Page 1

LS180.B LS185.B LS190.B Workshop

Manual

315 mm

Workshop Manual

Print No. 604.13.552.01 English - Printed in Italy

LS180.B LS185.B LS190.B

PROVEN PERFORMANCE


REPAIR MANUAL

LS180.B LS185.B LS190.B

1 3/24/2006


Contents INTRODUCTION DISTRIBUTION SYSTEMS

A

PRIMARY HYDRAULIC POWER SYSTEM

A.10.A

SECONDARY HYDRAULIC POWER SYSTEM

A.12.A

HIGH-FLOW HYDRAULIC POWER SYSTEM

A.16.A

ELECTRICAL POWER SYSTEM

A.30.A

LIGHTING SYSTEM

A.40.A

POWER PRODUCTION

B

ENGINE

B.10.A

FUEL AND INJECTION SYSTEM

B.20.A

AIR INTAKE SYSTEM

B.30.A

ENGINE COOLANT SYSTEM

B.50.A

LUBRICATION SYSTEM

B.60.A

STARTING SYSTEM

B.80.A

POWER TRAIN

C

POWER COUPLING Fixed coupling

C.10.B

TRANSMISSION Hydrostatic

C.20.F

TRAVELLING

D

FRONT AXLE

D.10.A

REAR AXLE

D.12.A

STEERING Steering clutch

D.20.F

PARKING BRAKE Hydraulic

D.32.C

WHEELS AND TRACKS Wheels

D.50.C

Final drive

D.15.A

BODY AND STRUCTURE

E

USER CONTROLS AND SEAT

E.32.A

USER PLATFORM

E.34.A

ENVIRONMENT CONTROL Heating system

E.40.B

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ENVIRONMENT CONTROL Air-conditioning system

E.40.C

SAFETY SECURITY ACCESSORIES Safety

E.50.B

WORKING ARM

H

BOOM Lift

H.20.B

SINGLE ARM Lift

H.40.B

SINGLE ARM TOOL ATTACHMENT Tilt

H.50.C

TOOLS AND COUPLERS

J

CARRYING Unarticulated tools

J.50.B

COUPLING Hydraulic coupling

J.80.C

COUPLING Mechanical coupling

J.80.B

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INTRODUCTION

604_13_552_01 1 3/24/2006

1


Contents INTRODUCTION Basic instructions ( - A.90.A.05) Torque ( - A.90.A.10) Conversion factors ( - A.92.A.21)

3 7 11

604_13_552_01 1 3/24/2006

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INTRODUCTION

Basic instructions ( - A.90.A.05) Technical Information This manual has been produced by a new technical information system. This new system is designed to deliver technical information electronically through CDROM and in paper manuals. A coding system called ICE has been developed to link the technical information to other Product Support functions e.g. Warranty. Technical information is written to support the maintenance and service of the functions or systems on a customers machine. When a customer has a concern on his machine it is usually because a function or system on his machine is not working at all, is not working efficiently, or is not responding correctly to his commands. When you refer to the technical information in this manual to resolve that customers concern, you will find all the information classified using the new ICE coding, according to the functions or systems on that machine. Once you have located the technical information for that function or system then you will find all the mechanical, electrical or hydraulic devices, components, assemblies and sub-assemblies for that function or system. You will also find all the types of information that have been written for that function or system, the technical data (specifications), the functional data (how it works), the diagnostic data (fault codes and troubleshooting) and the service data (remove, install adjust, etc.). By integrating this new ICE coding into technical information , you will be able to search and retrieve just the right piece of technical information you need to resolve that customers concern on his machine. This is made possible by attaching 3 categories to each piece of technical information during the authoring process. The first category is the Location, the second category is the Information Type and the third category is the Product: LOCATION - is the component or function on the machine, that the piece of technical information is going to describe e.g. Fuel tank. INFORMATION TYPE - is the piece of technical information that has been written for a particular component or function on the machine e.g. Capacity would be a type of Technical Data that would describe the amount of fuel held by the Fuel tank. PRODUCT - is the model that the piece of technical information is written for. Every piece of technical information will have those 3 categories attached to it. You will be able to use any combination of those categories to find the right piece of technical information you need to resolve that customers concern on his machine. That information could be: the description of how to remove the cylinder head a table of specifications for a hydraulic pump a fault code a troubleshooting table a special tool

