New Holland LS120 LS125 Skid-Steer Service Repair Manual (86615609) NH LS120 LS125 - PDF Download by www.heydownloads.com

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SKID-STEER REPAIR

LS120, LS125

Vol. 1

86615609

86615613

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SECTION 29 -- HYDROSTATIC TRANSMISSION Chapter 1 -- Pumps, Motors, Steering CONTENTS Section 29 000

Description

Page

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-2 Hydrostatic Drive System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-2 Hydrostatic Drive vs. Mechanical Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-4 Resting the Boom on Lockpins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-7

29 100 01

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-8 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-10

29 100 40

Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-11

29 100 46

Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-14

29 100 60

Hydrostatic Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-28

29 100 66

Hydrostatic Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-30 Hydrostatic System Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-41 Start-Up Procedure After Hydrostatic Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-43

29 100 36

Charge Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-47

29 100

Steering Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-48

29 100 36

Transmission Neutralizing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-49 Labor Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-52

29-1

SECTION 29 - HYDROSTATIC TRANSMISSION Op. 29 100

GENERAL INFORMATION

19994680

HYDROSTATIC DRIVE SYSTEM OVERVIEW

propulsion system and one gear pump for operating the hydraulic system. The hydraulic pump receives power directly from the engine. The two piston pumps are connected to the motors by high-pressure hoses. A lever controls each hydrostatic piston pump by engaging the traction drive belt which drives the hydrostatic pumps. There are two motors, one for each final drive right and left. The hydrostatic motors are connected to the axles by a #60 roller chain and sprockets that drive the wheels. The individual drive chains can be properly tensioned by moving an idler assembly for each final drive.

Normally, operators with loader experience can adapt to the controls of Model LS120 and LS125 loaders very quickly. However, hydrostatic-driven machines such as the LS120 and LS125 operate differently than mechanically driven units. Therefore, an operator may have to retrain himself for the transmission difference. An understanding of the characteristics and principles of the hydrostatic drive will help the operator use the loader at maximum efficiency. The Model LS120 and LS125 loaders feature a fully hydrostatic drive. The hydrostatic system consists of two variable displacement pumps for operating the

29-2

SECTION 29 - HYDROSTATIC TRANSMISSION Two forward and reverse control levers, 1, control the transmission pumps. The control levers connect to two neutralizer assemblies, 2, which automatically return the pintle arms to a positive neutral position. As the control levers move, they stroke the hydrostatic transmission pump pintle arms to the desired position to move the loader in the direction the levers are stroked, forward or reverse. Shock absorbers, or dampeners, 3, absorb hydrostatic vibrations before the vibrations reach the operatorâ&#x20AC;&#x2122;s arms. The dampeners absorb the normal hydrostatic pulsations and torque feedback generated by the drive train loads. This arrangement provides smoother operation and significantly reduces operator fatigue. NOTE: For efficient engine operation, always maintain full-load engine speed above 1000 RPM. Continued full load operation below 1000 RPM, or lugging, is unproductive and may cause early engine failure. Typically, skid steer operation requires rapid changes of speed and direction, with accompanying low speeds at times of heavy loader power demands. It is during these modes of operation that a hydrostatic transmission is more efficient than a mechanical drive train.

DANGER Always fasten the seat belt. This skid steer is a very stable unit, but can be upset if stopped suddenly when the bucket is raised and loaded. Therefore, never start the engine before securely fastening the seat belt. When a loader digs into a pile of dirt, the operator strives to exert maximum tractive effort with very little speed. The variable displacement hydrostatic pumps are destroked at this time. The destroked pumps drive the motors at the required slow speed while generating maximum torque to the wheels.

29-3

2 9247-04

SECTION 29 - HYDROSTATIC TRANSMISSION

HYDROSTATIC DRIVE VS. MECHANICAL DRIVE

Because of the positive relationship between the hydrostatic pumps and motors, the hydrostatic system aids deceleration of the machine when the pumps are stroked toward neutral position. This is the automatic braking characteristic of the hydrostatic transmissions. The hydrostatic drive also provides infinitely variable speed. The system can operate the loader within a full range from full speed reverse through neutral to full speed forward, and any speed in between, with no jumps, jerks, or flat spots. For instance, fast shuttle-loading work is done with no lost time changing direction. The smoother power transition and application from the transmission also provides maximum tractive effort on any terrain. The operator can ease the loader into a tough load without breaking traction because of the precise speed control.

There is minimum power loss in these hydrostatic systems because input speeds are reduced far below speeds attainable with slipping clutches in mechanical drive systems. To obtain maximum torque at the wheels, always remember to keep the control levers close to the neutral position. This differs from a mechanical drive unit, where the operator pushes the control levers as far forward as possible to prevent the clutches from slipping. The positive control of these hydrostatic drives at low speeds allows the operator to ease the bucket into loads, eliminating the impact loading technique often necessary with mechanically driven units. These hydrostatic loaders never have to be used as a ramrod, a practice that is hard on both the operator and machine.

29-4

SECTION 29 - HYDROSTATIC TRANSMISSION

5 2

3 6 1

19994681

3 The transmission system consists of two variable displacement piston pumps, 1, and two fixed displacement motors, 2. The motors transfer power to each chain case where the wheels are driven by a single roller chain reduction. The hydrostatic charge circuit gets supply oil from the control valve return line, 3. The hydraulic oil from the control valve passes through the charge filter, 4. After the filter, the oil goes either to the hydrostatic pumps or back to the reservoir, through an 80 PSI check valve, 5. The check valve ensures that the supply pressure to the hydrostatic piston pumps always stays above 5.5 bar (80 PSI). The charge oil pressure generally stays in the 5.8 to 8.0 bar (85 to 115 PSI) range, always providing

29-5

adequate oil flow to the hydrostatic pumps. The left and right piston pumps supply oil to the motors whenever the steering levers are activated. A case drain line, 6, connects the two piston pumps to the reservoir. The case drain line drains hot oil and effectively cools the piston pumps. The case drain line allows hot lubrication/leakby oil to travel through the piston pump cases to the reservoir. The hydrostatic motor cases do not have case drains. There are no high-pressure relief valves in the hydrostatic pumps. The ground drive is limited only by the engine power and the traction driving belt tension.

SECTION 29 - HYDROSTATIC TRANSMISSION

RESTING THE BOOM ON LOCKPINS Before servicing, making final drive chain or neutral adjustments, or making final drive repairs, the loader must be blocked up with all four wheels off the ground. The boom can be raised and supported on the boom lock pins for better access. Remove any attachment from the boom mounting plate. Raise the boom and support the boom on the lock pins.

DANGER Never work beneath a loader or boom when it is held up only by the hydraulic system. A broken hydraulic line could cause the boom to descend rapidly. Always actuate the boom lock before leaving a machine with the boom up or when servicing or repairing the unit with the boom up. Failure to do so could result in serious injury or death. PROCEDURE: 1. RAISE THE BOOM, EXTEND THE BOOM LOCK PINS, 1, AND LOWER THE BOOM ON THE BOOM LOCK PINS. 2. AFTER STOPPING THE ENGINE AND BEFORE UNBUCKLING THE SEAT BELT AND DISMOUNTING FROM THE LOADER, TURN “ON” THE IGNITION SWITCH. 3. PUSH BOTH THE BOOM AND BUCKET PEDALS TO RELIEVE ALL HYDRAULIC PRESSURE IN BOTH CIRCUITS. 4. TURN “OFF” THE IGNITION SWITCH. 5. SET THE PARKING BRAKE.

A3948-04

29-6

SECTION 29 - HYDROSTATIC TRANSMISSION

SPECIFICATIONS OIL SPECIFICATIONS Oil reservoir capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 liters (9 US gallons) Drain plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four (front & rear each side) Hydrostatic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 micron cartridge (NH634958) Maximum continuous temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107° C (225° F) Maximum intermittent temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121° C (250° F) Oil grade: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10W-30 API Service SHCG-4

HYDROSTATIC TRANSMISSION SYSTEM Hydrostatic Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1 cm3 (0.913 cu.in.) Case mounting bolts torque, 1/2″ x 1-1/2″ Grade 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 N⋅m (66 ft. lbs.) Case cover bolts torque, 3/8″ x 7/8″ Grade 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 - 50 N⋅m (27 - 37 ft. lbs.) Charge check valve plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 34 N⋅m (15 - 25 ft. lbs.) Hydrostatic Motor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Torque Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213.3 cm3 (12.9 cu.in.) Housing bolt torque, 5/16″ x 3-3/4″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N⋅m (30 ft. lbs.) Drive sprocket to hydrostatic motor shaft nut torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 N⋅m (150 ft. lbs.) Hydrostatic motor mounting bolt torque Carriage bolts, 1/2″ x 1-1/2″ Grade 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 N⋅m (66 ft. lbs.) Hex cap screw, 5/16″ x 5/8″ Grade 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 24 N⋅m (15 - 18 ft. lbs.) Charge pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 - 8.3 bar (80 - 120 PSI) Relief valve (forward/reverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No relief valve used

29-7

SECTION 29 - HYDROSTATIC TRANSMISSION Op. 29 100 01

HYDROSTATIC SYSTEM TROUBLESHOOTING PROBLEM

POSSIBLE CAUSE

CORRECTION

Machine will not move either direction

Parking brake engaged Engine to hydrostatic drive belt Low hydraulic oil Low charge pressure Incorrect oil Air in system Water in system Internal pump or motor damaged Linkages loose or broken

Release parking brake Check and repair or replace Check oil level Check charge pressure/repair Drain and replenish with proper oil Purge air and repair system Drain, clean, and replace oil Check pump/motor case drain flow Check and repair

One side moves, other side does not

Internal pump or motor damaged Linkage loose or broken Broken drive chain

Check pump/motor case drain flow Check and repair Check and repair

Noisy pump or motor

Air in system Wrong kind of oil Water in system Internal pump or motor damaged Linkage loose or broken

Purge air and repair system Drain, clean system and replace oil Drain, clean, and replace oil Check pump/motor case drain flow Check and repair

Low power

Low hydraulic oil Low charge pressure Air in system Internal pump or motor damaged

Check oil level Check charge pressure/repair Purge air and repair system Check pump/motor case drain flow

Sluggish response to changes in speed

Engine to hydrostatic drive belt Air in system Output pressure too low Linkage loose or broken Oil to heavy, cold weather Wrong kind of oil

Check and adjust Purge air and repair system Check pressure/replace relief valve Check and repair Allow unit to warm up before operating Drain, clean system and replace oil

29-8

SECTION 29 - HYDROSTATIC TRANSMISSION

PROBLEM

POSSIBLE CAUSE

Loader creeps with control levers in neutral position

Neutralizing spring mechanism not adjusted Pintle lever loose on pump pintle shaft Pintle shaft broken

Adjust spring mechanism

Loader does not run straight when both control levers are in the forward position

Steering lever stop bolts not adjusted correctly

Adjust steering

Engine runs but no ground drive

Broken traction drive belt Traction drive belt disengaged Spring on belt idler disconnected Oil on drive belt

Replace belt Engage traction drive belt Assemble idler properly Clean or replace belt

29-9

CORRECTION

Check key and tighten clamp bolt Replace pintle shaft

SECTION 29 - HYDROSTATIC TRANSMISSION

HYDROSTATIC SYSTEM TESTING Hydrostatic Pump Charge Pressure 1. Check the charge pressure to the hydrostatic transmission pumps by removing the 1/8â&#x20AC;ł pipe plug, 1, and installing a 20.7 bar (300 PSI) pressure gauge, 2. Within 5 to 10 seconds, the normal charge pressure should be 5.5 - 8.3 bar (80 - 120 PSI). 2. If charge pressure is low, remove the O ring caps, springs, and plunger assemblies at 3. Inspect for dirt buildup.

2 3

1 19994852

5 3. If charge pressure remains low, remove the 5.5 bar (80 PSI) check valve, 1, and inspect it for dirt buildup. The valve is not serviceable and must be IMPORTANT: If the charge pressure remains below 5.5 bar (80 PSI) for more than a few seconds, cease operation and determine the cause of low charge pressure. Failure to cease operation with a lack of charge oil could cause catastrophic failure of the transmissions.

19994853

29-10

SECTION 29 - HYDROSTATIC TRANSMISSION

HYDROSTATIC PUMP Op. 29 100 40 Removal NOTE: The control shaft, 1, and trunnion shaft, 2, lip-type seals can be replaced without removing the transmission pump. Remove the retaining ring and washer to replace the seals. IMPORTANT: Short circuits may occur if the battery is not disconnected. Disconnect the battery before moving the dashboard.

19994705

7 1. Remove the lock pin and swing open the engine compartment door. 2. Disconnect the negative (--) battery cable, 1. 3. Disconnect the positive (+) battery cable, 2. 4. Remove the operatorâ&#x20AC;&#x2122;s seat by lifting the seat up and disconnecting the seat switch harness connector.

9246-07

8 5. Remove the plastic ties, 1, securing the wire harness to the hydraulic pipe. 6. Remove the support plate bolts, 2, and the front seat belt bracket bolts, 3.

A3948-07

29-11

SECTION 29 - HYDROSTATIC TRANSMISSION 7. Remove the six dash bolts, 1, and the three hydraulic filter mounting bolts, 2, securing the dash. 8. Pull the dash, 3, forward and down.

19993689

10 9. Remove the six bolts and the right side shield, 1.

19993691

11 10. Remove the six bolts and the left side shield, 1.

19993688

2 12

29-12

SECTION 29 - HYDROSTATIC TRANSMISSION 11. Disconnect the feed hydraulic line, 1, on the side of the pump. Disconnect the hydraulic lines, 2, on the bottom of the pump.

30994704

2 13

12. Loosen the neutral adjustment rods, 1. 13. Remove the two springs, 2. 14. The cam shaft plate arm, 3, may be removed before or after pump removal. To remove the cam shaft plate arm before pump removal, remove the dampener bolt, 4, and loosen the two set screws, 5.

4 5

G97-388

14 15. Loosen the two set screws, 1, on the sheave, 2, and move the sheave toward the engine. NOTE: If the sheaves cannot be moved far enough to allow access to the pump mounting bolts, remove the engine. 16. Loosen the two pump mounting bolts and remove the pump.

2 1

19994888

29-13

SECTION 29 - HYDROSTATIC TRANSMISSION Op. 29 100 46 Disassembly and Inspection 1. Clean the outside of the pump thoroughly. 2. Mark the transmission pump housing, 1, to aid in reassembly.

30994706

16 3. Remove the key, 1. 4. Remove the four pump cover bolts, 2. 5. Lift up the pump cover evenly to avoid cutting the shaft seal.

30994707

17 6. Remove the O ring, 1, the gerotor gear, 2, and the pin, 3. 7. Examine the surfaces of the gerotor gear and the interior surface of the pump cover, 4, for scratches, wear, or other damage. 8. Replace any damaged parts.

30994711

3 18

29-14

SECTION 29 - HYDROSTATIC TRANSMISSION 9. Loosen four bolts, 1, on the end cap, 2. The end cap should separate slightly due to spring pressure. If separation does not occur, tap the end cap gently with a soft hammer. IMPORTANT: All rotating group, valve plate, end cap, and swash plate surfaces are machined and highly polished to fit. Avoid any damage to these surfaces.

30994712

19 IMPORTANT: The valve plate, 1, may tend to stay with the end cap when the end cap is removed. If the valve plate stays with the end cap, hold the plate in place and remove the plate and end cap as an assembly. 10. Remove the four bolts and remove the end plate.

19994714

20 11. Remove the gasket, 1, and the charge port O rings, 2.

1 2 30994713

29-15

SECTION 29 - HYDROSTATIC TRANSMISSION 12. Remove the valve plate. Examine the band, 1, and the feathering notches, 2, for wear or damage. 13. Polished areas are normal after long use, but scratches between the kidney ports or to the outside could cause pressure loss.

19994714

22 14. Examine the pin, 1 and the bearing, 2. If the pin is damaged, replace it. 15. If the bearing is worn or has loose needles, replace the bearing. 16. Press the new bearing into the end cap leaving 2.38 - 3.18 mm (0.094â&#x20AC;ł - 0.125â&#x20AC;ł) protruding beyond the face of the end cap.

1 2

30994715

23 17. Remove the charge port plugs, 1. 18. Be sure the springs, 2, have not collapsed and exert sufficient force against the balls, 3. 19. Examine the balls for burrs or nicks. Be sure the balls fit tightly against the machined check valve seats, 4, in the end cap. 20. Be sure the check valve seats are not damaged or worn.

3 2 1 19994840

3 2 1 24

29-16

SECTION 29 - HYDROSTATIC TRANSMISSION 21. Hold a hand over the rotating block assembly, 1, and tilt the pump case up to lower the block assembly into the hand.

CAUTION Do not attempt to disassemble the spring or other parts from the center of the block bore. The components are under high spring tension and could cause injury if disturbed.

1 30994841

25 NOTE: Any piston can go back into any block bore. The pistons are loose and may fall out of the block assembly during removal. 22. Pull the piston assemblies, 1, out of the block, 2. 23. Check the block bores for damage.

19994843

26 24. Check each piston assembly to be sure the slipper surface, 1, is flat and not scratched. The edges of the slipper surface should not be rounded. Be sure the oil hole, 2, is open and free of obstruction. 25. Check the piston slipper to barrel pivot, 3. The slipper should move freely but not be loose.

2 3

19994844

29-17

SECTION 29 - HYDROSTATIC TRANSMISSION 26. Check the pressure band, 1, for wear or scratches. 27. Replace the rotating group if any of the parts are damaged; the parts are not serviced separately.

19994845

28 28. Use a small screwdriver at 1 to aid in removing the replaceable thrust plate, 2. 29. Check for scratches or other damage that could cause oil pressure loss. 30. Replace the thrust plate if required. 31. Use a 3/16â&#x20AC;ł punch to drive the spring pins, 3, into the housing recesses behind the thrust plate to free the trunnion and control shafts.

1 2

19994846

29 32. The control shaft, 1, uses two spring pins, 2, while the trunnion shaft, 3, uses one spring pin, 4. 33. Pull the control and trunnion shafts out of the housing. 34. Wire rings, 5, hold the cover washers, 6, in place.

19994848

29-18

SECTION 29 - HYDROSTATIC TRANSMISSION 35. Remove the snap ring, 1, to remove the shaft, 2. 36. Press the shaft and bearing into the housing. 37. Check the bearing and shaft for wear or other damage.

2 19994847

31 38. Check the needle bearings, 1, for worn or loose needles. Replace the bearings if required. 39. Clean the housing thoroughly. 40. Flush the charge ports, 2.

1 19994849

32 IMPORTANT: Use care not to damage the bore or the housing when prying out the control and trunnion shaft seals.

IMPORTANT: If replacement is required, press the needle bearings in 0.0 - 0.4 mm (0â&#x20AC;ł - 1/64â&#x20AC;ł) below the lip-type seal counterbore.

41. Remove the retaining ring, 1, and washer, 2, on the lip-type seals on the control and trunnion shaft bores. 42. Pry out the seals. 19994850

29-19

SECTION 29 - HYDROSTATIC TRANSMISSION 43. Remove the snap ring, 1, and remove the bearing, 2, from the drive shaft. 44. Examine the seal and bearing areas of the shaft, 3, for wear or damage. 45. Inspect the gear splines, 4, for excessive wear. 46. Check the bearing balls for nicks or wear. 47. Replace the bearing or the shaft if wear is evident.

4 1

19994851

34 Reassembly 1. Install the bearing, 1, on the drive shaft and install the snap ring, 2.

1 2

19994851

35 2. Insert new lip-type seals, 1, for the trunnion and control shafts. 3. Replace the washer, 2, and retaining ring, 3, on the seals.

19994850

29-20

SECTION 29 - HYDROSTATIC TRANSMISSION 4. If replacement of the trunnion or control shaft needle bearings, 1, is required, press the bearings to 0.0 - 0.4 mm (0.000″ - 0.015″) below the counterbore for the shaft lip seal, 2.

1 2 19994849

37 5. Press the shaft, 1, and bearing, 2, into the housing. 6. Replace the snap ring, 3, to retain the shaft.

3 1 19994847

38 7. Install the wire rings, 1, to hold the cover washers, 2, in place.

19994848

29-21

SECTION 29 - HYDROSTATIC TRANSMISSION 8. Push the control shaft, 1, and trunnion shaft, 2, into the housing. 9. Align the control shaft, 1, and trunnion shaft, 2, with the spring pin holes, 3, in the swash plate. 10. Use a 3/16″ punch to drive two spring pins into the control shaft. Drive the end of the second spring pin 6.4 mm (0.25″) below the surface of the swash plate 11. Drive one spring pin into the trunnion shaft 6.4 mm (0.25″) below the surface of the swash plate. IMPORTANT: The swash plate should swing freely ± 15° from center.

19994846

12. Install the replaceable thrust plate, 4.

CAUTION Do not attempt to disassemble the spring or other parts from the center of the block bore. The components are under high spring tension and could cause injury if disturbed. IMPORTANT: All rotating group, valve plate, end cap, and swash plate surfaces are machined and highly polished to fit. Avoid any damage to these surfaces. 13. Install the piston assemblies, 1, in the block, 2. NOTE: The pistons should go back into the same block bore.

19994842

41 14. Slide the block assembly, 1, with pistons installed onto the drive shaft with the piston slippers against the thrust plate. 15. Slide the block onto the drive shaft with the three notches, 2, facing out.

1 30994841

2 42

29-22

SECTION 29 - HYDROSTATIC TRANSMISSION 16. Install the balls, 1, and the springs, 2, in the charge check valve seats, 3. 17. Install new O rings on the plugs, 4. Tighten the O ring plugs to 20 - 24 Nâ&#x2039;&#x2026;m (15 - 25 ft. lbs.)

19994840

43 18. Align the valve plate slot, 1, with the pin, 2, and install the valve plate on the protruding bearing, 3.

2 3

30994715

1 44

19. Make sure the feathering notches, 1, are facing out.

19994714

1 45

29-23

SECTION 29 - HYDROSTATIC TRANSMISSION 20. Install the gasket, 1, and the charge port O rings, 2.

1 2 30994713

46 21. Install the end plate, 1. IMPORTANT: To be sure of the correct internal assembly of the parts, slowly rotate the pump drive shaft and the control shaft while tightening the end cap bolts. The pump shaft should resist turning because of the rotating group spring load against the end cap. Turn the shaft with pliers after reassembly to check for correct assembly.

22. Install the four bolts, 2, on the end plate. Tighten the bolts alternately until the end cap and the housing are pulled completely together. Tighten the bolts to 36 - 50 Nâ&#x2039;&#x2026;m (27 - 37 ft. lbs.).

30994712

47 23. Install the gerotor gear, 1, and the pin, 2, if pin was removed.

2 1

30994710

29-24

SECTION 29 - HYDROSTATIC TRANSMISSION 24. Install a new O ring, 1, in the front cover.

19994709

49 25. Install the pump front cover, 1. Be sure the cover aligns with the scribed mark on the pump housing. 26. Install the four pump cover bolts, 2. Tighten the charge pump front cover bolts to 24 Nâ&#x2039;&#x2026;m (18 ft. lbs.).

30994708

50 27. Install the key, 1, in the shaft. NOTE: The pump drive shaft should have resistance to turning because of the rotating group spring pressure against the end cap. The shaft should turn easily with pliers.

19994705

29-25

SECTION 29 - HYDROSTATIC TRANSMISSION Re-Installation 1. Lower the pump into position and install the two pump mounting bolts. 2. Move the sheave over, 1, the pump drive shaft so there is 12 mm (0.5″) clearance between the sheave and support plate. Tighten the two set screws, 2, on the sheave.

1 2

19994888

52 3. Make sure the pump drive sheaves and the engine sheave are aligned correctly. If the engine sheave is not aligned, shift the engine in its mounting holes or use 3/8″ flat washers under the engine mounts. If the sheaves do not align easily, adjust as follows:

CORRECT

INCORRECT 19994987

53 • •

• • •

•

Remove the side shield or belly pan for better access. Set the right hydrostatic drive sheave, 1, with 12 mm (0.5″) clearance between the sheave and support plate. Align the left hydrostatic drive sheave, 2. Tighten the setscrews in both sheaves. Align the engine sheave with both hydrostatic drive sheaves. Shift the engine in its mounting holes or use 3/8″ flat washers under the engine mounts. Check the idler arm, 3, for clearance between the arm and the drive sheave, 4. Engage the belt clutching lever and check the idler alignment between the arm and idler. Adjust with 3/8″ washers as needed. Adjust the traction drive belt tension by loosening the bolts, 5, and moving the bracket, 6, until the spring length is 140 mm (5.5″). Support the loader off the ground and test the belt operation. If the belt does not track straight or runs to one side of the flat idler, remove the idler arm and twist it in a vise at 7.

4 7 3

G97-383

29-26

SECTION 29 - HYDROSTATIC TRANSMISSION 4. Install the cam shaft plate arm, 1, by installing the bolt and tightening the two set screws, 2. 5. Install the two springs, 3. 6. Tighten the neutral adjustment rods, 4.

G97-388

55 7. Connect the hydraulic feed lines, 1, on the side of the pump. Install the hydraulic lines, 2, on the bottom of the transmission pump. 8. Install the dash. 9. Install the side seat supports. 10. Install the plastic ties, 3, securing the wire harness to the hydraulic pipe. 11. Install all shields and fenders removed for the repair. 12. Install the operatorâ&#x20AC;&#x2122;s seat. 13. Connect the battery cables.

30994704

2 56

29-27

SECTION 29 - HYDROSTATIC TRANSMISSION

HYDROSTATIC MOTOR Op. 29 100 60 Removal 1. Remove the cotter pin, 1, and the castellated nut, 2.

1 30994685

2 57

2. Use a gear puller to remove the sprocket, 1, from the tapered shaft, 2.

2 1

19994686

58 3. Remove the two hydraulic lines, 1. 4. Remove the four nuts and washers, 2.

30994687

29-28

SECTION 29 - HYDROSTATIC TRANSMISSION 5. The motor assembly is sealed to the cast support plate, 1. Break the seal and remove the motor. Plug all open hydraulic ports and clean the motor case thoroughly. 6. The cast support plate should be removed only in case of an oil leak between the plate and the chain case side plate, 2. 7. Remove the eight washer head bolts, 3. 8. Clean any old silicone sealer off the cast support plate and the chain case side plate. Wipe off any excess silicone. IMPORTANT: Excess silicone sealer can break off and clog the gear pump strainer or the hydrostatic filter. Wipe off any excess silicone sealer squeezed out when installing the cast support plate.

30994688

Shaft Seal Replacement NOTE: The main shaft seal can be replaced without motor disassembly. 1. Remove the seal retaining snap ring, 1.

19994855

61 2. Turn the motor on end and insert two screwdrivers, 1, into the groove, 2, on the seal housing. NOTE: The seal should pop out easily because it is only held by an O ring in the motor housing. 3. Pop out the main shaft seal.

1 2

19994856

29-29

SECTION 29 - HYDROSTATIC TRANSMISSION 4. Remove the O ring, 1. 5. Inspect the seal area of the shaft, 2, for damage or wear. 6. Remove light scratches with fine emery cloth, polishing around the shaft. 7. Replace the shaft assembly if the scratches cannot be polished out. 8. Clean and oil the seal area. 9. Install a new O ring in the motor housing groove, 1.

2 1

19994857

63 10. Install a new seal assembly in the housing. 11. Tap the seal down until the snap ring groove in the motor housing is visible. 12. Place a snap ring in the groove with the seal retainer pin, 1, between the snap ring ends.

19994858

64 Op. 29 100 66 Disassembly 1. Mark the motor case, 1, for correct reassembly. NOTE: Units with parking brakes have a splined shaft at 2.

2 19994854

29-30

SECTION 29 - HYDROSTATIC TRANSMISSION 2. Remove the seal retaining snap ring, 1.

19994855

66 3. Turn the motor on end and insert two screwdrivers, 1, into the groove, 2, on the seal housing. NOTE: The seal should pop out easily because it is only held by an O ring in the motor housing. 4. Pop out the main shaft seal.

19994856

67 5. Remove the O ring, 1. 6. Inspect the seal area of the shaft, 2, for damage or wear. 7. Remove light scratches with fine emery cloth, polishing around the shaft. 8. Replace the shaft assembly if the scratches cannot be polished out.

2 1

19994857

29-31

SECTION 29 - HYDROSTATIC TRANSMISSION 9. Polish the motor shaft, 1. 10. Loosen and remove the eight bolts and seal washers, 2. IMPORTANT: The cover surfaces are machined and highly polished to fit. Avoid any damage to these surfaces.

2 3 1

11. Remove the cover, 3.

19994859

69 12. Remove and discard the quad ring, 1, the backup washer, 2, and the dust seal, 3.

1 2 19994862

3 70

13. Remove the O ring, 1, on the end cover.

19994861

29-32

SECTION 29 - HYDROSTATIC TRANSMISSION 14. Inspect the polished sealing area, 1, on the cover for deep scratches that could cause oil pressure loss. Replace the cover assembly if deep scratches are evident.

19994863

72 15. Remove the rotary valve, 1, and the two check balls, 2.

2 19994864

73 16. Inspect the polished sealing area, 1, on both sides of the rotary valve plate.

19994865

29-33

SECTION 29 - HYDROSTATIC TRANSMISSION 17. Inspect the plate, 1, for deep scratches that could cause oil pressure loss. Replace the rotary valve plate if deep scratches are found.

19994866

75 18. Remove the outer ring of the internal rotor assembly, 1, and the eight small rolls, 2.

19994867

76 19. Examine the internal surface, 1, of the outer ring for scratching or scoring.

19994868

29-34

SECTION 29 - HYDROSTATIC TRANSMISSION 20. Remove the rotor, 1, and the seven large rolls, 2.

19994869

78 21. Examine the inner ring, 1, for scoring or damage.

19994870

79 22. Remove the O ring, 1, from the motor housing. 23. Examine the housing sealing surfaces, 2, for scoring or damage. Replace the housing if required.

19994873

29-35

SECTION 29 - HYDROSTATIC TRANSMISSION Parts Inspection NOTE: Do not attempt to remove the heavy-duty snap rings holding the tapered roller bearings to the shaft. The bearing assemblies are not serviced separately from the shaft. 1. Remove the shaft assembly from the housing. Use a soft-faced hammer to tap the shaft if required. 2. Clean and oil all internal motor parts. 3. Examine the seal and bearing surfaces, 1, for scoring or damage. 4. Check for roller bearing wear by attempting to insert a 0.1524 mm (0.006â&#x20AC;ł) shim at 2. If the shim enters or if the shaft is heavily worn in the bearing or seal areas, replace the shaft assembly.

19994875

5. Inspect the housing for any excessive wear in the seal areas, 1, that could cause a leak. Inspect the housing case for cracks or other damage.

19994874

82 6. Check for rotor and roller wear. If the rotor or rollers show excessive wear, replace the complete rotor assembly.

19994871

29-36

SECTION 29 - HYDROSTATIC TRANSMISSION Reassembly 1. Install the inner rotor ring, 1.

19994870

84 2. Place the rotor, 1, over the inner rotor ring. 3. Install the seven large inner rollers, 2, between the inner rotor ring and the rotor.

19994869

85 4. Install the outer rotor ring, 1, observing the mark on the outside, 2, to match the original position. 5. Install the eight outer rollers, 3. 6. Push the rotor ring, 4, in one direction and check the clearance between the rotor and the outer ring on the short side, 5. Use a 0.305 mm (0.012â&#x20AC;ł) feeler gauge to check the clearance at the widest gap. If the clearance is excessive, replace the rotor assembly. NOTE: All parts for the rotor assembly are supplied in a kit. Rotor parts are not individually replaceable.

3 5

2 19994867

29-37

SECTION 29 - HYDROSTATIC TRANSMISSION 7. Time the rotary valve plate, 1, as follows: â&#x20AC;˘ Place the plate on the shaft. â&#x20AC;˘ Make sure that none of the inner rolls are visible through the plate holes, 2.

19994877

87 8. Coat all motor parts with oil prior to replacing the cover. 9. Install a new O ring, 1, in the motor body.

19994863

88 10. Install a new quad ring, 1, backup washer, 2, and dust seal, 3.

1 2 19994862

3 89

29-38

SECTION 29 - HYDROSTATIC TRANSMISSION 11. Install the cover, 1, aligning the marks, 2, for reassembly in original position. 12. Install eight bolts, 3, and seal washers. Tighten the bolts to 40 Nâ&#x2039;&#x2026;m (30 ft. lbs.).

3 1

19994860

90 Re-Installation 1. Clean any old silicone sealer off the cast support plate and the chain case side plate. Wipe off any excess silicone. IMPORTANT: Excess silicone sealer can break off and clog the gear pump strainer or the hydrostatic filter. Wipe off any excess silicone sealer squeezed out when installing the cast support plate. 2. Use a liberal amount of silicone sealer to install the cast support plate, 1. Use silicone sealer on the threads of the eight washer head bolts, 2. Wipe off excess sealer after installation. 3. Apply silicone sealer to the threads of the four motor carriage mounting bolts, 3.

2 1

3 30994688

4. Lower the motor into position and install the four nuts and washers, 1. Wipe off excess sealer. 5. Install the two hydraulic lines, 2.

30994687

29-39

SECTION 29 - HYDROSTATIC TRANSMISSION 6. Install the sprocket, 1, onto the tapered shaft, 2.

2 1

19994686

93 7. Install the flat washer, 1, and castellated nut, 2. Tighten to 207 Nâ&#x2039;&#x2026;m (150 ft. lbs.). Install the cotter pin, 3, into the castellated nut. 8. Reinstall the drive chains and adjust. 9. Clean the cover plate mating surface, 4. Apply a thin bead of silicone sealer around the mating surface and on the threads of the bolts before installing.

4 1

3 30994685

2 94

29-40

SECTION 29 - HYDROSTATIC TRANSMISSION

HYDROSTATIC SYSTEM CLEANING NOTE: All rebuilt components should be coated and filled with oil during rebuilding to ensure proper lubrication on start-up. 1. Change the system hydraulic filter, 1 (NH #634958). Change the filter again after 1 hour and 10 hours of operation and every 250 hours thereafter.

30994694

95 2. Remove the gear pump suction screen cap, 1, for screen removal. Remove, clean, and install the gear pump suction screen, 2. Tighten the cap snugly to prevent air leaks in the suction line. Clean the suction screen after 1 hour and 10 hours of operation and every 250 hours thereafter.

9247-03

96 3. Unscrew the breather assemblies, 1, from each chain case and pop the plastic cap from the nylon screen. 4. Clean the assemblies in kerosene and dry them before reinstallation. Clean the assemblies every 100 hours.

G97-403

29-41

SECTION 29 - HYDROSTATIC TRANSMISSION 5. Remove the center chain case covers, 1, for inspection. If contamination is visible, flush the chain case reservoirs with a suitable solvent as described below. • Remove the large drain plugs, 2, in the front and rear of each chain case. • Turn over the final drives by hand to dislodge any contamination particles on the chains or sprockets. Be sure all solvent is removed from the chain cases before sealing the cases. • Use Teflon tape or hydraulic sealer on the drain plug threads and install the drain plugs. • Fill the hydraulic reservoir with one of the approved oils (see Specifications). If the hydraulic oil is to be reused, filter it through a 10-micron filter before refilling the reservoirs.

19985896

2 98

CAUTION Be sure the loader is safely supported with all four wheels able to turn freely.

29-42

SECTION 29 - HYDROSTATIC TRANSMISSION

START-UP PROCEDURE AFTER HYDROSTATIC SERVICE 1. Make sure the Service/Operate switch is in the SERVICE position. 2. Clean the system as described above. NOTE: All rebuilt components should be coated and filled with oil during rebuilding to ensure proper lubrication on start-up. 3. Install a 20.7 (300 PSI) pressure gauge, 1, in the hydraulic line plug port, 2.

2 19994852

99 4. Loosen the gear pump pressure hose, 1, 3/4 turn to bleed air from the hydraulic system. IMPORTANT: Be sure the hydrostatic belt clutch is disengaged.

1 19985898

100 5. LS125 only - Disconnect the fuel shutoff solenoid wire connector, 1.

19993675

101

29-43

SECTION 29 - HYDROSTATIC TRANSMISSION 6. LS120 only - Disconnect the PU wire, 1, from the ignition coil positive (+) terminal, 2.

1 2 19993674

102 7. Crank the engine for 10 seconds or until there is oil at the gear pump line fitting, 1. Tighten the fitting after oil appears.

1 19985898

103 8. LS125 only - Reconnect the stop solenoid connector, 1.

19993675

104

29-44

SECTION 29 - HYDROSTATIC TRANSMISSION 9. LS120 only - Reconnect the PU wire, 1, to the ignition coil positive (+) terminal, 2.

1 2 19993674

105 10. Start the engine and set the engine speed at low idle. The charge pressure gauge should read 5.5 - 8.3 bar (80 - 120 PSI) within 5 to 10 seconds of start-up, indicating normal running conditions. IMPORTANT: If the charge pressure remains below 5.5 bar (80 PSI) for more than a few seconds, stop operation and determine the cause of low charge pressure. Failure to stop operation with a lack of charge oil could cause catastrophic failure of the transmissions. 11. After the charge pressure gauge indicates normal operation, set the engine speed at 1/2 throttle and let the engine run for 20 minutes to allow the filter to clean the hydraulic system. 12. Stop the engine and check the hydraulic reservoir oil level. Fill as needed.

CAUTION Do not operate the loader in any position other than while in the operatorâ&#x20AC;&#x2122;s seat with the seat belt securely fastened. 13. Sit in the loader and activate the boom and bucket pedals intermittently for 3 minutes at 1/2 throttle to bleed air from the system. 14. Engage the transmission belt clutch. 15. Slowly move the steering levers to activate the transmissions. 16. Continue to operate the system slowly with no load on the wheels until they turn smoothly and positively indicating trapped air has been bled back to the reservoir. 17. Stop the engine and check the hydraulic oil level in the reservoir. Fill as needed.

29-45

19994852

106

SECTION 29 - HYDROSTATIC TRANSMISSION 18. Check all line connections for leaks and tighten if necessary. 19. Run the loader for an additional 30 minutes while it is on blocks. 20. Change the hydraulic filter and clean the gear pump strainer.

NOTE: Do not change the hydraulic oil again unless it is contaminated with water or solvent. The filter has already started cleaning the new oil. Changing oil will restart the cleaning process. 21. Check for proper neutralizer adjustment to eliminate transmission creeping. 22. The loader can now be put into full operation.

