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Part number 51425750
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Farmlift 632
Farmlift 635
Farmlift 735
Farmlift 742
Farmlift 935
Telescopic Handler
SERVICE MANUAL
Farmlift 632
Farmlift 635
Farmlift 735
Farmlift 742
Farmlift 935
Stage IV
Telescopic Handler
Part number 51425750
English
November 2017
© 2017 CNH Industrial Italia S.p.A. All Rights Reserved.
SERVICEMANUAL
Link Product / Engine
Product Market Product Engine
FARMLIFT 632 STAGE IV
TELEHANDLER FARMLIFT 632
Europe F4HFE413Z*B002
FARMLIFT 635 STAGE IV
TELEHANDLER FARMLIFT 635
Europe F4HFE4149*B001
FARMLIFT 735 STAGE IV
TELEHANDLER FARMLIFT 735
Europe F4HFE413Z*B002
FARMLIFT 742 STAGE IV
TELEHANDLER FARMLIFT 742
Europe F4HFE4149*B001
FARMLIFT 935 STAGE IV
TELEHANDLER FARMLIFT 935
Europe F4HFE413Z*B002
51425750_EN 08/03/2018
Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase ............................................................. 10.1
[10.216] Fuel tanks .......................................................................... 10.2
[10.206] Fuel filters .......................................................................... 10.3
[10.202] Air cleaners and lines .............................................................. 10.4
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment ........................... 10.5
[10.400] Engine cooling system ............................................................. 10.6
[10.414] Fan and drive ...................................................................... 10.7
Transmission.............................................................................. 21
[21.113] Powershift transmission ............................................................ 21.1
[21.135] Powershift transmission external controls.......................................... 21.2
[21.155] Powershift transmission internal components...................................... 21.3
[21.120] Gearbox ............................................................................ 21.4
[21.109] Transmission cooler and lines...................................................... 21.5
[21.700] Torque converter ................................................................... 21.6
Four-Wheel Drive (4WD) system .................................................. 23
[23.314] Drive shaft.......................................................................... 23.1
Front axle system ....................................................................... 25
[25.100] Powered front axle ................................................................. 25.1
[25.102] Front bevel gear set and differential ............................................... 25.2
[25.108] Final drive hub, steering knuckles, and shafts ..................................... 25.3
Rear axle system........................................................................ 27
[27.100] Powered rear axle.................................................................. 27.1
[27.106] Rear bevel gear set and differential................................................ 27.2
[27.120] Planetary and final drives .......................................................... 27.3
51425750_EN 08/03/2018
[27.124] Final drive hub, steering knuckles, and shafts ..................................... 27.4
Brakes and controls .................................................................... 33
[33.202] Hydraulic service brakes ........................................................... 33.1
[33.110] Parking brake or parking lock ...................................................... 33.2
[33.220] Trailer brake hydraulic control...................................................... 33.3
[33.204] Front axle brake.................................................................... 33.4
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems.................................................................. 35.1
[35.104] Fixed displacement pump.......................................................... 35.2
[35.106] Variable displacement pump ....................................................... 35.3
[35.359] Main control valve.................................................................. 35.4
[35.357] Pilot system ........................................................................ 35.5
[35.128] Auxiliary hydraulic function control ................................................. 35.6
[35.752] Hydraulic fan drive cooling system................................................. 35.7
[35.100] Main lift system..................................................................... 35.8
[35.355] Hydraulic hand control ............................................................. 35.9
[35.701] Front loader arm hydraulic system ............................................... 35.10
[35.736] Boom hydraulic system .......................................................... 35.11
[35.734] Tool quick coupler hydraulic system ............................................. 35.12
[35.740] Telescopic arm hydraulic system................................................. 35.13
Steering..................................................................................... 41
[41.101] Steering control .................................................................... 41.1
[41.200] Hydraulic control components...................................................... 41.2
[41.216] Cylinders ........................................................................... 41.3
Cab climate control ..................................................................... 50
[50.200] Air conditioning..................................................................... 50.1
Electrical systems....................................................................... 55
[55.100] Harnesses and connectors......................................................... 55.1
51425750_EN 08/03/2018
[55.201] Engine starting system ............................................................. 55.2
[55.302] Battery.............................................................................. 55.3
[55.988] Selective Catalytic Reduction (SCR) electrical system ............................ 55.4
[55.047] Steering control system ............................................................ 55.5
[55.408] Warning indicators, alarms, and instruments ...................................... 55.6
[55.DTC] FAULT CODES.................................................................... 55.7
Telescopic single arm.................................................................. 83
[83.122] Telescopic arm ..................................................................... 83.1
Platform, cab, bodywork, and decals............................................. 90
[90.150] Cab................................................................................. 90.1
[90.105] Machine shields and guards ....................................................... 90.2
51425750_EN 08/03/2018
INTRODUCTION
51425750_EN 08/03/2018
1
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 required by advanced technology, sound judgment should govern the use and disposal of
products of a chemical and petrochemical nature.
NOTE: The following are recommendations that 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 that may cause considerable
spillage.
• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them 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 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 that should not be released into the atmosphere.
Your CASE IH 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.
51425750_EN 08/03/2018
3
INTRODUCTION
Safety rules
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 which, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, 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 which, 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 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.
51425750_EN 08/03/2018
4
INTRODUCTION
Personal safety
Carefully read this Manual before proceeding with main-
tenance, repairs, refuelling or other machine operations.
Repairs have to be carried out only by authorized and in-
structed staff; specific precautions have to be taken when
grinding, welding or when using mallets or heavy ham-
mers.
Not authorized persons are not allowed to repair or carry
out maintenance on this machine. Do not carry out any
work on the equipment without prior authorization.
Ask your employer about the safety instructions in force
and safety equipment.
