New holland l220 200 series skid steer loader service repair manual

service repair manual

1. Part number 84522361
1st edition English
June 2011
SERVICE MANUAL
L213 / L215 / L218 / L220
L223 / L225 / L230
200 Series Skid Steer Loader

C227 / C232 / C238
200 Series Compact Track Loader
Printed in U.S.A.
Copyright © 2011 CNH America LLC. All Rights Reserved. New Holland is a registered trademark of CNH America LLC.
Racine Wisconsin 53404 U.S.A.

2. SER VICE MANUAL
C227 ,C232 ,C238 ,L213 ,L215 ,L218 ,L220 ,L223 ,L225 ,L230
84522361 15/06/201 1
EN

3. Contents
INTRODUCTION
HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS A
PRIMAR YHYDRAULIC POWER SYSTEM ..............................................A.10.A
SECONDAR YHYDRAULIC POWER SYSTEM ..........................................A.12.A
HYDRAULIC COMMAND SYSTEM ......................................................A.14.A
HIGH-FLOW HYDRAULIC POWER SYSTEM ...........................................A.16.A
ELECTRICAL POWER SYSTEM ........................................................A.30.A
LIGHTING SYSTEM ......................................................................A.40.A
ELECTRONIC SYSTEM .................................................................A.50.A
FAUL TCODES ...........................................................................A.50.A
ENGINE AND PT OIN ...................................................................B
ENGINE ..................................................................................B.10.A
FUEL AND INJECTION SYSTEM ........................................................B.20.A
AIR INT AKE SYSTEM ....................................................................B.30.A
ENGINE COOLANT SYSTEM ...........................................................B.50.A
ST AR TING SYSTEM .....................................................................B.80.A
TRANSMISSION, DRIVE AND PT OOUT ........................................C
TRANSMISSION Hydrostatic .............................................................C.20.F
AXLES, BRAKES AND STEERING .................................................D
Final drive ................................................................................D.15.A
Final drive Hydraulic drive ................................................................D.15.C
STEERING Mechanical ..................................................................D.20.B
PARKING BRAKE Hydraulic .............................................................D.32.C
WHEELS AND TRACKS Tracks .........................................................D.50.B
WHEELS AND TRACKS Wheels .........................................................D.50.C
FRAME AND CAB ........................................................................E
FRAME Primary frame ...................................................................E.10.B
SHIELD ...................................................................................E.20.A
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4. USER CONTROLS AND SEA T..........................................................E.32.A
USER CONTROLS AND SEA TOperator seat ...........................................E.32.C
USER PLA TFORM .......................................................................E.34.A
ENVIRONMENT CONTROL Air-conditioning system ....................................E.40.C
SAFETY SECURITY ACCESSORIES Safety ............................................E.50.B
FRAME POSITIONING .................................................................F
ST ABILISING Ballasting ..................................................................F.20.B
TOOL POSITIONING ....................................................................G
LIFTING ..................................................................................G.10.A
TIL TING ..................................................................................G.20.A
LEVELLING ..............................................................................G.30.A
SECONDAR YFUNCTIONS Hydraulic ...................................................G.90.C
HITCH AND WORKING TOOL .......................................................H
BOOM Lift ................................................................................H.20.B
ARM TOOL ATT ACHMENT Tilt ...........................................................H.30.C
SINGLE ARM Lift .........................................................................H.40.B
SINGLE ARM TOOL ATT ACHMENT Tilt .................................................H.50.C
EXCA VATING AND LANDSCAPING ...............................................J
DIGGING Non-articulated digging tools ..................................................J.20.B
CARR YING Unarticulated tools ..........................................................J.50.B
COUPLING Mechanical coupling .........................................................J.80.B
COUPLING Hydraulic coupling ...........................................................J.80.C
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5. INTRODUCTION
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1

6. Contents
INTRODUCTION
Foreword -Ecology and the environment ......................................................3
Safety rules .....................................................................................4
2-Series
Safety rules -Personal Safety ..................................................................5
Safety rules .....................................................................................6
Basic instructions -Important notice regarding equipment servicing ...........................7
Torque -Minimum tightening torques for normal assembly .....................................8
2-Series
General specification -General Welding .....................................................13
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7. INTRODUCTION
Foreword -Ecology and the environment
Soil, air ,and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment
of some of the substances which are required by advanced technology ,sound judgement should govern the use and
disposal of products of achemical and petrochemical nature.
