SERVICE MANUAL T4.80F T4.90F T4.100F T4.110F T4.80LP T4.90LP T4.100LP T4.110LP Tractor PIN ZHLH00094 and above Part number 51523358 English August 2018 © 2018 CNH Industrial Italia S.p.A. All Rights Reserved.
T4.100F W ith cab [ZHLH01567T4.100F W ithout cab [ZHLH01600T4.100LP W ith cab [ZHLH04188T4.100LP W ithout cab [ZHLH00502T4.1 10F W ith cab [ZHLH00094T4.1 10F W ithout cab [ZHLH01580T4.1 10LP W ith cab [ZHLH01989T4.1 10LP W ithout cab [ZHLH02201T4.80F W ith cab [ZHLH01907T4.80F W ithout cab [ZHLH01219T4.80LP W ith cab [ZHLH04222T4.80LP W ithout cab [ZHLH03674T4.90F W ith cab [ZHLH01868T4.90F W ithout cab [ZHLH01862T4.90LP W ith cab [ZHLH03821T4.90LP W ithout cab [ZHLH04739 - ] 51523358 21/08/2018
SER VICE MANUAL
Link Product / Engine
Product Market Product Engine With cab [ZHLH01567 - ] Europe F5DFL413K*C001 With cab [ZHLH01567 - ] Asia Pacific F5DFL413K*C001 With cab [ZHLH01567 - ] Middle East Africa F5DFL413K*C001 Without cab [ZHLH01600 - ] Asia Pacific F5DFL413K*C001 T4.100F Without cab [ZHLH01600 - ] Europe F5DFL413K*C001 Without cab [ZHLH01600 - ] Middle East Africa F5DFL413K*C001 10F With cab [ZHLH00094 - ] Middle East Africa F5DFL413J*C002 10F With cab [ZHLH00094 - ] Asia Pacific F5DFL413J*C002 10F With cab [ZHLH00094 - ] Europe F5DFL413J*C002 10F Without cab [ZHLH01580 - ] Middle East Africa F5DFL413J*C002 T4.1 10F Without cab [ZHLH01580 - ] Asia Pacific F5DFL413J*C002 10F Without cab [ZHLH01580 - ] Europe F5DFL413J*C002 With cab [ZHLH01907 - ] Asia Pacific F5DFL413B*H001 With cab [ZHLH01907 - ] Europe F5DFL413B*H001 With cab [ZHLH01907 - ] Middle East Africa F5DFL413B*H001 T4.80F Without cab [ZHLH01219 - ] Middle East Africa F5DFL413B*H001 T4.80F Without cab [ZHLH01219 - ] Europe F5DFL413B*H001 Without cab [ZHLH01219 - ] Asia Pacific F5DFL413B*H001 T4.90F With cab [ZHLH01868 - ] Asia Pacific F5DFL413L*C001 T4.90F With cab [ZHLH01868 - ] Europe F5DFL413L*C001 T4.90F With cab [ZHLH01868 - ] Middle East Africa F5DFL413L*C001 T4.90F Without cab [ZHLH01862 - ] Middle East Africa F5DFL413L*C001 Without cab [ZHLH01862 - ] Europe F5DFL413L*C001 Without cab [ZHLH01862 - ] Asia Pacific F5DFL413L*C001 T4.100LP With cab [ZHLH04188 - ] Middle East Africa F5DFL413K*C001 T4.100LP With cab [ZHLH04188 - ] Asia Pacific F5DFL413K*C001 T4.100LP With cab [ZHLH04188 - ] Europe F5DFL413K*C001 T4.100LP Without cab [ZHLH00502 - ] Europe F5DFL413K*C001 Without cab [ZHLH00502 - ] Asia Pacific F5DFL413K*C001 T4.100LP Without cab [ZHLH00502 - ] Middle East Africa F5DFL413K*C001 T4.1 10LP With cab [ZHLH01989 - ] Europe F5DFL413J*C002 T4.1 10LP With cab [ZHLH01989 - ] Asia Pacific F5DFL413J*C002 T4.1 10LP With cab [ZHLH01989 - ] Middle East Africa F5DFL413J*C002 51523358 21/08/2018
Product Market Product Engine T4.1 10LP Without cab [ZHLH02201 - ] Europe F5DFL413J*C002 10LP Without cab [ZHLH02201 - ] Asia Pacific F5DFL413J*C002 10LP Without cab [ZHLH02201 - ] Middle East Africa F5DFL413J*C002 T4.80LP With cab [ZHLH04222 - ] Asia Pacific F5DFL413B*H001 T4.80LP With cab [ZHLH04222 - ] Europe F5DFL413B*H001 T4.80LP With cab [ZHLH04222 - ] Middle East Africa F5DFL413B*H001 T4.80LP Without cab [ZHLH03674 - ] Middle East Africa F5DFL413B*H001 Without cab [ZHLH03674 - ] Europe F5DFL413B*H001 Without cab [ZHLH03674 - ] Asia Pacific F5DFL413B*H001 T4.90LP With cab [ZHLH03821 - ] Middle East Africa F5DFL413L*C001 T4.90LP With cab [ZHLH03821 - ] Asia Pacific F5DFL413L*C001 T4.90LP With cab [ZHLH03821 - ] Europe F5DFL413L*C001 T4.90LP Without cab [ZHLH04739 - ] Middle East Africa F5DFL413L*C001 Without cab [ZHLH04739 - ] Asia Pacific F5DFL413L*C001 T4.90LP Without cab [ZHLH04739 - ] Europe F5DFL413L*C001 51523358 21/08/2018
Contents INTRODUCTION Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.1 14] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 Air cleaners and lines Intake and exhaust manifolds and muf fler Exhaust Gas Recirculation (EGR) exhaust treatment Engine cooling system Fan and drive Aftercooler Engine lubrication system 1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch mechanical release control Clutch hydraulic release control 10] Clutch and components T ransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [21.1 14] Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.130] Mechanical transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.100] Mechanical transmission hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 [21.140] Mechanical transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 12] Power shuttle transmission Power shuttle transmission external controls Power shuttle transmission hydraulic components Power shuttle transmission internal components Creeper 51523358 21/08/2018
