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Part number 47899776
1st
edition English
June 2015
SERVICE MANUAL
ENGINE - 10
POWER COUPLING - 19
FRONT AXLE SYSTEM - 25
REAR AXLE SYSTEM - 27
HYDROSTATIC DRIVE - 29
BRAKES AND CONTROLS - 33
Printed in U.S.A.
© 2015 CNH Industrial America LLC. All Rights Reserved.
New Holland is a trademark registered in the United States and many other countries,
owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates.
L230
Tier 4B (final)
200 Series Skid Steer Loader
PIN NFM483191 and above
C238
Tier 4B (final)
200 Series Compact Track Loader
PIN NFM470756 and above
Contents
INTRODUCTION
Foreword - Important notice regarding equipment servicing (*) ................................ 3
Safety rules (*) .................................................................................. 4
Safety rules - Personal safety (*) ............................................................... 5
Safety rules - Ecology and the environment (*) ................................................. 6
Torque - Minimum tightening torques for normal assembly (*) ................................. 7
Torque - Standard torque data for hydraulics (*) .............................................. 12
Basic instructions - Shop and assembly (*) ................................................... 14
Hydraulic contamination (*) ................................................................... 16
Capacities ..................................................................................... 17
Product identification (*) ...................................................................... 18
Product identification - Machine orientation (*) ............................................... 20
(*) See content for specific models
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INTRODUCTION
Foreword - Important notice regarding equipment servicing
C238
L230
All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or
local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manu-
facturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The manufacturer reserves the right to make improvements in design and changes in specifications at any time without
notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and
illustrative material herein are as accurate as known at time of publication but are subject to change without notice.
In case of questions, refer to your NEW HOLLAND CONSTRUCTION Sales and Service Networks.
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INTRODUCTION
Safety rules
C238
L230
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.
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INTRODUCTION
Safety rules - Personal safety
C238
L230
Carefully study these precautions, and those included in the external attachment operators
manual, and insist that they be followed by those working with and for you.
1. Thoroughly read and understand this manual and the attachment Operator’s Manual before operating this or any
other equipment.
2. Be sure all people and pets are clear of the machine before starting. Sound the horn, if equipped, three times
before starting engine.
3. Only the operator should be on the machine when in operation. Never allow anyone to climb on to the machine
while it is in motion. If the machine is equipped with an Instructors Seat, this must only be used for training
purposes. Passengers must not be allowed to use the Instructors Seat.
4. Keep all shields in place. Never work around the machine or any of the attachments while wearing loose clothing
that might catch on moving parts.
5. Observe the following precautions whenever lubricating the machine or making adjustments.
• Disengage all clutching levers or switches.
• Lower the attachment, if equipped, to the ground or raise the attachment completely and engage the cylinder
safety locks. Completing these actions will prevent the attachment from lowering unexpectedly.
• Engage the parking brake.
• Shut off the engine and remove the key.
• Wait for all machine movement to stop before leaving the operators platform.
6. Always keep the machine in gear while travelling downhill.
7. The machine should always be equipped with sufficient front or rear axle weight for safe operation.
8. Under some field conditions, more weight may be required at the front or rear axle for adequate stability. This is
especially important when operating in hilly conditions or/when using heavy attachments.
9. Always lower the attachment, shut off the engine, set the parking brake, engage the transmission gears, remove
the key and wait for all machine movement to stop before leaving the operators platform.
10. If the attachment or machine should become obstructed or plugged; set the parking brake, shut off the engine
and remove the key, engage the transmission gears, wait for all machine or attachment motion to come to a stop,
before leaving the operators platform to removing the obstruction or plug.
11. Never disconnect or make any adjustments to the hydraulic system unless the machine and/or the attachment is
lowered to the ground or the safety lock(s) is in the engaged position.
12. Use of the flashing lights is highly recommended when operating on a public road.
13. When transporting on a road or highway, use accessory lights and devices for adequate warning to the opera-
tors of other vehicles. In this regard, check local government regulations. Various safety lights and devices are
available from your NEW HOLLAND CONSTRUCTION dealer.
14. Practice safety 365 days a year.
15. Keep all your equipment in safe operating condition.
16. Keep all guards and safety devices in place.
17. Always set the parking brake, shut off the engine and remove the key, engage the transmission gears, wait for all
machine or attachment motion to come to a stop, before leaving the operators platform to service the machine
and attachment.
18. Remember: A careful operator is the best insurance against an accident.
19. Extreme care should be taken in keeping hands and clothing away from moving parts.
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INTRODUCTION
Safety rules - Ecology and the environment
C238
L230
Soil, air, and water quality is important for all industries and life in general. When legislation does not yet rule the
treatment of some of the substances that advanced technology requires, sound judgment should govern the use and
disposal of products of a chemical and petrochemical nature.
Familiarize yourself with the relative legislation applicable to your country, and make sure that you understand this
legislation. Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, anti-freeze,
cleaning agents, etc., with regard to the effect of these substances on man and nature and how to safely store, use,
and dispose of these substances.
Helpful hints
• Avoid the use of cans or other inappropriate pressurized fuel delivery systems to fill tanks. Such delivery systems
may cause considerable spillage.
• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of these products contain substances
that may be harmful to your health.
• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.
• Avoid spillage when you drain fluids such as used engine coolant mixtures, engine oil, hydraulic fluid, brake fluid,
etc. Do not mix drained brake fluids or fuels with lubricants. Store all drained fluids safely until you can dispose of
the fluids in a proper way that complies with all local legislation and available resources.
• Do not allow coolant mixtures to get into the soil. Collect and dispose of coolant mixtures properly.
• The air-conditioning system contains gases that should not be released into the atmosphere. Consult an air-condi-
tioning specialist or use a special extractor to recharge the system properly.
• Repair any leaks or defects in the engine cooling system or hydraulic system immediately.
• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.
• Protect hoses during welding. Penetrating weld splatter may burn a hole or weaken hoses, allowing the loss of oils,
coolant, etc.
Battery recycling
Batteries and electric accumulators contain several substances that can have a harmful
effect on the environment if the batteries are not properly recycled after use. Improper
disposal of batteries can contaminate the soil, groundwater, and waterways. NEW
HOLLAND CONSTRUCTION strongly recommends that you return all used batteries to a
NEW HOLLAND CONSTRUCTION dealer, who will dispose of the used batteries or recycle
the used batteries properly. In some countries, this is a legal requirement.