29-46

SECTION 29 - HYDROSTATIC TRANSMISSION

CHARGE CHECK VALVE Op. 29 100 36 Removal 1. Remove the belly pan, 1, from the bottom of the loader by removing the nine mounting bolts.

1 A1459-04

107 2. Loosen the hydraulic return line, 1, and remove the fitting, 2. 3. Unscrew the check valve, 3, from the elbow fitting, 4.

Inspection Inspect the check valve for dirt buildup. The check valve is factory set to 5.5 bar (80 PSI) and is not serviceable. The valve must be replaced if malfunctioning. The current replacement check valve is square in shape (part #9622040), replacing the previous hexagonal design.

Installation 1. Screw the check valve, 3, into the elbow fitting, 4. 2. Install the fitting, 2, and hydraulic line, 1. Make sure the arrow points to the reservoir. 3. Install the belly pan on the bottom of the loader with the nine mounting bolts.

29-47

4 19994853

108

SECTION 29 - HYDROSTATIC TRANSMISSION Op. 29 100

STEERING ADJUSTMENTS If the loader creeps or if the transmission makes noise when the arms are not being stroked, a neutralizing adjustment is required. 1. Remove any attachment such as a bucket or fork from the loader boom. 2. Raise the boom above the boom lock pins.

CAUTION Do not work under a raised boom unless it is properly supported on the boom lock pins. Do not work under a raised boom unless attachments have been removed from the loader attaching plate. 3. Support the loader with blocks, 1 and 2, at a good working height (about 300 to 350 mm, or 12″ to 14″). The wheels need not be removed. 4. Place the service/operate switch in the “Service” position.

19985896

2 109

5. Remove six bolts, 1, and remove the right fender assembly between the cab and the chain case.

19993691

2 110

29-48

SECTION 29 - HYDROSTATIC TRANSMISSION 6. Remove six bolts, 1, and remove the left fender assembly between the cab and the chain case.

19993688

2 111

7. Remove the seat. 8. Remove the four retaining bolts, 1, on each side shield and remove the shields.

19993689

112 Op. 29 130 06 Transmission neutralizing adjustment 1. Remove the dampener, 1, by removing the retaining bolts, 2. 2. Loosen the two adjustment nuts, 3, until the tension is just removed from the springs, 4. Be sure there is no slack in the springs.

2 3

CAUTION Be sure the wheels are clear of the ground. Remain clear of the wheels, the engine area, and all belts during adjustments. G97-388

3. Start the engine and engage the traction drive. 4. Tighten the adjustment nuts until no wheel creep is observed. NOTE: In the neutral position the arm, 5, should be vertical. 5. Install the neutralizer after adjustment is complete. 6. Repeat the adjustment for the other side of the loader. IMPORTANT: If the transmission neutralizing adjustment has been performed, adjust the control levers for vertical alignment.

29-49

5 113

SECTION 29 - HYDROSTATIC TRANSMISSION Control lever vertical adjustment 1. After the transmission neutralizing adjustment, check the control lever clearance in the full back position. The control lever should have a minimum clearance of 3.175 mm (0.125â&#x20AC;ł) at 1. 2. If the clearance is not within specification, adjust the control lever as follows.

A3948-06

114 3. Move the control lever to the full back position and adjust the position of the yoke, 1. 4. Loosen the jam nuts, 2, and move the yoke on the shaft, 3, until the control lever maintains clearance. IMPORTANT: If the control levers have been adjusted, perform the control lever stop bolt adjustment.

9247-02

115

29-50

SECTION 29 - HYDROSTATIC TRANSMISSION Control lever stop bolt adjustment 1. The adjustable transmission cam plate arm stop bolts prevent overloading of the internal transmission stops. IMPORTANT: If the stop bolts are not accurately set, the transmission cam plate shaft and the rubber connector in the control linkage can be damaged. 2. With the control lever in the full forward position, adjust the forward stop bolt, 1, to just touch the bottom of the control lever. 3. Release the control lever and turn the stop bolt out 1/2 turn. Tighten the jam nut. NOTE: The additional 1/2 turn ensures the stop bolts set the limit of control lever movement, not the transmission. 4. With the control lever in the full reverse position, adjust the reverse stop bolt, 2, to just touch the bottom of the control lever. 5. Release the control lever and turn the stop bolt out 1/2 turn. Tighten the jam nut. NOTE: The additional 1/2 turn ensures the stop bolts set the limit of control lever movement, not the transmission. 6. Install the support plate and install the bolts. 7. Install the seat belt bracket and the support plate bolts. 8. Reconnect the seat switch harness connector and install the operatorâ&#x20AC;&#x2122;s seat. 9. Remove the blocks and lower the loader to the ground. 10. Place the service/operate switch in the â&#x20AC;&#x153;Operateâ&#x20AC;? position. 11. Start the engine and allow it to warm up for several minutes. 12. With the engine speed at full power, engage the traction drive. The loader should not creep. 13. Push the control levers to full forward. The loader should move forward in a straight line. If not, turn the faster side control lever stop bolt out. 14. Retest the forward full throttle settings. 15. Place the control levers in the full reverse position. The loader should move forward in a straight line. If not, turn the faster side control lever stop bolt out. 16. Retest the reverse full throttle settings. 17. Install the right and left fenders.

29-51

9247-02

116

SECTION 29 - HYDROSTATIC TRANSMISSION

LABOR GUIDE

The following labor amounts are listed as a guide only. Working conditions and experience will vary the amount of time it actually takes to complete each job. Job

Labor-Hours

Check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Hydrostatic system testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Hydrostatic pump, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 Hydrostatic pump, overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Hydrostatic pump control shaft seal, replace on loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 Hydrostatic pump trunnion shaft seal, replace on loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Hydrostatic pump end cap, replace on loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Hydrostatic motor, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 Hydrostatic motor, overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Hydrostatic motor shaft seals, replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Steering controls and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3

29-52

SECTION 33 -- BRAKES AND CONTROLS Chapter 1 -- Parking Brake CONTENTS Section

Description

Page

33 000

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-4

33 110

Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-5 Labor Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-7

33-1

SECTION 33 - BRAKES AND CONTROLS Op. 33 000

GENERAL INFORMATION LS120 and LS125 skid steers have a mechanical parking brake. The parking brake should be engaged when parking the loader on an incline and before exiting the loader.

WARNING

Never exit the skid steer without first engaging the parking brake. Failure to do so could result in injury or machine damage if the skid steer should roll. The parking brake control handle is located to the right of the operator. The brake control handle is shown in the engaged position, 1. Raising the control level to the front of the loader, 2, disengages the brake. The parking brake locks the wheels to prevent movement while the unit is stationary. The parking brake linkage connects to the hydrostatic control levers, forward and reverse, to prevent stroking of the controls when the brake is engaged. When engaged, the linkage locks into the sprocket-type discs on the hydrostatic motor shafts, preventing shaft rotation and wheel movement. IMPORTANT: Never try to operate the unit with the parking brake engaged. Damage to the hydrostatic motor may result.

A1455-04

33-2

SECTION 33 - BRAKES AND CONTROLS

PARKING BRAKE SYSTEM TROUBLESHOOTING PROBLEM Parking brake will not hold loader

POSSIBLE CAUSE Park brake not engaged Brake not adjusted properly Handle not operating or latching Loose brake linkage

CORRECTION Engage parking brake Adjust parking brake Check handle components; repair or replace Inspect and repair linkage

Parking brake will not release

Brake not adjusted properly Handle not operating properly

Adjust parking brake Check handle components; repair or replace

Parking brake handle will not move or release

Handle not operating properly

Check handle components; repair or replace Check and repair linkage

Control linkage not moving Grinding noise when operating

Handle not releasing properly Brake not adjusted properly

33-3

Check handle components; repair or replace Adjust parking brake

SECTION 33 - BRAKES AND CONTROLS

TESTING Pre-test instructions: * Operator in seat with seat belt buckled. * Engine running at 1500 RPM. * Park brake disengaged position.

STEP

TEST

RESULT

PROBABLE CAUSE AND CORRECTION

Push both drive controls forward equally and loader should move without restriction.

YES NO

Brake system OK. Parking brake not releasing, check control handle. If OK go to next step.

Parking brake linkage not free, check for loosen or binding linkage. If OK go to next step.

Parking brake not releasing; check adjustment.

Pre-test instructions: * Operator in seat with seat belt buckled. * Engine running at 1500 RPM. * Park brake engaged position.

STEP

TEST

RESULT

PROBABLE CAUSE AND CORRECTION

Push both drive controls forward equally and loader should not move.

NO YES

Parking brake OK. Parking brake not adjusted properly. If OK go to next step.

Parking brake linkage loose or broken.

33-4

SECTION 33 - BRAKES AND CONTROLS Op. 33 110

PARKING BRAKE Adjustment The parking brake control handle, 1, is shown engaged. Rotate the handle up and to the front to disengage it. To adjust the parking brake linkage, loosen the jam nut, 2, and adjust clevis, 3, to get full rod into the sprockets.

2 3

A1455-04

2 Adjust nut, 1, to obtain the proper spring length of 44 mm (1-3/4â&#x20AC;ł) with the park brake disengaged. NOTE: After the linkage is adjusted, disengage the parking brake and check the clearance between rod, 2, and the sprockets at 3.

1 2

3 9247-10

3 The brake mechanism should fully engage the teeth, 1, of the hydrostatic motors. If the brake engages one motor, the brake will engage the other motor teeth as soon as the motor is activated. When disengaged, the rod, 2, should clear the sprockets, 3, with room to spare.

19994889

2 4

33-5

SECTION 33 - BRAKES AND CONTROLS With the parking brake engaged, adjust bolt, 1, for engagement into the hydrostatic control handle linkage, 2. This linkage prevents the movement of the hydrostatic control levers when the parking brake is engaged.

2 1

9247-04

5 On each side, the bolt, 1, should fit into the slot, 2, to prevent lever movement. The bolt adjustment is inside the slot, 3.

1 30994965

33-6

SECTION 33 - BRAKES AND CONTROLS

LABOR GUIDE

The following labor amounts are listed as a guide only. Working conditions and experience will vary the amount of time it actually takes to complete each job. Job

Labor-Hours

Parking brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5

33-7

SECTION 33 - BRAKES AND CONTROLS

33-8

SECTION 35 -- HYDRAULIC SYSTEM Chapter 1 -- Valves, Gear Pump, and Cylinders CONTENTS Section 35 000

Description

Page

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-2 Hydraulic System Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-3 Changing Buckets and Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-4 Resting the Boom on Lockpins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-8

35 710 02

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-9

35 724 50

Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-10

35 724 54

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-11

35 710 10

Hydraulic Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-18

35 710 20

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-18

35 730 10

Bucket Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-24

35 730 13

Bucket Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-25

35 710 10

Boom Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-29

35 730 18

Boom Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-30 Auxiliary Hydraulics Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-35 Auxiliary Hydraulics Handle Control/Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-43

35 705 05

Filter Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-45 Boom Lockout Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-46 Wiring Harnesses and Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-48 Labor Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-49

35-1

SECTION 35 - HYDRAULIC SYSTEM Op. 35 000

GENERAL INFORMATION

7 2 3 8

6 19994681

1 30.2 l/min. (8 US gpm) @3600 RPM to the master control valve, 4. The master relief valve, 5, limits maximum system pressure at 110 bar (1600 PSI). The master control valve supplies oil to the boom, 6, or bucket, 7, cylinders on demand. Return oil passes through the open master control valve and is filtered by the no-bypass type 10 micron filter, 8, before returning to the chain case reservoir.

The loader lift system consists of the oil strainer, gear pump, control valve, boom cylinders, and bucket cylinders. The chain case reservoir on either side of the loader provides the oil supply for the gear pump. A cross tube connects the two final drive cases to keep the oil levels even. The gear pump, 1, pulls oil from the chain case reservoir cross tube, 2, through the #100 mesh strainer, 3. The oil is pumped from the gear pump at

35-2

SECTION 35 - HYDRAULIC SYSTEM

HYDRAULIC SYSTEM COMPATIBILITY There are seven questions that must be answered before adapting attachments that require hydraulic oil power. 1. What is the hydraulic pressure requirement, minimum and maximum? Are they higher than the maximum pressure of the model? Model

Maximum Pressure

LS120

108 bar (1600 PSI)

LS125

108 bar (1600 PSI)

2. What is the hydraulic oil flow requirement? Is it more than the highest total flow rate of the skid-steer loader model? Model

Standard Hydraulics

High Flow Hydraulics

LS120

30.2 l/min. (8 GPM) @3600 RPM

N/A

LS125

30.2 l/min. (8 GPM) @3600 RPM

N/A

3. Will the attachment accept oil flow in both directions? If “YES”, nothing is required. If “NO”, install a check valve or cross into the attachment return line to prevent reverse oil flow to the attachment. Examples: Backhoes and trees spades with a separate control valve do not accept oil flow in both directions. 4. Must the attachment “free wheel” to a stop? If “YES”, a crossover relief connection must be installed on the attachment side to allow the attachment to “free wheel” to a stop after the skid steer hydraulics is turned off. If “NO”, nothing is required. Examples: Snow blowers must “free wheel” to a stop.

35-3

5. Will the attachment accept hydraulic system backpressure? If “YES”, nothing is required. If “NO”, the attachment will not function properly on a New Holland skid-steer loader. Normal backpressure for New Holland skid-steer loaders is between 200 to 250 PSI. Examples: Post drivers; some breakers; and some hand held hydraulic tools do not accept system backpressure. If all the skid-steer loader oil flow is not required to operate an attachment (e.g., shaver post driver), a flow divider can be installed into the hydraulic oil circuit on the attachment. The flow divider sends the required oil flow to the attachment and the remainder back to the normal skid-steer loader hydraulic circuits. 6. Does the attachment have a separate case drain oil line? If “NO”, nothing is required. If “YES”, install a separate case drain line to return the attachment case drain oil directly to the hydraulic oil reservoir. Example: Cold planners have a separate case drain oil line. NOTE: Most attachment case drains will not accept backpressure and must drain directly into the reservoir. 7. Does the attachment require circuit relief in the bucket circuit? If “NO”, nothing is required. If “YES”, install a bucket circuit relief valve on front of the control valve. Example: Some mini-backhoes attach like a bucket, and require bucket circuit relief.

SECTION 35 - HYDRAULIC SYSTEM

CHANGING BUCKETS AND ATTACHMENTS Rapid changing of boom-mounted attachments is made possible by the unique mounting system used on LS120 and LS125 skid steers. A pivoting mounting plate, 1, is supplied with the loader as standard equipment and remains attached to the boom. The hydraulic cylinder pins are not removed to change attachments. All attachments mate with the mounting plate, using a full length saddle, 2, which engages the top of the mounting plate.

19994961

CAUTION Attachments used with this loader must be compatible with the mounting system.

To mount an attachment, hydraulically tilt the mounting plate, 1, forward while guiding the crest of the mounting plate under the attachment saddle, 2.

1 G97-376

3 BE SURE TO REMOVE THE RETAINING PINS BEFORE ATTEMPTING TO MOUNT THE ATTACHMENT. As the mounting plate is hydraulically raised and rolled back, the back surface, 1, of the attachment comes to a rest flat against the front surface of the mounting plate, 2.

1 G97-412

35-4

SECTION 35 - HYDRAULIC SYSTEM When the attachment is fully supported, lower the boom until the boom is down on the loader frame. Roll the attachment out, stopping with the front edge about 50 mm (2â&#x20AC;ł) from the ground. Turn off the engine. Exit the loader. Install two pins, 1, one each side, and retain with hairpin cotter pins.

DANGER When attaching a bucket or attachment to the attachment mounting plate, exit the loader after stopping the engine to install the retaining pins. Never reach under an unsupported boom or attachment to install or remove pins. To remove an attachment, lower the attachment to the ground, stop the engine, and exit the loader. Remove the retaining pins from the mounting plate. Fasten the seat belt and start the loader, tilting the bucket forward so that the cutting edge is resting on the ground. Continue tilting the mounting plate forward and back away from the attachment at the same time.

CAUTION Drive slowly over rough ground and on slopes. Be alert for holes, ditches, and other irregularities that could overturn the loader. Avoid steep hillside operation which could overturn the loader. Do not work under overhangs, electric wires, or where there is danger of a slide. Wear an approved safety hat when operating the loader, and while in any work area.

35-5

G97-385

1 5

SECTION 35 - HYDRAULIC SYSTEM

A3948-04

35-6

SECTION 35 - HYDRAULIC SYSTEM

HYDRAULIC SYSTEM Control Valve System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open center Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two spool with power beyond capabilities Relief Valve Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 bar (1600 PSI) Retaining Bolts, Grade 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 - 24 N⋅m (16 - 18 ft. lbs.) Hydraulic Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.2 l/min. (8 US gpm) @3600 RPM Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 cm3 (0.512 cu.in.) per rev. Pump housing bolt torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 - 24 N⋅m (16 - 18 ft. lbs.) Boom Cylinder Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . New Holland Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double-acting Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.8 mm (2.0″) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 666.75 mm (26.25″) Rod Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 mm (1.25″) Piston Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 N⋅m (155 ft. lbs.) Bucket Cylinder Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . New Holland Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double-acting Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.63 mm (1.875″) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304.8 mm (12.00″) Rod Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2 mm (0.875″) Piston Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 N⋅m (82 ft. lbs.)

35-7

SECTION 35 - HYDRAULIC SYSTEM

HYDRAULIC SYSTEM TROUBLESHOOTING PROBLEM Engine lacks power

POSSIBLE CAUSE Carbon buildup in cylinder heads Auxiliary boom hydraulics control partly engaged

Boom arms will not raise or raise slowly

Low oil flow from pump Low relief valve pressure Seat switch unplugged Control linkage binding Bucket is overloaded Cylinder shafts are bent Cylinder seals are leaking Boom arms are binding at pivot points Bucket tilt valve spool is not returning to center position Incorrect oil used in hydraulic system

Bucket will not tilt back or tilts back slowly or tilts forward slowly

Low oil flow from pump Pump wear or damage Valve spool is not in correct position Cylinder shafts are bent Cylinder seals are leaking Bucket is overloaded Low relief valve pressure Incorrect oil used in hydraulic system

35-8

CORRECTION Remove engine and cylinder heads to clean carbon deposits to restore power Return control to neutral and lock in position when not in use Clean inlet screen Replace relief valve cartridge Plug in wiring at seat or solenoid Free linkage Reduce load Replace shafts Repair cylinders Locate and correct Correct binding control linkage. Spool centering spring or spacers are damaged Change oil Clean inlet screen Check pump flow. Replace if necessary Adjust control linkage. Spool centering springs or spacers are damaged Replace Repair cylinders Reduce load Check pressure and replace relief cartridge if pressure is not correct Change oil

SECTION 35 - HYDRAULIC SYSTEM

HYDRAULIC SYSTEM TESTING Op. 35 710 02 Main System Pressure Check 1. Install a 207 bar (3000 PSI) capacity pressure gauge in the bucket line at 1. 2. Start the engine and run it at full throttle. 3. Depress the toe end of the bucket pedal until the system bypasses. 4. Pressure should be 110 - 117 bar (1600 - 1700 PSI) when hydraulic oil temperature is 49° C (120° F). NOTE: The control valve can be serviced without removing the control valve from the loader.

1 A3948-03

5. Replace the main system relief valve, 1, if system pressure is not within specifications. NOTE: The relief valve is not serviceable. Replace a malfunctioning valve with a new valve marked 110 bar (1600 PSI).

1 19994891

8 Control Valve Operational Test The control valve directs oil flow from the gear pump to the boom and bucket cylinders. The bucket circuit has priority over the boom circuit resulting in boom slow down or stop if the bucket pedal is operated while the boom is moving. The boom has a detent or “float” position. When the toe end of the pedal is pushed the spool will “lock in” the valve until it is manually released by pushing the back end of the pedal.

35-9

SECTION 35 - HYDRAULIC SYSTEM

CONTROL VALVE Op. 35 724 50 Removal 1. Remove the belly pan, 1, from the bottom of the loader by removing the nine mounting bolts.

1 A1459-04

9 2. Disconnect the boom and bucket linkages by removing the cotter pins, 1.

30994694

10 3. Identify and disconnect all the hydraulic lines, 1, on the control valve.

19994676

35-10

SECTION 35 - HYDRAULIC SYSTEM 4. Remove the two through bolts, 1, securing the control valve to the frame cross bar, 2.

30994878

12 Op. 35 724 54 Disassembly 1. Remove the port fitting and elbows from the control valve ports. 2. Remove the master relief valve, 1.

1 19994891

13 Lift Check Valves 3. Lift check valves prevent any drop of the boom or the bucket when shifting the boom to “raise” or the bucket to “roll back”. Remove the two plugs, 1, from the check valves, 2.

1 19994892

35-11

SECTION 35 - HYDRAULIC SYSTEM 4. Inspect the check valve seats, 1, the plungers, 2, and the springs, 3, for damage and replace parts as required. 5. Use emery cloth to repair minor damage to the seat. 6. Install the plunger, spring, and valve plug using a new O ring.

2 19994893

15 Spools 7. Oil is directed through the control valve to the ports by means of two spools that extend through the housing. The bucket spool, 1, controls the bucket cylinders and the boom spool, 2, controls the boom cylinders. Oil enters the valve at the middle port, 3, on one side and exits the valve from the opposite port, 4. IMPORTANT: The interior of the control valve is extremely sensitive to foreign matter. Be sure the outside of the control valve is thoroughly clean before exposing the internal parts.

3 1

2 19994890

16 8. Remove the two plugs, 1, springs, 2, and detent balls, 3, from the boom detent cap, 4. 9. Remove the two cap screws, 5, from each cap and remove the caps.

5 4

19994894

35-12

SECTION 35 - HYDRAULIC SYSTEM IMPORTANT: Paint or corrosion on the exposed portions of the spools can contaminate the internal porting of the valve. Be sure the exposed portions of the spools are free of paint or corrosion before removing the spools.

10. Pull the spools out of the valve at the centering spring, 1, end of the spools.

1 19994895

18 11. Inspect the spool surfaces, 1, for scoring that could cause leakby. NOTE: If the spools are scored beyond repair, replace the control valve. Individual spools are not replaceable units. 12. Inspect the #10 centering spring screw, 2. If it is damaged or broken, replace with part #281070 and use Loctite 242 on the threads.

19994896

19 13. Remove the O rings, 1, at the front of the valve. 14. Examine the O ring seating areas, 2, for burrs or scoring. Remove minor damage with emery cloth.

1 2

19994897

35-13

SECTION 35 - HYDRAULIC SYSTEM 15. Remove the O rings, 1, at the rear of the valve. 16. Examine the O ring seating areas, 2, for burrs or scoring. Remove minor damage with emery cloth.

1 2

19994898

21 Reassembly 1. Install new O rings, 1, in the front of the control valve.

19994897

22 2. Install new O rings, 1, in the rear of the control valve.

19994898

35-14

SECTION 35 - HYDRAULIC SYSTEM 3. Install the boom spool, 1, on the left side of the control valve. 4. Install the bucket spool, 2, on the right side of the control valve. NOTE: If either spool binds in the housing, rotate the spool 180Â° and check for binding. If binding still occurs, replace the control valve.

2 19994895

24 5. Install the bucket spool cap, 1, and the boom spool detent cap, 2. 6. Place the detent balls, 3, the springs, 4, and the plugs, 5, in each side of the boom spool detent cap.

19994894

25 7. Install the lift check valve poppets, 1, and springs, 2. 8. Install the lift check valve plugs, 3, with new O rings.

3 19994892

35-15

SECTION 35 - HYDRAULIC SYSTEM 9. Install the master relief valve cartridge, 1, with a new O ring. 10. Install all port fittings and elbows removed during disassembly.

1 19994891

27 Re-Installation 1. Install the control valve, 1, on the frame crossbar, 2, with the two through bolts, 3, and nuts.

30994878

28 2. Reconnect all the hydraulic lines, 1, on the control valve.

19994676

35-16

SECTION 35 - HYDRAULIC SYSTEM 3. Connect the boom and bucket linkages with the cotter pins, 1. 4. Install the belly pan on the bottom of the loader with the nine mounting bolts.

30994694

35-17

SECTION 35 - HYDRAULIC SYSTEM

HYDRAULIC GEAR PUMP Op. 35 710 10 Removal 1. The gear pump is located below and between the two transmission pumps under the seat. 2. Remove and cap the suction line, 1, and the pressure line, 2. Cap the hydraulic supply line and the pump ports. NOTE: The pump can be removed more easily from the underside of the loader by removing the belly pan.

1 19985898

31 3. Remove the two nuts and bolts holding the sheave hub, 1. 4. Remove the pump from the sheave hub.

19991593

32 Op. 35 710 20 Disassembly 1. Mark the housing, 1, on an angle to ensure correct reassembly. Place the mark on the output side of the pump for easy identification. 2. Clean the pump thoroughly before disassembly. 3. Remove the key, 2, from the shaft.

19994880

35-18

SECTION 35 - HYDRAULIC SYSTEM 4. Clamp the pump in a soft jaw vise with the shaft pointing down. 5. Remove the four tie bolts, 1.

30994949

34 6. Remove the pump from the vise. 7. Bump the pump drive gear, 1, against a wooden block or tap the shaft with a soft faced hammer to open the pump. NOTE: The body of the pump will remain with either the front or back cover because of dowel pins. 8. Pull out the idler gear, 2. 9. Place the drive gear assembly, 1, in the bearing of the cover the body remains with, and tap gently with a soft face hammer to separate the body from the cover.

19994882

35 10. Removal of the two dowel pins, 1, is not required. 11. Remove the O rings from the front cover, 2, and the back cover, 3. Discard the old O rings.

19994883

2 36

35-19

SECTION 35 - HYDRAULIC SYSTEM 12. Remove the wear plate, 1, the hard fiber heat shield, 2, the pressed paper gasket, 3, and the black rubber diaphragm, 4. Discard the old seals if using a repair kit.

19994884

4 37

13. Remove the shaft seal, 1, and discard it.

19994885

38 Parts Inspection 1. Thoroughly clean all pump parts. NOTE: Remove minor nicks and burrs with emery cloth. 2. Inspect the drive gear shaft, 1, for a broken keyway under the gear. Examine the splines for wear. 3. Inspect the drive gear and the idler gear shafts at the bearing points and seal areas for rough surfaces or excessive wear. NOTE: Each gear and shaft assembly may be replaced separately. Replacement shafts and gears are only available as assemblies. 4. Inspect gear faces, 2, for scoring or excessive wear. Replace the assembly if necessary. 5. Check the snap rings, 3, on each side of the gears. Be sure the snap rings are not broken or missing and that they are seated in the groove to maintain gear position on the shaft.

19994884

2 39

35-20

SECTION 35 - HYDRAULIC SYSTEM 6. Check for scoring on the face of the back cover, 1. Replace the back cover if wear exceeds 0.038 mm (0.0015â&#x20AC;ł) or if scratches can be felt with a fingernail. 7. Check the bushings, 2, in the front and back covers for wear. Replace the cover if bushing wear is detected.

19994882

19994887

40 8. Check the gear pockets, 1, of the body for scoring or wear. Replace the body if worn.

19994883

41 Reassembly 1. Push a new black rubber diaphragm,1, into the grooves on the front cover with the hollow side down. Be sure the hole, 2. is on the output side of the pump. 2. Push the diaphragm into the groove with a dull tool to avoid damage.

19994886

35-21

SECTION 35 - HYDRAULIC SYSTEM 3. Press the thin gasket, 1, on top of the diaphragm. The hole on the long side is aligned with the hole in the diaphragm. 4. Push the hard fiber heat shield, 2, on top of the gasket, again aligning the holes. 5. Place the wear plate, 3, on top of the heat shield with the bronze side up. Make sure all the holes, 4, are aligned at 5. The entire wear plate must fit inside the raised rim of the front cover.

5 4 19994887

43 6. Install the O ring, 1, in the groove around the wear plate. NOTE: The wear plate must fit inside the raised rim of the front cover assembly. 7. Dip the shaft and gear assemblies in oil. 8. Install the drive gear shaft, 2, long end in the front cover bushing. 9. Install the idler gear, 3, in the other front cover bushing. 10. Install the two dowel pins, 4, if removed, in the body, 5, with the pins extending equally to either side of the body. 11. Apply a thin coat of heavy grease to both milled faces of the body. Slip the body over the gears onto the front plate. IMPORTANT: The notch, 6, aligns with the holes, 7, in the diaphragm, gasket, heat shield, and wear plate.

7 6

19994883

1 44

12. Install the O ring, 1, in the back cover, 2. 13. Slide the back cover over the gear shafts until the dowel pins, 3, are engaged.

3 1

3 2

19994882

35-22

SECTION 35 - HYDRAULIC SYSTEM 14. Install the four cover bolts, 1, and tighten to 21 24 N⋅m (16 - 18 ft. lbs.). 15. Oil the shaft seal. Work the shaft seal, 2, over the gear drive shaft, 3, being careful not to cut the rubber sealing lip. 16. Seat the shaft seal by tapping it with a soft faced hammer. 17. Rotate the pump shaft by hand with pliers. The pump should have a small amount of drag, but should turn freely after a short period of turning.

2 3

19994880

46 Re-Installation 1. Make sure the pump shaft, 1, goes into the solid part of the sheave, 2. The clearance between the pump housing and the pulley sheave at 3 should be 1.25 mm (0.050″). 2. Make sure the clamp half, 4, aligns correctly with the pulley sheave. 3. Install the bolts and nuts and tighten evenly side to side. Tighten the bolts to 20 - 24 N⋅m (15 - 18 ft. lbs.).

3 1

19994988

47 4. Attach the suction line, 1, and the pressure line, 2.

19985898

35-23

SECTION 35 - HYDRAULIC SYSTEM

BUCKET CYLINDER Op. 35 730 10 Removal

WARNING Fluid under pressure may have sufficient force to penetrate the skin and cause serious personal injury. If injured by escaping fluid, obtain medical assistance immediately. Serious infection or reaction can occur if medical treatment is not administered immediately. Always protect the skin and eyes from escaping fluid under pressure. Before disconnecting lines, hoses, or fittings, be sure that all pressure in the system has been relieved. Before applying pressure to a system, be sure all connections are tight and all fittings, lines, and hoses are undamaged. Gauges, gauge fittings, and hoses must have operating pressure ratings 25 percent higher than the highest pressure of the system. Never adjust relief valves to higher pressure relief settings than specified by the equipment manufacturer. 1. Remove any attachment. 2. Lower the boom to rest on the frame. Lower the front edge, 1, of the attachment mounting plate to the ground and turn the engine OFF. 3. Turn the ignition ON and push both the boom and tilt hydraulic foot pedals up and down to relieve any hydraulic pressure. NOTE: If the auxiliary boom hydraulic kit #802763 is installed, work the auxiliary control handle up and down while working the foot pedals to relieve hydraulic pressure in the auxiliary lines. 4. Turn the ignition switch OFF. 5. Remove the lock bolt, 2, and pivot pin, 3, at the bottom of the bucket cylinder.

2 1 3

19994961

35-24

SECTION 35 - HYDRAULIC SYSTEM 6. Mark the hydraulic hoses, 1, for correct reassembly. Disconnect and cap the hydraulic hoses. 7. Remove the lock bolt, 2, and pivot pin, 3, at the top of the bucket cylinder.

1 1

30994679

50 Op. 35 730 13 Disassembly 1. Clean the outside of the cylinder thoroughly. 2. Push the cylinder rod, 1, into of the barrel, 2, slowly to drain the oil. 3. Remove the set screw, 3, to unlock the bearing assembly.

1 19994907

51 4. With the bearing assembly, 1, unlocked, push the bearing assembly 25 - 50 mm (1â&#x20AC;ł - 2â&#x20AC;ł) into the barrel to expose the lock ring, 2. 5. Use a screwdriver to push the lock ring out of the barrel groove, 3. 6. Pivot the lock ring and remove it from the barrel. IMPORTANT: Examine the barrel groove area for scratches, nicks, or burrs. Remove any imperfections with emery cloth before removing the bearing and piston assembly or installing new seals. Cuts to the seals will cause leakage. 7. Secure the barrel in a vise and pull steadily on the rod to remove the rod assembly.

35-25

1 2

3 19994908

SECTION 35 - HYDRAULIC SYSTEM 8. Remove the locknut, 1, from the piston rod, 2.

19994909

53 9. Remove the piston head, 1, and the crown seal, 2, from the cylinder rod, 3.

1 3

19994910

54 10. Slide the bearing assembly off the cylinder rod. 11. Remove the O ring, 1, back-up ring, 2, the wiper seal, 3, and the shaft hydraulic seal, 4.

2 3

4 19994911

35-26

SECTION 35 - HYDRAULIC SYSTEM Reassembly 1. Inspect the cylinder rod, the bearing bore and the piston for scratches, nicks, or other damage that could cut seals or cause oil leakage. Pay particular attention to O ring and seal seats. Remove any scratches or shallow scores with emery cloth. 2. Replace all seals using Seal Repair Kit. 3. Thoroughly clean and dry all parts. Lightly oil all metal parts. 4. Install a new shaft hydraulic seal, 1, and new wiper seal, 2, into the bearing, 3. 5. Install a new backup washer, 4, and a new O ring, 5, with the backup washer toward the seal end of the bearing.

3 1

19994912

56 6. Install a new piston crown seal, 1. Carefully work it over the piston and into the groove, 2. The crown seal will stretch as it is installed. Use a ring compressor or hose clamp to compress the seal.

19994910

57 7. Liberally oil the inside of the bearing, 1, and slide it onto the cylinder rod with the seal end toward the threaded end of the piston rod. 8. Install the piston, 2, and locknut, 3, on the cylinder rod and tighten the locknut to 107 Nâ&#x2039;&#x2026;m (82 ft. lbs.). 9. Oil the piston head liberally and place it in the cylinder, 4. 10. Slide the piston into the cylinder until the bearing, 1, can be inserted.

19994909

35-27

SECTION 35 - HYDRAULIC SYSTEM 11. Push the bearing, 1, in until the retaining ring, 2, can be replaced in the groove, 3. 12. Install the retaining ring in the cylinder groove.

1 2

3 19994908

59 13. Pull the piston and rod assembly out far enough to seat the bearing, 1, against the retaining ring, 2, in the cylinder groove. Make sure the bearing is nearly flush with the end of the cylinder. 14. Install a 1/4″ set screw, 3, and tighten it securely against the groove on the bearing.

1 2

3 19994913

60 Re-Installation 1. Coat the pivot pins with anti-seize grease such as “Never-Seez” or “Moly-Kote GN” paste. Position the cylinder in place and slide the pivot pins, 1, through the boom and attachment plate at each end of the hydraulic cylinder. Install the lock bolts, 2, and tighten to 35 N⋅m (25 ft. lbs.). 2. Install the hydraulic lines, 3, to the proper ports.

3 3

30994679

35-28

SECTION 35 - HYDRAULIC SYSTEM

BOOM CYLINDER Op. 35 710 10 Removal

WARNING Fluid under pressure may have sufficient force to penetrate the skin and cause serious personal injury. If injured by escaping fluid, obtain medical assistance immediately. Serious infection or reaction can occur if medical treatment is not administered immediately. Always protect the skin and eyes from escaping fluid under pressure. Before disconnecting lines, hoses, or fittings, be sure that all pressure in the system has been relieved. Before applying pressure to a system, be sure all connections are tight and all fittings, lines, and hoses are undamaged. Gauges, gauge fittings, and hoses must have operating pressure ratings 25 percent higher than the highest pressure of the system. Never adjust relief valves to higher pressure relief settings than specified by the equipment manufacturer. 1. Lower the boom to rest on the frame. Remove any attachment. 2. Lower the attachment mounting plate front edge to rest on the ground. Turn the engine OFF. 3. Turn the ignition ON and push both the boom and tilt hydraulic foot pedals up and down to relieve any hydraulic pressure. NOTE: If the auxiliary boom hydraulic kit is installed, work the auxiliary control handle up and down while working the foot pedals to relieve hydraulic pressure in the auxiliary lines. 4. Turn the ignition switch OFF. 5. Place an container under the cylinder hydraulic hoses to catch dripping oil. 6. Loosen and remove the rear cylinder port fitting, 1. 7. Loosen and disconnect the two rear hydraulic hoses, 2, lines to the boom cylinder. Cap the hydraulic lines. 8. Loosen and remove the line clamp bolts, 3.

1 30994899

35-29

SECTION 35 - HYDRAULIC SYSTEM 9. Loosen and disconnect the front cylinder port fitting, 1. Cap the hydraulic lines. 10. Remove the lock bolts, 2, and remove the pivot pins, 3. Remove the hydraulic cylinder.

1 2

30994957

63 Op. 35 730 18 Disassembly 1. Clean the outside of the cylinder thoroughly. 2. Slowly pull the cylinder rod, 1, out of the cylinder, 2, to drain the oil. 3. Push the rod back in.

19994900

64 4. Remove the set screw, 1, to unlock the bearing assembly, 2. 5. Push the bearing assembly into the cylinder about 25 - 50 mm (1â&#x20AC;ł - 2â&#x20AC;ł) to expose the lock ring, 3. 6. Push the lock ring out of the cylinder groove, 4, with a screwdriver. 7. Pivot the lock ring and remove it from the cylinder.

2 3

1 19994901

4 65

35-30

SECTION 35 - HYDRAULIC SYSTEM 8. Secure the cylinder in a vise and pull steadily on the cylinder rod to remove the rod assembly. IMPORTANT: Scratches or nicks can cut the cylinder seals during reassembly causing leaks. Smooth any nicks or scratches with emery cloth before reassembly.

9. Remove the locknut, 1, and the piston assembly, 2, from the rod.

19994902

66 10. Remove the wear ring, 1, and the crown seal, 2, from the piston. 11. Examine the piston, especially the crown (seal) groove, for wear or damage. 12. Correct any damage with emery cloth. 13. Replace the crown and wear ring during reassembly.

19994903

67 14. Remove the O ring, 1, the hydraulic seal, 2, and the wiper seal, 3, from the bearing, 4. 15. Inspect the bearing for wear or damage. Remove any nicks or scratches that could cut the seals with emery cloth. 16. Replace the seals during reassembly.

