New holland w80btc compact wheel loader service repair manual

SERVICE MANUAL

W50BTC W60BTC W70BTC W80BTC

SERVICE MANUAL W50BTC - W60BTC - W70BTC - W80BTC COMPACT WHEEL LOADERS

Compact Wheel Loaders

Print No. 87734623B

Print No. 87734623B

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TO PREVENT ACCIDENTS The majority of accidents and injuries which occur in industry, on the farm, at home or on the road, are caused by the failure of some individual to follow simple and fundamental safety rules or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognizing the real cause and taking the necessary precautions, before the accident occurs.

Regardless of the care used in design and construction of any type of equipment, there may be conditions that cannot be completely safeguarded against, without interfering with reasonable accessibility and efficient operation.

A careful operator and / or technician is the best insurance against accidents. The complete observance of one simple rule would prevent many thousands of serious injuries each year.

This rule is: never attempt to clean, lubricate or adjust a machine while it is in motion.

Sď€ WARNING Before carrying out any maintenance operation, adjustment and or repair on machines equipped with attachments, controlled hydraulically or mechanically, make sure that the attachment is lowered and safely set on the ground. If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than

INDEX SECTION 00 - INTRODUCTION 1. SAFETY INSTRUCTIONS ............................................................................................................................ 1 2. GENERAL SAFETY INSTRUCTIONS.......................................................................................................... 2 3. TECHNICAL SPECIFICATIONS................................................................................................................. 12

SECTION 10 - ENGINE 1. DIESEL ENGINE .......................................................................................................................................... 1 2. FUEL SYSTEM ............................................................................................................................................. 2 3. COLD START DEVICE (NORTH AMERICA) ............................................................................................... 5

SECTION 25 - FRONT AXLES 1. REMOVAL AND INSTALLATION ................................................................................................................. 1 2. DIMENSIONS ............................................................................................................................................... 3 3. TECHNICAL SPECIFICATIONS................................................................................................................... 5 4. OIL CHANGE................................................................................................................................................ 9 5. DISASSEMBLY AND ASSEMBLY.............................................................................................................. 12 5.1 DISC BRAKE ASSY............................................................................................................................. 12 5.2 BRAKE CALIPER ................................................................................................................................ 19 5.3 REDUCTION GEAR (W50BTC) .......................................................................................................... 27 5.4 REDUCTION UNIT (W60BTC, W70BTC, W80BTC) ........................................................................... 30 5.5 WHEEL HUB (W50BTC)...................................................................................................................... 33 5.6 WHEEL HUB (W60BTC, W70BTC, W80BTC) .................................................................................... 42 5.7 WHEEL SHAFT (W60BTC, W70BTC, W80BTC) ................................................................................ 48 5.8 BRAKE AND WHEEL SHAFT (W60BTC, W70BTC, W80BTC “HIGH SPEED”)................................. 52 5.9 DIFFERENTIAL SUPPORT ................................................................................................................. 60 5.10 DIFFERENTIAL ASSY....................................................................................................................... 68 5.11 PINION............................................................................................................................................... 75 6. TROUBLESHOOTING................................................................................................................................ 81 7. SPECIAL TOOLS........................................................................................................................................ 84

SECTION 27 - REAR AXLES 1. REMOVAL AND INSTALLATION ................................................................................................................. 1 2. DIMENSIONS ............................................................................................................................................... 3 3. TECHNICAL SPECIFICATIONS................................................................................................................... 7 4. OIL CHANGE.............................................................................................................................................. 14 5. DISASSEMBLY AND ASSEMBLY.............................................................................................................. 18 5.1 MOTOR TB150 .................................................................................................................................... 18 5.2 MOTOR TB138.5 “HIGH SPEED” ....................................................................................................... 21 5.3 TRANSMISSION BOX TB150 ............................................................................................................. 25 5.4 TRANSMISSION TB138.5 “HIGH SPEED” ......................................................................................... 34 5.5 REDUCTION GEAR (W50BTC) .......................................................................................................... 54 5.6 REDUCTION UNIT (W60BTC, W70BTC, W80BTC) ........................................................................... 57

INDEX 5.7 WHEEL HUB (W50BTC)...................................................................................................................... 61 5.8 WHEEL HUB (W60BTC, W70BTC, W80BTC)..................................................................................... 70 5.9 WHEEL SHAFT (W60BTC, W70BTC, W80BTC) ................................................................................ 76 5.10 DIFFERENTIAL SUPPORT ............................................................................................................... 80 5.11 DIFFERENTIAL ASSY ....................................................................................................................... 88 5.12 LIMITED SLIP DIFFERENTIAL ASSY ............................................................................................... 94 5.13 PINION............................................................................................................................................. 101 6. TROUBLESHOOTING .............................................................................................................................. 107 7. SPECIAL TOOLS...................................................................................................................................... 110

SECTION 33 - BRAKE SYSTEM 1. BRAKE SYSTEM DIAGRAM ........................................................................................................................ 1 1.1 STANDARD DIAGRAM.......................................................................................................................... 1 1.2 “HIGH SPEED” DIAGRAM..................................................................................................................... 2 2. TECHNICAL SPECIFICATIONS................................................................................................................... 3 2.1 BRAKE PEDAL VALVE.......................................................................................................................... 3 2.2 PRESSURE SWITCHES ....................................................................................................................... 3 3. OPERATION ................................................................................................................................................. 4 3.1 SERVICE BRAKE OPERATION ............................................................................................................ 6 3.2 PARKING BRAKE OPERATION............................................................................................................ 8 4. BRAKE PEDAL VALVE................................................................................................................................. 9 5. PRESSURE SWITCHES ............................................................................................................................ 11 6. BRAKE ACCUMULATOR ........................................................................................................................... 12 6.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 12 7. CHECKS AND ADJUSTMENTS ................................................................................................................. 13 7.1 SERVICE BRAKE SYSTEM PRESSURE CHECK .............................................................................. 13 7.2 ACCUMULATOR PRESSURE CHECK ............................................................................................... 14 7.3 PEDAL ANGLE ADJUSTMENT ........................................................................................................... 15 7.4 “INCHING” VALVE ADJUSTMENT...................................................................................................... 16 8. TROUBLESHOOTING ................................................................................................................................ 17

SECTION 35 - HYDRAULIC SYSTEM 1. HYDRAULIC DIAGRAMS ............................................................................................................................. 1 1.1 HYDRAULIC DIAGRAM FOR W50BTC ................................................................................................ 1 1.2 HYDRAULIC DIAGRAM FOR W50BTC WITH OPTIONAL OUTFITS................................................... 3 1.3 HYDRAULIC DIAGRAM FOR W60BTC ................................................................................................ 5 1.4 HYDRAULIC DIAGRAM FOR W60BTC WITH OPTIONAL OUTFITS................................................... 7 1.5 HYDRAULIC DIAGRAM FOR W70BTC ................................................................................................ 9 1.6 HYDRAULIC DIAGRAM FOR W70BTC WITH OPTIONAL OUTFITS................................................. 11 1.7 HYDRAULIC DIAGRAM FOR W80BTC .............................................................................................. 13 1.8 HYDRAULIC DIAGRAM FOR W80BTC WITH OPTIONAL OUTFITS................................................. 15 2. TRANSMISSION......................................................................................................................................... 17 2.1 HYDRAULIC DIAGRAM....................................................................................................................... 17 2.2 OPERATION ........................................................................................................................................ 18 2.3 ADJUSTMENTS................................................................................................................................... 20 3. VARIABLE-DISPLACEMENT PISTON PUMP............................................................................................ 22 3.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 23 3.2 MAIN VALVES ..................................................................................................................................... 24