Nobody is allowed to seat on the operator’s place during
machine maintenance unless he is a qualified operator
helping with the maintenance work.
If it is necessary to move the equipment to carry out re-
pairs or maintenance, do not lift or lower the equipment
from any other position than the operator’s seat.
TULI12WEX2004AA 1
Never carry out any operation on the machine when the
engine is running, except when specifically indicated.
Stop the engine and ensure that all pressure is relieved
from hydraulic circuits before removing caps, covers,
valves, etc.
All repair and maintenance operations should be carried
out with the greatest care and attention.
Service stairs and platforms used in a workshop or in the
field should be built in compliance with the safety rules in
force.
Any functional disorders, especially those affecting the
safety of the machine, should therefore be rectified im-
mediately.
DANGER
Unexpected movement!
Make sure parking brake is applied. Secure
machine with wheel chocks.
Failure to comply will result in death or serious
injury.
D0013A
TULI12WEX2005AA 2
Before performing any work on the machine, attach a
maintenance in progress tag. This tag can be applied on
the left-hand control lever, safety lever or cab door.
51425750_EN 08/03/2018
5
SERVICE MANUAL
Engine
FARMLIFT 632 STAGE IV TELEHANDLER FARMLIFT 632
FARMLIFT 635 STAGE IV TELEHANDLER FARMLIFT 635
FARMLIFT 735 STAGE IV TELEHANDLER FARMLIFT 735
FARMLIFT 742 STAGE IV TELEHANDLER FARMLIFT 742
FARMLIFT 935 STAGE IV TELEHANDLER FARMLIFT 935
51425750_EN 08/03/2018
10
Engine - Engine and crankcase
Engine - Remove
WARNING
Hot surface possible!
Wait for all components to cool before performing any operation.
Failure to comply could result in death or serious injury.
W0251A
WARNING
Chemical hazard!
When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.
Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect
fluids in proper containers. Obey all local and environmental regulations when disposing of chemi-
cals.
Failure to comply could result in death or serious injury.
W0371A
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
NOTE: emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations. Use of tools that gen-
erate extreme vibrations, such as impact wrenches and hammers, will result in damage to emission sensors. Avoid
using these tools during any service procedure in close proximity of emission sensors. If the use of these tools cannot
be avoided, remove the sensors using extreme caution prior to performing any service procedure.
1. Park the machine on a firm level ground and lower the
boom arm to the floor.
2. Engage the parking brake.
3. Press the upper side of the battery isolator switch to
disconnect the battery. Stop the engine.
4. Move the joystick in all directions to release the hy-
draulic pressure.
LEIL17TLH1186AA 1
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10.1 [10.001] / 5
Engine - Engine and crankcase
5. Remove the drain plug of the hydraulic tank.
Drain the hydraulic oil from the hydraulic tank. Collect
the escaping fluid in a proper container.
LEIL17TLH1253AB 2
6. Remove the drain plug of the fuel tank.
Drain the fuel tank. Collect the escaping fluid in a
proper container.
LEIL17TLH1255AB 3
7. If equipped, remove the drive shaft cover guard (1).
LEIL17TLH1254AA 4
8. Remove the retaining bolts (2) and the nuts (3) that fix
the cover (1) to the frame lower side and to the engine
compartment.
9. Remove the cover (1) from the bottom side of the ma-
chine.
LEIL17TLH1178AB 5
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10.1 [10.001] / 6
Engine - Engine and crankcase
10. Locate the plate (1) under the lower hood.
Remove the two screws (2) and the plate (1) from to
the lower hood.
LEIL13TLH0427AB 6
11. Remove the drain plug (3) from the transmission main
housing and drain the transmission oil.
Tighten the drain plug (3) after the transmission oil is
drained off.
LEIL13TLH0428AB 7
12. Remove the drain plug (4) from the transmission
transfer box and drain the transmission oil.
Tighten the drain plug (4) after the transmission oil is
drained off.
LEIL13TLH0429AB 8
13. Drain the air conditioning system (if equipped). Refer
to Air conditioning - Service instruction - Evacuat-
ing the refrigerant (50.200).
14. Use an acceptable hydraulic jack to raise the tires off
the ground. Install acceptable jack stands under the
axles to support the machine.
Remove the wheels of the right-hand side of the ma-
chine.
LEIL17TLH1228AB 9
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10.1 [10.001] / 7
Engine - Engine and crankcase
15. Open the battery compartment. Remove the remote
drain plug on the engine oil pan.
LEIL17TLH0870AA 10
16. Attach the drain hose (1) (provided in the inner side of
the opening panel of the battery compartment) to the
remote drain plug.
Drain the engine oil completely and discard it following
the local environmental and waste regulations.
NOTE: see the operator’s manual for more information.
LEIL13TLH2138AB 11
17. Remove the fuel-prefilter from the lower hood frame.
Refer to Pre-filter - Remove (10.206).
LEIL17TLH0870AA 12
18. Remove the two cable ties (4).
Remove the block (5) from the air conditioning hoses
(1) and (2).
LEIL17TLH1263AA 13
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10.1 [10.001] / 8
Engine - Engine and crankcase
19. Disconnect the air conditioning hoses (1) and (2) from
the air conditioning compressor (3).
LEIL17TLH1260AA 14
20. Disconnect and remove the fuel pre-filter hose (1)
from the engine.
LEIL17TLH1261AA 15
21. Remove the battery from the machine. Refer to Bat-
tery - Remove (55.302).
22. Remove the lower hood together with the secondary
cooling package radiators. Refer to Lower guard -
Remove (90.105).
23. Remove the engine hood. Refer to Engine hood -
Remove (90.105).
24. Disconnect and remove the fuel hose (2) from the fuel
filter.
