service repair manual

1. Part number 48192604
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 IIIB
Telescopic Handler
Part number 48192604
English
August 2017
© 2017 CNH Industrial Italia S.p.A. All Rights Reserved.
SERVICEMANUAL

2. Link Product / Engine
Product Market Product Engine
Farmlift 632 telehandler 6m 120
HP
Europe F4HFE413C*A
Farmlift 635 Telehandler 6m 140
hp
Europe F4HFE413J*A
Farmlift 735 Telehandler 7m 120
HP - Dump Angle Increased
[FNHZF735NGKC35101 - ]
Europe F4HFE413C*A
Farmlift 742 Telehandler 7m 140
HP
Europe F4HFE413J*A
Farmlift 935 Telehandler 10m 120
HP
Europe F4HFE413C*A
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3. Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase ............................................................. 10.1
[10.218] Fuel injection system............................................................... 10.2
[10.202] Air cleaners and lines .............................................................. 10.3
[10.254] Intake and exhaust manifolds and muffler ......................................... 10.4
[10.400] Engine cooling system ............................................................. 10.5
[10.304] Engine lubrication system.......................................................... 10.6
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
[21.700] Torque converter ................................................................... 21.5
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
Brakes and controls .................................................................... 33
[33.202] Hydraulic service brakes ........................................................... 33.1
[33.110] Parking brake or parking lock ...................................................... 33.2
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4. [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
[35.701] Front loader arm hydraulic system ................................................. 35.9
[35.736] Boom hydraulic system .......................................................... 35.10
[35.734] Tool quick coupler hydraulic system ............................................. 35.11
[35.740] Telescopic arm hydraulic system................................................. 35.12
Steering..................................................................................... 41
[41.101] Steering control .................................................................... 41.1
[41.200] Hydraulic control components...................................................... 41.2
[41.216] Cylinders ........................................................................... 41.3
Cab climate control ..................................................................... 50
[50.104] Ventilation .......................................................................... 50.1
[50.200] Air conditioning..................................................................... 50.2
Electrical systems....................................................................... 55
[55.100] Harnesses and connectors......................................................... 55.1
[55.201] Engine starting system ............................................................. 55.2
[55.301] Alternator........................................................................... 55.3
[55.011] Fuel tank system ................................................................... 55.4
[55.512] Cab controls........................................................................ 55.5
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5. [55.404] External lighting .................................................................... 55.6
[55.514] Cab lighting ........................................................................ 55.7
[55.408] Warning indicators, alarms, and instruments ...................................... 55.8
[55.DTC] FAULT CODES.................................................................... 55.9
Telescopic single arm.................................................................. 83
[83.122] Telescopic arm ..................................................................... 83.1
Platform, cab, bodywork, and decals............................................. 90
[90.150] Cab................................................................................. 90.1
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6. INTRODUCTION
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7. 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.
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4

8. 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.
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5

9. INTRODUCTION
Lifting Dimensions
LEIL13TLH1387HA 4
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10. SERVICE MANUAL
Engine
Farmlift 632
Farmlift 635
Farmlift 735
Farmlift 742
Farmlift 935
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11. Engine - Engine and crankcase
Engine - General specification
NEF (New Engine Family), 4 cylinder, emission compliant to Tier4 specification
Direct Injection – High Pressure
Common Rail System
Turbocharged
Full flow engine oil filter
Pre-fuel filter with water separator
Aspirated air cleaner – Replaceable dry type with radial seal
Muffler – Selective Catalyst Reducer (SCR)
Fuel Tank – capacity 140 L
DEF/ADBLUE® Tank- capacity 32 L
Radiator with expansion bottle
Antifreeze: - 37 °C
Characteristics
Throttle, foot:
- Self-adjusting belt tensioner
- Balanced Engine
Bore and stroke 104 mm (4.09 in) x 132 mm (5.20 in)
Displacement 4.5 L (274 in³)
Compression Ratio 17:1
Number of cylinders (firing order) 4 (1-3-4-2)
Injection pressure pump type Bosch Cp 3.3
Revolution (from Flywheel side) Counterclockwise
Power
FARMLIFT 632 – FARMLIFT 735–
FARMLIFT 935
FARMLIFT 635 – FARMLIFT 742
Rated Power 81 kW at 2200 RPM 96 kW at 2200 RPM
Peak Power 89 kW at 1800 RPM 105 kW at 1900 RPM
Peak Torque 498 N·m at 1500 RPM 590 N·m at 1500 RPM
Engine speeds
Rated speed – full load 2200 RPM
Low Idle speed at no load 1025 – 1075 RPM
High Idle speed at no load (Engine not installed) 2280 – 2380 RPM
Stall
FARMLIFT 632 – FARMLIFT 735–
FARMLIFT 935
FARMLIFT 635 – FARMLIFT 742
Torque Converter Stall 1960 – 2020 RPM 2110 – 2170 RPM
Hydraulic Stall 2200 – 2300 RPM 2250 – 2350 RPM
Combined Stall 1570 – 1630 RPM 1820 – 1880 RPM
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12. Engine - Engine and crankcase
LEIL14TLH1060H 1
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13. Engine - Engine and crankcase
Engine - Remove
Place the machine on a flat surface.