INDEX 3.3 DISASSEMBLY.................................................................................................................................... 32 3.4 ASSEMBLY.......................................................................................................................................... 51 4. GEAR PUMP .............................................................................................................................................. 58 4.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 58 4.2 COMPONENTS ................................................................................................................................... 59 4.3 DISASSEMBLY AND ASSEMBLY....................................................................................................... 60 5. PRIORITY VALVE ...................................................................................................................................... 63 5.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 63 6. TRAVEL MOTOR........................................................................................................................................ 64 6.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 64 6.2 MAIN COMPONENTS ......................................................................................................................... 66 6.3 OPERATION........................................................................................................................................ 67 6.4 REMOVAL ........................................................................................................................................... 70 6.5 DISASSEMBLY AND ASSEMBLY....................................................................................................... 71 7. ONE-WAY DISTRIBUTOR VALVE............................................................................................................. 85 8. HYDRAULIC OIL TANK.............................................................................................................................. 86 8.1 OIL FILTER.......................................................................................................................................... 87 9. TROUBLESHOOTING................................................................................................................................ 88

SECTION 39 - FRAME 1. ARTICULATED JOINT.................................................................................................................................. 1 1.1 COMPONENTS ..................................................................................................................................... 1 1.2 DISASSEMBLY AND ASSEMBLY......................................................................................................... 2

SECTION 41 - STEERING SYSTEM 1. OPERATION................................................................................................................................................. 1 1.1 EMERGENCY STEERING .................................................................................................................... 3 1.2 PRESSURE ADJUSTMENT .................................................................................................................. 4 2. POWER STEERING ..................................................................................................................................... 5 2.1 TECHNICAL SPECIFICATIONS............................................................................................................ 6 2.2 COMPONENTS ..................................................................................................................................... 7 2.3 DISASSEMBLY AND ASSEMBLY......................................................................................................... 8 2.4 TROUBLESHOOTING......................................................................................................................... 24 2.5 SPECIAL TOOLS................................................................................................................................. 25 3. STEERING CYLINDER .............................................................................................................................. 26 3.1 REMOVAL AND INSTALLATION ........................................................................................................ 27 3.2 DISASSEMBLY.................................................................................................................................... 29 4. TROUBLESHOOTING................................................................................................................................ 34

SECTION 50 - HEATING AND AIR CONDITIONING SYSTEM 1. HEATING ...................................................................................................................................................... 1 2. AIR CONDITIONING .................................................................................................................................... 3 3. TROUBLESHOOTING................................................................................................................................ 29

INDEX SECTION 55 - ELECTRICAL SYSTEM 1. ELECTRICAL DIAGRAMS............................................................................................................................ 1 2. FUSES AND RELAYS ................................................................................................................................ 17 3. VOLTAGE AND CONTINUITY CHECK ...................................................................................................... 20 4. BATTERY.................................................................................................................................................... 21 4.1 REPLACEMENT .................................................................................................................................. 24 5. BULBS ........................................................................................................................................................ 25 6. TROUBLESHOOTING ................................................................................................................................ 29

SECTION 82 - WORKING EQUIPMENT 1. HYDRAULIC DIAGRAM................................................................................................................................ 2 2. OPERATION ................................................................................................................................................. 3 3. REMOVAL AND INSTALLATION ................................................................................................................. 4 4. QUICK TOOL COUPLER.............................................................................................................................. 6 4.1 COMPONENTS ..................................................................................................................................... 7 4.2 QUICK TOOL COUPLER CYLINDERS ................................................................................................. 8 5. BUCKET........................................................................................................................................................ 9 5.1 ASSEMBLY............................................................................................................................................ 9 5.2 DISASSEMBLY.................................................................................................................................... 10 5.3 BUCKET TEETH - REPLACEMENT.................................................................................................... 11 6. FORKS........................................................................................................................................................ 12 6.1 DISASSEMBLY AND ASSEMBLY....................................................................................................... 13 6.2 CHECKS .............................................................................................................................................. 14 7. CYLINDERS................................................................................................................................................ 16 7.1 BOOM CYLINDER ............................................................................................................................... 16 7.2 DUMPING CYLINDER ......................................................................................................................... 20 8. CONTROL VALVE ...................................................................................................................................... 24 9. LOAD HOLDING VALVE ............................................................................................................................ 27 9.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 27 10. TROUBLESHOOTING .............................................................................................................................. 28

SECTION 00 - INTRODUCTION 1. SAFETY INSTRUCTIONS ............................................................................................................................ 1 2. GENERAL SAFETY INSTRUCTIONS.......................................................................................................... 2 3. TECHNICAL SPECIFICATIONS................................................................................................................. 12

SECTION 00 - INTRODUCTION

1.

SAFETY INSTRUCTIONS

Carefully read the safety rules contained herein and follow advised precautions to avoid potential hazards and to safeguard your safety and personal integrity.

In this manual you will find the following indications:

S WARNING This symbol warns about the possibility of potential damages to the machine that can involve the operator’s safety.

S DANGER With specific warnings about potential dangers for the operator’s or other persons integrity directly or indirectly involved.

The non compliance with the warning preceded by the above mentioned key-words (WARNING and DANGER) can cause serious accidents or even the death of the persons involved.

Moreover in the present Manual have been given some instructions with texts in italics, preceded by the words NOTE and CAUTION, with following meanings for machine protection: NOTES: it emphasizes and underlines to the operator the correct technique or correct procedure to follow.

S WARNING It warns the operator of a possible hazard of machine damage in case he does not follow a determined procedure.

Your safety and that of people around you depends on you. It is essential that you understand this manual for the correct operation, inspection, lubrication and maintenance of this machine.

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SECTION 00 - INTRODUCTION

GENERAL SAFETY INSTRUCTIONS

Carefully read this Manual before proceeding with maintenance, repairs, refuelling or other machine operations.

Repairs have to be carried out only by authorized and instructed staff; specific precautions have to be taken when grinding, welding or when using mallets or heavy hammers.

Not authorized persons are not allowed to repair or carry out maintenance on this machine. Do not carry out any work on the equipment without prior authorization.

Ask your employer about the safety instructions in force and safety equipment.

Nobody is allowed to seat on the operator’s place during machine maintenance unless he is a qualified operator helping with the maintenance work.

If it is necessary to move the equipment to carry out repairs or maintenance, do not lift or lower the equipment from any other position than the operator’s seat.

Never carry out any operation on the machine when the engine is running, except when specifically indicated.

Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps, covers, valves, etc.

All repair and maintenance operations should be carried out with the greatest care and attention.

Service stairs and platforms used in a workshop or in the field should be built in compliance with the safety rules in force.

Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

SECTION 00 - INTRODUCTION

2.1

EMERGENCY

Be prepared for emergencies. Always keep at disposal on the machine a first aid kit and a fire extinguisher. Make sure that the fire extinguisher is serviced in accordance with the manufacturer’s instructions.

2.2

EQUIPMENT

Wear close fitting clothing and safety equipment appropriate for the job: Z safety helmet; Z safety shoes; Z heavy gloves; Z reflective clothing; Z wet weather clothing.

If the environment conditions make it necessary, the following personal safety equipment should be at hand: Z respirators (or dustproof masks); Z ear plugs or acoustic ears protections; Z goggles with lateral shield or masks for eyes protection.

Do not wear rings, wristwatches, jewels, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open jackets or shirts with open zips which could get caught into moving parts.

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2.3

SECTION 00 - INTRODUCTION

PLACING THE MACHINE IN SAFE CONDITIONS

Before carrying out any repair operation on this machine, place it in safe conditions.

Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.

Rest the bucket on the ground.

Place the direction-of-travel lever and gearshift lever in neutral position.

Immobilize the machine by means of the parking brake.

Stop the engine and remove the starter switch key.

Release the hydraulic pressure by operating the control levers in all directions.

Place some wedges under the wheels so as to prevent the machine from moving.

Make sure that the door and the engine guard are correctly fastened and lock the operator’s compartment door.

Check that no part of the machine is protruding onto the public highway. If this cannot be avoided, install signs in compliance with the relevant regulations.

SECTION 00 - INTRODUCTION

2.4

ENGINE - RADIATOR

Never leave the engine run in closed spaces without ventilation and not able to evacuate toxic exhaust gases. Keep the exhaust manifold and tube free from combustion materials.

Do not refuel with the engine running, especially if hot, as this increases fire hazard in case of fuel spillage.

Never attempt to check or adjust the fan belts when the engine is running.

Never lubricate the machine with the engine running.

Pay attention to rotary pieces and do not allow to anyone to approach to avoid becoming entangled.

