New holland cx7.90 combine harvesters service repair manual

CX7.80 / CX7.90 / CX8.70 / CX8.80
CX8.85 / CX8.90 / CR7.90 / CR8.80
CR8.90 / CR9.80 / CR9.90 / CR10.90
Combine
SERVICE MANUAL
Part number 47956056
English
March 2016
© 2016 CNH Industrial Belgium N.V. All Rights Reserved.
SERVICE
MANUAL
1/8
Part number 47956056
CX7.80 - CX8.90
CR7.90 - CR10.90
Combine

SERVICE MANUAL
CR10.90, CR7.90, CR8.80, CR8.90, CR9.80, CR9.90, CX7.80, CX7.90, CX8.70,
CX8.80, CX8.85, CX8.90
47956056 23/02/2016
EN

Link Product / Engine
Product Market Product Engine
CX7.80 TIER 4B [1957 - ] Europe F2CFE613F*B041
CX7.90 TIER 4B Tracks [1957 - ] Europe F2CFE613E*B043
CX7.90 TIER 4B Tires [1957 - ] Europe F2CFE613E*B043
CX8.80 Tracks TIER 4B [1957 - ] Europe F2CFE613E*B043
CX8.85 TIER 4B Tracks [1962 - ] Europe F2CFE613A*B041
CX8.85 TIER 4B Tires [1962 - ] Europe F2CFE613A*B041
CX8.90 TIER 4A tracks [1962 - ] Europe F3AFE613A*A
CX8.90 TIER 4A [1962 - ] Europe F3AFE613A*A
CR10.90 TIER 4B tracks [1947 - ] Europe F3JFE613A*B004
CR7.90 TIER 4B Europe F2CFE613A*B
CR7.90 TIER 4A [1946 - ] Europe F2CFE613A*A
CR8.80 TIER 4A [1946 - ] Europe F3AFE613A*A
CR8.80 TIER 4B TRACK Europe F3HFE613A*B009
CR8.80 TIER 4A tracks [1946 - ] Europe F3AFE613A*A
CR8.80 TIER 4B Europe F3HFE613A*B009
CR8.90 TIER 4B TRACK Europe F3GFE613B*B003
CR8.90 TIER 4A [1946 - ] Europe F3AFE613A*A
CR8.90 TIER 4A tracks [1946 - ] Europe F3AFE613A*A
CR8.90 CR8.90 TIER 4B third axle
[1961 - ]
Europe F3GFE613B*B003
CR8.90 TIER 4B Europe F3GFE613B*B003
CR9.80 TIER 4A 3 axle [1946 - ] Europe F3BFE613E*A
CR9.80 TIER 4A tracks [1946 - ] Europe F3BFE613E*A
CR9.80 TIER 4B 12.5 3 AXLE Europe F3HFE613A*B009
CR9.80 TIER 4B [1961 - ] Europe F3HFE613A*B009
CR9.80 TIER 4A [1946 - ] Europe F3BFE613E*A
CR9.80 TIER 4B [1961 - ] Europe F3HFE613A*B009
CR9.90 TIER 4B TRACK Europe F3HFE613A*B009
CR9.90 TIER 4A 3 axle [1947 - ] Europe F3BFE613D*A
CR9.90 TIER 4B Europe F3HFE613A*B009
CR9.90 TIER 4A [1954 - ] Europe F3BFE613D*A
CR9.90 TIER4A [1954 - ] Europe F3BFE613D*A
CR9.90 TIER 4A [1947 - ] Europe F3BFE613D*A
CR9.90 TIER 4A tracks [1947 - ] Europe F3BFE613D*A
47956056 23/02/2016

Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase ............................................................. 10.1
[10.216] Fuel tanks .......................................................................... 10.2
[10.254] Intake and exhaust manifolds and muffler ......................................... 10.3
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment ........................... 10.4
[10.400] Engine cooling system ............................................................. 10.5
[10.418] Rotary screen ...................................................................... 10.6
[10.450] Engine air compressor ............................................................. 10.7
Main gearbox and drive ............................................................... 14
[14.100] Main gearbox and drive ............................................................ 14.1
Transmission.............................................................................. 21
[21.114] Mechanical transmission ........................................................... 21.1
[21.130] Mechanical transmission external controls......................................... 21.2
[21.145] Gearbox internal components...................................................... 21.3
[21.182] Differential.......................................................................... 21.4
Front axle system ....................................................................... 25
[25.108] Final drive hub, steering knuckles, and shafts ..................................... 25.1
[25.310] Final drives ......................................................................... 25.2
Rear axle system........................................................................ 27
[27.124] Final drive hub, steering knuckles, and shafts ..................................... 27.1
Hydrostatic drive......................................................................... 29
[29.100] Transmission and steering hydrostatic control ..................................... 29.1
[29.204] Reservoir, cooler, and lines ........................................................ 29.2
[29.218] Pump and motor components...................................................... 29.3
[29.202] Hydrostatic transmission ........................................................... 29.4
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[29.300] Rear hydrostatic transmission...................................................... 29.5
Brakes and controls .................................................................... 33
[33.202] Hydraulic service brakes ........................................................... 33.1
[33.110] Parking brake or parking lock ...................................................... 33.2
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems.................................................................. 35.1
[35.300] Reservoir, cooler, and filters........................................................ 35.2
[35.106] Variable displacement pump ....................................................... 35.3
[35.102] Pump control valves................................................................ 35.4