Mandatory battery recycling
NOTE: The following requirements are mandatory in Brazil.
Batteries are made of lead plates and a sulfuric acid solution. Because batteries contain heavy metals such as lead,
CONAMA Resolution 401/2008 requires you to return all used batteries to the battery dealer when you replace any
batteries. Do not dispose of batteries in your household garbage.
Points of sale are obliged to:
• Accept the return of your used batteries
• Store the returned batteries in a suitable location
• Send the returned batteries to the battery manufacturer for recycling
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SERVICE MANUAL
Engine
C238 TIER 4B (FINAL) [NFM470756 - ]
L230 TIER 4B (FINAL) [NFM483191 - ]
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Engine - Engine and crankcase
Engine - Drain fluid
C238 TIER 4B (FINAL) [NFM470756 - ] NA
L230 TIER 4B (FINAL) [NFM483191 - ] NA
1. Remove the access cover (2) by removing the mount-
ing bolts (1).
931001637 1
2. Remove the drain plug (1).
3. When the oil has drained from the engine, install the
drain plug (1). Torque the drain plug (1) to 68 - 82 N·m
(50 - 60 lb ft).
RAIL14SSL0709AA 2
4. Install the access cover (1).
931001637 3
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Engine - Engine and crankcase
Engine - Remove
C238 TIER 4B (FINAL) [NFM470756 - ] NA
L230 TIER 4B (FINAL) [NFM483191 - ] NA
WARNING
Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine.
1. Disengage all drives.
2. Engage parking brake.
3. Lower all attachments to the ground, or raise and engage all safety locks.
4. Shut off engine.
5. Remove key from key switch.
6. Switch off battery key, if installed.
7. Wait for all machine movement to stop.
Failure to comply could result in death or serious injury.
W0047A
WARNING
Fire hazard!
When handling diesel fuel, observe the following precautions:
1. Do not smoke.
2. Never fill the tank when the engine is running.
3. Wipe up spilled fuel immediately.
Failure to comply could result in death or serious injury.
W0099A
WARNING
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or
other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or per-
forming work on the hydraulic system. Before applying pressure, make sure all connections are tight
and all components are in good condition. Never use your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your
doctor immediately.
Failure to comply could result in death or serious injury.
W0178A
WARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
Failure to comply could result in death or serious injury.
W0398A
Prior operation:
Tilt the ROPS.
Prior operation:
Disconnect the battery.
Prior operation:
Drain the coolant.
Prior operation:
Drain the engine oil.
Prior operation:
Evacuate the A/C system (if equipped).
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Engine - Engine and crankcase
1. Remove the access plate (1) for the engine oil pan from
the rear of the chassis.
RAPH12SSL0233AA 1
2. Disconnect the hose (1) for the oil drain plug from the
engine oil pan.
RAPH12SSL0232AA 2
3. Lift the tilting hood.
4. Disconnect the restriction sensor (1) for the air filter
from the air cleaner assembly.
5. Detach the air cleaner assembly (2) from the rear deck.
RAIL14SSL0803BA 3
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Engine - Engine and crankcase
6. If your machine is equipped with A/C, disconnect the
lines (1) from the A/C condenser.
7. Disconnect the condenser fan (2).
RAPH12SSL0075AA 4
8. Detach the hood strut (2) from the tilting hood (1).
9. Remove the tilting hood (1) from the rear deck.
RAIL14SSL0802BA 5
10. Remove the left-hand panel (1) from the chassis.
11. Repeat step 10 on the right-hand panel.
RAIL14SSL0801BA 6
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Engine - Engine and crankcase
12. Remove the rear deck (1) from the chassis.
RAIL14SSL0800BA 7
13. Unbolt the retainer, and remove the overflow con-
tainer.
RAIL14SSL0799BA 8
14. Detach the mount (1) for the oil dipstick tube from the
shroud.
15. Remove the hose (3) from the filler neck (2).
16. Remove the filler neck (2).
RAIL14SSL0796BA 9
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Engine - Engine and crankcase
17. Remove the air cooler (1) from the shroud.
RAIL14SSL0798BA 10
18. Detach the radiator hoses (1) from the radiator (2).
19. Remove the radiator (2) from the shroud.
RAIL14SSL0797BA 11
20. Remove the fan (1).
RAPH12SSL0062AA 12
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Engine - Engine and crankcase
21. Remove the shroud (1).
RAIL14SSL0795BA 13
22. Disconnect the NOx module (4), NH3 module (3), and
temperature sensor (2).
23. Remove any wire ties, P-clamps, and retainers that
are securing these wires.
24. Detach the NOx module (1) from the bracket for the
control modules.
RAIL14SSL0792BA 14
25. Remove the exhaust clamp (1).
RAIL14SSL0791BA 15
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Engine - Engine and crankcase
26. Disconnect the selective catalytic reduction (SCR)
muffler (1) from the muffler mounting bracket. Save
the hardware for reuse.
27. Remove the SCR muffler (1).
RAIL14SSL0853BA 16
28. Remove the retaining straps (1) for the SCR muffler.
RAIL14SSL0789BA 17
29. Disconnect the NOx module (4) and the temperature
sensor (2).
30. Remove any wire ties, P-clamps, and retainers that
are securing these wires.
31. Detach the control module (3) for the NOx sensor from
the bracket (1) for control modules.
32. Detach the bracket (1) for the control modules from
the chassis.
RAIL14SSL0788BA 18
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Engine - Engine and crankcase
33. Remove the exhaust clamp (2).
34. Detach the diesel oxidation catalyst (DOC) muffler (1)
from the muffler mounting bracket.
RAIL14SSL0787BA 19
35. Remove any wire ties, P-clamps, and retainers that
are securing wires to the muffler mounting bracket.
36. Remove the muffler mounting bracket (1).
RAIL14SSL0786BA 20
37. Disconnect the left coolant line (1) and right coolant
line (3).
38. Disconnect the DEF hose (2).
39. Disconnect the injector (4).
40. Remove the DOC muffler.
RAIL14SSL0785BA 21
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Engine - Engine and crankcase
41. Remove the exhaust clamp (1).
42. Remove the exhaust tube (2).
RAIL14SSL0784BA 22
43. Remove the cotter pin from the boom lock link (1).
44. Detach the cable support bracket (2) from the chassis.
RAIL14SSL0783BA 23
45. Detach the switch mounting bracket (1) for the positive
battery cable.
