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SERVICE MANUAL
SERVICEMANUAL
Part number 51546954
English
October 2018
© 2018 CNH Industrial Italia S.p.A. All Rights Reserved.
Part number 51546954
1/2
Farmlift 633
Farmlift 636
Farmlift 737
Farmlift 742
Farmlift 935
Telescopic Handler
Farmlift 633
Farmlift 636
Farmlift 737
Farmlift 742
Farmlift 935
Stage IV
Telescopic Handler
Link Product / Engine
Product Market Product Engine
FARMLIFT 633 STAGE IV 6
m (19.7 ft), 99 kW (133 Hp)
[FNHZP633NJKE00001 - ]
Europe F4HFE413Z*B002
FARMLIFT 636 STAGE IV 6
m (19.7 ft), 107 kW (145 Hp)
[FNHZK634NJKE00001 - ]
Europe F4HFE4149*B001
FARMLIFT 737 STAGE IV 7
m (22.9 ft), 99 kW (133 Hp)
[FNHZP737NJKE00001 - ]
Europe F4HFE413Z*B002
FARMLIFT 742 STAGE IV 7
m (22.9 ft), 107 kW (145 Hp)
[FNHZK742NJKE00001 - ]
Europe F4HFE4149*B001
FARMLIFT 935 STAGE IV 9
m (29.5 ft), 99 kW (133 Hp)
[FNHZP935NJKE00001 - ]
Europe F4HFE413Z*B002
51546954_EN 28/11/2018
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
51546954_EN 28/11/2018
[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
51546954_EN 28/11/2018
[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
[90.100] Engine hood and panels ........................................................... 90.2
[90.105] Machine shields and guards ....................................................... 90.3
51546954_EN 28/11/2018
INTRODUCTION
51546954_EN 28/11/2018
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.
51546954_EN 28/11/2018
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.
51546954_EN 28/11/2018
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.
51546954_EN 28/11/2018
5
INTRODUCTION
Part identification
LEIL17TLH1160GB 1
1. Quick coupler 7. Hydraulic fluid reservoir
2. Second telescopic arm section 8. DEF/ADBLUE® tank
3. First telescopic arm section 9. Fuel tank
4. Engine compartment 10. Cab door and hand holds
5. Battery compartment 11. Steps
6. Cab
51546954_EN 28/11/2018
53
SERVICE MANUAL
Engine
FARMLIFT 633 STAGE IV 6 m (19.7 ft), 99 kW (133 Hp) [FNHZP633NJKE00001
- ]
FARMLIFT 636 STAGE IV 6 m (19.7 ft), 107 kW (145 Hp) [FNHZK634NJKE00001
- ]
FARMLIFT 737 STAGE IV 7 m (22.9 ft), 99 kW (133 Hp) [FNHZP737NJKE00001
- ]
FARMLIFT 742 STAGE IV 7 m (22.9 ft), 107 kW (145 Hp) [FNHZK742NJKE00001
- ]
FARMLIFT 935 STAGE IV 9 m (29.5 ft), 99 kW (133 Hp) [FNHZP935NJKE00001
- ]
51546954_EN 28/11/2018
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
51546954_EN 28/11/2018
10.1 [10.001] / 7
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
51546954_EN 28/11/2018
10.1 [10.001] / 8
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.
LEIL18TLH0534AB 6
11. Locate the drain plug (3) under the lower engine hood.
LEIL18TLH0535AB 7
12. Open the engine hood and locate the breather (1).
13. Clean with care the breather (1) and the surrounding
area.
LEIL18TLH0975AB 8
14. To drain the oil remove the fill dipstick (1).
LEIL18TLH0490AA 9
51546954_EN 28/11/2018
10.1 [10.001] / 9
Engine - Engine and crankcase
15. Unscrew the drain plug (3). Drain all oil.
16. Clean with care and assemble the drain plug (3).
Tighten the drain plug (3) to 80 N·m (59 lb ft).
LEIL18TLH0535AB 10
17. Clean with care the breather (3) and the surrounding
area.
18. To drain the oil remove the inlet and level plug (1) and
outlet plug (2). Drain all oil.
19. Clean with care and assemble the plug (2).
Tighten the plug (2) to 60 N·m (44.3 lb ft).