4 19994905

1 68

35-31

SECTION 35 - HYDRAULIC SYSTEM Reassembly 1. Thoroughly clean and dry all parts. 2. Inspect the cylinder walls for damage. Remove any nicks or scratches that could cut the seals with emery cloth. 3. Lightly oil metal parts before reassembly. 4. Install a new hydraulic seal, 1, inside the bearing. 5. Install a new wiper seal, 2, inside the bearing with the lip facing outward. 6. Install a new O ring, 3, in the groove on the outside of the bearing.

3 2

1 19994904

69 7. Install a new wear ring, 1, on the piston. 8. Slowly work a new crown seal, 2, onto the piston. 9. The crown seal will stretch as it is worked onto the piston. Use a hose clamp in a ring compressor to compress the seal back to its original size.

19994903

70 10. Liberally oil the inside of the bearing, 1, and slide it over the piston rod with the seal end of the bearing toward the pivot pin end of the rod. 11. Install the piston assembly, 2, on the rod. 12. Install the locknut, 3, to retain the piston on the rod. Tighten the locknut to 203 Nâ&#x2039;&#x2026;m (155 ft. lbs.). 13. Oil the piston head liberally and insert it in the cylinder, 4. 14. Slide the piston into the cylinder until the bearing, 1, can be inserted.

4 19994902

35-32

SECTION 35 - HYDRAULIC SYSTEM 15. Push the bearing, 1 in until the retaining ring, 2, can be installed in the groove, 3. 16. Pull the piston and rod assembly out far enough to seat the bearing against the retaining ring, with the retaining ring in the cylinder groove. Make sure the bearing is nearly flush with the end of the cylinder. 17. Install a 1/4″ set screw, 4, and tighten it securely against the groove on the outside of the bearing.

19994901

72 Re-Installation 1. Coat the pivot pins with anti-seize grease such as “Never-Seez” or “Moly-Kote GN” paste. Position the cylinder in place and slide the pivot pins, 1, through the boom at each end of the hydraulic cylinder. Install the lock bolts and tighten to 35 N⋅m (25 ft. lbs.).

A3947-09

73 2. Connect the front port line, 1, to the boom cylinder and tighten securely.

30994957

35-33

SECTION 35 - HYDRAULIC SYSTEM 3. Connect the rear port line, 1, to the boom cylinder and tighten securely. 4. Install the hydraulic line clamps, 2. 5. Connect the two hydraulic hoses, 3, to the boom hydraulic lines and tighten securely.

1 30994899

35-34

SECTION 35 - HYDRAULIC SYSTEM

AUXILIARY HYDRAULICS CONTROL VALVE Removal 1. Remove rear post tubes, 1, from ports “A” and “B”. 2. Remove the return tube, 2, between the “OUT” port and tee fitting, 3. Remove the supply tube, 4, between the “IN” port and power-beyond port, 5, on the main control valve. 3. Remove the valve and mounting plate assembly, 6, by loosening the two 5/16″ x 3/4″ carriage bolts and flange nuts, 7.

3 4

1 5 10996664

7 76

4. Remove the control valve mounting plate, 1, by removing the two bolts and flange nuts, 2. 5. Remove the fittings, 3, from the control valve, 4. The tubes, 5, are shown for reference purposes only.

5 3 3 1

2 10996662

4 77

Disassembly 1. Clean the outside of the valve thoroughly before disassembly.

20000699

35-35

SECTION 35 - HYDRAULIC SYSTEM 2. Loosen the detent plug, 1, several turns. Remove the two capscrews, 2, securing the detent plate, 3, to the valve body. Remove the detent plate from the valve body.

2 3

20000700

79 3. Remove the detent plug, 1, spring, 2, and pawl, 3, from the detent plate.

1 2 3

20000701

80 4. Compress the spring, 1, by forcing the spool one direction and remove the retaining ring 2. Slide the spool, 3, out the other end of the control valve body. Keep the spring compressed and slide the spring assembly parts out of the valve.

CAUTION The centering spring is under tension, and will release when the spring is removed.

3 1 20000702

2 81

35-36

SECTION 35 - HYDRAULIC SYSTEM 5. Retain all the pieces of the centering spring assembly - the snap ring, 1, the shallow bracket, 2, the spring, 3, the spacer, 4, and deep bracket, 5.

20000703

82 6. After removing the main control spool, 1, from the valve body, remove the O rings, 2, from the control valve.

2 2

20000704

1 83

7. Remove the lift check plug, 1, and side plug, 2, from the valve.

20000705

2 84

35-37

SECTION 35 - HYDRAULIC SYSTEM 8. Remove the lift check spring, 1, and plunger, 2, from the control valve. Remove and discard the O rings, 3, on the plugs.

2 1

20000706

3 85

Inspection 1. Inspect the main control spool for any nicks, scores, burrs on the machined surfaces, 1. Any score that you can feel with a fingernail requires valve replacement. Repair minor damage by buffing with crocus cloth. If the damage cannot be repaired by buffing, the component must be replaced. 2. Inspect the valve body, 2, castings for cracks or distortion. 3. Lube the control spool and insert it into the valve. The spool should move freely through the whole length of the valve.

20000704

86 4. Measure the length of the control spool spring, 1. The spring should be at least 36.8 mm (1.45â&#x20AC;ł).

1 20000703

35-38

SECTION 35 - HYDRAULIC SYSTEM 5. Measure the length of the lift check spring, 1. The spring should be at least 16.79 mm (0.661â&#x20AC;ł). 6. Make sure the hole, 2, in the lift check plunger is not clogged with debris.

2 1

20000706

88 7. Inspect the detent pawl for damage. Inspect the edges, 1, of the seal areas for nicks and scores. If there is any noticeable damage, replace the pawl. 8. Inspect the detent plate, 2, for any obvious damage or excessive wear. Clean the plate with a non-residue cleaning solvent and dry thoroughly. Check that the pintle, 3, inside the plate compresses and springs back. 9. Measure the detent spring, 4, length. The spring should be at least 15.95 mm (0.628â&#x20AC;ł).

4 2

20000701

89 Reassembly 1. Install new O rings, 1, on the lift check plunger the side plug. Install the lift check plunger, 2, spring, 3, and plug, 4, into the control valve, and tighten securely. Install the side plug, 5, and tighten securely.

2 3

4 20000706

1 90

35-39

SECTION 35 - HYDRAULIC SYSTEM 2. Install new O rings, 1, into the control valve. Lubricate the machined surfaces of the main control spool, 2, and slide the spool into the valve body.

1 1

20000704

91 3. Assemble all the pieces of the spring assembly - the deep bracket, 1, the spacer, 2, the spring, 3, and the shallow bracket, 4.

20000703

92 4. Compress the spring assembly, 1, and slide it into position with the deep bracket, 2, toward the middle of the spool. Slide the spool through the spring and brackets, and install the snap ring, 3, on the spool end.

2 1 20000702

3 93

35-40

SECTION 35 - HYDRAULIC SYSTEM 5. Insert the pawl, 1, and detent spring, 2, into the detent plate, 3. Install the detent plug, 4, and tighten securely.

3 4 2 1

20000701

94 6. Install the detent plate, 1, on the valve body with the two capscrews, 2, and lock washers. 7. Position the control spool, 3, in its neutral position. In the neutral position, the control spool should spin with little effort. 8. Rotating the control spool 90Â° will put the control valve with or without a detent position for continuous or cylinder operation.

3 2 20000700

1 95

Re-Installation 1. Loosely install and position fittings, 1, on the control valve, 2, as shown. Do not install tubes, 3, until the control valve is installed in the skid steer. These tubes are shown for reference purposes only. 2. Loosely install the control valve on the mounting plate, 4, using two bolts and flange nuts, 5.

10996662

35-41

SECTION 35 - HYDRAULIC SYSTEM 3. Install the valve and mounting plate assembly, 1, in the skid steer, using two 5/16″ x 3/4″ carriage bolts and flange nuts, 2. 4. Attach the supply tube, 3, between the “IN” port and power-beyond port, 4, on the main control valve. Attach the return tube, 5, between the “OUT” port and tee fitting, 6. 5. Attach tubes, 7, from rear post to ports “A” and “B”.

10996664

35-42

SECTION 35 - HYDRAULIC SYSTEM

AUXILIARY HYDRAULICS HANDLE CONTROL / CABLE Removal 1. Remove the cable from the attaching bracket with clamp and screws, 1. Remove the control cable end through the cable pin, 2, by loosening the two jam nuts. 2. Remove the lock spring pin from the lower hole, 3. 3. Loosen the flange nut on the pivot bolt, 4, and remove the bolt and spacers through the pivot handle and control lever. 4. Slide the cable attaching bracket, 5, off the control lever. 5. Remove the cotter pins, 6, and remove the cable pin, 2, from the pivot handle. 6. Remove all clamps securing the control cable to the frame.

2 6 4

6 3 19995777

1 98

7. Remove the cotter pin, 1, securing the cable to the control valve spool, 2. Remove the valve spool sleeve from the cable by loosening the cable nut, 3.

3 10996662

99 Installation 1. Place cable pin, 1, in the pivot handle and secure with two cotter pins, 2. Bend the cotterpins so there are no exposed sharp edges. 2. Slide the cable attaching bracket, 3, onto the control lever. 3. Install the pivot bolt, 4, and spacers through the pivot handle and control lever. Secure with a flange nut. 4. Install the lock spring pin in the lower hole, 5. 5. Install the control cable end through the cable pin, 1, and secure with two jam nuts. Attach the cable to the attaching bracket with clamp and screws, 6.

35-43

1 2 4

2 5 19995777

6 100

SECTION 35 - HYDRAULIC SYSTEM 6. Route the cable, 1, down along the control lever, under the dash panel, and back to the control valve. 7. Secure the cable with the clamp, 2, on the dash panel, and secure to the center frame rail the main control valve with two clamps and 5/16″ x 3/4″ capscrews and flange nuts.

1 2

10996666

101 8. Screw the valve spool sleeve, 1, onto the cable and lock in place mid-thread with a cable nut, 2. Secure the cable to the control valve spool with a 3/16″ x 1-1/4″ cotter pin, 3. 9. There are two operating modes: • Motor Operation - Locks into “Detent Position” when engaged, requiring the operator to manually return the lever to neutral. For this mode, turn the spool so the cotter pin in spool is vertical. (When using a cylinder in this mode, the cylinder will leak down rapidly in neutral position.) • Cylinder Operation - Spring-loaded, “Non Detent” the spool returns to neutral when the lever is released. For this mode, turn the spool so the cotter pin in spool is horizontal.

2 10996662

102

10. Adjust the angle of the control handle by loosening jam nut, 1, and adjusting the cable end nut, 2, as required. If the desired angle cannot be achieved, adjust the threaded cable end at the control valve. 11. Bleed air from the hydraulic lines by operating an attachment for several cycles. 12. Recheck the hydraulic oil level and fill to the correct level on the dipstick using SAE10W-30 SH/CG-4 oil. 13. Reinstall the engine, if removed. 14. Install the seat and all shields removed for the repair.

1 19995777

103

35-44

SECTION 35 - HYDRAULIC SYSTEM

FILTER BASE Op. 35 705 05 Removal 1. Remove the seat. 2. Remove the hydraulic filter. 3. Loosen and disconnect the hydraulic fittings, 1. 4. Remove the three bolts, 2, securing the filter base to the support bracket. Inspection 1. Inspect the filter mating area of the base for damage or deformations that could cause a leak. 2. Inspect the filter base body for any cracks or damage.

30994879

104

Installation 1. Install the filter base on the support bracket with the three mounting bolts, 1. 2. Connect the hydraulic fittings, 2. 3. Install the hydraulic filter. 4. Install the seat.

30994879

1 105

35-45

SECTION 35 - HYDRAULIC SYSTEM

BOOM LOCKOUT SOLENOID Operation The loader is equipped with a boom lockout system that prevents boom operation (raising or lowering) if the operator is not in the seat. The boom lockout solenoid, 1, prevents hydraulic oil from operating the boom cylinders. The solenoid electromagnet pulls a plunger from the hydraulic valve allowing oil flow to and from the boom cylinders.

19990306

106 The ignition switch must be ON and the operator must be sitting completely in the loader seat before the boom lift circuit becomes operational. The seat assembly is spring loaded. Operator weight on the seat operates the switch, 1. The switch activates the solenoid assembly.

CAUTION

The boom lift circuit may be activated by placing sufficient weight on the seat. Do not place tools, tool boxes, etc. on the seat and do not push on the seat from outside the loader. 19990304

107

35-46

SECTION 35 - HYDRAULIC SYSTEM Testing To check the operation of the boom lockout: 1. Be sure the boom is lowered and any attachment is empty. 2. Start the engine and set engine speed to IDLE. 3. Be sure the traction drive is DISENGAGED. 4. While pressing the heel end of the boom pedal to raise the boom slowly, momentarily lift operator weight off the seat by holding on to the holes in the cab roof. 5. The boom should stop moving as soon as weight clears the seat. 6. The boom should resume movement as soon as the operator sits down on the seat. 7. If the boom does not operate as specified, check all electrical connections at the seat switch, the solenoid, and the ignition switch. 8. Check all wiring connectors. 9. If all connections are secure, check the seat switch for proper operation. 10. If the seat switch operates correctly, check for 12 Volts DC power at the solenoid switch with the seat switch activated. 11. If power is present at the solenoid with the seat switch activated, remove the solenoid. Disassembly and Reassembly 1. Separate the solenoid components by removing the nut or capnut from the top of the solenoid. 2. Check the solenoid parts for damage. 3. Reassemble the solenoid using new seals and O rings. The seal repair kit (part #9605346) includes the two O rings (parts #9825518 and #9825519).

2 3 4

19994994

9809959 108

1. 2. 3. 4. 5. 6. 7.

35-47

Cap Nut - 9825297 O Ring - 9825518 Coil Plunger Seals O Ring - 9825519 Valve Block

SECTION 35 - HYDRAULIC SYSTEM

WIRING HARNESSES AND SEAT SWITCH LS120 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Onan P218 Gas Engine Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Onan Alternator (20 Amp) Main Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9827113 Seat Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 861326 Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9847458

LS125 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E673 Diesel Engine Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator (20 Amp) Main Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9828624 Seat Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 861326 Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9847458

35-48

SECTION 35 - HYDRAULIC SYSTEM

LABOR GUIDE

The following labor amounts are listed as a guide only. Working conditions and experience will vary the amount of time it actually takes to complete each job. Job

Labor-Hours

Boom cylinder, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Boom cylinder, overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Boom lockout solenoid, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Boom lockout solenoid, overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Bucket cylinder, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Bucket cylinder, overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Control valve, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Control valve, overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Gear pump, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Gear pump, overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Hydraulic filter base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Hydraulic system testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5

35-49

SECTION 35 - HYDRAULIC SYSTEM

35-50

SECTION 39 -- FRAMES Chapter 1 -- ROPS CONTENTS Section

Description

Page

Cab / ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-2 90 152 46

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-2 Labor Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-6

39-1

SECTION 39 - FRAMES

CAB / ROPS Inspection 1. Inspect the ROPS front posts, 1, and roof cross support, 2, for any structural damage, cracks, or distortion.

2 1

A3947-14

1 2. Inspect the ROPS rear cab posts, 1, and roof beams, 2, for any structural damage.

2 1

19994960

2 Op. 90 152 46 Removal 1. Remove three top left side fender retaining screws, 1.

19993688

39-2

SECTION 39 - FRAMES 2. Remove three top right side fender retaining screws, 1.

19993691

4 3. Disconnect the wire harness from the control module, 1. 4. Remove the warning light(s) from the frame and disconnect the harness wires, 2. Remove the harness clamps, 3. 5. If equipped with a light kit, disconnect the wire harness at 4. 6. Remove the two frame screws, 5, at the rear of the cab.

2 4 1 3 A3948-02

5 7. Heat and cut the rear tamper-proof retaining bolts, 1, to remove from the ROPS and frame. 8. Remove the 1/2â&#x20AC;ł bolts, 2, from the inside of the frame.

19994962

2 6

39-3

SECTION 39 - FRAMES 9. Remove the front retaining bolts, 1, from the front corners of the ROPS. 10. With a suitable overhead lifting device, raise the ROPS off the frame.

19994958

7 Re-Installation 1. Lower the ROPS onto the frame. 2. Install the front 1/2″ bolts, 1, into the ROPS and frame, and tighten to 85 N⋅m (65 ft. lbs.).

19994958

8 3. Obtain two new tamper-proof retaining bolts. The bolt head, 1, snaps off at about 80 N⋅m (60 ft. lbs.). Be careful not to damage the bolt prior to installation.

1 19994989

39-4

SECTION 39 - FRAMES 4. Install the rear 1/2â&#x20AC;ł bolts, 1, into the ROPS and frame, and tighten to 85 Nâ&#x2039;&#x2026;m (65 ft. lbs.). 5. Tighten the tamper proof bolts, 2, until the head snaps off.

19994962

1 10

6. Install the two frame screws, 1, at the rear of the cab. 7. Reconnect the wire harnesses, warning light(s), and clamps. 8. Reinstall all shields removed.

A3948-02

39-5

SECTION 39 - FRAMES

LABOR GUIDE

The following labor amounts are listed as a guide only. Working conditions and experience will vary the amount of time it actually takes to complete each job. Job

Labor-Hours

Cab / ROPS, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0

39-6

SECTION 44 -- AXLES AND WHEELS Chapter 1 -- Axles, Drive Chain CONTENTS Section 44 100

Description

Page

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-2 Hydrostatic Drive System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-2 Final Drive and Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-4 Hydrostatic Drive vs. Mechanical Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-5 Resting the Boom on Lockpins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-8 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-9

44 106

Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-10 Rear Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-12

44 106 48

Drive Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-19 Drive Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-22 Drive Chain Idler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-22 Drive Chain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-23 Drive Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-25

44 511

Tires/Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-29 Labor Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-30

44-1

SECTION 44 - AXLES AND WHEELS Op. 44 100

GENERAL INFORMATION

19994680

HYDROSTATIC DRIVE SYSTEM OVERVIEW

propulsion system and one gear pump for operating the hydraulic system. The hydraulic pump receives power directly from the engine. The two piston pumps are connected to the motors by high-pressure hoses. A lever controls each hydrostatic piston pump for forward, reverse, and turning. Engaging the traction drive belt which drives the hydrostatic pumps. There are two motors, one for each final drive right and left. The hydrostatic motors are connected to the axles by a #60 roller chain and sprockets that drive the wheels. The individual drive chains can be properly tensioned by moving an idler assembly for each final drive.

44-2

SECTION 44 - AXLES AND WHEELS Two forward and reverse control levers, 1, control the transmission pumps. The control levers connect to two neutralizer assemblies, 2, which automatically return the pintle arms to a positive neutral position. As the control levers move, they stroke the hydrostatic transmission pump pintle arms to the desired position to move the loader in the direction the levers are stroked, forward or reverse. Shock absorbers, or dampeners, 3, absorb hydrostatic vibrations before the vibrations reach the operatorâ&#x20AC;&#x2122;s arms. The dampeners absorb the normal hydrostatic pulsations and torque feedback generated by the drive train loads. This arrangement provides smoother operation and significantly reduces operator fatigue. NOTE: For efficient engine operation, always maintain full-load engine speed above 1000 RPM. Continued full load operation below 1000 RPM, or lugging, is unproductive and may cause early engine failure. Typically, skid steer operation requires rapid changes of speed and direction, with accompanying low speeds at times of heavy loader power demands. It is during these modes of operation that a hydrostatic transmission is more efficient than a mechanical drive train.

DANGER Always fasten the seat belt. This loader is a very stable unit, but can be upset if stopped suddenly when the bucket is raised and loaded. Therefore, never start the engine before securely fastening the seat belt. When a loader digs into a pile of dirt, the operator strives to exert maximum tractive effort with very little speed. The variable displacement hydrostatic pumps are destroked at this time. The destroked pumps drive the motors at the required slow speed while generating maximum torque to the wheels.

44-3

2 9247-04

SECTION 44 - AXLES AND WHEELS

5 7

19994682

3 1. 2. 3. 4. 5.

Dipstick Adjusting Nuts Chain Idler Clamping Nuts Breather 13-Tooth Idler Sprocket

6. 7. 8. 9.

FINAL DRIVE AND DRIVE CHAIN Final drive chain routing, one continuous chain driven by the hydrostatic motor 12-tooth sprocket to the front and rear axle drive 32-tooth sprockets, and a 13-tooth idler sprocket. The idler sprocket is part of the chain tension device used to properly tighten the drive chain.

44-4

12-Tooth Drive Sprocket 32-Tooth Sprockets (2) Drain plugs (2) #60 Roller Chain

SECTION 44 - AXLES AND WHEELS

HYDROSTATIC DRIVE VS. MECHANICAL DRIVE There is minimum power loss in these hydrostatic systems because input speeds are reduced far below speeds attainable with slipping clutches in mechanical drive systems. To obtain maximum torque at the wheels, always remember to keep the control levers close to the neutral position. This differs from a mechanical drive unit, where the operator pushes the control levers as far forward as possible to prevent the clutches from slipping. The positive control of these hydrostatic drives at low speeds allows the operator to ease the bucket into loads, eliminating the impact loading technique often necessary with mechanically driven units. These hydrostatic loaders never have to be used as a ramrod, a practice that is hard on both the operator and machine.

44-5

SECTION 44 - AXLES AND WHEELS

A3948-04

44-6

SECTION 44 - AXLES AND WHEELS

FINAL DRIVE Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #60 roller chain, 3/4″ riveted Regular links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 links Connector link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . One master connector Motor drive sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 teeth Idler sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 teeth Axle drive sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 teeth Axle bearing nut torque . . . . . . . . . . . . . . . . . . . . . 47 N⋅m (35 ft. lbs.) and back off one flat of the castellated nut Drive sprocket to hydrostatic motor shaft nut torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 N⋅m (150 ft. lbs.) Chain idler clamping nut torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 N⋅m (90 ft. lbs.) Lug bolt torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 N⋅m (60 ft. lbs.) Hydrostatic motor mounting bolt torque: Carriage bolts, 1/2″ x 1-1/2″ Grade 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 N⋅m (66 ft. lbs.) Hex cap screw, 5/16″ x 5/8″ Grade 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 24 N⋅m (15 - 18 ft. lbs.) Axle cover bolts, 5/16″ x 5/8″ self-tapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 24 N⋅m (15 - 18 ft. lbs.)

44-7

SECTION 44 - AXLES AND WHEELS

TROUBLESHOOTING PROBLEM Both drive wheels on one side not powered

POSSIBLE CAUSE No hydrostatic motor shaft rotation Broken drive chain

CORRECTION Check for pump to motor oil flow and repair Check chain and repair

Chain case noise

Loose drive chains No oil in final drive Worn drive sprockets Bearing failure

Check and adjust chains Check oil level Check sprockets and repair Check axle and gearbox bearings and repair

Excessive axle play

Bearing failure on axle shaft Snap ring failure on axle shaft

Check bearings and repair Check axle bearing preload; repair

44-8

SECTION 44 - AXLES AND WHEELS

TESTING Pre-test instructions: * Operator in seat with seat belt buckled. * Engine running at high idle (full throttle). * Park brake disengaged position.

STEP

TEST

RESULT

PROBABLE CAUSE AND CORRECTION

Push both drive controls forward equally and loader should move in a straight line.

YES NO

Drive system OK. Engine stalls, wheels appear locked, check parking brake for engaged. If OK go to step 2. Slow or no power, refer to hydrostatic drive section.

2 3

Check final drive chain; if broken, repair. Pull both drive controls rearward equally and loader should move in a straight line.

YES NO

Drive system OK. Engine stalls, wheels appear locked, go to step 1. Wheels rotate slow or no power, go to step 1. One side of loader drags, go to step 2.

Pre-test instructions: * Lower boom and attachment to the ground. * Stop engine. * Jack loader with wheels off the ground. * Release parking brake.

STEP

TEST

RESULT

PROBABLE CAUSE AND CORRECTION

Rotate each tire by hand, tires move less than 1/4â&#x20AC;ł at tread.

YES NO

Drive system OK. Tires move more than 1/4â&#x20AC;ł at tread, check chain tension.

2 3

Both tires on one side rotate freely together, inspect drive motor. Tires rotate but are noisy.

YES NO

44-9

Check drive chain, axle bearings. Drive system OK.

SECTION 44 - AXLES AND WHEELS Op.44 106

AXLES FRONT AXLE REMOVAL NOTE: If an axle is being removed to replace a seal or the axle, the chain need not be disconnected or the sprocket removed. Use two long threaded bolts through the two cover bolt holes and press the sprocket against the axle hub and remove the axle from the outside. 1. Raise the boom and rest it on the lockpins. 2. Support the loader with all four wheels off the ground.

CAUTION Never work around or under a raised skid steer unless it is securely supported with suitable jack stands or blocking.

DANGER Always support the boom on the boom lock pins before leaving a machine with the boom up or when servicing or repairing the unit with the boom up - failure to do so could result in serious injury or death. 3. Remove the tire and wheel from the axle being repaired. 4. Drain the hydraulic oil from the final drive/reservoir case by removing plug on the rear of either chain case. Approximately 34 liters (9 US gallons) of oil must be drained. 5. Loosen the final drive chain idler retaining hardware, 1, enough to allow the idler assembly to slide to the rear. Back off the adjusting nut, 2, to loosen the drive chain. The chain idler hardware can also be accessed by removing the fenders.

A1454-10

44-10

SECTION 44 - AXLES AND WHEELS 6. To remove the front covers, 1, the pedal foot control assembly must be removed. Remove the step shield retaining hardware and step shield, 2. Remove the pedal shaft retaining hardware, 3.

30994958

6 7. Remove the two cotter pins, 1, at the control valve spools. Remove the complete control pedal assembly from the loader.

30994694

7 8. Remove four self-tapping screws, 1, and the axle cover, 2. The cover is sealed with silicone sealer between the cover and chain case wall.

19994695

1 8

44-11

SECTION 44 - AXLES AND WHEELS

REAR AXLE REMOVAL NOTE: If an axle is being removed to replace a seal or the axle, the chain need not be disconnected or the sprocket removed. Use two long threaded bolts through the two cover bolt holes and press the sprocket against the final drive case and remove the axle from the outside. 1. Raise the boom and rest it on the lockpins. 2. Support the loader with all four wheels off the ground.

CAUTION Never work around or under a raised skid-steer loader unless it is securely supported with suitable jack stands or blocking.

A1454-10

44-12

SECTION 44 - AXLES AND WHEELS 6. Access to the rear covers, 1, is from the bottom of the loader with the belly pan removed. Engine removed for clarity.

G97-383

10 7. To remove the belly pan, 1, use a floor jack and support the pan before removing the retaining hardware. With the pan supported, remove the hardware and lower the pan to the floor.

CAUTION Support the belly pan when removing the bolts so the pan does not drop. The belly pan is heavy and could cause injury if dropped.

1 A1459-04

11 8. Remove four self-tapping screws, 1, and the axle cover, 2. The cover is sealed with silicone sealer between the cover and chain case wall.

19994695

1 12

44-13

SECTION 44 - AXLES AND WHEELS Disassembly 1. Remove the cotter pin, 1, the castellated nut, 2, and the flat washer, 3. NOTE: If the axle is being removed to replace a seal or axle/hub assembly only, the final drive chain need not be disconnected or the sprocket removed. Use two longer threaded 5/16â&#x20AC;ł bolts through two cover bolt holes, 4, and tighten against the sprocket. This will hold the sprocket and bearing in position against the inner chain case side sheet for alignment on reassembly.

4 3 4 19994696

13 NOTE: The sprocket and inner roller bearing may fall down in the chain case. The sprocket can be rolled to the center cover opening for removal if necessary. 2. The axle assembly can now be removed from the outside of final drive case. NOTE: The sprocket and inner roller bearing, 1, may fall down in the chain case if the sprocket is not held in position.

30994698

14 3. Remove the single axle oil seal, 1. The single axle oil seal and outer bearing, 2, must be removed from the outside of axle tube.

1 2

30994699

44-14

SECTION 44 - AXLES AND WHEELS 4. Examine the replaceable inner, 1, and outer, 2, bearing races for wear or damage. Replace if required. The sprocket and chain can be moved to the center of the chain case to access the inner bearing if the bearing and race are being replaced. Using a suitable hammer and driver remove the inner bearing race, 1, to the inside of the case tube and outer bearing race, 2, to the outside of the case tube.

30994700

16 NOTE: The bearings, 1, are a slip fit on the axle and should be easily removable by hand. 5. Remove the bearings, 1, from the axle. 6. Examine the bearings for wear or damage. Clean the bearings in solvent and repack them with wheel bearing grease.

19994703

44-15

SECTION 44 - AXLES AND WHEELS Parts Inspection 1. Clean and inspect all parts thoroughly. 2. Inspect the axle tube, 1, in the race and seal areas. 3. Inspect the inner cover area, 2, for flatness. Inspect the cover-to-side-sheet fit for sealing.

30994701

18 4. Examine the axle shaft in the bearing, 1, and seal, 2, areas. Replace if worn in the seal area to the point there is not a good seal surface. Replace if worn in the bearing area if the bearing is looser than a hand fit. NOTE: The axle bearings are a slip fit on the axle and can easily be removed by hand. 5. Inspect the shaft splines where the drive sprocket rides for wear and sprocket fit. 6. Examine the axle in the bearing areas, 1, for signs of the bearing turning. 7. Examine the seal area, 2, for wear or grooving. Replace the axle if wear is excessive. 8. Inspect the hub in the lug bolt area, 3, for stripped threads or cracked hub.

1 2 3 30994702

44-16

SECTION 44 - AXLES AND WHEELS Reassembly 1. Using a suitable bearing race driver, install new inner and outer bearing races, 1. The race must be driven into and seated against the shoulder, 2, inside the axle tube.

1 2

30994700

20 2. Install the outer bearing, 1, in the bearing race and install a new bearing seal, 2, using Loctite Hydraulic Sealant #454 between the outer seal and the axle hub, 3. 3. Insert the axle from the outside. NOTE: Seal driver #FNH00065 may be used to install the seal, 2. 4. Insert the axle shaft into the axle tube, using caution to not cut the seal with the axle splines. If the sprocket and inner bearing were not removed, slide the axle in and fully seat the outer bearing on the axle shaft. If the inner bearing and sprocket were removed, do not fully seat axle.

1 2

30994699

21 5. Install the inner bearing, 1, on the axle from the inside.

30994698

44-17

SECTION 44 - AXLES AND WHEELS 6. Install the sprocket, 1, with the chain in place and secure it with a heavy washer.

30994697

23 7. Install the flat washer, 1, and castellated nut, 2, and tighten the nut to 47 Nâ&#x2039;&#x2026;m (35 ft. lbs.). With a soft faced mallet, tap the axle assembly in both directions to ensure proper bearing seating and retorque nut. Back off one flat on the castellated nut to the next locking hole in the nut. Install the cotter pin, 3. NOTE: The axle bearings are a slip fit on the axle and can easily be removed by hand. NOTE: Retighten the axle bearings after 500 hours of operation or sooner if end play is observed in the axles. 8. Clean the chain case sealing area, 4. 9. Apply a minimal coat of non-corrosive silicone sealer to the sealing area and to the threads of the cover bolts. IMPORTANT: If non-corrosive silicone is not used, severe corrosion and damage may occur to the final drive components.

19994696

10. Apply silicone sealer to the threads of the cover bolts, 1, and tighten to 20 - 24 Nâ&#x2039;&#x2026;m (15 - 18 ft. lbs.). 11. Install the boom/bucket foot control pedal assembly. 12. Install the belly pan, if removed. Use a floor jack to position and support the pan while installing the retaining hardware. IMPORTANT: Do not operate the skid-steer loader with the belly pan removed. Severe damage to the hydrostatic and hydraulic components could occur.

19994695

13. Install the wheel(s) and other shielding removed to make the repair.

1 25

44-18

SECTION 44 - AXLES AND WHEELS

DRIVE CHAIN AND IDLER Op. 44 106 48 DRIVE CHAIN REMOVAL 1. Remove any attachment such as a bucket or fork from the loader boom.

CAUTION Never work around or under a raised skid-steer loader unless it is securely supported with suitable jack stands or blocking.

DANGER Always support the boom on the boom lock pins before leaving a machine with the boom up or when servicing or repairing the unit with the boom up - failure to do so could result in serious injury or death. 2. Support the loader at a good working height with blocks, 1. A good working height is with the bottom frame about 300 - 350 mm (12â&#x20AC;ł-14â&#x20AC;ł) from the ground.

CAUTION Block the loader securely so it cannot fall.

3 3. Remove the front and rear wheels. 4. Remove the six fender bolts, 2, and remove the fender. 5. Drain the hydraulic oil from the reservoir case by removing the all four drain plugs, 3, from the chain case reservoir. The reservoir holds approximately 34 liters (9 US gallons) of oil. 6. Remove the center cover plate, 4, to gain access to the drive area and chain connector for chain and sprocket removal. Note the two top rear bolts, 5, are shorter than the other cover bolts for clearance with the chain idler bracket. IMPORTANT: The two top rear bolts on the access cover plate, 5, are shorter than the other cover plate bolts for clearance with the chain idler bracket. Be sure the short bolts are reinstalled in the top rear holes to prevent equipment damage.

44-19

4 30990297

1 26

SECTION 44 - AXLES AND WHEELS 7. Remove the six step shield retaining bolts, 1. Remove the step shield, 2.

1 30994948

27 8. Loosen and remove the two hydraulic lines, 1, on the motor.

30994687

28 9. Use a wrench or socket on the castellated nut, 1, to turn the chain drive until the master chain link is at 2.

30994684

2 29

44-20

SECTION 44 - AXLES AND WHEELS 10. Loosen the chain idler hardware, 1, and loosen the tension adjusting bolt, 2. Allow the assembly to slide to the rear, loosening the chain.

A1454-10

30 NOTE: Use a piece of wire, 1, to secure each end of the drive chain to a chain case hole, 2, to prevent losing the end of the chain when disconnecting the master link. 11. Disconnect the drive chain master link.

30994685

1 31

44-21

SECTION 44 - AXLES AND WHEELS DRIVE CHAIN REPLACEMENT 1. Attach the new chain to one end of the old chain with a master link. 2. Use a wrench or socket on the castellated nut, 1, to turn the chain drive. 3. Feed the new chain while turning the drive and removing the old chain. 4. Install the master link.

30994684

32 DRIVE CHAIN IDLER REPLACEMENT 1. Remove the adjuster clamping nuts, 1, and flat washers. 2. Remove the adjuster nut, 2, and lower the idler into the chain case.

A1454-10

33 3. Remove the cover plate, 1.

30994690

44-22

SECTION 44 - AXLES AND WHEELS 4. Lower the idler, 1 and remove it through the opening.

30994685

35 5. Check for any wear to the idler sprocket, 1, needle bearing, 2, or shaft, 3. Replace parts as necessary.

1 2

3 19994692

36 DRIVE CHAIN INSTALLATION 1. Install the idler shaft, 1, in the oiled needle bearing, 2. Slide the sprocket, 3, over the needle bearing and install one spacer, 4, on each side of the sprocket. Install the assembly in the bracket, 5. IMPORTANT: The bolt, 6, must be installed correctly to give proper clearance between the idler and outer chain case wall or the idler will be cocked, causing premature chain and/or sprocket wear. 2. Secure the idler assembly inside the bracket with a bolt, 6, and locknut, 7. IMPORTANT: The head of the bolt goes toward the chain case wall when the idler is installed. 3. Tighten the locknut to 108 Nâ&#x2039;&#x2026;m (80 ft. lbs.).

44-23

4 5 7 6

1 19994675

3 37

SECTION 44 - AXLES AND WHEELS 4. Install the idler bracket assembly, 1, in the top of the chain case.

19994691

1 38

5. Coat the cover plate, 1, with a thin layer of silicone sealer on both sides. Install the cover plate over the idler bolts, 2.

30994690

39 6. Install the stud weld assembly, 1, with the jam nut, 2, and adjusting nut, 3. Replace the stud washers and locknuts. 7. Snug but do not tighten the locknuts until the chain has been adjusted.

A1454-10

44-24

SECTION 44 - AXLES AND WHEELS DRIVE CHAIN ADJUSTMENT

CAUTION Be sure all four wheels are clear of the ground and free of obstruction. 1. Use chalk or some other marking device to mark the top of the rear tire, 1, as a reference. 2. Hold the rear wheel steady, and rotate the front wheel, 2, forward and backward to determine chain slack and record it. 3. Rotate the rear tire approximately 90° and check and record the slack. 4. Repeat the check at 180° and 270°. 5. Reposition the tire to the position with the least slack. Adjust chain tension if slack exceeds 6.5 mm (1/4″). Two methods can be used to tighten the final drive chains: Method #1 - Engine Stopped Method #2 - Engine Running Method #1 - Engine Stopped 1. Loosen the four idler clamping bolts, 1, just enough so the idler can be moved by tightening adjuster nut, 2. 2. Remove excess chain slack to 6.5 mm (0.25″) or less by tightening the adjuster nut. 3. Oil the clamping bolts before tightening the adjustment and clamping hardware. 4. Tighten the idler clamping bolts, 1, to 122 N⋅m (90 ft. lbs.). Tighten the jam nut, 3. IMPORTANT: The idler clamping bolts must be tightened to 122 N⋅m (90 ft. lbs.). Failure to securely tighten the idler clamping bolts will result in premature wear, parts failure, or catastrophic damage to the final drive.

44-25

G97-380

1 3 2

A1454-10

SECTION 44 - AXLES AND WHEELS 5. Hold the rear wheel, 1, steady, and rotate the front wheel, 2, forward and backward to recheck chain slack. IMPORTANT: Over-tensioning of the final drive chain can seriously damage the final drive. Always recheck chain tension after tightening the idler clamping bolts to ensure that the chain is not too tight.

1 G97-380

43 Method #2 - Engine Running 1. Chain adjustment with the engine running automatically adjusts the chain slack so it is neither too tight nor too loose. As the transmission turns the wheels, the idler is free to move to lessen chain tension if a tight spot is found. 2. Loosen the four idler clamping bolts, 1, just enough so the idler, 2, can be moved by tightening adjuster nut, 3. 3. Remove all slack from the chain by tightening the adjuster nut, moving the idler toward the rear of the loader.

3 2

A1454-10

44 4. Check by rocking the front wheel with the rear wheel held stationary.

G97-380

44-26

SECTION 44 - AXLES AND WHEELS 5. Tighten the four idler clamping nuts, 1, to 14 - 20 N⋅m (10 - 15 ft. lbs.). 6. Back off the adjusting nut, 2, about 3 mm (0.125″).