RAIL14SSL0782BA 24
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Engine - Engine and crankcase
46. Disconnect the line (1) from the diesel exhaust fluid
(DEF) sending unit.
47. Disconnect the restriction switch (3) for the air filter.
48. Disconnect the coolant return line (2) from the exhaust
gas recirculation (EGR) assembly.
RAIL14SSL0781BA 25
49. Disconnect the engine connectors (1) from the engine.
50. If your machine has A/C, disconnect the A/C lines (4)
to the A/C compressor.
51. If your machine has A/C, disconnect the A/C compres-
sor (5).
52. If your machine has A/C, disconnect the high pressure
switch (6) for the A/C system.
53. Disconnect the fuel filter lines (2), (3) from the fuel filter
housing.
RAIL14SSL0780BA 26
54. Detach the lines (1) for the remote, engine oil filter
from the engine.
931001923 27
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Engine - Engine and crankcase
55. If your machine has a cab heater, disconnect the
heater hose from the engine.
56. Disconnect the P clamp (2) for the hydraulic line from
the bell housing.
RAPH12SSL0058AA 28
57. Support the hydrostatic drive assembly with a suitable
lifting device (1).
RAPH12SSL0057AA 29
58. Remove the mounting bolts (1) for the hydrostatic
drive assembly.
931001928 30
59. Separate the hydrostatic drive assembly (2) from the
engine bell housing (1).
931001936 31
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Engine - Engine and crankcase
60. Remove the engine mounting hardware (1) at the front
of the engine.
61. Repeat step 60 at the rear of the engine.
RAPH12SSL0050AA 32
62. Detach the positive battery cable (2) from the starter.
63. Disconnect the starter (1).
64. Disconnect the alternator (3).
65. Disconnect the ground cable (5) from the engine.
66. If your machine has a cab heater, detach the heater
hose (4) from the engine.
RAIL14SSL0778BA 33
67. Detach the positive battery cable (1) from the alterna-
tor.
68. Detach the coolant line (2) for the SCR system from
the engine.
RAIL14SSL0779BA 34
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Engine - Engine and crankcase
69. Disconnect the feed line (1) and return line (2) for the
fuel from the injection pump.
RAIL14SSL0777BA 35
70. Attach adequate lifting equipment to the engine.
71. Carefully lift the engine from the chassis.
RAIL13SSL0127AA 36
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Engine - Engine and crankcase
Engine - Install
C238 TIER 4B (FINAL) [NFM470756 - ] NA
L230 TIER 4B (FINAL) [NFM483191 - ] NA
WARNING
Fire hazard!
When handling diesel fuel, observe the following precautions:
1. Do not smoke.
2. Never fill the tank when the engine is running.
3. Wipe up spilled fuel immediately.
Failure to comply could result in death or serious injury.
W0099A
WARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
Failure to comply could result in death or serious injury.
W0398A
1. Carefully lower the engine into the chassis.
RAIL13SSL0127AA 1
2. Connect the feed line (1) and return line (2) for the fuel
to the injection pump.
RAIL14SSL0777BA 2
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Engine - Engine and crankcase
3. Attach the positive battery cable (1) to the alternator.
4. Attach the coolant line (2) for the SCR system to the
engine.
RAIL14SSL0779BA 3
5. Attach the positive battery cable (2) to the starter.
6. Connect the starter (1).
7. Connect the alternator (3).
8. Attach the ground cable (5) to the engine.
9. Secure all wires, harnesses, and hoses away from hot
components.
10. If your machine has a cab heater, connect the heater
hose (4) to the male connector on the engine.
RAIL14SSL0778BA 4
11. Apply LOCTITE® 243™ to the threads of the engine
mounting hardware (1).
12. Install the hardware (1), and torque to 163 - 176 N·m
(120 - 130 lb ft).
RAPH12SSL0050AA 5
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Engine - Engine and crankcase
13. Apply LOCTITE® 243™ to the threads of the engine
mounting hardware (1).
14. Install the hardware (1), and torque to 163 - 176 N·m
(120 - 130 lb ft).
RAPH12SSL0077AA 6
15. Engage the hydrostatic drive assembly (2) to the en-
gine bell housing (1).
931001936 7
16. Apply LOCTITE® 243™ to the threads of the mounting
bolts (1) for the hydrostatic drive assembly.
17. Install the mounting bolts (1). Torque the mounting
bolts (1) for the hydrostatic drive assembly to 87 -
117 N·m (64 - 86 lb ft).
931001928 8
18. If your machine has a cab heater, connect the heater
hose (1) to the engine.
19. Connect the P clamp (2) for the hydraulic line to the
bell housing.
RAPH12SSL0058AA 9
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Engine - Engine and crankcase
20. Connect the lines (1) for the remote, engine oil filter to
the engine.
931001923 10
21. Connect the engine connectors (1) to the engine.
22. If your machine has A/C, connect the A/C lines (4) to
the A/C compressor.
23. If your machine has A/C, connect the A/C compressor
(5).
24. If your machine has A/C, connect the high pressure
switch (6) for the A/C system.
25. Connect the fuel filter lines (2), (3) to the fuel filter
housing.
26. Secure all wires, harnesses, and hoses away from hot
components.
RAIL14SSL0780BA 11
27. Connect the coolant return line (2) to the exhaust gas
recirculation (EGR) assembly.
28. Connect the restriction switch (3) for the air filter.
29. Connect the line (1) to the diesel exhaust fluid (DEF)
sending unit.
30. Secure all wires, harnesses, and hoses away from hot
components.
RAIL14SSL0781BA 12
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Engine - Engine and crankcase
31. Attach the switch mounting bracket (1) for the positive
battery cable to the chassis.
RAIL14SSL0782BA 13
32. Install the cable support bracket (2).
33. Attach the boom lock link (1) to the cable support
bracket.
RAIL14SSL0783BA 14
34. Attach the exhaust tube (2) to the exhaust manifold.
Torque the clamp (1) to 11 - 15 N·m (97 - 133 lb in).
RAIL14SSL0784BA 15
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Engine - Engine and crankcase
35. Place the diesel oxidation catalyst (DOC) muffler in
position.
