New holland w300 d tier 2 wheel loader service repair manual

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 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 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 maintenance, 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 repairs 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. 48083746_EN 01/08/2018 4

9. INTRODUCTION Emergency Be prepared for emergencies. Always keep a fire extinguisher 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 without proper ventilation which is able to evacuate toxic exhaust 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 engine is running. Never lubricate the machine with the engine running. TULI12WEX2009AA 5 48083746_EN 01/08/2018 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. 48083746_EN 01/08/2018 10.1 [10.001] / 3

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 48083746_EN 01/08/2018 10.1 [10.001] / 4

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 isolator) 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 48083746_EN 01/08/2018 10.1 [10.001] / 5

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, remove 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 container. 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. 48083746_EN 01/08/2018 10.1 [10.001] / 6

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 engine 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 radiator. 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 unfix the exhaust pipe support bracket (1) from the hydraulic 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 48083746_EN 01/08/2018 10.1 [10.001] / 7

16. Engine - Engine and crankcase 19. Loosen the clamp (2) to disconnect the exhaust system pipe (1) from the engine. LEIL17WHL0301AB 15 20. Remove the two bolts, washers and nuts (3) to unfix 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 48083746_EN 01/08/2018 10.1 [10.001] / 8

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 radiator 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 dipstick tube (1) through the wall. LEIL15WHL0819AB 22 48083746_EN 01/08/2018 10.1 [10.001] / 9

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 48083746_EN 01/08/2018 10.1 [10.001] / 10

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 48083746_EN 01/08/2018 10.1 [10.001] / 11

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 upper 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 elbow (1) from the air filter housing. LEIL17WHL0268AB 34 48083746_EN 01/08/2018 10.1 [10.001] / 12

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 48083746_EN 01/08/2018 10.1 [10.001] / 13

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 radiator tube (2) from the elbow radiator hose. Remove the two bolts and washers (arrows) to disconnect 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 48083746_EN 01/08/2018 10.1 [10.001] / 14

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 disconnect 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 connector (4). Recovery the refrigerant as indicated in Air conditioning - 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 compressor 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 control unit. LEIL15WHL1085AA 46 48083746_EN 01/08/2018 10.1 [10.001] / 15

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 48083746_EN 01/08/2018 10.1 [10.001] / 16

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 lifting 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. 48083746_EN 01/08/2018 10.1 [10.001] / 17

26. Engine - Engine and crankcase 74. Remove the bolts (1) and related washers. Remove the converter housing cover plate (2) and remove 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 turning the flywheel (clockwise) in 30° increments to expose each bolt, until all the twelve bolts are removed. LEIL15WHL1502AB 56 78. Remove the twelve bell housing bolts (1). LEIL15WHL1020AB 57 48083746_EN 01/08/2018 10.1 [10.001] / 18

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 upper 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 48083746_EN 01/08/2018 10.1 [10.001] / 19

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 engine. 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 isolators require replacement, remove and discard the isolators (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 isolator (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. 48083746_EN 01/08/2018 10.1 [10.001] / 20

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 48083746_EN 01/08/2018 10.1 [10.001] / 21

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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 hydraulic 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 48083746_EN 01/08/2018 10.1 [10.001] / 22

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 connectors (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 terminals. LEIL17WHL0306AB 14 48083746_EN 01/08/2018 10.1 [10.001] / 23

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 compressor 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, washers 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 machine and install the engine wall hold-down bolts (1). LEIL15WHL1055AB 18 48083746_EN 01/08/2018 10.1 [10.001] / 24

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 48083746_EN 01/08/2018 10.1 [10.001] / 25

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 48083746_EN 01/08/2018 10.1 [10.001] / 26

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 48083746_EN 01/08/2018 10.1 [10.001] / 27

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 position 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 install 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 48083746_EN 01/08/2018 10.1 [10.001] / 28

New holland w300 d tier 2 wheel loader service repair manual

New holland w300 d tier 2 wheel loader service repair manual

New holland w300 d tier 2 wheel loader service repair manual

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New holland w300 d tier 2 wheel loader service repair manual