W110 and W130 Wheel Loader

Service Manual
6-81160

Table of Contents
Description Section No. Form No.
General Tab 1
Section Index - General 6-81180
Standard Torque Specifications 1001 6-80470
Fluids and Lubricants 1002 6-81190
Metric Conversion Chart 1003 6-80690

Engines Tab 2
Section Index - Engines 6-81200
Engine and Radiator Removal and Installation 2000 6-81210
Stall Tests 2002 6-81220
For Engine Repair, See the Engine Service Manual 6-80940

Fuel System Tab 3

Section Index - Fuel System 6-81230
For Fuel System Repair, See the Engine Service Manual 6-80940

Electrical Tab 4
Section Index - Electrical 6-81240
Removal and Installation of Starter and Alternator 4001 6-81250
Electrical Specifications and Troubleshooting 4002 6-81260
Batteries 4003 6-81270
Instrument Cluster and Digital Display 4005 6-81280

Copyright © 2006 CNH America LLC.

CNH America LLC. All rights reserved.
245 E NORTH AVENUE Printed in U.S.A.
CAROL STREAM, IL 60188 U.S.A. Bur 6-81170 Issued March, 2006
 W110 and W130 Wheel Loader
Service Manual
6-81160

Table of Contents
Description Section No. Form No.
Steering Tab 5
Section Index - Steering 6-81290
Removal and Installation of Steering Components 5001 6-81300
Steering Specifications, Pressure Checks, and Troubleshooting 5002 6-81310
Steering Control Valve 5003 6-81320
Auxiliary Steering Priority Valve 5004 6-81330
Steering Cylinders 5005 6-81340
Center Pivot 5006 6-81350
Auxiliary Steering Motor and Pump 5007 6-81360

Power Train Tab 6

Section Index - Power Train 6-81370
Removal and Installation of Power Train Components 6001 6-81380
Transmission Specifications, Pressure Checks, and Troubleshooting 6002 6-81390
Transmission 6003 6-81400
Front Axle 6004 6-81410
Rear Axle 6004 6-81420
Drive Shafts, Center Bearing, and Universal Joints 6005 6-81430
Wheels and Tires 6006 6-81440
Transmission Control Valve 6007 6-81450

Brakes Tab 7
Section Index - Brakes 6-81460
Removal and Installation of Brake Components 7001 6-81470
Hydraulic Brake Troubleshooting 7002 6-81480
Brake Accumulators 7004 6-81490
Parking Brake 7008 6-81500

Hydraulics Tab 8
Section Index - Hydraulics 6-81510
Removal and Installation of Hydraulic Components 8001 6-81520
Hydraulic Specifications, Troubleshooting, and Pressure Checks 8002 6-81530
Cleaning the Hydraulic System 8003 6-81540
Loader Control Valve 8005 6-81550
Cylinders 8006 6-81560
Coupler Solenoid Locking Valve 8007 6-81570
Pilot Pressure Accumulator and Ride Control Accumulator 8013 6-81580
Ride Control Valve 8014 6-81590

Bur 6-81170 Issued 3-06 Printed in U.S.A.

 W110 and W130 Wheel Loader
Service Manual
6-81160

Table of Contents
Description Section No. Form No.

Mounted Equipment Tab 9

Section Index - Mounted Equipment 6-81600
Pedal and Levers 9001 6-81610
Air Conditioning Troubleshooting and System Checks For Systems with HFC-134a
Refrigerant 9002 6-81620

Air Conditioner System Service 9003 6-81630

Removal and Installation of Air Conditioning and Heater Components 9004 6-81640
Loader 9006 6-81650
ROPS Cab and ROPS Canopy 9007 6-81660
Cab Glass Installation 9010 6-81670

Electrical Schematic Foldouts and Hydraulic Schematic Foldouts In Rear Pocket 6-81680

NOTE: CNH America LLC reserves the right to make improvements in design or
changes in specifications at any time without incurring any obligation to install
them on units previously sold.

Copyright © 2006 CNH America LLC.