36. Connect the injector (4).
37. Connect the DEF hose (2).
38. Connect the left coolant line (1) and right coolant line
(3).
RAIL14SSL0785BA 16
39. Attach the muffler mounting bracket (1) to the chassis.
Torque the bolts to 27 - 37 N·m (20 - 27 lb ft).
40. Attach the cable support bracket (2) to the muffler
mounting bracket (1).
41. Secure all wires, harnesses, and hoses away from hot
components.
RAIL14SSL0786BA 17
42. Attach the DOC muffler to the muffler mounting
bracket. Torque the bolts (1) to 54 - 73 N·m (40 -
54 lb ft).
43. Attach the exhaust tube (3) to the DOC muffler.
Torque the clamp (2) to 11 - 15 N·m (97 - 133 lb in).
RAIL14SSL0787BA 18
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Engine - Engine and crankcase
44. Attach the bracket (1) for the control modules to the
chassis.
45. Attach the control module (3) for the NOx sensor to
the bracket (1).
46. Connect the control module (4) for the NOx sensor
and the temperature sensor (2).
47. Secure all wires, harnesses, and hoses away from hot
components.
RAIL14SSL0788BA 19
48. Install the retaining straps (1) for the selective catalytic
reduction (SCR) muffler onto the muffler bracket.
RAIL14SSL0789BA 20
49. Place the SCR muffler (1) on the muffler bracket.
50. Route the temperature sensor wire, NH3 control mod-
ule wiring, and NOx sensor wiring between the muf-
flers, muffler bracket, and chassis.
51. Secure all wires, harnesses, and hoses away from hot
components.
RAIL14SSL0790BA 21
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Engine - Engine and crankcase
52. Attach the exhaust tube (1) to the SCR muffler. Torque
the clamp (2) to 11 - 15 N·m (97 - 133 lb in).
53. Secure the SCR muffler to the muffler bracket by using
the hardware that was previously removed.
RAIL14SSL0791BA 22
54. Attach the NOx module (1) to the bracket for the con-
trol modules.
55. Connect the NOx module (4), NH3 module (3), and
temperature sensor (2).
56. Secure all wires, harnesses, and hoses away from hot
components.
RAIL14SSL0792BA 23
57. Loosely install the serpentine belt (2) for the alternator.
58. Loosen the alternator by loosening the mounting bolts
(3).
59. Turn the adjusting screw (1) clockwise to create a little
tension on the serpentine belt (2).
NOTE: Do not overtighten the adjusting screw. You will
not be able to install the cooling fan if the belt has been
tightened to specification on the pulleys.
RAIL14SSL0793BA 24
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Engine - Engine and crankcase
60. If your machine is equipped with A/C, loosely install
the serpentine belt (1) for the A/C compressor.
61. Loosen the A/C compressor by loosening the mount-
ing bolts (3).
62. Turn the adjusting screw (2) clockwise to create a little
tension on the belt.
NOTE: Do not overtighten the adjusting screw. You will
not be able to install the cooling fan if the belt has been
tightened to specification on the pulleys.
RAIL14SSL0794BA 25
63. Install the shroud (1).
RAIL14SSL0795BA 26
64. Apply LOCTITE® 243™ to the threads of the bolts (2),
and install the fan (1).
RAPH12SSL0062AA 27
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Engine - Engine and crankcase
65. Adjust the serpentine belt for the alternator by turning
the adjusting bolt (3).
NOTE: The alternator belt does not have a tensioning pro-
cedure. The alternator is adjusted all the way to the stop.
66. Torque the adjusting bracket bolt (2) to 50 N·m (37 lb
ft).
67. Torque the jam nut for the adjusting bolt (3) to 30 N·m
(22 lb ft).
68. Torque the mounting bolts (1) to 50 N·m (37 lb ft).
RCPH11SSL038AAP 28
69. If your machine is equipped with A/C, adjust the belt
for the A/C compressor by turning the adjusting screw
(1).
NOTE: The belt is tightened correctly when a force of
1.0 kg (2.2 lb) is applied to the center of the of the span of
the belt with a 3 mm (1/8 in) of deflection.
70. Tighten the mounting bolts (2).
RAPH12SSL0064BA 29
71. Readjust the shroud if there is not 13 mm (1/2 in) of
clearance (A) between the fan blades and the shroud.
RAPH14SSL0776BA 30
47685160 24/06/2015
10.1 [10.001] / 26
Engine - Engine and crankcase
72. Place the radiator (3) inside the shroud, but do not
install the hardware.
73. Attach the hoses (1) to the radiator. Torque the hose
clamps (2) to 3 - 4 N·m (27 - 35 lb in).
RAIL14SSL0797BA 31
74. Install the filler neck (2).
75. Attach the hose (2) to the filler neck. Torque the hose
clamp (3) to 3 - 4 N·m (27 - 35 lb in).
76. Attach the mounting (1) for the oil dipstick tube onto
the shroud.
RAIL14SSL0796BA 32
77. Install the bolts (1) for the radiator. Torque the bolts
(1) to 27 - 37 N·m (20 - 27 lb ft).
RAIL14SSL0797BA 33
47685160 24/06/2015
10.1 [10.001] / 27
Engine - Engine and crankcase
78. Install the air cooler (1). Torque the bolts (2) to 27 -
37 N·m (20 - 27 lb ft).
RAIL14SSL0798BA 34
79. Install the overflow container.
80. Attach the overflow hose (1) to the filler neck.
RAIL14SSL0799BA 35
81. Install the rear deck (1).
RAIL14SSL0800BA 36
47685160 24/06/2015
10.1 [10.001] / 28
Engine - Engine and crankcase
82. Install the left-hand panel (1).
83. Repeat step 82 on the right-hand panel.
RAIL14SSL0801BA 37
84. Install the tilting hood (1).
85. Attach the hood strut (2) to the tilting hood (1).
RAIL14SSL0802BA 38
86. If your machine has A/C, attach the lines (1) to the A/C
condenser.
87. If your machine has A/C, connect the condenser fan
(2).