LEIL18TLH0163AB 11
20. Drain the air conditioning system (if equipped). Refer
to Air conditioning - Service instruction - Evacuat-
ing the refrigerant (50.200).
21. 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 12
22. Open the battery compartment. Remove the remote
drain plug on the engine oil pan.
LEIL17TLH0870AA 13
51546954_EN 28/11/2018
10.1 [10.001] / 10
Engine - Engine and crankcase
23. 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 14
24. Remove the fuel-prefilter from the lower hood frame.
Refer to Pre-filter - Remove (10.206).
LEIL17TLH0870AA 15
25. Remove the two cable ties (4).
Remove the block (5) from the air conditioning hoses
(1) and (2).
LEIL17TLH1263AA 16
26. Disconnect the air conditioning hoses (1) and (2) from
the air conditioning compressor (3).
LEIL17TLH1260AA 17
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10.1 [10.001] / 11
Engine - Engine and crankcase
27. Disconnect and remove the fuel pre-filter hose (1)
from the engine.
LEIL17TLH1261AA 18
28. Remove the battery from the machine. Refer to Bat-
tery - Remove (55.302).
29. Remove the lower hood together with the secondary
cooling package radiators. Refer to Bottom engine
hood - Remove (90.100).
30. Remove the engine hood. Refer to Engine hood -
Remove (90.105).
31. Disconnect and remove the fuel hose (2) from the fuel
filter.
LEIL17TLH1264AB 19
32. Disconnect and remove the transmission oil cooling
hose (1) from the 90° elbow (3) installed on the trans-
mission.
33. Disconnect and remove the transmission oil cooling
hose (2) from the 90° elbow (4) installed on the trans-
mission.
34. Remove the 90° elbow (3) and the 90° elbow (4) from
the transmission.
LEIL18TLH0664AB 20
35. Drain the engine coolant and remove the main cooling
package radiators. Refer to Engine cooling system
- Remove - Main cooling package (10.400).
51546954_EN 28/11/2018
10.1 [10.001] / 12
Engine - Engine and crankcase
36. Disconnect and remove the main cooling package
hose (2) from the engine.
LEIL17TLH1256AB 21
37. Remove the clamp (1). Disconnect and remove the
aftercooler pipe (2) with the relevant air charge cooler
hose (3) from the engine.
38. Remove the clamp (4). Disconnect and remove the
aftercooler sleeve (5) from the engine.
LEIL17TLH1262AB 22
39. Remove the air-conditioning compressor. Refer to
Air-conditioning compressor - Remove (50.200).
40. Remove the Diesel Oxidation Catalyst (DOC) together
with all the relevant sensors. Refer to Diesel Oxida-
tion Catalyst (DOC) - Remove (10.500).
41. 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).
42. 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 23
43. Remove the Supply Module. Refer to Diesel Exhaust
Fluid (DEF)/AdBlue®/ARLA supply module - Re-
move (55.988).
44. Remove the PDU fuse box and the air cleaner assem-
bly. Refer to Air cleaner - Remove (10.202).
51546954_EN 28/11/2018
10.1 [10.001] / 13
Engine - Engine and crankcase
45. Disconnect and remove the oil cooler bypass hose (1)
from the check valve (5).
46. Disconnect and remove the hose (3) from the T-fitting
(4).
47. Disconnect and remove the hose (2) from the T-fitting
(4).
LEIL17TLH1336AB 24
48. 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 25
49. 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 26
50. 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 27
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10.1 [10.001] / 14
Engine - Engine and crankcase
51. 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 28
52. Remove the DEF/ADBLUE® heating control valve as
indicated in Coolant control valve - Remove - DEF/
AdBlue® heating control valve (10.500).
53. If equipped with engine coolant heater, disconnect the
cord (3) from the engine block.
54. 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 29
55. If equipped with cold start device, disconnect the en-
gine harness (2) from the grid heater relay (1).
56. 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 30
57. Disconnect the connector (1) and the connector
(2)from the respective connectors mounted on the
support bracket (7).
58. Cut and remove the cable tie (3) that secure the en-
gine harness to the support bracket (7).
59. 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 31
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10.1 [10.001] / 15
Engine - Engine and crankcase
60. 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 32
61. 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.
