pressure gauges - 1. Plug - 2. Maximum pressure adjust screw - 3. Lock-nut - 4. Minimum pressure adjust
screw - 5. Lock-nut - 6. Accumulators - 7 & 8. Pressure ports.
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Copyright © New Holland
Start the engine and let it run for about thirty seconds Operate the control lever two or three times always
to charge the accumulator. checking that the brake linkage moves completely.
Move the parking brake control lever to the “released” The machine, set on 30° slope, shall be stopped.
position.
2 1 4 7
M P
TO BRAKE
VALVE
PV T
5 6
TO PILOT VALVE
BLOCKING
3
T TO HYDRAULIC OIL
RESERVOIR
T. Discharge to oil reservoir - 1. Parking brake locking/release - 2. Three way valve - 3. Heat exchanger - 4. Check valve
- 5. Ram - 6. Parking brake - 7. Pressure relief valve.
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Copyright © New Holland
Accumulators fitted to the braking system are mem- - tighten the screw (2) to a torque of 11 Nm;
brane type, pre-charged using nitrogen.
- test accumulator sealing using soapy water;
Normal minimum membrane porosity and continued
use reduce pre-charge pressure in time and limit - screw on protective cover (1).
accumulator efficiency.
Recharge the accumulator if the pressure is lower than
It is advised to check the nitrogen pre-charge every rated value.
six months and restore it, if necessary.
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Copyright © New Holland
Using tool D 75298472 (fig. 3-21) screwed to the Close the nitrogen bottle tap.
accumulator' connection (see 3.10.4. before) proceed Wait five minutes.
as follows. Check on the pressure gauge (M) that inflating
pressure is 45 bar. Repeat the operation if lower.
Loosen the plug and screw in the hose from a nitrogen If pressure is higher, proceed as follows:
bottle complete with safety valve (V).
- slowly turn the handwheel (D2) to let the nitrogen
out and close;
WARNING - DANGER
- check on the pressure gauge (M) that pressure is
Use only nitrogen to recharge accumulators. Never as required. If not, repeat the operation;
use oxygen or other gases for any reason whatever
as explosion hazard may result. - turn the handwheel (D1) to screw in the accumulator
screw (2);
Slowly open the nitrogen bottle tap and check refilling - remove tool (D);
pressure as it increases on the pressure gauge (M).
- tighten the screw (2) to a torque of 11 Nm;
D1
D
M D1
D
1 D2
A
2
D. Accumulator 75298472 pre-charge test tool - D1. Plug control handwheel (2) - D2. Discharge tap - A. Nitrogen bottle-
M. Pressure gauge - V. Safety valve - 1. Protection cover - 2. Threaded plug.
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Copyright © New Holland
It is necessary to bleed the brake system when anyone Bleed the system as detailed below (this is a two-
of the conditions here below occurs: man operation):
- after replacing hydraulic oil in the attachment oil - position the machine on a level surface and start
reservoir; the engine;
- when air has entered the system because of poor - with the engine idling, one operator should release
sealing of hoses or charge pump; the bleed screw (two on each axle) while the other
is pressing the brake valve pedal. Tighten the bleed
- after disconnecting or replacing any of the system screw before releasing the brake pedal;
parts.
- repeat this operation until bleeding all air from the
system (fluid should come out of the bleed screw
free of bubbles);
S S
Fig. 3-22 Brake oil bleed screw (S) locations on the axle (1 for brake)
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Copyright © New Holland
1 A 1 B
The control of the wear on the 4 brake discs (for each Note — The check of the operational play must be
axle) is carried out after draining the oil from the group. performed with the brakes engaged by the pedal.
Remove inspection plugs (A) and (B);
The brake discs are to be replaced if a thickness gauge
blade of the 5.3 mm can be made to pass through the
steel discs.
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Copyright © New Holland
SECTION 4
STEERING SYSTEM
TABLE OF CONTENTS
The loader is of the articulated frames type. The steer- The complete system includes:
ing system uses two hydraulic cylinders controlled by - two gear pumps, one of which is used in case of
a control valve, to which the steering wheel is con- emergency;
nected through a set of rods, links and levers. The - a steering valve with priority valve;
steering force is applied between the front and rear - two hydraulic cylinders;
modules by a couple of cylinders powereds by the - connecting pipes;
steering valve. - steering box/steering column;
- steering wheel.
Also, the emergency steering circuit, besides the
pump, includes a multiple check valve and a diverter
valve.
Cylinder
Steering
Steering valve
box
To main circuit
Linkage Pump
Hydraulic reservoir
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NOTES:
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Copyright © New Holland
EMERGENCY STEERING
STEERING CYLINDERS
IN
245
245 bar bar
T 206 bar
EMERGENCY
STEERING PUMP DISCHARGE (IN COMMON WITH
EQUIPMENT CONTROL VALVE)
P PB
TO EQUIPMENT CONTROL
VALVE DELIVERY
TO BRAKE
VALVE
PILOT VALVE/BRAKE
AND STEERING PUMP
Fig. 4-2 Steering hydraulic circuit
The oil taken from the reservoir by the steering pump is delivered to the steering valve.
The steering valve regulates the pressure and the flow of the oil. Also, it is equipped with a
priority valve sending the excess oil from the steering circuit to the equipment circuit, when the
steering does not require all the oil. When the steering wheel is actuated, the steering valve is
activated, intercepting the oil coming from the pump, sending it to the steering cylinders. HYDRAULIC OIL RESERVOIR
The oil discharged returns through the steering wheel to the oil reservoir.
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Copyright © New Holland
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
Steering wheel
Upper shaft
Shaft support
Steering column
adjustment lever.
Steering wheel
Power link
Steering valve
Steering cylinder
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4 2
9 2
4 10 1
3
11 5
4 5
12
6
5 13 14 15 16
8 5
2 9
1
SECTION A-A
1. Dust cover - 2. Dust seal - 3. Rear cover - 4. Shim - 5. Steering box - 6. Ball block - 7. Shaft - 8. Bearing - 9. Pitman arm
- 10. Dust seal - 11. Bush- 12. Gear sector - 13. Bush - 14. Setting screw - 15. Shim - 16. Side cover.
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Copyright © New Holland
The steering valve is a control valve with a pressure valve plunger, directing the oil toward the steering
compensation valve providing a delivery proportional cylinders.
to the movement of the steering valve spool, The steering valve consists of a valve body, spool,
independently from the variation of the load pressure priority plunger, main pressure relief valve and two
(steering cylinder pressure). The steering valve is anticavitation safety valves.
equipped with a priority valve that, when no oil is The main pressure relief valve limits the pressure in
required by the steering system, commutes the steering cylinders to 210 bar.
automatically toward the equipment system. Thus, all As soon as such value is exceeded, the valve opens,
the oil coming from the steering pump flows to the connecting the steering system to the discharge.
equipment control valve. The excess oil, then, is directed to the hydraulic
As soon as the steering wheel is actuated, the priority reservoir and the pressure returns within the maximum
valve feels the pressure drop at one of its ends. The value.
action of the spring, plus the action of the pressure, The safety/anticavitation valves, set at 245 bar,
acting from the opposite side, is capable of moving the protect the two circuits of the steering cylinders from
overloads, when the control valve is in neutral.
9 mm
9 mm
(Stroke) 1 2
A B B
T
A A
P PB
1. Main pressure relief valve - 2. Safety and anticavitation valve - A. Cylinder port - B. Cylinder port - P. Pump port -
PB. outlet port (to main hydraulic circuit) - T. Discharge port.
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1 P 4
2
5
SECTION A-A T
3
SECTION B-B
7
A B
7
SECTION C-C
1. Plunger - 2. Main pressure relief valve - 3. Spool - 4. Spring - 5. Spring - 6. safety and anticavitation valve - 7. Safety and
anticavitation valve - 8. Spool spring cover.
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Copyright © New Holland
The steering cylinders control circuit is powered by a The pump sucks oil from the hydraulic reservoir, with
two section hydraulic pump. the steering system at rest, sending it to the equip-
One section of the pump powers, through a priority ment control valve. The oil flow in the delivery circuit
valve, the steering system. is proportional to the performance required.
The other section powers the brakes system and the A main pressure relief valve, set at 206 bar, regulates
power system pilot valve. the maximum pressure of the system, discharging
the pressure in excess.
Fig. 4-7 Installation of the steering pump on the transmission-torque converter group
Steering section
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Delivery side
Suction side
Suction Delivery
Rotation direction
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Copyright © New Holland
7 6 5 4 3 2 1
12 10 11 10 9 8
13 14 15 15 14 13
1. Mounting flange - 2. Driven gear - 3. Intermediate plate - 4. Centering dowel - 5. Covering plate - 6. Adapter- 7. Brakes/
power system pump - 8. Seals - 9. Washer - 10. Plate - 11. Driving gear - 12. Coupling sleeve - 13. Plate - 14. back-up ring
- 15. Seal.
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Copyright © New Holland
10
1
4
9
2
10
5 6
2 3 2
11
5
4 10
1
View from A
6 7 1 8
3
3 153 ± 30 Nm 6 89 ± 18 Nm
1. Steering valve - 2. Stroke end screw - 3. Steering box - 4. Rod - 5. Ball joint - 6. Support plate - 7. Rubber pad - 8. Rod -
9. Bearing - 10. Lever - 11. Pin.
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Copyright © New Holland
The steering control linkage transfers the movement The hinging shaft between the steering control rod
of the steering wheel to the spool of the steering val- and lever 10 (fig. 4.10) stands exactly on the pivot
ve, through the steering box located under the steering axle of the two frames of the machine. In this manner
column (cab). the perfect operation of the steering valve indepen-
dently from the angle of the frames.
(120)
B
35
C
D
30
A = 404 mm
- Set the length of the rod at value A indicated in the - Steer the loader on the spot and set the length of
sketch, before installing the leverage. the stop screws so that the gap between front and
- Set the length of stop B and C to the dimension rear frame is 15 mm.
indicated.
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Copyright © New Holland
4.5.2 OPERATION
LEVER
STEERING WHEEL
(STATIONARY)
STEERING BOX
STEERING VALVE IN
NEUTRAL
POWER LINK
PIN
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Copyright © New Holland
ROD
ROTATION OF
LEVER
SUPPORT
POINT
LEVER
ROTATION OF ROTATION OF
RELAY LEVER STEERING
WHEEL CLOCKWISE
SPOOL PUSHED
LEFTWARD
POWER LINK
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Copyright © New Holland
- After rotating the steering wheel clockwise, stop it - At his point, the front frame stops rotating,
and hold it in position. The steering linkage stops. maintaining the steering angle arranged by the
- Under the effect of the consequential rotation of the rotation of the steering wheel.
front frame, the linkage returns the rod connected
to the spool of the steering valve into neutral position
as well as the spool.