T ransmission cooler and lines
18] T ransmission/Rear drive Dif ferential Drive (4WD) system
control Drive (4WD) gearbox
Drive shaft
Front axle system
Powered front axle
Front bevel gear set and dif ferential
Final drive steering and shafts
Final drives front axle
Rear axle system
Powered rear axle
Rear bevel gear set and dif ferential
Planetary and final drives
Spur gear and final drives
Rear mechanical control
Front Power T f (PT control
Front Power T f (PT Brakes and controls
service brakes 10]
brake parking lock
Reverser unit 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
[23.314]
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [27.100]
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 [27.106]
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.4 Power T ake-Of f
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
[27.120]
[27.126]
(PT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic
51523358 21/08/2018
Parking
T railer brake hydraulic control Hydraulic systems Hydraulic systems [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 Remote control valves Main lift system 14] hitch control valve hitch hydraulic adjustment Front hitch controls and lines Front hitch cylinders and lines Hitches, drawbars, and implement couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [37.120] Rear three-point hitch linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.1 [37.162] Front hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.2 Front hitch linkage 10] Rear hitch Frames and ballasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering control Hydraulic control components Cylinders Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front wheels [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2 Cab climate control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heating V entilation Air conditioning 51523358 21/08/2018
Cab pressurizing system Electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [55.100] Harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.525] Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.015] Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.302] Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.01 Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.014] Engine intake and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 Exhaust Gas Recirculation (EGR) electrical system Electronic modules 1 Cab transmission controls [55.024] T ransmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13 [55.021] T ransmission pressure sensors and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14 [55.541] Cab Drive (FWD) controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15 Drive (4WD) control system Cab axle controls Cab Power T f (PT controls Rear Power T f (PT control system [55.049] Front Power T f (PT control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.20 [55.031] Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.21 [55.032] T railer brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.22 [55.512] Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.23 [55.035] Remote control valve electric control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.24 [55.051] Cab Heating, V entilation, and Air-Conditioning (HV AC) controls . . . . . . . . . . . . . . . . . 55.25 [55.050] Heating, V entilation, and Air-Conditioning (HV AC) control system . . . . . . . . . . . . . . . 55.26 51523358 21/08/2018
Cab hitch controls
Rear hitch electronic control system
Wiper and washer system
External lighting
External lighting switches and relays
Cab lighting
W arning and instruments
F AUL T CODES
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories
Platform, cab, bodywork, and decals
Cab Cab interior
Cab interior trim and panels
Cab doors and hatches
10] Operator platform less cab
18] Protections and footboards 14] Operator protections operator seat
operator seat
Engine hood and panels
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51523358 21/08/2018
INTRODUCTION 51523358 21/08/2018 1