WARNING 2

Stand clear of the wheels while the engine is running. NOTE: Rapid motion of the control lever may cause the idler to move more than desired. Do not move the control lever rapidly. 7. Start the engine at idle speed. 8. Slowly stroke the control lever to turn the wheels several times forward. 9. Slowly stroke the control lever back to turn the wheels several times backward. 10. Return the control lever to the neutral position. 11. Stop the engine. 12. Check for idler cover plate movement. Movement of the cover plate indicates that chain tension was too tight. Back off the adjusting nut and repeat the test. 13. When no further movement of the idler cover plate is observed, tighten the adjusting nut.

A1454-10

14. Oil the idler clamping bolts, 1, and tighten the nuts to 122 N⋅m (90 ft. lbs.). Tighten the jam nut, 2.

1 2

A1454-10

44-27

SECTION 44 - AXLES AND WHEELS 15. Recheck the chain slack at four different wheel positions (0°, 90°, 180°, and 270°) for 6.5 mm (0.25″) maximum front wheel movement at the tire tread when the rear wheel is held stationary. 16. Repeat the procedure for the opposite final drive chain.

G97-380

44-28

SECTION 44 - AXLES AND WHEELS Op. 44 511

TIRES/WHEELS The skid-steer loader can be equipped with the following tires and correct tire pressures. 5.70 x 12 . . . . . . . . . . . . . . . . . . . 3.5 bar (50 PSI) 23 x 850 - 12 . . . . . . . . . . . . . . . 2.0 bar (35 PSI) IMPORTANT: The loader will be hard to turn and the tires will wear faster if the correct tire pressure is not maintained. All lug bolts should be tightened to 80 Nâ&#x2039;&#x2026;m (60 ft. lbs.).

G97-402

44-29

SECTION 44 - AXLES AND WHEELS

LABOR GUIDE

The following labor amounts are listed as a guide only. Working conditions and experience will vary the amount of time it actually takes to complete each job. Job

Labor-Hours

Axle - front, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 Axle - rear, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Axle seal - front, replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 Axle seal - rear, replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Drive chain, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Final drive chain adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Final drive testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5

44-30

SECTION 00 -- GENERAL INFORMATION BOOK 1

Chapter 1 -- General Information CONTENTS Section

Description

Page

00 000

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2 About Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2 Company Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-3 Parts and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-3 Model Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-3 Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-5 General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-7 Hardware Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-9 Installation of Adjustable Fittings in Straight Thread O Ring Bosses . . . . . . . . . . . . . . . . 00-11 Hydraulic Tube and Fitting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-11 Pipe Thread Fitting Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-12 Lubricants and Coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-12 Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-12 Machine Model and Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13 Properly Support a Raised Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-14 Properly Support Boom On Boom Lock Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-14 Raising Boom Without Hydraulic Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-15 Raising Boom Without Battery Voltage (12 Volts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-16 Reattaching Cylinders After Repair With Boom Resting On Boom Lock Pins . . . . . . . . 00-18 Loading and Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-19 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-21 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-22 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-27

SECTION 10 -- ENGINE BOOK 1 CONTENTS Section 10 000

Description

Page

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

55 100

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Onan Gasoline Engine Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Engine Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 Assembly Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Pulse Pump Test Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21

10 001 10

Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24

55 301 40

Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24

10 202 40

Standard Air Cleaner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24

10 202 40

Heavy Duty Air Cleaner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25

10 001 53

Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29

10 103 70

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32

10 102 10

Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34

10 101 21

Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35

10 105 10

Connecting Rod and Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35

10 101 32

Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36

10 230 20

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37

10 230 20

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38 Component Disassembly, Inspection, Fits, And Clearances . . . . . . . . . . . . . . . . . . . . . . 10-40

10 101 32

Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40

10 101 56

Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47

10 105 22

Pistons, Piston Rings, and Connecting Rods Disassembly and Inspection . . . . . . . . . . 10-50

10 103 30

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52

10 103 10

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53 Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56 Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58

10 304 38

Engine Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59 Piston Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62

29 100 50

Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75

10 000

E673 Diesel Engine Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82 Cylinder Head and Valve Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82 Cylinder Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82 Diesel Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83 Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88 Assembly Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94 Metric Bolt Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96 Compression Test and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96

10 001 10

Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97

10 218 30

Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99

55 201 76

Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99

55 301 10

Temperature Sending Switch and ALternator Removal . . . . . . . . . . . . . . . . . . . . . . . . . 10-100

10 001 53

Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101

10 414 20

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101

10 402 10

Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101

10 250 16

External Oil Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101

10 101 14

Valve Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101

10 106 20

Rocker Shaft and Push Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101

10 101 21

Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102 Valve Tappet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102

10 223 10

Fuel Shut-Off Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102 Engine Timing Gear Cover, Timing Gears, and Camshaft . . . . . . . . . . . . . . . . . . . . . . 10-103

10 414 30

Crank Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103

10 236 10

Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103

10 230 24

Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103

10 304 44

Oil Sump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104

10 105 10

Connecting Rods, Bearings and Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105

10 103 70

Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106

10 102

Backplate and Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106

10 103 10

Crankshaft and Main Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106 Component Disassembly, Inspection, Fits, And Clearances . . . . . . . . . . . . . . . . . . . . 10-107

10 101 21

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107

10 101 55

Valve Seat Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108

10 101 32

Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109

10 106 20

Rocker Arm Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111

10 105 22

Pistons, Piston Rings, and Connecting Rods Disassembly and Inspection . . . . . . . . . 10-114 Pistons, Piston Rings, and Connecting Rods Reassembly . . . . . . . . . . . . . . . . . . . . . . . 10-118

10 103 10

Main Bearing and Thrust Bearing Removal and Inspection . . . . . . . . . . . . . . . . . . . . . . 10-119

10 103 30

Crankshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120 Crankshaft Journal Wear Limit and Bearing Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121 Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-123 Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124

10 106 40

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124

10 103 76

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-125 Timing Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126

10 304 38

Engine Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-127 Rear Oil Seal and Back Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-127 Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130 Fuel Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131 Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132 Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132 Fuel Shut-Off Solenoid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135

29 100 50

Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141

10 304 10

Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144

10 304 30

Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144

10 304 38

Oil Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-147

10 406 10

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150

10 402 28

Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150

10 402 30

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-156 Fuel System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162

10 236 10

Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-167 Governor and Timing Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-168

10 236 08

Spill-Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169 Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-173 Smoke Screw Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174 High Idle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174

10 230 24

Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-175

10 218 34

Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180 Labor Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-183

10 001 10

Labor Guide - Engine Removal From Skid Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-183

SECTION 29 -- HYDROSTATIC TRANSMISSION BOOK 2

Chapter 1 -- Pumps, Motors, Steering CONTENTS Section 29 000

Description

Page

29 100 01

29 100 40

Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-11

29 100 46

Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-14

29 100 60

Hydrostatic Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-28

29 100 66

29 100 36

Charge Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-47

29 100

Steering Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-48

29 100 36

SECTION 33 -- BRAKES AND CONTROLS BOOK 2

Chapter 1 -- Parking Brake CONTENTS Section

Description

Page

33 000

33 110

SECTION 35 -- HYDRAULIC SYSTEM BOOK 2

Chapter 1 -- Valves, Gear Pump, and Cylinders CONTENTS Section 35 000

Description

Page

35 710 02

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-9

35 724 50

Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-10

35 724 54

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-11

35 710 10

Hydraulic Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-18

35 710 20

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-18

35 730 10

Bucket Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-24

35 730 13

Bucket Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-25

35 710 10

Boom Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-29

35 730 18

35 705 05

SECTION 39 -- FRAMES BOOK 2

Chapter 1 -- ROPS CONTENTS Section

Description

Page

Cab / ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-2 90 152 46

SECTION 44 -- AXLES AND WHEELS BOOK 2

Chapter 1 -- Axles, Drive Chain CONTENTS Section 44 100

Description

Page

44 106

44 106 48

44 511

SECTION 55 -- ELECTRICAL SYSTEM BOOK 3

Chapter 1 -- Circuits, Alternators, Starters CONTENTS Section 55 000

Description

Page

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-4 Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-5

55 640

Control Module Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-7 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-8 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-14 Control Module Starting Circuit Voltage Flow -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-17 Control Module Starter Motor Voltage Flow -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-18 Control Module Starting Circuit Voltage Flow -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-19 Control Module Starter Motor Voltage Flow -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-20 Charging System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-21 Control Module Restraint System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-24 Control Module Restraint System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-26 Control Module Restraint System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-29 Control Module Restraint System Circuit Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-31 Control Module Diagnostic Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-37 Timer and Circuit Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-38 LS120 Diagnostic Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-39 LS120 Circuit Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-45 LS125 Diagnostic Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-50 LS125 Circuit Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-56 Removal, Installation and Wiring of Electrical Components . . . . . . . . . . . . . . . . . . . . . . . 55-61

10 223

Fuel Shutoff Solenoid -- LS 120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-62

10 223 10

Fuel Shutoff Solenoid -- LS 120 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-62

10 223

Fuel Shutoff Solenoid -- LS 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-64

10 223 10

Fuel Shutoff Solenoid -- LS 125 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-64

55 301 40

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-66

55 201

Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-68

55 201 10

Ignition Key Switch -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-69 Circuit Breakers -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-70

55 100 24

Circuit Breakers -- LS120 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-71 Circuit Breakers -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-72

55 100 24

Circuit Breakers -- LS125 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-74

55 640

Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-75 Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-76 Seat Switch Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-76

55 201 15

Seat Switch Wiring -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-76 Seat Belt Buckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-78

55 201 14

Seat Belt Buckle Assembly -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-78 Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-79

55 408

Warning Light -- LS120 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-79 Warning Light Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-80 Warning Light Bar -- LS125 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-80

55 418

Hourmeter -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-81 Start Relay -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-82

55 100 34

Start Relay -- LS120 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-82 Start Relay -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-84

55 100 34

Start Relay -- LS125 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-84 Glow Plug -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-85

55 201 76

Glow Plug -- LS125 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-85 Glow Plug Relay -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-87

55 100 34

Glow Plug Relay -- LS125 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-87 Glow Plug Controller -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-88

55 640

Glow Plug Controller -- LS125 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-88 Oil Pressure Switch -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-88

55 414 12

Oil Pressure Switch -- LS125 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-88 Water Temperature Switch -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-89

55 414 10

Water Temperature Switch -- LS125 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-89 Water Temperature Sensor -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-90

55 414 10

Water Temperature Sensor -- LS125 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-90 Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-91

55 100 74

Wire Harnesses LS120 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-91

55 100 74

Wire Harnesses LS125 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-102 Boom Lockout Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-117

55 301

Alternators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-119 Charging System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-120 Alternator Operation -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-121

55 301 04

Alternator System Inspection -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-122

55 301

Alternator Flywheel Removal -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-123

55 301 10

Alternator Removal -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-124

55 301 12

Alternator Disassembly -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-124

55 201

Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-128 Assembly Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-128 Starting Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-129 Starter Operation -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-132

55 201 50

Starter Removal -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-132 Starter Disassembly -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-132 Starter Inspection and Testing -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-134 Starter Brush Replacement ---LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-136 Starter Reassembly -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-136 Starter Installation -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-139 Starter Operation -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-140 Starter Specifications -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-142

55 201 50

Starter Removal -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-143 Starter Disassembly -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-143 Starter Inspection and Repair -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-145 Starter Tests ---LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-148 Starter Reassembly and Adjustments -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-151 Pinion Clearance Check and Adjustment -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-153 Starter Installation -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-154 Ignition System (LS120) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-155 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-155

55 201

Ignition System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-156 Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-157 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-157 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-158 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-158 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-158 Specific Gravity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-158 Battery Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-159 Optional Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-161 Flashing (Warning) Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-161

55 404

Rectangular Road, Work and Taillights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-161 Light Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-162 Troubleshooting Light Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-163 Flashing (Warning) Light Lamp or Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 55-164

55 404 10

Front Rectangular Light Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-164

55 404 10

Rear Rectangular Light Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-164

55 000

Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-165 Labor Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-166

SECTION 82 -- FRONT LOADER (Boom And Mounting Plate) BOOK 3

Chapter 1 -- Buckets, Boom CONTENTS Section 82 000

Description

Page

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-2 Changing Buckets and Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-4 Buckets and Utility Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-5

82 100 77

Boom Lockpin and Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-6

82 100 50

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-9

82 100 70

Attachment Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-17 Labor Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-18

SECTION 90 -- PLATFORMS AND DECALS BOOK 3

Chapter 1 -- Seat, Safety Decals CONTENTS Section

Description

Page

90 120 10

Operatorâ&#x20AC;&#x2122;s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-2

90 108

Machine Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4 Labor Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7

/6 /6 6HFWLRQ (OHFWULFDO 6\VWHP 6HFWLRQ )URQW /RDGHU %RRP DQG 0RXQWLQJ 3ODWH

6HFWLRQ 3ODWIRUPV DQG 'HFDOV

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+<'5267$7,& 75$160,66,21 %5$.(6 $1' &21752/6 +<'5$8/,& 6<67(0 )5$0(6 $;/(6 $1' :+((/6

6(&7,21 (/(&75,&$/ 6<67(0 6(&7,21 )5217 /2$'(5 %220 $1' 02817,1* 3/$7(

6(&7,21 3/$7)2506 $1' '(&$/6

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SECTION 55 -- ELECTRICAL SYSTEM Chapter 1 -- Circuits, Alternators, Starters CONTENTS Section 55 000

Description

Page

55 640

10 223

Fuel Shutoff Solenoid -- LS 120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-62

10 223 10

Fuel Shutoff Solenoid -- LS 120 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-62

10 223

Fuel Shutoff Solenoid -- LS 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-64

10 223 10

Fuel Shutoff Solenoid -- LS 125 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-64

55 301 40

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-66

55 201

Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-68

55 201 10

55 100 24

55-1

SECTION 55 - ELECTRICAL SYSTEM 55 100 24

Circuit Breakers -- LS125 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-74

55 640

55 201 15

55 201 14

55 408

55 418

55 100 34

55 201 76

55 100 34

55 640

55 414 12

55 414 10

55 100 74

Wire Harnesses LS120 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-91

55 100 74

55 301

55 301 04

Alternator System Inspection -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-122

55 301

Alternator Flywheel Removal -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-123

55 301 10

Alternator Removal -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-124

55 301 12

Alternator Disassembly -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-124

55-2

SECTION 55 - ELECTRICAL SYSTEM 55 201

55 201 50

55 201

55 404

55 404 10

Front Rectangular Light Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-164

55 404 10

Rear Rectangular Light Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-164

55 000

55-3

SECTION 55 - ELECTRICAL SYSTEM Op. 55 000

GENERAL INFORMATION boom lock solenoid valve. The operator must be sitting in the seat with the seat belt buckled to start the engine and unlock the boom lock solenoid. This system must be sequenced properly (sit in operatorâ&#x20AC;&#x2122;s seat, then buckle seat belt) to start the engine and operate the boom hydraulic circuit. This system stops boom movement if the operator unbuckles the seat belt or is out of the operatorâ&#x20AC;&#x2122;s seat for more than three seconds. The operator will have to resequence the system to resume boom operation. 6. Circuit Breakers - Protect the electrical circuits and glow plug heater (LS125 diesel engine only). 7. Glow Plug Heater - Provides aid in cold engine starting on the LS125 diesel engines only. 8. Fuel Solenoid - Controls fuel flow. The ignition key switch supplies the power for the solenoid. 9. Switches - Control electrical current flow for different electrical circuits, such as road and work lights, flasher light, etc. IMPORTANT: If any servicing or adjustments require the battery to be disconnected, or welding is required on the skid-steer loader, disconnect the negative (--) ground battery cable. Failure to disconnect the battery may result in damage to electrical components.

The LS120 and LS125 skid-steer loaders have a 12-volt negative (--) ground electrical system. The ignition key switch controls power to the starting circuit, fuel shutoff solenoid circuit, and the control module restraint system. Circuit breakers protect the main electrical circuits. A 15-amp circuit breaker protects the electrical system, starting circuit, and optional lights. A 6-amp circuit breaker protects the control module restraint system. A 30-amp circuit breaker protects the LS125 diesel engine glow-plug engine heating system. The electrical system provides 12 volts to the ignition key switch, starting circuit and other electrical components. The electrical system consists of the following components: 1. Battery - Power supply and storage. 2. Alternator and Regulator - Power supply and source to maintain fully charged system. 3. Starter Motor - To crank engine for starting. 4. Ignition Key Switch - Controls electrical circuits and paths of battery voltage. 5. Control Module Restraint System - This circuit connects the seat switch and seat belt switch to the control module, and the control module to the

55-4

SECTION 55 - ELECTRICAL SYSTEM

DEFINITION OF TERMS ALTERNATING CURRENT (AC) - A flow of electrons that reverses its direction of flow at regular intervals in a conductor. AMMETER - A unit of measure for the flow of current in a circuit. The ampere measures electricity like “gallons per minute” measures liquid flow. CIRCUIT - A continuous, unbroken path along a conductor through which electrical current can flow from a source, through various components, and back to the source.

OHMMETER - An instrument for measuring the resistance, in ohms, of an electrical circuit. OPEN CIRCUIT - An open circuit occurs when a circuit is broken, interrupting the flow of current through the circuit. RELAY - An electrical switch which opens and closes a circuit automatically when activated. RESISTANCE - The opposing force in a circuit. Resistance is measured in ohms.

CIRCUIT BREAKER - A device protecting an electrical circuit from overloads that can be reset, or will automatically reset.

SHORT CIRCUIT - A part of a circuit that meets with a part of the same circuit or that unintentionally touches a metallic object.

COLD CRANK RATING (CCA) - The cranking load capacity of a battery at low temperatures (cold cranking amperes at --18° C [0° F]).

SOLENOID - A circular coil used for producing a magnetic field.

CONTINUITY - Unbroken path along a conductor through which electrical current can flow. CURRENT - Movement of electricity along a conductor. Current is measured in amperes. DIODE - An electrical device that allows current to pass through in one direction only. DIODE (RESISTOR TYPE) - An electrical device that allows current to pass through in one direction only, and adds resistance as the electricity passes through. The electricity coming from this type diode will be less than that going into the diode. DIRECT CURRENT (DC) - A flow of electrons moving in the same direction along a conductor from a point of high potential to one of lower potential. FUSE - A device protecting an electrical circuit from overloads that needs replacing when blown.

55-5

SWITCHES - A device used to control and direct a current of electrons. A non-momentary switch remains in its position until changed. SWITCHES (MOMENTARY) - Momentary switches direct current to circuits, but return to a neutral position when released. VOLT - A unit of electrical pressure that causes current to flow in a circuit. VOLTAGE - The force generated to cause current to flow in an electrical circuit. Voltage is measured in volts. VOLTMETER - An instrument for measuring the force, in volts, of electrical current. Voltmeters are connected in parallel to the points where voltage is to be measured.

SECTION 55 - ELECTRICAL SYSTEM This chart shows the abbreviations for the various wire colors used to identify the electrical circuits.

The following are common terms used in electrical diagnostics and how they may affect the circuit and electrical components. The term “OPEN CIRCUIT” means there is no voltage traveling from the control point to the operating point. This means the wire carrying the voltage is open or broken and voltage cannot continue to flow. The effect is the operating component will not function. The term “SHORT CIRCUIT” means there is voltage being lost to another component wire or to ground. This could result in the wrong component being operated or the blowing of a circuit protection device (fuse or circuit breaker). The term “GROUNDED CIRCUIT” means the voltage is going directly to ground. This usually results in no component operation, a blown fuse or a tripped breaker. To test for an “OPEN CIRCUIT”, use a volt-ohmmeter and check from one end of the wire to the other. If voltage is not present, trace the circuit from the control point to the operating point until the open is found. To test for a “SHORT CIRCUIT”, use a volt-ohmmeter and check for very low resistance in different parts of the circuit or continuity between the circuit wire and ground. To test for a “GROUNDED CIRCUIT”, use a volt-ohmmeter and check for continuity between the circuit wire and ground.

55-6

Wire Color

Designation

Black

Dark Blue

DKBL

Light Blue

LTBL

Dark Brown

DKBR

Gray

Dark Green

DKGN

Light Green

LTGN

White

Orange

Pink

Purple

Red

Tan

Yellow

SECTION 55 - ELECTRICAL SYSTEM Op. 55 640

CONTROL MODULE CONNECTOR

The connector, 1, is a 12-pin connector and all pins have corresponding wires.

1 A1455-07

1 Looking at the end of the connector with the aligning grooves as shown, counting pins right to left: • • • •

Top row - pins 1 through 3 Second row - pins 4 through 7 Third row - pins 8 through 10 Bottom row - pins 11 and 12

19990287

CONNECTOR PIN #

WIRE COLOR

TO OR FROM COMPONENT

PK/LTBL

TO BOOM SOLENOID

W/DKBL

TO START RELAY

R/LTGN

FROM 6-AMP CIRCUIT BREAKER

T/W

TO SEAT SWITCH

FROM KEY SWITCH “ST” TERMINAL

FROM SEAT SWITCH

LTGN

FROM SEAT BELT SWITCH

PK/W

NOT USED

O/DKBR

FROM KEY SWITCH “IGN” TERMINAL

LTGN/R

TO SEAT BELT SWITCH

TO DASH PANEL GROUND

LTGN/W

TO SEAT BELT LIGHT (CONSOLE)

55-7

SECTION 55 - ELECTRICAL SYSTEM

SPECIFICATIONS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-volt negative ground Battery (anchored plates recommended) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE Group 70, 12-volt (side stud) Battery Rating (CCA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 amp @ --18° C (0° F) Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key start and solenoid

Circuit Protection Ignition (All Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 amp (#768115) Control Module Restraint System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 amp (#768106) Glow Plugs (LS125 Diesel Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 amp Fuel Solenoid Circuit (LS125 Diesel Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diodes (two)

Ignition System

Fuel Ignition Type Spark Plug Type Factory-Installed Plug Spark Plug Gap Spark Plug Tightening Torque

LS120 with P218 Engine

LS125 with E673 Engine

Gasoline

Diesel

Spark

Compression

AC - R42CLT3

----------

Champion RS 12YC

----------

0.64 mm (0.025″)

----------

31 - 41 N⋅m (25 - 30 ft. lbs.)

----------

Alternator LS120 P218 Onan gasoline engine (internal flywheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 amp LS125 E673 New Holland diesel engine (external) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 amp Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid State Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid State Minimum Voltage Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 volts AC Shaft Alignment (maximum bend) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 mm (0.003″) Regulator Voltage Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 15 volts DC Maximum Regulator Amperage Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 amp Flywheel/Pulley Assembly Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9 N⋅m (6 - 7 ft. lbs.)

55-8

SECTION 55 - ELECTRICAL SYSTEM Starter Amperage Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 amp Commutator Diameter New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.0 mm (1.26″) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.0 mm (1.22″) Commutator Out-Of-Round New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002″) Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.160″) Commutator Segment Depth Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008″) Shaft Alignment (Maximum Bend) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004″) Brush Length New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.0 mm (0.67″) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 mm (0.45″) Brush Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66 - 2.24 kg (3.66 - 4.94 lbs) Pinion Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 - 2.0 mm (0.02″ - 0.08″) Main Wiring Harness LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH#9827113 LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH#9828624

Optional Lights Round Warning (Flashing) Lamp Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH#130609 Lens/Bulb (#199) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH#277105 Rectangular White Lamp Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH#86533428 Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH#86533429 Rectangular Red Lamp Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH#9829515 Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH#86505510

Miscellaneous Electrical System Components Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key start and relay Hydrostatic Charge Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 bar (80 PSI) Hydrostatic Charge Pressure Low Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 bar (50 PSI) Solenoid (Boom Lockout) Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 ± 0.2 ohms Maximum Amperage Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 to 2.0 amp Engine Coolant Switch Closes at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108° - 112° C (226° - 234° F) Resets at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106° C (223° F) Engine Crankcase Oil Pressure Switch Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . above 0.4 bar (6 PSI) Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . below 0.4 bar (6 PSI) Glow Plug Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 ohm Engine Coolant Sender Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 ohms at 50° C (122° F) 52 ohms at 80° C (176° F) 27 ohms at 100° C (212° F) 16 ohms at 120° C (248° F)

55-9

SECTION 55 - ELECTRICAL SYSTEM

WIRING DIAGRAMS

19994669

LS120 CONTROL MODULE RESTRAINT SYSTEM - TROUBLESHOOTING 3

55-10

SECTION 55 - ELECTRICAL SYSTEM

19994670

LS120 CONTROL MODULE RESTRAINT SYSTEM - WIRING DIAGRAM 4

55-11

SECTION 55 - ELECTRICAL SYSTEM

19994671

LS125 CONTROL MODULE RESTRAINT SYSTEM - TROUBLESHOOTING 5

55-12

SECTION 55 - ELECTRICAL SYSTEM

19994672

LS125 CONTROL MODULE RESTRAINT SYSTEM - WIRING DIAGRAM 6

55-13

SECTION 55 - ELECTRICAL SYSTEM

TROUBLESHOOTING PROBLEM Engine will not crank

POSSIBLE CAUSE

CORRECTION

Operator not in seat; seat belt buckled out of sequence

Properly sequence the restraint system by sitting in seat and buckling seat belt

Low battery voltage

Recharge or replace battery

No battery voltage to control module

Check or replace 6-amp circuit breaker Check for open in R/LTGN wire to control module (no TIMER light)

No battery voltage to ignition key switch

Check or replace 15-amp circuit breaker Check for open in R/W wire to ignition switch “BAT” terminal

No battery voltage from ignition switch

Check for battery voltage from “ST” terminal through W wire to control module; if open, repair wire Check for battery voltage from “IGN” terminal through O/DKBR wire to control module; if open, repair wire Check for failed ignition key switch; replace if necessary Check for no ground or poor ground; repair as necessary

No start relay operation

Check for open in W/DKBL wire from control module to relay Test or replace start relay

No start solenoid operation

Test or replace start relay Check for open in W/R wire from start relay to start solenoid; repair as necessary Check for inoperative start solenoid; replace if necessary Check for inoperative starter motor; repair or replace as necessary

Engine cranks slowly

Belt clutch

Disengage belt clutch, especially in cold weather start-ups

Draw from hydraulic system

Check that control pedals are in neutral and the auxiliary hydraulic valve is not on

55-14

SECTION 55 - ELECTRICAL SYSTEM

PROBLEM Engine cranks but wonâ&#x20AC;&#x2122;t start

POSSIBLE CAUSE No power to fuel solenoid

CORRECTION Check for battery voltage to fuel solenoid, for open in O/LTBL wire or in 6-amp diode Check for open in LTBL/O wires or in 1-amp diode Check fuel solenoid for operation; repair or replace as necessary Check for no ground or poor circuit ground; repair as necessary Check for fuel in fuel tank; fill with fuel and bleed all the air from the system

Engine cranks and smokes but wonâ&#x20AC;&#x2122;t start (LS125 only)

No preheat; no glow plug operation

Check 30-amp glow plug circuit breaker; replace circuit breaker if inoperative Check for voltage in R/B wire from 30-amp circuit breaker to glow plug relay; if open in R/B wire, replace wire Check for open in W/DKBL wire from start relay to glow plug control; repair as necessary Check for inoperative glow plug relay; replace as necessary Check for voltage LTBL/B wire from glow plug control to glow plug relay; if open in LTBL/B wire, repair wire Check for faulty engine temperature sensor; replace if necessary Check for open in the PU/LTGN wire to resistor; repair wire as necessary Check for faulty resistor; replace as necessary Check for open in Y/LTGN wire from resistor to glow plug control; repair as necessary Check for inoperative glow controller; replace if necessary

plug

Check for bad glow plugs; replace as required

55-15

SECTION 55 - ELECTRICAL SYSTEM

PROBLEM Engine wonâ&#x20AC;&#x2122;t crank or start

Incomplete battery charging

POSSIBLE CAUSE

CORRECTION

Seat belt not buckled

Buckle seat belt

Loose or disconnected wiring

Inspect and fix any loose wiring

Faulty key switch

Repair the wiring connection or replace switch

Poor battery charging; or battery loses charge

Charge or replace battery

30-amp key main fuse blown

Replace fuse (or engine wiring harness, if necessary)

Excessive load for starter

Disconnect transmission belt clutch

Clogged air cleaner

Clean air cleaner

Damaged starter

Repair or replace starter

Faulty wiring

Inspect and correct

Battery electrolyte low

Add distilled water to correct level

Faulty battery

Replace battery

Alternator brush worn out

Replace brush

55-16

SECTION 55 - ELECTRICAL SYSTEM

19990273

CONTROL MODULE STARTING CIRCUIT VOLTAGE FLOW - LS120

through the R/LTGN wire to the control module, pin #3 of the wire harness connector.

Make sure the battery is connected and the control module Service/Operate switch is in the OPERATE position. 1. Sit in seat (seat switch activated); this is the first step in the start/boom lock solenoid sequence. 2. Buckle seat belt (seat belt activated); this is the second step in the start/boom lock solenoid sequence. 3. Turn ignition key switch to the “START” position. Five control module diagnostic lights should be on: • • • • •

START SOL (Solenoid) SEAT BELT TIMER

55-17

Battery voltage also continues through the R/W power wire from the auxiliary side of the 15-amp circuit breaker to the “B” battery terminal at the ignition key switch. Battery voltage continues through the switch and the O/DKBR wire to harness connector pin #9. The control module is grounded from harness connector pin #11 to frame ground. The control module sends battery voltage to the seat switch from connector pin #4 through the T/W wire. When the operator sits on the operator’s seat and the switch is closed (switch activated), battery voltage passes through resistor-type diodes in the T/W wire, lowering the voltage before the switch. The voltage returning to the control module through the T wire to connector pin #6 will be 1.2 - 1.6 volt less than battery voltage. When the ignition key switch is turned to the start position, battery voltage passes from the “ST” terminal through the W wire to pin #5 at the control module. Battery voltage continues from the control module pin #2 through the W/DKBL wire to the start relay. The start relay is then activated, connecting the battery side R wire to the start side W/R wire to the start solenoid. This activates the start solenoid, and the starter motor will engage, starting the engine.

SECTION 55 - ELECTRICAL SYSTEM

19990277

CONTROL MODULE STARTER MOTOR VOLTAGE FLOW - LS120

The ignition key switch receives its power from the auxiliary side of the 15-amp circuit breaker through the R/W wire. When the key is turned to the start position, power continues through the W wire to connector pin #5.

The control module then sends power from pin #2 through the W/DKBL wire to the start relay, activating the relay connecting the battery side of the relay to the out terminal. Power then continues through the W/R wire activating the start solenoid, beginning starter rotation and starting the engine.

55-18

SECTION 55 - ELECTRICAL SYSTEM

19994613

CONTROL MODULE STARTING CIRCUIT VOLTAGE FLOW - LS125

START SOL (Solenoid) SEAT BELT TIMER

55-19

Battery voltage continues through the R/W power wire from the auxiliary side of the 15-amp circuit breaker to the “B” battery terminal at the ignition key switch. Battery voltage continues through the switch and the O/DKBR wire to harness connector pin #9. Battery voltage also continues through the R/W power wire from the auxiliary side of the 15-amp circuit breaker to the start relay. The control module is grounded from harness connector pin #11 to frame ground. Battery voltage is sent to the seat switch from the control module connector pin #4 through the T/W wire. When the operator sits on the operator’s seat and the switch is closed (switch activated), battery voltage passes through resistor-type diodes in the T/W wire, lowering the voltage before the switch. The voltage returning to the control module through the T wire to connector pin #6 will be 1.2 - 1.6 volt less than battery voltage. When the ignition key switch is turned to the start position, battery voltage passes from the “ST” terminal through the W wire to pin #5 at the control module. Battery voltage continues from the control module pin #2 through the W/DKBL wire to the start relay. The start relay is then activated, connecting the battery terminal R/W wire to the start terminal W/R wire to the start solenoid. This activates the start solenoid, and the starter motor will engage, starting the engine.

SECTION 55 - ELECTRICAL SYSTEM

19994617

CONTROL MODULE STARTER MOTOR VOLTAGE FLOW - LS125

The control module then sends power from pin #2 through the W/DKBL wire to the start relay, activating the relay connecting the battery terminal of the relay to the out terminal. Power then continues through the W/R wire activating the start solenoid, beginning starter rotation and starting the engine.

55-20

SECTION 55 - ELECTRICAL SYSTEM

CHARGING SYSTEM TROUBLESHOOTING The working speed range of the alternator is 1600 - 5600 RPM. Set the skid-steer loader engine speed at full throttle RPM when performing alternator output tests.

TEST CONDITION

NORMAL READINGS

REMARKS

No-Load Voltage Test: With engine at full throttle, connect voltmeter leads across alternator terminals.

28 volts minimum

AC >

If less than 28 volts, check wires and/or wire connections inside alternator.

If permanent magnets are demagnetized; replace flywheel and magnet assembly.

Alternator Coil Continuity Test: With the engine stopped, connect circuit continuity tester between alternator terminals.

Continuity observed

If no continuity, check wiring inside alternator.

Open coil, repair or replace stator assembly.

Alternator Coil to Ground Test (Shorted): With the engine stopped, connect ohmmeter lead to one alternator terminal and the other lead to coil plate.

3000 minimum

ohms >

If less than 3000 ohms resistance, replace the alternator stator assembly.

Flywheel Magnet Test: Rotate flywheel by hand.

12 repulses/ rev.; > rotation should be smooth and uniform.

If no repulses and rotation is free-turning, the magnets are demagnetized; replace flywheel and magnet assembly.

Alternator/Regulator Output Tests: Connect voltmeter across battery terminals, connect ammeter in series in R (red) lead to starter motor battery terminal. Set engine speed to full throttle RPM, with no artificial load to battery.

Between 0.5 and > 14 amps

If amperage output is zero, the alternator or regulator is faulty, or there is a bad wiring connection. Check wiring and alternator separately, and repair or replace as required.

If amperage output is 0.5 - 14 amps and voltage is 14 volts or more, check for defective or undercharged battery.

Alternator/Regulator Output Tests (cont.): Apply artificial load to battery

14 amps at 14 > volts

If amperage exceeds 14 amps or voltage is more than 15 volts, replace the regulator

55-21

SECTION 55 - ELECTRICAL SYSTEM

TESTING Both the LS120 and LS125 skid-steer loaders are equipped with a boom lockout, solenoid valve restraint system controlled by a central control module. This system ties the seat, seat belt and ignition key switches into the boom lock solenoid valve circuit. If

19990273

the operator unbuckles the seat belt, is out of the seat, or turns the ignition key switch to the OFF position, the boom will not move. The following wiring diagrams show the individual restraint system circuits.

CONTROL MODULE RESTRAINT SYSTEM - LS120 11

55-22

SECTION 55 - ELECTRICAL SYSTEM

19994613

CONTROL MODULE RESTRAINT SYSTEM - LS125 12

55-23

SECTION 55 - ELECTRICAL SYSTEM

CONTROL MODULE RESTRAINT SYSTEM OPERATION

This is a sequence system to interlock the seat and seat belt into the engine start circuit and boom hydraulic circuit. The operator must properly sequence the system on LS120 and LS125 loaders equipped with this system. The operator must sit in the seat first, and then buckle the seat belt to activate the boom lock solenoid valve and to start the engine. If the operator unbuckles the seat belt, is out of the operatorâ&#x20AC;&#x2122;s seat, or turns the ignition key switch to the OFF position, the boom solenoid will activate and prevent movement of the boom. The control module has a Service/Operate switch, 1. The switch must be in the OPERATE position for normal engine starting and boom operation. When the switch is in the SERVICE position, the engine will start but the boom will not operate. Use the SERVICE position for service or adjustment of the hydrostatic system and final drives.

CAUTION

Before switching the service/operate switch to the service position, lower the boom and attachments to the ground or support the boom on the boom lock pins. The entire loader should be supported solidly with the wheels off the ground.

A1455-07

The control module has five diagnostic lights. The control module diagnostic lights are labeled: Control Module Circuit Starting

Diagnostic Light START

Boom Solenoid

SOL

Seat Switch

SEAT

Seat Belt Switch

BELT

Timer Circuit

TIMER

19990283

These lights will be explained in more detail in the DIAGNOSTIC LIGHTS section.

55-24

SECTION 55 - ELECTRICAL SYSTEM Start-Up Sequence The only proper start sequence is:

LS120

1. Sit in seat. (Seat belt warning light, 1, should go on.) 2. Buckle seat belt. (Seat belt warning light, 1, should go off.) 3. Start the engine. The operator must sit on the operator’s seat and buckle the seat belt. If the operator neglects to do either, the engine will not start. The switch located under the operator’s seat must be depressed to start the sequence. After the seat belt is buckled, the control module will now allow the operator to start the engine and use the boom and bucket. If after starting the engine, the operator unbuckles the seat belt, the control module interrupts the flow of power to the boom solenoid and the solenoid will close, preventing oil flow to and from the base end of the boom cylinders. The engine continues to run, but the boom won’t be operative. When the seat belt is rebuckled, the boom will operate again. If at any time, the operator leaves the seat for more than three seconds, the control module again prevents movement of the boom. To unlock the boom circuit, the operator must resequence the system by sitting on the seat and rebuckling the seat belt.

55-25

LS125

19990301

SECTION 55 - ELECTRICAL SYSTEM

CONTROL MODULE RESTRAINT SYSTEM TESTING

Before testing, make sure the control module Service/Operate switch is in the OPERATE position. The operator should remain in the operator’s seat while performing the following steps, in the order listed.

CAUTION If any of the functions fail to operate as described, further testing is required.

DANGER Do not operate the loader with a malfunctioning seat switch boom hydraulic interlock system. Engage the parking brake and lower the boom.

LS120

Testing Sequence: 1. Sit in the seat. • Console seat belt warning light, 1, should be ON.

LS125

19990301

16 •

Control module SEAT and TIMER diagnostic lights should be ON. If the TIMER diagnostic light fails to come on, there is no power to the control module from the 6-amp circuit breaker, the seat switch is not operating, or the seat belt switch is stuck in the closed position.

2. Raise off the seat. The following must happen: • SEAT light turns OFF. •

•

After two to five seconds, the TIMER light turns OFF. If the TIMER light does not go off after five seconds, replace the control module.

19990283

3. Sit back down and turn the ignition key switch to the ON position. • Nothing should happen. 4. Turn the ignition key to the START position and try starting engine. • Engine should not crank or start. •

•

Boom hydraulic circuit should not operate.

55-26

SECTION 55 - ELECTRICAL SYSTEM 5. Buckle the seat belt. • Console seat belt warning light, 1, should go OFF.

LS120

LS125

19990301

18 •

Control module SEAT, BELT, and TIMER diagnostic lights should be ON.

• • • 19990283

19 6. Turn the ignition key switch to the ON position. • Control module SOL, SEAT, BELT, and TIMER diagnostic lights should be ON.