CNH America LLC. All rights reserved.
245 E NORTH AVENUE Printed in U.S.A.
CAROL STREAM, IL 60188 U.S.A. Bur 6-81170 Issued March, 2006
 SECTION INDEX

GENERAL

Section Title Section Number

Standard Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001

Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003

Copyright © 2006 CNH America LLC.

CNH America LLC. All rights reserved.
245 E NORTH AVENUE Printed in U.S.A.
CAROL STREAM, IL 60188 U.S.A. Bur 6-81180 Issued March, 2006
 1001
Section
1001

GENERAL TORQUE SPECIFICATIONS

Copyright © 2006 CNH America LLC.

CNH America LLC. All rights reserved.
245 E NORTH AVENUE Printed in U.S.A.
CAROL STREAM, IL 60188 U.S.A. Bur 6-80470 Issued January, 2006
 1001-3

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special torques
are not given. These torques apply to fasteners with Grade 8 Bolts, Nuts, and Studs
both UNC and UNF threads as received from
suppliers dry, or when lubricated with engine oil. Not
applicable if special graphities, Molydisulfide
greases, or other extreme pressure lubricants are
Pound- Newton
used.
Size Inches metres
1/4 inch 144 to 180 16 to 20
Grade 5 Bolts, Nuts, and Studs
5/16 inch 288 to 348 33 to 39
3/8 inch 540 to 648 61 to 73

Pound- Newton Pound- Newton

Size Inches metres Size Feet metres
1/4 inch 108 to 132 12 to 15 7/16 inch 70 to 84 95 to 114
5/16 inch 204 to 252 23 to 28 1/2 inch 110 to 132 149 to 179
3/8 inch 420 to 504 48 to 57 9/16 inch 160 to 192 217 to 260
5/8 inch 220 to 264 298 to 358
Pound- Newton 3/4 inch 380 to 456 515 to 618
Size Feet metres
7/8 inch 600 to 720 814 to 976
7/16 inch 54 to 64 73 to 87
1.0 inch 900 to 1080 1220 to 1465
1/2 inch 80 to 96 109 to 130
1-1/8 inch 1280 to 1440 1736 to 1953
9/16 inch 110 to 132 149 to 179
1-1/4 inch 1820 to 2000 2468 to 2712
5/8 inch 150 to 180 203 to 244
1-3/8 inch 2380 to 2720 3227 to 3688
3/4 inch 270 to 324 366 to 439
1-1/2 inch 3160 to 3560 4285 to 4827
7/8 inch 400 to 480 542 to 651
NOTE: Use thick nuts with Grade 8 bolts.
1.0 inch 580 to 696 787 to 944
1-1/8 inch 800 to 880 1085 to 1193
1-1/4 inch 1120 to 1240 1519 to 1681
1-3/8 inch 1460 to 1680 1980 to 2278
1-1/2 inch 1940 to 2200 2631 to 2983

Bur 6-80470 Issued 1-06 Printed in U.S.A.

1001-4

TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following torques when specifications are not
given. Grade 10.9 Bolts, Nuts, and Studs
These values apply to fasteners with coarse threads
as received from supplier, plated or unplated, or 10.9
when lubricated with engine oil. These values do not
apply if graphite or Molydisulfide grease or oil is Pound- Newton
used. Size Inches metres
M4 36 to 48 4 to 5
Grade 8.8 Bolts, Nuts, and Studs M5 84 to 96 9 to 11
M6 132 to 156 15 to 18
8.8
M8 324 to 384 37 to 43

Pound- Newton
Size Inches metres Pound- Newton
M4 24 to 36 3 to 4 Size Feet metres

M5 60 to 72 7 to 8 M10 54 to 64 73 to 87

M6 96 to 108 11 to 12 M12 93 to 112 125 to 150

M8 228 to 276 26 to 31 M14 149 to 179 200 to 245

M10 456 to 540 52 to 61 M16 230 to 280 310 to 380

M20 450 to 540 610 to 730

Pound- Newton M24 780 to 940 1050 to 1275

Size Feet metres M30 1470 to 1770 2000 to 2400
M12 66 to 79 90 to 107 M36 2580 to 3090 3500 to 4200
M14 106 to 127 144 to 172
Grade 12.9 Bolts, Nuts, and Studs
M16 160 to 200 217 to 271
M20 320 to 380 434 to 515
12.9
M24 500 to 600 675 to 815
M30 920 to 1100 1250 to 1500
Usually the torque values specified for grade 10.9
M36 1600 to 1950 2175 to 2600 fasteners can be used satisfactorily on grade 12.9
fasteners.