LEIL17TLH1264AB 16
51425750_EN 08/03/2018
10.1 [10.001] / 9
Engine - Engine and crankcase
25. Disconnect and remove the transmission oil cooling
hose (1) from the 90° elbow (3) installed on the trans-
mission.
26. Disconnect and remove the transmission oil cooling
hose (2) from the fitting (4) installed on the transmis-
sion.
27. Remove the 90° elbow (3) and the fitting (4) from the
transmission.
LEIL17TLH1265AB 17
28. Drain the engine coolant and remove the main cooling
package radiators. Refer to Engine cooling system
- Remove - Main cooling package (10.400).
29. Disconnect and remove the main cooling package
hose (2) from the engine.
LEIL17TLH1256AB 18
30. Remove the clamp (1). Disconnect and remove the
aftercooler pipe (2) with the relevant air charge cooler
hose (3) from the engine.
31. Remove the clamp (4). Disconnect and remove the
aftercooler sleeve (5) from the engine.
LEIL17TLH1262AB 19
32. Remove the air-conditioning compressor. Refer to
Air-conditioning compressor - Remove (50.200).
33. Remove the Diesel Oxidation Catalyst (DOC) together
with all the relevant sensors. Refer to Diesel Oxida-
tion Catalyst (DOC) - Remove (10.500).
34. Remove the Selective Catalytic Reduction (SCR) muf-
fler and catalyst together with all the relevant sensors.
Refer to Selective Catalytic Reduction (SCR) muf-
fler and catalyst - Remove (10.500).
51425750_EN 08/03/2018
10.1 [10.001] / 10
Engine - Engine and crankcase
35. Remove the clamp (2) that secure the radiator tube
assembly (1) to the engine (frame side).
Disconnect and remove the radiator tube assembly (1)
from the engine.
LEIL17TLH1342AB 20
36. Remove the Supply Module. Refer to Diesel Exhaust
Fluid (DEF)/AdBlue®/ARLA supply module - Re-
move (55.988).
37. Remove the PDU fuse box and the air cleaner assem-
bly. Refer to Air cleaner - Remove (10.202).
38. Disconnect and remove the oil cooler bypass hose (1)
from the check valve (5).
39. Disconnect and remove the hose (3) from the T-fitting
(4).
40. Disconnect and remove the hose (2) from the T-fitting
(4).
LEIL17TLH1336AB 21
41. Remove the four bolts (1) and related washers (2) that
secure the tube (3) to the pump (4).
Remove the tube (3) from the pump (4).
LEIL17TLH1308AB 22
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Engine - Engine and crankcase
42. Remove the nut (1) and related washer (2) that secure
the ground strap (4) and the engine harness (3) to the
frame.
Disconnect the ground strap (4) and the engine har-
ness (3) from the frame.
LEIL17TLH1309AB 23
43. Remove the nut (1) and related washer (2) that secure
the battery disconnect cable (3) and the alternator ca-
ble (4) to the engine starter (5).
Disconnect the battery disconnect cable (3) and the
alternator cable (4) from the engine starter (5).
LEIL17TLH1317AB 24
44. Remove the bolt (1) and related washer (2) that secure
the P-clamp (3) to the engine block.
Remove the P-clamp (3) to separate the battery dis-
connect to PDU fuse box cable (4) from the engine
block.
LEIL17TLH1319AB 25
45. Remove the DEF/ADBLUE® heating control valve as
indicated in Coolant control valve - Remove - DEF/
AdBlue® heating control valve (10.500).
46. If equipped with engine coolant heater, disconnect the
cord (3) from the engine block.
47. Remove the bolt (1) and related washer (2) that secure
the P-clamp (4) to the engine block.
Remove the P-clamp (4) to separate the cord (3) of
the engine coolant heater from the engine block.
LEIL17TLH1320AB 26
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10.1 [10.001] / 12
Engine - Engine and crankcase
48. If equipped with cold start device, disconnect the en-
gine harness (2) from the grid heater relay (1).
49. Remove the nut (4) and related washer (5) that secure
the grid heater cable (3) to the grid heater relay (1).
Disconnect the grid heater cable (3) from the grid
heater relay (1).
LEIL17TLH1315AB 27
50. Disconnect the connector (1) and the connector
(2)from the respective connectors mounted on the
support bracket (7).
51. Cut and remove the cable tie (3) that secure the en-
gine harness to the support bracket (7).
52. Remove the nut (5) and related washer (6) that secure
the P-clamp (4) to the support bracket (7).
Remove the P-clamp (4) to separate the engine har-
ness from the support bracket (7).
LEIL17TLH1311AB 28
53. Remove the nut (1) and related washer (2) that secure
the engine harness (3) to the frame.
Disconnect the engine harness (3) from the frame.
LEIL17TLH1312AB 29
54. Remove the main hydraulic pump from the transmis-
sion. Refer to Variable displacement pump - Re-
move (35.106).
NOTE: if equipped with fixed displacement gear pump, re-
fer to Fixed displacement pump - Remove (35.104) in-
stead.
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Engine - Engine and crankcase
55. Disconnect the engine harness from the transmission
speed sensor.
LEIL17TLH1313AB 30
56. Loosen and remove the four screws (5) and the two
bearing straps (6) to disconnect the rear part of the
front drive shaft (3) from the drive shaft joint (7) of the
transfer box.
NOTICE: support the front drive shaft during removal using
a suitable tool.
LEIL14TLH1138AB 31
57. Loosen and remove the four screws (8) and the two
bearing straps (9) to disconnect the front part of the
rear drive shaft (10) from the drive shaft joint (11) of
the transfer box.
NOTICE: support the rear drive shaft during removal using
a suitable tool.
LEIL14TLH1140AB 32
58. Attach a suitable lifting device to support the engine
and transmission assembly at the points provided.