[35.359] Main control valve.................................................................. 35.5
[35.322] Regulated/Low pressure system ................................................... 35.6
[35.220] Auxiliary hydraulic pump ........................................................... 35.7
[35.410] Header or attachment height system .............................................. 35.8
[35.602] Header or attachment leveling system ............................................. 35.9
[35.760] Header reverser drive ............................................................ 35.10
[35.992] Stone trapping system ........................................................... 35.11
[35.994] Positive Straw Discharge (PSD) ................................................. 35.12
[35.796] Chaff spreader control ........................................................... 35.13
[35.440] Grain tank unload system ........................................................ 35.14
[35.450] Traction variator system.......................................................... 35.15
Steering..................................................................................... 41
[41.101] Steering control .................................................................... 41.1
[41.200] Hydraulic control components...................................................... 41.2
[41.432] Autoguidance steering ............................................................. 41.3
Tracks and track suspension........................................................ 48
[48.138] Track rollers ........................................................................ 48.1
[48.130] Track frame and driving wheels .................................................... 48.2
[48.134] Track tension units ................................................................. 48.3
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[48.100] Tracks .............................................................................. 48.4
Cab climate control ..................................................................... 50
[50.100] Heating ............................................................................. 50.1
[50.104] Ventilation .......................................................................... 50.2
[50.200] Air conditioning..................................................................... 50.3
Electrical systems....................................................................... 55
[55.000] Electrical system ................................................................... 55.1
[55.100] Harnesses and connectors......................................................... 55.2
[55.201] Engine starting system ............................................................. 55.3
[55.301] Alternator........................................................................... 55.4
[55.988] Selective Catalytic Reduction (SCR) electrical system ............................ 55.5
[55.640] Electronic modules ................................................................. 55.6
[55.029] Gearbox electric system ........................................................... 55.7
[55.019] Hydrostatic drive control system ................................................... 55.8
[55.512] Cab controls........................................................................ 55.9
[55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls................. 55.10
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system............... 55.11
[55.662] Header height control ............................................................ 55.12
[55.628] Threshing electrical control ...................................................... 55.13
[55.426] Harvest material flow control system............................................. 55.14
[55.624] Residue handling control......................................................... 55.15
[55.785] Precision farming system ........................................................ 55.16
[55.911] Global Positioning System (GPS) ................................................ 55.17
[55.680] Autopilot/Autoguidance .......................................................... 55.18
[55.518] Wiper and washer system........................................................ 55.19
[55.404] External lighting .................................................................. 55.20
[55.405] External lighting switches and relays ............................................ 55.21
[55.514] Cab lighting ...................................................................... 55.22
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[55.408] Warning indicators, alarms, and instruments .................................... 55.23
[55.DTC] FAULT CODES.................................................................. 55.24
Attachments/Headers.................................................................. 58
[58.900] Belt feeding ........................................................................ 58.1
Product feeding .......................................................................... 60
[60.105] Floating roll, feed chain, and drive ................................................. 60.1