How to Use this Manual This manual is divided into Sections. Each Section is then divided into Chapters. Contents pages are included at the beginning of the manual, then inside every Section and inside every Chapter. An alphabetical Index is included at the end of a Chapter. Page number references are included for every piece of technical information listed in the Chapter Contents or Chapter Index. Each Chapter is divided into four Information types: (D) Technical Data (specifications) for all the mechanical, electrical or hydraulic devices, components and, assemblies. (C) Functional Data (how it works) for all the mechanical, electrical or hydraulic devices, components and assemblies. 604_13_552_01 1 3/24/2006

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INTRODUCTION

(G) Diagnostic Data (fault codes, electrical and hydraulic troubleshooting) for all the mechanical, electrical or hydraulic devices, components and assemblies. (F) Service data (remove disassembly, assemble, install) for all the mechanical, electrical or hydraulic devices, components and assemblies.

Sections Sections are grouped according to the main functions or a systems on the machine. Each Section is identified by a letter A, B, C etc. The amount of Sections included in the manual will depend on the type and function of the machine that the manual is written for. Each Section has a Contents page listed in alphabetic/numeric order. This table illustrates which Sections could be included in a manual for a particular product. SECTION A - Distribution Systems B - Power Production C - Power Train D - Travelling E - Body and Structure F - Frame Positioning G - Tool Positioning H - Working Arm J - Tools and Couplers K - Crop Processing L - Field Processing PRODUCT Tractors Vehicles with working arms: backhoes, excavators, skid steers, ..... Combines, forage harvesters, balers, .... Seeding, planting, floating, spraying equipment, .... Mounted equipment and tools, .....

X X X X X X X X

X X X X X

X X

X X

X X X X X X X X

X X X X X X

X

X X

X X X

X X

X

Chapters Each Chapter is identified by a letter and number combination e.g. Engine B.10.A The first letter is identical to the Section letter i.e. Chapter B.10 is inside Section B, Power Production. CONTENTS The Chapter Contents lists all the (D) technical data (specifications), (C) functional data (how it works), (F) service data (remove, install adjust, etc..) and (G) diagnostic data (fault codes and troubleshooting) that have been written in that Chapter for that function or system on the machine. Contents POWER PRODUCTION ENGINE _ 10.A TECHNICAL DATA ENGINE - General specification (B.10.A - D.40.A.10) FUNCTIONAL DATA ENGINE - Dynamic description (B.10.A - C.30.A.10) SERVICE ENGINE - Remove (B.10.A - F.10.A.10) DIAGNOSTIC ENGINE - Troubleshooting (B.10.A - G.40.A.10) INDEX 604_13_552_01 1 3/24/2006

4

3

4 5 6


REPAIR MANUAL DISTRIBUTION SYSTEMS

LS180.B LS185.B LS190.B

1 3/24/2006

A


Contents DISTRIBUTION SYSTEMS - A

PRIMARY HYDRAULIC POWER SYSTEM

A.10.A

SECONDARY HYDRAULIC POWER SYSTEM

A.12.A

HIGH-FLOW HYDRAULIC POWER SYSTEM

A.16.A

ELECTRICAL POWER SYSTEM

A.30.A

LIGHTING SYSTEM

A.40.A

LS180.B , LS185.B , LS190.B LS180.B , LS185.B , LS190.B LS180.B , LS185.B , LS190.B

LS180.B , LS185.B , LS190.B LS180.B , LS185.B , LS190.B

1 3/24/2006

A


DISTRIBUTION SYSTEMS - A PRIMARY HYDRAULIC POWER SYSTEM - 10.A

LS180.B LS185.B LS190.B

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A.10.A / 1


Contents DISTRIBUTION SYSTEMS - A PRIMARY HYDRAULIC POWER SYSTEM - 10.A TECHNICAL DATA PRIMARY HYDRAULIC POWER SYSTEM Capacity (A.10.A - D.40.A.20)

4

Special tools (A.10.A - D.20.A.40)

4

General specification (A.10.A - D.40.A.10)

5

Relief valve

General specification (A.10.A.16 - D.40.A.10)

6

Hydraulic pump General specification (A.10.A.20 - D.40.A.10)

7

Oil filter by-pass General specification (A.10.A.25 - D.40.A.10)