If hands, clothes or tools get caught in the fan blades or in the transmission belt, this can cause amputations, violent tears and generate condition of serious danger; for this reason avoid touching or to come close to all rotary or moving parts.

A violent jet of the coolant from the radiator can cause damages and scalds.

If you are to check the coolant level, you have to shut off the engine previously and to let cool down the radiator and its pipes. Slowly unscrew the cap to release the inside pressure.

If necessary, remove the cap with hot engine, wear safety clothes and equipment, then loosen the cap slowly to relieve the pressure gradually.

When checking the fuel, oil and coolant levels, use exclusively explosion proof classified lamps. If this kind of lamps are not used fires or explosions may occur.

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2.5

SECTION 00 - INTRODUCTION

HYDRAULIC SYSTEMS

Splashes of fluids under pressure can penetrate the skin causing serious injuries.

Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

Relieve the residual pressure by moving the hydraulic control levers several times.

Tighten all connections before applying pressure.

To protect the eyes wear a facial shield or safety goggles.

Protect your hands and body from possible splashes of fluids under pressure.

Swallowing hydraulic oil is a severe health hazard.

When hydraulic oil has been swallowed, avoid vomiting, but consult a doctor or go to a hospital.

If an accident occurs, see a doctor familiar with this type of injury immediately.

Any fluid penetrating the skin must be removed within few hours to avoid serious infections.

Flammable splashes may originate because of the heat near pipes with fluids under pressure, with the result of serious scalds for the persons hit. Do not weld or use torches near pipes containing fluids or other flammable materials.

Pipes under pressure can accidentally be pierced when the heat expands beyond the area immediately heated.

Arrange for fire resistant temporary shields to protect hoses or other components during welding.

Have any visible leakage repaired immediately.

Escaping oil pollutes the environment. Soak up any oil that has escaped with a proper binding agent.

Sweep up binding agent and dispose of it separately from other waste.

Never search for leakages with the fingers, but use a piece of cardboard and always wear goggles.

Never repair damaged piping; always replace it. Replace hydraulic hoses immediately on detecting any damage or leak.

Always store hydraulic oil in the original containers.

SECTION 00 - INTRODUCTION

HOSES AND TUBES Always replace hoses and tubes if the cone end or the end connections on the hose are damaged.

When installing a new hose, loosely connect each end and make sure the hose takes up the designed position before tightening the connections. Clamps should be tightened sufficiently to hold the hose without crushing and to prevent chafing.

After hose replacement to a moving component, check that the hose does not foul by moving the component through the complete range of travel.

Be sure any hose which has been installed is not kinked or twisted.

Hose connections which are damaged, dented, crushed or leaking, restrict oil flow and the productivity of the components being served. Connectors which show signs of movement from the original position have failed and will ultimately separate completely.

A hose with a frayed outer sheath will allow the water penetration. Concealed corrosion of the wire reinforcement will subsequently occur along the hose length with resultant hose failure.

Ballooning of the hose indicates an internal leakage due to structural failure. This condition rapidly deteriorates and total hose failure soon occurs.

Kinked, crushed, stretched or deformed hoses generally suffer internal structural damage which can result in oil restriction, a reduction in the speed of operation and ultimate hose failure.

Free-moving, unsupported hoses must never be allowed to touch each other or related working surfaces. This causes chafing which reduces hose life.

O-RINGS Replace O-rings, seal rings and gaskets whenever they are disassembled.

Never mix new and old seals or O-rings, regardless of condition. Always lubricate new seal rings and Orings with hydraulic oil before installation to relevant seats.

This will prevent the O-rings from rolling over and twisting during mounting which will jeopardize sealing.

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2.6

SECTION 00 - INTRODUCTION

BATTERY

Batteries give off explosive gases.

Never handle naked flames and unshielded light sources near batteries, never smoke.

To prevent any risk of explosion, observe the following instructions: Z when disconnecting the battery cables, always disconnect the negative (-) cable first; Z to reconnect the battery cables, always connect the negative (-) cable last; Z never short-circuit the battery terminals with metal objects; Z do not weld, grind or smoke near a battery.

Battery electrolyte causes severe burns. The battery contains sulphuric acid. Avoid any contact with the skin, eyes or clothing.

Antidote: Z EXTERNAL: rinse well with water, removing any soiled clothing.

Z INTERNAL: avoid vomiting. Drink water to rinse your mouth. Consult a doctor.

Z EYES: rinse abundantly with water for 15 minutes and consult a doctor.

Z When the electrolyte of a battery is frozen, it can explode if you attempt to charge the battery or if you try to start the engine using a booster battery.

Always keep the battery charged to prevent the electrolyte freezing.

Provide good ventilation when changing a battery or using a battery in an enclosed space. Always protect your eyes when working near a battery.

Never set tools down on the battery. They may induce a short circuit, causing irreparable damage to the battery and injuring persons.

Never wear metal necklaces, bracelets or watchstraps when working on the battery. The metal parts may induce a short circuit resulting in burns.

Dispose of used batteries separately from other waste in the interests of environmental protection.

SECTION 00 - INTRODUCTION

2.7

FLAMMABLE LIQUIDS

When handling flammable liquids: Z do not smoke; Z keep away from unshielded light sources and naked flames.

Fuels often have a low flash point and are readily ignited.

Never attempt to extinguish burning liquids with water. Use: Z dry powder; Z with carbon dioxide; Z with foam.

Water used for extinguishing purposes would vaporize instantaneously on contact with burning substances and spread burning oil, for example, over a wide area. Water generates short circuits in the electrical system, possibly producing new hazards.

Stay away from open flames during refilling of hydraulic oil or fuel.

Fuel or oil splashes can cause slipping and therefore accidents; clean immediately and accurately the areas eventually smeared.

Always tighten the safety plugs of fuel tank and hydraulic oil tank firmly.

Never use fuel to clean the machine parts eventually smeared with oil or dust.

Use a non-inflammable product for cleaning parts.

Always perform fuel or oil refilling in well aired and ventilated areas.

During refuelling hold the pistol firmly and keep it always in contact with the filler neck until the end of the refuelling, to avoid sparkles due to static electricity.

Do not overfill the tank but leave a space for fuel expansion.

Never refuel when the engine is running.

Take all the necessary safety measures when welding, grinding or when working near a naked flame.

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2.8

SECTION 00 - INTRODUCTION

TYRES

Before inflating the tyres, always check the condition of rims and the outer condition of tyres to find out the presence of dents, cuts, tears of reinforcement plies or other faults. Before inflating a tyre, make sure that there are no nearby persons, then position yourself at tread side.

Make sure that the inflating pressure of tyres is the same prescribed by manufacturer and that the pressure of the right tyre corresponds to the pressure of the left tyre.

Never use reconditioned rims because possible welds, heat treatments or brazings not performed correctly can weaken the wheels and cause following damages or failures. Deflate the tyres before their disassembly.

Before taking out possible jammed objects from the rims, it is necessary to deflate the tyres. Inflate tyres by means of a pistol complete with extension and pressure switch of control.

2.9

CLEANING

Clean the exterior of all components before carrying out any form of repair. Dirt and dust can reduce the efficient working life of a component and lead to costly replacement.

Solvents should be checked that they are suitable for the cleaning of components and also that they do not risk the personal safety of the user.

Dirt from oil or grease and scattered tools or faulty pieces are dangerous for persons, because they can generate slipping or falls.

For the machine cleaning, use a jet of warm water or steam under pressure and commercial detergents.

Never use fuel, petroleum or solvents, because the first ones leave an oily layer that favours the sticking of dust, while solvents (even if weak) damage the paint and favour the formation of rust.

Never use water jets or steam on sensors, connectors or other electric components.

Prevent that the water jet penetrates inside the cab.

SECTION 00 - INTRODUCTION

2.10 WASTE DISPOSAL Improperly disposing of waste can threaten the environment.

Each country has its own Regulations on this subject. It is therefore advisable to prepare suitable containers to collect and store momentarily all solid and fluid materials that must not be scattered in the environment to avoid pollution.

At preset intervals these products will be delivered to disposal stations legally recognized and present in this Country.