ROD
SUPPORT
POINT
ROD
LEVER ROTATION
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Copyright © New Holland
When the steering wheel is rotated leftward, the spool Also the operation of the linkage under reaction is
is pulled toward the rear side of the loader, allowing opposite, although the spool is returned, in any case,
pressurised oil to flow toward the cylinders in a into neutral, as a consequence of the stopping of the
direction opposite to the situation of the clockwise steering wheel.
steering.
LEVER ROTATION
SUPPORT
POINT
ROTATION OF
STEERING WHEEL
RELAY LEVER ANTICLOCKWISE
ROTATION
SPOOL PULLED
RIGHTWARD
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Copyright © New Holland
The two, double acting, steering cylinders, with rod 4.6.1 REMOVAL
and cylinder sleeve mounted, respectively, to the front
and rear module of the frame. Proceed as follows:
The loader is steered by extracting or retracting the - drain the oil from the equipment reservoir;
rod. - disconnect the oil pipes;
- from the rod side, loosen the retaining plate securing
Specifications: screw and extract the pin;
Cylinder bore ..................................... 80 mm (3.14") - disconnect the greasing pipe of the pivot pin from
Rod diameter ..................................... 45 mm (1.77") the left cylinder;
Piston stroke ............... 542 ± 2 mm (21.33 ± 0.07") - from the bottom side, loosen the retaining plate
Weight ............................................... 34 kg (75 lbs) securing screw and extract the pin;
- remove the cylinder assembly.
1 1 2 3 4 8 9 10 11 12 2
13 3
5 6 7 Section 14
17 4 15
16
2 1050 Nm
1. Cylinder head - 2. O-Ring - 3. Back-up ring - 4. O-Ring - 5. Mud scraper - 6. Bushing - 7. Seal - 8. Cylinder rod - 9. Cylinder
sleeve - 10. Piston seal - 11. O-Ring - 12. Piston - 13. Stop screw - 14. Steel ball - 15. Ball bushing - 16. Snap ring - 17.
Pressure pick-up plug.
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Copyright © New Holland
Loosen cylinder head (1) and extract rod (8) complete Reinstall the cylinder on the machine, reversing the
with piston (12). removal sequence.
Loosen the piston securing screw (13), then loosen it After starting the engine, check, with repeated
from the cylinder rod (8). movements of the steering, that the cylinder rod does
not show signs of leakages.
In the event the ball bushing has an excessive play,
replace it as follows: Handle all components with great care.
Do not place hands and fingers between parts. Wear
- remove retaining snap rings (16); glasses, gloves and safety shoes.
- using a punch or a press, extract bushing (15) from
its seat, taking care to push on the outer side of the
bushing only.
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Copyright © New Holland
General description
The emergency steering circuit has the purpose of when the machine is moving forward or backward,
allowing the steering of the machine, in the event of the flow of oil to the emergency circuit is ensured.
accidental cutting-off of the engine or in case of failure The oil sucked by the emergency pump flows, through
of the main steering pump. a multiple check valve, to the diverter valve that, in
Its intervention is signalled by the activation of an case of failure of the steering pump, acts in a manner
indicator light located on the right of the dashboard. allowing the flow of oil toward the steering control val-
The configuration of the device includes a gear pump ve and the cylinders.
keyed directly to the 3rd - 4th speed shaft, so that,
Steering valve
Equipment-
steering-brakes
pump 1.5 bar
Steering
emergency
pump
Cab dashboard
C H
Emergency steering
indicator
1\10h
HOUR METER
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Copyright © New Holland
Multiple Check
Valve
Diverter
Valve Check Valve
Check Valve
1. PUMP
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Copyright © New Holland
2. DIVERTER VALVE
To hydraulic reservoir
To steering valve
Sensor seat
AT
Piloting (from P1
steering pump)
P
Plunger
Fig. 4-20
P
To diverter
valve
A B
T
Discharge
P
A B
Fig. 4-21
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Copyright © New Holland
SECTION 5
The load handling system is composed of: booms, The three bucket pivot pins and the lower strut hinging
strut, link, bucket, bucket cylinder, boom cylinders, pin are equipped with O-rings. All pivot pins are
pins. mounted with securing screws.
The bucket positioner device and the boom kick-out For the part relative to bucket and boom cylinders,
ensure an optimised efficiency of the equipment. please refer to Section 6 (Hydraulic system).
All pivot pins of the handling system have dust seals
to prevent the entry of debris.
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Copyright © New Holland
3 4
11
8 9
7 7
12
8
12
9 11
10 10
Note — Apply grease to the inner surfaces of the bushings and dust seals, prior to inserting the pins. Apply rust
preventing oil to the inner surfaces of the bosses.
1. Bucket - 2. Strut - 3. Boom - 4. Bucket cylinder - 5. Link - 6. Boom cylinder - 7. Locking screw - 8. Dust seal - 9. Bushing -
10. Pin - 11. Grease fitting - 12. O-ring
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1 1
1
1
1
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
D
D
Section D-D
Note — On the central hinging of the link (section D-D) the bushes must be oriented with the outer grooves
directed inword.
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Copyright © New Holland
5.1.1 BUCKET
A standard bucket, with a screw-on reversible cutting available. The choice of the type of bucket, as a
edge, is supplied as a standard. Upon request, a function of the material and the work conditions, is
welded cutting edge and a bolted teeth version is essential, to ensure an efficient performance.
Note - 1 1070 Nm 1
Note - 1 1940 Nm
2 1070 Nm
2
1
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4 B
2
3
1. Positioner bar - 2. Proximity switch - 3. Switch setting nut - 4. Bucket positioner indicators
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
The kick-out device stops the loader booms at a pre- The maximum lifting of the booms can be adjusted
determined heights, during the raise phase. (It is set proceeding as follows:
at the Plant at a height just below full stroke). - start the engine and raise the booms to the maxi-
When the booms raise lever is pulled backward, be- mum height desired;
yond the stroke end, it is kept automatically in detent - cut-off the engine;
by a solenoid inside the pilot valve. This type of detent - loosen securing screws "4" and move plate "2" as
makes the loader booms to raise automatically until required;
a pre-determined height is reached, to which corre- - tighten the securing screws;
sponds the release of the control lever, that returns to - start the engine and raise the booms a few times to
neutral position. make sure that the position is correctly set.
The maximum actuating distance of the device with
respect to plate "5" is 5 mm (0.19"). To comply with
such tolerance, please move the securing nuts of
sensor "1" as required.
2 4
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A
30
580
Fig. 5-7
Set lower bucket hinging pin axis at 580 mm (22.83 in) from ground.
Extend bucket cylinder to its max. position and then retract it by 5 mm (0.19").
Weld the two upper abutting end plugs "A" to the bucket. Plug thickness shall be equal to the span between boom
and bucket.
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20
Fig. 5-8
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Copyright © New Holland
5.3 FRAME
20
21
19
6 22
4
2
5
1
15 14
18
22
5
3 23
4
32
13
11 24 29
9 25 31
17 30
12 26 26
28 27
8
14
12
10
11
1. Bearing - 2. Cap - 3. Cover - 4. Seal - 5. Shim - 6. Valve - 7. Split pin - 8. Bearing - 9. Cap - 10. Cap - 11. Seal - 12. Shim
- 13. Screw 16x120 - 14. Grease fitting - 15. Front frame - 16. Pin - 17. Shim - 18. Shim - 19. Pin - 20. Screw 16 x 25 - 21.
Washer - 22. Bushing - 23. Pin - 24. Bushing - 25. Bushing - 26. Washer 16 x 30 x 3 - 27. Screw 16 x 55 - 28. Screw 16 x
100 - 29. Shim - 30. Washer - 31. Shim - 32. Rear frame.
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(Upper hinging)
3 1
1 7
4 2
3
8
(Lower hinging)
13
3 1
14
15
16
10
17 4
11
12 18
1
2
1. Cover - 2. Dust seal - 3. Bushing - 4. Cover - 5. Shim - 6. Grease fitting - 7. Bearing - 8. Pin - 9. Bushing - 10. Cover - 11.
Shim - 12. Washer - 13. Pin - 14. Cover - 15. Shim - 16. Bearing - 17. Dust seal - 18. Bushing.
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Copyright © New Holland
WARNING
The steering action could crush the body betwe-
en the two modules (front and rear) of the frame.
Block the articulation with the safety bar, prior to
transporting the machine or performing repair
interventions. On the other hand, relocate the sa-
(With loader under repairs)
fety bar in its original position, prior to starting
operating the machine.
Fig. 5-12 Safety bar
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Copyright © New Holland
SECTION 6
The configuration of the hydraulic system is as follows: Once the speed of 7 km/h (4.3 mp/h) is exceeded, a
An hydraulic oil reservoir with a capacity of 97 l (25.62 solenoid valve automatically activates the system,
USG), capacity of the system about 160 l (42.26 USG) connecting the cylinder chambers with the
mounted centrally on the right side of the loader, com- accumulator and allowing the actuation of the damping
plete with filter protected by a by-pass valve set at 1 effect.
bar, located on the return oil circuit from the actuators. A sequence valve set at 120 bar (1740 psi), has the
An hydraulic pump with a by-pass valve mounted on function of protecting the accumulator from pressure
the transmission housing and driven by a gear secured peaks.
to the converter pump wheel.
A two-section, monobloc type control valve receives
the oil from the pump, setting the system pressure
through a main pressure relief valve set at 206 bar.
The control valve, as already stated is a two section
series type feeding two circuits: bucket roll back/dump
and boom raising and lowering.
Each one of these two circuits is equipped with safety
and anti-cavitation valves, preventing dangerous
pressure peaks that could occur in the pipes and
cylinders. Each section is equipped with a spool,
hydraulically piloted by a power assisted pilot valve;
the control valve control circuit operates at a pressure
of about 30 bar (435 psi) and it is connected with the
brakes circuit. The pilot valve can be hydraulically cut-
off by a three-way diverter valve (stop valve), so that
the accidental actuation of the levers, causing possible
undesired reactions by the equipment, is prevented.