RAPH12SSL0075AA 39
47685160 24/06/2015
10.1 [10.001] / 29

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New holland l230 tier 4 b (final) skid steer loader service repair manual pin nfm483191 and above

  • 1. Part number 47899776 1st edition English June 2015 SERVICE MANUAL ENGINE - 10 POWER COUPLING - 19 FRONT AXLE SYSTEM - 25 REAR AXLE SYSTEM - 27 HYDROSTATIC DRIVE - 29 BRAKES AND CONTROLS - 33 Printed in U.S.A. © 2015 CNH Industrial America LLC. All Rights Reserved. New Holland is a trademark registered in the United States and many other countries, owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates. L230 Tier 4B (final) 200 Series Skid Steer Loader PIN NFM483191 and above C238 Tier 4B (final) 200 Series Compact Track Loader PIN NFM470756 and above
  • 2. Contents INTRODUCTION Foreword - Important notice regarding equipment servicing (*) ................................ 3 Safety rules (*) .................................................................................. 4 Safety rules - Personal safety (*) ............................................................... 5 Safety rules - Ecology and the environment (*) ................................................. 6 Torque - Minimum tightening torques for normal assembly (*) ................................. 7 Torque - Standard torque data for hydraulics (*) .............................................. 12 Basic instructions - Shop and assembly (*) ................................................... 14 Hydraulic contamination (*) ................................................................... 16 Capacities ..................................................................................... 17 Product identification (*) ...................................................................... 18 Product identification - Machine orientation (*) ............................................... 20 (*) See content for specific models 47685160 24/06/2015 2
  • 3. INTRODUCTION Foreword - Important notice regarding equipment servicing C238 L230 All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel, strictly complying with the instructions given, and using, whenever possible, the special tools. Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall be responsible for any subsequent damages. The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manu- facturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer. In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer. The manufacturer reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication but are subject to change without notice. In case of questions, refer to your NEW HOLLAND CONSTRUCTION Sales and Service Networks. 47685160 24/06/2015 3
  • 4. INTRODUCTION Safety rules C238 L230 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. 47685160 24/06/2015 4
  • 5. INTRODUCTION Safety rules - Personal safety C238 L230 Carefully study these precautions, and those included in the external attachment operators manual, and insist that they be followed by those working with and for you. 1. Thoroughly read and understand this manual and the attachment Operator’s Manual before operating this or any other equipment. 2. Be sure all people and pets are clear of the machine before starting. Sound the horn, if equipped, three times before starting engine. 3. Only the operator should be on the machine when in operation. Never allow anyone to climb on to the machine while it is in motion. If the machine is equipped with an Instructors Seat, this must only be used for training purposes. Passengers must not be allowed to use the Instructors Seat. 4. Keep all shields in place. Never work around the machine or any of the attachments while wearing loose clothing that might catch on moving parts. 5. Observe the following precautions whenever lubricating the machine or making adjustments. • Disengage all clutching levers or switches. • Lower the attachment, if equipped, to the ground or raise the attachment completely and engage the cylinder safety locks. Completing these actions will prevent the attachment from lowering unexpectedly. • Engage the parking brake. • Shut off the engine and remove the key. • Wait for all machine movement to stop before leaving the operators platform. 6. Always keep the machine in gear while travelling downhill. 7. The machine should always be equipped with sufficient front or rear axle weight for safe operation. 8. Under some field conditions, more weight may be required at the front or rear axle for adequate stability. This is especially important when operating in hilly conditions or/when using heavy attachments. 9. Always lower the attachment, shut off the engine, set the parking brake, engage the transmission gears, remove the key and wait for all machine movement to stop before leaving the operators platform. 10. If the attachment or machine should become obstructed or plugged; set the parking brake, shut off the engine and remove the key, engage the transmission gears, wait for all machine or attachment motion to come to a stop, before leaving the operators platform to removing the obstruction or plug. 11. Never disconnect or make any adjustments to the hydraulic system unless the machine and/or the attachment is lowered to the ground or the safety lock(s) is in the engaged position. 12. Use of the flashing lights is highly recommended when operating on a public road. 13. When transporting on a road or highway, use accessory lights and devices for adequate warning to the opera- tors of other vehicles. In this regard, check local government regulations. Various safety lights and devices are available from your NEW HOLLAND CONSTRUCTION dealer. 14. Practice safety 365 days a year. 15. Keep all your equipment in safe operating condition. 16. Keep all guards and safety devices in place. 17. Always set the parking brake, shut off the engine and remove the key, engage the transmission gears, wait for all machine or attachment motion to come to a stop, before leaving the operators platform to service the machine and attachment. 18. Remember: A careful operator is the best insurance against an accident. 19. Extreme care should be taken in keeping hands and clothing away from moving parts. 47685160 24/06/2015 5
