New Holland 200 Series Skid Steer Loader/Compact Track Loader OEM Service & Repair Manual

Part number 84423865 1st edition English July 2011 SERVICE MANUAL L213 / L215 / L218 / L220 L223 / L225 / L230 200 Series Skid Steer Loader C227 / C232 / C238 200 Series Compact Track Loader

Contents INTRODUCTION HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS A PRIMARY HYDRAULIC POWER SYSTEM .............................................. A.10.A SECONDARY HYDRAULIC POWER SYSTEM.......................................... A.12.A HYDRAULIC COMMAND SYSTEM ...................................................... A.14.A HIGH-FLOW HYDRAULIC POWER SYSTEM ........................................... A.16.A ELECTRICAL POWER SYSTEM ........................................................ A.30.A LIGHTING SYSTEM...................................................................... A.40.A ELECTRONIC SYSTEM ................................................................. A.50.A FAULT CODES ........................................................................... A.50.A ENGINE AND PTO IN ................................................................... B ENGINE .................................................................................. B.10.A FUEL AND INJECTION SYSTEM ........................................................ B.20.A AIR INTAKE SYSTEM .................................................................... B.30.A ENGINE COOLANT SYSTEM ........................................................... B.50.A STARTING SYSTEM ..................................................................... B.80.A TRANSMISSION, DRIVE AND PTO OUT ........................................ C TRANSMISSION Hydrostatic............................................................. C.20.F AXLES, BRAKES AND STEERING................................................. D Final drive ................................................................................ D.15.A Final drive Hydraulic drive ................................................................ D.15.C STEERING Mechanical .................................................................. D.20.B PARKING BRAKE Hydraulic ............................................................. D.32.C WHEELS AND TRACKS Tracks ......................................................... D.50.B WHEELS AND TRACKS Wheels......................................................... D.50.C FRAME AND CAB ........................................................................ E FRAME Primary frame ................................................................... E.10.B SHIELD ................................................................................... E.20.A 84423865 25/07/2011

USER CONTROLS AND SEAT .......................................................... E.32.A USER CONTROLS AND SEAT Operator seat ........................................... E.32.C USER PLATFORM ....................................................................... E.34.A ENVIRONMENT CONTROL Heating system ............................................ E.40.B ENVIRONMENT CONTROL Air-conditioning system .................................... E.40.C SAFETY SECURITY ACCESSORIES Safety ............................................ E.50.B FRAME POSITIONING ................................................................. F STABILISING Ballasting .................................................................. F.20.B TOOL POSITIONING .................................................................... G LIFTING .................................................................................. G.10.A TILTING .................................................................................. G.20.A LEVELLING .............................................................................. G.30.A SECONDARY FUNCTIONS Hydraulic ................................................... G.90.C HITCH AND WORKING TOOL ....................................................... H BOOM Lift ................................................................................ H.20.B ARM TOOL ATTACHMENT Tilt........................................................... H.30.C SINGLE ARM Lift ......................................................................... H.40.B SINGLE ARM TOOL ATTACHMENT Tilt ................................................. H.50.C EXCAVATING AND LANDSCAPING ............................................... J DIGGING Non-articulated digging tools .................................................. J.20.B CARRYING Unarticulated tools .......................................................... J.50.B COUPLING Mechanical coupling......................................................... J.80.B COUPLING Hydraulic coupling ........................................................... J.80.C 84423865 25/07/2011

84423865 25/07/2011

INTRODUCTION 84423865 25/07/2011 1

Contents INTRODUCTION Foreword - Ecology and the environment ...................................................... 3 Safety rules ..................................................................................... 4 2 - Series Safety rules - Personal safety .................................................................. 5 Safety rules ..................................................................................... 6 Basic instructions - How To Use and Navigate Through This Manual .......................... 7 Basic instructions - Important notice regarding equipment servicing ......................... 12 Basic instructions - Shop and Assembly ...................................................... 13 Torque - Minimum tightening torques for normal assembly ................................... 15 2 - Series Torque - Standard torque data for hydraulics ................................................. 20 General speciﬁcation - Biodiesel Fuels ....................................................... 22 General speciﬁcation - General Welding ..................................................... 23 84423865 25/07/2011 2

INTRODUCTION Foreword - Ecology and the environment Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment of some of the substances which are required by advanced technology, sound judgement should govern the use and disposal of products of a chemical and petrochemical nature. NOTICE: The following are recommendations which may be of assistance: • Become acquainted with and ensure that you understand the relative legislation applicable to your country. • Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning agents, etc., with regard to their effect on man and nature and how to safely store, use and dispose of these substances. • Agricultural consultants will, in many cases, be able to help you as well. HELPFUL HINTS • Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems which may cause considerable spillage. • In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances which may be harmful to your health. • Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems. • Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc. Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper way to comply with local legislation and available resources. • Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should not be allowed to get into the soil but should be collected and disposed of properly. • Do not open the air-conditioning system yourself. It contains gases which should not be released into the at- mosphere. Your NEW HOLLAND CONSTRUCTION dealer or air conditioning specialist has a special extractor for this purpose and will have to recharge the system properly. • Repair any leaks or defects in the engine cooling or hydraulic system immediately. • Do not increase the pressure in a pressurized circuit as this may lead to a component failure. • Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of oils, coolant, etc. 84423865 25/07/2011 3

INTRODUCTION Safety rules 2 - Series 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 and on machine decals, you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you. Read and understand all the safety messages in this manual before you operate or service the machine. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. The color associated with DANGER is RED. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. The color associated with WARNING is ORANGE. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. The color associated with CAUTION is YELLOW. FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation which, if not avoided, could result in machine or property damage. The color associated with Notice is BLUE. Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety. Information NOTE: Note indicates additional information which clarifies steps, procedures, or other information in this manual. Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage. 84423865 25/07/2011 4

INTRODUCTION Safety rules - Personal safety Carefully study these precautions, and those included in the external attachment operators manual, and insist that they be followed by those working with and for you. 1. Thoroughly read and understand this manual and the attachment 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 un- expectedly. • 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 operators of other vehicles. In this regard, check local government regulations. Various safety lights and devices are available from your NEW HOLLAND CONSTRUCTION dealer. 14. Practice safety 365 days 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. 84423865 25/07/2011 5

INTRODUCTION Safety rules BT09A213 1 84423865 25/07/2011 6

New Holland 200 Series Skid Steer Loader/Compact Track Loader OEM Service & Repair Manual

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