[60.110] Feeder housing..................................................................... 60.2
[60.150] Feeder drive system ............................................................... 60.3
[60.165] Feeder reverse system............................................................. 60.4
[60.112] Stone trapping system ............................................................. 60.5
[60.260] Rotor ............................................................................... 60.6
Threshing .................................................................................. 66
[66.000] Threshing .......................................................................... 66.1
[66.260] Threshing mechanism drive system ............................................... 66.2
[66.331] Rotor ............................................................................... 66.3
[66.330] Drum ............................................................................... 66.4
[66.360] Drum/Rotor housing................................................................ 66.5
[66.321] Drum/Rotor variator with electrical control ......................................... 66.6
[66.105] Concave............................................................................ 66.7
[66.101] Concave conveyor plate ........................................................... 66.8
[66.110] Concave control system............................................................ 66.9
Separation ................................................................................. 72
[72.220] Discharge beater ................................................................... 72.1
[72.350] Beater .............................................................................. 72.2
[72.420] Rotary separator ................................................................... 72.3
[72.440] Straw-flow beater .................................................................. 72.4
[72.110] Straw walker drive system ......................................................... 72.5
[72.101] Straw walkers and shafts .......................................................... 72.6
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Residue handling........................................................................ 73
[73.300] Positive Straw Discharge (PSD) ................................................... 73.1
[73.230] Straw chopper...................................................................... 73.2
[73.210] Straw chopper drive system........................................................ 73.3
[73.220] Straw chopper frame ............................................................... 73.4
[73.335] Chaff spreader ..................................................................... 73.5
[73.410] Opti-Spread™ system.............................................................. 73.6
Cleaning.................................................................................... 74
[74.000] Cleaning............................................................................ 74.1
[74.101] Cleaning drive systems ............................................................ 74.2
[74.110] Grain pan........................................................................... 74.3
[74.114] Upper shaker shoe ................................................................. 74.4
[74.118] Lower shaker shoe ................................................................. 74.5
[74.125] Clean grain and return cross auger housing ....................................... 74.6
[74.130] Fan housing ........................................................................ 74.7
[74.136] Fan drive system ................................................................... 74.8
[74.140] Tailings return system .............................................................. 74.9
Crop storage / Unloading............................................................. 80
[80.101] Clean grain elevator................................................................ 80.1
[80.150] Grain tank .......................................................................... 80.2
[80.175] Grain tank unload drive system .................................................... 80.3
[80.180] Grain tank unload .................................................................. 80.4
Platform, cab, bodywork, and decals............................................. 90
[90.154] Cab doors and hatches ............................................................ 90.1
[90.110] Operator platform less cab ......................................................... 90.2
[90.118] Protections and footboards......................................................... 90.3
[90.124] Pneumatically-adjusted operator seat.............................................. 90.4
[90.105] Machine shields and guards ....................................................... 90.5
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INTRODUCTION
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1

INTRODUCTION
Safety rules
LEGAL OBLIGATIONS
This machine may be equipped with special guarding or other devices in compliance with local legislation. Some to
these require active use by the operator. Therefor, check local legislations on the usage of this machine.