The equipment control valve is connected with the
steering circuit. The excess oil arriving from the
steering pump is sent, with steering in neutral, to the
equipment circuit through a priority valve.
The circuit includes also, as an optional, a stress
reducing device when the machine is travelling on
rough terrain with a full bucket, the device is called
L.T.S. (Load Travel Stabiliser).
It is known, in fact, that during the travel of the
machine on rough terrain, the load of materials causes
a troublesome pitching of the unit, reflecting on the
stability of the machine itself, of the load and on the
operator’s comfort.
In this case, a big hydraulic accumulator, pre-loaded
with nitrogen and capable of absorbing the dynamic
loads, is connected through a block of valves with
the boom cylinders.
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Copyright © New Holland
Torque converter
housing
Oil reservoir
Pump
Main hydraulic
circuit
Bucket
dumping
cylinder
Control
valve
Boom left
cylinder
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Copyright © New Holland
A T
NEUTRAL
BOOM
CYLINDERS
STEERING VALVE
B STOP VALVE
P
B2 EQUIPMENT
PILOT VALVE 1 3
274 bar
X A2
Pb2 Pa2 A1
B1 B1
230 bar 186 bar
2
A1
T1
P1 P2 T2
ACCUMULATOR
TO PARKING BRAKE
Y PRESSURE
TO DISCHARGE FROM RELIEF VALVE
STEERING VALVE
0.7 l
LTS VALVE
(OPTIONAL)
MX MA A Y T 30 bar
PV T
HEAT
EXCHANGER
EQUIPMENT PUMP
WITH QUICK
DISCHARGE VALVE
172
x
bar
RETURN
FILTER
EQUIPMENT PUMP 1 bar
OIL RESERVOIR
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Copyright © New Holland
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
The circuit controlling the hydraulic cylinders is The pressure established in the delivery circuit is
powered by an hydraulic pump sucking oil from the proportional to the performance required and it is, in
hydraulic reservoir and sending it to the equipment any case, limited by the pressure relief valve.
control valve. This valve, set at 210 bar (3046 psi), regulates the
maximum pressure of the system, discharging
pressure in excess.
2 1
1
B 6
A. From hydraulic oil reservoir (suction) - B. To equipment control valve (delivery) - 1. Equipment pump - 2. Pump drive
sleeve - 3. Torque converter - 4. Transmission pump - 5. By-pass valve - 6. O-Ring.
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Copyright © New Holland
37 35 36 38 14 9 5 1 3 4 13 11
B A
E
D C
B A
6 7 6 7
10 2 5 10 12
Detail C Detail D 6 6 7 8
7
8
26 30 29 28 27 24 30 25 30
32
23
20
22 22
31
17 19 21 34 33 15 16 18
Section B - B Section A - A
Longitudinal section
discharge valve
172 bar
1. Gear plate - 2. Drive gear - 3. Driven gear - 4. Mounting flange - 5. Plate - 6. Seal - 7. Retainer - 8. Plate - 9. Dowel - 10.
O-Ring (high temperature) - 11. Seal (high temperature) - 12. Circlip - 13. Washer- 14. Pump cover - 15. Plunger - 16. Valve
(check) - 17. Plug - 18. Elastic ring - 19. Spring - 20. Plug - 21. O-Ring - 22. O-Ring - 23. Nut - 24. Setting valve - 25. Nut - 26.
Plug - 27. Spring guide - 28. Spring - 29. Rod - 30. O-Ring - 31. Plug - 32. O-Ring - 33. Plug - 34. O-Ring - 35. Screw (L= 85.5
mm) - 36. Screw (L= 132 mm) - 37. Screw (L= 188.5 mm) - 38. Washer.
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Copyright © New Holland
1) Gear plate
One of the methods to obtain a better volumetric
efficiency of a gear pump is the design allowing
the end of the teeth to stay in contact with the
inner wall of the chamber containing the gear itself.
Consequently, once the pump starts running, marks
left by the gear teeth are shown around the suction
port (fig. 6-5).
The contact mark is normal as long as it is less
than 1/2 the inner circumference of the gear cavity.
Dimension a of the mark depth (fig. 6-6) is normal
if it as about 0.05 mm (0.0019 in). When dimension
a exceeds 0.15 mm (0.0059 in) also the shaft and
bearings can wear out. Thus, these items as well, Contact mark
must be thoroughly checked.
If a is ≥ 0.15 mm (0.0059 in), replace the pump
with a new one. Fig. 6-6 Dimension of mark depth
d
Ø
Contact mark
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Suction side
Irregularities Discharge
side
Suction side
Irregularities
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Copyright © New Holland
View from C
3 4
1. Safety and anticavitation valve (186 bar ±10) - 2. Main pressure relief valve (206 bar ± 10) - 3. Safety and anticavitation valve (274
bar ± 10) - 4. Safety and anticavitation valve (230 bar ± 10) - A1 - B1 Bucket spool section - A2 -B2 booms spool section -
P1. Oil inlet (from pump) - P2. Oil inlet (from steering valve)- T1. Discharge - T2. Discharge (from steering valve).
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Copyright © New Holland
LP
HP
4 LP
5
LP
HP
Fig. 6-12 Operation (A)
LP
1 2 3
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Copyright © New Holland
LP
LP 2
HP
HP
LP
1 3 5
1 LP 3
b) Operation (A)
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Copyright © New Holland
When pilot valve (4) opens, the pressure on the If the pressure at port (HP) connected to the
raer side of piston valve (1) decreases, moving cylinder is lower than the value in low pressure
piston valve (1). Consequently, the orifice of piston duct (LP), being a condition for potential cavitation,
valve (1) closes so that the pressure on the rear make-up valve (2) moves proportionally to the
side of safety valve (3) decreases further. surface difference on which a negative pressure
intervenes. Consequently, to avoid cavitations, oil
can flow from low pressure duct (LP) to port (HP)
connected to the cylinder.
LP
LP 2
HP
HP
1 LP 3 4
LP
Fig. 6-16 Operation (B)
d) Operation (C)
LP
HP
LP 3
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3 functions hydraulic
pilot valve
Radiator
Piloting/brakes pump
Pilot system
pressure
regulating valve
accumulator
Brakes/pilot valve
high pressure filter
Implement
control valve Heat exchanger
Third hydraulic
function lever
To reservoir
To control valve To control valve Feeding
(port PV)
Note — The lay-out represent the variation regarding the 3 functions hydraulic pilot valve.
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Copyright © New Holland
6.4.1 DESCRIPTION
20.5° 20.5°
(Code)
P
[1] [3]
[3]
Booms
A2 A1 P
1: Port A1 - coil side (booms A1
T
B2 B1 raise) B1
[2]
[1] 2: Port A2 - coil side (bucket
[2] roll-in) A2
Bucket
B2
3: Port B1 - coil side (float)
T
Bucket Booms
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16
1
17
2
3
4
12
13
5 14
15
6
7
8
9
19 18
10
11
T
B2 A2
View from A
1. Nut- 2. Rocker arm - 3. Adjusting screw - 4. Support flange - 5. Piston - 6. Spring - 7. Cup - 8. Split pin - 9. Spring - 10.
Plunger - 11. Valve body - 12. Solenoid - 13. Plate- 14. Piston - 15. Guide - 16. Screw connecting upper ans lower bodies
- 17. Dust boot - 18. O-Ring - 19. Electrical connection.
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1 18
19
2
3
4
14
5 15
16
6 17
7
8
9
20
10
11 21
12
13
B1 A1
View from A
1. Nut - 2. Rocker arm - 3. Adjusting screw - 4. Support flange - 5. Piston - 6. Spring guide - 7. Spring - 8. Cup - 9. Spring
support ring - 10. Split pin - 11. Spring - 12. Plunger - 13. Valve body - 14. Solenoid - 15. Cap - 16. Piston - 17. Guide - 18.
Screw connecting upper and lower boides - 19. Dust boot - 20. O-Ring - 21. Electrical connections.
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Copyright © New Holland
Output
Maximum torque on levers: 80 Nm pressure (bar)
15˚ Tightening torque on ports: 30 Nm
24˚ 17˚
Push rod
stroke (mm)
Lever
angle (dg)
4 P
2
T 1
View F F
2
1 2 3
4
4 5 6
7 8 9
View F F
1 2 3
4 5 6
REPERE
CONNECT. REPERE COLOR
CONNECT. WIRE
1
El. detent port 1 1 Gray
4
2 2 Black
El. detent port 3 3 Red
5
3 4 Blue
El. detent port 4 5 Yellow
6
6 Green
7 White
8 Brown
9 None
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Copyright © New Holland
Stroke-end detent
Only the ports requiring a stroke-end detent of the
control lever are equipped with this device.
Solenoid block
An additional spring (7) under plate (12)warns by in-
creasing the force required to press this spring, that
the stroke of pusher group (5) and control lever (1) is
nearing its limit. Once this limit is reached, ring (10) is
touching solenoid armature (11). If the solenoid is
energised, control lever (1) is held in this position by
the magnetic force. The block is released automati-
cally, once the solenoid is de-energised.
Fig. 6-24
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2
3
Torque: 30 Nm
5
7
Torque: 10 Nm 9 Port 2
Port 1-3-4 8
Torque: 10 Nm
9 Port 2
Torque: 10 Nm 1 HANDGRIP ASS.LY
6 2 LEVER GROUP
Torque: 48 Nm 3 GROMMET
10 4 BUTTON KIT
5 NUT
13 Port 2 6 SHIM SET
11 7 JOINT HOLDER PLATE
14 Port 2
8 U-JOINT GROUP
18 9 PUSHER GROUP
Port 1-3-4 12 10 CENTRAL U-JOINT
11 FLANGE
12 SOLENOID 24 VOLT
13 INTERMED. PISTON
14 PISTON GUIDE
16 16 PROT. BUSH GROUP
Torque: 5 Nm
17 PLUGS
19
18 6-WAY BLOCK
17 19 VALVE BODY
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Copyright © New Holland
pressure
Output
1 2
(bar)
1 25˚ 25˚ 2
Pushing
stroke
T Lever
T angle
T P
P P
1 2
4
1 HYDRAULIC CONNECTIONS DATA:
Ports P, T, 1, 2: G1/4 Pipe thread ISO228-1;
ISO 1179 matching port type
5 2 1 HANDGRIP
2 GROMMET
3 LEVER
6
4 LEVER SECURING GROUP
3 (tightening torque of screws: 1.2 Nm)
5 LEVER FULCRUM
6 COVER GROUP (tightening torque
of screws: 8 Nm)
7 PLATE
7
8 PISTON GROUP
9 SPRINGS
10 VALVE BODY
Fig. 6-26 3rd hydraulic function pilot valve for single lever equipment control
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Copyright © New Holland
The reservoir contains the hydraulic oil for the main Inside the reservoir a filter is mounted, on the oil return
hydraulic system, the steering system and the brakes line, equipped with a by-pass valve that, in case of
system. clogging of the filtering element, discharges the oil
directly into the reservoir.