• • • • 19990283

55-27

SECTION 55 - ELECTRICAL SYSTEM 7. Turn the ignition key switch to the START position. • Control module START, SOL, SEAT, BELT, TIMER and diagnostic lights should be ON. • Engine should start and operate. • Control module START light will go OFF when the ignition key is returned to the run position. • Boom and bucket hydraulic circuits should operate when controls are moved.

• • • • • 19990283

21 8. Unbuckle the seat belt. • Console seat belt warning light, 1, should come ON. • Engine should keep operating. • Control module TIMER and SEAT diagnostic lights should be ON; the SOL and BELT lights should go OFF. • Boom hydraulic circuit should not operate. • Bucket hydraulic circuit should still operate.

LS120

LS125

9. Buckle the seat belt. • Console seat belt warning light should go OFF. • Control module TIMER, SEAT, BELT, and SOL diagnostic lights should be ON. • Boom and bucket hydraulic circuits should operate normally.

19990301

If all the above functions operate correctly, the boom lockout circuit is good. If any of the functions fail to operate as described, further testing is required. Refer to Troubleshooting below, or the DIAGNOSTIC LIGHTS section below. If at any time the control module timer diagnostic light fails to come ON, there is no power to the control module from the 6-amp circuit breaker, the seat switch is not operating, or the seat belt switch is stuck. NOTE: Control module Start light will go OFF when the ignition key is returned to the run position after the engine is started. The Start light will only be on during the engine cranking mode.

55-28

SECTION 55 - ELECTRICAL SYSTEM

CONTROL MODULE RESTRAINT SYSTEM TROUBLESHOOTING PROBLEM Engine will not start

POSSIBLE CAUSE

CORRECTION

Operator not sitting in seat with seat belt buckled

Sit in seat and buckle seat belt

Seat switch unplugged

Reconnect seat switch connector

Inoperative seat switch

Replace switch

Operator did not sequence system correctly

Resequence system; sit in seat and buckle seat belt

No battery voltage to the control module (no timer light)

Check for battery voltage to 6-amp circuit breaker Check 6-amp circuit breaker Check R/LTGN power wire from 6-amp circuit breaker to control module

No battery voltage from control module to start relay

Check W/DKBL wire for open

Inoperative start relay

Replace relay

Loose connection between module and wire harness

control

No battery voltage to starter

Repair connector/retainer clip Check battery connections

positive

(+)

cable

Check battery connections

negative

(--)

cable

Check battery No battery voltage to ignition key switch

Check 15-amp circuit breaker Check battery voltage to 15-amp circuit breaker Check R/W power wire from 15-amp circuit breaker to ignition key switch

55-29

SECTION 55 - ELECTRICAL SYSTEM

PROBLEM

POSSIBLE CAUSE

CORRECTION

Engine will start but boom will not move

Service/Operate switch in the SERVICE position

Turn switch to the OPERATE position

No battery voltage from control module to boom solenoid

Check for open in PK/LTBL power wire to solenoid Check solenoid connection

Loose connection between module and wire harness

Engine running and boom will not move

control

ground/wire

and

Repair connector/retainer clip

SOL (solenoid) diagnostic light does not come on

No resistor-type diodes (or open diodes) in T/W wire of seat wire harness; replace seat wire harness

Inoperative solenoid

Replace solenoid

Operator unbuckled seat belt

Rebuckle seat belt

SOL (solenoid) diagnostic light does not come on

System out of sequence, resequence system; sit in seat and buckle seat belt

Intermittent operation of seat belt buckle switch

Dirt buildup in buckle; clean buckle assembly Inoperative seat belt switch; replace seat belt assembly

Loose connection between module and wire harness

control

Repair connector/retainer clip

No battery voltage from control module to boom solenoid

Check for open in PK/LTBL power wire to solenoid

TIMER diagnostic light goes off

Check solenoid connection

ground/wire

and

Tripping of 6-amp circuit breaker or faulty breaker; replace breaker Loose connection between module and wire harness

control

Solenoid coil to high amperage draw tripping 6-amp breaker; replace solenoid coil Repair connector/retainer clip

55-30

SECTION 55 - ELECTRICAL SYSTEM

CONTROL MODULE RESTRAINT SYSTEM CIRCUIT TESTING

Test circuits with a volt-ohmmeter. Before checking the individual circuits, make sure the battery voltage is okay. The battery should be in the range of 11 to 14 volts. If the battery is not properly charged, the restraint and starting circuits will not function correctly. If the problem is intermittent, check that the wire harness connector to the control module has a good, tight connection. If the connection is loose, the wire harness connector pins may lose contact with the control module connector. Connector Inspection The connector should be threaded straight and snugly onto the control module connector. If the connector is loose, check the pins and make sure they are not bent. To check the continuity of certain pins, remove the wire harness connector plug from the control module. To prevent damage to the wire harness or control module connectors, follow these steps.

Connector Removal Rotate the lock ring, 1, counterclockwise. Unscrew the lock ring completely off the control module. Pull the plug, 2, straight down from the module. IMPORTANT: If the connector is not removed and reinstalled straight, damage to the pins may occur. Connector Installation Align the grooves in the harness connector plug with the tab on the control module. Push the connector onto the module as straight and as far as possible. Turn the lock ring counterclockwise until the harness plug is snug, to maintain a good connection and seal. IMPORTANT: If the connector is not removed and reinstalled straight, damage to the pins may occur.

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1 2 A1455-07

SECTION 55 - ELECTRICAL SYSTEM Harness Continuity Check The connector is a 12-pin connector and all pins have corresponding wires. Looking at the end of the connector with the aligning grooves as shown, counting pins right to left: • • • •

Top row - pins 1 through 3 Second row - pins 4 through 7 Third row - pins 8 through 10 Bottom row - pins 11 and 12 19990287

24 CONNECTOR PIN #

CHECK FOR CONTINUITY WITH THE...

PK/LTBL wire at the boom solenoid

W/DKBL wire at the start relay

R/LTGN wire at the 6-amp circuit breaker

T/W wire at the seat switch

W wire at the key switch “ST” terminal

T wire at the seat switch

LTGN wire at the seat belt switch

O/DKBR wire at the key switch “IGN” terminal

LTGN/R wire at the seat belt switch

B wire at the dash panel ground

LTGN/W wire at seat belt light (console)

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SECTION 55 - ELECTRICAL SYSTEM Ignition Key Switch Test 1. Check the ignition key switch “B” battery terminal, 1, for battery voltage with a voltmeter. If there is no battery voltage, check for voltage on the R/W wire to the “AUX” terminal on the 15-amp circuit breaker. Also check that the circuit breaker is receiving battery voltage. 2. Turn the ignition key to the ON position, and check the ignition key switch “IGN” terminal, 2, for battery voltage. If there is no battery voltage, replace the ignition switch.

19993678

2 25

3. With the ignition key in the ON position, check for battery voltage at main wire harness T/W wire, 1, at the seat switch harness connector. If there is no battery voltage, there is an open in the T/W wire; replace the main harness.

19990300

26 Seat Switch Wire Harness Test NOTE: The seat harness must have a three-inch length bulge, 1. There are two resistor-type diodes in the T/W wire inside this harness. These resistors cut the voltage returning from the seat switch to the control module by 1.2 to 1.6 volt. The control module reads this voltage drop when the operator is sitting in the seat, and the module is set for the next step of the start-up sequence. If the harness does not have these diodes, the control module will not light the SOL (solenoid) light and will not unlock the solenoid.

19990302

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SECTION 55 - ELECTRICAL SYSTEM 1. Check the T/W and T wire continuity at the seat wire harness plug, 1, with the seat harness connected and the switch depressed. Set the volt-ohmmeter to Diode Test and place the positive probe on the T/W wire side of the seat switch harness. Place the negative probe on the T wire side of seat switch harness. • Continuity - OK • No Continuity - Reverse leads and retest. If still no continuity, test individual wires as described below

19990303

28 2. Check the T wire continuity. Place the one probe on the T wire, 1, side of main harness connector. Place the other probe on the T wire, 2, side at the seat switch connector. • Continuity with Low Resistance - OK • No Continuity - Replace seat wire harness

3. Check the T/W wire continuity. Set the volt-ohmmeter to Diode Test and place the positive probe on the T/W wire side, 3, of main harness connector. Place the negative probe on the T/W wire, 4, side at the seat switch connector. • Continuity - OK • No Continuity - Reverse leads and retest. If still no continuity, replace seat wire harness

19990302

4. Check the T/W wire resistor diodes. Reconnect the seat wire harness in the cab. With the ignition key switch ON and the seat switch connected and closed, check the voltage at the T/W wire, 1. The voltage should be 1.2 to 1.6 volt less than battery voltage. • 1.2 to 1.6 less than battery - OK • Battery voltage - replace seat wire harness • More than 1 volt less than battery - replace seat wire harness

19993681

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SECTION 55 - ELECTRICAL SYSTEM Seat Switch Test 1. Check the seat switch at the switch connector. 2. Place the positive probe on one leg of connector, 1. 3. Place the negative probe on the other leg of connector, 2. 4. Depress the switch. • Continuity with No Resistance - OK • No Continuity - Replace switch 5. Release the switch. • No Continuity - OK • Continuity - Stuck switch; replace switch Seat Belt Buckle Switch Test 1. Check the seat belt buckle switch at the belt wire harness connector. 2. Place the one probe on the male pin side of harness connector, 1. 3. Place the other probe on the female side of harness connector, 2. 4. Leave the seat belt unbuckled. • No Continuity - OK • Continuity - Replace seat belt buckle assembly 5. Buckle the seat belt. • Continuity - OK • No Continuity - Replace seat belt buckle assembly NOTE: The seat belt should activate the buckle switch with clearances between 4.1 and 5.8 mm (0.16″ - 0.23″) at 3, before the buckle latches. The belt and buckle should securely latch before the belt and buckle bottom out. If the seat belt assembly does not fall within these specifications, replace the complete seat belt assembly.

55-35

1 2

19990304

3 1 19990305

SECTION 55 - ELECTRICAL SYSTEM Boom Solenoid Circuit and Valve Testing 1. With the ignition key in the ON position, check for battery voltage at the female connector PK/LTBL wire, 1, of the main harness. Sit in the seat and buckle the seat belt. The meter should show battery voltage. If there is no battery voltage, there is an open in the PK/LTBL wire; replace the harness. If the solenoid failure is due to being shorted, it can contribute to tripping of the 15-amp circuit breaker and possible wire harness damage.

3 2

2. Check the resistance of the solenoid coil using a ohmmeter. Insert one meter probe into the female connector, 2, of coil wire and touch the other probe to the male connector, 3, of the coil wire. • 7.0 to 9.0 ohms - OK • More than 9.0 ohms - There is a shorted circuit within the coil; replace solenoid coil • Less than 7.0 ohms - There is an open circuit within the coil; replace solenoid coil

19990306

3. Check the amperage draw of the solenoid coil by connecting an ammeter in line with the PK/LTBL power wire female connector, 1, from the main harness to the male connector, 2, of the solenoid connector. Sit in the seat, buckle the seat belt, and turn the ignition switch ON. • 1.0 to 2.0 amps - OK • No meter reading - Check the power wire from the seat switch/ignition key switch. If the circuit is open; repair power wire • More than 2.0 amps - There is a shorted circuit in the coil; replace solenoid coil

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SECTION 55 - ELECTRICAL SYSTEM

CONTROL MODULE DIAGNOSTIC LIGHTS The control module has five diagnostic lights. The diagnostic lights and the following Troubleshooting Flow Charts help locate the possible causes of loader electrical problems. The control module lights are: Control Module Circuit Starting

Diagnostic Lights START

Boom Solenoid

SOL

Seat Switch

SEAT

Seat Belt Switch

BELT

Timer Circuit

TIMER

NOTE: The TIMER and SEAT diagnostic lights should both turn ON when the seat switch is activated as the operator sits in the seat. The diagnostic lights follow a regular sequence during the normal start-up steps. Make sure the control module Service/Operate switch is in the OPERATE position. Step #1 - Sit in the seat. • •

SEAT light turns ON. TIMER light turns ON.

Step #2 - Buckle seat belt. •

BELT light turns ON.

Step #3 - Turn ignition key switch to the ON/RUN position. •

SOL light turns ON.

Step #4 - Turn the ignition key switch to the START position. •

START/IGN light turns ON (goes out when key is released).

Step #5 - Normal operation; four lights remain on. • • • •

SOL SEAT BELT TIMER

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19990283

SECTION 55 - ELECTRICAL SYSTEM

TIMER LIGHT AND CIRCUIT TEST 1. Sit in the seat and make sure two diagnostic lights are on: • SEAT light turns ON. • TIMER light turns ON. If the TIMER diagnostic light fails to come on, there is no power to the control module from the 6-amp circuit breaker, the seat switch is not operating, or the seat belt switch is stuck. Test these circuits.

•

19990283

2. Raise off the seat. The following must happen: • SEAT light turns OFF. • After two to five seconds, the TIMER light turns OFF.

If the TIMER light does not go off after five seconds, replace the control module.

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SECTION 55 - ELECTRICAL SYSTEM

LS120 DIAGNOSTIC FLOW CHART

Use the following diagnostic and troubleshooting chart to isolate a loader electrical problem. Use these charts in conjunction with the diagnostic lights and the individual electrical wiring circuit diagrams that follow. The individual diagrams show - and the text explains - the loader start-up steps and current flow.

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NOTE: NEVER TEST WITH THE SEAT OUT OF THE LOADER OR THE SEAT SWITCH HARNESS BYPASSED. THE SEAT SWITCH AND SEAT WIRING HARNESS MUST BE IN THE CIRCUIT FOR ALL TESTING.

SECTION 55 - ELECTRICAL SYSTEM

Battery Voltage 11 - 14V?

Charge or replace battery.

Is seat belt buckle switch stuck?

Sit in seat. Timer and seat light should both turn ON. NOTE: Never test with the seat out of the machine.

Timer light ON?

Yes Replace seat belt buckle. Yes

Seat light ON?

Yes

Check power supply (Seat) at seat switch plug for battery voltage.

Reconnect plug. Check wire harness: Check continuity between Pins #4 and #6 at control module wire harness connector with seat switch depressed.

Check power supply (Control Module): Test for battery voltage at Pin #3 (power) and Pin #11 (ground). Yes

Go To A

No Go To B

(Open circuit in T or T/W wires). Replace wire harness. Replace control module.

Check seat switch wire harness. See Seat Wire Harness Test.

Check seat switches.

OK Replace seat switch wire harness.

Check continuity of Pins #4 and #6 to ground.

OK Replace control module.

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Replace wire harness.

Replace switches.

SECTION 55 - ELECTRICAL SYSTEM

Console seat belt light ON?

Check wire harness: Check for continuity between Pins #11 and #12 at control module wire harness connector.

Yes

Buckle seat belt.

Check continuity of B (ground) wire between plug and console light.

Seat belt light ON?

(Open circuit in B wire.) Replace wire harness.

Check LTGN/R wire at seat belt buckle switch connector to frame ground for 1.2 to 1.8 volts below actual system battery voltage.

Replace light.

Yes

(Open circuit in LTGN/W wire). Replace wire harness.

Replace control module.

Check continuity of Pin #10.

Yes

Check continuity of LTGN/W wire between plug and console light.

Check continuity between Pin #7 and #10 with seat belt buckled.

Check continuity of Pin #7.

OK Replace control module.

Check belt buckle switch continuity when buckled.

Check belt buckle switch. No

Console seat belt light OFF?

Replace belt buckle.

Replace belt buckle half.

(Open circuit in LTGN or LTGN/ R wires.) Replace wire harness

Light goes dim.

Replace control module.

Yes

Turn ignition key to ON position.

Solenoid light ON?

Check for battery voltage between Pins #9 and #11 at control module connector.

Check O/DKBR wire for battery voltage Pin #9 to frame ground.

Yes

Go To C

Go To D

Go To E

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Check dash panel ground.

SECTION 55 - ELECTRICAL SYSTEM

B Check Pin #3: Test for battery voltage from Pin #3 to frame ground.

Check power supply at 6 amp circuit breaker aux. terminal for battery voltage.

Check power supply at battery terminal of 6 amp circuit breaker for battery voltage.

Yes

Check ground: Test Pin #11 (B wire) for proper ground to dash panel.

Check power supply at 15 amp circuit breaker for battery voltage.

Yes

(Open circuit in R/LTGN wire.) Replace wire harness.

Replace circuit breaker.

(Open circuit in B wire.) Replace wire harness.

D Check voltage across seat switch wire harness with seat switch depressed. Test probe into T and T/W wire for 1.2 to 1.6 volts.

E No

Check for battery voltage at ignition terminal of ignition switch.

Replace seat switch wire harness.

OK Replace control module.

(O/DKBR wire open circuit.) Replace wire harness.

Replace ignition switch.

No Check for battery voltage at R/W wire on battery terminal of ignition switch. No Check continuity of R/W wire from ignition switch to 15 amp circuit breaker and check circuit breaker. Repair as needed.

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SECTION 55 - ELECTRICAL SYSTEM

Boom solenoid operating?

Check for power at solenoid: Test for battery voltage at PK/ LTBL and B wire at solenoid plug.

Yes

Check continuity of Pin #1 to frame ground.

Yes

Check voltage between Pin #5 to frame ground for battery voltage.

Yes

Check for battery voltage at start terminal of ignition switch. Yes

(Open circuit in W wire.) Replace wire harness.

Check continuity Pin #2 to Pin #11.

Replace control module.

Check continuity of Pin #2 to frame ground. Ignition switch in Start position.

(Open circuit PK/LTBL wire.) Replace wire harness.

Replace control module.

The unit operates correctly.

The control module is in Service mode. Service mode allows unit to be started but keeps boom solenoid locked to prevent movement of boom and bucket.

Check B wire connection. Repair ground.

Replace solenoid.

Check solenoid operation.

Engine start light? Ignition Start position.

Check continuity at B wire of solenoid plug to frame ground.

(Open circuit in W/DKBL wire.) Replace wire harness.

Go To F

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Check dash panel ground.

Replace ignition switch.

SECTION 55 - ELECTRICAL SYSTEM

Unit starts?

Yes

Check for battery voltage at Pin #5 to frame ground.

Check for battery voltage at start term of ignition switch.

Yes

Replace ignition switch.

Yes

(Open circuit in W wire.) Replace wire harness.

Check continuity of Pin #2 to frame ground.

Yes

Check continuity of W/DKBL to B wire on start relay terminal. Yes

Replace control module.

(Open circuit in W/DKBL wire.) Replace wire harness.

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Replace relay.

SECTION 55 - ELECTRICAL SYSTEM

19990273

LS120 CIRCUIT DIAGNOSTICS

The following diagrams and text show and explain voltage (current) flow for the start-up sequence steps. The diagnostic lights on the control module are connected to the individual circuits to help isolate the cause of the problem. Pre-Operation Voltage - LS120 • Make sure the battery is connected. • Put the ignition key switch in the OFF position. • The control module Service/Operate switch can be in either position. • Do not sit in the operator’s seat (seat switch not activated). • Check that no diagnostic lights are on. The power originates at the battery and continues through the R positive battery cable to the battery

55-45

side of the start relay. From the relay, power goes through the R cable to the start solenoid on the starter. The power continues through the R wire to the battery side of the 15-amp circuit breaker, then through the R wire to the 6-amp circuit breaker. The power continues from the 6-amp circuit breaker through the R/LTGN wire to the control module, pin #3 of the wire harness connector. Battery voltage also continues from the auxiliary side of the 15-amp circuit breaker, through the R/W power wire, to the “B” battery terminal at the ignition key switch. The control module is grounded from harness connector pin #11 to frame ground. This circuit should show battery voltage when testing.

SECTION 55 - ELECTRICAL SYSTEM

19990274

37 Step #1 Voltage Flow - LS120 Make sure the battery is connected, the Service/Operate switch is in the OPERATE position, and the ignition key is in the OFF position. Step #1 - Sit in seat. (Seat switch activated.) Two diagnostic lights should be on: • •

SEAT TIMER

The power originates at the battery and continues through the R positive battery cable to the battery side of the start relay. From the relay, power goes through the R cable to the start solenoid on the starter. The power continues through the R wire to the battery side of the 15-amp circuit breaker, then through the R wire to the 6-amp circuit breaker. The power continues from the 6-amp circuit breaker through the R/LTGN wire to the control module, pin #3 of the wire harness connector. The control module sends battery voltage to the seat switch from connector pin #4 through the T/W wire. When the operator sits on the operator’s seat and the switch is closed (switch activated), battery voltage passes through resistor-type diodes in the T/W wire to the switch, lowering the voltage before the switch. The voltage returning to the control module through the T wire to connector pin #6 will be 1.2 - 1.6 volts less than battery voltage.

The control module is grounded from harness connector pin #11 to frame ground. Battery voltage continues from connector pin #12 through the LTGN/W wire to the console warning light, turning on the Fasten Seat Belt light. The light is grounded to frame ground. Problems, Causes and Corrections 1. TIMER and SEAT light go OFF. a. Check the 6-amp and 15-amp circuit breakers for proper wiring as shown, battery side to battery side. b. Check the battery voltage “IN” and “OUT” of the 6-amp circuit breaker. If the voltage difference is more than 0.5 volt, replace the circuit breaker. c. Check the R/LTGN power wire from the circuit breaker to the control module for a loose connection or short. 2. Console Fasten Seat Belt light does not light. a. Check the LTGN/W power wire from the control module to the seat belt indicator light for an open. b. Check for a blown or loose light bulb. c. Check the light ground for poor or no ground.

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SECTION 55 - ELECTRICAL SYSTEM

19990275

38 Step #2 Voltage Flow - LS120 Make sure the battery is connected, the Service/Operate switch is in the OPERATE position, and the ignition key is in the OFF position. Step #1 - Sit in seat. (Seat switch activated.) Step #2 - Buckle seat belt. (Seat belt switch activated.) Three diagnostic lights should be on: • • •

When the seat belt is buckled and the voltage returns to the control module, the module will turn off the console Fasten Seat Belt light. Problems, Causes and Corrections 1. BELT diagnostic light does not turn ON. a. Check the seat belt for proper operation; check for an open switch. b. Check the LTGN/R power wire to switch for open.

SEAT BELT TIMER

c. Check the LTGN return wire for open.

NOTE: The seat and seat belt switches must be activated in sequence to start the loader engine and activate the boom solenoid.

2. Console Fasten Seat Belt light does not go OFF and the SEAT and BELT diagnostic lights are ON. a. This indicates the seat belt is stuck; replace seat belt assembly.

The power originates at the battery and goes to the 6-amp circuit breaker. The power continues through the R/LTGN wire to the control module, pin #3 of the wire harness connector.

3. Console Fasten Seat Belt light comes on intermittently. a. Dirt in seat belt buckle; clean buckle.

The control module is grounded from harness connector pin #11 to frame ground.

b. Misadjusted seat belt switch; replace seat belt assembly.

Battery voltage goes from connector pin #10 through the LTGN/R wire to the seat belt buckle switch. When the seat belt is buckled (switch activated), the voltage returning to the control module pin #7 through the LTGN wire will be 1.2 - 1.8 volts below battery voltage.

c. Incorrect seat belt spade to seat belt buckle, replace complete seat belt assembly. DO NOT MIX THE TWO DIFFERENT SEAT ASSEMBLY HALVES.

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SECTION 55 - ELECTRICAL SYSTEM

19990276

39 Step #3 Voltage Flow - LS120 Make sure the battery is connected and the Service/Operate switch is in the OPERATE position. Step #1 - Sit in seat. (Seat switch activated.) Step #2 - Buckle seat belt. (Seat belt switch activated.) Step #3 - Switch the ignition key switch to the ON position. Four diagnostic lights should be on: • • • •

SOL SEAT BELT TIMER

The power originates at the battery and proceeds to the 6-amp circuit breaker. The power continues through the R/LTGN wire to the control module, pin #3 of the wire harness connector. Battery voltage also continues through the R/W power wire from the auxiliary side of the 15-amp circuit breaker to the “B” battery terminal at the ignition key switch. Battery voltage continues through the switch and the O/DKBR wire to harness connector pin #9.

The control module is grounded from harness connector pin #12 to frame ground. Battery voltage continues from harness connector pin #1 through the PK/LTBL wire to the boom solenoid. The solenoid is grounded to the main frame. Problems, Causes and Corrections 1. SOL (solenoid) light does not turn ON. a. Restraint system was not sequenced properly; resequence by sitting in seat and buckling seat belt. b. Check the seat switch wire harness for a 3-inch bulge for resistor-type diodes that cause proper voltage drop from seat switch; install new harness with diodes. c. Seat wire harness unplugged from seat wire harness with diode; reconnect plug. NOTE: Seat must be in loader and proper wire harness with diode installed for the control module to see the voltage drop to activate the system. NEVER USE A JUMPER WIRE AT THE MAIN WIRE HARNESS CONNECTOR TO JUMP THE SEAT AND HARNESS.

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SECTION 55 - ELECTRICAL SYSTEM 2. Solenoid does not activate. a. Check the ignition key switch for battery voltage and proper operation. b. Check the O/DKBR wire from the ignition switch to the control module for battery voltage or open; if open, replace wire harness. c. Check the PK/LTBL wire from the control module to the solenoid for battery voltage or open. d. Check the boom solenoid ground wire and grounding point behind the dash panel. 3. TIMER and SOL diagnostic lights turn OFF and boom will not move. The control module SEAT and BELT diagnostic lights are ON. Console Fasten Seat Belt light is ON. a. Check the ground wires and connections for good ground. b. Check the solenoid for excessive amperage draw, causing the 6-amp circuit breaker to trip and cut power to the control module. c. Check the 15-amp and 6-amp circuit breakers for proper wiring and power in to the battery side of both breakers.

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d. Check the 6-amp breaker in and out voltage. There should be no more than 0.5 volt difference. If the difference is more than 0.5 volts, replace breaker. e. Check the PK/LTBL wire for a short. IMPORTANT: Never use a jumper wire at the main wire harness connector to jump the seat and wire harness.

CAUTION If the seat and support assembly was removed for servicing, reinstall the seat assembly, reconnect the seat wire harness to the main harness and secure the seat in the normal operating position. Do not operate the skid-steer loader with a malfunctioning restraint system. To avoid potential serious injury, do not rewire to bypass the seat switch, seat belt switch, control module, or restraint system.

SECTION 55 - ELECTRICAL SYSTEM

LS125 DIAGNOSTIC FLOW CHART

NOTE: NEVER TEST WITH THE SEAT OUT OF THE LOADER OR THE SEAT SWITCH HARNESS BYPASSED. THE SEAT SWITCH AND SEAT WIRING HARNESS MUST BE IN THE CIRCUIT FOR ALL TESTING.

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SECTION 55 - ELECTRICAL SYSTEM

Battery Voltage 11 - 14V?

Charge or replace battery.

Is seat belt buckle switch stuck?

Sit in seat. Timer and seat light should both turn ON. NOTE: Never test with the seat out of the machine.

Timer light ON?

Yes Replace seat belt buckle. Yes

Seat light ON?

Yes

Check power supply (Seat) at seat switch plug for battery voltage.

Reconnect plug. Check wire harness: Check continuity between Pins #4 and #6 at control module wire harness connector with seat switch depressed.

Check power supply (Control Module): Test for battery voltage at Pin #3 (power) and Pin #11 (ground). Yes

Go To A

No Go To B

(Open circuit in T or T/W wires). Replace wire harness. Replace control module.

Check seat switch wire harness. See Seat Wire Harness Test.

Check seat switches.

OK Replace seat switch wire harness.

Check continuity of Pins #4 and #6 to ground.

OK Replace control module.

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Replace wire harness.

Replace switches.

SECTION 55 - ELECTRICAL SYSTEM

Console seat belt light ON?

Check wire harness: Check for continuity between Pins #11 and #12 at control module wire harness connector.

Check continuity of LTGN/W wire between plug and console light.

Yes

Buckle seat belt.

Check continuity of B (ground) wire between plug and console light.

Seat belt light ON?

(Open circuit in B wire.) Replace wire harness.

Replace light.

Check continuity between Pin #7 and #10 with seat belt buckled.

Yes

Replace control module. Check LTGN/R wire at seat belt buckle switch connector to frame ground for 1.2 to 1.8 volts below actual system battery voltage.

(Open circuit in LTGN/W wire.) Replace wire harness.

Check continuity of Pin #10.

Yes

Check continuity of Pin #7.

OK Replace control module.

Check belt buckle switch continuity when buckled.

Check belt buckle switch. No

Console seat belt light OFF?

Replace belt buckle.

Replace belt buckle half.

(Open circuit in LTGN or LTGN/ R wires.) Replace wire harness

Light goes dim.

Replace control module.

Yes

Turn ignition key to ON position.

Solenoid light ON?

Check for battery voltage between Pins #9 and #11 at control module connector.

Check O/DKBR wire for battery voltage Pin #9 to frame ground.

Yes

Go To C

Go To D

Go To E

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Check dash panel ground.

SECTION 55 - ELECTRICAL SYSTEM

B Check Pin #3: Test for battery voltage from Pin #3 to frame ground.

Check power supply at 6 amp circuit breaker aux. terminal for battery voltage.

Yes

Check ground: Test Pin #11 (B wire) for proper ground to dash panel.

Check power supply at battery terminal of 6 amp circuit breaker for battery voltage.

Check power supply at 30 amp circuit breaker for battery voltage.

Yes

(Open circuit in R/LTGN wire.) Replace wire harness.

Replace circuit breaker.

(Open circuit in B wire.) Replace wire harness.

D Check voltage across seat switch wire harness with seat switch depressed. Test probe into T and T/W wire for 1.2 to 1.6 volts.

E No

Replace seat switch wire harness.

Check for battery voltage at ignition terminal of ignition switch.

(O/DKBR wire open circuit.) Replace wire harness.

Replace ignition switch.

Replace control module.

Check for battery voltage at R/W wire on battery terminal of ignition switch. No Check continuity of R/W wire from ignition switch to 15 amp circuit breaker and check circuit breaker. Repair as needed.

55-53

SECTION 55 - ELECTRICAL SYSTEM

Boom solenoid operating?

Check for power at solenoid: Test for battery voltage at PK/ LTBL and B wire at solenoid plug.

Check continuity at B wire of solenoid plug to frame ground.

Yes

Check continuity of Pin #1 to frame ground.

Yes

Check voltage between Pin #5 to frame ground for battery voltage.

Check for battery voltage at start terminal of ignition switch. Yes

(Open circuit in W wire.) Replace wire harness.

The unit operates correctly.

The control module is in Service mode. Service mode allows unit to be started but keeps boom solenoid locked to prevent movement of boom and bucket.

Ignition switch in Start position.

Yes

Replace control module.

Check continuity of Pin #2 to frame ground.

(Open circuit PK/LTBL wire.) Replace wire harness.

Replace control module.

Check continuity Pin #2 to Pin #11.

Replace solenoid.

Check B wire connection. Repair ground.

Check solenoid operation.

Engine start light? Ignition Start position.

(Open circuit in W/DKBL wire.) Replace wire harness.

Go To F

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Check dash panel ground.

Replace ignition switch.

SECTION 55 - ELECTRICAL SYSTEM

Unit starts?

Yes

Check for battery voltage at Pin #5 to frame ground.

Yes

Check for battery voltage at start term of ignition switch.

Replace ignition switch.

Yes

(Open circuit in W wire.) Replace wire harness.

Check continuity of Pin #2 to frame ground.

Yes

Check continuity of W/DKBL to B wire on start relay terminal. Yes

Replace control module.

55-55

(Open circuit in W/DKBL wire.) Replace wire harness.

Replace relay.

SECTION 55 - ELECTRICAL SYSTEM

19994613

LS125 CIRCUIT DIAGNOSTICS

The following diagrams and text show and explain voltage (current) flow for the start-up sequence steps. The diagnostic lights on the control module are connected to the individual circuits to help isolate the cause of the problem. Pre-Operation Voltage - LS125 • Make sure the battery is connected. • Put the ignition key switch in the OFF position. • The control module Service/Operate switch can be in either position. • Do not sit in the operator’s seat (seat switch not activated). • Check that no diagnostic lights are on. The power originates at the battery and continues through the R positive battery cable to the start

solenoid at the starter. From the starter, power goes through the R wire to the battery side of the 30-amp breaker, then through the R wire to the 6-amp circuit breaker. The power continues from the 6-amp circuit breaker through the R/LTGN wire to the control module, pin #3 of the wire harness connector. Battery voltage continues through the R/W power wire from the auxiliary side of the 15-amp circuit breaker to the “B” battery terminal at the ignition key switch. Battery voltage also continues through the R/W power wire from the auxiliary side of the 15-amp circuit breaker to the start relay. The control module is grounded from harness connector pin #11 to frame ground. This circuit should show battery voltage when testing.

55-56

SECTION 55 - ELECTRICAL SYSTEM

19994614

41 Step #1 Voltage Flow - LS125 Make sure the battery is connected, the Service/Operate switch is in the OPERATE position, and the ignition key is in the OFF position. Step #1 - Sit in seat. (Seat switch activated.) Two diagnostic lights should be on: • •

SEAT TIMER

The power originates at the battery and continues through the R positive battery cable to the start solenoid at the starter. From the starter, power goes through the R wire to the battery side of the 30-amp breaker, then through the R wire to the 6-amp circuit breaker. The power continues from the 6-amp circuit breaker through the R/LTGN wire to the control module, pin #3 of the wire harness connector. The control module sends battery voltage to the seat switch from connector pin #4 through the T/W wire. When the operator sits on the operator’s seat and the switch is closed (switch activated), battery voltage passes through resistor-type diodes in the T/W wire to the switch, lowering the voltage before the switch. The voltage returning to the control module through the T wire to connector pin #6 will be 1.2 - 1.6 volts less than battery voltage.

1. TIMER and SEAT light go OFF. a. Check the 6-amp and 30-amp circuit breakers for proper wiring as shown, battery side to battery side. b. Check the battery voltage “IN” and “OUT” of the 6-amp circuit breaker. If the voltage difference is more than 0.5 volt, replace the circuit breaker. c. Check the R/LTGN power wire from the circuit breaker to the control module for a loose connection or short. 2. Console Fasten Seat Belt light does not light. a. Check the LTGN/W power wire from the control module to the seat belt indicator light for an open. b. Check for a blown or loose light bulb. c. Check the light ground for poor or no ground.

55-57

SECTION 55 - ELECTRICAL SYSTEM

19994615

42 Step #2 Voltage Flow - LS125 Make sure the battery is connected, the Service/Operate switch is in the OPERATE position, and the ignition key is in the OFF position. Step #1 - Sit in seat. (Seat switch activated.) Step #2 - Buckle seat belt. (Seat belt switch activated.) Three diagnostic lights should be on: • • •

SEAT BELT TIMER

c. Check the LTGN return wire for open.

NOTE: The seat and seat belt switches must be activated in sequence to start the loader engine and activate the boom solenoid.

2. Console Fasten Seat Belt light does not go OFF and the SEAT and BELT diagnostic lights are ON. a. This indicates the seat belt is stuck; replace seat belt assembly.

The power originates at the battery and goes to the 6-amp circuit breaker. The power continues through the R/LTGN wire to the control module, pin #3 of the wire harness connector.

3. Console Fasten Seat Belt light comes on intermittently. a. Dirt in seat belt buckle; clean buckle.

The control module is grounded from harness connector pin #11 to frame ground.

b. Misadjusted seat belt switch; replace seat belt assembly.

c. Incorrect seat belt spade to seat belt buckle, replace complete seat belt assembly. DO NOT MIX THE TWO DIFFERENT SEAT ASSEMBLY HALVES.

55-58

SECTION 55 - ELECTRICAL SYSTEM

19994616

43 Step #3 Voltage Flow - LS125 Make sure the battery is connected and the Service/Operate switch is in the OPERATE position. Step #1 - Sit in seat. (Seat switch activated.) Step #2 - Buckle seat belt. (Seat belt switch activated.) Step #3 - Switch the ignition key switch to the ON position. Four diagnostic lights should be on: • • • •

SOL SEAT BELT TIMER

55-59

c. Seat wire harness unplugged from seat wire harness with diode; reconnect plug. NOTE: Seat must be in loader and proper wire harness with diode installed for the control module to see the voltage drop to activate the system. NEVER USE A JUMPER WIRE AT THE MAIN WIRE HARNESS CONNECTOR TO JUMP THE SEAT AND HARNESS.

SECTION 55 - ELECTRICAL SYSTEM d. Check the 6-amp breaker in and out voltage. There should be no more than 0.5 volt difference. If the difference is more than 0.5 volts, replace breaker.

2. Solenoid does not activate. a. Check the ignition key switch for battery voltage and proper operation. b. Check the O/DKBR wire from the ignition switch to the control module for battery voltage or open; if open, replace wire harness. c. Check the PK/LTBL wire from the control module to the solenoid for battery voltage or open. d. Check the boom solenoid ground wire and grounding point behind the dash panel. 3. TIMER and SOL diagnostic lights turn OFF and boom will not move. The control module SEAT and BELT diagnostic lights are ON. Console Fasten Seat Belt light is ON. a. Check the ground wires and connections for good ground. b. Check the solenoid for excessive amperage draw, causing the 6-amp circuit breaker to trip and cut power to the control module.

e. Check the PK/LTBL wire for a short. IMPORTANT: Never use a jumper wire at the main wire harness connector to jump the seat and wire harness.

c. Check the 30-amp and 6-amp circuit breakers for proper wiring and power in to the battery side of both breakers.

55-60

SECTION 55 - ELECTRICAL SYSTEM

REMOVAL, INSTALLATION AND WIRING OF ELECTRICAL COMPONENTS This section demonstrates and explains the correct wiring of switches, relays, circuit breakers, senders, and solenoids. The text and tables indicate when and where battery voltage should be for the electrical components with the ignition key switch ON or OFF. This section explains the removal and installation of the switches, relays, control module, and main wire harness. Before repairing, changing, or adding any electrical components, read the following precautionary statements.

55-61

IMPORTANT: If any servicing or adjustments require the battery to be disconnected, or whenever welding on the skid-steer loader, disconnect the negative (--) ground battery cable. Failure to disconnect the battery may result in damage to the electrical system and components. IMPORTANT: Before removing the control module, disconnect the negative (--) battery cable. Failure to do so may cause damage to the control module.