FUNCTIONAL DATA PRIMARY HYDRAULIC POWER SYSTEM Identification (A.10.A - C.40.C.01)

8

9

Hydraulic schematic frame 01 (A.10.A - C.20.H.01)

10

Hydraulic schematic frame 02 (A.10.A - C.20.H.02)

11

Hydraulic schematic frame 03 (A.10.A - C.20.H.03)

13

Hydraulic schematic frame 04 (A.10.A - C.20.H.04)

15

Hydraulic schematic frame 05 (A.10.A - C.20.H.05)

17

Hydraulic schematic frame 06 (A.10.A - C.20.H.06)

18

Hydraulic pump 19

Sectional view (A.10.A.20 - C.10.A.30)

SERVICE PRIMARY HYDRAULIC POWER SYSTEM Cleaning (A.10.A - F.30.A.10)

20

Decontaminating (A.10.A - F.30.A.60)

24

Relief valve

Flow test (A.10.A.16 - F.40.A.45)

26

Pressure test (A.10.A.16 - F.40.A.30)

28

Hydraulic pump Flow test (A.10.A.20 - F.40.A.45)

29

Disassemble (A.10.A.20 - F.10.A.25)

31

Visual inspection (A.10.A.20 - F.40.A.10)

36

Assemble (A.10.A.20 - F.10.A.20)

38

Remove (A.10.A.20 - F.10.A.10)

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45

Install (A.10.A.20 - F.10.A.15)

Charge pump 47

Pressure test (A.10.A.21 - F.40.A.30)

Reservoir

Apply vacuum (A.10.A.22 - F.35.A.50)

51

Filling (A.10.A.22 - F.60.A.10)

52

Remove (A.10.A.22 - F.10.A.10)

53

Install (A.10.A.22 - F.10.A.15)

56

Visual inspection (A.10.A.22 - F.40.A.10)

58

Oil filter

Remove (A.10.A.24 - F.10.A.10)

59

Install (A.10.A.24 - F.10.A.15)

60

Oil cooler

Remove (A.10.A.32 - F.10.A.10)

61

Install (A.10.A.32 - F.10.A.15)

62

DIAGNOSTIC Sensing system Temperature sensor - Testing (A.10.A.95.90 - G.40.A.20)

63

Filter restriction sensor - Testing (A.10.A.95.94 - G.40.A.20)

63

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic pump - Disassemble (A.10.A.20 - F.10.A.25) 1.

2.

3.

Draw alignment marks on the housing with a white marker. These marks will be referenced during assembly.

GD98J801

1

GD98J802

2

GD98J803

3

Loosen and remove the socket bolts and washers.

Remove the cover.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

4.

5.

6.

Remove the gear plate.

GD98J804

4

GD98J805_2

5

GD98J806

6

Remove the dowel pins.

Rotate the gear teeth until one gear tooth is centered inside two gear teeth. Draw a mark with a white marker. This mark will be referenced during assembly.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

7.

8.

9.

Remove the drive shaft.

GD98J807

7

GD98J808

8

GD98J809

9

Remove the idler shaft.

Remove the wear plate from the cover.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

10.

11.

12.

Remove the wear plate from the body.

GD98J810

10

GD98J811_2

11

GD98J812_2

12

Remove and discard the seal ring from the cover.

Remove and discard the seal ring from the body.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

13.

14.

Remove and discard the top seal from the body.

GD98J813

13

GD98J814

14

Remove and discard the bottom seal from the body.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic pump - Visual inspection (A.10.A.20 - F.40.A.10) 1.

2.

3.

Inspect the brass surfaces of the wear plates for wear. Replace as required.

GD98J815

1

GD98J816

2

GD98J817_2

3

Inspect the drive and idler shafts for wear or damage. Replace as required.

Inspect the bearing sleeves of the drive and idler shafts in the body and cover for wear or damage. Replace as required.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

4.

Inspect the body and cover surfaces for wear or damage. Replace as required.

GD98J818_2

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4


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic pump - Assemble (A.10.A.20 - F.10.A.20) 1.

2.

Lubricate the bottom seal with clean hydraulic oil and insert the bottom seal into the groove of the body.

GD98J814

1

GD98J813

2

GD98J812_2

3

Lubricate the top seal with clean hydraulic oil and insert the top seal into the groove of the body.