2
3
4
5 6
B
H ➤
E ➤ C
D ➤
➤
B A
➤
F ➤
E
13
12
11
1. Oil filter cover - 2. O-Ring - 3. Spring - 4. Filter holder - 5. Oil return filter - 6. Plug - 7. Introduction filter - 8. Breather pipe
- 9. Reservoir - 10. Oil level indicator- 11. Cover - 12. O-Ring - 13. Inspection passage - A. From heat exchanger - B. From
equipment control valve- C. To steering pump - D. To equipment pump - E. To diverter valve (em.st.) - F. To Emer. St. PUMP.
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Copyright © New Holland
6.6 CYLINDERS
Booms cylinders:
Type: ......................................................................................................................... Kayaba double acting
Q.ty: ........................................................................................................................................................ 2
Inside diameter of cylinder: ................................................................................................. 160 mm (6.30")
Diameter of rod ..................................................................................................................... 90 mm (3.54")
Cylinder rod stroke ............................................................................................................ 880 mm (34.64")
Weight (unit) ....................................................................................................................... 191 Kg (421 lbs)
Bucket cylinder:
Type: ......................................................................................................................... Kayaba double acting
Q.ty: ........................................................................................................................................................ 1
Inside diameter of cylinder: ................................................................................................. 190 mm (7.48")
Diameter of rod: .................................................................................................................... 95 mm (3.74")
Cylinder rod stroke: ........................................................................................................... 550 mm (21.65")
Weight (unit): ................................................................................................................. 188 Kg (414.4 lbs)
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1
5 6 3 8 7 9 10 11 12 2
13 3
1 2 4 15 14
(Inner Section)
17 18
16
4
Note - 1 603 Nm
2 5200 Nm
4 51 Nm
1. Mud scraper - 2. Sliding ring - 3. O-Ring - 4. Seal - 5. Front head - 6. O-Ring retainer - 7. Cylinder sleeve - 8. Rod - 9. Slide
ring - 10. Seal Ring/O-Ring - 11. Piston - 12. Lock nut - 13. Lock screw - 14. Steel ball - 15. Shim - 16. Steel pipe -
17. Bushing - 18. Mud scraper.
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Copyright © New Holland
12 2 3 5 4 7 9 8 6 2
1
10 3
1 7 6 13 11
(Inner Section)
14 15
16
Note - 1 1140 Nm
2 13900 Nm
4 92.4 Nm
1. Mud scraper ring - 2. O-ring holder - 3. O-Ring - 4. Cylinder sleeve - 5. Rod - 6. Seal - 7. O-ring - 8. Piston - 9. Seal/o-ring
- 10. Holding screw - 11. Steel ball - 12. Front sleeve - 13. Shim - 14. Bush - 15. Mud scraper - 16. Steel pipe.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
The L.T.S. (Load Travel Stabilizer) system, supplied POSITION 1 (L.T.S. ON)
as an optional, ensures a better driving comfort and a Automatic gearbox
reduction of dynamic loads on the components of the The transmission control unit automatically engages
machine (frame, axles etc.) when the unit travels with the L.T.S. system whenever the speed of the machine
or without load. exceeds 7 km/h (4.3 mp/h) and disengages it when
Without the L.T.S. system, the machine is subject, the speed drops, thus allowing the loading and dump-
as a result of irregular terrains, to unwanted pitching, ing of the bucket without unwanted movements of the
increasing with the travel speed. boom. The indicator comes on when the system is
With the L.T.S. system ON, the terrain irregularities ON and stays out when the system is OFF.
are absorbed by the equipment. In this manner, it is This position is recommended for normal use of the
possible to exploit completely the potential of the system.
machine, especially on uneven terrains, without
stressing mechanical components and providing max. Manual gearshifting
comfort for the operator. The L.T.S. is OFF when the gearshift lever is in first
speed.
The system includes, essentially:
- A switch (incorporating the indicator) located on the POSITION 2 (L.T.S. CONSTANTLY ON)
dashboard, to activate or disactivate the system; The indicator stays constantly ON.
- A piston type accumulator (oil capacity = 5.5 Liters; This position is useful only to allow the discharge of
gas capacity = 6 Liters) preloaded with nitrogen and the accumulator in view of maintenance or repair in-
connected to the boom raise/lowering cylinders; terventions (for this purpose, it is necessary to place
- A valve block controlled by a solenoid valve. the equipment control valve in float position).
This position can be used for occasional operation
only, to obtain the cushion effect at speeds below
5 km/h (3.1 mp/h).
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Copyright © New Holland
Automatic transmission
logic box
A.T.C.
To "est-37"
transmission
controller
Steering
valve
LTS valve
Hydraulic accumulator
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Copyright © New Holland
1
2
6 Y
X2 B
7 5
X1 4 EQUIPMENT
CONTROL
VALVE
MX MA A Y T
T A L.T.S. VALVE
TYPE MHRSM25 B2X/EG26C4M
X2 B
Y
X1
MA
MX
1. Accumulator - 2. Solenoid valve "1"- 3. Discharge - 4. Cylinder bottom side valve - 5. Cylinder rod side valve -
6. Sequence valve - 7. Equipment control valve - 8. Boom cylinders.
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Copyright © New Holland
Testing of electrical system Raise the boom to max. height and insist in this posi-
tion (valve activation) for about five seconds.
Start the engine. Lower the bucket to the ground.
Place the L.T.S. switch on position 2; the indicator Engage the L.T.S. system placing the L.T.S. switch
must come ON. into position 2 (the indicator must come ON).
Bring the engine to medium/high speed and raise the The bucket should raise about 200 mm (7.87 in).
boom to max. height.
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Copyright © New Holland
M
D1
M
WARNING
Prior to any maintenance intervention on the equip-
ment and the L.T.S. systems it is required that the
accumulator is discharged to avoid pressurised
fluid from escaping.
D
D2
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Copyright © New Holland
With tool applied to the accumulator connection - Close the valve of the nitrogen bottle.
proceed as explained below: Wait for about five minutes.
- Remove the cap and install the hose of the nitrogen - Check on pressure gauge (M) that the filling pressure
bottle equipped with pressure reduction valve (V). is 18 bar. If it is lower, repeat the operation.
- With valve (D2) closed, open slowly the valve of - Remove the filling rig.
the nitrogen bottle and check the filling pressure
increment on the pressure gauge (M). - Tighten screw (2) to a torque of 11 Nm.
M D1
A
V
D
D2
Fig. 6-34
A. Nitrogen bottle - D. Tool 75298472 - D1. Handle - D2. Discharge valve - M. Pressure gauge - V. Pressure reduction
valve.
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Copyright © New Holland
The variant allows the use of a multi-purpose bucket A three spool equipment control valve is arranged, a
(4 in 1) or other attachements requiring a third hydraulic third control lever in the cab besides the hydraulic
function. piping.
Lever of supplementary
hydraulic function
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Copyright © New Holland
Auxiliary section
Fig. 6-36 Configuration of 3 section control valve for 3rd hydraulic function
A3 A2 (3) A1
T P
B3 B2 (1) B1
(2)
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
6.9 TROUBLESHOOTING
Torque converter
Section A-A
Rear
Pilot system
FWD. circuit
REV.
a
3 2a
4a 1a
Pressure
pick-up
points
Fig. 6-39
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
SECTION 7
ELECTRICAL SYSTEM
CONTENTS
SAFETY RULES
WARNING
When working on the electrical system, always
wear safety glasses and remove rings, wrist
watches or any other metal jewellery.
DISCONNECT
WARNING
Prior to any maintenance or repair of electrical A C
components, disconnect the grounding cable B
“A” from the negative post “B” of the battery.
Disconnect cable “C” from positive post “D”.
BATTERY 12V x 2
GROUND
WARNING
NEVER PLACE METAL OBJECTS on the battery
to avoid short-circuits.
WARNING
BATTERY GASES ARE FLAMMABLE.
Never get near batteries with open flames or sparks. During recharging, the generation of gases is
higher.
WARNING
BATTERY GASES ARE DANGEROUS if contacting the skin or other materials.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
The above mentioned groups are connected among them by five multiple connectors located under the cab near
the frame front securing points.
1
1
1
B
2
3 4 5
Fig. 7-1
A. Left side connectors - B. Right side connectors - 1. Cab wires - 2. Front frame wires - 3. Rear frame wires - 4. Transmission
wires - 5. Engine wires.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
24-23
X
W K
V J L
H B
U M
G A C
T N
F
LEFT SIDE E
D
S O
VIEW OF CAB
R P
Q
X21
Fig. 7-2
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
24-31
31 20
30 6 21
19 9
18 2 10
29 7 3 22
17 1 11
28 8 4 23 RIGHT SIDE VIEW
16
15
6
13
12
OF CAB
27 14 24
26 25
X20
Fig. 7-3
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
24-21
H
X J
W K
G B
V L
F A C
U
E D
M RIGHT SIDE VIEW
T N
OF CAB
S P
R
X22
Fig. 7-4
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
24-18
6 7
8
18
9
1
17
10
5 2
16
RIGHT SIDE VIEW
4 3
11 OF CAB
15
12
14 13
X23
Fig. 7-5
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
23
22
24
17 21
14 12
20
2
19
18
3 28 4
5 15
1 30 29
23
32 6 24
13
11 31 27
10
9
8
16 26
7
25
Fig. 7-6
1. Right side wire - 2. Electronic controller - 3. Band - 4. Electronic controller - 5. Wire - 6. Electronic board - 7. Electronic
board - 8. Solenoid switch - 9. Timer K1-10 - 10. Timer K5-11 - 11. Electric wire - 12. Seal - 13. Relay - 14. Electric wire -
14. Electric wire - 15. Electronic controller - 16. Wire - 17. Electric wire - 18. Electronic controller - 19. Rear plate - 20. Seal
- 21. Spacer - 22. Threaded insert - 23. Screw - 24. Washer - 25. Flasher - 26. Fuse 5A, 3A, 7.5A, 10A, 15A - 27. Plate -
28. Electronic controller - 29. Seal - 30. Electronic controller - 31. Electronic controller - 32. Serial system.
The main connections in the cab can be reached by removing the rear and right side plastic panels.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
7.3 FUSES
WARNING
3
Always disconnect the battery grounding cable
prior to cleaning, repairing, connecting or
disconnecting any wire of the electrical system, to 2
prevent personal injuries. 1
Always keep all lights mounted on the machine in
working conditions. Replace all burnt-out bulbs as
soon as possible.