62. 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 33
63. 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 34
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10.1 [10.001] / 16
Engine - Engine and crankcase
64. Attach a suitable lifting device to support the engine
and transmission assembly at the points provided.
LEIL18TLH0712AB 35
65. Remove the bolt (1), the washers (2) and (6), the two
shock absorbers (4), and the nut (5) to disconnect the
front right-hand support bracket (3) from the frame.
66. Remove the three bolts (7) and related washers (8)
to disconnect the front right-hand support bracket (3)
from the transmission.
LEIL18TLH0709AB 36
67. Remove the bolt (1), the washer (2), and the two shock
absorbers (3) to disconnect the front left-hand support
bracket (4) from the frame.
68. Remove the three bolts (5) and related washers (6) to
disconnect the front left-hand support bracket (4) from
the transmission.
LEIL18TLH0710AB 37
69. Remove the bolt (1), the washer (2), the two spacers
(9), the two shock absorbers (3), the spacer (4), and
the nut (5) to disconnect the rear support bracket (8)
from the engine block.
70. Remove the four bolts (7) and related washers (6)
to disconnect the rear support bracket (8) from the
frame.
LEIL18TLH0711AB 38
71. 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.
51546954_EN 28/11/2018
10.1 [10.001] / 17
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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.
LEIL18TLH0712AB 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 (7) and related washers (6) to con-
nect the rear support bracket (8) to the frame.
Tighten the four bolts (7) to 210.0 – 285.0 N·m (154.9
– 210.2 lb ft).
4. Install the bolt (1), the washer (2), the two spacers (9),
the two shock absorbers (3), the spacer (4), and the nut
(5) to connect the rear support bracket (8) to the engine
block.
Tighten the bolt (1) to 210.0 – 285.0 N·m (154.9 –
210.2 lb ft).
LEIL18TLH0711AB 2
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10.1 [10.001] / 18
Engine - Engine and crankcase
5. Install the three bolts (7) and related washers (8) to
connect the front right-hand support bracket (3) to the
transmission.
Tighten the three bolts (7) to 121.0 – 164.0 N·m (89.2
– 121.0 lb ft).
6. Install the bolt (1), the washers (2) and (6), the two
shock absorbers (4), and the nut (5) to connect the front
right-hand support bracket (3) to the frame.
Tighten the bolt (1) to 210.0 – 285.0 N·m (154.9 –
210.2 lb ft).
LEIL18TLH0709AB 3
7. Install the three bolts (5) and related washers (6) to
connect the front left-hand support bracket (4) to the
transmission.
Tighten the three bolts (5) to 121.0 – 164.0 N·m (89.2
– 121.0 lb ft).
8. Install the bolt (1), the washer (2), and the two shock
absorbers (3) to connect the front left-hand support
bracket (4) to the frame.
Tighten the bolt (1) to 210.0 – 285.0 N·m (154.9 –
210.2 lb ft).
LEIL18TLH0710AB 4
9. 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 5
10. 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 6
51546954_EN 28/11/2018
10.1 [10.001] / 19
Engine - Engine and crankcase
11. 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.
12. Connect the engine harness (3) to the frame using the
nut (1) and related washer (2).
LEIL17TLH1312AB 7
13. 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).
14. Secure the engine harness to the support bracket (7)
with the cable tie (3).
15. Connect the connector (1) and the connector (2) to
the respective connectors mounted on the support
bracket (7).
LEIL17TLH1311AB 8
16. 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).
17. Connect the engine harness (2) to the grid heater relay
(1).
LEIL17TLH1315AB 9
51546954_EN 28/11/2018
10.1 [10.001] / 20
Engine - Engine and crankcase
18. If equipped with engine coolant heater, connect the
cord (3) to the engine block.
19. 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
20. Install the DEF/ADBLUE® heating control valve as in-
dicated in Coolant control valve - Install - DEF/Ad-
Blue® heating control valve (10.500).
21. 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
22. 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
23. Connect the ground strap (4) and the engine harness
(3) to the frame using the nut (1) and related washer
(2).