LEIL17TLH1323AB 33
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Engine - Engine and crankcase
59. Remove the two bolts (5), the related washers (6) and
the four shock absorbers (7) to disconnect the support
brackets (1) and (2) from the frame.
60. Remove the four bolts (4) and related washers (3) to
disconnect the support brackets (1) and (2) from the
transmission.
LEIL17TLH1321AB 34
61. Remove the bolt (1), the related washer (2), the two
spacers (3), the two shock absorbers (4), the spacer
(8) and the nut (9) to disconnect the support bracket
(7) from the engine block.
62. Remove the four bolts (5) and related washers (6) to
disconnect the support bracket (7) from the frame.
LEIL17TLH1322AB 35
63. Slowly raise engine from the frame. Be sure that
all the wire harness connections and the hoses have
been disconnected and are clear of the engine. Re-
move the engine from the machine.
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10.1 [10.001] / 15
Engine - Engine and crankcase
Engine - Install
WARNING
Chemical hazard!
When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.
Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect
fluids in proper containers. Obey all local and environmental regulations when disposing of chemi-
cals.
Failure to comply could result in death or serious injury.
W0371A
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
NOTE: emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations. Use of tools that gen-
erate extreme vibrations, such as impact wrenches and hammers, will result in damage to emission sensors. Avoid
using these tools during any service procedure in close proximity of emission sensors. If the use of these tools cannot
be avoided, remove the sensors using extreme caution prior to performing any service procedure.
1. Attach a suitable lifting device to support the engine and
transmission assembly at the points provided.
LEIL17TLH1323AB 1
2. Slowly move engine into position to the right of the
frame. Be sure all harness connections and hoses are
out of the way or positioned correctly for reconnecting,
before lowering engine.
3. Install the four bolts (5) and related washers (6) to con-
nect the support bracket (7) to the frame.
Tighten the four bolts (5) to 210.0 – 285.0 N·m (154.9
– 210.2 lb ft).
4. Install the bolt (1), the related washer (2), the two spac-
ers (3), the two shock absorbers (4), the spacer (8) and
the nut (9) to connect the support bracket (7) to the en-
gine block.
Tighten the bolt (1) to 210.0 – 285.0 N·m (154.9 –
210.2 lb ft).
LEIL17TLH1322AB 2
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10.1 [10.001] / 16
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Engine - Engine and crankcase
5. Install the four bolts (4) and related washers (3) to con-
nect the support brackets (1) and (2) to the transmis-
sion.
Tighten the four bolts (4) to 210.0 – 285.0 N·m (154.9
– 210.2 lb ft).
6. Install the two bolts (5), the related washers (6) and
the four shock absorbers (7) to connect the support
brackets (1) and (2) to the frame.
Tighten the two bolts (5) to 210.0 – 285.0 N·m (154.9 –
210.2 lb ft).
LEIL17TLH1321AB 3
7. Install the four screws (5) and the two bearing straps
(6) to connect the rear part of the front drive shaft (3) to
the drive shaft joint (7) of the transfer box.
Tighten the four screws (5) to 74.5 – 83.1 N·m (54.9 –
61.3 lb ft).
NOTICE: support the front drive shaft during installation
using a suitable tool.
LEIL14TLH1138AB 4
8. Install the four screws (8) and the two bearing straps
(9) to connect the front part of the rear drive shaft (10)
to the drive shaft joint (11) of the transfer box.
Tighten the four screws (8) to 74.5 – 83.1 N·m (54.9 –
61.3 lb ft).
NOTICE: support the rear drive shaft during installation us-
ing a suitable tool.
LEIL14TLH1140AB 5
9. Connect the engine harness to the transmission speed
sensor.
LEIL17TLH1313AB 6
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Engine - Engine and crankcase
10. Install the main hydraulic pump to the transmission
and reconnect the relevant hydraulic lines. Refer to
Variable displacement pump - Install (35.106).
NOTE: if equipped with fixed displacement gear pump,
refer to Fixed displacement pump - Install (35.104) in-
stead.
11. Connect the engine harness (3) to the frame using the
nut (1) and related washer (2).
LEIL17TLH1312AB 7
12. Secure the engine harness to the support bracket (7)
with the P-clamp (4).
Install the P-clamp (4) to the support bracket (7) using
the nut (5) and related washer (6).
13. Secure the engine harness to the support bracket (7)
with the cable tie (3).
14. Connect the connector (1) and the connector (2) to
the respective connectors mounted on the support
bracket (7).
LEIL17TLH1311AB 8
15. If equipped with cold start device, connect the grid
heater cable (3) to the grid heater relay (1) using the
nut (4) and related washer (5).
16. Connect the engine harness (2) to the grid heater relay
(1).
LEIL17TLH1315AB 9
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10.1 [10.001] / 18
Engine - Engine and crankcase
17. If equipped with engine coolant heater, connect the
cord (3) to the engine block.
18. Secure the cord (3) of the engine coolant heater to the
engine block with the P-clamp (4).
Install the P-clamp (4) to the engine block using the
bolt (1) and related washer (2).
Tighten the bolt (1) to 48.7 – 65.9 N·m (35.9 – 48.6 lb
ft).
LEIL17TLH1320AB 10
19. Install the DEF/ADBLUE® heating control valve as in-
dicated in Coolant control valve - Install (10.500).
20. Secure the battery disconnect to PDU fuse box cable
(4) to the engine block with the P-clamp (3).
Install the P-clamp (3) to the engine block using the
bolt (1) and related washer (2).
LEIL17TLH1319AB 11
21. Connect the battery disconnect cable (3) and the al-
ternator cable (4) to the engine starter (5) using the
nut (1) and related washer (2).