SECTION 55 - ELECTRICAL SYSTEM Op. 10 223

FUEL SHUTOFF SOLENOID - LS120

The LS120 fuel shutoff solenoid is located on the front of the engine compartment at 1. The ignition key switch controls the fuel solenoid through the ignition coil, 2. The LS120 skid steer fuel solenoid receives battery voltage from the â&#x20AC;&#x153;IGNâ&#x20AC;? ignition terminal at the ignition key switch through the LTBL/B wire to the ignition coil positive (+) terminal. Voltage then travels through the PU wire to the solenoid.

2 19992824

44 Op. 10 223 10 Removal 1. Remove the latch pin and open the rear door. 2. Turn the fuel shutoff valve, 1, OFF in the fuel line, 2, at the bottom of the fuel tank. 3. Disconnect the negative (--) battery cable.

19991587

45 4. Remove the power wire, 1, from the ignition coil and the ground wire, 2, from the frame. 5. Mark and remove the IN and OUT fuel line hoses from the solenoid. 6. Remove the solenoid retaining clamp, 3, and remove the solenoid from the loader. 7. Remove the solenoid adapters.

3 2

19992824

1 46

55-62

SECTION 55 - ELECTRICAL SYSTEM Installation 1. Install the straight adapter, 1, to the inlet side, 2, of the solenoid and the 90 degree adapter, 3, to the outlet side, 4, of the solenoid.

19993711

47 2. Attach the solenoid with the retaining clamp, 1, attach the ground wire, 2, and tighten securely. 3. Attach the fuel line hoses to the solenoid. Check the rubber fuel line for any deterioration; replace if required.

1 2

19992824

48 4. Connect the solenoid power wire, 1, to the positive (+) terminal, 2, on the ignition coil. 5. Turn the fuel tank shutoff valve to the ON position. 6. Reconnect the negative (--) battery cable. 7. Install any shield removed for the repair, close and securely latch the rear door.

1 2 19993674

55-63

SECTION 55 - ELECTRICAL SYSTEM Op. 10 223

FUEL SHUTOFF SOLENOID - LS125

The LS125 fuel shutoff solenoid is located at the injection pump at 1. The ignition key switch controls the solenoid through two diodes.

The LS125 skid steer fuel solenoid receives battery voltage from the “IGN” terminal at the ignition key switch through the O/LTBL wire to a 6-amp diode. The battery voltage then continues through the LTBL/O wire to a 1-amp diode or through the LTBL/O wire, 2, to the fuel solenoid.

1 19993675

50 CONTINUITY WIRING TEST Disconnect the solenoid power wire, 2. With a voltmeter, touch one lead to the solenoid wire. Touch the other lead to a clean ground on the solenoid and turn the starter switch to the ON/RUN position. Observe the voltmeter reading. • •

More than 9.0 volts - OK Less than 8.9 volts - Check for shorted or open circuit, burned out fuse or faulty battery.

Op. 10 223 10 Removal 1. Remove the latch pin and open the rear door. 2. Unplug the LTBL/O wire, 1, connected to the solenoid. 3. Rotate the solenoid, 2, counterclockwise to remove the solenoid from the injection pump.

2 19993675

55-64

SECTION 55 - ELECTRICAL SYSTEM Inspection 1. Measure the protrusion of the plunger, 1, from the solenoid at 2. The plunger should protrude between 25.5 - 26.4 mm (1.00″ - 1.04″). If it is not within limits, replace the solenoid assembly.

2 52 2. Energize the solenoid, drawing the plunger into the body. Measure the protrusion of the plunger, 1, from the solenoid. The plunger should protrude between 11.5 - 14.5 mm (0.45″ - 0.57″). If it is not within the limits, replace the solenoid assembly.

53 Installation 1. Install a new sealing washer. 2. Thread the solenoid, 1, into the injection pump. 3. Attach the LTBL/O power wire, 2, to the solenoid terminal. 4. Install any shields removed. Close and securely latch the rear door.

2 1 19993675

55-65

SECTION 55 - ELECTRICAL SYSTEM

BATTERY Op. 55 301 40 Removal 1. Remove the latch pin and open the rear door. On LS120 loaders only, the top hood, 1, may be unlatched and pivoted up as shown. 2. Remove the negative (--) battery cable, 2. 3. Remove the positive (+) battery cable, 3. 4. Loosen the battery hold down clip, 4. 5. Slide the battery to the rear to remove from the support plate, 5.

3 2 4 5

9246-07

55 SPECIFICATIONS Battery type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt - SAE group 70 Battery rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 amps @ --18° C (0° F) Side Stud Overall dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1/4″ long x 7″ wide x 8-1/2″ high

A battery with anchored elements, top and bottom, is recommended due to possible rough operating conditions.

WARNING Do not lay metal objects across the posts of a battery to determine the battery’s charge. The air directly above the battery may be filled with explosive hydrogen gas and sparks may cause an explosion.

55-66

SECTION 55 - ELECTRICAL SYSTEM Installation 1. Thoroughly clean any dirt from the support plate. 2. Position the battery with the positive (+) post, 1, toward the front of the engine compartment. 3. Position the hold down clip, 2, on the battery base, 3, and tighten the retaining hardware. Use caution not to over-tighten the retaining clip and damage the battery. 4. Connect the positive (+) RED cable, 4, to the positive (+) terminal and the negative (--) BLACK cable, 5, to the negative (--) terminal. Do not overtighten. Observe the tightening specifications on the battery label. IMPORTANT: These loaders are a negative ground system. Always attach (--) to (--) negative terminals and (+) to (+) terminals. Crossing of terminal polarity may cause damage to the electrical system and alternator charging circuit. NEVER OPERATE THE LOADER WITH THE BATTERY DISCONNECTED.

WARNING Engine starting with a booster battery requires extreme care as batteries produce explosive gases. The slightest spark can cause an explosion. When starting a loader using a booster battery, ALWAYS FOLLOW THESE SAFETY STEPS: 1. COVER EACH BATTERY WITH A PIECE OF CARPET OR OTHER HEAVY MATERIAL. DO NOT REMOVE THE BATTERY VENT CAPS. 2. CONNECT ONE CABLE TO THE POSITIVE TERMINAL OF THE WEAK BATTERY. CONNECT THE OTHER END OF THE CABLE TO THE POSITIVE TERMINAL OF THE STRONGER BATTERY. 3. CONNECT THE SECOND CABLE TO THE NEGATIVE TERMINAL OF THE STRONGER BATTERY. 4. CONNECT THE REMAINING CABLE TO THE ENGINE BLOCK OR STARTER GROUND TERMINAL. REVERSE THIS PROCEDURE WHEN DISCONNECTING.

55-67

1 4 5 2 3

9246-07

SECTION 55 - ELECTRICAL SYSTEM Op. 55 201

IGNITION KEY SWITCH

The ignition key switch controls the flow of current from the battery to the loader engine starting circuit and other electrical functions and switches.

IGNITION KEY SWITCH WIRING - LS120 Battery Voltage

Color

Destination

R/W

From 15-amp circuit breaker

All Times

LTBL/B

To ignition coil (+) terminal

Key ON position

O/DKBR

To control module

Key ON position

To hour meter

Key ON position

To control module

Key “START” position

DKBR/O

To flasher switch

Key ON position

To light switch

Key ON position

19990294

IGNITION KEY SWITCH WIRING - LS125 Battery Voltage

Color

Destination

R/W

From 15-amp circuit breaker

All Times

O/LTBL

To diode in fuel solenoid circuit

Key ON position

O/DKBR

To control module

Key ON position

To glow plug relay

Key ON position

To hour meter

Key ON position

To control module

Key “START” position

DKBR/O

To flasher switchh

Key ON position

To light switch

Key ON position

To warning light bar

Key ON position

To regulator

Key ON position

O PU/Y LTGN/B

rectifier/

19992823

55-68

SECTION 55 - ELECTRICAL SYSTEM Op. 55 201 10 Removal 1. Disconnect the negative (--) battery cable. 2. Remove the seat and support assembly. 3. For better access, remove the dash panel retaining hardware, 1, and hydraulic filter support hardware, 2. Rotate the panel down for access to the back side of panel. 4. Remove the wire connections from the ignition key switch. 5. Remove the switch retaining nut, 3, on the front of the dash panel and remove the switch.

2 1 19993689

1 3 59

Installation 1. Reattach the wires to the switch as shown above. 2. Align the switch with the hole in the dash panel and attach the switch to the panel with the retaining nut. 3. Reinstall the dash panel, positioning the wires and harness to prevent damage. Install the panel and hydraulic filter retaining hardware. 4. Reinstall the seat and support assembly into the loader. Reconnect the seat wire harness plug. 5. Reconnect the negative (--) battery cable.

55-69

SECTION 55 - ELECTRICAL SYSTEM

CIRCUIT BREAKERS - LS120 15-Amp Circuit Breaker - LS120 The 15-amp circuit breaker protects the electrical system in case of a electrical overload. This circuit breaker resets automatically when the breaker cools or when the circuit is no longer overloaded. For control module restraint loaders, the breaker is also a junction point where the 6-amp circuit breaker receives its battery voltage, from the battery side of the 15-amp breaker.

4 3 2

15-Amp Circuit Breaker Wiring - LS120 Destination

Battery Voltage

From start relay

All times

R/W

To “BAT” terminal of ignition switch

All times

To “BAT” terminal of 6-amp circuit breaker (if equipped)

All times

Ref

Color

2 3

19990273

6-Amp Circuit Breaker - LS120 This circuit breaker is used only on loaders with the control module restraint system. The circuit breaker provides battery voltage and protects the control module restraint system. 6-Amp Circuit Breaker Wiring - LS120 Battery Voltage

Ref

Color

Destination

From the “BAT” side of the 15-amp circuit breaker

All times

R/LTGN

To the module

All times

control

55-70

SECTION 55 - ELECTRICAL SYSTEM Testing - LS120 Use a voltmeter to test a circuit breaker. The battery voltage must not drop more than 0.5 volt across the breaker.

1. Check voltage in, 1, from red wire battery side. 2. Check voltage out, 2, at the other side of the breaker. NOTE: If the voltage difference is more than 0.5 volt, replace the breaker.

19991590

61 Op. 55 100 24 Removal - LS120 1. Remove the latch pin and open the door. 2. Remove the 6-amp breaker wires, 1, and hardware, 2, and remove the breaker.

1 19991590

62 3. Remove the right side fender. 4. Remove the wires from the 15-amp circuit breaker terminals, 1. 5. Remove the circuit breaker retaining hardware, 2, and remove the breaker. Installation - LS120 1. Attach the breakers using the retaining hardware removed. 2. Reattach the wires to the proper sides of the breakers. 3. Reinstall the right side fender, and close and securely latch the rear door.

55-71

2 1

19993713

SECTION 55 - ELECTRICAL SYSTEM

CIRCUIT BREAKERS - LS125

LS125 loaders have three circuit breakers:

30-amp breaker (middle), 1. 6-amp breaker (left), 2. 15-amp breaker (right), 3.

• • •

The R wire from the start solenoid connects to one side of the 30-amp, 1, breaker. The two other R wires at this terminal go to the 6-amp, 2, and 15-amp, 3, breakers. The R/B wire from the other terminal of the 30-amp goes to the glow plug relay.

19993667

The R/LTGN wire from the 6-amp circuit breaker goes to the control module. On the 15-amp breaker, one R/W wire goes to the start relay and the other R/W wire goes to the “BAT” terminal of the key start switch. 30-Amp Circuit Breaker - LS125 The 30-amp circuit breaker protects the electrical system in case of a electrical overload. This circuit breaker resets automatically when the breaker cools or when the circuit is no longer overloaded. The breaker is in series with the glow plug circuit. The breaker is also a junction point where the 15-amp and 6-amp circuit breakers receive battery voltage, from the battery side of the 30-amp breaker. 30-Amp Circuit Breaker Wiring - LS125 Battery Voltage

Ref

Color

From the solenoid

start

All times

To the “BAT” side of the 15-amp circuit breaker

All times

Destination

1 4

To the “BAT” side of the 6-amp circuit breaker

All times

R/B

To the glow plug relay

All times

19994613

55-72

SECTION 55 - ELECTRICAL SYSTEM 15-Amp Circuit Breaker - LS125 The 15-amp circuit breaker protects the electrical system in case of a electrical overload. This circuit breaker resets automatically when the breaker cools or when the circuit is no longer overloaded. 15-Amp Circuit Breaker Wiring - LS125 Battery Voltage

Ref

Color

Destination

From the “BAT” side of the 30-amp circuit breaker

All times

R/W

To “BAT” terminal of ignition switch

All times

R/W

To start relay

All times

6-Amp Circuit Breaker - LS125 The circuit breaker provides battery voltage and protects the control module restraint system. This circuit breaker resets automatically when the breaker cools or when the circuit is no longer overloaded. 6-Amp Circuit Breaker Wiring - LS125 Battery Voltage

Ref

Color

Destination

From the “BAT” side of the 30-amp circuit breaker

All times

R/LTGN

To the module

All times

control

Circuit Breaker Wiring - LS125 The 30-amp breaker receives battery voltage from the start solenoid terminal through the R wire. The 15-amp and 6-amp circuit breakers receive battery voltage from the 30-amp breaker connection through two R wires.

Battery voltage passes through the 30-amp breaker and continues through the R/B wire to the glow plug relay.

Battery voltage passes through the 15-amp breaker and continues through two R/W wires. One R/W wire goes to the “BAT” terminal of the ignition key switch. The other R/W wire goes to the start relay.

5 1

Battery voltage passes through the 6-amp breaker and continues through the R/LTGN wire to the control module. 19994613

55-73

SECTION 55 - ELECTRICAL SYSTEM Testing - LS125 Use a voltmeter to test a circuit breaker. The battery voltage must not drop more than 0.5 volt across the breaker.

1. Check voltage in, 1, from red wire battery side. 2. Check voltage out , 2, at the other side of the breaker. NOTE: If the voltage difference is more than 0.5 volt, replace the breaker.

19993699

67 Op. 55 100 24

Removal - LS125 • 30-amp breaker (middle), 1. • 6-amp breaker (left), 2. • 15-amp breaker (right), 3.

1. Remove the latch pin and open the engine door. 2. Remove the battery as described in this section. 3. Remove the wires from the circuit breaker terminals. 4. Remove the circuit breaker retaining hardware and remove the breaker.

19993667

8 68

Installation - LS125 1. Attach the breaker using the retaining hardware previously removed. 2. Reattach the wires as shown to the proper side of the breakers. Attach the R battery cable, 4, to the 30-amp breaker. Attach the two R breaker connector wires, 5, from the 30-amp breaker to the 6-amp and 15-amp breakers. Attach the R/B wire, 6, for the glow plug relay to the other side of the 30-amp breaker. Attach the R/LTGN wire, 7, for the ignition module to the other side of the 6-amp breaker. Attach the R/W wires, 8, to the other side of the 15-amp breaker. 3. Reinstall the battery as described in this section. 4. Close and securely latch the rear door.

55-74

SECTION 55 - ELECTRICAL SYSTEM Op. 55 640

CONTROL MODULE Removal 1. Rotate the lock ring, 1, counterclockwise. 2. Unscrew the lock ring completely off the control module. 3. Pull the plug, 2, straight down from the module. 4. Remove the module retaining hardware, 3, and remove the module from the loader. IMPORTANT: If the connector is not removed and reinstalled straight, damage to the pins may occur.

Installation 1. Mount the control module with the retaining hardware, 1. Include the wire harness mounting clip, 2, under the left bolt head. 2. Align the grooves in the harness connector plug with the tab on the control module. 3. Push the connector onto the module as straight and as far as possible. 4. Turn the lock ring counterclockwise until the harness plug is snug, to maintain a good connection and seal. IMPORTANT: If the connector is not removed and reinstalled straight, damage to the pins may occur.

55-75

1 2 A1455-07

19993673

SECTION 55 - ELECTRICAL SYSTEM

SEAT SWITCH

The seat assembly is equipped with a push button switch attached to the bottom of the seat. When the operator sits in the seat, the switch depresses and closes the switch. The closed switch allows current to pass through the switch and return to the control module. There is also a resistor-type diode incorporated in the seat wire harness. NOTE: When testing the seat switch and wire harness, the seat and diode must be in place for proper operation.

SEAT SWITCH WIRING

The seat switch receives battery voltage from the control module through the T/W wire. Battery voltage passes through resistor-type diodes in the seat harness before the switch. The voltage drops 1.2 1.6 volts in the T/W wire. When the switch is depressed (closed), the lowered voltage returns to the control module through the T wire. The bulge in the harness shows the location of the resistor-type diodes.

19990274

71 Op. 55 201 15 Removal 1. Lift the front of the seat up and slide the seat to the front about 200 mm (8â&#x20AC;ł). Reach behind the seat and unplug the seat switch wire harness from the main wire harness, 1.

19990300

55-76

SECTION 55 - ELECTRICAL SYSTEM 2. Loosen and remove the screw, 1, holding the seat harness clip under the pan support. 3. Remove the seat retaining hardware, 2, and remove the seat from the support. 4. Unplug the wire harness, 3, from the seat switch.

3 1

19990303

73 5. Remove the switch retaining hardware, 1, and remove the switch from seat pan. Do not pry on switch base, or damage to the base may occur.

19990304

74 Installation 1. Insert the switch, 1, into the seat bottom making sure the switch is seated into the hole in the seat pan. IMPORTANT: If the switch is not seated properly when the retaining hardware is tightened, the switch flange will be broken. 2. Reconnect the wire harness connector, 2, to the switch. Make sure the connector latch is engaged and the connector is locked in place. 3. Install the seat harness retaining clip on the seat pan support with a bolt, 3, and nut. 4. Attach the seat assembly to the support plate with four capscrews, 4. Tighten the capscrews and the harness clip bolt. 5. Place the seat assembly in the loader, and plug the seat switch wire harness into the main wire harness. Slide the seat assembly into place, locating the front of the seat support over the locating pins.

55-77

2 3

1 19990303

SECTION 55 - ELECTRICAL SYSTEM

SEAT BELT BUCKLE ASSEMBLY

The seat belt buckle is equipped with a switch that is activated when the seat belt spade is inserted into the buckle. When the operator buckles the seat belt, voltage returns to the control module. Op. 55 201 14

Removal 1. Disconnect the negative (--) battery cable. 2. Unplug the seat belt wire harness, 1. 3. Remove the seat belt buckle pivot retaining bolt, 2. IMPORTANT: The switch inside the belt buckle is not serviced separately. Also, when replacing the belt assembly, replace it with a like brand assembly. DO NOT MIX SEAT BELT ASSEMBLIES. The two brands, Amsafe and Indiana Mills, are different designs and the parts are not compatible.

2 19990305

76 Inspection 1. Make sure the spade, 1, is not bent enough to prevent buckle engagement. 2. Check the buckle, 2, operation for proper latching and unlatching. 3. Make sure the belt, 3, extends completely. 4. Test the switch, 4, for continuity in the latched position. IMPORTANT: The switch inside the belt buckle is not serviced separately

19994643

77 Installation 1. Install the seat belt buckle with the pivot retaining bolt, 1. 2. Plug in the seat belt wire harness, 2. 3. Reconnect the negative (--) battery cable.

1 19990305

55-78

SECTION 55 - ELECTRICAL SYSTEM

WARNING LIGHT WIRING - LS120

The wiring of the LS120 warning light is shown here.

19994670

79 Op. 55 408 Removal - LS120 1. Remove the two screws, 1, holding the warning light case to the frame. 2. Disconnect the B ground wire and the LTGN/W wire from the light terminals.

8690-11

80 Installation - LS120 1. Reconnect the B ground wire, 1, and LTGN/W wire, 2, to the warning light. 2. Install the two screws securing the warning light case to the frame.

2 1 19993680

55-79

SECTION 55 - ELECTRICAL SYSTEM

WARNING LIGHT BAR WIRING - LS125

The wiring of the LS125 warning light bar is shown here.

19994672

82 Op. 55 408 Removal - LS125 1. Remove the four screws, 1, holding the warning light case to the frame. 2. Disconnect the wires of the light requiring replacement.

A1456-12

83 Installation - LS125 1. Reconnect the wires according to the “WARNING LIGHT BAR WIRING - LS125” diagram above. Connect the LTGN/W wire to the fasten seat belt light, 1. Connect the Y/DKBL wire to the alternator light, 2. Connect the Y/B wire to the engine oil pressure light, 3. Connect the Y/DKGN wire to the water temperature light, 4. Connect the LTBL/GY wire to the glow plug wait light, 5. Connect the PU/Y wires, 6, to the second terminals of lights. Connect ground wires, 7, to ground in light bar case, 8. 2. Install the four screws holding the warning light case to the frame.

1 8

7 2 3

4 19993679

5 84

55-80

SECTION 55 - ELECTRICAL SYSTEM

HOURMETER Op. 55 418

Removal 1. Disconnect the negative (--) battery cable. 2. Remove the seat and support. 3. Loosen the securing nut, 1, on the hourmeter bolt. 4. Remove the PU wire, 2, and ground wire, 3, from the hourmeter. 5. Remove the hourmeter from the dash panel. Installation 1. Install the PU wire, 2, and ground wire, 3, on the hourmeter terminal. 2. Attach the hourmeter to the dash panel bracket with the securing nut, 1. 3. Check the ground connection at 4. 4. Install the dash panel securing hardware. 5. Reconnect the negative (--) battery cable.

55-81

19993678

3 85

SECTION 55 - ELECTRICAL SYSTEM

START RELAY - LS120

WIRING - LS120 Ref

Color

W/R

W/DKBL

1 Destination

From battery To start solenoid From module

Battery Voltage

All times

Key START position

control Key START position

R/DKBL

From rectifier/ regulator

Engine running

To start solenoid

All times

To â&#x20AC;&#x153;BATâ&#x20AC;? side of 15-amp circuit breaker

All times

2 19990273

Op. 55 100 34 Removal - LS120 1. Remove the latch pin and open the door. 2. The top engine hood on LS120 models can be raised for better engine compartment access. 3. Remove the battery as described in this section. 4. Remove the tray support hardware, 1.

19991590

87 5. Disconnect the wires from the start relay, 1, terminals noting the wire position and routing.

19993713

55-82

SECTION 55 - ELECTRICAL SYSTEM 6. Note the position of the B ground strap, 1, under the one retaining bolt. Loosen and remove the two retaining nuts and bolts, 2.

19991590

89 Installation - LS120 1. Place the B ground strap, 1, under the one retaining bolt. Install the relay with the two retaining bolts and nuts, 2. 2. Reconnect the wires according to the â&#x20AC;&#x153;START RELAY WIRING - LS120â&#x20AC;? diagram above. 3. Reinstall the tray with the support hardware, 3. 4. Install the battery as described in this section. 5. Close and securely latch the rear door.

3 1

19991590

55-83

SECTION 55 - ELECTRICAL SYSTEM

START RELAY 1

WIRING - LS125 Battery Voltage

Ref

Color

Destination

R/W

From 15-amp circuit breaker

All Times

W/R

To start solenoid

Key START position

W/DKBL

From module

W/DKBL

To glow controller

plug Key START position

To ground

Key START position

3 5

control Key START position

19994625

Op. 55 100 34 Removal - LS125 1. Remove the latch pin and open the engine door. 2. Disconnect the negative (--) battery cable. 3. Remove the start relay cover retaining hardware, 1.

19993669

92 4. Disconnect the wires from the start relay, 1. 5. Remove the relay retaining hardware, 2.

Installation - LS125 1. Install the relay with the retaining hardware. 2. Reconnect the wires according to the “START RELAY WIRING - LS125” diagram above. 3. Install the relay cover using the hardware removed. 4. Connect the negative (--) battery cable. 5. Close and securely latch the rear door.

19993676

55-84

SECTION 55 - ELECTRICAL SYSTEM

GLOW PLUG - LS125 1

Op. 55 201 76 Removal 1. Remove the latch pin and open the engine door. 2. Disconnect the negative (--) battery cable. 3. Disconnect the LTBL/Y wire, 1, from the first glow plug.

19993675

94 4. Remove the glow plug bar, 1, by loosening the nuts, 2, holding the glow plug bar to the glow plugs. Turn the glow plugs, 3, counterclockwise to remove from the engine block.

2 95 5. Measure the resistance of the glow plug from the electrode, 1, to the housing, 2. The resistance should be close to 1.0 ohm, and not over 1.5 ohm. If the resistance is high or low, replace the glow plug. If the resistance is 0 ohm, the glow plug is short circuited; check the glow plug circuit wiring for damage.

1 OHMMETER

55-85

SECTION 55 - ELECTRICAL SYSTEM Installation 1. Install the glow plug, 1, into the engine block. 2. Install the glow plug bar, 2, and tighten the securing nut, 3, on each glow plug. 3. Reconnect the LTBL/Y wire to the first glow plug terminal. 4. Connect the negative (--) battery cable. 5. Close and securely latch the rear door.

3 97

55-86

SECTION 55 - ELECTRICAL SYSTEM

GLOW PLUG RELAY - LS125

WIRING Battery Voltage

Ref

Color

Destination

R/B

From 30-amp circuit breaker

All Times

LTBL/Y

To glow plugs

Key ON position

From switch

Key ON position

To glow controller

LTBL/B

ignition plug

Key ON position

From glow plug controller

Key ON position

3 5

19994626

Op. 55 100 34 Removal 1. Remove the latch pin and open the engine door. 2. Disconnect the negative (--) battery cable. 3. Remove cover hardware, 1.

19993669

99 4. Disconnect the wires from the glow plug relay. 5. Remove the retaining hardware, 1, and remove the relay.

Installation 1. Install the relay using the hardware removed. 2. Reconnect the wires according to the “GLOW PLUG RELAY WIRING” diagram above. 3. Connect the negative (--) battery cable. 4. Close and securely latch the rear door.

19993677

100

55-87

SECTION 55 - ELECTRICAL SYSTEM

GLOW PLUG CONTROLLER - LS125

Op. 55 640 Removal 1. Remove the latch pin and open the engine door. 2. Disconnect the negative (--) battery cable. 3. Unplug the wire connector, 1, from the glow plug controller. 4. Remove the controller retaining hardware, 2, and remove the controller.

1 19993668

Installation 1. Install the glow plug controller using the hardware removed. 2. Reconnect the wires harness connector. 3. Connect the negative (--) battery cable. 4. Close and securely latch the rear door.

101

OIL PRESSURE SWITCH - LS125 Op. 55 414 12 Removal 1. Remove the latch pin and open the engine door. 2. Disconnect the negative (--) battery cable. 3. Remove engine side shield. 4. Disconnect the Y/B wire, 1, from the switch, 2. 5. Remove the oil pressure switch.

2 1 19993670

Installation 1. Apply pipe sealant to the threads of the switch and install into the engine block. 2. Reconnect the Y/B wire to the glow plug terminal. 3. Connect the negative (--) battery cable. 4. Close and securely latch the rear door.

102

55-88

SECTION 55 - ELECTRICAL SYSTEM

WATER TEMPERATURE SWITCH - LS125 Op. 55 414 10 Removal 1. Remove the Y/DKGN wire, 1, from the sensor by removing the phillips head screw, 2. 2. Drain the cooling system down below the switch level to prevent loss of coolant. 3. Remove the switch from the water pump. 4. If possible, test the operation of the switch at different temperatures. The switch should close at 108° - 112° C (226° - 234° F) and reset, or open, at 106° C (223° F). Installation 1. Apply pipe sealant to the threads of the switch an install the switch into the side of the water pump. 2. Plug the Y/DKGN wire into the sensor. 3. Refill the cooling system with coolant previously removed or a 50/50 mixture of a permanent-type antifreeze. 4. Operate the unit to remove air from the cooling system, and recheck the coolant level.

55-89

19993695

103

SECTION 55 - ELECTRICAL SYSTEM

WATER TEMPERATURE SENSOR - LS125 Op. 55 414 10

Removal 1. Unplug the PU/LTGN wire, 1, from the sensor, 2. 2. Drain the cooling system down below the sensor level to prevent loss of coolant. 3. Remove the sensor from the water pump. 4. Test the resistance of the sensor at different temperatures and compare to the chart below. Resistance Temperature 50° C (122° F)

154 ohms

80° C (176° F)

52 ohms

100° C (212° F)

27 ohms

120° C (248° F)

16 ohms

2 19993671

104

5. Remove the sensor resistor, 1, from the connector with Y/LTGN and PU/LTGN wires. Check that the resistance is close to 2000 ohms. Reinstall the resistor.

1 19993693

105 Installation 1. Apply pipe sealant to the threads of the sensor, 1, and install the sensor into the top of the water pump. 2. Plug the PU/LTGN wire into the sensor, 2. 3. Refill the cooling system with coolant previously removed or a 50/50 mixture of a permanent-type antifreeze. 4. Operate the unit to remove air from the cooling system, and recheck the coolant level.

1 19993671

106

55-90

SECTION 55 - ELECTRICAL SYSTEM

WIRE HARNESSES WIRE HARNESS - LS120 Op. 55 100 74 Removal - LS120 1. Remove the latch pin and open the rear door. Disconnect the negative (--) battery cable, 1, and the positive (+) battery cable, 2.

9246-07

107 2. Remove the right fender retaining hardware, 1, and remove the fender, 2.

19993691

108 3. Remove the left fender retaining hardware, 1, and remove the fender, 2.

19993688

2 109

55-91

SECTION 55 - ELECTRICAL SYSTEM 4. Disconnect the boom lock solenoid connector, 1, and remove the clamp, 2, securing the harness to the frame.

19993694

110 5. Remove the seat, 1, and seat support, 2, from the loader by moving the seat forward about 8â&#x20AC;ł and disconnecting the seat switch wire harness.

2 A3948-02

111 6. Remove the plastic ties, 1, securing the seat switch branch, 2, of the harness to the hydraulic hose, 3.

2 1 19994606

3 112

55-92

SECTION 55 - ELECTRICAL SYSTEM 7. Remove the clamp, 1, securing the cab area harness to the right side frame, 2, behind the key switch, 3. Remove any plastic ties in the cab area.

3 19993698

113 8. Remove the dash panel hardware, 1, and hydraulic filter support hardware, 2, and rotate the dash assembly, 3, down to access the back side of the dash and switches.

3 1

2 1

19993689

114 9. Remove the wires from the four terminals of the ignition key switch, 1.

19993678

1 115

55-93

SECTION 55 - ELECTRICAL SYSTEM 10. Remove the R/LTGN wire, 1, from the 6-amp circuit breaker. Remove the clamp, 2, securing the wire harness to the battery tray.

19993700

116 11. Remove the R/W wire, 1, from the 15-amp circuit breaker. Remove the R/DKBL wires, 2, and the W/DKBL wire, 3, from the start relay.

3 1

19993713

117 12. Disconnect the LTBL/B wire, 1, from the positive terminal of the ignition coil. 13. Remove the R/DKBL wire, 2, from the middle â&#x20AC;&#x153;BATâ&#x20AC;? battery terminal of the rectifier/regulator.

2 1 19993674

118

55-94

SECTION 55 - ELECTRICAL SYSTEM 14. Remove the two clamps, 1, securing the wire harness to the top of the engine.

19993701

119 15. Disconnect the seat belt buckle harness, 1, from the main harness connector, 2. Remove the two clamps, 3, securing the harness segment to the right frame. Remove any plastic ties, 4, attaching the harness to other wires or hoses.

3 4 19993712

3 120

16. Remove the console light retaining hardware, 1.

8690-11

121

55-95

SECTION 55 - ELECTRICAL SYSTEM 17. Disconnect the LTGN/W wire, 1, and the B wire, 2, from the light.

1 2

19993680

122 18. Remove the clamp, 1, securing the warning light harness to the left side of the control module. 19. Remove the round connector, 2, from the control module by loosening the ring and pulling straight down on the connector. 20. Remove the clamps, 3, securing the wire harness to the frame. Remove the wire harness from the loader.

19993673

123

55-96

SECTION 55 - ELECTRICAL SYSTEM Installation - LS120 1. Begin the routing of the main wire harness at the front right ROPS post. Locate the harness junction, 1, of the control module and light bar console and use the clamps, 2, to secure the harness at this location. 2. Position the harness to prevent contact with the parking brake handle, 3, and right hydrostatic forward/reverse control lever, 4. Route the rest of the harness back to the engine compartment. 3. Attach the round connector, 5, to the control module. Install the harness connector on the module straight, then turn the connector ring to tighten the connector to the module. 4. Route the warning light harness up the front right cab post and secure with the clamp, 6, on the left side of the control module.

6 5 1

2 19993673

124

5. Route the harness up the ROPS post to the light bar console. Connect the LTGN/W wire, 1, to the fasten seat belt light and the B wire, 2, to the other terminal.

1 2 19993680

125 6. Secure the console light with the retaining hardware, 1.

8690-11

126

55-97

SECTION 55 - ELECTRICAL SYSTEM 7. Route the harness along the right side of the loader and feed the dash branch, 1, into the cab area under the spring, 2.

19993696

127 8. Secure the harness with two clamps, 1, along the right frame. Connect the thin seat belt buckle branch, 2, to the buckle connector. Secure other accessory wires in the area to the harness with a plastic tie, 3.

1 3 19993712

1 128

9. Route the cab area harness, 1, to the back side of the dash area to the ignition key switch, 2.

19993678

2 129

55-98

SECTION 55 - ELECTRICAL SYSTEM 10. Connect the wires to the ignition switch as indicated. Terminal

LS120

BAT

R/W

IGN

LTBL/B O/DKBR PU

ACC

DKBR/O* O* 19990294

* optional light circuits

130

11. Secure the cab area harness with a clamp, 1, at the right side frame, 2, behind the key switch, 3.

19993698

3 131

12. Reinstall the dash panel hardware, 1, making sure the harness will not be damaged or contact any moving parts.

1 1

19993689

132

55-99

SECTION 55 - ELECTRICAL SYSTEM 13. Route the seat switch harness to the center of the cab at 1, and secure with the plastic wire ties, 2. Route the boom solenoid wire harness, 3, to the left side of the cab area under the left hydrostatic pump, 4.

3 2 1

19994606

133 14. Route the boom lock solenoid wire harness back along the left side of loader to the solenoid connector, 1. Secure the harness with the clamp, 2, and plug the connector into the solenoid connector.

19993694

2 134

15. Attach the correct wires to the start relay. Attach the R positive battery cable, R/DKBL wire from harness, and R wire from the “BAT” side of the 15-amp circuit breaker to the battery power side of the start relay, 1. Attach the W/DKBL wire from the harness to the “ST” start terminal, 2. Check that the W/R wire connection from the start motor solenoid to the starter side of the start relay is good. 16. Attach the correct wires to the 15-amp circuit breaker. Attach the R/W wire, 3, to the breaker terminal. Make sure the two R wires (one from the start relay and one to the 6-amp circuit breaker) are on the other terminal of the circuit breaker, 4. Secure the harness to the battery support tray with the clamp, 5. NOTE: If the square breaker terminals are marked, the two red wires must attach to the “BAT” battery terminal, and the R/W wire must attach to the “AUX” auxiliary terminal.

5 3 19993713

135

55-100

SECTION 55 - ELECTRICAL SYSTEM 17. Attach the R/LTGN wire from the harness to the 6-amp circuit breaker terminal, 1. Make sure the R wire connection, 2, from the 15-amp circuit breaker is good.

19993700

136 18. Route the harness through the clamps, 1, on top of the engine.

19993701

137 19. Attach the LTBL/B wire from the harness to the positive (+) terminal on the ignition coil at 1. 20. Plug the R/DKBL wire, 2, to the middle â&#x20AC;&#x153;BATâ&#x20AC;? battery terminal of the rectifier/regulator, 3. 21. Connect the positive (+) battery cable and the negative (--) battery cable to the battery. 22. Reinstall seat and support assembly. 23. Reinstall the fenders and any shields removed. 24. Close and securely latch the rear door.

3 2 1 19993674

138

55-101

SECTION 55 - ELECTRICAL SYSTEM

WIRE HARNESS - LS125

Op. 55 100 74

Removal - LS125 1. Remove the latch pin and open the rear door. Disconnect the negative (--) battery cable, 1, and the positive (+) battery cable, 2.

A1456-09

139 2. Remove the right fender retaining hardware, 1, and remove the fender, 2.

19993691

140 3. Remove the left fender retaining hardware, 1, and remove the fender, 2.

19993688

2 141

55-102

SECTION 55 - ELECTRICAL SYSTEM 4. Disconnect the R/W wires, 1, from the 15-amp breaker. Disconnect the R/B wire, 2, from the 30-amp breaker. Disconnect the R/LTGN wire, 3, from the 6-amp breaker. Disconnect the three R wires from the other terminal of the 30-amp breaker, 4.

2 3

4 1

19993667

142 5. Remove the Y/B oil pressure switch wire, 1, from the oil pressure switch.

1 19993670

143 6. Remove the LTBL/Y glow plug wire, 1, from the first glow plug, 2. Unplug the LTBL/O wire, 3, from the fuel shutoff solenoid. Remove the Y/B oil pressure switch wire, 4, from the clamp, 5, on the boom solenoid base.

1 4 5

2 19993675

144

55-103

SECTION 55 - ELECTRICAL SYSTEM 7. Unplug the glow plug controller connector, 1, and the regulator/rectifier connector, 2. Remove the relay covers, 3, and remove the clamp, 4, securing the harness to the frame.

1 3

2 19993669

145 8. Disconnect the wires from the glow plug relay, 1.

19993677

146 9. Disconnect the wires from the start relay, 1. Disconnect all the ground connections on the frame, 2.

1 2

19993676

147

55-104

SECTION 55 - ELECTRICAL SYSTEM 10. Disconnect the boom lock solenoid connector, 1, and remove the clamp, 2, securing the harness to the frame.

19993694

148 11. Remove the seat, 1, and seat support, 2, from the loader by moving the seat forward about 8â&#x20AC;ł and disconnecting the seat switch wire harness.

2 A3948-02

149 12. Remove the plastic ties, 1, securing the seat switch branch, 2, of the harness to the hydraulic hose, 3.

2 1 19994606

3 150

55-105

SECTION 55 - ELECTRICAL SYSTEM 13. Remove the clamp, 1, securing the cab area harness to the right side frame, 2, behind the key switch, 3. Remove any plastic ties in the cab area.

19993698

151 14. Remove the dash panel hardware, 1, and hydraulic filter support hardware, 2, and rotate the dash assembly, 3, down to access the back side of the dash and switches.

3 1

19993689

152 15. Remove the wires from the four terminals of the ignition key switch, 1.

