Carefully lift the engine assembly from the machine.

1. © 2018 CNH Industrial Italia S.p.A. All Rights Reserved.
SERVICE
MANUAL
1/2
Part number 48083746
W270D
W300D
Wheel Loader
SERVICE MANUAL
W270D
W300D
Tier 2
Wheel Loader
Part number 48083746
English
July 2018

2. SERVICE MANUAL
W270D ZBAR - EH, NEW CAB TIER2
W300D ZBAR - EH, NEW CAB TIER2
48083746_EN 01/08/2018
EN

3. Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase ............................................................. 10.1
[10.216] Fuel tanks .......................................................................... 10.2
[10.202] Air cleaners and lines .............................................................. 10.3
[10.400] Engine cooling system ............................................................. 10.4
[10.414] Fan and drive ...................................................................... 10.5
[10.310] Aftercooler.......................................................................... 10.6
[10.304] Engine lubrication system.......................................................... 10.7
Transmission.............................................................................. 21
[21.113] Powershift transmission ............................................................ 21.1
[21.135] Powershift transmission external controls.......................................... 21.2
[21.105] Powershift transmission hydraulic components.................................... 21.3
[21.155] Powershift transmission internal components...................................... 21.4
Four-Wheel Drive (4WD) system .................................................. 23
[23.314] Drive shaft.......................................................................... 23.1
Front axle system ....................................................................... 25
[25.100] Powered front axle ................................................................. 25.1
[25.102] Front bevel gear set and differential ............................................... 25.2
[25.108] Final drive hub, steering knuckles, and shafts ..................................... 25.3
Rear axle system........................................................................ 27
[27.100] Powered rear axle.................................................................. 27.1
[27.106] Rear bevel gear set and differential................................................ 27.2
[27.120] Planetary and final drives .......................................................... 27.3
Brakes and controls .................................................................... 33
[33.202] Hydraulic service brakes ........................................................... 33.1
48083746_EN 01/08/2018

4. [33.110] Parking brake or parking lock ...................................................... 33.2
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems.................................................................. 35.1
[35.300] Reservoir, cooler, and filters........................................................ 35.2
[35.106] Variable displacement pump ....................................................... 35.3
[35.359] Main control valve.................................................................. 35.4
[35.357] Pilot system ........................................................................ 35.5
[35.204] Remote control valves ............................................................. 35.6
[35.752] Hydraulic fan drive cooling system................................................. 35.7
[35.701] Front loader arm hydraulic system ................................................. 35.8
[35.723] Front loader bucket hydraulic system .............................................. 35.9
Frames and ballasting ................................................................. 39
[39.100] Frame .............................................................................. 39.1
Steering..................................................................................... 41
[41.101] Steering control .................................................................... 41.1
[41.200] Hydraulic control components...................................................... 41.2
[41.216] Cylinders ........................................................................... 41.3
[41.910] Auxiliary steering ................................................................... 41.4
Wheels...................................................................................... 44
[44.511] Front wheels........................................................................ 44.1
[44.520] Rear wheels........................................................................ 44.2
Cab climate control ..................................................................... 50
[50.100] Heating ............................................................................. 50.1
[50.200] Air conditioning..................................................................... 50.2
Electrical systems....................................................................... 55
[55.100] Harnesses and connectors......................................................... 55.1
[55.201] Engine starting system ............................................................. 55.2
48083746_EN 01/08/2018

5. [55.301] Alternator........................................................................... 55.3
[55.512] Cab controls........................................................................ 55.4
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system................. 55.5
[55.415] Loader arm and bucket control system ............................................ 55.6
[55.530] Camera............................................................................. 55.7
[55.518] Wiper and washer system.......................................................... 55.8
[55.DTC] FAULT CODES.................................................................... 55.9
Front loader and bucket............................................................... 82
[82.100] Arm................................................................................. 82.1
[82.300] Bucket.............................................................................. 82.2
Platform, cab, bodywork, and decals............................................. 90
[90.150] Cab................................................................................. 90.1
[90.118] Protections and footboards......................................................... 90.2
[90.120] Mechanically-adjusted operator seat............................................... 90.3
[90.124] Pneumatically-adjusted operator seat.............................................. 90.4
[90.105] Machine shields and guards ....................................................... 90.5
48083746_EN 01/08/2018

6. INTRODUCTION
48083746_EN 01/08/2018
1

7. INTRODUCTION
Safety rules
Personal safety
This is the safety alert symbol. It is used 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 you will find the signal words DANGER, WARNING, and CAUTION followed by special in-
structions. 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 a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT
IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.