  • 6. INTRODUCTION Safety rules - Ecology and the environment C238 L230 Soil, air, and water quality is important for all industries and life in general. When legislation does not yet rule the treatment of some of the substances that advanced technology requires, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature. Familiarize yourself with the relative legislation applicable to your country, and make sure that you understand this legislation. Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, anti-freeze, cleaning agents, etc., with regard to the effect of these substances on man and nature and how to safely store, use, and dispose of these substances. Helpful hints • Avoid the use of cans or other inappropriate pressurized fuel delivery systems to fill tanks. Such delivery systems may cause considerable spillage. • In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of these products contain substances that may be harmful to your health. • Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems. • Avoid spillage when you drain fluids such as used engine coolant mixtures, engine oil, hydraulic fluid, brake fluid, etc. Do not mix drained brake fluids or fuels with lubricants. Store all drained fluids safely until you can dispose of the fluids in a proper way that complies with all local legislation and available resources. • Do not allow coolant mixtures to get into the soil. Collect and dispose of coolant mixtures properly. • The air-conditioning system contains gases that should not be released into the atmosphere. Consult an air-condi- tioning specialist or use a special extractor to recharge the system properly. • Repair any leaks or defects in the engine cooling system or hydraulic system immediately. • Do not increase the pressure in a pressurized circuit as this may lead to a component failure. • Protect hoses during welding. Penetrating weld splatter may burn a hole or weaken hoses, allowing the loss of oils, coolant, etc. Battery recycling Batteries and electric accumulators contain several substances that can have a harmful effect on the environment if the batteries are not properly recycled after use. Improper disposal of batteries can contaminate the soil, groundwater, and waterways. NEW HOLLAND CONSTRUCTION strongly recommends that you return all used batteries to a NEW HOLLAND CONSTRUCTION dealer, who will dispose of the used batteries or recycle the used batteries properly. In some countries, this is a legal requirement. Mandatory battery recycling NOTE: The following requirements are mandatory in Brazil. Batteries are made of lead plates and a sulfuric acid solution. Because batteries contain heavy metals such as lead, CONAMA Resolution 401/2008 requires you to return all used batteries to the battery dealer when you replace any batteries. Do not dispose of batteries in your household garbage. Points of sale are obliged to: • Accept the return of your used batteries • Store the returned batteries in a suitable location • Send the returned batteries to the battery manufacturer for recycling 47685160 24/06/2015 6
  • 7. SERVICE MANUAL Engine C238 TIER 4B (FINAL) [NFM470756 - ] L230 TIER 4B (FINAL) [NFM483191 - ] 47685160 24/06/2015 10
  • 8. Engine - Engine and crankcase Engine - Drain fluid C238 TIER 4B (FINAL) [NFM470756 - ] NA L230 TIER 4B (FINAL) [NFM483191 - ] NA 1. Remove the access cover (2) by removing the mount- ing bolts (1). 931001637 1 2. Remove the drain plug (1). 3. When the oil has drained from the engine, install the drain plug (1). Torque the drain plug (1) to 68 - 82 N·m (50 - 60 lb ft). RAIL14SSL0709AA 2 4. Install the access cover (1). 931001637 3 47685160 24/06/2015 10.1 [10.001] / 3
  • 9. Engine - Engine and crankcase Engine - Remove C238 TIER 4B (FINAL) [NFM470756 - ] NA L230 TIER 4B (FINAL) [NFM483191 - ] NA WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine. 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in death or serious injury. W0047A WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or per- forming work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A Prior operation: Tilt the ROPS. Prior operation: Disconnect the battery. Prior operation: Drain the coolant. Prior operation: Drain the engine oil. Prior operation: Evacuate the A/C system (if equipped). 47685160 24/06/2015 10.1 [10.001] / 4
  • 10. Engine - Engine and crankcase 1. Remove the access plate (1) for the engine oil pan from the rear of the chassis. RAPH12SSL0233AA 1 2. Disconnect the hose (1) for the oil drain plug from the engine oil pan. RAPH12SSL0232AA 2 3. Lift the tilting hood. 4. Disconnect the restriction sensor (1) for the air filter from the air cleaner assembly. 5. Detach the air cleaner assembly (2) from the rear deck. RAIL14SSL0803BA 3 47685160 24/06/2015 10.1 [10.001] / 5
  • 11. Engine - Engine and crankcase 6. If your machine is equipped with A/C, disconnect the lines (1) from the A/C condenser. 7. Disconnect the condenser fan (2). RAPH12SSL0075AA 4 8. Detach the hood strut (2) from the tilting hood (1). 9. Remove the tilting hood (1) from the rear deck. RAIL14SSL0802BA 5 10. Remove the left-hand panel (1) from the chassis. 11. Repeat step 10 on the right-hand panel. RAIL14SSL0801BA 6 47685160 24/06/2015 10.1 [10.001] / 6
  • 12. Engine - Engine and crankcase 12. Remove the rear deck (1) from the chassis. RAIL14SSL0800BA 7 13. Unbolt the retainer, and remove the overflow con- tainer. RAIL14SSL0799BA 8 14. Detach the mount (1) for the oil dipstick tube from the shroud. 15. Remove the hose (3) from the filler neck (2). 16. Remove the filler neck (2). RAIL14SSL0796BA 9 47685160 24/06/2015 10.1 [10.001] / 7
  • 13. Engine - Engine and crankcase 17. Remove the air cooler (1) from the shroud. RAIL14SSL0798BA 10 18. Detach the radiator hoses (1) from the radiator (2). 19. Remove the radiator (2) from the shroud. RAIL14SSL0797BA 11 20. Remove the fan (1). RAPH12SSL0062AA 12 47685160 24/06/2015 10.1 [10.001] / 8
  • 14. Engine - Engine and crankcase 21. Remove the shroud (1). RAIL14SSL0795BA 13 22. Disconnect the NOx module (4), NH3 module (3), and temperature sensor (2). 23. Remove any wire ties, P-clamps, and retainers that are securing these wires. 24. Detach the NOx module (1) from the bracket for the control modules. RAIL14SSL0792BA 14 25. Remove the exhaust clamp (1). RAIL14SSL0791BA 15 47685160 24/06/2015 10.1 [10.001] / 9