NOTICE: The following are recommendations which may be of assistance:
• Become acquainted with and ensure that you understand the relative legislation applicable to your country .
• Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning
agents, etc., with regard to their effect on man and nature and how to safely store, use and dispose of these
substances.
• Agricultural consultants will, in many cases, be able to help you as well.
HELPFUL HINTS
• Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems which may cause considerable
spillage.
• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances which
may be harmful to your health.
• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.
• Avoid spillage when draining offused engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids,
etc. Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in
aproper way to comply with local legislation and available resources.
• Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should
not be allowed to get into the soil but should be collected and disposed of properly .
• Do not open the air -conditioning system yourself. Itcontains gases which should not be released into the at-
mosphere. Your NEW HOLLAND CONSTRUCTION dealer or air conditioning specialist has aspecial extractor
for this purpose and will have to recharge the system properly .
• Repair any leaks or defects in the engine cooling or hydraulic system immediately .
• Do not increase the pressure in apressurized circuit as this may lead to acomponent failure.
• Protect hoses during welding as penetrating weld splatter may burn ahole or weaken them, allowing the loss of
oils, coolant, etc.
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8. INTRODUCTION
Safety rules
2-Series
Personal safety
This isthe safety alert symbol. Itisused to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury .
Throughout this manual and on machine decals, you will find the signal words DANGER, WARNING, and CAUTION
followed by special instructions. These precautions are intended for the personal safety of you and those working
with you.
Read and understand all the safety messages in this manual before you operate or service the machine.
DANGER indicates ahazardous situation which, ifnot avoided, will result in death or serious injury .The
color associated with DANGER is RED.
WARNING indicates ahazardous situation which, ifnot avoided, could result in death or serious injury .
The color associated with WARNING is ORANGE.
CAUTION, used with the safety alert symbol, indicates ahazardous situation which, ifnot avoided, could result
in minor or moderate injury .The color associated with CAUTION is YELLOW .
FAILURE TOFOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESUL T
IN DEA TH OR SERIOUS INJUR Y.
Machine safety
NOTICE: Notice indicates asituation which, ifnot avoided, could result in machine or property damage. The color
associated with Notice is BLUE.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety .
Information
NOTE: Note indicates additional information which clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about astep, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.
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9. INTRODUCTION
Safety rules -Personal Safety
Carefully study these precautions, and those included in the external attachment operators
manual, and insist that they be followed by those working with and for you.
1. Thoroughly read and understand this manual and the attachment operators manual before operating this or any
other equipment.
2. Be sure everyone isclear of the machine before starting. Blow the horn, ifequipped, three times before starting
engine.
3. Only the operator should be on the machine when in operation. Never allow anyone to climb on to the machine
while itis in motion. Ifthe machine is equipped with an Instructors Seat, this must only be used for training
purposes. Passengers must not be allowed to use the Instructors Seat.
4. Keep all shields inplace. Never work around the machine or any of the attachments while wearing loose clothing
that might catch on moving parts.
5. Observe the following precautions whenever lubricating the machine or making adjustments.
• Disengage all clutching levers or switches.
• Lower the attachment, ifequipped, to the ground or raise the attachment completely and engage
the cylinder safety locks .Completing these actions will prevent the attachment from lowering un-
expectedly .
• Engage the parking brake.
• Shut offthe engine and remove the key .
6. Always keep the machine in gear while going downhill.
7. The machine should always be equipped with suf ficient front or rear axle weight for safe operation.
8. Under some field conditions, more weight may be required at the front or rear axle for adequate stability .This
is especially important when operating in hilly conditions or/when using heavy attachments.
9. Always lower the attachment, shut offthe engine, set the parking brake, engage the transmission gears and
remove the key before leaving the operators platform.
10. Ifthe attachment or machine should become obstructed or plugged; set the parking brake, shut offthe engine
and remove the key ,engage the transmission gears, wait for all machine or attachment motion to come to a
stop, before leaving the operators platform to removing the obstruction or plug.
11. Never disconnect or make any adjustments to the hydraulic system unless the machine and /or the attachment
is lowered to the ground or the safety lock(s) is in the engaged position.