NOTE: The top seal will be placed on top of the bottom seal.

3.

Lubricate the new seal ring with clean hydraulic oil and insert the new seal ring into the groove of the body.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

4.

5.

6.

Lubricate the new seal ring with clean hydraulic oil and insert the new seal ring into the groove of the cover.

GD98J811_2

4

GD98J810

5

GD98J809

6

Place the wear plate on top of the new seals on the body.

Place the wear plate on top of the new seal on the cover.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

7.

8.

9.

Insert the idler shaft through the wear plate, and into the housing.

GD98J808

7

GD98J807

8

GD98J806

9

Insert the drive shaft through the wear plate, and into the housing.

During the gear pump disassembly, the gear teeth were aligned and then marked. Please refer to Hydraulic pump - Disassemble (A.10.A.20 F.10.A.25). Ensure that the meshed teeth marks, on the drive shaft and the idler shaft, are properly aligned.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

10.

11.

12.

Insert the guide dowels into the housing.

GD98J805_2

10

GD98J804

11

GD98J803

12

Align and slide the gear plate down the shafts and guide dowels until it is snug against the body.

During the gear pump disassembly, alignment marks were placed on the housing for the body and cover. Please refer to Hydraulic pump - Disassemble (A.10.A.20 - F.10.A.25). Align and place the cover on top of the body

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

13.

Secure the cover on top of the body with washers and socket bolts. Tighten the socket bolts in a cross pattern sequence to a torque of 34 Nm.(300 lb in) Do not overtighten the socket bolts.

GD98J802

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13


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic pump - Remove (A.10.A.20 - F.10.A.10) 1.

2.

Raise the operators seat and lock in the up position. Loosen and remove the mounting bolts and washers for the cover plate. Remove the cover plate to gain access to the hydraulic pump.

bd04h165

1

bd05f004_1

2

bd05f004_2

3

Place a shop towel under the gear pump (1).

3.

Remove the cap from the hydraulic reservoir.

4.

Connect a vacuum pump to the hydraulic reservoir. CAS10192

5.

Reservoir - Apply vacuum (A.10.A.22 - F.35.A.50) Start the vacuum pump.

6.

Tag and disconnect the hose from the fitting at the suction port (2) of the gear pump.

7.

Install a plug in the hose and a cap on the fitting.

8.

Tag and disconnect the hose from the fitting at the pressure port (3) of the gear pump. If machine is equipped with High-Flow, tag and disconnect the High-Flow pressure hose at the fitting on the pump.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

9.

Install a plug(s) in the hose(s) and a cap(s) on the fitting(s).

10.

Stop the vacuum pump.

11.

Loosen and remove the pump mounting bolts and washers (4).

bd05f004_3

12.

Remove the gear pump from the hydrostatic pump mounting location.

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4


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic pump - Install (A.10.A.20 - F.10.A.15) Prior operation: Before pump installation, apply Molykote G-4700 (P/N 86983138) to the pump and the coupling splines. Pre-fill the pump with clean hydraulic oil. Inspect O-ring on the pump pilot and replace if necessary. Lubricate the O-ring with clean hydraulic oil. 1.

Hold the pump in the mounting location. Rotate the gear pump shaft until it aligns with the coupling splines at the rear of the hydrostatic pump. After the splines are aligned, move the pump inward until the mounting flange is flush with the mounting surface of the hydrostatic pump.

2.

Apply Loctite 243 to the pump mounting bolts (4). Install washers on the bolts and install the bolts (4) into the pump mounting flange. Tighten the mounting bolts (4).

3.

Reservoir - Apply vacuum (A.10.A.22 - F.35.A.50) Start the vacuum pump.

4.

Remove the cap from the fitting and the plug from the pressure hose. If the machine is equipped with High-Flow remove the cap from the fitting and the plug from the High-Flow hose.

5.

Connect the hose to the pressure port fitting (3) and High-Flow port fitting (if equipped) of the pump and tighten the fitting(s).

6.

Remove the cap from the fitting and the plug from the suction hose

7.

Connect the hose to the suction port fitting (2) of the pump and tighten the hose clamp.

8.

Stop the vacuum pump. Disconnect the vacuum pump from the hydraulic reservoir and install the reservoir cap on the reservoir filler neck.

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bd05f004_3

1

bd05f004_2

2

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