Contents INTRODUCTION Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Note the Owner W ARNINGS FOR AIR CONDITIONING SYSTEM REP AIR OPERA TIONS (*) 4 Safety rules (*) 5 Safety rules SAFETY REGULA TIONS 6 Personal safety CAB AIR CONDITIONING SYSTEM (*) 9 Safety rules - Ecology and the environment Engine cooling system - Basic instructions (*) 1 1 Basic instructions - Shop and assembly T orque - Standard torque data for hydraulic connections Capacities Consumables Plates - Product identification (*) Product identification (*) See content for specific models 51523358 21/08/2018 2
Foreword - Important notice regarding equipment servicing
All repair and maintenance work listed this manual must carried out only qualified dealership strictly complying with the instructions and whenever the special
Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall responsible for any subsequent
The manufacturer and all the organizations its distribution chain, including - without limitationnational, regional, local reject any responsibility for damages caused parts and / components not approved the facturer , including those used for the servicing repair the product manufactured marketed the manufacturer any case, warranty given attributed the product manufactured marketed the manufacturer case damages caused parts and / components not approved the manufacturer
The manufacturer reserves the right make improvements design and changes specifications any time without notice and without incurring any obligation install them units previously and illustrative material herein are accurate known time publication but are subject change without notice.
case refer your NEW HOLLAND Sales and Service
INTRODUCTION
51523358 21/08/2018 3
Safety rules
With cab [ZHLH04188 - ]
cab [ZHLH00502 - ]
cab [ZHLH01989 - ]
[ZHLH02201 - ]
[ZHLH04222 - ]
[ZHLH03821 - ]
[ZHLH04739 - ]
Personal safety
This the safety alert symbol. used alert you potential personal injury hazards. Obey all safety messages that follow this symbol avoid possible death injury
Throughout this manual you will find the signal words W and CAUTION followed special structions. These precautions are intended for the personal safety you and those working with you.
Read and understand all the safety messages this manual before you operate service the
DANGER indicates a hazardous situation not will result death serious injury
W ARNING indicates a hazardous situation not could result death serious injury
CAUTION indicates a hazardous situation not could result minor moderate injury
F AILURE T O FOLLOW DANGER, W ARNING, AND CAUTION MESSAGES COULD RESUL T DEA SERIOUS INJUR Y .
Machine safety
NOTICE: Notice indicates a situation not could result machine property
Throughout this manual you will find the signal word Notice followed special instructions prevent machine property The word Notice used address practices not related personal safety Information
NOTE: Note indicates additional information that clarifies other information this
Throughout this manual you will find the word Note followed additional information about a step, procedure, other information the The word Note not intended address personal safety property
INTRODUCTION
- - - MEA - -Without
- - - MEA - -10LP With
- - - MEA - -10LP Without
- - - MEA - -With cab
- - - MEA - -Without
- - - MEA - -With
- - - MEA - -Without
- - - MEA - - -
cab
cab [ZHLH03674 - ]
cab
cab
51523358 21/08/2018 5
Safety rules SAFETY REGULA TIONS T O
PREVENT ACCIDENTS
Most accidents injuries that occur workshops are the result non - - observance simple and fundamental safety
For this MOST CASES THESE ACCIDENTS CAN A VOIDED: foreseeing possible causes and sequently acting with the necessary caution and Accidents may occur with all types vehicle, regardless how well was designed and built.
A careful and judicious service technician the best guarantee against Precise observance the most basic safety rule normally suf ficient avoid many serious
DANGER: Never carry out any lubrication maintenance operations when the engine
GENERAL
• Carefully follow specified repair and maintenance
• not wear jewellery , unbuttoned loose articles clothing such as: torn open jackets shirts with open zips that may remain entangled moving advised wear approved safety non - - slip footwear , safety
• not carry out repair operations with someone sitting the driver ’ s seat, unless the person a trained technician who assisting with the operation
• Operate the vehicle and use the implements exclusively from the driver ’ s seat.
