New Holland Wheel Loader 545, 545H, 645 Service Manual
FILE DETAILS:
New Holland Wheel Loader 545, 545H, 645 Service Manual
Size: 98 MB
Format: PDF
Language: English
Number of Pages : 830 pages
Brand: New Holland
Type of document: Service Manual
Model: 545, 545H, 645
Part No: 73058626
DESCRIPTION:
New Holland Wheel Loader 545, 545H, 645 Service Manual
FOREWORD:
Always furnish serial number it making an inquiry to dealerortactory about this machine. Many equipment owners employthe Dealer Service Department for all work other than routine lubrication and minor service. This practice is encouraged. as our Dealers are well iniomied and equipped to render efficient service by factory trained mechanics This manual may not be reprinted or reproduced. either in whole or in part. without written permission of Fiataiils ®. Illustrations show standard and optional items.
GENERAL :
Study the Operation and Maintenance Instruction Manual be- fore starting, operating, maintaining, fueling. or servicing machine. – Read and heed all machine-mounted safety signs before starting, operating, maintaining, fueling or servicing machine. Machine~mounted safety signs have been color coded yellow with black border and lettering for WARNING and red with white border and lettering for DANGER points. Never attempt to operate the machine or its tools from any position other than seated in the operator’s seat. Keep head, body, limbs, hands and feet inside operator’s compartment at alltirnes to reduce exposure to hazards outside the operator’s compartment.
- Do not allow unauthorized personnel to operate service or maintain this machine. Aiways check work area for dangerous features. The follow. ing are examples of dangerous work areas: slopes. over hangs, timber. demolitions. fire. high walls, drop off, back fills, rough terrain, ditches. ridges, excavations, heavy traffic, crowded parking, crowded maintenance and closed areas. Use extreme care when in areas such as these. An operator must know the machine‘s capabilities. When working on slopes or near drop offs be alert to avoid loose or soft conditions that could cause sudden tipping or loss of control.
- Do not jump on or off machine. Keep two hands and one foot, or two feet and one hand, in contact with steps grab rails and handles at all times. Do not use controls or hoses as hand holds when climbing on or off machine. Hoses and controls are movable and do not provide a send support. Controls also may be inadvertently moved causing accidental machine or equipment movement. Keep operator‘s compartment, stepping points, grab-rails and handles clear of foreign objects, oil. grease. mud or snow accumulation to minimize the danger of sliping or stumbling. Clean mud or grease from shoes before attempting to mount or operate the machine.
- Be careful of slippery conditions on stepping points, hand rails. and on the ground. Wear safety boots orshoes that have a high slip resistant sole material. ‘ Foryour personal protection. Do not attempt to climb on or off machine while machine is in motion. Never leave the machine unattended with the engine running. Always look up machine when leaving it unattended. Return keys to authorized security. Heed all shut down procedures of the Operation and Maintenance instruction Manual.
- Always set the parking brake when leaving the machine for any reason.Do not wear rings, wrist watches, jewelry. loose or hanging apparel. such as ties. torn clothing. scarves. unbuttoned or unzipped jackets that cen catch on moving parts. Wear proper safety equipment as authorized for the job. Examples: hard hats. safety shoes. heavy gloves. ear protectors. safety glasses or goggles, reflector vests. or respirators.