LEIL17TLH1317AB 12
22. Connect the ground strap (4) and the engine harness
(3) to the frame using the nut (1) and related washer
(2).
LEIL17TLH1309AB 13
51425750_EN 08/03/2018
10.1 [10.001] / 19

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Case ih farmlift 632 stage iv telescopic handler service repair manual

  • 1. Part number 51425750 1/2 Farmlift 632 Farmlift 635 Farmlift 735 Farmlift 742 Farmlift 935 Telescopic Handler SERVICE MANUAL Farmlift 632 Farmlift 635 Farmlift 735 Farmlift 742 Farmlift 935 Stage IV Telescopic Handler Part number 51425750 English November 2017 © 2017 CNH Industrial Italia S.p.A. All Rights Reserved. SERVICEMANUAL
  • 2. Link Product / Engine Product Market Product Engine FARMLIFT 632 STAGE IV TELEHANDLER FARMLIFT 632 Europe F4HFE413Z*B002 FARMLIFT 635 STAGE IV TELEHANDLER FARMLIFT 635 Europe F4HFE4149*B001 FARMLIFT 735 STAGE IV TELEHANDLER FARMLIFT 735 Europe F4HFE413Z*B002 FARMLIFT 742 STAGE IV TELEHANDLER FARMLIFT 742 Europe F4HFE4149*B001 FARMLIFT 935 STAGE IV TELEHANDLER FARMLIFT 935 Europe F4HFE413Z*B002 51425750_EN 08/03/2018
  • 3. Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase ............................................................. 10.1 [10.216] Fuel tanks .......................................................................... 10.2 [10.206] Fuel filters .......................................................................... 10.3 [10.202] Air cleaners and lines .............................................................. 10.4 [10.500] Selective Catalytic Reduction (SCR) exhaust treatment ........................... 10.5 [10.400] Engine cooling system ............................................................. 10.6 [10.414] Fan and drive ...................................................................... 10.7 Transmission.............................................................................. 21 [21.113] Powershift transmission ............................................................ 21.1 [21.135] Powershift transmission external controls.......................................... 21.2 [21.155] Powershift transmission internal components...................................... 21.3 [21.120] Gearbox ............................................................................ 21.4 [21.109] Transmission cooler and lines...................................................... 21.5 [21.700] Torque converter ................................................................... 21.6 Four-Wheel Drive (4WD) system .................................................. 23 [23.314] Drive shaft.......................................................................... 23.1 Front axle system ....................................................................... 25 [25.100] Powered front axle ................................................................. 25.1 [25.102] Front bevel gear set and differential ............................................... 25.2 [25.108] Final drive hub, steering knuckles, and shafts ..................................... 25.3 Rear axle system........................................................................ 27 [27.100] Powered rear axle.................................................................. 27.1 [27.106] Rear bevel gear set and differential................................................ 27.2 [27.120] Planetary and final drives .......................................................... 27.3 51425750_EN 08/03/2018
  • 4. [27.124] Final drive hub, steering knuckles, and shafts ..................................... 27.4 Brakes and controls .................................................................... 33 [33.202] Hydraulic service brakes ........................................................... 33.1 [33.110] Parking brake or parking lock ...................................................... 33.2 [33.220] Trailer brake hydraulic control...................................................... 33.3 [33.204] Front axle brake.................................................................... 33.4 Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems.................................................................. 35.1 [35.104] Fixed displacement pump.......................................................... 35.2 [35.106] Variable displacement pump ....................................................... 35.3 [35.359] Main control valve.................................................................. 35.4 [35.357] Pilot system ........................................................................ 35.5 [35.128] Auxiliary hydraulic function control ................................................. 35.6 [35.752] Hydraulic fan drive cooling system................................................. 35.7 [35.100] Main lift system..................................................................... 35.8 [35.355] Hydraulic hand control ............................................................. 35.9 [35.701] Front loader arm hydraulic system ............................................... 35.10 [35.736] Boom hydraulic system .......................................................... 35.11 [35.734] Tool quick coupler hydraulic system ............................................. 35.12 [35.740] Telescopic arm hydraulic system................................................. 35.13 Steering..................................................................................... 41 [41.101] Steering control .................................................................... 41.1 [41.200] Hydraulic control components...................................................... 41.2 [41.216] Cylinders ........................................................................... 41.3 Cab climate control ..................................................................... 50 [50.200] Air conditioning..................................................................... 50.1 Electrical systems....................................................................... 55 [55.100] Harnesses and connectors......................................................... 55.1 51425750_EN 08/03/2018