Turn the Steering Mode selector (1) to 4WS (Four
Wheel Steering) mode (left side positions).
Steer the wheels fully to the left side.
Turn off the engine, and disconnect the batteries from
the button (2).
Apply the label “DO NOT START" to the starting key.
LEIL13TLH0987AB 1
Loosen and remove the bolts and straps that fasten the
rear and front drive shaft transmission.
Disconnect the drive shaft from transmission.
LEIL13TLH0949AB 2
Drain the hydraulic oil (see Operator’s manual).
Drain the oil transmission (see Operator’s manual).
Raise the engine hood (1). Attach a suitable lifting de-
vice and support the engine hood.
Release the top of the engine hood (1) by the lift cylin-
ders (2).
Loosen and remove the hinges hood mounting bolts (3)
and (4). Remove the engine hood (1) from the machine.
Open the battery compartment and disconnect the bat-
tery from the machine.
LEIL13TLH0950AB 3
Disconnect the ground cable from the frame.
LEIL13TLH0951AB 4
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14. Engine - Engine and crankcase
Open the secondary cooling package cover (side trans-
mission) and remove the two wiring harness (1) and (2)
from the fan cooling.
LEIL13TLH0952AB 5
Loosen the knobs and access to the radiators.
LEIL13TLH0953AA 6
Drain the air conditioning system (optional) and discon-
nect the condenser hoses (1) and (2) from the con-
denser then remove them.
LEIL13TLH0954AB 7
Disconnect the hoses (1) and (2) from the transmission
oil cooler (radiator side).
LEIL13TLH0955AB 8
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15. Engine - Engine and crankcase
Disconnect two hoses (1) and (2) from the fuel cooling
radiator.
LEIL13TLH0956AB 9
Loosen the screws (1) and remove the DEF/ADBLUE®
injectors cover (2) located behind the rear fender.
Loosen the securing bolts (3) and (4) and washers from
machine.
Remove the engine cover and pulling to the side.
Place a suitable container below radiator drain.
LEIL13TLH0958BB 10
Remove drain cap (1) and drain the engine coolant. To
facilitate the discharge remove the introduction radiator
cap (2) of the liquid radiator. Install the drain plug and
radiator cap after coolant has drained.
LEIL13TLH0959AB 11
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16. Engine - Engine and crankcase
Disconnect the wiring harness from fuel filter sensor.
LEIL13TLH0990AB 12
Disconnect the fuel line hose from fuel filter.
Loosen the screw (2) and remove the fuel filter (1) with
support bracket from the frame.
Loosen the screw (3) and remove the hydraulic oil filter
(4) from the engine.
LEIL13TLH0960AB 13
Tag and remove the grid heater cable.
LEIL13TLH0989AB 14
Tag and disconnect the connectors of the engine wiring
harness as listed below:
(X-936)
(X-934)
(X-935)
Tag and disconnect the connectors of the transmission
wiring harness listed below:
(X-939)
(X-931)
(X-938)
(X-933)
(X-937)
(X-932)
LEIL13TLH0961BB 15
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17. Engine - Engine and crankcase
Tag and disconnect the wiring harness connectors
(X-239) and (X-231) from the starter.
LEIL13TLH0986AB 16
Tag and disconnect the wiring harness connector
(X-237) from the alternator.
LEIL13TLH0962AB 17
Open the fuse cover (1).
LEIL13TLH0963AB 18
Tag and disconnect the connector of the electrical wiring
harness as listed below:
(X-986)
(X-923)
(X-926)
(X-892)
(X-893)
(X-929)
LEIL13TLH0964AB 19
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18. Engine - Engine and crankcase
Tag and disconnect the wiring harness connectors
listed below from the power Junction box:
(X-105)
(X-106)
(X-107)
(X-127)
(X-129)
(X-128)
LEIL13TLH0966AB 20
Disconnect the connectors (X-172C), (X-172B), and
(X-918) of the DeNOx wiring harness connectors
(X-172C), (X-172B), and (X-918).