12. Use of the flashing lights is highly recommended when operating on apublic road.
13. When transporting on aroad or highway ,use accessory lights and devices for adequate warning to the operators
of other vehicles. In this regard, check local government regulations. Various safety lights and devices are
available from your NEW HOLLAND CONSTRUCTION dealer .
14. Practice safety 365 days ayear .
15. Keep all your equipment in safe operating condition.
16. Keep all guards and safety devices in place.
17. Always set the parking brake, shut offthe engine and remove the key ,engage the transmission gears, wait for all
machine or attachment motion to come to astop, before leaving the operators platform to service the machine
and attachment.
18. Remember: Acareful operator is the best insurance against an accident.
19. Extreme care should be taken in keeping hands and clothing away from moving parts.
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10. SER VICE MANUAL
HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS
C227 ,C232 ,C238 ,L213 ,L215 ,L218 ,L220 ,L223 ,L225 ,L230
84522361 15/06/201 1
A

11. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
Hydraulic pump -Flow test Loader hydraulic pump
NOTE: Two persons are required to perform the flowmeter tests for safety to avoid possible injury .One person must
be seated in the operators seat when the engine is running. The second person is to control the flowmeter and take
the readings.
1. Park the machine on alevel surface. Lower the
loader bucket to the floor .Stop the engine.
2. Disconnect the hose from the loader pump pressure
port (1) at Test Point 1. Install aplug in the hose.
Connect the flowmeter inlet hose to the fitting at the
pressure port (1) of the pump. Ifequipped with high
flow ,disconnect the hose from the high flow pressure
port (2) .Install aplug in the hose. Connect asecond
flowmeter inlet hose to the fitting at the pressure port
(2) of the pump.
NOTE: The first picture is for models equipped with ahy-
draulic gear pump only .The second picture is for models
equipped with ahydraulic gear pump with high flow option.
931002073 1
931001956 2
3. Put the flowmeter outlet hose into the hydraulic reser-
voir .Use wire to fasten the flowmeter outlet hose be-
low the surface of the hydraulic oil.
4. Make sure that the oil level in the hydraulic reservoir
is correct.
5. Make sure that the pressure valve of the flowmeter
is opened completely .
6. The oil must be at operating temperature. Ifthe oil
isnot at operating temperature, run the engine at full
throttle and close the pressure valve of the flowmeter
until the pressure gauge indicates 103 bar (1500 psi).
Continue to run the engine at full throttle until the
temperature of the oil is 52°C (125°F). Then open
the pressure valve completely .
7. Make sure that the pressure valves are opened com-
pletely .Adjust the engine speed to 2300 r/min (rpm)
and read the flow gauge. Read the flow and record
the reading as test number 1.
8. Slowly close the pressure valve on the flowmeter on
the loader pump until the pressure gauge indicates
97 bar (1400 psi). Keep the engine running at 2300
r/min (rpm). Read the flow and record the reading as
test number 2.
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12. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
9. Slowly close the pressure valve on the flowmeter un-
til the pressure gauge indicates 124 bar (1800 psi).
Keep the engine running at 2300 r/min (rpm). Read
the flow and record the reading as test number 3.
10. Slowly close the pressure valve on the flowmeter un-
til the pressure gauge indicates 152 bar (2200 psi).
Keep the engine running at 2300 r/min (rpm). Read
the flow and record the reading as test number 4.
11. Open the pressure valve completely .Ifthe high flow
pump is installed, repeat steps 8thru 10 on the high
flow section. Then decrease the engine speed to low
idle and stop the engine.
NOTE: Understanding the results of the tests are outlined
in the steps below .
12. If the output at minimum pressure was less than
the specification for Gear Pump Flow to Loader
(Machine in Neutral) refer to PRIMAR Y HY -
DRAULIC POWER SYSTEM -General specifi-
cation (A.10.A) ,the problem can be arestriction
between the reservoir and the gear pump, or the
problem can be abadly worn or damaged gear
pump.
13. If the output at minimum pressure was more
than the specification refer to PRIMAR YHY -
DRAULIC POWER SYSTEM -General specifica-
tion (A.10.A) ,there are no problems between the
reservoir and the gear pump. However ,the gear
pump can be worn or damaged and still have good
flow at minimum pressure.