LEIL17TLH1309AB 13
51546954_EN 28/11/2018
10.1 [10.001] / 21

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Case ih farmlift 737 stage iv telescopic handler service repair manual

  • 1. SERVICE MANUAL SERVICEMANUAL Part number 51546954 English October 2018 © 2018 CNH Industrial Italia S.p.A. All Rights Reserved. Part number 51546954 1/2 Farmlift 633 Farmlift 636 Farmlift 737 Farmlift 742 Farmlift 935 Telescopic Handler Farmlift 633 Farmlift 636 Farmlift 737 Farmlift 742 Farmlift 935 Stage IV Telescopic Handler
  • 2. Link Product / Engine Product Market Product Engine FARMLIFT 633 STAGE IV 6 m (19.7 ft), 99 kW (133 Hp) [FNHZP633NJKE00001 - ] Europe F4HFE413Z*B002 FARMLIFT 636 STAGE IV 6 m (19.7 ft), 107 kW (145 Hp) [FNHZK634NJKE00001 - ] Europe F4HFE4149*B001 FARMLIFT 737 STAGE IV 7 m (22.9 ft), 99 kW (133 Hp) [FNHZP737NJKE00001 - ] Europe F4HFE413Z*B002 FARMLIFT 742 STAGE IV 7 m (22.9 ft), 107 kW (145 Hp) [FNHZK742NJKE00001 - ] Europe F4HFE4149*B001 FARMLIFT 935 STAGE IV 9 m (29.5 ft), 99 kW (133 Hp) [FNHZP935NJKE00001 - ] Europe F4HFE413Z*B002 51546954_EN 28/11/2018
  • 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 51546954_EN 28/11/2018
  • 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 51546954_EN 28/11/2018
  • 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 [90.100] Engine hood and panels ........................................................... 90.2 [90.105] Machine shields and guards ....................................................... 90.3 51546954_EN 28/11/2018
  • 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. 51546954_EN 28/11/2018 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. 51546954_EN 28/11/2018 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. 51546954_EN 28/11/2018 5
  • 10. INTRODUCTION Part identification LEIL17TLH1160GB 1 1. Quick coupler 7. Hydraulic fluid reservoir 2. Second telescopic arm section 8. DEF/ADBLUE® tank 3. First telescopic arm section 9. Fuel tank 4. Engine compartment 10. Cab door and hand holds 5. Battery compartment 11. Steps 6. Cab 51546954_EN 28/11/2018 53
  • 11. SERVICE MANUAL Engine FARMLIFT 633 STAGE IV 6 m (19.7 ft), 99 kW (133 Hp) [FNHZP633NJKE00001 - ] FARMLIFT 636 STAGE IV 6 m (19.7 ft), 107 kW (145 Hp) [FNHZK634NJKE00001 - ] FARMLIFT 737 STAGE IV 7 m (22.9 ft), 99 kW (133 Hp) [FNHZP737NJKE00001 - ] FARMLIFT 742 STAGE IV 7 m (22.9 ft), 107 kW (145 Hp) [FNHZK742NJKE00001 - ] FARMLIFT 935 STAGE IV 9 m (29.5 ft), 99 kW (133 Hp) [FNHZP935NJKE00001 - ] 51546954_EN 28/11/2018 10
  • 12. 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 51546954_EN 28/11/2018 10.1 [10.001] / 7
  • 13. 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 51546954_EN 28/11/2018 10.1 [10.001] / 8
  • 14. 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. LEIL18TLH0534AB 6 11. Locate the drain plug (3) under the lower engine hood. LEIL18TLH0535AB 7 12. Open the engine hood and locate the breather (1). 13. Clean with care the breather (1) and the surrounding area. LEIL18TLH0975AB 8 14. To drain the oil remove the fill dipstick (1). LEIL18TLH0490AA 9 51546954_EN 28/11/2018 10.1 [10.001] / 9
  • 15. Engine - Engine and crankcase 15. Unscrew the drain plug (3). Drain all oil. 16. Clean with care and assemble the drain plug (3). Tighten the drain plug (3) to 80 N·m (59 lb ft). LEIL18TLH0535AB 10 17. Clean with care the breather (3) and the surrounding area. 18. To drain the oil remove the inlet and level plug (1) and outlet plug (2). Drain all oil. 19. Clean with care and assemble the plug (2). Tighten the plug (2) to 60 N·m (44.3 lb ft). LEIL18TLH0163AB 11 20. Drain the air conditioning system (if equipped). Refer to Air conditioning - Service instruction - Evacuat- ing the refrigerant (50.200). 21. 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 12 22. Open the battery compartment. Remove the remote drain plug on the engine oil pan. LEIL17TLH0870AA 13 51546954_EN 28/11/2018 10.1 [10.001] / 10