  • 15. Engine - Engine and crankcase 26. Disconnect the selective catalytic reduction (SCR) muffler (1) from the muffler mounting bracket. Save the hardware for reuse. 27. Remove the SCR muffler (1). RAIL14SSL0853BA 16 28. Remove the retaining straps (1) for the SCR muffler. RAIL14SSL0789BA 17 29. Disconnect the NOx module (4) and the temperature sensor (2). 30. Remove any wire ties, P-clamps, and retainers that are securing these wires. 31. Detach the control module (3) for the NOx sensor from the bracket (1) for control modules. 32. Detach the bracket (1) for the control modules from the chassis. RAIL14SSL0788BA 18 47685160 24/06/2015 10.1 [10.001] / 10
  • 16. Engine - Engine and crankcase 33. Remove the exhaust clamp (2). 34. Detach the diesel oxidation catalyst (DOC) muffler (1) from the muffler mounting bracket. RAIL14SSL0787BA 19 35. Remove any wire ties, P-clamps, and retainers that are securing wires to the muffler mounting bracket. 36. Remove the muffler mounting bracket (1). RAIL14SSL0786BA 20 37. Disconnect the left coolant line (1) and right coolant line (3). 38. Disconnect the DEF hose (2). 39. Disconnect the injector (4). 40. Remove the DOC muffler. RAIL14SSL0785BA 21 47685160 24/06/2015 10.1 [10.001] / 11
  • 17. Engine - Engine and crankcase 41. Remove the exhaust clamp (1). 42. Remove the exhaust tube (2). RAIL14SSL0784BA 22 43. Remove the cotter pin from the boom lock link (1). 44. Detach the cable support bracket (2) from the chassis. RAIL14SSL0783BA 23 45. Detach the switch mounting bracket (1) for the positive battery cable. RAIL14SSL0782BA 24 47685160 24/06/2015 10.1 [10.001] / 12
  • 18. Engine - Engine and crankcase 46. Disconnect the line (1) from the diesel exhaust fluid (DEF) sending unit. 47. Disconnect the restriction switch (3) for the air filter. 48. Disconnect the coolant return line (2) from the exhaust gas recirculation (EGR) assembly. RAIL14SSL0781BA 25 49. Disconnect the engine connectors (1) from the engine. 50. If your machine has A/C, disconnect the A/C lines (4) to the A/C compressor. 51. If your machine has A/C, disconnect the A/C compres- sor (5). 52. If your machine has A/C, disconnect the high pressure switch (6) for the A/C system. 53. Disconnect the fuel filter lines (2), (3) from the fuel filter housing. RAIL14SSL0780BA 26 54. Detach the lines (1) for the remote, engine oil filter from the engine. 931001923 27 47685160 24/06/2015 10.1 [10.001] / 13
  • 19. Engine - Engine and crankcase 55. If your machine has a cab heater, disconnect the heater hose from the engine. 56. Disconnect the P clamp (2) for the hydraulic line from the bell housing. RAPH12SSL0058AA 28 57. Support the hydrostatic drive assembly with a suitable lifting device (1). RAPH12SSL0057AA 29 58. Remove the mounting bolts (1) for the hydrostatic drive assembly. 931001928 30 59. Separate the hydrostatic drive assembly (2) from the engine bell housing (1). 931001936 31 47685160 24/06/2015 10.1 [10.001] / 14
  • 20. Engine - Engine and crankcase 60. Remove the engine mounting hardware (1) at the front of the engine. 61. Repeat step 60 at the rear of the engine. RAPH12SSL0050AA 32 62. Detach the positive battery cable (2) from the starter. 63. Disconnect the starter (1). 64. Disconnect the alternator (3). 65. Disconnect the ground cable (5) from the engine. 66. If your machine has a cab heater, detach the heater hose (4) from the engine. RAIL14SSL0778BA 33 67. Detach the positive battery cable (1) from the alterna- tor. 68. Detach the coolant line (2) for the SCR system from the engine. RAIL14SSL0779BA 34 47685160 24/06/2015 10.1 [10.001] / 15
  • 21. Engine - Engine and crankcase 69. Disconnect the feed line (1) and return line (2) for the fuel from the injection pump. RAIL14SSL0777BA 35 70. Attach adequate lifting equipment to the engine. 71. Carefully lift the engine from the chassis. RAIL13SSL0127AA 36 47685160 24/06/2015 10.1 [10.001] / 16
  • 22. Engine - Engine and crankcase Engine - Install C238 TIER 4B (FINAL) [NFM470756 - ] NA L230 TIER 4B (FINAL) [NFM483191 - ] NA WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A 1. Carefully lower the engine into the chassis. RAIL13SSL0127AA 1 2. Connect the feed line (1) and return line (2) for the fuel to the injection pump. RAIL14SSL0777BA 2 47685160 24/06/2015 10.1 [10.001] / 17
  • 23. Engine - Engine and crankcase 3. Attach the positive battery cable (1) to the alternator. 4. Attach the coolant line (2) for the SCR system to the engine. RAIL14SSL0779BA 3 5. Attach the positive battery cable (2) to the starter. 6. Connect the starter (1). 7. Connect the alternator (3). 8. Attach the ground cable (5) to the engine. 9. Secure all wires, harnesses, and hoses away from hot components. 10. If your machine has a cab heater, connect the heater hose (4) to the male connector on the engine. RAIL14SSL0778BA 4 11. Apply LOCTITE® 243™ to the threads of the engine mounting hardware (1). 12. Install the hardware (1), and torque to 163 - 176 N·m (120 - 130 lb ft). RAPH12SSL0050AA 5 47685160 24/06/2015 10.1 [10.001] / 18
  • 24. Engine - Engine and crankcase 13. Apply LOCTITE® 243™ to the threads of the engine mounting hardware (1). 14. Install the hardware (1), and torque to 163 - 176 N·m (120 - 130 lb ft). RAPH12SSL0077AA 6 15. Engage the hydrostatic drive assembly (2) to the en- gine bell housing (1). 931001936 7 16. Apply LOCTITE® 243™ to the threads of the mounting bolts (1) for the hydrostatic drive assembly. 17. Install the mounting bolts (1). Torque the mounting bolts (1) for the hydrostatic drive assembly to 87 - 117 N·m (64 - 86 lb ft). 931001928 8 18. If your machine has a cab heater, connect the heater hose (1) to the engine. 19. Connect the P clamp (2) for the hydraulic line to the bell housing. RAPH12SSL0058AA 9 47685160 24/06/2015 10.1 [10.001] / 19
  • 25. Engine - Engine and crankcase 20. Connect the lines (1) for the remote, engine oil filter to the engine. 931001923 10 21. Connect the engine connectors (1) to the engine. 22. If your machine has A/C, connect the A/C lines (4) to the A/C compressor. 23. If your machine has A/C, connect the A/C compressor (5). 24. If your machine has A/C, connect the high pressure switch (6) for the A/C system. 25. Connect the fuel filter lines (2), (3) to the fuel filter housing. 26. Secure all wires, harnesses, and hoses away from hot components. RAIL14SSL0780BA 11 27. Connect the coolant return line (2) to the exhaust gas recirculation (EGR) assembly. 28. Connect the restriction switch (3) for the air filter. 29. Connect the line (1) to the diesel exhaust fluid (DEF) sending unit. 30. Secure all wires, harnesses, and hoses away from hot components. RAIL14SSL0781BA 12 47685160 24/06/2015 10.1 [10.001] / 20