1 19993678

153

55-106

SECTION 55 - ELECTRICAL SYSTEM 16. Disconnect the seat belt buckle harness, 1, from the main harness connector, 2.

1 2

19990305

154 17. Disconnect the water temperature switch wire, 1, from the switch by unscrewing the phillips head screw, 2.

19993695

155 18. Disconnect the water temperature sensor wire, 1, from the sensor on the top of the water pump.

19993671

156

55-107

SECTION 55 - ELECTRICAL SYSTEM 19. Disconnect the alternator harness connector, 1, from the alternator connector. Remove the R and R/DKBL wires, 2, from the starter terminal with the red battery power cable, 3. Remove the W/R wire, 4, from the starter terminal. Remove the black ground wires from the ground stud, 5.

1 2

19993692

157 20. Remove the large clamps, 1, securing the thickest harness segment at rear cab frame plate. Remove any plastic ties, 2, attaching the harness to other wires or hoses.

2 19993693

158 21. Remove the four retaining screws on the light bar.

A1456-12

159

55-108

SECTION 55 - ELECTRICAL SYSTEM 22. Disconnect the wires from the lights. The ground wires do not have to be disconnected.

19993679

160 23. Remove the clamp, 1, securing the warning light harness to the left side of the control module. 24. Remove the round connector, 2, from the control module by loosening the ring and pulling straight down on the connector. 25. Remove the clamps, 3, at the junction of the wire harness. Remove the wire harness from the loader.

19993673

161

55-109

SECTION 55 - ELECTRICAL SYSTEM Installation - LS125 1. Begin the routing of the main wire harness at the front right ROPS post. Locate the harness junction, 1, of the control module and light bar console and use the clamps, 2, to secure the harness at this location. 2. Position the harness to prevent contact with the parking brake lever, 3, and right hydrostatic forward/reverse control lever, 4. Route the rest of the harness back to the engine compartment. 3. Attach the round connector, 5, to the control module. Install the harness connector on the module straight, then turn the connector ring to tighten the connector to the module. 4. Route the warning light harness up the front right cab post and secure with the clamp, 6, on the left side of the control module.

6 5 4

1 2 19993673

162

5. On the light bar, connect the LTGN/W wire to the fasten seat belt light, 1. Connect the Y/DKBL wire to the alternator light, 2. Connect the Y/B wire to the engine oil pressure light, 3. Connect the Y/DKGN wire to the water temperature light, 4. Connect the LTBL/GY wire to the glow plug wait light, 5. Connect the PU/Y wires, 6, to the second terminals of lights. Check the condition of the ground wires, 7, and the ground stud, 8, connection. 6. Reattach the light bar with the four retaining screws.

1 8

7 2 3

4 19993679

5 163

7. Route the harness along the right side of the loader and feed the dash branch, 1, into the cab area under the spring, 2.

1 19993696

164

55-110

SECTION 55 - ELECTRICAL SYSTEM 8. Secure the thickest segment of the harness with clamps, 1, at the rear cab frame plate. Feed the alternator, 2, and starter, 3, branches to the rear of the loader. Feed the thin seat belt buckle branch, 4, into the cab area. Secure other accessory wires in the area to the harness with a plastic tie, 5.

1 4 5 1 3

19993693

165 9. Plug in the alternator harness connector, 1, into the connector from the alternator. Attach the R and R/DKBL wires, 2, from the harness to the starter terminal with the red battery power cable, 3. Attach the W/R wire, 4, to the starter terminal. Route the harness branch, 5, with the water temperature sensor and switch wires to the alternator area. Connect the harness branch, 6, with the black wires to the ground stud, 7.

4 3 2

19993692

5 166

10. Connect the water temperature switch wire, 1, to the switch with the phillips head screw, 2.

19993695

167

55-111

SECTION 55 - ELECTRICAL SYSTEM 11. Plug the water temperature sensor wire, 1, into the sensor on the top of the water pump.

19993671

168 12. Route the seat belt buckle harness, 1, through the gap in the left corner of the cab. Plug the buckle belt connector, 2, into the main harness connector.

1 2

19990305

169 13. Route the cab area harness, 1, to the back side of the dash area to the ignition key switch, 2.

19993678

2 170

55-112

SECTION 55 - ELECTRICAL SYSTEM 14. Connect the wires to the ignition switch as indicated. LS125 Terminal BAT

R/W

IGN

O/LTBL O/DKBR PU (2)

ACC

PU/Y LTGN/B DKBR/O* O*

19992823

171

* optional light circuits

15. Secure the cab area harness with a clamp, 1, at the right side frame, 2, behind the key switch, 3.

19993698

3 172

16. Reinstall the dash panel hardware, 1, and hydraulic filter support hardware, 2, making sure the harness will not be damaged or contact any moving parts.

2 1

19993689

173

55-113

SECTION 55 - ELECTRICAL SYSTEM 17. Route the seat switch harness to the center of the cab, 1, and secure with two plastic ties, 2. Route the boom solenoid wire harness, 3, to the left side of the cab area under the left hydrostatic pump.

3 1 2 19994606

174 18. Route the boom lock solenoid wire harness back along the left side of loader, to the solenoid, 1. Secure the harness with the clamp, 2, and plug the connector into the solenoid connector.

19993694

2 175

19. Connect the correct wires to the start relay. Connect the R/W wire, 1, to the top post. Connect the W/R wire, 2, to the middle post. Connect the W/DKBL wires, 3, to the left bottom post. Connect the ground wire, 4, to the bottom right terminal, and all the ground connections to the frame, 5.

3 2

4 5

19993676

176

55-114

SECTION 55 - ELECTRICAL SYSTEM 20. Connect the correct wires to the glow plug relay. Connect the R/B wire, 1, to the top post. Connect the LTBL/Y wire, 2, to the middle post. Attach the LTBL/B wire, 3, to the bottom left terminal. Connect the PU wires, 4, to the bottom right terminal.

3 4

19993677

177 21. Plug in the glow plug controller connector, 1, and the regulator/rectifier connector, 2. Install the relay covers and clamp the harness to the frame, 3.

3 2

19993669

178 22. Attach the LTBL/Y glow plug wire, 1, to the first glow plug, 2. Plug the LTBL/O wire, 3, into the fuel shutoff solenoid, 4. Secure the Y/B oil pressure switch wire, 5, to the boom solenoid base with a small clamp, 6.

1 5 6 4

19993675

179

55-115

SECTION 55 - ELECTRICAL SYSTEM 23. Attach the Y/B oil pressure switch wire, 1, to the oil pressure switch, 2.

2 1 19993670

180 24. Connect the R/W wires, 1, to the 15-amp breaker. Connect the R/B wire, 2, to the 30-amp breaker. Connect the R/LTGN wire, 3, to the 6-amp breaker. Connect the three R wires to the other terminal of the 30-amp breaker, 4. 25. Connect the positive (+) battery cable and the negative (--) battery cable to the battery. 26. Reinstall seat and support assembly. 27. Reinstall the fenders and any shields removed. 28. Close and securely latch the rear door.

2 3

19993667

1 181

55-116

SECTION 55 - ELECTRICAL SYSTEM

BOOM LOCKOUT SOLENOID OPERATION

The loader is equipped with a boom lockout system that prevents boom operation (raising or lowering) if the operator is not in the seat. The boom lockout solenoid, 1, prevents hydraulic oil from operating the boom cylinders. The solenoid electromagnet pulls a plunger from the hydraulic valve allowing oil flow to and from the boom cylinders.

19990306

182 The ignition switch must be ON and the operator must be sitting completely in the loader seat before the boom lift circuit becomes operational. The seat assembly is spring loaded. Operator weight on the seat operates the switch, 1. The switch activates the solenoid assembly.

CAUTION The boom lift circuit may be activated by placing sufficient weight on the seat. do not place tools, tool boxes, etc. on the seat and do not push on the seat from outside the loader.

19990304

183

55-117

SECTION 55 - ELECTRICAL SYSTEM Testing To check the operation of the boom lockout: 1. Be sure the boom is lowered and any attachment is empty. 2. Start the engine and set engine speed to IDLE. 3. Be sure the traction drive is DISENGAGED. 4. While pressing the heel end of the boom pedal to raise the boom slowly, momentarily lift operator weight off the seat by holding on to the holes in the cab roof. 5. The boom should stop moving as soon as weight clears the seat. 6. The boom should resume movement as soon as the operator sits down on the seat. 7. If the boom does not operate as specified, check all electrical connections at the seat switch, the solenoid, and the ignition switch. 8. Check all wiring connectors. 9. If all connections are secure, check the seat switch for proper operation. 10. If the seat switch operates correctly, check for 12 Volts DC power at the solenoid switch with the seat switch activated. 11. If power is present at the solenoid with the seat switch activated, remove the solenoid. Disassembly and Reassembly 1. Separate the solenoid components by removing the nut or capnut from the top of the solenoid. 2. Check the solenoid parts for damage. 3. Reassemble the solenoid using new seals and O rings. The seal repair kit (part #9605346) includes the two O rings (parts #9825518 and #9825519).

2 3 4

19994994

9809959 184

1. 2. 3. 4. 5. 6. 7.

55-118

Cap Nut - 9825297 O Ring - 9825518 Coil Plunger Seals O Ring - 9825519 Valve Block

SECTION 55 - ELECTRICAL SYSTEM Op. 55 301

ALTERNATORS LS120 ALTERNATOR SPECIFICATIONS LS120 equipped with P218 Onan engine - internal flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 amp Rectifier/Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid State

TESTING LS120 CHARGING SYSTEMS - ALTERNATOR OUTPUT TEST Battery (Engine Not Running) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 13 Volts DC Regulator (Engine Running - No Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6 - 14.7 Volts DC Stator AC Voltage(Engine Running - No Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Volts AC @1800 RPM 57 Volts AC @3600 RPM Stator Resistance(Engine Not Running) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.19 ohms

LS125 ALTERNATOR SPECIFICATIONS LS125 (E673 New Holland Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 amp Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Flywheel Rectifier/Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid State Shaft alignment (maximum bend) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 mm (0.003″) Regulator voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 15 volts DC Maximum regulator amperage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Amp Flywheel/pulley assembly retaining nut torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9 N⋅m (6 - 7 ft. lbs.) Minimum voltage output (Engine Running - No Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Volts AC Alternator coil to ground resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 megohms

55-119

SECTION 55 - ELECTRICAL SYSTEM

CHARGING SYSTEM TROUBLESHOOTING The working speed range of the alternator is 1600 - 5600 RPM. Set the skid-steer loader engine speed at full throttle RPM when performing alternator output tests.

TEST CONDITION

NORMAL READINGS

REMARKS

No-Load Voltage Test: With engine at full throttle, connect voltmeter leads across alternator terminals.

28 volts minimum

AC >

If less than 28 volts, check wires and/or wire connections inside alternator.

If permanent magnets are demagnetized; replace flywheel and magnet assembly.

Alternator Coil Continuity Test: With the engine stopped, connect circuit continuity tester between alternator terminals.

Continuity observed

If no continuity, check wiring inside alternator.

Open coil, repair or replace stator assembly.

Alternator Coil to Ground Test (Shorted): With the engine stopped, connect ohmmeter lead to one alternator terminal and the other lead to coil plate.

3 Megohms > minimum

If less than 3 Megohms resistance, replace the alternator stator assembly.

Flywheel Magnet Test: Rotate flywheel by hand.

12 repulses/ rev.; > rotation should be smooth and uniform.

If no repulses and rotation is free-turning, the magnets are demagnetized; replace flywheel and magnet assembly.

Alternator/Regulator Output Tests: Connect voltmeter across battery terminals, connect ammeter in series in R (red) lead to starter motor battery terminal. Apply artificial load to battery.

14 amp at 14 volts >

If amperage exceeds 14 amps or voltage is more than 15 volts, replace the regulator.

Alternator/Regulator Output Tests (cont.): Set engine speed to full throttle RPM, with no artificial load on battery.

Between 0.5 and > 14 amps

If amperage output is zero, the alternator or regulator is faulty, or there is a bad wiring connection. Check wiring and alternator separately, and repair or replace as required.

If amperage output is 0.5 - 14 amps and voltage is more than 14 volts, check for defective or undercharged battery.

55-120

SECTION 55 - ELECTRICAL SYSTEM

1 3

19990279

185

ATERNATOR OPERATION - LS120 1. Alternator 2. Voltage regulator/rectifier 3. Battery The engine is equipped with a permanent magnet flywheel alternator, 1, and a solid-state voltage regulator/rectifier, 2. Alternator output is in direct proportion to engine RPM. Power required for accessories reduces the power available to recharge the battery, 3. IMPORTANT: Reversing positive and negative battery connections or allowing the engine to run without being connected to the alternator will result in electrical system damage. A discharged battery or a weak ignition spark indicates trouble in the charging system. Before checking the charging system, test the battery.

55-121

NOTE: Charging system tests require a fully charged battery. Be sure the engine is being run long enough and fast enough to recharge the battery after each start. The regulator/rectifier, 2, has built-in protection against open circuits or short circuits on the output B+ terminal. Either condition will cause the regulator/rectifier to shut off and appear to be malfunctioning. Before checking the regulator/rectifier, check all wiring between the regulator/rectifier B+ terminal and the battery positive (+) terminal for short circuits, open circuits, or excessive resistance (shorts). If the battery is extremely discharged, it may not have enough power to activate the regulator/rectifier.

SECTION 55 - ELECTRICAL SYSTEM Op. 55 301 04 ALTERNATOR SYSTEM INSPECTION - LS120 1. Be sure the regulator/rectifier connectors, 1, are inserted correctly. The plugs must be fully inserted onto the spade clips. 2. Make sure the alternator stator leads, 2, are not shorted together. 3. Check the regulator/rectifier ground connection, 3, through the mounting bolt. The mating surface must be clean and the fastener tightened properly. 4. Use a hand held tachometer to run the engine between 1800 and 2500 RPM. Install a clamp-on ammeter on the positive (+) battery cable. If no charging is evident, proceed with the Alternator Output Test.

3 2

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186

ALTERNATOR OUTPUT TEST - LS120 1. Use a volt-ohmmeter and check the battery voltage with the engine off. If voltage is not at least 11 volts, charge the battery before proceeding. 2. With the engine running, check the battery terminal voltage (regulator output) using a DC voltmeter. â&#x20AC;˘ If voltage is greater than 15 volts, replace the regulator/rectifier assembly. â&#x20AC;˘ If voltage is between 13.5 and 15 volts, place a load on the replace the regulator/rectifier assembly. If the amperage increases, the system is okay. If the amperage charge does not increase, measure the voltage from the B+ terminal of the regulator/rectifier with the engine speed at 3600 RPM. If the B43G engine is less than 28 volts or the P218 engine is less than 57 volts, replace the stator. If the voltage is much higher than these values, replace the regulator/rectifier. If the voltage is less than 13.5 volts, examine all wires for loose, broken, or corroded connections. Check fuses. Check all ground connections. Correct as necessary to ensure continuity between the regulator/rectifier B+ terminal and the battery positive (+) terminal. 3. If battery voltage remains low with the engine running, stop the engine and disconnect the alternator stator leads, 1, from the regulator/rectifier. Restart the engine and check AC voltage at the stator leads. If AC voltage is within specifications, replace the regulator/rectifier. â&#x20AC;˘

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187

55-122

SECTION 55 - ELECTRICAL SYSTEM 4. Stop the engine and connect one ohmmeter lead to a stator lead, 1, and the other to a frame ground, 2. (Use the â&#x20AC;&#x153;Rx1â&#x20AC;? scale to detect grounds.) The ohmmeter should show no continuity. If the ohmmeter shows continuity, test the stator resistance. Connect the ohmmeter between the stator leads, 1 and 3, to measure the stator resistance. If resistance is not within 0.1 0.2 ohms, replace the stator. If resistance readings are within specifications, low AC voltage may be due to loss of magnetism. If so, replace the blower wheel assembly.

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Op. 55 301

ALTERNATOR FLYWHEEL REMOVAL LS120

Refer to Section 10 - Engine for complete engine and alternator flywheel removal procedures.

ALTERNATOR OPERATION - LS125

The alternator is a permanent magnet type alternator having a fixed magnetic field. The alternator does not have rectifying diodes and produces alternating current to the regulator. The alternator consists of a flywheel with magnets, 1, a stator, 2, armature coil and plate, 3, and bearings, 4. The regulator assembly is a current rectifier and voltage regulator unit. The regulator controls the voltage output to maintain the system at 14 - 15 volts.

3 2 1

189

55-123

SECTION 55 - ELECTRICAL SYSTEM Op. 55 301 10

ALTERNATOR REMOVAL - LS125 1. Remove the latch pin and open the door. 2. The right fender may also be removed for more accessibility. 3. Remove the negative (--) battery cable. 4. Remove the wires from the terminals on the alternator. 5. Loosen the adjusting strap pivot bolt, 1, and remove the retaining bolt, 2. Remove the alternator from the engine.

1 2

A1690-09

190 Op. 55 301 12 FLYWHEEL BODY

ALTERNATOR DISASSEMBLY - LS125 1. Place the alternator pulley, 1, in a vise. NOTE: Never clamp the alternator flywheel body, 2, in a vise or damage to the alternator assembly may occur.

2 1

CLAMP RANGE

191

55-124

SECTION 55 - ELECTRICAL SYSTEM

6 7

10 11 4

8 3

19993687

192 ALTERNATOR COMPONENTS - LS125 1. 2. 3. 4. 5. 6.

Flywheel Cover Coil Plate Stator Bearings Retaining Nut Spring Washer

7. 8. 9. 10. 11.

2. Loosen retaining nut, 5. 3. Remove the spring washer, 6, and flat washer, 7. 4. Remove the alternator from the vise, and remove the flywheel cover, 1, from the coil plate, 2. 5. Loosen the screw, 9, and remove the clamp, 8.

55-125

Flat Washer Clamp Clamp Screw Stator Screws Collar

6. Remove the screws, 10, and pull out the stator complete, 3, from the coil plate, 2. 7. Remove the bearings, 4, from the coil plate, 3, and flywheel cover, 1.

SECTION 55 - ELECTRICAL SYSTEM

6 7

10 11 4

8 3

19993687

193 ALTERNATOR COMPONENTS - LS125 1. 2. 3. 4. 5. 6.

Flywheel Cover Coil Plate Stator Bearings Retaining Nut Spring Washer

ALTERNATOR REASSEMBLY - LS125 1. Install new bearings, 4, in the coil plate, 2, and flywheel cover, 1, by applying pressure on the outer race of the bearing. 2. Install the stator, 3, into the coil plate, 2, and then install retaining screws, 10. 3. Install clamp, 8, and secure with screw, 9. 4. Install the flywheel cover, 1, into the coil plate, 2.

7. 8. 9. 10. 11.

Flat Washer Clamp Clamp Screw Stator Screws Collar

5. Clamp the assembly into a vise by clamping onto the pulley of the flywheel assembly. Never clamp the flywheel body in a vise, or internal damage may occur. 6. Install flat washer, 7, spring washer, 6, and nut, 5. 7. Tighten retaining nut, 5, to 8 - 9 Nâ&#x2039;&#x2026;m (6 - 7 ft. lbs.).

55-126

SECTION 55 - ELECTRICAL SYSTEM

ALTERNATOR INSTALLATION - LS125 1. Install the lower retaining pivot bolt, 1, and upper bolt, 2. 2. Install drive belt and pivot the alternator to tighten the drive belt to 1.4 - 2.3 kg (3 - 5 lbs) force applied to the center span with 3.2 mm (0.125â&#x20AC;ł) deflection in belt and tighten all hardware. 3. Connect the wires to the proper terminals on the alternator. 4. Connect the negative (--) battery cable. 5. Reinstall any shields removed for the repair and close the door and secure with the latch pin.

2 1

A1690-09

194

55-127

SECTION 55 - ELECTRICAL SYSTEM Op. 55 201

STARTERS ASSEMBLY TORQUE LS120 P218

LS125 E673

N⋅m

ft. lbs.

N⋅m

ft. lbs.

25 - 28

19 - 21

45 - 57

34 - 42

Solenoid Screws

6.1

4.5

4.9

3.7

Brushing Retaining Screws

3.7

2.8

--------

Through Bolts

5.8

4.3

4.9

3.7

Starter Mounting Bolts

55-128

SECTION 55 - ELECTRICAL SYSTEM

STARTING CIRCUIT TROUBLESHOOTING PROBLEM Engine will not crank

POSSIBLE CAUSE

CORRECTION

Operator not in seat; seat belt buckled out of sequence

Properly sequence the restraint system by sitting in seat and buckling seat belt

Low battery voltage

Recharge or replace battery

No battery voltage to control module

Check or replace 6-amp circuit breaker Check for open in R/LTGN wire to control module (no TIMER light)

No battery voltage to ignition key switch

Check or replace 15-amp circuit breaker Check for open in R/W wire to ignition switch “BAT” terminal

No battery voltage from ignition switch

No start relay operation

Check for open in W/DKBL wire from control module to relay Test or replace start relay

No start solenoid operation

Engine cranks slowly

Belt clutch

Disengage belt clutch, especially in cold weather start-ups

Draw from hydraulic system

Check that control pedals are in neutral and the auxiliary hydraulic valve is not on

55-129

SECTION 55 - ELECTRICAL SYSTEM

POSSIBLE CAUSE

PROBLEM Engine cranks wonâ&#x20AC;&#x2122;t start

but

No power to fuel solenoid

Engine cranks and smokes but wonâ&#x20AC;&#x2122;t start

No preheat; no glow plug operation

plug

Check for bad glow plugs; replace as required

55-130

SECTION 55 - ELECTRICAL SYSTEM

PROBLEM Engine wonâ&#x20AC;&#x2122;t crank or start

Incomplete charging

battery

POSSIBLE CAUSE

CORRECTION

Seat belt not buckled

Buckle seat belt

Loose or disconnected wiring

Inspect and fix any loose wiring

Faulty key switch

Repair the wiring connection or replace switch

Poor battery charging; or battery loses charge

Charge or replace battery

15-amp key main fuse blown

Replace fuse (or engine wiring harness, if necessary)

Excessive load for starter

Disconnect transmission belt clutch

Clogged air cleaner

Clean air cleaner

Damaged starter

Repair or replace starter

Faulty wiring

Inspect and correct

Battery electrolyte low

Add distilled water to correct level

Faulty battery

Replace battery

Alternator brush worn out

Replace brush

55-131

SECTION 55 - ELECTRICAL SYSTEM

STARTER OPERATION - LS120

If the engine cranks slowly or not at all, check the starting system electrical circuits. Check for these conditions first: • • •

Low battery charge Defective battery cables Corroded or loose electrical connections

During cranking, the starter pinion gear meshes quickly with the flywheel ring gear and spins the engine. Once the engine starts, the solenoid opens, disengaging and stopping the starter motor. Low ambient temperatures can contribute to cranking problems. If the battery is charged and electrical connections are satisfactory, remove the starter motor for further inspection.

Op. 55 201 50

STARTER REMOVAL - LS120

WARNING Accidental starting of the engine can result in severe personal injury or death. Disconnect the negative (--) battery cable and spark plug wires before servicing engine, controls, or associated equipment. 1. Disconnect the negative (--) battery cable first. Then disconnect the positive (+) battery cable. 2. Disconnect the starter battery cable from the terminal, 1. 3. Remove the starter mounting bolts and remove the starter motor.

19994674

1 195

STARTER DISASSEMBLY - LS120 1. Pull off the black plastic cap. Remove the “M” terminal nut, 1, and wire lead.

19994605

1 196

55-132

SECTION 55 - ELECTRICAL SYSTEM

10 14

7 1

20 21 19

18 2

19993714

17 16

197 STARTER COMPONENTS - LS120 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Solenoid mounting screws Front bracket Dust seal Armature shims Snap ring Collar Clutch assembly Lever Wear plate Rubber plug Solenoid

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

2. Remove the two solenoid mounting screws, 1, and remove the solenoid. 3. Scribe a mark across the rear bracket and the center frame assembly to aid in reassembly. Remove the two through bolts, 20. 4. Separate the end cap, 18, and center frame assembly, 15, from the front bracket, 2.

55-133

Armature Plastic cap Cap nut Center frame assembly Brushes Brush holder End cap Bushings Through bolts Brush holder mounting screws

5. Carefully remove the armature, 12, and lever, 8, from the front bracket, noting the direction of the lever, wear plate, 9, and rubber plug, 10. 6. Remove the two brush holder retaining screws, 21, and separate the rear bracket, 10, from the center frame assembly, 15. 7. Remove the brush holder assembly, 17, from the frame assembly by pulling the brushes, 16, out.

SECTION 55 - ELECTRICAL SYSTEM 8. Push the stopper, 1, toward the pinion and remove the snap ring, 2. 9. Remove the stopper and overrunning clutch from the armature shaft.

19994607

198

STARTER INSPECTION AND TESTING LS120 1. Visually inspect the starter for worn or damaged parts. Repair all damaged or worn parts. If the commutator is dirty or discolored, clean it with commentator paper (Number 00 to 000). Use low pressure air to blow grit off after cleaning. If the commutator is scored, rough, or worn, turn it down on a lathe. Clean around the brushes and holders, wiping off all brush and dirt. 2. Replace the brushes if they are shorter than 11.5 mm (0.45″). Slide the brushes back and forth in the brush holders to ensure free movement.

CAUTION Cleaning the overrunning clutch in liquid cleaning solution will result in damage to the starter. Do not clean the overrunning clutch in liquid cleaning solutions. 3. If the rear bushing is worn or damaged, replace the burning and rear bracket as an assembly. Check the armature thrust gap after replacing the rear bracket and bushing. If the front bushing must be replaced, do not remove the cap from the front bracket. Remove the front bushing by tapping the bushing from inside with an 11 mm x 1.5 (7/16″ x 14 NC) tap. Thread an 11 mm (7/16″) capscrew into the bushing and use a slide hammer to remove the bushing. 4. Inspect the overrunning clutch pinion and the armature spline for worn or damaged teeth. If the pinion gear is worn or damaged, inspect the flywheel ring gear as well.

55-134

SECTION 55 - ELECTRICAL SYSTEM 5. Rotate the pinion. Replace the pinion if it does not spin freely in one direction and lock in the other. 6. Push the solenoid plunger in and release it. The plunger should return it its original position. While holding the plunger all the way in, measure continuity between terminals “M” and “B”. If there is no continuity, replace the solenoid. If the solenoid is replaced, check the pinion clearance. 7. Test the armature for grounds with an ohmmeter. Touch each commutator bar, 1, with one ohmmeter lead while holding the other lead on the armature shaft or core. If the ohmmeter reading is low, there is a grounded armature; replace the armature. 8. Test the armature for open circuits with an ohmmeter. Check for continuity between commutator segments. If high resistance indicates an open circuit, replace the armature.

19994609

199 9. Test the armature for short circuits using a growler tester. Rest the armature in the growler. Hold a thin steel blade (e.g., hacksaw blade), 1, parallel to the core and just above it while slowly rotating the armature in the growler, 2. A shorted armature will cause the blade to vibrate and be attracted to the core. Replace the armature if any shorts are detected. 10. Use the ohmmeter to check the field coils for continuity between the brushes. If there is no continuity, the field coil is open. With the field coil mounted in the frame, check for continuity between the field coil and the frame. Low resistance indicates the coil is shorted to the frame. Replace the field coil if it is shorted or open. 11. Check for shorts between the positive (+) side of the brush holder and the base. If there is continually, replace the brush holder assembly.

55-135

19994610

200

SECTION 55 - ELECTRICAL SYSTEM

STARTER BRUSH REPLACEMENT - LS120 1. Cut the old positive brush from the pigtail, 1, at the brush. Be careful not to cut the field coil. Clean 6.5 - 9.5 mm (1/4″ - 3/8″) of the brush end of the pigtail with sandpaper or emery cloth. 2. Push the prepared end of the pigtail lead into the hole in the replacement brush from the small chamfered side. Solder the pigtail lead to the replacement brush on the large chamfered side using 50/50 tin/lead, resin core solder and a standard 240/325 Watt soldering iron. Use a file to remove any excess solder extending beyond the brush surface.

19994611

CAUTION

201

Material protruding from the soldered side surface of the brush can cause equipment damage. Do not use excessive solder. Heat and file any excessive material from the surface of the brush.

STARTER REASSEMBLY - LS120 1. Install the seal in the nose housing. Install the clutch, 1, on the armature shaft. 2. Slide the stopper, 2, onto the armature shaft. Position the snap ring, 3, in the groove in the armature shaft. 3. Pull the stopper all the way over the snap ring. It may be necessary to tap the snap ring into the groove with a punch while maintaining tension on the stopper. 4. Apply lubrication (e.g., Multemp PS No. 2) to the following points: • Armature shaft spline • Bushings on each end of the armature • Stopper on the armature shaft • Pinion gear • Sliding port of lever

19994608

3 202

55-136

SECTION 55 - ELECTRICAL SYSTEM 5. Fit the lever, 1, into the clutch, 2.

2 19994623

203 6. Install the armature and lever, 1, into the front bracket, 2. 7. Install the lever wear plate, 3, and rubber plug, 4.

1 3

19994624

204

55-137

SECTION 55 - ELECTRICAL SYSTEM

7 1

20 21 19

18 2

19993714

17 16

205 STARTER COMPONENTS - LS120 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Solenoid mounting screws Front bracket Dust seal Armature shims Snap ring Collar Clutch assembly Lever Wear plate Rubber plug Solenoid

8. Position the center frame assembly, 15, over the armature on the front bracket, 2. 9. Install the brush holder assembly, 17. Position the brushes, 16, in the brush holder. Make sure positive (+) lead wires are not grounded. 10. Install shims, 4, as required on the rear end of the armature shaft to obtain an armature shaft thrust gap of 0.05 - 0.50 mm (0.002″ - 0.020″). Install new shims if the rear bracket has been replaced.

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Armature Plastic cap Cap nut Center frame assembly Brushes Brush holder End cap Bushings Through bolts Brush holder mounting screws

11. Install the end cap, 18. Secure the brush holder to the end cap with two machine screws, 21. Tighten to 3.7 N⋅m (2.8 ft. lbs.). 12. Install and tighten the two through bolts, 20, to 5.8 N⋅m (4.3 ft. lbs.). 13. Install solenoid, 11, with the plunger in the lever, 8. Secure the solenoid to the front bracket, 2, with two machine screws, 1. Tighten the solenoid screws to 6.1 N⋅m (4.5 ft. lbs.).

55-138

SECTION 55 - ELECTRICAL SYSTEM

WARNING Application of battery power to the starter motor will cause the pinion gear to spin. Reinstall the wire lead to the “M” terminal, 1, after checking pinion clearance.

19994605

1 206

STARTER INSTALLATION - LS120 1. Make sure the mounting surface is clean and oil free. 2. Install the starter motor. Tighten mounting bolts to 25 - 28 N⋅m (19 - 21 ft. lbs.). 3. Reconnect the starter battery cable and from the “B” terminal and the start solenoid lead from the spade connector. 4. Reconnect the battery cables to the battery.

55-139

SECTION 55 - ELECTRICAL SYSTEM

STARTER OPERATION - LS125

The starting system consists of a starter motor, solenoid coil, ignition key switch, relay, and heavy-duty wiring. The starter motor has a direct drive pinion mounted on the armature shaft enclosed in the nose cone of the starter housing. The pinion assembly is shifted into engagement with the ring gear by a fork connected to the starter motor plunger. The starter solenoid is mounted on top of the starter motor assembly and incorporates two windings, a pull-in winding and a holding winding.

19994646

207

Starter Solenoid Assembly When the key switch is turned to the â&#x20AC;&#x153;STARTâ&#x20AC;? position and the restraint control module is satisfied that the operator is sitting in the seat and the seat belt is buckled in sequence the solenoid coil windings are energized. The magnetic field attracts the solenoid plunger, moving plunger and fork, engaging the starter pinion into the starter ring gear on the engine flywheel. A set of contact points on the other end of the plunger closes the contacts and connects battery current to the starter motor.

6 4

Closing the starter motor contact points causes battery voltage to appear at both ends of the solenoid pull-in winding, making it ineffective. The hold-in winding, which is connected to ground, continues to hold the plunger in the closed position. Canceling the pull-in coil reduces the solenoid current draw during engine cranking. When the key switch is released, it opens the solenoid circuit and a spring pushes the solenoid plunger out of the housing, opening the motor contact points and disengaging the pinion from the ring gear.

19994644

208 1. 2. 3. 4. 5. 6.

55-140

Key Switch Pull-in Winding Hold-in Winding Pinion Gear Battery Spring

SECTION 55 - ELECTRICAL SYSTEM Overrunning Clutch Assembly To prevent the engine from driving the starter motor after the engine is started, the pinion is assembled into an overrunning clutch. The clutch consists of an outer shell, a cam with tapered notches, spring loaded rollers and a pinion collar which acts as the clutch hub. When the starter motor begins cranking the engine, the rollers move into the narrow ends of the cam tapers where they wedge against the pinion gear collar. With the rollers wedged, the armature rotates the locked assembly through the splined sleeve. After the engine starts and before the pinion can disengage the ring gear, the flywheel will cause the ring gear to spin the pinion faster than the armature. The faster moving pinion causes the rollers to move into the wide end of the cam taper unlocking the pinion from the clutch. The unlocked action allows the pinion to turn freely without speeding up the starter motor armature. The overrunning clutch is serviced as a complete assembly only.

55-141

4 3

1 2

19994645

209 1. 2. 3. 4. 5. 6. 7. 8. 9.

Spring Roller Roller Snap Ring Sleeve Washer Sleeve Sleeve Spring Clutch Cam Roller Pinion

SECTION 55 - ELECTRICAL SYSTEM

STARTER SPECIFICATIONS - LS125 Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185086540 Amperage Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 amp Commutator Diameter New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.0 mm (1.26″) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.4 mm (1.23″) Commutator Out-Of-Round New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002″) Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.160″) Commutator Segment Depth Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008″) Shaft Alignment (Maximum Bend) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004″) Brush Length Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 mm (0.45″) Brush Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36 - 2.54 kg (2.99 - 5.60 lbs) Pinion Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 - 2.0 mm (0.02″ - 0.08″)

55-142

SECTION 55 - ELECTRICAL SYSTEM Op. 55 201 50

STARTER REMOVAL - LS125 1. Remove the latch pin and open the door. 2. The right fender may also be remove for more accessibility. 3. Remove the negative (--) battery cable. 4. Remove the plastic cover and disconnect the R and R/DKBL wires and battery cable from the starter motor terminal, 1. Remove the W/R wire from the solenoid terminal, 2. 5. Remove the two starter mounting bolts, 3, and remove the starter from the engine adapter plate.

19993692

210

STARTER DISASSEMBLY - LS125 1. Disconnect the field coil terminal wire, 1, from the solenoid, 2. 2. Remove the two solenoid mounting screws, 3, and remove the solenoid and plunger assembly from the motor housing. Retain the shim or shims, 4, for reassembly and pinion clearance adjustment.

1 3

19994647

211 3. Remove the two brush holder screws, 1, and two through bolts, 2, and remove the rear housing, 3.

3 1

2 19994648

212

55-143

SECTION 55 - ELECTRICAL SYSTEM 4. Remove the two brushes, 1, and remove the brush holder assembly, 2. Retain the brush springs, 3. 5. Remove the field coils and housing assembly, 4.

1 2 19994649

213 6. Remove the armature, 1, and lever, 2, from the front bracket, 3. Take the lever off the armature. Remove the rubber seal and plate, 4, from the front bracket.

19994650

214 7. Remove the stopper, 1, and snap ring, 2, from the inside and retain any shims. Remove the clutch, 3, from the armature arm, 4.

3 4

19994651

215

55-144

SECTION 55 - ELECTRICAL SYSTEM

STARTER INSPECTION AND REPAIR LS125 1. Use a shop towel lightly dampened in clean solvent and low pressure air to clean all starter components. 2. Using a fine grit sandpaper, clean the commutator. NOTE: Do not use emery type abrasive to clean the commutator segments. 3. Inspect the armature shaft bushings in the pinion housing and rear frame cover. Replace the bushings if scored or if excessively worn. 4. Inspect the armature windings for broken or burned insulation or loose connections. 5. Inspect the field coils for burned or broken insulation and loose connections. 6. Inspect the brush holders for damaged springs or loose rivets. 7. Inspect the brushes in the holders for sticking or binding conditions. 8. Measure the length of the brushes. If the brushes measure less than 11.5 mm (0.45″) replace the brushes: • New - 17.0 mm (0.67″) • Min. - 11.5 mm (0.45″) 9. Inspect the commutator for burned spots which may indicate an open armature coil. 10. Using a spring scale, 1, measure the brush spring tension as shown, with a sling, 2, connecting the scale and brush, 3. Replace springs having less than 1.66 kg (3.7 lbs) tension: • New - 1.95 kg (4.3 lbs) • Min. - 1.66 kg (3.7 lbs)

2 3

19994652

216

55-145

SECTION 55 - ELECTRICAL SYSTEM 11. Position the armature in a set of V-blocks, 1, as shown. Using a dial indicator, 2, rotate the armature slowly and observe the dial indicator reading. If the armature run out is greater than 0.05 mm (0.002″), replace the armature.

1 19994653

217 12. Using the dial indicator as shown, rotate the armature between two centering points and observe the dial indicator reading. The amount of armature shaft bend is determined by using 1/2 of the dial indicator reading. Replace the armature if the deflection (1/2 of reading) is greater than 0.1 mm (0.004″).

19994654

218 13. Measure the insulator depth of the commutator segments, 1. If the depth of the insulator, 2, is less than 0.2 mm (0.008″) use a suitable cutting tool and cut the insulator to the proper depth.

0.2 mm (0.008″)

19994655

219

55-146

SECTION 55 - ELECTRICAL SYSTEM

19994656

220 14. Inspect the pinion and ring gear teeth for excessive wear or damage. Replace the pinion and ring gear assemblies if they are excessively milled, pitted or have damaged teeth. Check the pinion clutch action for sticking or binding. Replace the clutch assembly if defective.

55-147

SECTION 55 - ELECTRICAL SYSTEM

STARTER TESTS - LS125 Armature Coil Continuity Test 1. Using an ohmmeter, touch one ohmmeter lead to one commutator segment, 1, and the other ohmmeter lead to the adjacent segment, 2, and observe the ohmmeter reading. 2. Repeat this procedure on each adjacent set of commutator segments. • Low resistance reading - Good • High resistance reading - Faulty armature coil, Replace armature.