• not carry out operations the vehicle with the engine unless specifically
• Stop the engine and ensure that all pressure relieved from hydraulic circuits before removing
• All repair and maintenance operations must carried out using extreme care and
• Service steps and platforms used a workshop the field should built compliance with the safety rules
• Disconnect the batteries and label all controls indicate that the vehicle being serviced. Block the machine and all equipment which should
• not check fill fuel tanks, accumulator batteries, nor use starting liquid when smoking near naked flames, these fluids are
• Brakes are inoperative manually released for repair maintenance such cases, the machine should kept constantly under control using blocks similar
• The fuel nozzle should always contact with the filling Maintain this position until filling operations are completed order avoid possible sparks caused the accumulation static electricity .
• Only use specified towing points for towing the tractor , connect parts carefully sure that all pins and / locks are secured position before applying traction. Never remain near the towing cables chains that are operating under load
• T ransport vehicles that cannot driven using a trailer a low - - loading platform trolley ,
• When loading unloading the vehicle from the trailer (or other means select a flat area capable sustaining the trailer truck firmly secure the tractor the truck trailer and lock the wheels the position.
• Electric battery - - chargers and similar equipment must only powered auxiliary power supplies with ficient ground insulation avoid electrical shock
• Always use suitable hoisting lifting devices when raising moving heavy
• T ake extra care bystanders are
• Never pour gasoline diesel oil into wide and low
• Never use diesel oil other inflammable liquids cleaning Use non - flammable non - toxic prietary
• W ear safety goggles with side guards when cleaning parts with compressed air
• Limit the air pressure a maximum bar ( psi ) , according local
51523358 21/08/2018
INTRODUCTION
6
• not run the engine confined spaces without suitable
• not use naked cause sparks the area when fuel filling handling highly inflammable
• Never use naked flames for lighting when working the machine checking for
• All movements must carried out carefully when working under , near the vehicle and wear protective ment: goggles and special footwear
• When carrying out checks with the engine request the assistance operator the driver ’ s The operator must maintain visual contact with the service technician all times.
• operating outside the position the vehicle a flat surface and lock working a lock the vehicle position and move a flat area soon safely possible.
• Damaged bent chains cables are not use them for lifting
Always use suitable protective gloves when handling chains
• Chains should always safely Ensure that fastening device strong enough hold the load persons should stop near the fastening trailing chains
• Maintenance and repair operations must carried out a CLEAN and Y eliminate any water oil spillage immediately
• not create piles oil grease - - soaked rags they represent a serious fire hazard; store them a closed metal container
Before starting the vehicle make sure that the driver ’ s seat locked position and always check that the area free persons
• Empty pockets all objects that may fall unobserved into the vehicle parts when
• the presence protruding metal use protective goggles goggles with side special footwear and
• Handle all parts carefully , not put your hands fingers between moving parts, wear suitable safety clothing -safety gloves and
WELDING OPERA TIONS
• When use protective safety devices: tinted safety special gloves and footwear All persons present the area where welding taking place must wear tinted NEVER LOOK A T THE WELDING ARC YOUR EYES ARE NOT SUIT ABL Y
• Where remove the part tool that requires arc welding from the tractor
• Disconnect both battery Isolate the cable ends avoid contact with each other and the tractor
• Position the welder ground clamp near possible the area where welding taking
• Remove the electronic control units located the tractor welding carried out near these control units.
• Never allow welding cables lay near across any electrical wiring electronic component while welding progress.