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 that clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about a step, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.
48083746_EN 01/08/2018
3

8. INTRODUCTION
Personal safety
Carefully read this Manual before proceeding with main-
tenance, repairs, refuelling or other machine operations.
Repairs have to be carried out only by authorized and in-
structed staff; specific precautions have to be taken when
grinding, welding or when using mallets or heavy ham-
mers.
Non-authorized persons are not allowed to repair or carry
out maintenance on this machine. Do not carry out any
work on the equipment without prior authorization.
Ask your employer about the safety instructions in force
and safety equipment.
Nobody should be allowed in the cab during machine
maintenance unless he is a qualified operator helping
with the maintenance work.
If it is necessary to move the equipment to carry out re-
pairs or maintenance, do not lift or lower the equipment
from any other position than the operator’s seat.
TULI12WEX2004AA 1
Never carry out any operation on the machine when the
engine is running, except when specifically indicated.
Stop the engine and ensure that all pressure is relieved
from hydraulic circuits before removing caps, covers,
valves, etc.
All repair and maintenance operations should be carried
out with the greatest care and attention.
Service stairs and platforms used in a workshop or in the
field should be built in compliance with the safety rules in
force.
Any functional disorders, especially those affecting the
safety of the machine, should therefore be rectified im-
mediately.
DANGER
Unexpected movement!
Make sure parking brake is applied. Secure
machine with wheel chocks.
Failure to comply will result in death or serious
injury.
D0013A
TULI12WEX2005AA 2
Before performing any work on the machine, attach a
maintenance in progress tag. This tag can be applied on
the left-hand control lever, safety lever or cab door.
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4

9. INTRODUCTION
Emergency
Be prepared for emergencies. Always keep a fire extin-
guisher and first aid kit readily available. Ensure that the
fire extinguisher is serviced in accordance with the man-
ufacturer’s instructions.
SMIL12WEX0174AA 3
Equipment
Wear close fitting clothing and safety equipment appropri-
ate for the job:
• Safety helmet
• Safety shoes
• Heavy gloves
• Reflective clothing
• Wet weather clothing
If working conditions require, the following personal safety
equipment should be on hand:
• Respirators (or dust proof masks)
• Ear plugs or acoustic ears protections
• Goggles with lateral shield or masks for eye protection
Do not wear rings, wristwatches, jewelry, unbuttoned or
flapping clothing such as ties, torn clothes, scarves, open
jackets or shirts with open zips which could get caught into
moving parts.
TULI12WEX2008AA 4
Engine - Radiator
Never leave the engine running in enclosed spaces with-
out proper ventilation which is able to evacuate toxic ex-
haust gases- Keep the exhaust manifold and tube free
from combustible materials.
Do not refuel with the engine running, especially if hot, as
this increases fire hazard in case of fuel spillage.
Never attempt to check or adjust the belts when the en-
gine is running.
Never lubricate the machine with the engine running.
TULI12WEX2009AA 5
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5

10. SERVICE MANUAL
Engine
W270D ZBAR - EH, NEW CAB TIER2
W300D ZBAR - EH, NEW CAB TIER2
48083746_EN 01/08/2018
10

11. Engine - Engine and crankcase
Engine - General specification
W270D ZBAR - EH, NEW CAB TIER2 ANZ --- APAC --- LA --- MEA
Engine with 4 Speed Transmission
A. Low idle 870-930 RPM
Alternate low idle 670-730 RPM
Alternate accelerated idle 1270-1330 RPM
Working idle (setting from factory) 1020-1080 RPM
B. Maximum No Load RPM 2162-2212 RPM
C. Converter Stall 1973-2123 RPM
D. Hydraulic Stall 1885-2195 RPM
E. Converter & Hydraulic Stall 1487-1797 RPM
Temperature of the torque converter oil 82 – 104 °C (180 – 219 °F)
Temperature of the hydraulic oil 54 – 57 °C (129 – 135 °F)
NOTE: hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the
bucket held rolled back and the engine at Wide Open Throttle (WOT) in max power mode.