  • 26. Engine - Engine and crankcase 31. Attach the switch mounting bracket (1) for the positive battery cable to the chassis. RAIL14SSL0782BA 13 32. Install the cable support bracket (2). 33. Attach the boom lock link (1) to the cable support bracket. RAIL14SSL0783BA 14 34. Attach the exhaust tube (2) to the exhaust manifold. Torque the clamp (1) to 11 - 15 N·m (97 - 133 lb in). RAIL14SSL0784BA 15 47685160 24/06/2015 10.1 [10.001] / 21
  • 27. Engine - Engine and crankcase 35. Place the diesel oxidation catalyst (DOC) muffler in position. 36. Connect the injector (4). 37. Connect the DEF hose (2). 38. Connect the left coolant line (1) and right coolant line (3). RAIL14SSL0785BA 16 39. Attach the muffler mounting bracket (1) to the chassis. Torque the bolts to 27 - 37 N·m (20 - 27 lb ft). 40. Attach the cable support bracket (2) to the muffler mounting bracket (1). 41. Secure all wires, harnesses, and hoses away from hot components. RAIL14SSL0786BA 17 42. Attach the DOC muffler to the muffler mounting bracket. Torque the bolts (1) to 54 - 73 N·m (40 - 54 lb ft). 43. Attach the exhaust tube (3) to the DOC muffler. Torque the clamp (2) to 11 - 15 N·m (97 - 133 lb in). RAIL14SSL0787BA 18 47685160 24/06/2015 10.1 [10.001] / 22
  • 28. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
  • 29. Engine - Engine and crankcase 44. Attach the bracket (1) for the control modules to the chassis. 45. Attach the control module (3) for the NOx sensor to the bracket (1). 46. Connect the control module (4) for the NOx sensor and the temperature sensor (2). 47. Secure all wires, harnesses, and hoses away from hot components. RAIL14SSL0788BA 19 48. Install the retaining straps (1) for the selective catalytic reduction (SCR) muffler onto the muffler bracket. RAIL14SSL0789BA 20 49. Place the SCR muffler (1) on the muffler bracket. 50. Route the temperature sensor wire, NH3 control mod- ule wiring, and NOx sensor wiring between the muf- flers, muffler bracket, and chassis. 51. Secure all wires, harnesses, and hoses away from hot components. RAIL14SSL0790BA 21 47685160 24/06/2015 10.1 [10.001] / 23
  • 30. Engine - Engine and crankcase 52. Attach the exhaust tube (1) to the SCR muffler. Torque the clamp (2) to 11 - 15 N·m (97 - 133 lb in). 53. Secure the SCR muffler to the muffler bracket by using the hardware that was previously removed. RAIL14SSL0791BA 22 54. Attach the NOx module (1) to the bracket for the con- trol modules. 55. Connect the NOx module (4), NH3 module (3), and temperature sensor (2). 56. Secure all wires, harnesses, and hoses away from hot components. RAIL14SSL0792BA 23 57. Loosely install the serpentine belt (2) for the alternator. 58. Loosen the alternator by loosening the mounting bolts (3). 59. Turn the adjusting screw (1) clockwise to create a little tension on the serpentine belt (2). NOTE: Do not overtighten the adjusting screw. You will not be able to install the cooling fan if the belt has been tightened to specification on the pulleys. RAIL14SSL0793BA 24 47685160 24/06/2015 10.1 [10.001] / 24
  • 31. Engine - Engine and crankcase 60. If your machine is equipped with A/C, loosely install the serpentine belt (1) for the A/C compressor. 61. Loosen the A/C compressor by loosening the mount- ing bolts (3). 62. Turn the adjusting screw (2) clockwise to create a little tension on the belt. NOTE: Do not overtighten the adjusting screw. You will not be able to install the cooling fan if the belt has been tightened to specification on the pulleys. RAIL14SSL0794BA 25 63. Install the shroud (1). RAIL14SSL0795BA 26 64. Apply LOCTITE® 243™ to the threads of the bolts (2), and install the fan (1). RAPH12SSL0062AA 27 47685160 24/06/2015 10.1 [10.001] / 25
  • 32. Engine - Engine and crankcase 65. Adjust the serpentine belt for the alternator by turning the adjusting bolt (3). NOTE: The alternator belt does not have a tensioning pro- cedure. The alternator is adjusted all the way to the stop. 66. Torque the adjusting bracket bolt (2) to 50 N·m (37 lb ft). 67. Torque the jam nut for the adjusting bolt (3) to 30 N·m (22 lb ft). 68. Torque the mounting bolts (1) to 50 N·m (37 lb ft). RCPH11SSL038AAP 28 69. If your machine is equipped with A/C, adjust the belt for the A/C compressor by turning the adjusting screw (1). NOTE: The belt is tightened correctly when a force of 1.0 kg (2.2 lb) is applied to the center of the of the span of the belt with a 3 mm (1/8 in) of deflection. 70. Tighten the mounting bolts (2). RAPH12SSL0064BA 29 71. Readjust the shroud if there is not 13 mm (1/2 in) of clearance (A) between the fan blades and the shroud. RAPH14SSL0776BA 30 47685160 24/06/2015 10.1 [10.001] / 26
  • 33. Engine - Engine and crankcase 72. Place the radiator (3) inside the shroud, but do not install the hardware. 73. Attach the hoses (1) to the radiator. Torque the hose clamps (2) to 3 - 4 N·m (27 - 35 lb in). RAIL14SSL0797BA 31 74. Install the filler neck (2). 75. Attach the hose (2) to the filler neck. Torque the hose clamp (3) to 3 - 4 N·m (27 - 35 lb in). 76. Attach the mounting (1) for the oil dipstick tube onto the shroud. RAIL14SSL0796BA 32 77. Install the bolts (1) for the radiator. Torque the bolts (1) to 27 - 37 N·m (20 - 27 lb ft). RAIL14SSL0797BA 33 47685160 24/06/2015 10.1 [10.001] / 27
  • 34. Engine - Engine and crankcase 78. Install the air cooler (1). Torque the bolts (2) to 27 - 37 N·m (20 - 27 lb ft). RAIL14SSL0798BA 34 79. Install the overflow container. 80. Attach the overflow hose (1) to the filler neck. RAIL14SSL0799BA 35 81. Install the rear deck (1). RAIL14SSL0800BA 36 47685160 24/06/2015 10.1 [10.001] / 28
  • 35. Engine - Engine and crankcase 82. Install the left-hand panel (1). 83. Repeat step 82 on the right-hand panel. RAIL14SSL0801BA 37 84. Install the tilting hood (1). 85. Attach the hood strut (2) to the tilting hood (1). RAIL14SSL0802BA 38 86. If your machine has A/C, attach the lines (1) to the A/C condenser. 87. If your machine has A/C, connect the condenser fan (2). RAPH12SSL0075AA 39 47685160 24/06/2015 10.1 [10.001] / 29