Bur 6-80470 Issued 1-06 Printed in U.S.A.

 1001-5

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

37 Degree Flare Fitting Straight Threads with O-ring

Tube OD Thread Pound- Newton Tube OD Thread Pound- Newton
Hose ID Size Inches metres Hose ID Size Inches metres
1/4 inch 7/16-20 72 to 144 8 to 16 1/4 inch 7/16-20 144 to 228 16 to 26
6.4 mm 6.4 mm
5/16 inch 1/2-20 96 to 192 11 to 22 5/16 inch 1/2-20 192 to 300 22 to 34
7.9 mm 7.9 mm
3/8 inch 9/16-18 120 to 300 14 to 34 3/8 inch 9/16-18 300 to 480 34 to 54
9.5 mm 9.5 mm
1/2 inch 3/4-16 180 to 504 20 to 57 1/2 inch 3/4-16 540 to 804 57 to 91
12.7 mm 12.7 mm
5/8 inch 7/8-14 300 to 696 34 to 79
15.9 mm Tube OD Thread Pound- Newton
Hose ID Size Feet metres
Tube OD Thread Pound- Newton 5/8 inch 7/8-14 58 to 92 79 to 124
Hose ID Size Feet metres 15.9 mm
3/4 inch 1-1/16-12 40 to 80 54 to 108 3/4 inch 1-1/16-12 80 to 128 108 to 174
19.0 mm 19.0 mm
7/8 inch 1-3/16-12 60 to 100 81 to 135 7/8 inch 1-3/16-12 100 to 160 136 to 216
22.2 mm 22.2 mm
1.0 inch 1-5/16-12 75 to 117 102 to 158 1.0 inch 1-5/16-12 117 to 187 159 to 253
25.4 mm 25.4 mm
1-1/4 inch 1-5/8-12 125 to 165 169 to 223 1-1/4 inch 1-5/8-12 165 to 264 224 to 357
31.8 mm 31.8 mm
1-1/2 inch 1-7/8-12 210 to 250 285 to 338 1-1/2 inch 1-7/8-12 250 to 400 339 to 542
38.1 mm 38.1 mm

Split Flange Mounting Bolts

Pound- Newton
Size Inches metres
5/16-18 180 to 240 20 to 27
3/8-16 240 to 300 27 to 34
7/16-14 420 to 540 47 to 61

Pound- Newton
Size Feet metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203

Bur 6-80470 Issued 1-06 Printed in U.S.A.

 Section
2000

ENGINE AND RADIATOR REMOVAL AND INSTALLATION

2000

Copyright © 2006 CNH America LLC.

CNH America LLC. All rights reserved.
245 E NORTH AVENUE Printed in U.S.A.
CAROL STREAM, IL 60188 U.S.A. Bur 6-81210 Issued March, 2006
 2000-3

ENGINE

Removal STEP 7

STEP 1
Park machine on a level surface and lower bucket to
floor. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Move loader
control lever back and forth at least 30 times to
release any pressure from hydraulic circuit.

STEP 2

BD03J111

Open the engine compartment side panel, attach a

lifting eye to the hole in the lower portion of the panel.

STEP 8

BD00M030

Put articulation lock in LOCKED position.

STEP 3
Slowly loosen the filler cap for hydraulic reservoir to
release air pressure in hydraulic reservoir.

STEP 4 BD03J110

Put master disconnect switch in OFF position.
STEP 5
Disconnect battery cable from LH battery negative
post. Put a plastic cap over the negative post.
Attach lifting straps to the hinge side of the hood,
attach suitable lifting equipment to the straps and
take up slack in the straps.
STEP 9

STEP 6
Disconnect battery cable from RH battery positive
post. Put a plastic cap over the positive post.

BD03J112

Disconnect the gas cylinders from the side panel and

hood. Remove hinge pins, remove panel from
machine.