ACCIDENT PREVENTION
Most accidents or injuries that occur in workshops are the result of non compliance to simple and fundamental safety
principles. For this reason, IN MOST CASES THESE ACCIDENTS CAN BE AVOIDED by applying the fundamental
safety principles, acting with the necessary caution and care.
Accidents may occur with all types of machine, regardless of how well the machine in question was designed and
built.
CAUTION
Unexpected machine movement!
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 minor or
moderate injury.
C0038A
SAFETY REQUIREMENTS FOR FLUID POWER SYSTEMS AND COMPONENTS - HY-
DRAULICS (EUROPEAN STANDARD EN982)
• Flexible hose assemblies must not be constructed from hoses which have been previously used as part of a hose
assembly.
• Do not weld hydraulic pipes: when flexible hoses or piping are damaged, replace them immediately.
• It is forbidden to modify a hydraulic accumulator by machining, welding or any other way.
• Before removing hydraulic accumulators for servicing, the liquid pressure in the accumulators must be reduced to
zero.
• Pressure check on hydraulic accumulators must be carried out by a method recommended by the accumulator
manufacturer.
• Take care not to exceed the maximum allowed pressure of the accumulator. After any check or adjustment, check
for leakages or gas in the hoses or tubes.
SAFETY RULES
General guidelines
• Carefully follow specified repair and maintenance procedures.
• When appropriate, use P.P.E (Personal Protective Equipment)
• Do not wear rings, wristwatches, jewellery, unbuttoned or loose articles of clothing such as: ties, torn clothing,
scarves, open jackets or shirts with open zips that may remain entangled in moving parts. It is advised to wear
approved safety clothing, e.g.: non-slip footwear, gloves, safety goggles, helmets, etc.
• Do not carry out repair operations with someone sitting in the driver's seat, unless the person is a trained technician
who is assisting with the operation in question.
• Do not operate the machine or use any of the implements from different positions, other than the driver's seat.
• Do not carry out operations on the machine with the engine running, unless specifically indicated.
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5

INTRODUCTION
• Bring all hydraulic cylinders to the home positions (down, retracted, etc.) before engine shut down.
• Stop the engine and check that the hydraulic circuits are pressure-free before removing caps, covers, valves, etc.
• All repair and maintenance operations must be carried out using extreme care and attention.
• Service steps and platforms used in the workshop or elsewhere should be built according to the applicable stan-
dards and legislation.
• Disconnect the Power Take-Off (PTO) and label the controls to indicate that the machine is being serviced.
• Brakes are inoperative when manually released for repair or maintenance purposes. Use blocks or similar devices
to secure the machine in these conditions.
• Only use specified towing points for towing the machine. Connect parts carefully. Make sure that all pins and/or
locks are secured in position before applying traction. Never remain near the towing bars, cables or chains that are
operating under load.
• When loading or unloading the machine from the trailer (or other means of transport), select a flat area capable of
sustaining the trailer or truck wheels. Firmly secure the machine to the truck or trailer and lock the wheels in the
position used by the carrier.
• Electric heaters, battery-chargers and similar equipment must only be powered by auxiliary power supplies with
efficient ground insulation to avoid electrical shock hazards.
• Always use suitable hoisting or lifting devices when raising or moving heavy parts.
• Keep bystanders away.
• Never use gasoline, diesel oil or other inflammable liquids as cleaning agents. Use non-inflammable, non toxic
commercially available solvents.
• Wear safety goggles with side guards when cleaning parts with compressed air.
• Never use open flames for lighting when working on the machine or checking for leaks.
• When carrying out checks with the engine running, request the assistance of an operator in the driver's seat. The
operator must maintain visual contact with the service technician at all times.
• If operating outside the workshop, position the machine on a flat surface and lock in position. If working on a slope,
lock the machine in position. Move to a flat area as soon as is safely possible.
• Maintenance and repair operations must be carried out in a clean and dry area. Clean up any water or oil spillage
immediately.