14. Loss of output at 152 bar (2200 psi) indicates that
the gear pump is worn or damaged. Todetermine
the efficiency of the gear pump, divide the flow indi-
cation from test number 4by the flow indication from
test number 1. This answer multiplied by 100 is the
percent efficiency of the gear pump. Ifthe efficiency
of the gear pump is less than 70%, repair or replace
the gear pump. Ifthe efficiency of the gear pump is
more than 70%, the pump is good.
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13. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
Hydraulic pump -Install
NOTE: Before pump installation, apply Molykote G-4700 (P/N86983138) to the pump and the coupling splines. Pre -fill
the pump with clean hydraulic oil. Inspect O-ring on the pump pilot and replace ifnecessary .Lubricate the O-ring with
clean hydraulic oil.
1. Hold the pump in the mounting location. Rotate the
gear pump shaft until italigns with the coupling (1)
splines at the rear of the hydrostatic pump. Shown
with call out (X) After the splines are aligned, move
the pump inward until the mounting flange is flush
with the mounting surface of the hydrostatic pump.
931 11555A 1
2. Apply Loctite 243 to the pump mounting bolts (4) .In-
stall washers on the bolts and install the bolts into the
pump mounting flange. Tighten the mounting bolts .
931001928 2
3. Connect gear pump hydraulic hoses (A) and (B) ,as
shown.
931001956 3
4. Connect the gear pump supply hose (1) and tighten
hose clamp.
931001955 4
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14. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
5. Connect case drain hose (2) and secure with clamp.
931001963 5
6. Connect hydraulic hose (3) ,as shown.
931001972 6
7. Connect left hand side drive motor hoses (C) and (D) .
931001971 7
8. Connect right hand side motor hoses (5) and (6) .
931001970 8
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15. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
9. Connect the top hydraulic hose (7) .
931001966 9
10. Connect the oil supply hose (8) and tighten hose
clamp.
931001965 10
11. Connect right hand side hydraulic tube (9) .
931001964 11
12. Connect charge pressure switch (10) and secure
with nut.
931001963 12
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16. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
13. Connect the right hand side back up alarm connec-
tions (11).
931001962 13
14. Connect the left hand side back up alarm connec-
tions (12) .
9310021 15 14
15. Connect the control wires (E) and (F) located on the
bottom of pumps.
931001961 15
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17. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
Charge pump -Pressure test
Testing the low -pressure charge system is safer and usually more informative than going into the high -pressure test
ports. Toobtain as much system information as possible, charge pressure readings must be taken in neutral as well
as working the system in both the forward and reverse directions.
With the system in neutral, only charge pressure is present in the closed loop. At this time, the leakage from the
system isthe least and the charge pressure isthe highest. As the system ispressurized, the leakage from the system
will increase and the charge pump flow will make up for this leakage. With more of the charge pump oil flowing to
the closed loop, less oil will flow across the charge pressure relief valve, and therefore the pressure will be slightly
less. Ifthe leakage from the system is excessive, the charge pressure will drop offmore. This slight drop in charge
pressure between the system in neutral and with the system under load indicates the condition of the closed loop
system components.
1. Raise and securely block the unit offthe ground.
2. Remove the brake release lines from the tee fitting
that connects to the Bport (1) of the brake valve (2)
and cap lines.
931002074 1
3. Cap the tee fitting that connects to the Bport of the
brake valve.
4. Connect a4,137 kPa (41 bar) (600 psi) pressure
gauge to the charge pressure test port. Remove the
hose from the tee fitting and install a4,137 kPa(600
psi) pressure gauge.
5. Ifthe hydraulic oil is not at operating temperature,
run the engine at full throttle and hold the bucket con-
trol lever in the ROLLBACK position for 30 seconds.
Then return the bucket control lever to NEUTRAL for
15 seconds. Repeat this cycle until the temperature
of the oil is at least 52°C (125°F).
6. Continue to run the engine at full throttle. Read
the pressure gauge and record the Charge Pressure
reading. Stop the engine.
7. The pressure reading must be 25 -28 bar (362 -410
psi) or the relief valve must be adjusted with shims.
8. Ifthe pressure is correct, go to step 10. Ifthe pres-
sure is not correct, loosen the cap on the hydraulic
reservoir .Remove the plug, shim(s), spring, and
poppet for the charge pressure relief valve.
9. Inspect the parts of the charge relief valve. Ifthe
parts are good, add shim(s) from the shim kit, refer
to parts manual, and repeat steps 5through 9until
the pressure is correct.