  • 5. [55.201] Engine starting system ............................................................. 55.2 [55.302] Battery.............................................................................. 55.3 [55.988] Selective Catalytic Reduction (SCR) electrical system ............................ 55.4 [55.047] Steering control system ............................................................ 55.5 [55.408] Warning indicators, alarms, and instruments ...................................... 55.6 [55.DTC] FAULT CODES.................................................................... 55.7 Telescopic single arm.................................................................. 83 [83.122] Telescopic arm ..................................................................... 83.1 Platform, cab, bodywork, and decals............................................. 90 [90.150] Cab................................................................................. 90.1 [90.105] Machine shields and guards ....................................................... 90.2 51425750_EN 08/03/2018
  • 7. 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 required by advanced technology, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature. NOTE: The following are recommendations that 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 that may cause considerable spillage. • In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them 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 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 that should not be released into the atmosphere. Your CASE IH 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. 51425750_EN 08/03/2018 3
  • 8. INTRODUCTION Safety rules 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 which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, 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 which, 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 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. 51425750_EN 08/03/2018 4
  • 9. INTRODUCTION Personal safety Carefully read this Manual before proceeding with main- tenance, repairs, refuelling or other machine operations. Repairs have to be carried out only by authorized and in- structed staff; specific precautions have to be taken when grinding, welding or when using mallets or heavy ham- mers. Not authorized persons are not allowed to repair or carry out maintenance on this machine. Do not carry out any work on the equipment without prior authorization. Ask your employer about the safety instructions in force and safety equipment. Nobody is allowed to seat on the operator’s place during machine maintenance unless he is a qualified operator helping with the maintenance work. If it is necessary to move the equipment to carry out re- pairs or maintenance, do not lift or lower the equipment from any other position than the operator’s seat. TULI12WEX2004AA 1 Never carry out any operation on the machine when the engine is running, except when specifically indicated. Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps, covers, valves, etc. All repair and maintenance operations should be carried out with the greatest care and attention. Service stairs and platforms used in a workshop or in the field should be built in compliance with the safety rules in force. Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified im- mediately. DANGER Unexpected movement! Make sure parking brake is applied. Secure machine with wheel chocks. Failure to comply will result in death or serious injury. D0013A TULI12WEX2005AA 2 Before performing any work on the machine, attach a maintenance in progress tag. This tag can be applied on the left-hand control lever, safety lever or cab door. 51425750_EN 08/03/2018 5
  • 10. SERVICE MANUAL Engine FARMLIFT 632 STAGE IV TELEHANDLER FARMLIFT 632 FARMLIFT 635 STAGE IV TELEHANDLER FARMLIFT 635 FARMLIFT 735 STAGE IV TELEHANDLER FARMLIFT 735 FARMLIFT 742 STAGE IV TELEHANDLER FARMLIFT 742 FARMLIFT 935 STAGE IV TELEHANDLER FARMLIFT 935 51425750_EN 08/03/2018 10
  • 11. Engine - Engine and crankcase Engine - Remove WARNING Hot surface possible! Wait for all components to cool before performing any operation. Failure to comply could result in death or serious injury. W0251A WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemi- cals. Failure to comply could result in death or serious injury. W0371A 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 NOTE: emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations. Use of tools that gen- erate extreme vibrations, such as impact wrenches and hammers, will result in damage to emission sensors. Avoid using these tools during any service procedure in close proximity of emission sensors. If the use of these tools cannot be avoided, remove the sensors using extreme caution prior to performing any service procedure. 1. Park the machine on a firm level ground and lower the boom arm to the floor. 2. Engage the parking brake. 3. Press the upper side of the battery isolator switch to disconnect the battery. Stop the engine. 4. Move the joystick in all directions to release the hy- draulic pressure. LEIL17TLH1186AA 1 51425750_EN 08/03/2018 10.1 [10.001] / 5
  • 12. Engine - Engine and crankcase 5. Remove the drain plug of the hydraulic tank. Drain the hydraulic oil from the hydraulic tank. Collect the escaping fluid in a proper container. LEIL17TLH1253AB 2 6. Remove the drain plug of the fuel tank. Drain the fuel tank. Collect the escaping fluid in a proper container. LEIL17TLH1255AB 3 7. If equipped, remove the drive shaft cover guard (1). LEIL17TLH1254AA 4 8. Remove the retaining bolts (2) and the nuts (3) that fix the cover (1) to the frame lower side and to the engine compartment. 9. Remove the cover (1) from the bottom side of the ma- chine. LEIL17TLH1178AB 5 51425750_EN 08/03/2018 10.1 [10.001] / 6
  • 13. Engine - Engine and crankcase 10. Locate the plate (1) under the lower hood. Remove the two screws (2) and the plate (1) from to the lower hood. LEIL13TLH0427AB 6 11. Remove the drain plug (3) from the transmission main housing and drain the transmission oil. Tighten the drain plug (3) after the transmission oil is drained off. LEIL13TLH0428AB 7 12. Remove the drain plug (4) from the transmission transfer box and drain the transmission oil. Tighten the drain plug (4) after the transmission oil is drained off. LEIL13TLH0429AB 8 13. Drain the air conditioning system (if equipped). Refer to Air conditioning - Service instruction - Evacuat- ing the refrigerant (50.200). 14. Use an acceptable hydraulic jack to raise the tires off the ground. Install acceptable jack stands under the axles to support the machine. Remove the wheels of the right-hand side of the ma- chine. LEIL17TLH1228AB 9 51425750_EN 08/03/2018 10.1 [10.001] / 7