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2000-4
STEP 10 STEP 16
Repeat steps 7 through 9 for the other side panel.

STEP 11
Attach lifting straps to the center hood section.

STEP 12
Connect lifting equipment to the lifting straps. Take
up all slack in strap connected to hood.

STEP 13

BC03J056

Remove the four rear grill mounting bolts, remove the

grill. Remove the six rear grill frame mounting bolts
and nuts, remove the frame.

STEP 17

BD03J115

Remove two nuts and bolts and four washers

securing the rear of the hood.

STEP 14

BD03J103

Tag and disconnect engine wiring harness connector

from air filter restriction switch.

BD03J116

Remove the two front bolts and washers securing the

front of the hood.

STEP 15
Carefully raise and remove hood from loader. Lower
hood onto suitable platform and disconnect lifting
equipment.

Bur 6-81210 Issued 3-06 Printed in U.S.A.

 2000-5
STEP 18 STEP 21

1 2
19 1
3 3
2
1

12 5 5
6 1
2
7

3 8
BC03J132

1. BOLT
9 2. WASHER
10 3. DRIVE BELT GUARD
Remove four bolts (1) and washers (2) securing drive
belt guard (3) to the frame.
10
11
BS02J036

1. CLAMP 7. TUBE
2. INTAKE HOSE 8. HOSE
3. CLAMP 9. LOCK NUT
4. HOSE 10. WASHER
5. CLAMP 11. BOLT
6. HOSE 12. AIR CLEANER
Loosen clamp (1) on air cleaner intake hose (2) and
remove intake hose.

STEP 19
Loosen clamps (3 and 5) on crankcase hose (6) and
turbocharger intake hose (8). Disconnect hose (6)
from breather pipe. Disconnect hose (8) with tube (7)
attached from turbocharger.

STEP 20
Support air cleaner assembly (12) and remove two
lock nuts (9), bolts (11), four washers (10). Remove
air cleaner (12) and associated par ts as an
assembly.

Bur 6-81210 Issued 3-06 Printed in U.S.A.

2000-6
STEP 22 STEP 26

8
10
5
1
1
6

9 2
4 6
8 3
2 3
1
5
7
4
8
5 7
BS02J048

1. CLAMP 5. CLAMP
2. TUBE 6. TUBE
3. HOSE 7. HOSE
4. CLAMP 8. CLAMP
BC03J131
Loosen two clamps (1). Remove tube (2) and hose
1. CLAMP 6. FRONT BRACKET
2. BOLT 7. REAR BRACKET
(3) as an assembly.
3. WASHER 8. MUFFLER
4. BOLT 9. CLAMP STEP 27
5. WASHER 10. EXHAUST TUBE ELBOW Loosen two clamps (5). Remove tube (6) and hose
Remove clamp (1) securing exhaust tube elbow (10) (7) as an assembly.
to muffler (8).
STEP 28
STEP 23
At front of engine, remove two bolts (2) and washers
(3) securing muffler front mounting bracket (6).

STEP 24
Suppor t muffler (8) and brackets (6 and 7) and
remove two bolts (4) and washers (5) at rear of
e n g i n e. R e m ove mu f f l e r a n d b ra cke t s a s a n
assembly from engine.

STEP 25
Loosen clamp (9) and remove exhaust tube elbow BD03J096
(10) from turbocharger. Disconnect grounding strap from left side of engine.

Bur 6-81210 Issued 3-06 Printed in U.S.A.

 2000-7
STEP 29 STEP 32

3 BD03J098

2 Identify, tag, and disconnect engine harness from

1
alternator.
BS02J056

1. ACORN NUT 4. COVER STEP 33

2. NUT 5. B+ STUD
3. WASHER
Remove acorn nut (1), nut (2), and washer (3)
securing cover (4) to starter. Remove cover.

STEP 30
Remove nut and washer securing cables to starter
B+ stud (5). Identify, tag, and disconnect both cables.

STEP 31

Identify, tag, and disconnect connector from engine

coolant temperature sender. Remove bolt and
washer securing cable clamp to engine.