NOTICE: For the following test the machine MUST be
raised up on supports until the tires are above the floor .
This is asafety procedure ifthe hydraulic parking brakes
fail to hold.
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18. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
10. After you get the correct charge pressure in NEU-
TRAL, do the following steps:
A. Start and run the engine at low idle. Increase
the engine speed to full throttle. Ifequipped with
2speed, shift into transport (high) range. Slowly
move one of the direction control levers FOR WARD
to load the hydrostatic piston pump and drive mo-
tor without decreasing the engine speed. DO NOT
Lug the Engine. Reduced engine speed causes de-
creased charge pump flow ,which will affect the pres-
sure readings. Repeat for the opposite side (only
move one lever at atime).
B. Read the pressure gauge. The pressure must be
within 138 kPa (1.5 bar) (20 psi) of the pressure in
step 6.
C. Repeat Steps Aand Bwith the direction control
levers in REVERSE.
Interpretation of the results:
Once the charge pressure meets specifications with
the levers in the neutral position, compare the pres-
sure readings under load with the neutral readings.
The readings should be highest with the levers in the
NEUTRAL position, for this is when the direct act-
ing charge relief has to handle the greatest amount
of oil flow .The maximum dif ference in charge pres-
sure readings between the system in neutral and
the system loaded in both directions must be not
greater than 138 kPa (1.5 bar) (20 psi). Any dif fer-
ence greater than 138 kPa (1.5 bar) (20 psi) indicates
excessive leakage from the closed loop, which will
require repair .
NOTE: The charge pressure drop indicates internal leak-
age from the system with the system under load. This is
caused by less oil flowing over the charge relief and there-
fore, the lower pressure. Excessive leakage (greater than
138 kPa (1.5 bar) (20 psi) will result in slower drive speed
on that side of the machine, but depending on what isdam-
aged in the system, the leakage may only show up under
heavy load conditions.
NOTE: Todetermine ifthe problem is in the pump or the
motor do the following:
11. On the side (left or right) that the charge pressure
dropped more than 138kPa (1.5 bar) (20psi), cap the
two high -pressure lines that supply the drive motor .
The lines can be capped at either the pump or at the
motor ,which ever is easiest.
NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is
caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than
138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is
damaged in the system, the leakage may only show up under heavy load conditions.
12. With the lines capped to the drive motor ,start and run
the engine at low idle. Increase the engine speed
to full throttle. Slowly move the direction control
lever that is being tested FOR WARD to load the hy-
drostatic piston pump without decreasing the engine
speed. DO NOT Lug the Engine. Reduced engine
speed causes decreased charge pump flow ,which
will affect the pressure readings.
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19. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is
caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than
138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is
damaged in the system, the leakage may only show up under heavy load conditions.
13. Read the pressure gauge. The pressure must be
within 138 kPa (1.5 bar) (20 psi) of the pressure in
step 6.
NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is
caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than
138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is
damaged in the system, the leakage may only show up under heavy load conditions.
14. Repeat Steps 11and 12 with the direction control
levers in REVERSE.
Interpretation of the results with the two high -pres-
sure lines capped to the drive motors:
Ifthe charge pressure drops more than 138 kPa (1.5
bar) (20 psi) of the pressure in step 6, the leakage is
in the pump.
Remember that this isaclosed loop hydrostatic sys-
tem. Ifone component fails, the debris will be sent
directly to the mating component and cause damage.
As this damage progresses, contamination will return
to the reservoir through the case drain system. At
the very least once afailure has occurred, the mat-
ing component in the hydrostatic system must be in-
spected for damage. Ifany contamination has been
returned to the reservoir ,tear down and inspection
of both complete closed loop systems is necessary
since the same charge pump feeds them. Also, be-
cause the hydraulic system shares the reservoir with
the hydrostatic system, all lines, and components
must be thoroughly cleaned to prevent contamina-
tion from reentering the repaired system.
NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is
caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than
138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is
damaged in the system, the leakage may only show up under heavy load conditions.
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20. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
Charge pump -Pressure test (Machines Equipped with EH Controls)
1. Connect a4,137 kPa (41 bar) (600 psi) pressure
gauge to test port, (1) see next figure.
NOTICE: For the following test the machine MUST be
raised up on supports until the tires are above the floor .
This isasafety procedure ifthe parking brakes fail to hold.