Engine - General specification
W300D ZBAR - EH, NEW CAB TIER2 ANZ --- APAC --- LA --- MEA
Engine with 4 Speed Transmission
A. Low idle 870-930 RPM
Alternate low idle 670-730 RPM
Alternate accelerated idle 1270-1330 RPM
Working idle (setting from factory) 1020-1080 RPM
B. Maximum No Load RPM 2162-2212 RPM
C. Converter Stall 1973-2123 RPM
D. Hydraulic Stall 1885-2195 RPM
E. Converter & Hydraulic Stall 1487-1797 RPM
Temperature of the torque converter oil 82 – 104 °C (180 – 219 °F)
Temperature of the hydraulic oil 54 – 57 °C (129 – 135 °F)
NOTE: hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the
bucket held rolled back and the engine at Wide Open Throttle (WOT) in max power mode.
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12. Engine - Engine and crankcase
Engine - Remove
Prior operation:
Engine hood - Remove (90.105)
1. Park the machine on a level surface and lower the
bucket to the ground. Put the articulation lock (1) in
LOCKED position.
LEIL15WHL1782AA 1
2. Push the hydraulic functions lock-out switch in the nor-
mal operation position.
LEIL16WHL1125AA 2
3. Move the loader hydraulic control handle to the raise
and lower position in order to release any hydraulic
pressure in the lift circuit.
4. Move the loader control handle in and out of the tilt
position several times, this will relieve any pressure in
the pilot accumulator.
5. Release the pressure in the ride control accumulator
with the bleeder valve in the ride control valve load
travel stabilizer.
6. Actuate the brake pedal several times to discharge
brake accumulators.
LEIL15WHL0564AA 3
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13. Engine - Engine and crankcase
7. Slowly loosen the filler cap on the hydraulic oil tank to
release air pressure.
LEIL15WHL0825AA 4
8. Locate the timed disconnect switch in the battery box.
Put the timed disconnect switch in the OFF position.
LEIL15WHL0663AA 5
9. Tag and disconnect the positive cable (battery to isola-
tor) cable (1) and the positive cable (isolator to starter)
(2) from the battery isolator.
Disconnect the connector (3) from the timed disconnect
switch.
LEIL16WHL1528AB 6
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14. Engine - Engine and crankcase
10. Loosen and remove the bolts that hold the battery
cover in place on both the left-hand and right-hand
rear of the machine.
Disconnect the battery cable from the battery.
LEIL16WHL0891AB 7
LEIL15WHL1489AA 8
11. Open the access cover.
Place a suitable container below radiator drain, re-
move the radiator cap and coolant drain plug (arrow)
to drain the engine coolant. Reinstall the drain plug
and radiator cap after the coolant has drained.
NOTE: see machine specifications for cooling system vol-
ume.
LEIL15WHL0719AB 9
12. Open the access cover.
Place a suitable container below the engine oil drain.
Remove the drain plug and drain the oil into the con-
tainer. Reinstall drain plug.
NOTE: see machine specifications for engine oil sump vol-
ume.
RCPH11WHL104AAH 10
13. Loosen the clamp on the air intake hose under the air
inlet engine hood.
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15. Engine - Engine and crankcase
14. Remove the mounting bolts (arrows) from engine
compartment top cover (1).
15. Attach a suitable lifting device and lift strap to the en-
gine compartment cover and exhaust stack. Carefully
remove the cover (1), the exhaust stack (2) and the
precleaner (3) as an assembly.
LEIL15WHL0679AB 11
16. Disconnect the radiator vent hose (1) from the radia-
tor. Remove the P-clamps that secure the hose to the
left-hand muffler support bracket.
Tag and disconnect the ENG_H connector.
LEIL17WHL0307AB 12
17. Remove the hydraulic oil lines (1) and related fittings.
LEIL15WHL0682AB 13
18. Remove the two bolts, washers and nuts (2) to un-
fix the exhaust pipe support bracket (1) from the hy-
draulic tank.
Remove the clamp saddle (5), U-bolt (6), washers and
nuts to separate the exhaust system pipe (4) from the
bracket (1).
LEIL17WHL0302AB 14
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16. Engine - Engine and crankcase
19. Loosen the clamp (2) to disconnect the exhaust sys-
tem pipe (1) from the engine.