Hereunder are listed some products of the machine requiring disposal: Z lubricating oil; Z brake system oil; Z coolant mixture, condensation rests and pure antifreeze; Z fuel; Z oil and fuel filter elements; Z air filter elements; Z battery.

Also polluting rags, paper, sawdust and gloves must be disposed in compliance with the same procedures.

Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service centre to recover and recycle used air conditioning refrigerants. Obtain information on the proper way to recycle or dispose of waste from your local environmental or recycling centre, or from your Dealer.

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SECTION 00 - INTRODUCTION

3.

TECHNICAL SPECIFICATIONS

3.1

MAIN COMPONENTS

1.

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4.

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Wheel loader bucket Tilt dumping cylinder Lifting cylinder Fuel tank Cab Hydraulic oil tank Air filter Diesel engine

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Hydraulic pumps Battery Rear axle Transmission Steering cylinder Front axle Working attachment Attachment quick coupler

SECTION 00 - INTRODUCTION

3.2

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DIMENSIONS AND PERFORMANCE WITH BUCKET

BUCKET - DIMENSIONS A Total length B Cab height C Bucket width D Wheel width E Dumping height F Dumping reach G Maximum height of bucket pin H Dumping depth I Wheel base J Track K Clearance from ground to axle L Rear overhang M Tyre width (*) R Tyre radius (*) W Clearance from ground to drive shaft Operating weight (with standard bucket)

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) kg (lb)

W50BTC 5360 (211.02) 2710 (107.70) 1900 (74.80) 1841 (72.48) 2525 (99.40) 825 (32.50) 3240 (127.55) 93 (3.66) 2182 (85.90) 1480 (58.26) 330 (13) 1203 (47.36) 361 (14.21) 483 (19.01) 400 (15.74)

W60BTC 5490 (216.14) 2790 (109.84) 2050 (80.70) 1910 (75.19) 2550 (100.39) 785 (30.90) 3267 (128.62) 96 (3.77) 2250 (88.60) 1526 (60.07) 330 (13) 1267 (49.88) 384 (15.11) 508 (19.99) 415 (16.33)

W70BTC 5590 (220.07) 2790 (109.84) 2100 (88.70) 1910 (75.19) 2570 (101.18) 845 (33.26) 3360 (132.28) 107 (4.21) 2350 (92.51) 1526 (60.07) 330 (13) 1267 (49.88) 384 (15.11) 508 (19.99) 415 (16.33)

W80BTC 5650 (222.44) 2790 (109.84) 2100 (82.70) 1954 (76.92) 2616 (102.99) 890 (35.03) 3440 (135.43) 106 (4.17) 2350 (92.51) 1570 (61.81) 330 (13) 1267 (49.88) 384 (15.11) 508 (19.99) 415 (16.33)

4615 (10153) 4920 (10824)

5430 (11946)

5770 (12695)

(*) these dimensions apply when considering 12.5-20 tyres for W50BTC and 14.5-20 tyres for W60BTC - W70BTC W80BTC

BUCKET - PERFORMANCE Standard bucket capacity

m3 (ft3)

W50BTC 0.7 (24.7)

W60BTC 0.8 (28.2)

W70BTC 1 (35.3)

W80BTC 1.1 (38.8)

Tensile force Dumping load - ISO axis Dumping load - turned by 40° ISO Bucket width Lifting capacity at ground

kg (lb) kg (lb) kg (lb) mm (in) mm (in)

3800 (8360) 3345 (7359) 2945 (6500) 1900 (74.80) 4260 (167.71)

4550 (10010) 3495 (7689) 3100 (6820) 2050 (80.70) 5520 (217.32)

4410 (10010) 4245 (9339) 3630 (7986) 2100 (88.70) 4410 (173.62)

5100 (11220) 4420 (9724) 3755 (8261) 2100 (88.70) 6060 (238.58)

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3.3

SECTION 00 - INTRODUCTION

DIMENSIONS AND PERFORMANCE WITH FORKS

BUCKET WITH FORKS - DIMENSIONS Total length with forks mm (in) Width of fork support mm (in) Fork weight kg (lb) A Clearance from ground mm (in) B Height with maximum outreach mm (in) C Maximum height mm (in) D Outreach at ground mm (in) E Maximum outreach mm (in) F Outreach at maximum height mm (in) G Outreach of coupler pin of bucket mm (in) with forks H Coupler pin switch and centre of mm (in) gravity R Tyre radius (*) mm (in) Payload on level ground kg (lb) Payload on rough ground kg (lb) Operating weight kg (lb)

W50BTC 1200 (47.24) 1450 (57.08) 336 (741) 100 (3.93) 1311 (51.61) 2960 (116.53) 771 (30.35) 1335 (52.55) 600 (23.62) 1630 (64.17)

W60BTC 1200 (47.24) 1450 (57.08) 336 (741) 100 (3.93) 1336 (52.59) 2987 (117.59) 731 (28.77) 1315 (51.77) 580 (22.83) 1630 (64.17)

340 (13.38)

340 (13.38)

W70BTC W80BTC 1200 (47.24) 1200 (47.24) 1450 (57.08) 1450 (57.08) 336 (741) 336 (741) 100 (3.93) 100 (3.93) 1393 (54.84) 1393 (54.84) 3080 (121.25) 3160 (124.40) 731 (28.77) 798 (31.41) 1340 (52.75) 1390 (54.72) 610 (24.01) 587 (23.11) 1650 (64.96) 1700 (66.92) 340 (13.38)

340 (13.38)

543 (21.37) 562 (22.12) 562 (22.12) 562 (22.12) 1640 (3608) 1780 (3916) 2120 (4664) 2215 (4873) 1230 (2706) 1335 (2937) 1590 (3498) 1660 (3652) 4655 (10241) 4895 (10769) 5370 (11814) 5690 (12518)

(*) this dimension applies when considering 12.5-20 tyres for W50BTC and 14.5-20 tyres for W60BTC - W70BTC W80BTC

LIFTING LOADS At L1 = 500 mm (19.68 in) At L2 = 800 mm (31.49 in) At L3 = 1000 mm (39.37 in) At L4 = 1200 mm (47.24 in)

kg (lb) kg (lb) kg (lb) kg (lb)

W50BTC 1600 (3520) 1400 (3080) 1250 (2750) 1000 (2200)

W60BTC 1700 (3740) 1500 (3300) 1250 (2750) 1000 (2200)

W70BTC 1950 (4290) 1550 (3410) 1250 (2750) 1000 (2200)

W80BTC 2250 (4950) 1550 (3410) 1250 (2750) 1000 (2200)

SECTION 00 - INTRODUCTION

3.4

15

WEIGHTS W50BTC

W60BTC

W70BTC

Engine

kg (lb)

Front axle

kg (lb)

230 (506)

Rear axle (gearbox included) and travel motor

kg (lb)

312 (686)

Cab

kg (lb)

470 (1034)

Variable-displacement pump

kg (lb)

30 (66)

Hydraulic motor

kg (lb)

35 (77)

Lifting equipment

kg (lb)

Lifting cylinder

kg (lb)

30 (66)

Cylinder for quick coupler

kg (lb)

12 (26)

Counterweight

kg (lb)

3.5

300 (660) 318 (700) 251 (552)

420 (942)

393 (865)

315 (693)

600 (1320)

415 (913)

650 (1433)

760 (1676)

NOISE W50BTC W60BTC W70BTC W80BTC 98 dB (A) 100 dB (A) 75 dB (A)

External noise level LWA Internal noise level LpA

3.6

W80BTC

DIESEL ENGINE W50BTC

Iveco model

W60BTC

W70BTC

F5C E9454 C* A F5C E9454 D* A F5C E9454 A* A F5C E9454 B* A

Operation

4-stroke diesel engine

Number of cylinders

4

Bore

mm (in)

99 (3.89)

Stroke

mm (in)

104 (4.09)

cm3 (in3)

3202 (195.36)

Total displacement Maximum torque (at 1400 rpm) Power ISO 9249 Rated rpm

Nm kW/CV rpm

Ignition order

220 (162.26)

260 (191.76)

275 (202.82)

310 (228.64)