NOTE: You will need two people to perform this test. The
operator seat must be in the raised position to gain access
to the hydrostatic pump.
201 11248 1
2. Ifthe hydraulic oil isnot at operating temperature run
the engine at full throttle and hold the bucket con-
trol lever in the ROLLBACK position for 30 seconds.
Then return the bucket control lever to NEUTRAL for
15 seconds. Repeat this cycle until the temperature
of the oil is at least 52°C (125°F).
3. Continue to run the engine at full throttle. Read
the pressure gauge and record the Charge Pressure
reading. Stop the engine.
4. The pressure must be aminimum of 2,413 kPa (24
bar) (350 psi) at full throttle.
5. Ifthe pressure iscorrect go to step 7. Ifthe pressure
is not correct loosen the cap on the hydraulic reser-
voir .Remove the plug, shim(s), spring, and poppet
for the charge relief valve. See figure below .
6. Inspect the parts of the charge relief valve (1) .Ifthe
parts are good, add shim(s) from the shim kit and
repeat steps 1through 4until the pressure iscorrect.
201 11248 2
7. After you get the correct charge pressure in NEU-
TRAL, do the following steps.
NOTICE: For the following test the machine MUST be
raised up on supports until the tires are above the floor .
This isasafety procedure ifthe parking brakes fail to hold.
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21. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
8. (A.) Start and run the engine at low idle. Engage the
parking brake. Ifequipped with 2speed, shift into
transport (high) range.
(B.) Increase the engine speed to full throttle. Slowly
move the ground drive control lever FOR WARD to
load the hydraulic piston pumps without decreasing
the engine speed.
(C.) Read the pressure gauge. The pressure must
be within 138 kPa (1.5 bar) (20 psi) of the pressure
in step 3.
(D.) Repeat Steps Band Cwith the ground drive
control lever in REVERSE position.
Interpretation of the results:
Once the charge pressure meets specifications with
the levers in the neutral position, compare the pres-
sure readings under load with the neutral readings.
The readings should be highest with the levers in the
NEUTRAL position, for this is when the direct act-
ing charge relief has to handle the greatest amount
of oil flow .The maximum dif ference in charge pres-
sure readings between the system in neutral and
the system loaded in both directions must be not
greater than 138 kPa (1.5 bar) (20 psi). Any dif fer-
ence greater than 138 kPa (1.5 bar) (20 psi) indicates
excessive leakage from the closed loop, which will
require repair .
NOTE: The charge pressure drop indicates internal leak-
age from the system with the system under load. This is
caused by less oil flowing over the charge relief and there-
fore, the lower pressure. Excessive leakage (greater than
138 kPa (1.5 bar) (20 psi) will result in slower drive speed
on that side of the machine, but depending on what isdam-
aged in the system, the leakage may only show up under
heavy load conditions.
NOTE: Todetermine ifthe problem is in the pump or the
motor do the following:
9. On the side (left or right) that the charge pressure
dropped more than 138kPa (1.5 bar) (20psi), cap the
two high -pressure lines that supply the drive motor .
The lines can be capped at either the pump or at the
motor ,which ever is easiest.
NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is
caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than
138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is
damaged in the system, the leakage may only show up under heavy load conditions.
10. With the lines capped to the drive motor ,start and run
the engine at low idle. Increase the engine speed
to full throttle. Slowly move the direction control
lever that is being tested FOR WARD to load the hy-
drostatic piston pump without decreasing the engine
speed. DO NOT Lug the Engine. Reduced engine
speed causes decreased charge pump flow ,which
will affect the pressure readings.
NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is
caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than
138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is
damaged in the system, the leakage may only show up under heavy load conditions.
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22. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
11. Read the pressure gauge. The pressure must be
within 138 kPa (1.5 bar) (20 psi) of the pressure in
step 3.
NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is
caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than
138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is
damaged in the system, the leakage may only show up under heavy load conditions.
12. Repeat Steps 9and 10 with the direction control
levers in REVERSE.
Interpretation of the results with the two high -pres-
sure lines capped to the drive motors:
Ifthe charge pressure drops more than 138 kPa (1.5
bar) (20 psi) of the pressure in step 3, the leakage is
in the pump.
Remember that this isaclosed loop hydrostatic sys-
tem. Ifone component fails, the debris will be sent
directly to the mating component and cause damage.