LEIL17WHL0301AB 15
20. Remove the two bolts, washers and nuts (3) to un-
fix from the muffler the bracket (1) that supports the
check valve (2). Loosen the clamp (4) to disconnect
the aspirator engine hose from the muffler.
LEIL17WHL0300AB 16
21. Attach a suitable lift equipment to the left-hand and
right-hand support brackets (1), (4).
Remove the hardware to unfix the left-hand and right-
hand support brackets (1), (4) from the hydraulic tank
and engine wall.
Move the exhaust system assembly (left-hand and
right-hand support brackets (1), (4), muffler supports
(2), muffler (3)) out of the machine.
NOTE: be sure all wire harness connections and hoses are
out of the way during removal.
LEIL17WHL0304AB 17
22. Loosen the V-band clamp (1) to disconnect the air
intercooler inlet elbow (2). Discard the O-ring.
Loosen the clamps (3) to disconnect the air intercooler
inlet tube (4).
NOTE: for clarity, the engine wall is not shown in the figure.
LEIL17WHL0259AB 18
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17. Engine - Engine and crankcase
23. Loosen the clamps (3) to disconnect the air intake tube
(4).
NOTE: for clarity, the engine wall is not shown in the figure.
LEIL17WHL0260AB 19
24. Loosen the clamps (2) to disconnect the upper radia-
tor tube (1).
NOTE: for clarity, the engine wall is not shown in the figure.
25. Remove the V-band clamp (1) to disconnect the air
intake elbow (2) from the turbocharger. Discard the
O-ring.
LEIL17WHL0261AB 20
LEIL17WHL0262AB 21
26. Remove the oil dipstick P-clamp (2). Pull the oil dip-
stick tube (1) through the wall.
LEIL15WHL0819AB 22
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18. Engine - Engine and crankcase
27. Tag and disconnect the cable (grid heater power relay
to heater) (1) and cable (ground heater) (2).
LEIL17WHL0303AB 23
28. Tag and disconnect the WSH connector (1) from the
fuel pre-filter. Remove the bolt, washer and nut (2)
to unfix the P-clamp securing the wire to the support
bracket.
Tag and disconnect the WIF connector from the fuel
pre-filter.
LEIL17WHL0297AB 24
29. Remove the bolt, washer and nut to unfix the P-clamp
securing the pressure hoses of the air conditioning
compressor to the support bracket.
LEIL17WHL0296AB 25
30. Disconnect the fuel hose (tank to pre-filter) (2) and fuel
hose (pre-filter to engine) (1).
LEIL17WHL0299AB 26
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19. Engine - Engine and crankcase
31. Remove the bolts, washers and nuts (2), (3) to unfix
fuel pre-filter (1) from the support bracket.
NOTE: pay attention to the GRD_WIF wire release at the
location (2); tag the wire.
LEIL17WHL0298AB 27
32. Loosen the clamp (2) on the crankcase vent hose (1).
33. Remove the bolt (3) with related washers and nut to
separate the two clamps (4) from the hose support
bracket (5).
34. Loosen the clamp (6) on the crankcase vent hose (1).
35. Cut the straps (7).
36. Remove the crankcase vent hose (1).
LEIL15WHL0669AB 28
37. Loosen the P-clamps (2) on the engine to crankcase
vent filter hose (1).
38. Remove the engine to the crankcase vent filter hose
(1).
39. Remove the drain hose filter (3) from the crankcase
vent filter.
LEIL15WHL0670AB 29
40. Loosen the bolts (2) to remove the crankcase vent
filter (1) from the machine.
LEIL15WHL1138AB 30
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20. Engine - Engine and crankcase
41. Loosen the four nuts (2) and related washers (3) that
hold the support bracket (1) of the crankcase vent filter
to the rear chassis.
NOTE: one of these four nuts (2) is used to secure a
P-clamp that hold the wiring harness to the support bracket
(1).
LEIL15WHL1140AB 31
42. Remove the two washers and nuts (5) to unfix the air
intake bracket (1) from the hydraulic tank.
43. Remove the saddle, U-bolt, washers and nuts (2) to
separate the air intake upper hose (3) from the air
intake bracket (1).