  • 14. Engine - Engine and crankcase 15. Open the battery compartment. Remove the remote drain plug on the engine oil pan. LEIL17TLH0870AA 10 16. Attach the drain hose (1) (provided in the inner side of the opening panel of the battery compartment) to the remote drain plug. Drain the engine oil completely and discard it following the local environmental and waste regulations. NOTE: see the operator’s manual for more information. LEIL13TLH2138AB 11 17. Remove the fuel-prefilter from the lower hood frame. Refer to Pre-filter - Remove (10.206). LEIL17TLH0870AA 12 18. Remove the two cable ties (4). Remove the block (5) from the air conditioning hoses (1) and (2). LEIL17TLH1263AA 13 51425750_EN 08/03/2018 10.1 [10.001] / 8
  • 15. Engine - Engine and crankcase 19. Disconnect the air conditioning hoses (1) and (2) from the air conditioning compressor (3). LEIL17TLH1260AA 14 20. Disconnect and remove the fuel pre-filter hose (1) from the engine. LEIL17TLH1261AA 15 21. Remove the battery from the machine. Refer to Bat- tery - Remove (55.302). 22. Remove the lower hood together with the secondary cooling package radiators. Refer to Lower guard - Remove (90.105). 23. Remove the engine hood. Refer to Engine hood - Remove (90.105). 24. Disconnect and remove the fuel hose (2) from the fuel filter. LEIL17TLH1264AB 16 51425750_EN 08/03/2018 10.1 [10.001] / 9
  • 16. Engine - Engine and crankcase 25. Disconnect and remove the transmission oil cooling hose (1) from the 90° elbow (3) installed on the trans- mission. 26. Disconnect and remove the transmission oil cooling hose (2) from the fitting (4) installed on the transmis- sion. 27. Remove the 90° elbow (3) and the fitting (4) from the transmission. LEIL17TLH1265AB 17 28. Drain the engine coolant and remove the main cooling package radiators. Refer to Engine cooling system - Remove - Main cooling package (10.400). 29. Disconnect and remove the main cooling package hose (2) from the engine. LEIL17TLH1256AB 18 30. Remove the clamp (1). Disconnect and remove the aftercooler pipe (2) with the relevant air charge cooler hose (3) from the engine. 31. Remove the clamp (4). Disconnect and remove the aftercooler sleeve (5) from the engine. LEIL17TLH1262AB 19 32. Remove the air-conditioning compressor. Refer to Air-conditioning compressor - Remove (50.200). 33. Remove the Diesel Oxidation Catalyst (DOC) together with all the relevant sensors. Refer to Diesel Oxida- tion Catalyst (DOC) - Remove (10.500). 34. Remove the Selective Catalytic Reduction (SCR) muf- fler and catalyst together with all the relevant sensors. Refer to Selective Catalytic Reduction (SCR) muf- fler and catalyst - Remove (10.500). 51425750_EN 08/03/2018 10.1 [10.001] / 10
  • 17. Engine - Engine and crankcase 35. Remove the clamp (2) that secure the radiator tube assembly (1) to the engine (frame side). Disconnect and remove the radiator tube assembly (1) from the engine. LEIL17TLH1342AB 20 36. Remove the Supply Module. Refer to Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA supply module - Re- move (55.988). 37. Remove the PDU fuse box and the air cleaner assem- bly. Refer to Air cleaner - Remove (10.202). 38. Disconnect and remove the oil cooler bypass hose (1) from the check valve (5). 39. Disconnect and remove the hose (3) from the T-fitting (4). 40. Disconnect and remove the hose (2) from the T-fitting (4). LEIL17TLH1336AB 21 41. Remove the four bolts (1) and related washers (2) that secure the tube (3) to the pump (4). Remove the tube (3) from the pump (4). LEIL17TLH1308AB 22 51425750_EN 08/03/2018 10.1 [10.001] / 11
  • 18. Engine - Engine and crankcase 42. Remove the nut (1) and related washer (2) that secure the ground strap (4) and the engine harness (3) to the frame. Disconnect the ground strap (4) and the engine har- ness (3) from the frame. LEIL17TLH1309AB 23 43. Remove the nut (1) and related washer (2) that secure the battery disconnect cable (3) and the alternator ca- ble (4) to the engine starter (5). Disconnect the battery disconnect cable (3) and the alternator cable (4) from the engine starter (5). LEIL17TLH1317AB 24 44. Remove the bolt (1) and related washer (2) that secure the P-clamp (3) to the engine block. Remove the P-clamp (3) to separate the battery dis- connect to PDU fuse box cable (4) from the engine block. LEIL17TLH1319AB 25 45. Remove the DEF/ADBLUE® heating control valve as indicated in Coolant control valve - Remove - DEF/ AdBlue® heating control valve (10.500). 46. If equipped with engine coolant heater, disconnect the cord (3) from the engine block. 47. Remove the bolt (1) and related washer (2) that secure the P-clamp (4) to the engine block. Remove the P-clamp (4) to separate the cord (3) of the engine coolant heater from the engine block. LEIL17TLH1320AB 26 51425750_EN 08/03/2018 10.1 [10.001] / 12
  • 19. Engine - Engine and crankcase 48. If equipped with cold start device, disconnect the en- gine harness (2) from the grid heater relay (1). 49. Remove the nut (4) and related washer (5) that secure the grid heater cable (3) to the grid heater relay (1). Disconnect the grid heater cable (3) from the grid heater relay (1). LEIL17TLH1315AB 27 50. Disconnect the connector (1) and the connector (2)from the respective connectors mounted on the support bracket (7). 51. Cut and remove the cable tie (3) that secure the en- gine harness to the support bracket (7). 52. Remove the nut (5) and related washer (6) that secure the P-clamp (4) to the support bracket (7). Remove the P-clamp (4) to separate the engine har- ness from the support bracket (7). LEIL17TLH1311AB 28 53. Remove the nut (1) and related washer (2) that secure the engine harness (3) to the frame. Disconnect the engine harness (3) from the frame. LEIL17TLH1312AB 29 54. Remove the main hydraulic pump from the transmis- sion. Refer to Variable displacement pump - Re- move (35.106). NOTE: if equipped with fixed displacement gear pump, re- fer to Fixed displacement pump - Remove (35.104) in- stead. 51425750_EN 08/03/2018 10.1 [10.001] / 13