BS02J055
Identify and tag rear chassis harness wire connected
to starter solenoid terminal. Disconnect rear chassis
harness wire from terminal.
STEP 34
If wheel loader is equipped with air conditioning,
identify, tag, and disconnect connector from air
conditioner compressor clutch. Identify. tag, and
disconnect connector from air conditioning high
pressure switch.
STEP 35
Support air conditioning compressor and remove
bolts securing compressor. Remove compressor and
place on battery cover.

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2000-8
STEP 36 STEP 41

BD03J144 BD03J089

Remove bolts and bracket securing fuel line to rear of Disconnect injection pump fuel solenoid and oil
engine. pressure sending unit.

STEP 37 STEP 42

BD03J145 BD03J090

Remove bolts, nuts and clamps securing wiring

harness to rear of engine. STEP 43
Connect a vacuum pump to hydraulic reservoir. If a
STEP 38 vacuum pump is not available, drain the hydraulic oil
(hydraulic reservoir holds 68.5 liters (18 gallons) of
If equipped, identify, tag, and disconnect wire from
oil). Tur n on vacuum pump (if available). Tag,
grid heater.
disconnect, and plug hoses connected to brake
pump. Plug hoses securely and cap fittings. Turn off
STEP 39 vacuum pump.
If equipped, identify, tag, and disconnect connector
from fuel filter heater.

STEP 40
If equipped, identify, tag, and disconnect connector
from fuel filter temperature switch.

Bur 6-81210 Issued 3-06 Printed in U.S.A.

 2000-9
STEP 44 STEP 46

BD03J142

Remove bracket mounting hydraulic brake pump

lines and fuel line from bell housing.

STEP 45

BS02J069

Loosen two clamps. Disconnect and remove bottom

hose.

STEP 47

1
3

6 8
BD00M031

Put a 37.8 liter (10 gallon) container below radiator

drain. Remove cap and drain coolant into container. 7 7
Install cap after coolant has drained.
5 2
4 4

BS02J068

1. CLAMP 5. HOSE
2. BLEED LINE HOSE 6. PIPE
3. CLAMP 7. TIE STRAP
4. CLAMP 8. HOSE
Loosen two clamps (1) securing bleed line hose (2).
Disconnect bleed line hose (2) from fittings.

Bur 6-81210 Issued 3-06 Printed in U.S.A.

2000-10
STEP 48 STEP 51
Loosen clamps (3 and 4). Disconnect and remove
hose (5) from engine and pipe (6). Disconnect and
remove pipe (6) with bleed line hose (2) attached
from hose (8). If necessary, cut, remove, and discard
tie straps (7) to separate bleed line hose (2) from
pipe (6).
4
STEP 49
10

3
7
9 8 2
1
6
5
BS02J070

BD00M031 1. NUT 6. WASHER

Put a 18.9 liter (5 gallon) container below engine oil 2. WASHER 7. U-BOLT
drain . R em ove cap and drain e ng in e o il into 3. BALL JOINT 8. CLAMP
4. THROTTLE LEVER 9. THROTTLE CABLE
container. Install cap after oil has drained.
5. NUT 10. SUPPORT BRACKET

STEP 50 Remove nut (1) and washer (2) securing ball joint (3)
to throttle lever (4).

STEP 52
Remove two nuts (5) and washers (6), U-bolt (7), and
clamp (8) securing throttle cable (9) to suppor t
bracket (10). Position throttle cable away from
engine.

STEP 53

BS02J065

Disconnect hose from elbow installed in engine oil

pan. Put a plug in hose and a cap on fitting.
4
3

1
2

BS02J072

1. BOLT 3. FUEL SUPPLY HOSE

2. CLAMP 4. FUEL RETURN HOSE

Bur 6-81210 Issued 3-06 Printed in U.S.A.