44. Loosen the clamp (4) to disconnect the air intake up-
per hose (3).
LEIL17WHL0270AB 32
LEIL17WHL0269AB 33
45. Tag and disconnect the air restriction switch (7) from
the air cleaner. Cut the strap.
46. Loosen the clamps (6) to disconnect the air intake
hose (3) from the plenum and engine turbocharger.
47. Loosen the clamp (5) to disconnect the air intake
plenum (2) from the elbow.
48. Loosen the clamp (4) to disconnect the air intake el-
bow (1) from the air filter housing.
LEIL17WHL0268AB 34
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21. Engine - Engine and crankcase
49. Remove the bolts, washers and nuts (1) to unfix the
air cleaner bracket (2) from the engine wall.
50. Remove the four nuts and washers (3) to unfix the air
cleaner bracket (2) from the rear chassis. Move the
air cleaner (4) with the air cleaner bracket (2) out of
the machine.
LEIL17WHL0267AB 35
51. Disconnect the engine heater cable from the engine.
LEIL17WHL0305AB 36
52. Cut the cable ties (9).
53. Remove the bolt, washers, nut and two P-clamps (8)
from the bracket (4).
54. Remove the bolt, washers, nut and P-clamp (7) from
the bracket (4).
55. Remove the clamp (6) to disconnect the engine vent
hose (5) from the engine.
56. Disconnect the fill hose (2) from the 90° elbow (1).
Disconnect the 90° elbow (1) from the engine. Discard
the O-ring.
57. Remove the brackets (3) and (4) from the engine
block.
LEIL17WHL0264AB 37
58. Loosen the clamps (7) to disconnect the heater return
tube (2) and heater supply tube (3).
Remove the bolt, washer, nut (1) and two P-clamps
(4) to separate the tubes from the engine.
Remove the bolt, washer (5) and two P-clamps (4) to
separate the tubes from the bracket (6).
LEIL17WHL0256AB 38
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22. Engine - Engine and crankcase
59. Remove the bolt, washer (6) and two P-clamps (4) to
separate the heater supply and return tubes (3), (2)
from the bracket (5).
Remove the bolts and washers (7), (8) to unfix the
bracket (5) from the engine.
Disconnect the heater supply tube (3) from the engine.
Disconnect the heater return tube (2) from the zinc
lower radiator tube (1).
LEIL17WHL0255AB 39
60. Loosen the clamp (1) to disconnect the zinc lower ra-
diator tube (2) from the elbow radiator hose.
Remove the two bolts and washers (arrows) to discon-
nect the zinc lower radiator tube (2) from the engine.
Discard the O-ring.
LEIL17WHL0253AB 40
61. Attach a lifting equipment to the engine wall (2). Re-
move the engine wall hold-down bolts (1) to unfix the
engine wall from the rear chassis. Lift and remove the
engine wall.
NOTE: prior to remove the engine wall to be sure that all
the P-clamp installed on the wall are be removed.
LEIL15WHL1055AB 41
62. Remove the drive belt on the engine.
LEIL17WHL0266AB 42
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23. Engine - Engine and crankcase
63. Tag and disconnect the ALT_B and ALT_5 connectors
(4), (5).
Remove the bolts, washers and nut (2), (3) to discon-
nect the alternator (1) from the engine.
LEIL17WHL0265AB 43
64. Cut the cable strap (5). Tag and disconnect the
ACT_10 connector from air compressor clutch con-
nector (4).
Recovery the refrigerant as indicated in Air condi-
tioning - Service instruction (50.200).
Disconnect the low-pressure line (3) from the suction
port (compressor to condenser hose) and the high-
pressure line (2) from the discharge port (cab to com-
pressor hose) of the air-conditioning compressor. Im-
mediately install protective caps on the open ports and
lines.
Remove the mounting bolts (6) to disconnect the air
conditioning compressor (1).
LEIL17WHL0263AB 44
65. Remove the P-clamps that secure the wires
to the engine block. Tag and disconnect the
GND_ENG1, GND_ENG3, GND_ENG4 terminals
and GND_CENG1, GND_CENG2 terminals.
LEIL17WHL0306AB 45
66. Disconnect the electrical connector to the engine con-
trol unit.
LEIL15WHL1085AA 46
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24. Engine - Engine and crankcase
67. Tag and disconnect the ST wire (1) from the engine
starter.