F9A EMPTY 3A
F9B EMPTY 3A
F9A F9B F9C F10A F10B F10C
F9C CENTR. LUBRICATION (OPT) 7.5A
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Copyright © New Holland
WIRES
777 To battery +
772 To diverter box
50A
WIRES
777 To battery +
773 To alternator
777 773
777 780
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
7 - 10
X7 X8
+ACC I +B I
M6 M5
F5C 10A
167
X1-1 FRONT WORK LIGHT
FARO LAV. ANT
F7A 15A F1A 7.5A
D15 441
R15 LIGHT
X4-1 ++CEIL
PLAFONIERA
D19 D1
R19 R1
2.2K 1/4w
5mm
F5B 10A
168 2.2K 1/4w 5mm 2.2K 1/4w
WORK
FARO LAV.
X1-2 REAR LIGHT
POST 5mm
F8B 5A
D14 F1B 7.5A
R14 CUM38 - 367 706
PARK. BRAKE
+5W FRENO PARCHEGGIO
X2-1 + 5W X4-2 B +B+HAZARDLIGHTS
LUCI EMERGENTA
D23 D2
R23 R2
2.2K 1/4w 5mm
F6C 5A
169 2.2K 1/4w 5mm 2.2K 1/4w
5 LTS
X1-3 + +5W E.V.S.V.
LTS
5mm
F8A 5A F11A 7.5A
R18 D18 963 925
COMPRESSORE
X2-2 + COMPRESSOR X4-3 HORN RELAY
RELE AVV. ACUSTIO
R9 D9 D31
R31
2.2K 1/4w 5mm
F3C 5A
171 2.2K 1/4w 5mm 2.2K 1/4w
ENG. 5mm
993
X1-4 BUCKET
C.V. AGGANCIO BENNA F8C 7.5A
D9 F12B 7.5A
R9 X1-5 + +PROXIMITY
PROXIMITY 995 153
994 24C. DOUBLE SW SW
X1-6 + +BUCKETPOS.PROX.
PROX POS. BENNA X2-3 + 24 C. DOPPIQ COM. X4-4 B +B+LIGHT
SW LUCI
D24 X2-4 ACC
+ ACC
R24 960 D35
B R35
2.2K 1/4w X2-5 + SOLEN
SOLENOIDA +A+B
5mm PROX.
X2-6 + PEDAL
PROX. PEDALE
F4A 5A 922 LCD
879 2.2K 1/4w 5mm X2-7 + LCD 2.2K 1/4w
LIGHTS 838 5mm
+15HAZARD.
X1-7 + 15 LUCI EMERGENZA X2-8 + ACC.
ACC
838
D10 X2-9 FRONT
ALIM. INSTR.POW.
STRUM. ANT.
F10A 7.5A
R10 839 721
X2-10 DUZZER
DUZZER LIGHTER
X4-5 + CIG.
+ ACCENDISIGARI
839 RELAY BACK-UP
X2-11 B6B6
RELE BACK-UP
D28
2.2K 1/4w X2-12 + ACC
+ACC T/R. E.V
T/Rb S.V.b R28
5mm 871
X2-13 CONTR.
+ +SPIA 2 INDIC.
2 COMMANDO
F2C 7.5A
880 2.2K 1/4w
+TERGI WIPER
X1-7 + REAR ANTERIORE 5mm
D6 F10B 10A
R6
X4-6 + 30 FA
CUM07
R29 D29
2.2K 1/4w 5mm CUM08
F1C 7.5A CUM17
149 2.2K 1/4w
X1-4 + +1515LIGHT SW
SW LUCI
5mm
112 F9A 3A
D3 X1-5 + 15
+ 15FLASHER
LAMPEGGIO F12A 10A
R3
X3-1 N.C. X4-7 + 30 FB
D25
R26 D34 CUM18
2.2K 1/4w R34
5mm CUM28
F6A 7.5A
2.2K 1/4w 5mm 2.2K 1/4w
809
Fig. 7-13
R36 D36
FUSE UNIT DIAGRAM
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
X3-11 POS. ANT.LIGHT.
DX.
339
R20 D20 X3-12 LH TAIL
LUCE LIGHT.
POS. SX
336
2.2K 1/4w X3-13 LH HEADLIGHT
LUCE INGOMBRO SX
5mm 339
X3-14 LH HEADLIGHT
TUV POS. ANT. SX
F3A 15A 450
2.2K 1/4w X3-15 INSTR.
RETROILLUMIN.
LIGHT STRUM.
5mm 450
X3-16 CIG.
LUCELIGHTER LIGHT
ACCENDISIGARI
996
D13 X3-17 ++C.V. F/R
C.V.F/R RELAY
RELE
R13
N.C.
X1-20 N.C.
D5 N.C.
X1-21 N.C.
R5
X5
893
MMREAR CENTR.
CENTR. POST 1
ACC REAR CENTR.
804
ACC. CENTR. POST 2
711
++HEATER
RISCALDAMENTO 3
KEY
949
MMFROM
DA CHIAVE 4
+ FROM KEY
724
BB+ DA CHIAVE 5
N.C.
N.C. 6
JACK 12V
CB - OPTIONAL
F4C - 5A
SEAT HEATER - OPTIONAL
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
The operating status monitor system monitors the The cluster guage unit consists of meters including
loader operating status by means of the sensors and the speedometer, monitor lamps (warning lamps) which
switches installed on the loader and siplays the indicates whether or not each system is operating
information on the cluster guage unit in the operator's properly, and indicator lamps.
compartment to inform the operator of the current
operating status of the loader.
4-6-
13 22 12 25 2 3 8-15 5 7 16 21 26 1 23 11 18-19
10 17 27-28
CN1 CN3
CN2
Fig. 7-15
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Copyright © New Holland
Positions on connections
Connection CN1
Connection CN1
Connection CN2
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17
Connection CN2
18 19 20 21
22 23 24 25 26
Connection CN3
28
27
Connection CN3
FM : FUEL METER
WTM : ENGINE WATER TEMPERATURE GAUGE
OTM : TRANSMISSION OIL TEMPERATURE GAUGE
EHM : ENGINE HOUR METER
SM : SPEEDOMETER
L1-L13 : MONITOR LAMPS
L14 - L18 : INSTRUMENT LAMPS
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Copyright © New Holland
↑ ↑ ↑ ↑ ↑
↑
1° Measurement point 67°C00 102°C00 50°C00 120°C00 E00 F00
Standard value Ω
49.8Ω Ω
16.8Ω Ω
91.7Ω Ω
10.4Ω Ω
80Ω Ω
10Ω
Fig. 7-17
a b c d
e f g h i l m
Fig. 7-18
a. Seat heater (opt.) - b. Transmission cut-off when braking - c. Transmission automation engagement - d. Boom kick-off
engagement (3 pos.) - e. Segnalatore preriscaldo - f. Radiator fan reverser - g. LTS (opt.) - h. Blocking valves cut-off(opt)
- i. Direction auxiliary reverser neutraliser - l, m, n. Not used.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
C H C H
1 2 3 4
8
2
1 A
9 7
10
12
13
11
1. Automatic transmission controller (ATC) - 2. Forward-Reverse controller - 3. Control panel - 4. Gearshift pilot valve -
5. Kick-down/Shift-down functions button - 6. Forward-Reverse diverter (opt) - 7. Forward-Reverse diverter neutraliser
switch -Reverse (opt.) - 8. Transmission automation engagement switch - 9. LTS device switch (opt) - 10. Transmission -
11. Transmission sensors - 12. LTS accumulator control group - 13. Accelerator pedal sensor.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
3
4
ND
ND
X1
4
3
2
1
1
X2
1
2
3
4
X3
SPEED SELECTION
1 = 1st speed SPEED SELECTION
2 = 2nd speed F = FORWARD
3 = 3rd speed R = REVERSE
4 = 4th speed N = NEUTRAL
2 3 N
1 4 R F
H VP
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
17 16 15 14 X 13 12 11 10 13 12 11 X 10 9 8
9 8 7 6 5 4 3 2 1 7 6 5 4 3 2 1
X19 X54
Fig. 7-21
WARNING
IT IS ESSENTIAL THAT DURING THE CONNECTION AND DISCONNEXTION PHASES OF THE ATC THE
ELECTRICAL SYSTEM IS DISCONNECTED (BATTERY CUT-OFF SWITCH AND STARTER SWITCH IN
POSITION "OFF") TO PREVENT POSSIBLE DAMGAES TO IT.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
VCC
C1
1000uF
R3
+
5W
PREARRANGEMENT MARK
MARK 13 way
13 vie yellow
giallo
K1 SOLO PREDISPOSIZIONE
ONLY J1
DR 24V
1 N.C.
VCC 2 CONTROLLER
ALIM.CENTRALINA POWER
(871) (871)
3 SPEED INPUT(ATC814)
INPUT MARCIA (ATC814)
R1
4 SPEED INPUT(ATC926)
INPUT MARCIA (ATC926)
5 SW
SW 3˚3RD 4TH SPEED
4˚ MARCIA(ATC939,ATC941)
6 (ATC939,ATC941)
SW 1˚ ST
2˚ MARCIA(ATC938,ATC940)
2K2 7 SW
GND1FILTRI2NDATCSPEED
(N1)
1/2W 8 (ATC938,
E.V. LTS (-)ATC940)
(954)
D1 9
GND FILTERS
E.V. LTS (-) (954) ATC (N1)
10
S.V. LTS
LTS DA ATC(-)(ATC865)
(954)
K2 S.V. LTS (-) (954)
INGRESSO PARKING BRAKE (ATC 665)
11 LTS FROM ATC (ATC865)
DR 24V 1N4007 12 SPIA PARKING BRAKE (996)
PARKING BRAKE INPUT (ATC665)
13 SPIA PARKING
PARKING BRAKEBRAKE (996) (996)
INDIC.