 2000-11
Remove bolt (1) and washer securing clamp (2) STEP 56
holding in-line fuel filter to engine block. Tag and
disconnect fuel supply hose (3) from priming pump. 3
Plug hose and cap fitting. Tag and disconnect fuel 4
return hose (4) from fuel injection pump. Plug hose
and cap fitting. 6
STEP 54
9
8

6
7
5

BD01D200

At front of engine, remove six bolts securing drive

shaft to engine coupling. Use a pry bar to move drive
shaft away from engine coupling. 2
1
STEP 55
BS02J073
Connect lifting equipment to engine lifting brackets.
Take up all slack in lifting equipment. 1. NUT 6. ENGINE MOUNT
2. WASHER 7. BOLT
3. BOLT 8. WASHER
4. WASHER 9. MOUNTING BRACKET
5. WASHER
Remove nut (1), washer (2), bolt (3), and washer (4)
securing engine and mounting brackets to chassis.

STEP 57
Slowly raise engine from rear chassis. Check and be
sure all harness connections, hoses, and throttle
cable have been disconnected and are positioned
out of the way. Remove engine from machine.

Bur 6-81210 Issued 3-06 Printed in U.S.A.

2000-12

Installation STEP 61
Disconnect lifting equipment from engine lifting
STEP 58 brackets.

3 STEP 62
4

6 140 141

9
8

6
7 BD01D200

At front of engine, position drive shaft on engine

5 coupling. Put Loctite 242 on threads of six bolts.
Install six bolts and tighten to a torque of 53 to 62 Nm
(39 to 46 pound-feet).

STEP 63
2
1

BS02J073

1. NUT 6. ENGINE MOUNT

2. WASHER 7. BOLT
3. BOLT 8. WASHER
4. WASHER 9. MOUNTING BRACKET
5. WASHER
If engine mounting brackets (9) were removed,
position bracket on engine and secure using bolts (7)
and washers (8). Torque bolts to 118 to 130 Nm
(87 to 98 pound-feet). If necessary, install new BD03J142
engine mount (6) in mounting bracket. Repeat this Install bracket mounting hydraulic brake pump lines
step to install remaining engine mounting brackets and fuel line to bell housing.
and engine mounts as necessary.
STEP 64
STEP 59 Tur n on vacuum pump connected to hydraulic
Connect suitable lifting equipment to engine lifting reservoir. Remove caps from brake pump fittings and
brackets. Slowly raise engine and move into position plugs from brake pump hoses. Connect hoses to
over rear chassis. Be sure all harness connections brake pump following tags installed during removal.
and hoses are out of the way then lower engine. Put Remove and discard tags. Turn off and disconnect
washer (5) between front engine mount (6) and vacuum pump from hydraulic reservoir.
chassis. Install washers (4 and 5), bolt (3), washer
(2), and nut (1) in engine front mounts. Lower engine
into position.

STEP 60
Torque bolts (3) to a torque of 244 to 298 Nm
(180 to 220 pound-feet).

Bur 6-81210 Issued 3-06 Printed in U.S.A.

 2000-13
STEP 65 STEP 67
Install ball joint (3) on throttle lever (4) and secure
using washer (2) and nut (1).

STEP 68
4
3

1
2

BS02J072

1. BOLT 3. FUEL SUPPLY HOSE

2. CLAMP 4. FUEL RETURN HOSE BS02J065

Remove plug from fuel return hose (4) and cap from Remove plug from oil drain hose and cap from fitting
fuel injection pump fitting. Connect fuel return hose installed in engine oil pan. Connect hose to fitting
to fuel injection pump. Remove plug from fuel supply and tighten.
hose (3) and cap from priming pump fitting. Connect
fuel supply hose to priming pump. Position clamp (2)
holding in-line fuel filter and secure to engine block
using washer and bolt (1).

STEP 66

4
10

3
7
9 8 2
1
6
5
BS02J070

1. NUT 6. WASHER
2. WASHER 7. U-BOLT
3. BALL JOINT 8. CLAMP
4. THROTTLE LEVER 9. THROTTLE CABLE
5. NUT 10. SUPPORT BRACKET
Route throttle cable (9) up and over towards fuel
injection pump. Put clamp (8), throttle cable (9), and
U-bolt (7) on support bracket (10) and secure using
two washers (6) and nuts (5).

Bur 6-81210 Issued 3-06 Printed in U.S.A.