LEIL15WHL1299AB 47
68. Tag and disconnect the negative cable (starter to
ground) (1), the negative cable (battery to starter) (2)
from the engine starter.
Tag and disconnect the positive cable (battery isolator
to starter) (3) and CPWR, XM1C connectors (4), (5)
from the engine starter.
LEIL16WHL1527AB 48
69. Remove the three nuts (1) from the engine starter.
Remove the engine starter.
LEIL15WHL1331BB 49
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25. Engine - Engine and crankcase
70. Disconnect the hydraulic fittings (2) and (3) from the
hydraulic oil supply tube (1).
LEIL17WHL0258AB 50
71. Loosen the two clamps to disconnect the hydraulic oil
return tube (2) from the lower hose (1).
LEIL17WHL0257AB 51
72. Connect a suitable lifting equipment to the engine lift-
ing brackets (1).
Take up all slack in lifting equipment.
LEIL15WHL1086AB 52
73. Loosen and remove the bolts (1) that fasten the center
drive shaft (2) to the transmission.
NOTICE: the bolts (1) that fasten the center drive shaft (2)
to the transmission must be replaced when removed.
LEIL15WHL1207AB 53
NOTE: steps 74 and 75 are related only to NEW HOLLAND CONSTRUCTION W270D.
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26. Engine - Engine and crankcase
74. Remove the bolts (1) and related washers.
Remove the converter housing cover plate (2) and re-
move the flex plate bolts.
LEIL15WHL1330AB 54
75. Remove the twelve flex plate bolts (1).
LEIL15WHL1019AB 55
NOTE: steps 76 and 77 are related only to NEW HOLLAND CONSTRUCTION W300D.
76. Remove the cover (1). Remove the plug (2) to gain
access to the flywheel.
77. Turn the flywheel (clockwise as seen from the engine
front) until one of the torque converter bolts is visible
through the hole, and remove the bolt. Continue turn-
ing the flywheel (clockwise) in 30° increments to ex-
pose each bolt, until all the twelve bolts are removed.
LEIL15WHL1502AB 56
78. Remove the twelve bell housing bolts (1).
LEIL15WHL1020AB 57
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27. Engine - Engine and crankcase
79. Loosen the oil drain hose (15) and the O-ring (14) from
the elbow (13).
80. Separate the engine mounting brackets (8) from the
engine.
Remove the engine bracket upper bolts (11) and the
related washers (12).
Remove the engine bracket upper bolts (9) and the
related washers (10).
Separate the engine mounting brackets (8) from the
engine mounting plate (7). Remove the bolt (1), the
washers (2), rubber lower isolator (3), the rubber up-
per isolator (4) the washer (5) and the nut (6).
LEIL15WHL1326BB 58
81. Slowly raise the engine from the rear chassis. Be sure
that all the wire harness connections and the hoses
have been disconnected and are clear of the engine.
Guide the oil drain hose from the frame as the engine
is lifted. Remove the engine from machine.
LEIL15WHL1082AA 59
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28. Engine - Engine and crankcase
Engine - Install
1. Attach a suitable lifting equipment to the engine lifting
brackets (1).
LEIL15WHL1142AB 1
2. Install the two engine mounting brackets (8) to the en-
gine.
Tighten the engine bracket upper bolts (11) and related
washers (12) to a torque of 170 – 231 N·m (125.4 –
170.4 lb ft).
Tighten the engine bracket lower bolts (9) and related
washers (10) to a torque of 69.6 – 79.6 N·m (51.3 –
58.7 lb ft).
3. Inspect the engine mounts. If the engine rubber isola-
tors require replacement, remove and discard the isola-
tors (3) and (4). Place the engine over the rear chassis.
Install the bolts (1), washers (2), rubber lower isolators
(3), engine mounting plate (7), rubber upper isolators
(4), washers (5) and nuts (6) to fix the engine to the
rear chassis. Tighten the bolts (1) to a torque of 397 –
447 N·m (292.8 – 329.7 lb ft).
Install new rubber lower isolator (2) and new upper iso-
lator (4).
4. Tighten the oil drain hose (15) with a new O-ring (14)
to the elbow (13).
LEIL15WHL1326BB 2
5. Install the twelve bell housing bolts (1). Tighten the bell
housing bolts (1) to a torque of 54 – 60 N·m (40 – 44 lb
ft).