• Do not create piles of oil or grease-soaked rags as they represent a serious fire hazard. Always store rags in a
closed metal container.
• Before engaging the machine, make sure that there are no persons within the machine or implement range of action.
• Empty your pockets of all objects that may fall accidentally unobserved into the machine inner compartments.
• When metal parts are sticking out, use protective goggles or goggles with side guards, helmets, special footwear
and gloves.
• When welding, use protective safety devices: tinted safety goggles, helmets, special overalls, gloves and footwear.
All persons present in the area where welding is taking place must wear tinted goggles. NEVER LOOK DIRECTLY
AT THE WELDING ARC WITHOUT SUITABLE EYE PROTECTION.
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6

SERVICE MANUAL
Engine
CR10.90, CR7.90, CR8.80, CR8.90, CR9.80, CR9.90, CX7.80, CX7.90, CX8.70,
CX8.80, CX8.85, CX8.90
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10

Engine - Engine and crankcase
Engine - Remove
NOTE: The engine and cooling system used in the combine is designed to be removed as a modular unit. The follow-
ing engine removal procedure demonstrates the removal of the engine only from the module. This procedure takes
into consideration the possible unavailability of proper, or sufficient lifting equipment for complete module removal.
When possible, remove the engine and cooling system module as designed.
1. Remove the gearbox and hydraulic pumps from the en-
gine. (Refer to Main gearbox and drive - Remove
(14.100))
Place a suitable container (1) below the coolant drain
hose (2).
NOTE: Depending on model, the cooling system has a
coolant capacity between 50 - 60 l (13.2 - 15.9 US gal). Be
sure to use clean containers with adequate capacity when
draining the cooling system.
10013105_780 1
2. Refer to Expansion tank - Remove (10.400) for the
coolant fluid drain and removal of the engine coolant
reservoir.
NOTE: Depending on the model, the combine engine has an oil capacity between 29 - 35 l (7.7 - 9.2 US gal). Be
sure to use clean containers with adequate capacity when draining the engine oil.
3. Remove the cap (1) and turn the engine oil drain valve
(2), to the open position. Drain all of the engine oil into
suitable containers.
10013107 2
4. Loosen and remove the mounting hardware from the
protection cover (1).
Remove the cover (1) from the engine compartment.
ZEIL09CR0245A0B 3
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10.1 [10.001] / 3

5. Secure the engine cover with an adequate rope. Attach
the rope to a lifting device, able to carry the engine
cover and stair assembly.
Disconnect the shock absorber (1) from the engine
cover (2).
ZEIL09CR0246A0B 4
6. Remove the two retaining rings (1), washers (2) and
hinge pins (3) from the engine cover.
Remove the engine cover from the combine.
ZEIL09CR0247A0B 5
7. Refer to Exhaust muffler - Remove (10.254) for re-
moval of the exhaust pipe.
8. Loosen the hardware (1) and remove the support (2).
9. Loosen the clamps (3) from the air inlet pipe (4).
Remove the air inlet pipe (4).
ZEIL09CR0248A0B 6
10. Remove the air cleaner assembly, if necessary, refer
to Air cleaner - Remove (10.202).
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11. Loosen the clamps (1) and remove the air lines (2).
Loosen the clamps (3).
Loosen and remove the hardware (4) and remove the
air duct (5) from the combine.
ZEIL09CR0249A0B 7
Depending on model/options, an additional air tube (7)
needs to be removed/disconnected, loosen the coupler
(6) from the air compressor.
ZEIL09CR0250A0B 8
12. Loosen the coupler (1) and disconnect the fuel line (2)
from the ECU cooler.
Loosen the coupler (4) and disconnect the fuel hose
towards the injection pump from the fuel line (5).
Loosen and remove the clamp (3).
13. Loosen and disconnect the compressed air tube (7) at
the connector (6).
Loosen and remove the clamp (8).