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2000-14
STEP 69 STEP 71

1
3

6 8
105
7 7
106
5 2
4 4 105

BS02J069

Put clamps on hose. Connect hose between bottom

pipe and engine coolant inlet. Position clamps and
tighten to a torque of 10.1 to 11.3 Nm
BS02J068 (90 to 100 lb-inch).
1. CLAMP 5. HOSE
2. BLEED LINE HOSE 6. PIPE STEP 72
3. CLAMP 7. TIE STRAP If equipped, position and support air conditioning
4. CLAMP 8. HOSE
compressor on mounting bracket. Secure using bolts
Put clamp (3) on hose (8). Connect pipe (6) to hose washers.
(8). Position clamp (3) and tighten to a torque of 10.1
to 11.3 Nm (90 to 100 lb-inch). Put clamps (4) on STEP 73
hose (5). Connect hose (5) to pipe (6) and engine If wheel loader is equipped with air conditioning,
coolant outlet. Position clamps (4) and tighten to a connect connector to air conditioning compressor
torque of 10.1 to 11.3 Nm (90 to 100 lb-inch). clutch following tag installed during removal. Connect
connector to air conditioning high pressure switch
STEP 70 following tag installed during removal. Remove and
Put hose clamps (1) on bleed line hose (2) and discard tags.
connect hose to fittings. Position clamps (1) and
tighten to a torque of 10.1 to 11.3 Nm (90 to 100 STEP 74
lb-inch). Install three tie straps (7) to secure bleed Install drive belt, take up slack in drive belt and
line hose (2) to pipe (6). tighten bolts.

Bur 6-81210 Issued 3-06 Printed in U.S.A.

 2000-15
STEP 75 STEP 81

BD03J089

Connect injection pump fuel solenoid and oil BD03J098

pressure sending unit. Connect wires to alternator.

STEP 76 STEP 82
If equipped, connect connector to fuel filter
temperature switch following tag installed during
removal. Remove and discard tag.

STEP 77
If equipped, connect connector to fuel filter heater
following tag installed during removal. Remove and
discard tag.

STEP 78
If equipped, connect wire to grid heater following tag
installed during removal. Remove and discard tag. BS02J055

Connect harness wire to starter solenoid terminal

STEP 79 following tag installed during removal. Remove and
Connect connector to engine coolant temperature discard tag.
sender following tag installed during removal.
Remove and discard tag.

STEP 80

BD03J145

Position clamp holding engine harness on flywheel

housing cover.

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2000-16
STEP 83 STEP 86

5
1
4

2
4 6
3 3
2 1
BS02J056 1
1. ACORN NUT 4. COVER 5
2. NUT 5. B+ STUD
3. WASHER
8
Connect cables to starter B+ stud (5) following tags 7
installed during removal. Install nut and washer to
BS02J048
secure cables. Remove and discard tags from
cables. 1. CLAMP 5. CLAMP
2. TUBE 6. TUBE
3. HOSE 7. HOSE
STEP 84
4. CLAMP 8. CLAMP
Put cover (4) on starter. Install washer (3), nut (2),
Install tube (6) and hose (7) as an assembly. Tighten
and acorn nut (1) to secure cover (4).
two clamps (5) to a torque of 10.1 to 11.3 Nm (90 to
100 lbs-inch).
STEP 85
STEP 87
Install tube (2) and hose (3) as an assembly. Tighten
two clamps (1) to a torque of 10.1 to 11.3 Nm (90 to
100 lbs-inch).

BD03J096

Connect grounding strap from left side of engine.

Bur 6-81210 Issued 3-06 Printed in U.S.A.

 2000-17
STEP 88 STEP 90
At front of engine, install two washers (3) and bolts
(2) to secure muffler front mounting bracket (6).
Tighten bolts (2) to a torque of 118 to 133 Nm (87 to
8 98 pound-feet). Tighten bolts (4) to a torque of 68 to
10
77 Nm (50 to 56 pound-feet).