TABLE OF CONTENTS:
New Holland Wheel Loader 545, 545H, 645 Service Manual
73047530-Brakes and Air Systems......................................................................................................................... 1 Supplement No. 2 Service Manual Form 73047530 ( Same as 3047530-5) Brakes and Air System 545, 545H, 645 Wheel Loaders ............................. 5 Table of Contents .................................................................................................................................. 15 Topic I - Brakes ................................................................................................................................... 18 Topic II - Wheel Brakes ............................................................................................................................ 20 Topic III - Master Brake Cylinder .................................................................................................................. 33 Topic IV - Bleeding of Hydraulic System ............................................................................................................ 40 Topic V - Parking Brake ............................................................................................................................ 42 Topic VI - Vacuum Pump.............................................................................................................................. 45 Topic VII - Compressor/ Governor ................................................................................................................... 52 Topic VIII - Governor .............................................................................................................................. 60 Topic IX - Hydrovac (545 Models Only) .............................................................................................................. 62 Topic X - Air Reservoir Tank (TL645 Only) ......................................................................................................... 68 Topic XI - Air Pak (TL645 Only) .................................................................................................................... 69 Topic XII - Air Cleaner and Check Valve - Vacuum (TL545's) ........................................................................................ 79 Topic XIII - Troubleshooting and Test Procedures .................................................................................................. 81 73053547-Axles.......................................................................................................................................... 89 Supplement No 9. Service Manual Form 73053547 - Axles 545, 545-B, 545H, 605-B, 645, 645-B, 745, 745-B, 745H, 745H-B Wheel Loaders .................. 92 Supplement No 8. Service Manual Form 73053547 - Axles 545, 545H, 605, 745, 745H Wheel Loaders (Incl. Series B) .................................... 93 Supplement No 7. Service Manual Form 3053547-0 - Axles 545, 545H, 605, 645, 745, 745H, Wheel Loaders (Including Series B) ......................... 94 Supplement No 6. Service Manual Form 3053547-0 - Axles 545, 545H, 605, 645, 745, 745H, Wheel Loaders (Including Series B) ..................... 95 Supplement No 5. Service Manual Form 3053547-0 - Axles 545, 545H, 605, 645, 745, 745H, Wheel Loaders (Including Series B) ..................... 96 Supplement No 4. Service Manual Form 3053547-0 - Axles 545, 545H, 605, 645, 745, 745H, Wheel Loaders (Including Series B) ...................... 97 Supplement No 3. Service Manual Form 3053547-0 - Axles 545, 545H, 605, 645, 745, 745H, Wheel Loaders (Including Series B) ...................... 98 Supplement No 2. Service Manual Form 3053547-0 - Axles 545, 545H, 605, 645, 745, 745H, Wheel Loaders ............................................... 99 Supplement No 1. Service Manual Form 3053547-0 - Axles 545, 545H, 645, 745, Wheel Loaders ..........................................................100 Table of Contents ..................................................................................................................................110 Topic 1 - General Information and Description ......................................................................................................111 Topic 2 - Trouble Shooting .........................................................................................................................115 Topic 3 - Removal and Installation of Axles .......................................................................................................117 Topic 4 - Differential Removal and Disassembly ....................................................................................................120 Topic 5 - Cleaning and Inspection ..................................................................................................................123 Topic 6 - Assemble Components ......................................................................................................................124 Topic 7 - Planetary Hubs ..........................................................................................................................132 Topic 8 - Cleaning and Inspection .................................................................................................................138 Topic 9 - Assembly and Installation ................................................................................................................139 Topic 10 - Drive Shafts ............................................................................................................................146 Topic 11 - Torque Specifications ...................................................................................................................153 Topic 12 - Wheels and Tires .......................................................................................................................156 Topic 13 - No Spin Differential Removal and Disassembly (Special Equipment) .......................................................................158 73055458-Bucket and Chassis.............................................................................................................................173 Supplement No. 4 - Service Manual Form 73055458 Bucket and Chassis 545, 545H, 545-B, 605-B, 645, 645-B, 745, 745H, 745-B, 745-C Wheel Loaders .....176 Supplement No. 3 - Service Manual Form 73055458 Bucket and Chassis 545, 545H, 545-B, 605-B, 645, 645-B, 745, 745H, 745-B, 745-C Wheel Loaders ....177 Supplement No. 2 - Service Manual Form 3055458 -8 Bucket and Chassis 545, 545H, 605, 645, 745, & 745H (Including Series B) Wheel Loaders ........178 Supplement No. 1 - Service Manual Form 3055458-8 Bucket and Chassis 545, 545H, 645, 745, Wheel Loaders ..........................................179 Table of Contents ..................................................................................................................................187 General Description ................................................................................................................................188 Bucket and Linkage .................................................................................................................................189 Fenders, Ladder, Hood, Bonnet, and Hand Rail .......................................................................................................194 Platform and Seat Assembly ........................................................................................................................195 Fuel Tank ..........................................................................................................................................196 Main Frame and Pivot Pins ..........................................................................................................................199 Torque Specifications ..............................................................................................................................207 Linkage Wear Limits ................................................................................................................................207 ROPS Cab ..........................................................................................................................................209 Index ..............................................................................................................................................214 Conversion Tables ..................................................................................................................................215 73068993-Power Steering................................................................................................................................. 