  • 20. Engine - Engine and crankcase 55. Disconnect the engine harness from the transmission speed sensor. LEIL17TLH1313AB 30 56. Loosen and remove the four screws (5) and the two bearing straps (6) to disconnect the rear part of the front drive shaft (3) from the drive shaft joint (7) of the transfer box. NOTICE: support the front drive shaft during removal using a suitable tool. LEIL14TLH1138AB 31 57. Loosen and remove the four screws (8) and the two bearing straps (9) to disconnect the front part of the rear drive shaft (10) from the drive shaft joint (11) of the transfer box. NOTICE: support the rear drive shaft during removal using a suitable tool. LEIL14TLH1140AB 32 58. Attach a suitable lifting device to support the engine and transmission assembly at the points provided. LEIL17TLH1323AB 33 51425750_EN 08/03/2018 10.1 [10.001] / 14
  • 21. Engine - Engine and crankcase 59. Remove the two bolts (5), the related washers (6) and the four shock absorbers (7) to disconnect the support brackets (1) and (2) from the frame. 60. Remove the four bolts (4) and related washers (3) to disconnect the support brackets (1) and (2) from the transmission. LEIL17TLH1321AB 34 61. Remove the bolt (1), the related washer (2), the two spacers (3), the two shock absorbers (4), the spacer (8) and the nut (9) to disconnect the support bracket (7) from the engine block. 62. Remove the four bolts (5) and related washers (6) to disconnect the support bracket (7) from the frame. LEIL17TLH1322AB 35 63. Slowly raise engine from the frame. Be sure that all the wire harness connections and the hoses have been disconnected and are clear of the engine. Re- move the engine from the machine. 51425750_EN 08/03/2018 10.1 [10.001] / 15
  • 22. Engine - Engine and crankcase Engine - Install WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemi- cals. Failure to comply could result in death or serious injury. W0371A 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 NOTE: emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations. Use of tools that gen- erate extreme vibrations, such as impact wrenches and hammers, will result in damage to emission sensors. Avoid using these tools during any service procedure in close proximity of emission sensors. If the use of these tools cannot be avoided, remove the sensors using extreme caution prior to performing any service procedure. 1. Attach a suitable lifting device to support the engine and transmission assembly at the points provided. LEIL17TLH1323AB 1 2. Slowly move engine into position to the right of the frame. Be sure all harness connections and hoses are out of the way or positioned correctly for reconnecting, before lowering engine. 3. Install the four bolts (5) and related washers (6) to con- nect the support bracket (7) to the frame. Tighten the four bolts (5) to 210.0 – 285.0 N·m (154.9 – 210.2 lb ft). 4. Install the bolt (1), the related washer (2), the two spac- ers (3), the two shock absorbers (4), the spacer (8) and the nut (9) to connect the support bracket (7) to the en- gine block. Tighten the bolt (1) to 210.0 – 285.0 N·m (154.9 – 210.2 lb ft). LEIL17TLH1322AB 2 51425750_EN 08/03/2018 10.1 [10.001] / 16
  • 23. 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.
  • 24. Engine - Engine and crankcase 5. Install the four bolts (4) and related washers (3) to con- nect the support brackets (1) and (2) to the transmis- sion. Tighten the four bolts (4) to 210.0 – 285.0 N·m (154.9 – 210.2 lb ft). 6. Install the two bolts (5), the related washers (6) and the four shock absorbers (7) to connect the support brackets (1) and (2) to the frame. Tighten the two bolts (5) to 210.0 – 285.0 N·m (154.9 – 210.2 lb ft). LEIL17TLH1321AB 3 7. Install the four screws (5) and the two bearing straps (6) to connect the rear part of the front drive shaft (3) to the drive shaft joint (7) of the transfer box. Tighten the four screws (5) to 74.5 – 83.1 N·m (54.9 – 61.3 lb ft). NOTICE: support the front drive shaft during installation using a suitable tool. LEIL14TLH1138AB 4 8. Install the four screws (8) and the two bearing straps (9) to connect the front part of the rear drive shaft (10) to the drive shaft joint (11) of the transfer box. Tighten the four screws (8) to 74.5 – 83.1 N·m (54.9 – 61.3 lb ft). NOTICE: support the rear drive shaft during installation us- ing a suitable tool. LEIL14TLH1140AB 5 9. Connect the engine harness to the transmission speed sensor. LEIL17TLH1313AB 6 51425750_EN 08/03/2018 10.1 [10.001] / 17
  • 25. Engine - Engine and crankcase 10. Install the main hydraulic pump to the transmission and reconnect the relevant hydraulic lines. Refer to Variable displacement pump - Install (35.106). NOTE: if equipped with fixed displacement gear pump, refer to Fixed displacement pump - Install (35.104) in- stead. 11. Connect the engine harness (3) to the frame using the nut (1) and related washer (2). LEIL17TLH1312AB 7 12. Secure the engine harness to the support bracket (7) with the P-clamp (4). Install the P-clamp (4) to the support bracket (7) using the nut (5) and related washer (6). 13. Secure the engine harness to the support bracket (7) with the cable tie (3). 14. Connect the connector (1) and the connector (2) to the respective connectors mounted on the support bracket (7). LEIL17TLH1311AB 8 15. If equipped with cold start device, connect the grid heater cable (3) to the grid heater relay (1) using the nut (4) and related washer (5). 16. Connect the engine harness (2) to the grid heater relay (1). LEIL17TLH1315AB 9 51425750_EN 08/03/2018 10.1 [10.001] / 18
  • 26. Engine - Engine and crankcase 17. If equipped with engine coolant heater, connect the cord (3) to the engine block. 18. Secure the cord (3) of the engine coolant heater to the engine block with the P-clamp (4). Install the P-clamp (4) to the engine block using the bolt (1) and related washer (2). Tighten the bolt (1) to 48.7 – 65.9 N·m (35.9 – 48.6 lb ft). LEIL17TLH1320AB 10 19. Install the DEF/ADBLUE® heating control valve as in- dicated in Coolant control valve - Install (10.500). 20. Secure the battery disconnect to PDU fuse box cable (4) to the engine block with the P-clamp (3). Install the P-clamp (3) to the engine block using the bolt (1) and related washer (2). LEIL17TLH1319AB 11 21. Connect the battery disconnect cable (3) and the al- ternator cable (4) to the engine starter (5) using the nut (1) and related washer (2). LEIL17TLH1317AB 12 22. Connect the ground strap (4) and the engine harness (3) to the frame using the nut (1) and related washer (2). LEIL17TLH1309AB 13 51425750_EN 08/03/2018 10.1 [10.001] / 19