1 STEP 91
6 Install clamp (1). Tighten clamp (1) to a torque of 20
to 25 Nm (15 to 18 pound-feet). Tighten clamp (9) to
a torque of 4.8 to 5.2 Nm (42.5 to 46 pound-feet).
9
STEP 92
8 2
2 3 1
3
7
4

5
2 1

BC03J131

1. CLAMP 6. FRONT BRACKET

2. BOLT 7. REAR BRACKET
3. WASHER 8. MUFFLER
4. BOLT 9. CLAMP BC03J132

5. WASHER 10. EXHAUST TUBE ELBOW 1. BOLT

Put clamp (9) on exhaust tube elbow (10). Install 2. WASHER
exhaust tube elbow and clamp on turbocharger. Do 3. DRIVE BELT GUARD
not tighten clamp at this time. Position drive belt guard (3) and secure using four
washers (2) and bolts (1) to the frame.
STEP 89
Install and support muffler (8) and brackets (6 and 7)
on engine while connecting muffler to exhaust tube
elbow (10). Install two washers (5) and bolts (4)
finger tight.

Bur 6-81210 Issued 3-06 Printed in U.S.A.

2000-18
STEP 93 STEP 97
Remove plastic cap installed over the negative post
1 during removal. Connect battery cable to LH battery
4 negative post.
3
2 STEP 98
1

12 5 5
6
7

3 8
BD03J103

Connect engine wiring harness connector to air filter

9 restriction switch following tag installed during
10 removal. Remove and discard tag.

STEP 99
10
11
BS02J036

1. CLAMP 7. TUBE
2. INTAKE HOSE 8. HOSE
3. CLAMP 9. LOCK NUT
4. HOSE 10. WASHER
5. CLAMP 11. BOLT
6. HOSE 12. AIR CLEANER
Position air cleaner assembly (12) and support as an
assembly. Secure using two washers (10), bolts (11)
and lock nuts (9).

STEP 94 BC03J056

Connect turbocharger intake hose (8) attached to Install the frame and secure with six mounting bolts
tube (7) to turbocharger and crankcase hose (6) to and nuts. Install the grill and secure with four
breather pipe. Position clamps (3 and 5) and tighten. mounting bolts.
Tighten clamps (3) to a torque of 10.1 to 11.3 Nm (90
to 100 lb-inch). STEP 100
Carefully raise and position hood onto loader.
STEP 95
Connect air cleaner intake hose (2) between cooling
frame and air cleaner inlet. Position clamp (1) and
tighten to a torque of 3.6 to 4.5 Nm (32.4 to 39.6
lb-inch).

STEP 96
Remove plastic cap installed over the positive post
during removal. Connect battery cable to RH battery
positive post.

Bur 6-81210 Issued 3-06 Printed in U.S.A.

 2000-19
STEP 101 STEP 106

BD03J116 BD00M031
Install the two front bolts and washers securing the Check and make sure that drain caps are tight.
front of the hood.
STEP 107
STEP 102 Install a new oil filter on engine. Fill engine with 10.5
liters (11 quarts) of New Holland AMBRA engine oil
(SAE 15W-40).

STEP 108
If hydraulic reservoir was drained, fill reservoir with
68.5 liters (18 gallons) of New Holland AMBRA
Hydrosystem 46 fluid.

STEP 109
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
capacity is 34.1 liters (9 gallons). Install the radiator
BD03J115
cap. Fill the coolant reservoir up to the FULL mark on
Install two nuts and bolts and four washers securing
the reservoir.
the rear of the hood.
STEP 110
STEP 103
Put master disconnect switch in ON position.
Place engine compartment side panel into position.
WARNING: Hot coolant can spray out if radiator cap
STEP 104 is removed. To remove radiator cap: Let system cool,
turn to first notch, then wait until all pressure is
released. Scalding can result from fast removal of
radiator cap.

STEP 111
Start engine and run the engine at low idle. Run the
engine at operating temperature for approximately
five minutes to completely mix the Ethylene Glycol
an d wat er. Wh en the coo lan t is at o pe ra tin g
temperature, stop the engine. When engine has
cooled, check the coolant level at the reservoir.

BD03J112 STEP 112

Install hinge pins, connect the gas cylinders to the Lower and close hood side panels.
side panel and hood.
STEP 113
STEP 105 Put articulation lock in OPERATING position.
Repeat steps 103 and 104 for the other side panel.
Bur 6-81210 Issued 3-06 Printed in U.S.A.