40 / 54

48 / 64

55 / 74

61 / 82

2300

2300

2500

2500

1,3,4,2

Compression ratio Weight

W80BTC

17 ± 0.5 : 1 kg (lb)

300 (660)

16

SECTION 00 - INTRODUCTION

TIGHTENING TORQUES Component

Tightening torque (Nm) (lbf·ft)

Oil pan plug

50 (36.87)

1/8 G plug (crankcase)

40 (29.50)

3/8 G plug (crankcase)

15 (11.06)

Water drain plug (crankcase)

40 (29.50)

Inspection covers

25 (18.43)

Timing gearbox cover

25 (18.43)

Timing gearbox

25 (18.43)

Flywheel case (M8)

35 (25.81)

Flywheel case (M12)

120 (88.50)

Cylinder head - 1st phase (M12)

65 (47.94)

Cylinder head - 2nd phase (M12)

90 (66.38)

Cylinder head - 3rd phase (M12)

60 (44.25)

Rocker shaft assy

25 (18.43)

Head cover

25 (18.43)

Valve adjusting nut

20 (14.75)

Suction manifold

25 (18.43)

Exhaust manifold

15 (11.06)

Heat exchanger

25 (18.43)

Drive shaft pulley

350 (258.14)

Flywheel

30 (22.12)

Injectors (screw)

25 (18.43)

Injectors (nut)

30 (22.12)

Fuel filter

25 (18.43)

Oil filter

25 (18.43)

Oil pump

25 (18.43)

Water pump

25 (18.43)

Alternator

50 (36.87)

Fuel pump

25 (18.43)

Sensors (oil pressure, water temperature, etc.)

25 (18.43)

SECTION 00 - INTRODUCTION

3.7

17

BRAKES SYSTEM

BRAKE PEDAL VALVE Allowable service pressure .................................................................................................... 175 bar (2538 psi) Adjusted pressure ...................................................................................................................... 55 bar (797 psi) Pressure of brake on disc .......................................................................................................... 55 bar (797 psi) Accumulator charging valve Preloading pressure............................................................................................................... 175 bar (2537 psi) “Cut-in” pressure .................................................................................................................... 120 bar (1740 psi) “Cut-off” pressure................................................................................................................... 150 bar (2175 psi) PRESSURE SWITCHES Brake light pressure switch Infeed pressure ........................................................................................................................... 3.5 bar (51 psi) Function ..........................................................................................................................................when closing Brake accumulator charge pressure switch Infeed pressure ........................................................................................................................ 80 bar (1160 psi) Function ........................................................................................................................................... bidirectional

18

3.8

SECTION 00 - INTRODUCTION

STEERING SYSTEM

System pressure .................................................................................................................... 175 bar (2537 psi) POWER STEERING W50BTC - W60BTC W70BTC

W80BTC

OSPC200LS

OSPC315LS

Model Displacement

cm3/rev (in3/rev)

200 (12.20)

315 (19.22)

Rated oil flow

l/min (gal/min)

20 (5.30)

32 (8.40)

kg (lb)

5.8 (13)

6.2 (14)

bar (psi)

240 (3840)

240 (3840)

Weight Relief valve adjustment Tightening torques Component

Tightening torque (Nm) (lbf·ft)

Steering wheel nut

55 (40.56)

Steering column bracket

23 (16.97)

End cover

30 (22.12)

Connector

45 (33.19)

Adaptors

55 (40.56)

Check valve

30 (22.12)

STEERING CYLINDER W50BTC

W60BTC

Quantity

W70BTC

W80BTC

1

Ø rod

mm (in)

32 (1.25)

40 (1.57)

Ø piston

mm (in)

70 (2.75)

80 (3.14)

Stroke

mm (in)

300 (11.81)

300 (11.81)

3.9

HYDRAULIC SYSTEM

PRESSURE ADJUSTMENT Working attachment Primary safety pressure ......................................................................................................... 250 bar (3625 psi) Secondary safety pressure - tilt dumping cylinder bottom side.............................................. 280 bar (4059 psi) Secondary safety pressure - tilt dumping cylinder rod side.................................................... 250 bar (3625 psi) Secondary safety pressure - boom cylinder bottom side ....................................................... 280 bar (4059 psi)

SECTION 00 - INTRODUCTION

19

VARIABLE-DISPLACEMENT PUMP W50BTC System

W60BTC

W70BTC

W80BTC

Pump with adjustment depending on engine rpm AV4VG40DA1D2 A4VG56DA1D2 A4VG56DA1D2 A4VG71DA1D2 / 32R / 32R / 32R / 32R

Model Displacement

cm3/rev (in3/rev)

40 (2.44)

56.0 (3.41)

56.0 (3.41)

71.0 (4.33)

Power

kW (hp)

35.7 (46.1)

38.0 (51)

48.3 (61.8)

52.8 (70.8)

Transmission through Service revolutions (= engine rated speed)

diesel engine direct drive, i = 1.0 rpm

2300

2300

2500

2500

Maximum oil delivery

l/min (gal/min)

88.8 (23.40)

131.3 (34.60)

136.0 (35.80)

173.4 (45.70)

Supply pressure (rotation speed at full load)

bar (psi)

25 (362)

27 (391)

27 (391)

27 (391)

Adjustment start

bar (psi)

50 (725) (at 1100 rpm)

50 (725) (at 1100 rpm)

50 (725) (at 1100 rpm)

50 (725) (at 1100 rpm)

Adjustment end

bar (psi)

400 (5801) (at 1800 rpm)

400 (5801) (at 1900 rpm)

400 (5801) (at 1900 rpm)

400 (5801) (at 1900 rpm)

Pressure cut-off

bar (psi)

High-pressure relief valves - opening -

bar (psi)

Hydraulic motor adjustment bar (psi) start Voltage

430 (6234) 465 (6744)

245 (3553)

467 (6773)

467 (6773)

467 (6773)

190 (2755)

245 (3553) (190 (2755) “high speed” models)

215 (3118)

V

12

GEAR PUMP

Model Displacement

cm3/rev (in3/rev)

Maximum pressure

bar (psi)

W50BTC

W60BTC

W70BTC

W80BTC

022R0020KB

032R0020KB

028R0020KB

032R0020KB

22.5 (1.37)

32 (1.95)

28 (1.7)

32 (1.95)

270 (3914)

20

SECTION 00 - INTRODUCTION

HYDRAULIC CYLINDERS W50BTC

W60BTC

W70BTC

W80BTC

Lifting cylinder Quantity

1

Ø rod

mm (in)

50 (1.96)

55 (2.16)

55 (2.16)

60 (2.36)

Ø piston

mm (in)

90 (3.54)

100 (3.93)

100 (3.93)

110 (4.33)

Stroke

mm (in)

721 (28.38)

728 (28.66)

718 (28.26)

730 (28.74)

Tilt dumping cylinder Quantity

1

Ø rod

mm (in)

50 (1.96)

55 (2.16)

55 (2.16)

60 (2.36)

Ø piston

mm (in)

90 (3.54)

100 (3.93)

100 (3.93)

110 (4.33)

Stroke

mm (in)

459 (18.07)

454 (17.87)

490 (19.29)

490 (19.29)

Quick coupler cylinder Quantity

1

Ø rod

mm (in)

25 (0.98)

25 (0.98)

25 (0.98)

25 (0.98)

Ø piston

mm (in)

40 (1.57)

40 (1.57)

40 (1.57)

40 (1.57)

Stroke

mm (in)

60 (2.36)

60 (2.36)

60 (2.36)

60 (2.36)