VCC
PARKING BRAKE INDIC. (996)
R2 D2
1N4007
2K2
1/2W
Fig. 7-22
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
JI
+S.W.F/R 986
+ E.V. F/RRELAY
RELE' 13
OUT ATC034 (X19) D1
OUTREV.
REV.ATCATC(-)(-) 12
S.V. 004 (X21)
E.V.REVERSE
REVERSE(-) (-) 11
S.V. FROM ATC ATC033 (X19)
E.V. F DA ATC 4
S.V. 003 (X21) IN5408 3A D2
E.V.FF(-)
(-) 9
+S.V. 987 (X2)
+ E.V.AAand
e BB (-) 2
OUT ATC002-002 (X19 X21)
OUT E.V.BB(-)
S.V. (-) 8
OUT ATC001 (X19 X21) D3 IN4007
OUTS.V.A
E.V. A(-)(-) 1
EM. 834 (X57)
SPIASTEER.
EM. STERZOINDIC. 5
EM.
SPIASTEER.
EM. STERZOINDIC. 844 (X19 X23)
10
N.C.
N.C IN5408 3A D4
3 556
85
85 RELAY
RELE' B. b ALARM
ALARM 6
INPUT
INPUT REVERSE
REVERSE 7 D8 IN4007
IN4007
MARK II 13 WAY 90°
MARK II 13 VIE 90˚ D5
ATC022
IN4007
D6
IN4007
D7
IN4007
Fig. 7-23
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
km\h Wire
cut-off
SOL. B Flashing 4th lamp 0.5 Hz
Failure
TR. B Flashing 4th lamp 1 Hz
OTHER CHECK
{ INPUT SIGNAL
OUTPUT SIGNAL
MEMORY
machine. N
Proceed as follows:
Fig. 7-25
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
Battery Ground
–
Fig. 7-26
OFF
AC
H C R B M
ON
STAR
T
L BG
B G1 G2 ACC M ST POSIZIONE
POSITION
H B ST
OFF
ACC
G2 G1
ON M ACC
START
Fig. 7-27
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
000
WIRE
870 to starting key through fuse 6D
780 to fuse 150 Amp
782 to cold starter resistor
000 to ground
TECHNICAL DATA
Nominal voltage: 24 V
870
780
782
Fig. 7-28
WIRE
700 to connection box
802
802 to starter safety solenoid switch
888 to starter motor
000 to ground e
TECHNICAL DATA
Nominal voltage: ≤ 24 V 700 888
Coil nominal current: ≤ 2 A
Nominal load: 100 A G B
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Copyright © New Holland
WIRE
772 to diverter box
869 to connection w7electric cut-off
913 to timer K24 913
000 to ground
e
TECHNICAL DATA
Nominal voltage: ≤ 24 V
772 869
Coil nominal current: ≤ 2 A
Nominal load: 100 A
G B
000 g
Fig. 7-31
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Copyright © New Holland
WIRES 556
772 to battery
197 to fuse 3E (7.5 Amp)
558 to connection 21N 85
772 30 197
87a
87
556 to connection 21M
86
Electric diagram
Fig. 7-33
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
7.9.5 DIODES K 23 - K 25
DIODE K 23
WIRE 000
876 to connection w/ amplifier EN 40
876
000 to connection w/ amplifier EN 40
870
DIODE K 25
WIRE
000 000
870 to cold starter relay coil
913 913
000 position 87a and 87c to ground
Fig. 7-36
30 87d
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Copyright © New Holland
WIRE
903 to fuse AD
87
913 to electric cut-off coil K 22
917 to fuse 5 D 86
000 to ground
TECHNICAL DATA
Operating voltage: 24 V 30 85
Kick-out output timer: 590 ms
Kick-out cycle repeating time: 5 ± 1 s
Maximum kick-out output current: 50 A
Intake at rest: ≤ 7 mA
TIMER
ACTUATION DIAGRAM
ENGINE CUT-OFF
SOLENOID
+ 30 30 85 86 87
KICK-OUT
HOLDING
+ 16
COMMON
- 31
Fig. 7- 38
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Copyright © New Holland
804
M 85 R
30
G
86
N
WIRE
804 to starter switch ("ACC")
N to ground
R to relay board (+B)
M to fuse F5A (15Amp)
TECHNICAL DATA
R
Nominal voltage: 24 V
Nominal current: 90A 30 85 86 G
Resistance: 140 Ω
Electric diagram
Contact closing voltage: 5 to 18V
Contact re-opening voltage: 8 to 20V Fig. 7-40
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
86 87 87
85 30
Electric diagram
Fig. 7-41
CABLES
1 to cab cable connector R
B
N to position 86 on seat relay 2 RELAY 1
R to position 87 on seat relay 2 M 4
(BUCKET)
2 to cab cable connector
B to position 30 on diodes seat
M to cab cable connector N 1
4 to equipment control connector
Fig. 7-42
CABLES
N to position 86 on seat relay 1
N to position 87a on diodes seat RELAY 2 R 5
R to position 87 on seat relay 1 (BUCKET)
H
3 to cab cable connector
5 to equipment control connector
N N
Fig. 7-43
7.9.9 SINGLE LEVER CONTROL DIODES BOX
LOCATION: Under the equipment control inside box "APV12".
WIRE
B Position 30 to position 30 on seat relay 1
N Position 87a to position 86 on seat relay 2 and position 87c
N Position 87c to position 87a on diodes seat
H Position 87d to position 30 on relay 2
N 87a
87b
87c B
30 87d
N
30
N
87a 87b 87c
87d H
Fig. 7-44
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
WIRES
1 To front wire connector 85
B 30 M
87a
R To position 30
87
M To front cable connector 86
B To position + of LTS solenoid valve timer
R R
Fig. 7-45
87a
87
B Bridge of position 86 to 87
2 To timed solenoid valve EV1 86
B To position + of LTS timer
4 To connection solenoid valves EV2-EV3 B
85 87 87a
Diode 1N4004 86 30
Fig. 7-46
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
WIRES
3 4 To connection solenoid valves EV2-EV3
B To position 87 of relay "1"
B To position 86 of relay "2"
H To position 85 of relay "2"
3
B P
L
B
Fig. 7-48
K4
K5 K6 K7 K8
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
X 3-4 +HORN
X 3-15 N.C.
k3
FLASHER UNIT
X 2-3 + LOW BEAM RELAY
STARTER
NEUTRALISER
Fig. 7-51
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
1 2
Fig. 7-52
7.10.1 STOP LIGHTS PRESSURE SWITCH 7.10.3 BRAKES ACCUMULATOR OIL LOW
PRESSURE SWITCH
WIRES
117 To fuse 1E (4 Amp) WIRES
175 To stop lights 613 613 To indicator on instr. panel through conn.
x14
TECHNICAL DATA 000 To front frame ground
Thread: M10 x 1
Setting: 1.8 ± 0.5 bar TECHNICAL DATA
Thread: R 1/8 conica
Setting: 60 ± 5 bar
WIRES
974 To transmission cut-off switch on right panel
of cab
975 To pos. 1 of transmission cut-off switch
TECHNICAL DATA
Thread: M10 x 1
Setting: 15 ± 1 bar
Tightening torque: 20 Nm
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
WIRES
663 663 To indicator on instrum. panel through x14
000 To front frame ground
TECHNICAL DATA
Setting (closing of contact): 57 ÷ 67 mbar
Tightening: tighten manually, without using tools
663
000
Fig. 7-53
503
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
Fig. 7-55
Fig. 7-56
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
528
552
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
996 978
550
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
559
Fig. 7-61 LOCATION - Left side of torque converter, on transmission cooling pipe
ACCELERATOR PEDAL
CAB FLOOR
538 981
000
1.5 - 3 mm SENSOR
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Copyright © New Holland
BLACK
BLUE
BEOWN
981
BLACK
BLUE
A
BROWN
980
Fig. 7-64 LOCATION - On front frame, in correspondence with the left boom pivot
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
2rd speed
1rd speed
sensor
sensor
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Copyright © New Holland
WIRES
555 To fuel level indicator (dashboard)
557 To fuel level instrument (dashboard)
INDICATOR
24V3W
A
FULL
24V V
3/4 262
409
25
272
(55˚)
1/2
R500
227
110˚
(55˚)
320
1/4
409
WARNING
557
POINT 555
EMPTY (Ω)
FULL 10
3/4 19
1/2 32
1/4 49.5
EMPTY 80 Floater
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
Copyright © New Holland
7.11 ALTERNATOR
OPTIMAL CONNECTIONS TO
TERMINAL I
TYPICAL WIRING DIAGRAM
DIODE (5 Amp)
637
10 OHM, 30 W A
50 OHM, 10 W
773 110 OHM RECOMMENDED
I
I
I
BULB 3 CP
BAT
522 W
IGN SWITCH
WHEN THE INDICATOR B+
LIGHT COMES ON I
WARNING: DO NOT SHUNT AMPEROMETRO
000 EXCEED 1 Amp output BAT+ HF
A
II
CHARGING LINE CABLE
TACHOMETER Ø 6 CABLE OR BAT
CHARGE INDICATOR LARGER V
LOAD
RECOMMENDED CHARGING
SYSTEM INDICATOR
KICK-DOWN
YU FORW/REV. SINGLE E-CONTACT
DOUBLE E-CONTACT
1
24˚ 17˚
2
4
NEUTRAL
SINGLE E-CONTACT YU
3 yellow black grey withe
Grip YU F
1 2 3
LOCATION - Right side of operator's seat
4 5 6
7 8 9
Fig. 7-70
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7.13.1 HORN
WIRES
138 To horn "K7"
000 To ground
TECHNICAL DATA
Nominal voltage: 24 V
Input: ≤ 5A (0.2 Ω)
Sound level:: 117 db a 1.2 m
138 000
TECHNICAL DATA
Nominal voltage: 24 V
Sound level: adjustable (97 - 107 - 112 db)
DETAIL OF SOUND POWER SELECTION
BRIDGE
MIN. MED.