LEIL15WHL1020AB 3
NOTE: steps 6 and 7 are related only to NEW HOLLAND CONSTRUCTION W270D.
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29. Engine - Engine and crankcase
6. Install the twelve flex plate bolts (1). Tighten the flex
plate bolts (1) to a torque of 33 – 41 N·m (24 – 30 lb
ft).
LEIL15WHL1019AB 4
7. Apply DOW 732 RTV SILICONE CLEAR to the converter
housing cover plate (1).
Install the converter housing cover plate (2).
LEIL15WHL1330AB 5
NOTE: step 8 is related only to NEW HOLLAND CONSTRUCTION W300D.
8. Turn the flywheel (clockwise as seen from the engine
front) until one of the torque converter bolts location is
visible through the hole, and install the bolt. Continue
turning the flywheel (clockwise) in 30 ° increments to
expose each bolt location, until all the twelve bolts are
installed.
Install the plug (2). Install the cover (1).
LEIL15WHL1502AB 6
9. Hold the center drive shaft (2) in position and install
the bolts (1) that fasten the center drive shaft (2) to the
transmission.
Tighten the bolts to a torque of 136 – 149 N·m (100 –
110 lb ft).
LEIL15WHL1207AB 7
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31. Engine - Engine and crankcase
10. Use two clamps to connect the hydraulic oil return tube
(2) to the lower hose (1) and secure them.
LEIL17WHL0257AB 8
11. Connect the hydraulic fittings (2) and (3) to the hy-
draulic oil return tube (1).
LEIL17WHL0258AB 9
12. Position the engine starter on the machine.
Install the three flange nuts (1) to secure the engine
starter to the engine. Tighten the flange nuts to 40 –
48 N·m (30 – 35 lb ft).
LEIL15WHL1331BB 10
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32. Engine - Engine and crankcase
13. Install the negative cable (starter to ground) (1), the
negative cable (battery to starter) (2) on the engine
starter. Tighten the related nut.
Use existing hardware to mount the positive cable
(battery isolator to starter) (3) and CPWR, XM1C con-
nectors (4), (5) to the engine starter. Torque to 22.5 –
29.4 N·m (16.6 – 21.7 lb ft).
LEIL16WHL1527AB 11
14. Install and tighten the ST wire (1) to the engine starter.
LEIL15WHL1299AB 12
15. Connect the electrical connector to the engine control
unit.
LEIL15WHL1085AA 13
16. Secure the wires to the engine block with clamps.
Connect the GND_ENG1, GND_ENG3, GND_ENG4
terminals and GND_CENG1, GND_CENG2 termi-
nals.
LEIL17WHL0306AB 14
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33. Engine - Engine and crankcase
17. Install the air conditioning compressor (1) with the
mounting bolts (6).
Connect the low-pressure line (3) to the suction port
(compressor to condenser hose). Connect the high-
pressure line (2) to the discharge port (cab to com-
pressor hose) of the air-conditioning compressor.
Connect the ACT_10 connector to air compressor
clutch connector (4) and secure it to the compressor
with the cable strap (5).
LEIL17WHL0263AB 15
18. Install the alternator (1) to the engine with bolts, wash-
ers and nut (2), (3). Connect the ALT_B and ALT_5
connectors (4), (5).
LEIL17WHL0265AB 16
19. Install the drive belt on the engine.
LEIL17WHL0266AB 17
20. Attach lifting equipment to the engine wall (2). Posi-
tion the engine wall in the correct position on the ma-
chine and install the engine wall hold-down bolts (1).
LEIL15WHL1055AB 18
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34. Engine - Engine and crankcase
21. Connect the zinc lower radiator tube (2) to the elbow
radiator hose with the clamp (1). Torque the clamp to
10.1 – 11.3 N·m (7.4 – 8.3 lb ft).
Install the zinc lower radiator tube (2) to the engine
with two bolts and washers (arrows). Use a new
O-ring at the tube-engine joining.
LEIL17WHL0253AB 19
22. Connect the heater return tube (2) to the zinc lower
radiator tube (1).
Connect the heater supply tube (3) to the engine.
Torque to 21 – 27 N·m (15.5 – 19.9 lb ft).