ACCUMULATORS BRAKE ACCUMULATOR Capacity ............................................................................................................................. 0.32 litres (0.10 gal) Maximum pressure................................................................................................................ 210 bar (3045 psi) Service temperature..................................................................................... -10 °C / +80 °C (+14 °F / +176 °F) Filling gas .............................................................................................................................................. nitrogen Filling gas overpressure .............................................................................................. 25 ± 1 bar (362 ± 15 psi) Weight ............................................................................................................................................. 1.3 kg (3 lb) QUICK COUPLER CYLINDER ACCUMULATOR Capacity ............................................................................................................................... 0.6 litres (0.15 gal) Maximum pressure................................................................................................................ 330 bar (4784 psi) Service temperature..................................................................................... -10 °C / +80 °C (+14 °F / +176 °F) Filling gas .............................................................................................................................................. nitrogen Precharge pressure..................................................................................................... 50 ± 1 bar (724 ± 15 psi) Weight ............................................................................................................................................. 3.3 kg (7 lb) RIDE CONTROL ACCUMULATOR Capacity ............................................................................................................................. 0.75 litres (0.20 gal) Maximum pressure................................................................................................................ 330 bar (4784 psi) Service temperature..................................................................................... -10 °C / +80 °C (+14 °F / +176 °F) Filling gas .............................................................................................................................................. nitrogen Filling gas overpressure .............................................................................................. 25 ± 1 bar (362 ± 15 psi) Weight ................................................................................................................................................ 4 kg (9 lb)

SECTION 00 - INTRODUCTION

21

TRAVEL MOTOR Type Displacement Qmax / Qmin Maximum speed Delivery pressure Service pressure Pressure increasing spring Voltage

W50BTC W60BTC W70BTC W80BTC A6VM80HA1U1 / 63W A6VM107HA1U1 / 63W 80 / 18.8 80 / 23.7 cm3 80 / 24.8 107 / 34.5 3 (6.52 / 2.10) (4.88 / 1.14) (4.88 / 1.44) (4.88 / 1.51) (in ) rpm 4352 5289 5289 4811 bar 25 25 25 25 (psi) (362) (362) (362) (362) bar 245 190 245 215 (psi) (3552) (2755) (3552) (3117) bar 10 10 10 10 (psi) (145) (145) (145) (145) V 12

TRAVEL MOTOR “HIGH SPEED” W60BTC

Type Displacement Qmax / Qmin Maximum speed Delivery pressure Service pressure Pressure increasing spring Voltage

cm3 (in3) rpm bar (psi) bar (psi) bar (psi) V

W70BTC W80BTC A6VM80HA1R1 / 63W 80 / 26.5 (4.88 / 1.62) 80 / 29.2 (4.88 / 1.78) 80 / 35.4 (4.88 / 2.16) 4770 4770 4770 25 25 25 (362) (362) (362) 190 190 215 (2755) (2755) (3117) 10 10 10 (145) (145) (145) 12

3.10 ELECTRICAL SYSTEM (EUROPE MODELS) STANDARD ELECTRICAL SYSTEM Service voltage ............................................................................................................................................ 12 V Battery (quantity 1) Capacity (20 h)........................................................................................................................................... 95 Ah Discharge current....................................................................................................................................... 900 A Weight (with electrolyte).................................................................................................................. 25 kg (55 lb) ELECTRICAL SYSTEM WITH COLD START DEVICE Service voltage ............................................................................................................................................ 12 V Battery (quantity 2) Capacity (20 h)........................................................................................................................................... 74 Ah Discharge current....................................................................................................................................... 680 A Weight (with electrolyte).................................................................................................................. 18 kg (40 lb)

3.11 ELECTRICAL SYSTEM (NORTH AMERICA MODELS) Service voltage ............................................................................................................................................ 12 V Battery Capacity (20 h)........................................................................................................................................... 95 Ah Critical current............................................................................................................................................ 900 A Weight............................................................................................................................................. 25 kg (55 lb)

22

SECTION 00 - INTRODUCTION

3.12 BUCKETS W50BTC SAE capacity

m3 3

(ft )

W60BTC

W70BTC

W80BTC

0.65 0.70 0.80 0.80 0.90 0.90 1.00 1.00 1.10 1.20 (22.95) (24.72) (28.25) (28.25) (31.78) (31.78) (35.31) (35.31) (38.84) (42.37)

Width

mm 1800 1900 1900 2050 2050 2050 2100 2100 2100 2100 (in) (70.86) (74.80) (74.80) (80.70) (80.70) (80.70) (82.67) (82.67) (82.67) (82.67)

Weight

kg 250 (lb) (550)

265 (583)

295 (650)

315 (693)

335 (737)

335 (737)

365 (803)

365 (803)

370 (814)

410 (902)

3.13 AXLES FRONT AXLE W50BTC

Model Differential type Bevel gear reduction ratio Reduction gear ratio Total reduction ratio Input rotation direction Bevel gear play Pinion bearing preload (measured on D = 34.5 mm (1.35 in) without seal rings) Ring gear-pinion bearing total preload (measured on D = 34.5 mm (1.35 in) without seal rings) Dynamic load Static load Service brake torque Parking brake torque Maximum service pressure

W60BTC - W70BTC W80BTC 28.16 (CA147195) 28.25 (CA150144) limited slip 2.90 / 1 3.66 / 1 6.00 / 1 6.00 / 1 17.45 / 1 22.00 / 1 clockwise 0.17 ÷ 0.24 mm (0.006 ÷ 0.009 in) P = 9.2 ÷ 13.7 daN (20.68 ÷ 30.79 lbf) T= (P+3.1)+(P+4.7) daN T= (P+0.96)+(P+10.56) lbf

T= (P+2.5)+(P+3.8) daN T= (P+5.62)+(P+8.54) lbf

55000 Nm (40565 lbf·ft) 137500 Nm (101415 lbf·ft) 980 Nm (722 lbf·ft) 780 Nm (575 lbf·ft) 55 bar (797 psi)

“HIGH SPEED” FRONT AXLE W60BTC - W70BTC - W80BTC Model Differential type

28.25 (CA147188) limited slip

Bevel gear reduction ratio

3.66 /1

Reduction gear ratio

6.00 / 1

Total reduction ratio

22.00 / 1

Input rotation direction

clockwise

Bevel gear play

0.17 ÷ 0.24 mm (0.006 ÷ 0.009 in)

Pinion bearing preload (measured on D = 34.5 mm (1.35 in) without seal rings)

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf)

Ring gear-pinion bearing total preload (measured on D = 34.5 mm (1.35 in) without seal rings)

T= (P+2.5)+(P+3.8) daN T= (P+5.62)+(P+8.54) lbf

Maximum service pressure

55 bar (797 psi)

SECTION 00 - INTRODUCTION

23

REAR AXLE W50BTC

W60BTC - W70BTC

W80BTC

Model

CA147194+CA150145 28.16 + TB150

CA147189+CA150146 28.20 + TB150

CA147186+CA150147 28.20 + TB150

Differential type

CA147194: standard CA150145: limited slip

CA147189: standard CA150146: limited slip

CA147186: standard CA150147: limited slip

Bevel gear reduction ratio

2.91 / 1

3.66 / 1

3.66 / 1

Reduction gear ratio

6.00 / 1

6.00 / 1

6.00 / 1

Transmission box reduction ratio

2.257 / 1

2.257 / 1

2.053 / 1

Total reduction ratio

39.38 / 1

49.65 / 1

45.156 / 1

Input rotation direction Bevel gear play

counterclockwise 0.18 ÷ 0.23 mm (0.007 ÷ 0.0090 in)

Pinion bearing preload (measured on D = 34.8 mm (1.37 in) without seal rings) Ring gear-pinion bearing total preload T= (P+3.1)+(P+4.7) daN (measured on D = T= (P+6.96)+(P+10.56) lbf 34.8 mm (1.37 in) without seal rings)

0.17 ÷ 0.24 mm (0.006 ÷ 0.0094 in) P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf)

T= (P+2.5)+(P+3.8) daN T= (P+5.62)+(P+8.54) lbf

“HIGH SPEED” REAR AXLE W60BTC - W70BTC - W80BTC Model Differential type Dry weight

CA147187 28.20 + TB138.5 limited slip /

Bevel gear reduction ratio

3.66 /1

Reduction gear ratio

6.00 / 1

Transmission box reduction (1°)

2.75 / 1

Total reduction (1°)

60.5 / 1

Transmission box reduction (2°)

1.163 / 1

Total reduction (2°)

25.28 / 1

Input rotation direction Bevel gear play

counterclockwise 0.17 ÷ 0.24 mm (0.0066 ÷ 0.0094 in)

Pinion bearing preload (measured on D = 34.8 mm (1.37 in) without seal rings)

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf)