ZEIL09CR0251A0B 9
14. Loosen the hose clamps (1) and remove the top
coolant pipe (2) from the engine and radiator neck.
10013111 10
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15. Loosen the clamps (1) and remove the air pipe (2).
16. Loosen the clamp (3) and disconnect the water hose
from the cooling system.
ZEIL09CR0252A0B 11
17. Remove the main drive belt (1) from the engine.
18. Disconnect the electrical connectors (1).
ATTENTION: Do not disconnect any of the air conditioning
lines or hoses during compressor removal, as serious in-
jury could result.
19. Remove the mounting bolts and nuts (2) from the air
conditioning compressor (3).
Remove the compressor from the engine and tie the
assembly out of the way.
10013117 12
20. From inside the grain tank, loosen the mounting nuts
on the carriage bolts (1) and turn the rotary screen
drive pulley adjusting bolt (2) counter clockwise, to
release the tension on the drive belt (3). Remove the
drive belt.
10013118 13
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21. From inside the grain tank, loosen the hose clamp (1)
and disconnect the lower coolant hose (2) from the
engine.
10013123 14
22. Disconnect the main engine electrical harness con-
nector (1).
10004682 15
23. If installed, open the rotary screen door and discon-
nect the rotary screen brush electrical connector (1).
10013132 16
24. Feed the connector and wire loom (1) and grommet (2)
through the hole in the radiator frame. Secure the wire
loom and connector to the engine to prevent damage
during removal.
NOTE: Removal of the rubber grommet in the radiator
frame hole may be necessary to remove the radiator
screen brush electrical connector.
10013133 17
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25. Loosen the nut (1) and remove the oil hose (2) from
the hose guide (3).
10013125 18
26. Cut the wire ties (1) and separate the engine wire har-
ness (2), from the gearbox wire harness (3).
Secure each harness to prevent damage during en-
gine removal.
10013126 19
27. Loosen the hose clamp (1) and disconnect the rear
heater hose (2) from the engine.
10013127 20
28. Loosen the hose clamp (1) and disconnect the front
heater hose (2) from the engine.
10013128 21
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29. Remove the nut and bolt (1) from the front engine
support bracket (2).
10013129 22
30. Remove the banjo bolt (1) from the engine oil pan (2).
Disconnect the oil hoses (3) and plug the hole in the
oil pan (2).
10010863 23
31. Loosen and remove the nut (1). Disconnect the main
starter cable (2) from the starter solenoid (3).
10013130 24
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32. Attach a suitable chain to the front lift eye (1) and to
the ECU bracket (2) at the rear of the engine.
20013162 25
33. Connect the lift chain to a suitable lifting device.
Raise the lifting device enough to support the engine
during removal of the engine mounting bolts.
10013136 26
34. Loosen the two front, engine mounting bolts (1) and
nuts (2) on each side of the engine. Do not remove
the mounting bolts at this time.
10013137 27
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35. Loosen the four rear, engine mounting bolts (1) on
each side of the engine. Do not remove the mounting
bolts at this time.
With the engine securely supported by the lifting de-
vice, remove all of the engine mounting bolts loosened
in the previous steps.
Carefully lift the engine from the frame and remove
from the combine.
10013138 28
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Engine - Remove
CR10.90 TIER 4B tracks [1947 - ] WE
CR7.90 WE
CR8.80 WE
CR8.90 WE
CR9.80 WE
CR9.90 WE
CX7.80 WE
CX7.90 WE
CX8.70 WE
CX8.80 WE
CX8.85 WE
CX8.90 WE
Prior operation:
Remove the left-hand side shielding and left-hand side rear shield. Refer to Side shields - Remove (90.105).
WARNING
Hot surface possible!
Wait for all components to cool before perform-
ing any operation.
Failure to comply could result in death or seri-
ous injury.
W0251A
NOTICE: Clean the engine thoroughly before removing parts to prevent dirt ingress into engine critical parts, refer to
the operator’s manual.