As this damage progresses, contamination will return
to the reservoir through the case drain system. At
the very least once afailure has occurred, the mat-
ing component in the hydrostatic system must be in-
spected for damage. Ifany contamination has been
returned to the reservoir ,tear down and inspection
of both complete closed loop systems is necessary
since the same charge pump feeds them. Also, be-
cause the hydraulic system shares the reservoir with
the hydrostatic system, all lines, and components
must be thoroughly cleaned to prevent contamina-
tion from reentering the repaired system.
NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is
caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than
138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is
damaged in the system, the leakage may only show up under heavy load conditions.
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23. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
Reservoir -Apply vacuum
1. Remove the cap from the hydraulic reservoir .
2. Install an adapter cap CAS1871 on the filler neck.
3. Connect the vacuum pump CAS10193 to the
adapter .
4. Start the vacuum pump.
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24. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
Reservoir -Filling
1. Lower the loader lift arms to the ground and shut off
the engine.
2. Clean the reservoir filler cap and the area around the
filler cap with cleaning solvent.
3. Turn the filler cap 1/2turn to relieve air pressure from
the reservoir .Do not remove the filler cap from the
reservoir until the pressure is relieved.
4. Remove the filler cap from the reservoir .
5. Add the correct oil, CNH MA T3509 ,to the reservoir
until the proper oil level inthe reservoir isestablished.
Fill the reservoir until the oil level is at the midpoint
of the sight gauge. Install the reservoir cap.
6. Start and run the engine and operate the hydraulics.
Lower the loader lift arms to the ground. Stop the
engine and check the oil level in the reservoir .Add
oil as required.
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25. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
Reservoir -Visual inspection
1. Check the reservoir for wear ,cracks, and leaks. Re-
pair as required.
NOTICE: Do not modify the strainer ,as any material that
gets past the strainer can go directly to the gear pump,
control valve, cylinders, and auxiliary hydraulic attachment
and cause major damage to these components.
2. Inspect the strainer .Remove and replace if the
strainer is dirty or clogged.
3. Inspect the return line port, and suction line port, for
cracks and debris buildup. Repair as required.
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27. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
Filter -Remove
Prior operation:
Reservoir -Apply vacuum (A.10.A) .
1. The filter base can be removed by opening the rear
door and lifting the rear engine hood. Loosen and
remove the filter element (1) from the filter base.
2. Remove the ground wire (2) .
93107491 1
3. Remove the inlet, (3) ,and outlet, (4) ,oil lines and
cap to prevent loss of oil.
4. Stop vacuum pump.
5. Loosen and remove the filter base mounting bolts (5) .
93106865 2
6. Remove the filter base assembly from the unit.
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28. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
Filter -Install
Prior operation:
Reservoir -Apply vacuum (A.10.A) .
1. Reinstall the filter base with the hardware previously
removed (1) .Torque the mounting hardware to 20
Nm (15 lb ft).
93106865 1
2. Reinstall the hydraulic lines (2) and (3) and tighten
the lines to seat line on fittings; loosen and re-torque.
93107491 2
3. Stop vacuum pump.
4. Connect the ground wire (4) to the filter sensor .
93106865 3
5. Coat the seal ring on anew filter element with clean
10W -30 oil, and tighten the new filter element hand
tight 23.0 -17.6 N·m (17 -13 lb ft).
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29. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
Oil cooler -Remove for models equipped with ISM engine
L213, L215, L218, L220
Prior operation:
Radiator -Remove (B.50.A) .
1. Drain hydraulic oil reservoir by removing drain plug
(1) .
931001657 1
2. Ifrequired, remove fan shroud mounting hardware
(1) .
931001660 2
3. Remove engine oil dip stick mounting bolt (1) .
931001661 3
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30. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
4. Remove coolant overflow hose (1) and tank bracket
(2) .
931001662 4
5. Remove fan shroud (1) .
931002064 5
6. Label and disconnect cooler hydraulic lines (1) and
cap open ports.
931001666 6
7. Remove oil cooler mounting hardware (1) from both
left and right hand sides.
931001665 7
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31. HYDRAULIC, PNEUMA TIC, ELECTRICAL, ELECTRONIC SYSTEMS -PRIMAR YHYDRAULIC POWER SYSTEM
8. Remove oil cooler (1) from the machine.
931001667 8
Next operation:
Oil cooler -Install for machines equipped with ISM engine (A.10.A)
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