Disconnect the connectors (X-908), (X-925), (X-223),
(X-224), (X-245), and (X-424) of the engine wiring har-
ness.
LEIL13TLH0967AB 21
LEIL13TLH0968AB 22
LEIL13TLH0969AB 23
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19. Engine - Engine and crankcase
Open the lever and disconnect wiring harness connec-
tor from DeNOx supply module.
LEIL13TLH0988AB 24
Disconnect the supply and return line hoses (1) from
the bottom of the DeNOx supply module.
LEIL13TLH0991AB 25
Loosen and remove the four bolts (1) from frame and
remove the support bracket of the DeNOx supply mod-
ule (2) from frame.
LEIL13TLH0971AB 26
Loosen the clamps (2) and remove the exhaust mani-
fold (1) of the turbocharger.
Disconnect and remove the expansion tank hoses from
tank (3).
LEIL13TLH0972AB 27
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20. Engine - Engine and crankcase
Tag and disconnect the wiring harness (temperature /
humidity) sensor (4) from air filter.
Loosen the clamps (1) and remove the intake pipe (2)
from air filter housing (3) and turbocharger.
Unscrew the two securing bolts from the support
bracket filter and remove the air filter.
LEIL13TLH0973AB 28
Loosen the clamps (2) and remove the air cooler outlet
hose (1).
Remove the air cooler inlet hose (3) and (4) from hy-
draulic oil cooler.
Plug the hoses to avoid the access of debris.
LEIL13TLH0974AB 29
Disconnect the water inlet (5).
Loosen the clamp and disconnect the air inlet and outlet
hoses (5) and (6).
Plug the hoses to avoid the access of debris.
LEIL13TLH0975AB 30
For models with variable displacement pump:
Loosen and remove the four bolts (2) and washers (15)
connecting the suction hose (3) to the variable displace-
ment pump (1). Disconnect the suction hose (3).
Tag and disconnect the case drain hose (4) and the load
sensing hose (5) from the variable displacement pump
(1).
LEIL14TLH1061AB 31
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22. Engine - Engine and crankcase
Loosen and remove the four bolts (6) connecting the
pressure hose (8) to the two semi–flanges (7).
Plug all the hoses to avoid the access of debris.
NOTE: remove and discard the O-rings from the hydraulic
fittings.
LEIL14TLH0253AB 32
For models with fixed displacement pump:
Loosen and remove the four bolts (2) connecting the
suction hose (3) to the fixed displacement pump.
Loosen and remove the pressure hose (6) to the fixed
displacement pump.
Position hoses away from transmission.
Plug the hoses to avoid the access of debris.
NOTE: remove and discard the O-rings from the hydraulic
fittings.
LEIL14TLH0996AB 33
The engine is secured to the machine frame by way of
three mountings:
• one lateral, outer (1);
• one lateral, inner (4);
• One rear (3).
Remove the screws, the washers and the nuts form the
shock absorber.
LEIL13TLH0977AB 34
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23. Engine - Engine and crankcase
Attach a suitable host equipment to support the engine.
NOTICE: handle all parts with care. Never place hands or
fingers between one part and another. Always wear type
- approved safety gear and clothing: glasses / goggles,
gloves and industrial footwear. Using lifting equipment ap-
propriate for the load to be lifted, sling the engine at the
points provided and rest it on a suitable stand.
NOTICE: lift and handle all parts with heavy lifting equip-
ment of suitable rated capacity. Make sure that the parts
are secured by appropriate hooks and slings. Use the eye-
bolts provided for the purpose. Do not stand under sus-
pended loads. Beware of persons standing near the load
to be lifted. LEIL13TLH0978AA 35
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24. Engine - Engine and crankcase
Engine - Install
Install the engine in the reverse order followed during
removal.
Tighten the nuts and the bolts to 210 – 285 N·m (154.9
– 210.2 lb ft)
Engine support items:
1. Bracket
2. Bracket
3. Support
4. Shock absorber
5. Washer
6. Bolt M16X130
7. Spacer
8. Spacer
9. Washer
10. Bolt M16X40
11. Bolt M16X70
12. Hexagonal nut
13. Washer
14. Bolt M16X160
15. Shock absorber
LEIL14TLH0997AB 1
LEIL14TLH0998AB 2
LEIL14THL0962B 3
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