  • 16. Engine - Engine and crankcase 23. 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 14 24. Remove the fuel-prefilter from the lower hood frame. Refer to Pre-filter - Remove (10.206). LEIL17TLH0870AA 15 25. Remove the two cable ties (4). Remove the block (5) from the air conditioning hoses (1) and (2). LEIL17TLH1263AA 16 26. Disconnect the air conditioning hoses (1) and (2) from the air conditioning compressor (3). LEIL17TLH1260AA 17 51546954_EN 28/11/2018 10.1 [10.001] / 11
  • 17. Engine - Engine and crankcase 27. Disconnect and remove the fuel pre-filter hose (1) from the engine. LEIL17TLH1261AA 18 28. Remove the battery from the machine. Refer to Bat- tery - Remove (55.302). 29. Remove the lower hood together with the secondary cooling package radiators. Refer to Bottom engine hood - Remove (90.100). 30. Remove the engine hood. Refer to Engine hood - Remove (90.105). 31. Disconnect and remove the fuel hose (2) from the fuel filter. LEIL17TLH1264AB 19 32. Disconnect and remove the transmission oil cooling hose (1) from the 90° elbow (3) installed on the trans- mission. 33. Disconnect and remove the transmission oil cooling hose (2) from the 90° elbow (4) installed on the trans- mission. 34. Remove the 90° elbow (3) and the 90° elbow (4) from the transmission. LEIL18TLH0664AB 20 35. Drain the engine coolant and remove the main cooling package radiators. Refer to Engine cooling system - Remove - Main cooling package (10.400). 51546954_EN 28/11/2018 10.1 [10.001] / 12
  • 18. Engine - Engine and crankcase 36. Disconnect and remove the main cooling package hose (2) from the engine. LEIL17TLH1256AB 21 37. Remove the clamp (1). Disconnect and remove the aftercooler pipe (2) with the relevant air charge cooler hose (3) from the engine. 38. Remove the clamp (4). Disconnect and remove the aftercooler sleeve (5) from the engine. LEIL17TLH1262AB 22 39. Remove the air-conditioning compressor. Refer to Air-conditioning compressor - Remove (50.200). 40. Remove the Diesel Oxidation Catalyst (DOC) together with all the relevant sensors. Refer to Diesel Oxida- tion Catalyst (DOC) - Remove (10.500). 41. 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). 42. 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 23 43. Remove the Supply Module. Refer to Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA supply module - Re- move (55.988). 44. Remove the PDU fuse box and the air cleaner assem- bly. Refer to Air cleaner - Remove (10.202). 51546954_EN 28/11/2018 10.1 [10.001] / 13
  • 19. Engine - Engine and crankcase 45. Disconnect and remove the oil cooler bypass hose (1) from the check valve (5). 46. Disconnect and remove the hose (3) from the T-fitting (4). 47. Disconnect and remove the hose (2) from the T-fitting (4). LEIL17TLH1336AB 24 48. 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 25 49. 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 26 50. 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 27 51546954_EN 28/11/2018 10.1 [10.001] / 14
  • 20. Engine - Engine and crankcase 51. 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 28 52. Remove the DEF/ADBLUE® heating control valve as indicated in Coolant control valve - Remove - DEF/ AdBlue® heating control valve (10.500). 53. If equipped with engine coolant heater, disconnect the cord (3) from the engine block. 54. 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 29 55. If equipped with cold start device, disconnect the en- gine harness (2) from the grid heater relay (1). 56. 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 30 57. Disconnect the connector (1) and the connector (2)from the respective connectors mounted on the support bracket (7). 58. Cut and remove the cable tie (3) that secure the en- gine harness to the support bracket (7). 59. 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 31 51546954_EN 28/11/2018 10.1 [10.001] / 15
  • 21. Engine - Engine and crankcase 60. 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 32 61. 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. 62. 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 33 63. 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 34 51546954_EN 28/11/2018 10.1 [10.001] / 16