Ring gear-pinion bearing total preload (measured on D = 34.8 mm (1.37 in) without seal rings)

T= (P+2.5)+(P+3.8) daN T= (P+5.62)+(P+8.54) lbf

24

SECTION 00 - INTRODUCTION

TIGHTENING TORQUES Component Wheel nuts Cardan shaft Front axle fastening Front axle fastening (pin retainer)

Tightening torque (Nm) (lbf¡ft) 550 (405.65) 34 (25.07) 350 (258.14) 79 (58.26)

Rear axle fastening

350 (258.14)

Fastening of variable-displacement pump to engine

250 (184.40)

Fastening of travel motor to transmission

725 (534.73)

Counterweight

390 (287.64)

Engine supports

140 (103.25)

Cab elastic supports

240 (177.01)

SECTION 00 - INTRODUCTION

25

3.14 SUPPLY CHART Quantity (litres)

Suggested product

New Holland Standard

International Standard

Viscosity

Water and alcohol

-

-

-

2.2 (0.60)

Cooling system

AMBRA Agriflu antifreeze 50% water 50%

NH 900 A

CUNA NC 956-16

-

16.5 (4.30)

Fuel system

Decanted and filtered diesel fuel

-

-

-

95 (25)

SAE 15W40

8.5 (2.20)

Component to refill Window washer tank

Oil AMBRA SUPER GOLD or oil Engine (without filter) AMBRA MASTERGOLD HSP

Brake system

Oil tank Hydraulic system

NH 330 G

API CF-4 MIL-L-2104 F LEVEL

NH 330 H

API CF-4/CH-4 ACEA E7/E5

see Hydraulic system

-

-

-

-

HYDROSYSTEM 68 (-10 to + 50 °C) (-14 to +122 °F)

NH 668

ISO VG 68 DIN 51524

-

40 (10.5) 40 (10.5) 40 (10.5) 40 (10.5) 56 (14.8) 67 (17.7) 67 (17.7) 74 (19.5)

HYDROSYSTEM 32 (-25 to + 20 °C) (-13 to + 68 °F)

NH 632

ISO VG 32 DIN 51524

-

40 (10.5) 40 (10.5) 40 (10.5) 40 (10.5) 56 (14.8) 67 (17.7) 67 (17.7) 74 (19.5)

HYDROSYSTEM 46 HV (-20 to + 40 °C) (-4 to +104 °F)

NH 646 H

ISO VG 46 DIN 51524

-

40 (10.5) 40 (10.5) 40 (10.5) 40 (10.5) 56 (14.8) 67 (17.7) 67 (17.7) 74 (19.5)

HYDROSYSTEM 46 BIO-S Biodegradable Oil (special equipment)

NH 646 BS

ISO VG 46 DIN 51524

-

40 (10.5) 40 (10.5) 40 (10.5) 40 (10.5) 56 (14.8) 67 (17.7) 67 (17.7) 74 (19.5)

7.5 (1.98) 2x0.7

Front axle: - differential - side gearboxes Rear axle: - differential - side gearboxes - gear box

Air conditioning system: - coolant - oil (compressor) Greasing of grease nipples

W50BTC W60BTC W70BTC W80BTC

8

8

8

(2.11) 2x0.6

(2.11) 2x0.6

(2.11) 2x0.6

(2x0.18) (2x0.16) (2x0.16) (2x0.16) AMBRA HYPOIDE 90 LS Oil

NH 520 B

API GL5

SAE 80W-90

7.5

8

8

8

(1.98) 2x0.7

(2.11) 2x0.7

(2.11) 2x0.7

(2.11) 2x0.7

(2x0.18) (2x0.18) (2x0.18) (2x0.18) 0.75 0.75 0.75 0.75 (0.20) (0.20) (0.20) (0.20)

1.05 (0.30)

R 134a PAG SP 20

-

-

-

135 cm3 (8.26 in3)

AMBRA GR9 Multi purpose grease

NH 710 A

NLGI2

-

-

26

NOTES:

SECTION 00 - INTRODUCTION

SECTION 10 - ENGINE 1. DIESEL ENGINE .......................................................................................................................................... 1 2. FUEL SYSTEM ............................................................................................................................................. 2 3. COLD START DEVICE (NORTH AMERICA) ............................................................................................... 5

SECTION 10 - ENGINE

SECTION 10 - ENGINE

1.

DIESEL ENGINE

Refer to the REPAIR MANUAL of the IVECO ENGINE Print number 87736548A

1

2

2.

SECTION 10 - ENGINE

FUEL SYSTEM

The fuel system consists simply of a tank (3) ensuring fuel supply to diesel engine (1) by means of pipes (2).

SECTION 10 - ENGINE

2.1

FUEL TANK

System capacity: 95 litres

1.

2.

3.

4.

5.

6.

7.

8.

9.

Fuel tank Screw Washer Washer Nut Washer Nut Washer Screw

10.

11.

12.

13.

14.

15.

16.

17.

18.

Plate Ring Sleeve Plug Gauge Washer Screw Rod Rod

3

4

2.2

SECTION 10 - ENGINE

FUEL

Use commercially available diesel fuel with less than 0.5% sulphur content. If the sulphur content is higher, oil change intervals should be reduced. The following fuel specifications / standards are approved: Z DIN EN 590 Z BS 2869 Z ASTM D 975-96; 1-D and 2-D Z NATO Code F-54 / F-34 / F-44 and XF 63 Exhaust emission values which may be determined in the case of type approval tests always refer to the fuels prescribed by the authorities for the type approval test.

WINTER-GRADE FUEL Waxing may occur at low temperatures, clogging the fuel system and reducing engine efficiency.

If the ambient temperature is less than 0 °C (+32 °F) use winter-grade fuel, suitable down to -15 °C (+5 °F) should be used; this fuel is available at the filling stations well in advance of the cold season.

Diesel fuel containing additives (Super diesel) is often available, for use down to -20 °C (-4 °F) approximately.

Z At temperatures below -15 °C (+5 °F) or -20 °C (-4 °F), add petroleum to diesel fuel. The relevant percentages are given in the adjacent diagram.

If summer-grade diesel fuel must be used at temperatures below 0 °C (+32 °F), up to 60% petroleum can be added (see diagram).

In most cases, adequate resistance to cold can also be obtained by adding a fluidizing additive for winter operation: Legend: I Summer-grade diesel fuel II

Winter-grade diesel fuel

A

Outer temperature

B

Percentage of petroleum

SCAUTION Diesel fuels must never be mixed with gasoline.

SECTION 10 - ENGINE

3.

COLD START DEVICE (NORTH AMERICA)

The engine can be provided with an optional heating device for starting at particularly low temperatures.

1. Heater 2. Cable

5

6

NOTES:

SECTION 10 - ENGINE

SECTION 25 - FRONT AXLES 1. REMOVAL AND INSTALLATION ................................................................................................................. 1 2. DIMENSIONS ............................................................................................................................................... 3 3. TECHNICAL SPECIFICATIONS................................................................................................................... 5 4. OIL CHANGE................................................................................................................................................ 9 5. DISASSEMBLY AND ASSEMBLY.............................................................................................................. 12 5.1 DISC BRAKE ASSY............................................................................................................................. 12 5.2 BRAKE CALIPER ................................................................................................................................ 19 5.3 REDUCTION GEAR (W50BTC) .......................................................................................................... 27 5.4 REDUCTION UNIT (W60BTC, W70BTC, W80BTC) ........................................................................... 30 5.5 WHEEL HUB (W50BTC)...................................................................................................................... 33 5.6 WHEEL HUB (W60BTC, W70BTC, W80BTC) .................................................................................... 42 5.7 WHEEL SHAFT (W60BTC, W70BTC, W80BTC) ................................................................................ 48 5.8 BRAKE AND WHEEL SHAFT (W60BTC, W70BTC, W80BTC “HIGH SPEED”)................................. 52 5.9 DIFFERENTIAL SUPPORT ................................................................................................................. 60 5.10 DIFFERENTIAL ASSY....................................................................................................................... 68 5.11 PINION............................................................................................................................................... 75 6. TROUBLESHOOTING................................................................................................................................ 81 7. SPECIAL TOOLS........................................................................................................................................ 84

SECTION 25 - FRONT AXLES

SECTION 25 - FRONT AXLES

1

The wheel loaders can be equipped with different types of front axles: W50BTC

W60BTC

W70BTC

W80BTC

CA147195

Z

/

/

/

CA150144

/

Z

Z

Z

CA147188 (“HIGH SPEED”)

/

Z

Z

Z

1.