NOTICE: Make sure that the area around the hydraulic connectors is clean before disconnecting lines. Dirt contami-
nation will cause hydraulic component damage and/or failure.
Engine cover
1. Open the engine cover. Remove the lock nuts (1) and
remove the gas strut. (2).
ZEIL15CR00029AA 1
2. Close the engine cover. Remove the retaining rings (3),
the washers (4)and the pins (5).
3. Use a suitable lifting device to remove and to transport
the engine cover to the ground.
ZEIL15CR00006AA 2
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4. Open the grain tank.
5. Swing open the unload tube.
6. Close the upper sieve fully.
NHIL14CR00067AA 3
CAUTION
Unexpected machine movement!
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 minor or mod-
erate injury.
C0038A
WARNING
Hot surface possible!
Wait for all components to cool before perform-
ing any operation.
Failure to comply could result in death or seri-
ous injury.
W0251A
Drain fluids
7. Drain the engine coolant into a clean, suitable con-
tainer. Refer to the operator’s manual.
ZEIL15CR00007AA 4
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8. Drain the following fluids into a clean, suitable con-
tainer. Refer to the operator’s manual.
• Hydraulic oil.
• Engine oil, if necessary.
• Engine gearbox oil.
ZEIL09CR00271AA 5
Exhaust system
9. Remove the clamps (7A) and (7B) and remove the ex-
haust tube (6).
ZEIL15CR00043AA 6
10. Mark the connectors on the back of the Diesel Oxida-
tion Catalyst (DOC) (9) and disconnect:
1. The Diesel Exhaust Fluid (DEF)/AdBlue® dos-
ing module valve connector (12A).
2. Diesel Exhaust Fluid (DEF)/AdBlue® feed line
(11).
3. The engine feed coolant line (8). From cylin-
der head to the Diesel Exhaust Fluid (DEF)/Ad-
Blue® dosing module.
4. The engine feed coolant return line (10). From
Diesel Exhaust Fluid (DEF)/AdBlue® dosing
module to radiator return coolant tube .
NOTE: Have a suitable container ready and use the appro-
priate plugs on the Diesel Exhaust Fluid (DEF)/AdBlue®
dosing module and the Diesel Exhaust Fluid (DEF)/Ad-
Blue® dosing module feed line (11). Clean up any Diesel
Exhaust Fluid (DEF)/AdBlue® spill immediately.
ZEIL15CR00045AA 7
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11. Cut the straps and remove the Diesel Exhaust Fluid
(DEF)/AdBlue® feed line (11).
12. Remove the clamp (14).
13. Remove the hardware (13).
14. Remove the hardware (15) and remove the Diesel Ox-
idation Catalyst (DOC) (9).
ZEIL15CR00044AA 8
NOTE: The DOC weights approximately 36 kg (79.4 lb). Use a suitable lifting device and lift the DOC on the two for
seen lifting eyes.
Engine gearbox
15. Remove the following belts from the engine gearbox
drive pulleys, refer to the operator’s manual.
1. The unloading drive belt.
2. The main belt.
3. The chopper front drive belt.
ZEIL14CR00334AA 9
16. Remove the clamps (18) and the hardware (19) of the
wire harness (17).
ZEIL15CR00049AA 10
17. Mark all the connectors of the wire harness (17) that
are shown.
18. disconnect the connectors (17D) and (17I) of the wire
harness (17).
ZEIL15CR00050AA 11
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19. Mark all the connectors mentioned of the wire harness
(17) then disconnect the connectors (17A), (17B),
(17C), (17D), (17E), (17F), (17G) and (17H).
ZEIL15CR00049AA 12
20. On the bottom front side of the engine gearbox, dis-
connect the connector (17J) from the wire harness
(17).
21. Remove the banjo bolt (18) and remove the drain hose
from the engine gearbox.