  • 22. Engine - Engine and crankcase 64. Attach a suitable lifting device to support the engine and transmission assembly at the points provided. LEIL18TLH0712AB 35 65. Remove the bolt (1), the washers (2) and (6), the two shock absorbers (4), and the nut (5) to disconnect the front right-hand support bracket (3) from the frame. 66. Remove the three bolts (7) and related washers (8) to disconnect the front right-hand support bracket (3) from the transmission. LEIL18TLH0709AB 36 67. Remove the bolt (1), the washer (2), and the two shock absorbers (3) to disconnect the front left-hand support bracket (4) from the frame. 68. Remove the three bolts (5) and related washers (6) to disconnect the front left-hand support bracket (4) from the transmission. LEIL18TLH0710AB 37 69. Remove the bolt (1), the washer (2), the two spacers (9), the two shock absorbers (3), the spacer (4), and the nut (5) to disconnect the rear support bracket (8) from the engine block. 70. Remove the four bolts (7) and related washers (6) to disconnect the rear support bracket (8) from the frame. LEIL18TLH0711AB 38 71. 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. 51546954_EN 28/11/2018 10.1 [10.001] / 17
  • 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 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. LEIL18TLH0712AB 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 (7) and related washers (6) to con- nect the rear support bracket (8) to the frame. Tighten the four bolts (7) to 210.0 – 285.0 N·m (154.9 – 210.2 lb ft). 4. Install the bolt (1), the washer (2), the two spacers (9), the two shock absorbers (3), the spacer (4), and the nut (5) to connect the rear support bracket (8) to the engine block. Tighten the bolt (1) to 210.0 – 285.0 N·m (154.9 – 210.2 lb ft). LEIL18TLH0711AB 2 51546954_EN 28/11/2018 10.1 [10.001] / 18
  • 25. Engine - Engine and crankcase 5. Install the three bolts (7) and related washers (8) to connect the front right-hand support bracket (3) to the transmission. Tighten the three bolts (7) to 121.0 – 164.0 N·m (89.2 – 121.0 lb ft). 6. Install the bolt (1), the washers (2) and (6), the two shock absorbers (4), and the nut (5) to connect the front right-hand support bracket (3) to the frame. Tighten the bolt (1) to 210.0 – 285.0 N·m (154.9 – 210.2 lb ft). LEIL18TLH0709AB 3 7. Install the three bolts (5) and related washers (6) to connect the front left-hand support bracket (4) to the transmission. Tighten the three bolts (5) to 121.0 – 164.0 N·m (89.2 – 121.0 lb ft). 8. Install the bolt (1), the washer (2), and the two shock absorbers (3) to connect the front left-hand support bracket (4) to the frame. Tighten the bolt (1) to 210.0 – 285.0 N·m (154.9 – 210.2 lb ft). LEIL18TLH0710AB 4 9. 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 5 10. 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 6 51546954_EN 28/11/2018 10.1 [10.001] / 19
  • 26. Engine - Engine and crankcase 11. 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. 12. Connect the engine harness (3) to the frame using the nut (1) and related washer (2). LEIL17TLH1312AB 7 13. 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). 14. Secure the engine harness to the support bracket (7) with the cable tie (3). 15. Connect the connector (1) and the connector (2) to the respective connectors mounted on the support bracket (7). LEIL17TLH1311AB 8 16. 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). 17. Connect the engine harness (2) to the grid heater relay (1). LEIL17TLH1315AB 9 51546954_EN 28/11/2018 10.1 [10.001] / 20
  • 27. Engine - Engine and crankcase 18. If equipped with engine coolant heater, connect the cord (3) to the engine block. 19. 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 20. Install the DEF/ADBLUE® heating control valve as in- dicated in Coolant control valve - Install - DEF/Ad- Blue® heating control valve (10.500). 21. 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 22. 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 23. Connect the ground strap (4) and the engine harness (3) to the frame using the nut (1) and related washer (2). LEIL17TLH1309AB 13 51546954_EN 28/11/2018 10.1 [10.001] / 21