MAX
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16 AZZURRO-GIALLO/LIGHT BLUE-YELLOW
+Batteria/+Battery
15 ROSSO/RED
+Chiave/+Key
6 BIANCO-NERO/WHITE-BLACK
+Luci/+Light
12 NERO/BLACK
Massa/Ground
18 VIOLA-BIANCO/VIOLET-WHITE
9 ROSA-NERO/PINK-BLACK
Sensore temperatura aria esterna
19 ROSA-NERO/PINK-BLACK External air temperature sensor
11 1
12 2
10 ROSSO-NERO/RED-BLACK
13 3 Sensore temperatura aria interna
20 ROSSO-NERO/RED-BLACK Internal air temperature sensor
14 4
15 5
16 6 2 AZZURRO-BIANCO/LIGHT BLUE-WHITE
17 7
18 8 13 BIANCO-WHITE 4 6
19 9
Connector
Connettore(for
(percontrol unit) to be
la centralina) daused in thenel
utilizzare wiring:
cablaggio:
20 10 Molex MiniFit 20 way female 3 2 1
Molex MiniFit 20 vie portaholder cod.cod.
femmina 557-20R
557-20R
Rel eccitato=ricircolo
4 MARRONE-BIANCO/BROWN-WHITE
87 Usato per attuatore di ricircolo
87 Used only for recycling acuator
86 85
30
1 VERDE/GREEN 87
All'impianto di
87 Tasto A/C condizionamento
86 85
30 A/C Switch To A/C system
11 BLU/BLUE
3 GIALLO/YELLOW
5 MARRONE/BROWN
2.5 mm2 +chiave
87 87 87
87 87
86 85 86 85 86 85
30 30 30
+chiave
+ chiave
key
a
22a Velocità
nd
Velocità
Speed
22nd Speed 1a Velocità
1st Speed a
1 Velocità
st
33aa Velocità 1 Speed
thVelocità Elettroventilatore
3 Speed
3rd Speed Marrone Electric fan
Marrone
Brown Nero
Nero
Black
Blu
Blue
Blu
Azzurro-gialo
Azzurro-giallo
Fig. 7-74 Light blue-yellow
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SECTION 8
CAB
CONTENTS
Fig. 8-1
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Copyright © New Holland
8.2 REPAIR
8.2.1 CAB (REMOVAL/INSTALLATION) Loosen the four safety screws and the four screws
securing the cab to the frame.
Removal Provide a suitable hoist above the cab and hook it to
Park the machine on level ground and block wheels the lifting eyebolts( q.ty 4) . These should have been
securely to prevent motion. screwed in at the cab top beforehand (cab weight:
Disconnect the battery isolator switch. 700 kg approx.). Take out any slack in the lifting chains.
WARNING
Always disconnect the battery isolator switch be-
WARNING
fore cleaning, repairing, overhauling or parking
the machine. Always use hoists or similar devices of suitable
capacity to lift or move heavy components. Ensure
that the sling is perfectly made.
Use the lifting eyes.
Fig. 8-3
3 2 1
Fig. 8-4
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Disconnect the four connections A-B-C-D from the Disconnect the two heater hoses located in the rear
bottom of the cab, on the left side, loosening the Allen right side of the cab.
screws retaining the connection. Make sure that all connections on the machine are
Disconnect the throttle pedal linkage, ball joint (5), disconnected, then lift the cab, moving it sideways.
link (6) from steering column (10). Loosen the screws
securing the brake pedal valve and remove the pedal
assembly, without disconnecting the pipes. Reinstallation
From the right side of the cab, open the panel and The installation is the reversal of the removal.
label the hoses of the equipment control levers (3) Tighten the cab screws to the frame to the specified
and three way valve (4). Disconnect the piping of the torque.
windshield washer from the reservoir, and disconnect
the piping of the parking brake valve from the right
side of the cab.
Close the heater feeding valves.
4
3
10
5
11
6
1 7 2 A B C D 11 1
8 1
Fig. 8-6
1. Safety screw M30 - 2. Safety screw M24 - 3. Tequipment control lever pipes - 4. Three-way valve pipes - 5. Throttle ball
joint - 6. Steering lever ball joint - 7. Cab and frame front securing nut M16 - 8. Cab and frame rear securing nut M16 -
9. Throttle pedal - 10. Steering column - 11. Elastic pads.
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The front windscreen wiper motor (1) is located at the Note 1 — Before setting the wiper blades in motion,
front of the steering column. The front windscreen wiper operate the windscreen washer to minimise the risk
has two intermittent working speeds: 35 strokes per of scratching the glass.
min (slow) and 55 strokes per min (fast).
A dog-leg mechanism transforms the motor shaft ro-
tary motion into 45° strokes of the wiping arm. Note 2 — Use the cleaning fluid DP1 diluted with water
dependent upon working temperature. A 50% deter-
gent/water solution does not freeze down to -10°C
The rear windscreen wiper motor (2) is located under (14 °F). Below this temperature, use cleaning fluid only.
the cab trim behind the driver’s seat, on the right-hand
side. The rear windscreen motor has but one speed
(approx. 54 strokes per min).
Internal gears provide an 80° oscillation of the wiping Pump hoses are connected to the nozzles located at
arm. the sides of the wiping arms.
4 5
Fig. 8-7
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8.4 HEATER
8.4.1 GENERALITIES
3
- adjust air temperature; 9
- control air flow intensity;
- admit air from the outside or recirculate the air
inside the cab.
5
A 8
Fig. 8-10
1. Electrical fan
2. Outside air filter
B
3. Filtering panel
4. Heat exchanger
5. Shroud
Fig. 8-9 6. Housing
7. Water lines
8. Air ducting
9. Feed valve
Specifications
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1
7 3
Fig. 8-12
Fig. 8-11
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1. Push a pointed object through the adhesive from 1. Place the glass momentarily in position and mark
inside the cab and insert the wire. with adhesive tape to position it correctly during
final bonding.
2. Using the wire, cut the adhesive all around the
glass. Lift out the glass using two suction cups.
Fig. 8-14
Fig. 8-13
WARNING
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Copyright © New Holland
3. Shake well the glass activator bottle before use 5. Punch the membrane in the threaded connection.
(at least 1 minute after ball separation from the
sediment). Apply an even continuous bead of
activator along the black stencil using the applicator
supplied.
Fig. 8-18
Fig. 8-16
6. Cut off the nozzle and apply a smooth continuous
bead of BETASEAL sealant-adhesive along the
edge of the body or windscreen keeping the gun
4. Remove the sealant cartridge bottom cover and vertical.
salts therein.
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Copyright © New Holland
Glass assembly
WARNING
1. Position the glass in its seat slightly pressing it. Any variation to instructions specified, such as
use of materials after expire date or improper work
procedures, may negatively affect the results of
the operation. The manufacturer does not assume
any responsibility for damages which may derive
to persons and/or things.
Fig. 8-20
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8 - 10 CAB W230
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W230 CAB 8 - 11
The operation principle can be summarised as follows: the refrigerant, Freon R134a, in its gaseous state, is
sucked by the compressor at low pressure and forwarded to final compression. The gas, heated by the compres-
sion, flows, still in a gaseous state, into the condenser, where, under the effect of the cooling provided by the air
flow through the action of the fan, reaches the condensation point, passing into a high pressure liquid state.
Consequently, the refrigerant at liquid state, reaches the dehydration filter that has the function of trapping
impurities, absorbing moisture trapped by the system and operates as a reserve tank for the refrigerant. Then, the
Freon reaches the expansion thermostatic valve that has the purpose of regulating the refrigerant flow in the low
pressure evaporator, causing the passage from liquid to gaseous state. At the same time, the air passing through
the evaporator, under the effect of the fan, at a temperature exceeding the refrigerator contained in the evaporator
itself, causes its boiling and a full evaporation, releasing heat. Cooled air, deposits on the fins of the evaporator
part of its moisture content, under the form of small droplets, dropping into the containers and unloaded outside
the cab.
Cooled and dehumidified air is directed to the cab. The refrigerant, at the evaporator outlet, is sucked again by the
compressor, re-staring the cycle.
Condenser
Intake
High
pressure
Low
pressure
Pressure Filter
switch
Fig. 8-21
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8 - 12 CAB W230
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W230 CAB 8 - 13
Electronic
Control controller
board
Condenser
Air
compressor
Hose
Filter
Transmitter
Sensor
Primary
air filter
Evaporator
Secondary
air filter
Valve Hydraulic
connection
Sensor
Fan
Radiator
Motor
Thermostat
Hose
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Copyright © New Holland
8 - 14 CAB W230
1 4
2 5
6 7 8 9
1. Inner temperature increment - 2. Inner temperature decrement - 3. Indication of inner temperature - 4. Fan speed
increment - 5. Fan speed decrement - 6. Auto function - 7. A/C compressor activation/deactivation - 8. Re-circulation -
9. Outer temperature.
In the event of troubles, the display shows the following error codes:
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W230 CAB 8 - 15
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Copyright © New Holland
8 - 16 CAB W230
IN ACCORDING WITH ISO 10263 - Position the O-Ring against the bulge in the pipe
when connecting hoses and pipes.
8.6.4 SERVICE PRECAUTIONS - Coat the piping connections and the O-Rings with
PAG oil.
- Fit the nuts and unions tightly against the base of
WARNING the companion pieces then hand tighten the nut as
Direct contact with refrigerant can cause frostbite much as possible. Then, tighten to the specific
or blindness. torque.
Always wear safety glasses and protective gloves.
Do not work with refrigerant colse to the face. Note - Always use oil specified for R134a system to
coat the O-Rings.
CAUTION
O-Ring
PAG oil, in the R134a systems, absorbs moisture
quickly when exposed to the atmosphere. Union
Fig. 8-23
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W230 CAB 8 - 17
OIL
WARNING
When removing refrigerant from the air conditioner
system, always use a refrigerant recovery unit
made especially for R134a.
(Special tool 380001326).
Oil-refrigerant
Condensation separation
CAUTION temperature
range Blending range
Cap the oil container after use and the air
conditioner system parts, when servicing. Vaporization
Never mix compressor oil with other types of oil. temperature
range
Fig. 8-26
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8 - 18 CAB W230
Manifold gauge
Charging hose
Charging hose
Coupler
Vacuum pump
Refrigerant container
Fig. 8-27
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W230 CAB 8 - 19
8.6.6 DISCHARGING
CAUTION
WARNING When the pointer moves toward 0 (zero) the system
is not leak-proof. Check the system to identify
Do not release the refrigerant into the air. leakages and fix tem.