ZEIL15CR00046AA 13
22. Mark and disconnect the following hydraulic hoses
from the engine hydraulics pump (19).
1. Hose (20)
2. Hose (21)
3. Hose (22)
4. Hose (23)
5. Hose (24)
6. Hose (25)
NOTE: Have a suitable container readily available to col-
lect any residual hydraulic oil. Use stops and/or plugs to
prevent oil spill and to protect against dirt ingress. ZEIL15CR00051AA 14
from the cleaning fan and active spreader pump (27).
1. Hose (26)
2. Hose (28)
3. Hose (29)
4. Hose (30)
prevent oil spill and to protect against dirt ingress.
ZEIL15CR00052AA 15
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from the hydrostatic pump (31).
1. Hose (32)
2. Hose (33)
3. Hose (34)
4. Hose (35)
5. Hose (36)
ZEIL15CR00052AA 16
25. Disconnect the following hydraulic tubes:
1. Tube (37)
NOTE: Loosen other end of the tube and swing
out of the way.
2. Tube (38)
NOTE: Loosen other end of the tube and swing
out of the way.
ZEIL15CR00049AA 17
26. Disconnect the hydraulic tubes (39), (40), (41) and the
hose (42) from the engine hydraulics manifold (43).
ZEIL15CR00073AA 18
27. Suspend the engine gearbox (46) on the lifting point
indicated by the arrow.
28. Remove all eleven bolts (44) and the lock washers
(45) from the engine gearbox (46).
ZEIL15CR00055AA 19
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Cooling circuits
29. Remove the covers as shown.
ZEIL15CR00010AA 20
30. Remove the hardware (48) and the cooling group
cover (47).
ZEIL15CR00011AA 21
31. Open the filler cap (50).
32. Remove the hose (48), the hose (49) and the hose
(54).
33. Remove the hardware (52), the clamps (53) and the
coolant reservoir (51).
ZEIL15CR00008AA 22
ZEIL15CR00009AA 23
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34. Loosen the clamps (55) and remove the air tube (56).
ZEIL15CR00012AA 24
35. Loosen the clamps (59) and remove the air tube (60).
36. Disconnect the connector (12B) from the air humidity
sensor.
37. Loosen the clamps (58), the clamp (61) and remove
the filter outlet tube (57).
ZEIL15CR00013AA 25
38. Disconnect the connector (12C) from the air filter clog-
ging sensor.
ZEIL15CR00067AA 26
39. Loosen the clamp (64). Remove the hardware of the
clamp (63) and remove the hose (62) from the blow-by
filter (65).
40. Disconnect the connector (12D) from the 12 V power
socket.
ZEIL15CR00014AA 27
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41. Remove the hardware (66), (69), (70), (71) and (72).
Remove support (67) and (68).
ZEIL15CR00014AA 28
42. Loosen the clamp (74) and remove the hose (75).
43. Remove the hardware (73) and remove the blow-by
filter (65).
ZEIL15CR00030AA 29
44. Loosen the clamp (77) of the air inlet channel (78) .
ZEIL15CR00016AA 30
45. Loosen the clamp (80).
46. Remove the hardware (79).
47. Remove the air inlet channel (78).
ZEIL15CR00015AA 31
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48. Near the engine coolant drain tap, loosen the clamp
(81) of the engine coolant outlet tube (82).
ZEIL15CR00018AA 32
49. Loosen the hose clamp (81) of the engine coolant out-
let tube (82).
50. Remove the hardware (83) and remove the engine
coolant outlet tube (82).
ZEIL15CR00017AA 33
51. At the front of the engine, loosen the hose clamp (84)
of the engine coolant inlet tube rubber coupler (85).
ZEIL15CR00019AA 34
52. Loosen the ventilator belt. Keep the nut and the jam
nut locked together to turn the rod.
NOTE: Only loosen the nut and the jam nut separately to
adjust the tension. Refer to the operator’s manual.
ZEIL15CR00021AA 35
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