Install the bracket (5) to the engine with bolts and
washers (7), (8). Install the two P-clamps (4) to the
bracket (5) with bolt and washer (6), so to secure the
heater supply and return tubes (3), (2).
LEIL17WHL0255AB 20
23. Connect the heater return tube (2) and heater supply
tube (3) with the clamps (7).
Secure the tubes with two P-clamps (4) fixed to the
engine with bolt, washer and nut (1).
Secure the tubes with two P-clamps (4) fixed to the
bracket (6) with bolt and washer (5).
LEIL17WHL0256AB 21
24. Install the brackets (3) and (4) to the engine block with
two bolts and washers.
25. Connect the fill hose (2) to the engine through the 90°
elbow (1). Use a new O-ring and Loctite 592 sealant.
26. Connect the engine vent hose (5) to the engine with
the clamp (6). Torque the clamp to 1.1 N·m (0.8 lb ft).
27. Install the P-clamp (7) to the bracket (3) with bolt,
washers and nut and secure the fill hose (2).
28. Install the two P-clamps (8) to the bracket (4) with
bolt, washers and nut and secure the fill hose (2) and
engine vent hose (5).
29. Secure the fill hose (2) and engine vent hose (5) with
the cable ties (9).
LEIL17WHL0264AB 22
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35. Engine - Engine and crankcase
30. Connect the engine heater cable to the engine.
LEIL17WHL0305AB 23
31. Place the air cleaner (4) with the air cleaner bracket
(2) in the correct position. Install the four nuts and
washers (3) to fix the air cleaner bracket (2) to the rear
chassis.
32. Tighten the bolts (1) with related washers and nuts to
install the air cleaner bracket (2) to the engine wall.
LEIL17WHL0267AB 24
33. Connect the air intake elbow (1) to air filter housing
with clamp (4). Torque the clamp to 4 – 4.5 N·m (3 –
3.3 lb ft).
34. Connect the air intake plenum (2) to elbow with clamp
(5). Torque the clamp to 4 – 4.5 N·m (3 – 3.3 lb ft).
35. Connect the air intake hose (3) to plenum and engine
turbocharger with two clamps (6). Torque the clamps
to 4 – 4.5 N·m (3 – 3.3 lb ft).
36. Connect the air restriction switch (7) to the air cleaner
and secure the wire with strap.
LEIL17WHL0268AB 25
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36. Engine - Engine and crankcase
37. Install the air intake bracket (1) to the hydraulic tank
with two washers and nuts (5).
38. Install and tighten the clamp (2) to air intake bracket
(1).
39. Connect the air intake upper hose (3) with clamp (4).
Torque the clamp to 4 – 4.5 N·m (3 – 3.3 lb ft).
LEIL17WHL0270AB 26
LEIL17WHL0269AB 27
40. Tighten the four nuts (2) and related washers (3) to
install the support bracket (1) of the crankcase vent
filter to the rear chassis.
LEIL15WHL1140AB 28
41. Tighten the two bolts and washers (2) to install the
crankcase vent filter (1) on the support bracket.
LEIL15WHL1138AB 29
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37. Engine - Engine and crankcase
42. Connect the oil drain hose (3) to the crankcase vent
filter.
43. Tighten the two clamps (2) to connect the hose (1) to
engine and crankcase vent filter.
LEIL15WHL0670AB 30
44. Place the crankcase vent hose (1) in the correct posi-
tion on the engine.
45. Install new four straps (7) to secure the two hoses from
crankcase vent filter.
46. Tighten the clamp (6) to connect the hose (1) to the
crankcase vent filter.
47. Tighten the bolt (3) with related washers and nut to in-
stall the two P-clamps (4) on the hose support bracket
(5).
NOTE: install the P-clamps (4) in such a way to secure the
two hoses from crankcase vent filter.
48. Install the clamp (2) to connect the hose (1) to air
cleaner tube.
LEIL15WHL0669AB 31
49. Install the fuel pre-filter (1) to the support bracket with
the bolts, washers and nuts (2), (3).
NOTE: use installation at the location (2) to attach
GRD_WIF wire.
LEIL17WHL0298AB 32
50. Connect the fuel hose (tank to pre-filter) (2) and fuel
hose (pre-filter to engine) (1).
LEIL17WHL0299AB 33
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