Discharge refrigerant only into the refrigerant
recovery unit.
Evacuation
There are various methods of charging refrigerant into
the air conditioner system. these include using 1. Operate the vacuum pump.
refrigerant recovery units and direct charging using a 2. Open both manifold gauge valves
scale. 3. Evacuate the system for at least 20 minutes.
4. Close both manifold gauge valves.
Fig. 8-29
1. Leave the system as it is for 5 to 10 minutes.
Ensure the low pressure gauge needle does not
move towards the atmospheric pressure side 2. Disconnect the utility hose from the vacuum pump
(gauge pressure 0). and connect it to the refrigerant container.
3. Purge air from the utility hose.
4. Record the refrigerant weight.
5. Open the refrigerant container valve.
6. Slowly open the manifold gauge's low pressure side
valve to charge refrigerant from the low pressure
side valve to charge refrigerant from the low pres-
sure side.
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Copyright © New Holland
8 - 20 CAB W230
CAUTION
Pressure in low pressure line
Do not overcharge the system.
Time
Initial Leak check Compressor stops
Use an electronic leakage detector to check the
connections of the system for any possible seepage.
Fig. 8-31
Inspection procedure
Evacuation
Refrigerant
charging
Electronic leak detector
380001327
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W230 CAB 8 - 21
Inspection sequence
CAUTION
Clean all inspection points.
Check all connections carefully.
To prevent incorrect diagnoses, ensure there is
no refrigerant or cigarette smoke in the vicinity of
the vehicle.
Inspection points
Fig. 8-32
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8 - 22 CAB W230
8.6.9 TROUBLESHOOTING
Troubleshooting chart
2. Broken wiring Check the fan motor earth and connectors. Repair the wiring or
or bad connection connect correctly.
3. Fan motor Check the two lead wires from the motor with a circuit Replace.
malfunction tester. If there is no conductance, the motor is malfunction-
ing.
4. Broken resistor wiring Check resistor conductance using a circuit tester. If there is Replace.
no conductance, the wiring is broken.
5. fan motor switch Operate the fan switches in sequence and check whether Replace.
failure the fan operates.
2. Air leak Check the cooling unit case fittings. Repair of adjust.
3. Defective thermo Check whether the evaporator is frozen. Check the switch Replace.
switch using a circuit tester.
(c) Insufficient cooling although air flow and compressor operation are normal
1. Insufficient There will be little temperature difference between the low- Repair any leaks and
refrigerant. and high-pressure sides. Air bubbles or a "cloudy" flow will recharge the refrigerant
be visible in the sightglass. to the correct level.
2. Excessive refrigerant The high-pressure side pressure will be high and even if Drain small quantity of
the condenser is cooled using water, air bubbles will not refrigerant until air
appear in the sightglass. bubbles appear
periodically through the
window.
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Copyright © New Holland
W230 CAB 8 - 23
3. Magnetic clutch
related
• Oil on the clutch The magnetic clutch face is dirty, causing it to slip. Replace, or clean the
surface clutch surface.
• Open coil Clutch does not engage and there is no reading when a Replace.
circuit tester is connected between the coil terminals.
• Broken wiring or poor Clutch will not engage at all. Inspect the earth and connec- Repair.
earth tions.
• Wiring harness Test the conductance of the pressure switch, Check operation,
components thermoswitch, relay, etc. referring to the wiring
diagram, and replace
defective parts.
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Copyright © New Holland
8 - 24 CAB W230
Normal compressor suction and discharge pressures at an atmospheric temperature of 30 ~ 35° C (86 ~ 95°F) and
engine speed of approx. 1500 rpm are:
High pressure side pressure : 1.47 ~ 1.67 MPa (15 ~ 17 kg/cm)
Low pressure side pressure: 0.13 ~ 0.2 MPa (1.3 ~ 2.0 kg/cm)
Low -pressure side pres- The pressure in the low-pressure side becomes, normally, too high
sure too high. when the pressure on the high-pressure side is excessive. As ex-
plained here below, the check that follows is performed only when
the pressure on the low-pressure side is too high.
1. Defective The magnetic clutch switch turns off before the outlet air tempera- Adjust or replace.
thermoswitch. ture is sufficiently low.
2. Defective compressor The high- and low-pressure side gauge pressures equalize when Repair or replace the com-
gasket or valve. the magnetic clutch is turned off. pressor.
3. Poor expansion valve Frost has adhered to the compressor connector so that the tem- Install the temperature sen-
temperature sensor con- perature is lower than that of the evaporator outlet side piping. sor against the low-pressure
tact. pipe.
4. The expansion valve Same as above, or there is little pressure fluctuation when the Replace.
opens too far. temperature sensor is places against the pipe and then removed.
5. Clogged compressor The compressor connector is cool but the low-pressure hose is Remove and clean the fil-
suction filter. not. ter.
Low-pressure side
pressure too low.
2. Clogged receiver drier. Considerable temperature difference between the inlet and outlet Replace the receiver drier.
sides, or the tank is frosted.
3. Clogged expansion The expansion valve's inlet side is frosted. Clean the filter or replace
valve. the expansion valve.
4. Expansion valve tem- The expansion valve's outlet side is chilled, and low pressure Clean or replace the piping.
perature sensor gas leak gauge indicates a vacuum.
(damaged capillary tube,
etc.)
5. Clogged or blocked pip- When the piping is clogged or blocked, the low-pressure gauge Clean or replace piping.
ing. reading will decrease, or a negative reading may be shown.
High-pressure side
pressure too high.
1. Poor condenser cooling. Dirty or clogged condenser. Cooling fan does not operate cor- Clean, and repair the fan.
rectly. Blown fuse, broken wiring or poor contact. Fan motor mal- Repair the wiring or replace
function. the fuses.
High-pressure side
pressure too low
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Copyright © New Holland
W230 CAB 8 - 25
Normal pressures
Low pressure side High pressure side
Low-pressure side: 0.13 ~ 0.2 MPa (1.3 ~ 2.0 kg/cm2)
0.13 - 0.2 MPa 1.47 - 1.67 MPa High-pressure side 1.47 ~ 1.67 MPa (15 ~ 17 kg/cm2)
{1.3 - 2.0 kg/cm2} {15 - 17 kg/cm2}
7
Conditions
6 8 1.5 2.0
4
5
5
9
10
1.0 15 20 2.5 Atmospheric temperature: 30 ~ 35°C (86 ~ 95 °F)
10 10 25
3
2
11
12
0.5 5
0
30 3.0 Engine speed: 1.500 rpm
35
1
0
0 15
14
13 0
3.5 Blower speed: HI (high-speed)
15
Insufficient refrigerant
Indications:
• Low pressures on both the low pressure and high-
pressure sides;
Fig. 8-33
• Discharge temperature will not decrease.
Cause: Refrigerant leakage.
Remedy: Inspect using a gas leak detector, repair
the leak, and replenish the refrigerant.
6 7 8 1.5 2.0
5 9
1.0 15 20 2.5
4 5 10
10 10 25
11
3 0.5 5 3.0
30
2 12
0 35
0 15 13
1 0
3.5
0 14
15
Fig. 8-34
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8 - 26 CAB W230
0.25 - 0.29 MPa 2.26 MPa Indication: both the low and high pressures are too
{2.5 - 3.0 kg/cm2} {23 kg/cm2}
high.
6 7 8 1.5
4
5 9
10
1.0 15
2.0
20 2.5
Causes:
5
10
3
10
11
12
0.5 5
25
30 3.0 • Pressure increment due to excessive refrigerant.
2 0 35
1
0 15
14
13 0
3.5
• Insufficient condenser cooling.
0
15
Remedy:
• Clean the condenser.
• Inspect and adjust the fan belt and condenser motor.
• Check the refrigerant level.
Fig. 8-35
2
11
12
0.5 5
0
30 3.0 Cause: Air entered the cooling system. When the
35
1
0
0 15
14
13 0
3.5 suction is not applied, the reading of the
15
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W230 CAB 8 - 27
Infiltration of moisture
Low pressure side High pressure side
0.25 MPa
{2.5 kg/cm2}
2.16 - 2.26 MPa
{22 - 23 kg/cm2}
Indication: Both the low and high pressures are too
high.
6 7 8 1.5
4
5 9
10
1.0 15
2.0
20 2.5
Causes: Improper refrigerant charge;
5
10 10 25
11
3
2 12
0.5 5
0 35
30 3.0
Defective expansion valve;
0 15 13
1
0
15
14
0
3.5
Improper temperature sensor installa-
tion.
Remedy:
• Check temperature sensor installation, and
insulation;
• If normal, replace the expansion valve.
Fig. 8-37
3
10
11
0.5 5
10 25
30 3.0
• The high and low pressures are already equal when
12
2
1
0 15 13 0
0 35
3.5
operation is stopped.
0 14
15
Fig. 8-38
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8 - 28 CAB W230
Infiltration of moisture
Low pressure side High pressure side
Vide - 0.13 MPa 0.59 - 1.77 MPa Indication: The low-pressure side pressure
{Vide - 1.3 kg/cm2} {6 - 18 kg/cm2}
alternates between a vacuum and normal
6 7 8 1.5 2.0
pressure.
5 9
4 5
10
10
11
1.0
10
15 20
25
2.5
Causes: Moisture has frozen in the air conditioner
3 0.5 5 3.0
2
0
12
0
30
35
system, clogging the expansion valve,
1 15 13 0
0
15
14
3.5
which then blocks the air conditioner
system. When the ice melts, normal
operation resumes.
Remedy:
• Replace the receiver drier.
• Evacuate the system.
• Recharge with refrigerant to the proper level.
Fig. 8-39
4
5
5
9
10
1.0 15 20 2.5 0.59 MPa {5 ~ 6 kgf/cm}.
10 10 25
11
3 0.5 5 3.0
30
2
1
0 15 13
12
0
0 35 • Ice or condensation are forming on the piping
3.5
0
15
14
connections of the drier receiver or the expansion
valve.
Causes:
• The air conditioner system is blocked by ice or dirt.
• The air conditioner system is shut off by a defective
expansion valve temperature sensor.
Remedy: Stop operation and check for ice or
Fig. 8-40 contamination.
• If the problem is moisture, evacuate the system.
• Replace the expansion valve temperature sensor if
defective.
• Replace the receiver drier.
• Recharge with refrigerant to the proper level.
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