0 Supplement No. 1 Service Manual Form 73068993 - Power Steering 545,545-H, 545-B, 605-B, 645, 645-B, Wheel Loaders ................................219 Table of Contents ..................................................................................................................................227 Topic 1 - Description and Operation ................................................................................................................228 Topic 1A - Emergency Steering (Special Equipment) ..................................................................................................234 Topic 2 - Service and Maintenance ..................................................................................................................236 Topic 3 - Troubleshooting ..........................................................................................................................249 Topic 4 - Power Steering Cylinders .................................................................................................................255 Topic 5 - Power Steering Pump ......................................................................................................................262 Topic 6 - Power Steering Gear Assembly .............................................................................................................281 Topic 7 - Hydraulic Pump ...........................................................................................................................308 Topic 8 - Demand Valve .............................................................................................................................315 Topic 9 - Test and Adjustment Procedures ...........................................................................................................326 Topic 10 - Pressure Line, Fittings, Hoses and Tubing ...............................................................................................337 Topic 11 - Torque Values ...........................................................................................................................344 Alphabetical Index .................................................................................................................................345 73124400-Bucket Hydraulic Systems.......................................................................................................................348 Supplement No. 1 Service Manual Form 73124400 Bucket Hydraulic Systems 545 thru 745-C Wheel Loaders ................................................351 Table of Contents ..................................................................................................................................352 Safety Rules .......................................................................................................................................357 General ...........................................................................................................................................365 Hydraulic System Specifications ....................................................................................................................366 Description and Operation ..........................................................................................................................368 Troubleshooting and Testing ........................................................................................................................372 Hydraulic Pump Repair ..............................................................................................................................387 Hydraulic Control Valve Repair .....................................................................................................................395 Hydraulic Cylinder Repair ..........................................................................................................................448 Hydraulic Fittings, Hoses and Tubing ...............................................................................................................475 Service Tools ......................................................................................................................................480 Torque Values ......................................................................................................................................483 73146366-Electrical Systems.............................................................................................................................485 Safety Rules .......................................................................................................................................486 Table of Contents ..................................................................................................................................493 General Description ................................................................................................................................494 Troubleshooting ....................................................................................................................................495 Changing Circuit ...................................................................................................................................498 Starting Circuit ...................................................................................................................................506 Ignition Circuit ...................................................................................................................................508 Accessory Ciruits ..................................................................................................................................512 Batteries ..........................................................................................................................................514 Electrical System Schematics .......................................................................................................................519 73158517-Quick Reference Service Specifications.........................................................................................................677 Table of Contents ..................................................................................................................................680 Machine List, F.I. Pump Type and Pump Part No., Engine Timing, And Machine Specification Page Numbers ..............................................681 Fuel Specifications, Diesel/ Engine Lubricant Specifications .......................................................................................686 Machine Lubricant/ Viscosity Specification Table ...................................................................................................687 Table of Lubricants ................................................................................................................................691 Viscosity Charts ...................................................................................................................................692 Conversion Factors .................................................................................................................................693 Definitions and Abbreviations ......................................................................................................................697 Model Specifications ...............................................................................................................................698 Fuel Consumption ...................................................................................................................................808 Fiat Engines Common to Fiatallis ...................................................................................................................810 Interchangeability of Components in Crawlers .......................................................................................................812 Tires Sizes ........................................................................................................................................814 Interchangeability of Components in Excavators .....................................................................................................815 Crawler Tractor Weights ............................................................................................................................816 Machine Dimensions .................................................................................................................................817
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PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.