1 19994657

221 Armature Coil Ground Test Using an ohmmeter, touch one lead to the armature shaft, 1, and the other lead to each of the commutator segments, 2, one at a time and observe the ohmmeter reading. • •

High resistance reading - Good armature Low resistance reading - Grounded armature coil, Replace armature.

19994658

222 Armature Coil Short Circuit Test Place the armature on a growler tester, 1, and rotate the armature, 2, while holding a metal strip, 3, against the armature cores as shown. If the metal strip vibrates a short circuit is indicated and the armature must be replaced.

19994659

223

55-148

SECTION 55 - ELECTRICAL SYSTEM Solenoid Pull-In Coil Continuity Test Using an ohmmeter, touch one lead to the solenoid motor terminal, 1, and the other lead to the switch terminal, 2, and observe the ohmmeter reading. • •

Low resistance - Good High resistance - Faulty coil, Replace solenoid

2 19994660

224 Solenoid Hold-In Coil Continuity Test Using an ohmmeter, touch one lead to the switch terminal, 1, and the other lead to the solenoid housing, 2, and observe the ohmmeter reading. • •

Low resistance - Good High resistance - Faulty coil, Replace coil

2 19994661

1 225

Field Coil Continuity Test Using an ohmmeter, touch one lead to a brush to field coil connector, 1, and the other lead to the other brush to field coil connector, 2, and observe the ohmmeter reading. • •

1 2

Low resistance - Good High resistance - Faulty coil, Replace field coil assembly

19994662

226

55-149

SECTION 55 - ELECTRICAL SYSTEM Field Coil Ground Test Using an ohmmeter, touch one lead to the starter field coil frame, 1, and the other lead to one of the field coil brush connectors, 2, and observe the ohmmeter reading. • •

2 1

High resistance - Good Low resistance - Grounded coil, Replace field coil assembly

19994663

227 Brush Holder Ground Test Using an ohmmeter, touch on lead to one of the insulated brush holders, 1, and the other lead to the brush holder plate, 2, and observe the ohmmeter reading. • •

High resistance - good Low resistance - grounded brush holder; replace brush holder assembly

2 19994664

228

55-150

SECTION 55 - ELECTRICAL SYSTEM

STARTER REASSEMBLY AND ADJUSTMENTS - LS125

1. Slide the overrunning clutch assembly, 1, onto the armature shaft, 2, and reinstall any shims removed. Install the stopper, 3, and snap ring, 4, making sure the ring is properly seated.

19994651

229 2. Install the rubber seal and plate, 1, into the front bracket, 2. Install the lever, 3, on the armature, 4, and install the assembly into the front bracket.

1 4

19994650

230 3. Reinstall the field coils and housing assembly, 1, up against the front bracket, 2. Reinstall the two brushes, 3, and springs, 4, in the brush holder, 5, and install the assembly into housing.

1 3

4 5

3 19994649

231

55-151

SECTION 55 - ELECTRICAL SYSTEM 4. Reinstall the rear housing, 1, the two through bolts, 2, and two brush holder screws, 3.

1 3

2 19994648

232 5. Install the solenoid and plunger assembly, 1, using the same number of shims, 2, and two retaining bolts, 3. NOTE: When installing the solenoid and shims use the shims that were removed, during the next step you will be checking the pinion clearance and adjustment if required.

1 3

19994647

2 233

55-152

SECTION 55 - ELECTRICAL SYSTEM

PINION CLEARANCE CHECK AND ADJUSTMENT - LS125

Bench check the assembled starter as follows: 1. With the field coil wire removed from the solenoid terminal, 1, insulate the wire from the housing. NOTE: Failure to disconnect and insulate the wire will cause the motor to spin when the battery is connected for testing. 2. Use a battery and connect a jumper cable from the battery negative (--) terminal to the housing as shown at 2. 3. Connect another jumper wire from the battery terminal to the solenoid switch terminal at 3. 4. Connect a jumper wire to the solenoid motor terminal at 1, and touch the other end to the starter housing as shown at 4. This shifts the pinion into the cranking position where it will remain until the battery is disconnected. IMPORTANT: Do not keep the battery connected any longer than necessary, as overheating of the solenoid may result.

3 1 2

19994665

4 234

5. Push the pinion, 1, back toward the motor to eliminate any over travel. 6. Using a feeler gauge, measure the clearance, 2, between the pinion and the thrust collar as shown. The pinion clearance should be between 0.5 - 2.0 mm (0.02 - 0.08â&#x20AC;ł).

2 19994666

235

55-153

SECTION 55 - ELECTRICAL SYSTEM 7. Add or subtract shims, 1, as required between the solenoid and housing to achieve the required clearance. NOTE: Excessive clearance is an indication of worn shifting components. Adding shims decreases the pinion clearance. 8. Remove the insulation previously installed between field coil wire and the starter housing and connect the field coil terminal wire, 2, to the solenoid terminal, 3. 9. Reinstall the starter on the engine and reconnect the wires to the proper terminals. Reinstall the plastic cover over the starter terminals. 10. Reconnect the negative (--) battery cable. 11. Reinstall any shields removed for this repair. Close the rear door and securely latch in place.

19994647

236

STARTER INSTALLATION - LS125

1. Install the starter with the two mounting bolts, 1. Attach the R and R/DKBL wires and the red battery cable to the starter terminal, 2. Plug the W/R wire into the starter terminal, 3. Make sure the black wires, 4, are secure on the ground stud, 5. 2. Connect the negative (--) battery cable to the battery. 3. Reinstall seat and support assembly. 4. Reinstall the fenders and any shields removed. 5. Close and securely latch the rear door.

19993692

1 237

55-154

SECTION 55 - ELECTRICAL SYSTEM

IGNITION SYSTEM - LS120 The LS120 P218 engine has an electronic battery ignition system. No distributor is required because both plugs fire simultaneously. The electronic ignition module, 1, is located on the engine gear cover behind the flywheel. The module receives a trigger from magnets in the trigger ring, 2, that rotates with the engine crankshaft.

1 19993685

238

IGNITION COIL

Test the primary and secondary windings within the ignition coil. Make sure the ignition power is OFF and the coil is at approximately 21Â° C (70Â° F). 1. Disconnect all leads from the top of the ignition coil. 2. Using an ohmmeter, place the black lead on the negative (--) coil terminal, 1, where the B ignition module wire was connected. Place the red lead on the positive (+) coil terminal, 2, where the LTBL/B power wire was connected. Primary coil resistance should read between 2.90 - 3.60 ohms. 3. Change the resistance scale on the ohmmeter. Place the ohmmeter leads inside the spark plug cable holes, 3. Secondary coil resistance should be between 14,500 - 19,800 ohms. If either primary and secondary windings are out of tolerance, replace the coil.

55-155

2 19991597

239

SECTION 55 - ELECTRICAL SYSTEM Op. 55 201

IGNITION SYSTEM FAULT ISOLATION 1. Check all electrical connections to make sure they are clean and tight.

WARNING Accidental starting of the engine can result in severe personal injury. Always ground the spark tester away from the spark plug holes. 2. Pull both spark plug wires off the spark plugs and remove the plugs. Connect an approved spark tester to one spark wire and ground it well away from the spark plug hole. 3. Turn the key ON and crank the engine over for five seconds while observing the spark. Repeat the test with the other spark plug. If a spark occurs regularly at both plugs, the problem is not in the ignition system. IMPORTANT: Incorrect wiring can cause electronic ignition damage. Do not attach any lead or jumper (such as B+) to the coil negative (--) terminal. 4. Connect a jumper lead directly from the positive (+) battery terminal to the positive (+) coil terminal, 1. The positive coil terminal has the smaller diameter of the two threaded posts. 5. Crank the engine over while watching for a spark. If a spark occurs, the problem is in the circuitry between the battery and the coil. 6. Connect the positive lead of a voltmeter to the negative (--) coil terminal, 2. The negative coil terminal has the larger diameter of the two threaded posts. Connect the negative lead of the voltmeter to engine ground. Turn the ignition key ON. 7. Slowly turn the flywheel clockwise by hand while observing the voltmeter. Voltage switches from about 1 volt to about 12 volts and back each revolution. If the voltage does not switch correctly, replace the electronic ignition module. NOTE: Replacement of the electronic ignition module requires removal of the engine and flywheel. Refer to Section 10 - Engine for removal procedures.

19993674

240

CAUTION Incorrect wiring can cause electronic ignition damage. Do not attach any lead or jumper (such as B+) to the coil negative terminal. Install the spark plugs and reconnect the spark plug wires. If the ignition module is being replaced, be sure to connect the orange lead from the new ignition module to the positive (+) terminal of the coil and the black lead to the negative (--) terminal.

55-156

SECTION 55 - ELECTRICAL SYSTEM

IGNITION TIMING

The ignition is preset at the factory and is not adjustable.

SPARK PLUGS

Check the spark plug following every 100 hours. Replace spark plugs that show signs of fouling or electrode erosion. Set the spark plug gap to 0.64 mm (0.025â&#x20AC;³). 19994618

241

55-157

SECTION 55 - ELECTRICAL SYSTEM

BATTERY BATTERY INSPECTION

WARNING Ignition of explosive battery gases can result in severe personal injury. Do not smoke or allow any ignition source near the battery. Keep the battery case clean and dry. Accumulations of moisture or dirt will accelerate discharge and battery failure.

BATTERY SPECIFICATIONS Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt - SAE group 70 Battery Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 amps @ --18째 C (0째 F) Side Stud System Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative (--) Minimum Voltage Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 volts AC

SPECIFIC GRAVITY TEST

Check battery cells with a hydrometer, 1. Specific gravity should be between 1.260 and 1.290 at 25째 C (77째 F). If one or more cells are low on water, add distilled water, then recharge the battery. Allow no foreign matter to fall into the cells.

CAUTION Battery electrolyte contains caustic sulfuric acid. avoid contact with skin or clothing. If splashed in the eyes, flush immediately with fresh water. Keep the battery terminals clean and tight. Check the battery cables for pinching or abrasion. Use recommended battery tools when connecting or disconnecting leads. After connecting leads, apply a light coat of petroleum jelly or grease to retard corrosion.

19994619

242

IMPORTANT: Reversing battery leads can damage electronic circuits. Do not reverse battery connections.

55-158

SECTION 55 - ELECTRICAL SYSTEM

BATTERY JUMP STARTING

Jump start (boost) a weak battery using a charge booster battery. Use the following procedure to prevent starter damage, battery damage, and personal injury.

WARNING Jump starting a battery incorrectly can cause the battery to explode, resulting in personal injury or death. Batteries give off hydrogen gas, especially during charging or jump starting. Ignition of explosive battery gases can result in severe personal injury. Do not smoke or allow any ignition source near the battery. Attempting to jump start a frozen battery can cause the battery to explode. Inspect battery cells for ice before attempting to jump start when ambient temperature is below 0° C (32° F). 1. Disconnect any engine load by disengaging the traction drive belt using the lever, 1, beneath the operator’s seat. 2. Use good quality, heavy duty jumper (booster) cables. 3. Use a booster battery with similar characteristics to the installed battery (see Specifications). 4. Attach one end of the positive (red) booster cable to the positive (+) terminal of the booster battery. 5. Attach the other end of the positive cable to the positive (+) terminal of the installed battery.

WARNING

1 A3948-06

Electrical arcing can cause serious personal injury. Do not allow positive and negative cable ends to touch. Electrical arcing can cause ignition of explosive battery gases resulting in severe person injury. Do not allow positive and negative cable ends to touch. 6. Attach one end of the negative cable (black) to the negative (--) terminal of the booster battery. 7. Attach the other end of the negative cable to a solid chassis ground of the assisted loader. 8. If the booster battery is installed in another vehicle, start the booster vehicle engine to use alternator output and avoid unnecessary loading of the booster battery.

55-159

243

SECTION 55 - ELECTRICAL SYSTEM 9. Turn the ignition switch ON and attempt to start the installed engine. Never crank the engine for more than 30 seconds.

CAUTION Overcranking the engine can cause starter damage. Allow the starter to cool for five minutes if engaged for 30 seconds.

11. Once the engine starts, disconnect the negative cable from chassis ground. Then disconnect the positive cable from the positive (+) terminal of the installed battery. Do not allow cable ends to touch. 12. Disconnect the negative (--) cable from the booster battery. Disconnect the positive (+) cable from the booster battery.

10. Allow the starter to cool for at least five minutes before another attempt.

55-160

SECTION 55 - ELECTRICAL SYSTEM

OPTIONAL ELECTRICAL EQUIPMENT FLASHING (WARNING) LIGHT

The optional flashing light, 1, consists of one amber lamp that provides a flashing light that is visible from the front and rear of the skid-steer loader.

G97-373

244 Op. 55 404

RECTANGULAR ROAD, WORK AND TAILLIGHTS

The optional equipment in this package consists of two headlights and one rear operating light. The rear light has a switch, 1, on the lamp assembly to turn off the work light and turn on a red taillight.

19985887

245

55-161

SECTION 55 - ELECTRICAL SYSTEM

LIGHT CIRCUITS

19985888

246

55-162

SECTION 55 - ELECTRICAL SYSTEM

TROUBLESHOOTING LIGHT CIRCUITS PROBLEM No lights turn ON

POSSIBLE CAUSE

CORRECTION

No battery voltage to the on/off switch

Check the O (orange) wire from the ignition “ACC” terminal for battery voltage; if voltage at “ACC”, there is an open in orange wire - replace orange wire Check road/work light circuit ground; if poor or no ground, repair

One light will not turn ON

No battery voltage to the lamp

Check power wire to lamp, if no voltage, there’s an open in the power wire, replace wire Check lamp assembly ground

Flashing lamp will not light

Blown lamp

Replace lamp

Blown bulb

Replace bulb

No battery voltage to lamp

Check for open in DKBR/O power wire to flasher; if open, replace wire Check for open in Y (yellow) wire to lamp; if open, replace wire Check of no or poor ground; repair ground If all wiring is good, replace flasher unit

No battery voltage to switch

55-163

Check for open in DKBR/O power wire from “ACC” ignition switch terminal; if open, replace wire

SECTION 55 - ELECTRICAL SYSTEM

FLASHING (WARNING) LIGHT LAMP OR BULB REPLACEMENT

Remove the lens screw, 1, from the center of the lens. Remove the lens and replace the bulb by rotating the bulb counterclockwise to remove the bulb from the socket.

19993706

247 Op. 55 404 10

FRONT RECTANGULAR LIGHT LAMP REPLACEMENT

Unplug the lens connector, 1, and rotate the bulb holder, 2, to remove the bulb from the case.

1 19993704

248 Op. 55 404 10

REAR RECTANGULAR LIGHT LAMP REPLACEMENT

To replace the white lamp, slide the lamp to the left, 1. Unplug the lens connector and rotate the bulb holder to remove the bulb from the case. To replace the red lamp, remove the rubber lamp retainer, 2, from the plastic shell by removing the four self-tapping screws. Pull the lamp from the shell and remove the wires from the lamp. 19985887

249

55-164

SECTION 55 - ELECTRICAL SYSTEM Op. 55 000

HORN

The horn switch, 1, on the handle connects directly to the horn in the front frame. To replace the switch, loosen the nut, 2, on the left control handle, 3, and remove the B (black) and DKGN/R wires from the switch.

1 3 19995045

250 To replace the horn, disconnect the O/B power wire, 1, and remove the mounting bolt, 2.

The horn operates on battery voltage from the â&#x20AC;&#x153;ACCâ&#x20AC;? terminal of the ignition key switch.

19993703

251

19995713

Horn Wiring Diagram 252

55-165

SECTION 55 - ELECTRICAL SYSTEM

LABOR GUIDE

The following labor amounts are listed as a guide only. Working conditions and experience will vary the amount of time it actually takes to complete each job. Job

Labor-Hours

LS120 Alternator, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 LS125 Alternator, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Battery, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Boom lockout solenoid, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Boom lockout solenoid, overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Circuit breaker, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Console lights, remove and replace (each) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 Flasher light switch (optional), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Flasher assembly (optional), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 Flasher light bulb (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 Flasher lamp assembly (optional), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 Flasher wire harness (optional), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Fuel Shutoff solenoid, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Glow plug circuit breaker (LS125 only), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Glow plug controller (LS125 only), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 Glow plug relay (LS125 only), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Horn, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Hourmeter, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Ignition key switch, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Oil pressure switch, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Restraint control module, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Road/work lamp (optional), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Road/work light assembly (optional), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 Road/work light switch (optional), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Road/work taillight lamp (optional), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Road/work taillight assembly (optional), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 Road/work light wire harness (optional), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Seat belt assembly, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Seat switch, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Start relay, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Starter motor, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Warning light, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 Water temperature sender (LS125 only), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Water temperature switch (LS125 only), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 Wire harness (main), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Wire harness (seat), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5

55-166

SECTION 82 -- FRONT LOADER (Boom And Mounting Plate) Chapter 1 -- Buckets, Boom CONTENTS Section 82 000

Description

Page

82 100 77

Boom Lockpin and Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-6

82 100 50

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-9

82 100 70

82-1

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) Op. 82 100

GENERAL INFORMATION CHANGING BUCKETS AND ATTACHMENTS

Rapid changing of boom-mounted attachments is made possible by the unique mounting system used on LS120 and LS125 skid steers. A pivoting mounting plate, 1, is supplied with the loader as standard equipment and remains attached to the boom. The hydraulic cylinder pins are not removed to change attachments.

All attachments mate with the mounting plate, using a full length saddle, 2, which engages the top of the mounting plate.

19994961

CAUTION Attachments used with this loader must be compatible with the mounting system.

To mount an attachment, hydraulically tilt the mounting plate, 1, forward while guiding the crest of the mounting plate under the attachment saddle, 2.

1 G97-376

2 BE SURE TO REMOVE THE RETAINING PINS BEFORE ATTEMPTING TO MOUNT THE ATTACHMENT. As the mounting plate is hydraulically raised and rolled back, the back surface, 1, of the attachment comes to a rest flat against the front surface of the mounting plate, 2.

1 G97-412

82-2

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) When the attachment is fully supported, lower the boom until the boom is down on the loader frame. Roll the attachment out, stopping with the front edge about 50 mm (2â&#x20AC;ł) from the ground. Turn off the engine. Exit the loader. Install two pins, 1, and retain with hairpin cotter pins.

82-3

G97-385

1 4

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)

SPECIFICATIONS Operating Weight* LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 898.1 kg (1980 lbs.) LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 957.1 kg (2110 lbs.) * With 22 kg (48 lbs.) fuel tank full , 79 kg (175 lbs.) operator, 1067 mm (42″) utility bucket, 5.70 x 12 tires and 27 kg (60 lbs.) battery . Operating Capacity SAE operating load per SAE J818 LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 kg (675 lbs.) LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 kg (700 lbs.)

Bucket Capacity Cutting Edge #

Skid Bar #

Capacity Struck

Capacity Heaped

34.5 kg (76 lbs.)

764025

764032

0.10 m3 (3.48 ft.3)

0.13 m3 (4.75 ft.3)

42″ Utility (1067 mm)

40.4 kg (89 lbs.)

764033

764032

0.11 m3 (4.06 ft.3)

0.15 m3 (5.33 ft.3)

47″ Utility (1194 mm)

62.1 kg (137 lbs.)

766444

764032

0.13 m3 (4.54 ft.3)

0.17 m3 (5.97 ft.3)

Bucket

Weight

36″ Utility* (914 mm)

* Use 36″ Utility fork with 5.70 x 12 tires only. Fork Options Cutting Edge #

Skid Bar #

Tine #

54.4 kg (120 lbs.)

764025

766449

766440

63.5 kg (147 lbs.)

766033

766449

766440

Fork

Weight

36″ Utility* (914 mm) 42″ Utility (1067 mm)

* Use 36″ Utility fork with 5.70 x 12 tires only.

82-4

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)

BUCKETS AND UTILITY FORKS 1

36″ (0.91 m) bucket (800854) (4.57 ft.3 [0.13 m3]) The 36″ (0.91 m) bucket includes a 0.375″ (9.5 mm) thick cutting blade.

42″ (1.06 m) bucket (800855) (5.33 ft.3 [0.15 m3]) The 42″ (1.06 m) utility bucket includes a cutting blade and has greater capacity in an average material handling operation.

47″ (1.19 m) utility bucket (800856) (5.97 ft.3 [0.17 m3]) A wider, medium-duty bucket for operations where narrow aisles or doorways are not a problem.

36″ utility fork (800857) The utility fork includes six heavy-duty tines for handling bulky, hard-to-work-with materials.

42″ utility fork (800858) The utility fork includes seven heavy-duty tines for handling bulky, hard-to-work-with materials.

82-5

G97-370

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) Op. 82 100 77

BOOM LOCKPIN AND LINKAGE Removal 1. Lower the boom to rest on the frame. Lower the attachment mounting plate front edge to rest on the ground. Turn the engine OFF. 2. Turn the ignition ON and push both the boom and tilt hydraulic foot pedals up and down to relieve any hydraulic pressure. Turn the ignition switch OFF. 3. Remove the boom lock cover, 1, by removing the two bolts, 2.

A3948-09

2 6

4. Remove the spring, 1, from the fixed bottom post and bolt post. 5. Count the number of spacer washers, 2, over the handle pivot for reassembly. Loosen and remove the through bolt, 3, securing the handle pivot to the roof frame. 6. Separate the connecting rods, 4, from the handle pivot and remove all the components from the cab roof.

3 1

20000671

7 Inspection 1. Make sure the pins, 1, and connecting rods, 2, are not deformed. Check that the push-on retainers, 3, are securely in place, and the rods pivot easily.

20000672

82-6

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 2. Check that the handle pivot, 1, spins around the bushing, 2, with little effort. 3. Check that the spring, 3, has no bent coils or bent end hooks.

1 2

3 20000673

9 Installation 1. Insert the lockpins,1, and connecting rods, 2, into position with the rod ends pointing down.

20000674

10 2. Install the handle pivot, 1, and insert the connecting rod ends, 2, into the handle holes. 3. Secure the handle with the through bolt, 3, flat washer, 4, bushing, and spacer washers, 5. Tighten securely. 4. Connect the spring, 6, to the fixed bottom post and handle bolt post.

4 3 20000671

6 11

82-7

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 5. Fasten the boom lock cover, 1, to the frame with the two bolts, 2. Lubricate the bushing area, 3, of the handle.

1 3

A3948-09

2 12

6. Lubricate each pin, 1, and check for proper boom lock operation. Lockpins should protrude at least 25.4 mm (1.0â&#x20AC;ł) from the frame. Handle and pins should remain in both fully engaged or fully disengaged positions with some spring tension resistance.

A3947-13

82-8

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) Op. 82 100 50

BOOM Removal

WARNING Fluid under pressure may have sufficient force to penetrate the skin and cause serious personal injury. If injured by escaping fluid, obtain medical assistance at once. Serious infection or reaction can occur if medical treatment is not administered immediately. Always protect the skin and eyes from escaping fluid under pressure. Before disconnecting lines, hoses, or fittings, be sure that all pressure in the system has been relieved. Before applying pressure to a system, be sure all connections are tight and all fittings, lines, and hoses are not damaged. Gauges, gauge fittings, and hoses must have operating pressure ratings 25 percent higher than the highest pressure of the system. Never adjust relief valves to higher pressures than specified by the equipment manufacturer. 1. Lower the boom to rest on the frame. Remove any attachment. 2. Lower the attachment mounting plate front edge to rest on the ground. Turn the engine OFF. 3. Turn the ignition ON and push both the boom and tilt hydraulic foot pedals up and down to relieve any hydraulic pressure. NOTE: If the auxiliary boom hydraulic kit #802763 is installed, work the auxiliary control handle, 1, up and down while working the foot pedals to relieve hydraulic pressure in the auxiliary lines.

4. Turn the ignition switch OFF.

19994959

82-9

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 5. Remove the attachment mounting plate by removing the lock bolts, 1, and pivot pins.

19994961

15 6. Disconnect the bucket hydraulic line connections, 1. Cap the hydraulic lines. 7. Remove the bucket cylinders by removing the lock bolts, 2, and pivot pins, 3.

1 1

30994679

16 8. Loosen and remove the bucket hydraulic line connection, 1. 9. Loosen and remove the hydraulic line clamp, 2. 10. Auxiliary Hydraulics - Disconnect the auxiliary hydraulic line clamp, 3.

2 1

30994955

82-10

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 11. The bucket hydraulic lines are routed under the right boom arm. Place a bucket under the connections to catch oil. Mark and disconnect the hydraulic line connection, 1.

30994951

18 12. Auxiliary Hydraulics - The auxiliary boom hydraulic lines are routed under the left side of the boom. Place a bucket under the connections to catch oil. Mark and disconnect the two hydraulic line connections, 1, under the front of the boom arm.

19994950

19 13. Mark and disconnect the two bucket hydraulic line connections, 1, under the rear of the right boom arm.

30994953

82-11

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 14. Auxiliary Hydraulics - Mark and disconnect the two hydraulic line connections, 1, under the rear of the left boom arm.

1 19994952

21 15. Loosen and remove the three hydraulic line clamps, 1, on the right boom arm. For loaders equipped with auxiliary hydraulics, remove the clamps on the left boom arm. Pull the hydraulic lines out from under the boom.

A3947-09

22 16. Disconnect the hydraulic line, 1, on the front port of both boom cylinders. 17. Remove the lock bolt, 2, and pivot pin, 3, from the front of both boom cylinders.

1 3

30994957

82-12

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 18. Remove the lock bolts, 1, and pivot pins, 2, from the boom arms and frame. 19. Use a suitable lifting device to lift the boom clear of the loader.

1 2

30994954

24 Installation 1. Use a suitable lifting device to lift the boom onto the loader. 2. Coat all pivot pins with anti-seize grease such as “Never-Seez” or “Moly-Kote GN” paste. Attach the rear of the boom by installing the pivot pins, 1, and lock bolts, 2, on the both sides of the loader. Tighten the lock bolts to 35 N⋅m (25 ft. lbs.).

2 1

30994954

25 3. Install the pivot pins, 1, and lock bolts, 2, at the front of each boom cylinder. Tighten the lock bolts to 35 N⋅m (25 ft. lbs.). 4. Connect the hydraulic line, 3, on the front port of each boom cylinder.

3 1

30994957

82-13

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 5. Install the hydraulic lines with three clamps, 1, on the right boom arm. For loaders equipped with auxiliary hydraulics, install the lines with three clamps on the left boom arm.

A3947-09

27 6. Connect the two hydraulic line connections, 1, under the rear of the right boom arm.

30994953

28 7. Auxiliary Hydraulics - Connect the two hydraulic line connections, 1, under the rear of the left boom arm.

1 19994952

82-14

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 8. Connect the two hydraulic line connections, 1, under the front of the right boom arm.

30994951

30 9. Auxiliary Hydraulics - Connect the hydraulic line connection, 1, under the front of the left boom arm.

19994950

31 10. Install the bucket cylinders by inserting the pivot pins, 1, and tightening the lock bolts, 2, to 35 Nâ&#x2039;&#x2026;m (25 ft. lbs.). 11. Connect the bucket hydraulic line connections, 3.

3 3

30994679

82-15

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) 12. Install the hydraulic line clamp, 1. 13. Auxiliary Hydraulics - Install the auxiliary hydraulic line clamp, 2.

30994955

33 14. Install the attachment mounting plate by inserting pivot pins and tightening the lock bolts, 1, to 35 Nâ&#x2039;&#x2026;m (25 ft. lbs.).

19994961

82-16

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE) Op. 82 100 70

ATTACHMENT MOUNTING PLATE Removal 1. Lower the boom completely and lower the front of the mounting plate to the ground. 2. Loosen the bucket cylinder pin retaining bolts, 1. Remove the pins. 3. Raise the boom so the attachment plate pins, 2, clear the tires, 3. 4. Loosen the attachment plate pin retaining bolts, 4, and remove the pins.

3 1

1 19994961

35 Inspection 1. Inspect the plate for any cracks in the plates or in the weld areas. 2. Inspect the pin holders, 1, for excessive wear or distortion. 3. Inspect the main mounting plate, 2, for any damage or distortion. 4. Inspect the front edge, 3, of the mounting plate for any cracks in the plate or weld areas.

19994963

36 Installation 1. Coat the pivot pins with anti-seize grease such as “Never-Seez” or “Moly-Kote GN” paste. Raise the plate into position and install the pins, 1, connecting the bottom of the plate to the boom. Install the pins, 2, connecting the middle of the plate to the bucket cylinders. 2. Install the retaining lock bolts and tighten to 35 N⋅m (25 ft. lbs.).

19994961

82-17

SECTION 82 - FRONT LOADER (BOOM AND MOUNTING PLATE)

LABOR GUIDE

The following labor amounts are listed as a guide only. Working conditions and experience will vary the amount of time it actually takes to complete each job. Job

Labor-Hours

Boom (including hydraulic lines), remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 Attachment mounting plate, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5

82-18

SECTION 90 -- PLATFORMS AND DECALS Chapter 1 -- Seat, Safety Decals CONTENTS Section

Description

Page

90 120 10

Operatorâ&#x20AC;&#x2122;s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-2

90 108

90-1

SECTION 90 - PLATFORMS AND DECALS

OPERATORâ&#x20AC;&#x2122;S SEAT Op. 90 120 10 Removal and Disassembly 1. Lift the front of the seat, 1, up and slide the seat to the front about 200 mm (8â&#x20AC;ł). Reach behind the seat and unplug the seat switch wire harness from the main wire harness.

1 A3948-02

1 2. Loosen and remove the screw, 1, holding the seat harness clip under the pan support. 3. Remove the seat retaining hardware, 2, and remove the seat from the support. 4. Unplug the wire harness, 3, from the seat switch.

19990303

2 5. Remove the switch retaining hardware, 1, and remove the switch from seat pan. Do not pry on switch base, or damage to the base may occur.

19990304

1 3

90-2

SECTION 90 - PLATFORMS AND DECALS Installation 1. Insert the switch, 1, into the seat bottom making sure the switch is seated into the hole in the seat pan. IMPORTANT: If the switch is not seated properly when the retaining hardware is tightened, the switch flange will be broken. 2. Reconnect the wire harness connector, 2, to the switch. Make sure the connector latch is engaged and the connector is locked in place. 3. Install the seat harness retaining clip on the seat pan support with a bolt, 3, and nut. 4. Attach the seat assembly to the support plate with four capscrews, 4. Tighten the capscrews and the harness clip bolt. 5. Place the seat assembly in the loader, and plug the seat switch wire harness into the main wire harness. Slide the seat assembly into place, locating the front of the seat support over the locating pins.

90-3

1 19990303

SECTION 90 - PLATFORMS AND DECALS Op. 90 108

MACHINE SAFETY DECALS The following safety decals have been placed on the machine in the areas indicated. They are intended for your personal safety and for those working with you. Please take this manual and walk around your machine to note the content and location of these warning signs.

Review these warning signs and the operating instructions detailed in this manual with your machine operators. Keep the decals legible. If they are not legible, replace. The decal part numbers are listed with each decal.

8 1 2 3

9 7

90-4

SECTION 90 - PLATFORMS AND DECALS

2 DANGER: THIS CAB IS PROVIDED FOR YOUR SAFETY. DO NOT REMOVE THE CAB.

PART #766417

CAUTION: DO NOT ALLOW ANYONE TO OPERATE THE LOADER WITHOUT PROPER INSTRUCTION. PART #86521688

4 CAUTION: AVOID OVERTURN. NEVER LIFT MORE THAN THE MAXIMUM SAE LOAD RATING OF THE LOADER. NEVER TRANSPORT A LOADED BUCKET AT FULL HEIGHT. OPERATE THE LOADER WITH LOAD AS LOW AS POSSIBLE.

3 WARNING: NEVER OPERATE THE LOADER WITHOUT THE SEAT BELT SECURELY FASTENED.

LS120 - 306 KG (600 LBS.) (#857679) LS125 - 318 KG (700 LBS.) (#9828824)

PART #86521686

PART #849959

90-5

SECTION 90 - PLATFORMS AND DECALS

5 DANGER: BEFORE EXITING THE LOADER, LOWER THE LIFT ARMS AND ATTACHMENT TO THE GROUND OR REST LIFT ARMS ON THE BOOM STOPS. STOP ENGINE AND ENGAGE THE PARKING BRAKE. PART #86521683

6 DANGER: DO NOT ALLOW PASSENGERS TO RIDE ON THE LOADER AT ANY TIME. PART #86521685

8 WARNING: KEEP CLEAR! ROTATING FAN â&#x20AC;&#x201D; STOP ENGINE. PART #9828825

7 CAUTION: SWITCHES IN SEAT AND SEAT BELT PREVENT OPERATION OF LIFT ARMS AND STARTER UNLESS OPERATOR IS IN SEAT WITH SEAT BELT BUCKLED. DO NOT BYPASS SWITCHES.

CAUTION: DO NOT USE STARTING FLUID. AIR HEATER MAY IGNITE STARTING FLUID AND CAUSE AN EXPLOSION.

PART #9604252

PART #847363

90-6

SECTION 90 - PLATFORMS AND DECALS

LABOR GUIDE

The following labor amounts are listed as a guide only. Working conditions and experience will vary the amount of time it actually takes to complete each job. Job

Labor-Hours

Operatorâ&#x20AC;&#x2122;s seat, switch, or support, remove and replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8

90-7

SECTION 90 - PLATFORMS AND DECALS

90-8

SECTION 00 -- GENERAL INFORMATION BOOK 1

Chapter 1 -- General Information CONTENTS Section

Description

Page

00 000

SECTION 10 -- ENGINE BOOK 1 CONTENTS Section 10 000

Description

Page

55 100

10 001 10

Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24

55 301 40

Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24

10 202 40

Standard Air Cleaner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24

10 202 40

Heavy Duty Air Cleaner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25

10 001 53

Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29

10 103 70

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32

10 102 10

Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34

10 101 21

Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35

10 105 10

Connecting Rod and Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35

10 101 32

Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36

10 230 20

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37

10 230 20

10 101 32

Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40

10 101 56

Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47

10 105 22

Pistons, Piston Rings, and Connecting Rods Disassembly and Inspection . . . . . . . . . . 10-50

10 103 30

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52

10 103 10

10 304 38

29 100 50

Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75

10 000

10 001 10

Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97

10 218 30

Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99

55 201 76

Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99

55 301 10

Temperature Sending Switch and ALternator Removal . . . . . . . . . . . . . . . . . . . . . . . . . 10-100

10 001 53

Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101

10 414 20

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101

10 402 10

Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101

10 250 16

External Oil Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101

10 101 14

Valve Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101

10 106 20

Rocker Shaft and Push Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101

10 101 21

10 223 10

10 414 30

Crank Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103

10 236 10

Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103

10 230 24

Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103

10 304 44

Oil Sump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104

10 105 10

Connecting Rods, Bearings and Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105

10 103 70

Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106

10 102

Backplate and Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106

10 103 10

10 101 21

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107

10 101 55

Valve Seat Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108

10 101 32

Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109

10 106 20

Rocker Arm Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111

10 105 22

10 103 10

Main Bearing and Thrust Bearing Removal and Inspection . . . . . . . . . . . . . . . . . . . . . . 10-119

10 103 30

10 106 40

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124

10 103 76

10 304 38

29 100 50

10 304 10

Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144

10 304 30

Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144

10 304 38

10 406 10

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150

10 402 28

Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150

10 402 30

10 236 10

10 236 08

10 230 24

Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-175

10 218 34

10 001 10

Labor Guide - Engine Removal From Skid Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-183

SECTION 29 -- HYDROSTATIC TRANSMISSION BOOK 2

Chapter 1 -- Pumps, Motors, Steering CONTENTS Section 29 000

Description

Page

29 100 01

29 100 40

Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-11

29 100 46

Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-14

29 100 60

Hydrostatic Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-28

29 100 66

29 100 36

Charge Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-47

29 100

Steering Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-48

29 100 36

SECTION 33 -- BRAKES AND CONTROLS BOOK 2

Chapter 1 -- Parking Brake CONTENTS Section

Description

Page

33 000

33 110

SECTION 35 -- HYDRAULIC SYSTEM BOOK 2

Chapter 1 -- Valves, Gear Pump, and Cylinders CONTENTS Section 35 000

Description

Page

35 710 02

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-9

35 724 50

Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-10

35 724 54

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-11

35 710 10

Hydraulic Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-18

35 710 20

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-18

35 730 10

Bucket Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-24

35 730 13

Bucket Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-25

35 710 10

Boom Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-29

35 730 18

35 705 05

SECTION 39 -- FRAMES BOOK 2

Chapter 1 -- ROPS CONTENTS Section

Description

Page

Cab / ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-2 90 152 46

SECTION 44 -- AXLES AND WHEELS BOOK 2

Chapter 1 -- Axles, Drive Chain CONTENTS Section 44 100

Description

Page

44 106

44 106 48

44 511

SECTION 55 -- ELECTRICAL SYSTEM BOOK 3

Chapter 1 -- Circuits, Alternators, Starters CONTENTS Section 55 000

Description

Page

55 640

10 223

Fuel Shutoff Solenoid -- LS 120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-62

10 223 10

Fuel Shutoff Solenoid -- LS 120 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-62

10 223

Fuel Shutoff Solenoid -- LS 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-64

10 223 10

Fuel Shutoff Solenoid -- LS 125 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-64

55 301 40

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-66

55 201

Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-68

55 201 10

55 100 24

Circuit Breakers -- LS125 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-74

55 640

55 201 15

55 201 14

55 408

55 418

55 100 34

55 201 76

55 100 34

55 640

55 414 12

55 414 10

55 100 74

Wire Harnesses LS120 -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-91

55 100 74

55 301

55 301 04

Alternator System Inspection -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-122

55 301

Alternator Flywheel Removal -- LS120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-123

55 301 10

Alternator Removal -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-124

55 301 12

Alternator Disassembly -- LS125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-124

55 201

55 201 50

55 201

55 404

55 404 10

Front Rectangular Light Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-164

55 404 10

Rear Rectangular Light Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-164

55 000

SECTION 82 -- FRONT LOADER (Boom And Mounting Plate) BOOK 3

Chapter 1 -- Buckets, Boom CONTENTS Section 82 000

Description

Page

82 100 77

Boom Lockpin and Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-6

82 100 50

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-9

82 100 70

SECTION 90 -- PLATFORMS AND DECALS BOOK 3

Chapter 1 -- Seat, Safety Decals CONTENTS Section

Description

Page

90 120 10

Operatorâ&#x20AC;&#x2122;s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-2

90 108