1.

2.

3.

4.

5.

REMOVAL AND INSTALLATION

Front axle Plate Screw Nut Locknut

6.

7.

8.

9.

10.

Brake tie-rod Nut Cup Wheel Cardan shaft

2

SECTION 25 - FRONT AXLES

REMOVAL Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity.

Rest the bucket on the ground.

Place the direction-of-travel lever and gearshift lever in neutral position.

Immobilize the machine by means of the parking brake.

Stop the engine and remove the starter switch key.

Release the hydraulic pressure by operating the control levers in all directions.

Remove the cups (8) and unscrew nuts (7) from both sides.

Remove the two wheels (9).

Disconnect the cardan joint (10).

Position the fork-lift truck laterally with the forks under front axle (1), lift the front axle and support it.

Release the tie-rod (6) from the brake disc.

Disconnect the pipes of the disc brake (W50BTC) and of the multi-plate brake (W60BTC, W70B, W80B).

Unscrew and remove the nuts (4) and (5).

Remove the screws (3) and the plates (2).

Lower the forks and remove the front axle (1).

INSTALLATION The assembly of the front axle is to be carried out in the reverse order.

Tighten the nuts (4) and (5) to the prescribed torque 350 Nm (258.14 lbf·ft) and the wheel nuts (7) to the prescribed torque 500 Nm (368.78 lbf·ft).

Fill oil in the hubs and in the axle reduction gears (see Operator’s manual).

Bleed air from the multi-plate brake (W60BTC, W70BTC, W80BTC).

Adjust the parking brake.

SECTION 25 - FRONT AXLES

2.

DIMENSIONS

CA147195 (W50BTC)

CA150144 (W60BTC, W70BTC, W80BTC)

3

4

SECTION 25 - FRONT AXLES

CA147188 “HIGH SPEED” (W60BTC, W70BTC, W80BTC)

SECTION 25 - FRONT AXLES

3.

5

TECHNICAL SPECIFICATIONS

FRONT AXLE CA147195 (W50BTC) Model Differential type Dry weight

28.16 limited slip 230 kg (506 lb)

Bevel gear reduction ratio

2.90 / 1

Reduction gear ratio

6.00 / 1

Total reduction ratio

17.45 / 1

Input rotation direction

clockwise

Bevel gear play

0.17 ÷ 0.24 mm (0.006 ÷ 0.009 in)

Pinion bearing preload (measured on D = 34.5 mm (1.35 in) without seal rings)

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf)

Ring gear-pinion bearing total preload (measured on D = 34.5 mm (1.35 in) without seal rings)

T = (P + 3.1) ÷ (P + 4.7) daN T = (P + 6.96) ÷ (P + 10.56) lbf

Maximum service pressure

55 bar (797 psi)

Differential oil capacity

7.5 litres (2 gal)

Reduction gear oil capacity (each side)

0.7 litres (0.18 gal)

FRONT AXLE CA150144 (W60BTC, W70BTC, W80BTC) Model Differential type Dry weight

28.25 limited slip 318 kg (700 lb)

Bevel gear reduction ratio

3.667 / 1

Reduction gear ratio

6.00 / 1

Total reduction ratio

22.00 / 1

Input rotation direction

clockwise

Bevel gear play

0.17 ÷ 0.24 mm (0.006 ÷ 0.009 in)

Pinion bearing preload (measured on D = 34.5 mm (1.35 in) without seal rings)

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf)

Ring gear-pinion bearing total preload (measured on D = 34.5 mm (1.35 in) without seal rings)

T = (P + 2.5) ÷ (P + 3.8) daN T = (P + 5.62) ÷ (P + 8.54) lbf

Maximum service pressure

55 bar (797 psi)

Differential oil capacity

8 litres (2.10 gal)

Reduction gear oil capacity (each side)

0.6 litres (0.20 gal)

6

SECTION 25 - FRONT AXLES

FRONT AXLE “HIGH SPEED” CA147188 (W60BTC, W70BTC, W80BTC) Model Differential type Dry weight

28.25 limited slip 318 kg (700 lb)

Bevel gear reduction ratio

3.667 / 1

Reduction gear ratio

6.00 / 1

Total reduction ratio

22.00 / 1

Input rotation direction

clockwise

Bevel gear play

0.17 ÷ 0.24 mm (0.006 ÷ 0.009 in)

Pinion bearing preload (measured on D = 34.5 mm (1.35 in) without seal rings)

P = 9.2 ÷ 13.7 daN (P = 20.68 ÷ 30.80 lbf)

Ring gear-pinion bearing total preload (measured on D = 34.5 mm (1.35 in) without seal rings)

T = (P + 2.5) ÷ (P + 3.8) daN T = (P + 5.62) ÷ (P + 8.54) lbf

Maximum service pressure

55 bar (797 psi)

Differential oil capacity

8 litres (2.10 gal)

Reduction gear oil capacity (each side)

0.6 litres (0.20 gal)

SECTION 25 - FRONT AXLES TIGHTENING TORQUES

7

8

SECTION 25 - FRONT AXLES

BRAKE DISC THICKNESS

New friction disc thickness = 10 ± 0.1 mm (0.39 ± 0.003 in) Worn disc minimum thickness = 8.8 mm (0.34 in) Disc ref. CA119682 - q.ty 1

New friction disc thickness = 11.7 ± 0.05 mm (0.46 ± 0.001 in) Disc ref. CA125584 - q.ty 1

LIMITED SLIP DIFFERENTIAL DISCS THICKNESS

New counterdisc thickness = 1.5 ± 0.03 mm (0.059 ± 0.001 in) Worn counterdisc minimum thickness = 1.4 mm (0.055 in) Disc ref. CA110643 - q.ty 10

New friction disc thickness = 1.6 ± 0.03 mm (0.062 ± 0.001 in) Worn disc minimum thickness = 1.45 mm (0.057 in) Disc ref. CA110644 - q.ty 8

Disc ref. CA110642 - q.ty 2 New friction disc thickness = 2.8 ± 0.03 mm (0.11 ± 0.001 in) Worn disc minimum thickness = 2.7 mm (0.10 in)

SECTION 25 - FRONT AXLES

4.

9

OIL CHANGE

Oil filler and level plug

1

Oil drain plug

2

Air breather valve

3

Filler, level and drain plug for reduction gear oil

4

Brake oil bleeding

5

10

SECTION 25 - FRONT AXLES

Before draining the oil from the central axle body, operate the relevant air breather valve (3) to eliminate any possible internal pressure.

To drain the oil from the central axle body, unscrew the level plug (1) first, then the drain plug (2).

Drain the oil completely.

Clean the drain plug (2) and screw it back in.

Always operate the relevant air breather valve (3) to eliminate any possible internal pressure.

Unscrew the oil filler plug (1) and fill in specified oil up to the level hole.

Wait for the oil to flow into the axle, then check the level and top up, if necessary.

Screw in the filler plug (1) again.

Before draining the oil from the reduction gear, turn the gear so that the plug (4) is in the highest possible position [position A].

Partially unscrew the plug to release any possible internal pressure.

Rotate the reduction gear with the plug (4) oriented downwards [position B].

Remove the plug and drain the oil completely.

SECTION 25 - FRONT AXLES

Rotate the reduction gear until the hole of the plug (4) is in horizontal position.

Fill in. The oil level should be flush with the hole.

Tighten the plug (4) again.

11

12

5.

SECTION 25 - FRONT AXLES

DISASSEMBLY AND ASSEMBLY

Some of the following pictures could not show exactly the installed axle, but the procedure is the same.

5.1

DISC BRAKE ASSY

DISASSEMBLY Remove the breather valve (1). Loosen the screw (14). Remove the connector (13) and the breather pipe (3) from the brake caliper (5).

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