• Metal cables tend fray with repeated Always use suitable protective devices when handling
ART
• Never start the engine confined spaces that are not equipped with adequate ventilation for exhaust gas
• Never place the body , hands fingers near fans rotating
ENGINE
• Always loosen the radiator cap slowly before removing allow any remaining pressure the system Coolant should topped only when the engine stopped idle
• Never fill with fuel when the engine especially order prevent the outbreak fire a result fuel spillage
• Never check adjust fan belt tension when the engine running. Never adjust the fuel injection pump when the vehicle 51523358
INTRODUCTION
21/08/2018 7
Engine T4.100F W ith cab [ZHLH01567T4.100F W ithout cab [ZHLH01600T4.100LP W ith cab [ZHLH04188T4.100LP W ithout cab [ZHLH00502T4.1 10F W ith cab [ZHLH00094T4.1 10F W ithout cab [ZHLH01580T4.1 10LP W ith cab [ZHLH01989T4.1 10LP W ithout cab [ZHLH02201T4.80F W ith cab [ZHLH01907T4.80F W ithout cab [ZHLH01219T4.80LP W ith cab [ZHLH04222T4.80LP W ithout cab [ZHLH03674T4.90F W ith cab [ZHLH01868T4.90F W ithout cab [ZHLH01862T4.90LP W ith cab [ZHLH03821T4.90LP W ithout cab [ZHLH04739 - ] 51523358 21/08/2018
SER VICE MANUAL
Contents Engine[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 14] Pump drives Fuel tanks [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 Air cleaners and lines Intake and exhaust manifolds and muf fler Exhaust Gas Recirculation (EGR) exhaust treatment [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 Fan and drive Aftercooler [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 1 51523358 21/08/2018
Engine - Remove from transmission
W ARNING
Burn hazard!
very careful avoid contact with hot fluids. fluid extremely hot, allow cool a moderately warm temperature before proceeding.
Failure comply could result death serious injury W0362A
W ARNING
Hot surface possible!
W ait for all components cool before performing any
Failure comply could result death serious injury . W0251A
CAUTION
Hot area!
Use care when working near hot components. W ear protective gloves.
Failure comply could result minor moderate injury . C0034A
W ARNING
Chemical hazard!
When handling fuel, lubricants, and other service chemicals, follow the instructions.
W ear Personal Protective Equipment (PPE) not smoke use open Collect fluids proper containers. Obey all local and environmental regulations when disposing chemicals.
Failure comply could result death serious injury W0371A
Prior operation:
Remove the front ballast - See Front ballast - Remove (39.140)
Carefully clean the area around the central drain plug (1) the
Use a suitable container collect the transmission
Loosen the central drain plug (1) the transmission and drain the transmission oil.
Replace the central drain plug (1) the transmission.
T ighten the central drain plug (1) the
Carefully clean all the parts contaminated any ing hydraulic
Remove the cab – See Cab and platform - Remove
Remove the transmission drive shaft going from the transmission the front axle - See Front drive shaftRemove (23.314) .
Engine - Engine and crankcase
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Use a suitable hydraulic lift and position under the oil sump the
Use a second suitable hydraulic lift and position under the swinging arm (1) .
1 Remove the snap ring fixing the half bushes (1) the rear ball joint (2) the swinging arm (3)
Push down the hydraulic lifts and extract the half bushes (1) the rear ball joint (2)
Carefully clean the area around the couplings (1) the intermediate delivery and return pipes the transmission oil exchanger
Use a suitable container collect the transmission Loosen the couplings (1) the intermediate delivery and return pipes the transmission oil exchanger
- Engine and crankcase
Engine
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16. Carefully clean the area around the coupling (1) the intermediate dif ferential oil delivery pipe the left - hand side the
17. Use a suitable container collect the transmission oil.
18. Loosen the coupling (1) the intermediate dif ferential oil delivery pipe the left - hand side the
Carefully clean the area around the coupling (1) the intermediate delivery pipe connected the sion oil filter
Use a suitable container collect the transmission
Loosen the coupling (1) the intermediate delivery pipe connected the transmission oil filter .
22. Carefully clean all the parts contaminated any ing hydraulic
23. Carefully clean the area around the sleeve (1) the intermediate delivery pipe connected the sion oil filter
Use a suitable container collect the transmission
25. Loosen the two screw collars (2) the sleeve (1) the intermediate delivery pipe connected the mission oil filter
Loosen the screw collar (3) fixing the sleeve (1) the intermediate delivery pipe connected the sion oil filter
Disconnect the sleeve (1) the intermediate delivery pipe connected the transmission oil filter
Carefully clean all the parts contaminated any ing hydraulic
Carefully clean the area around the connector (1) the steering sensor
30. Disconnect the steering sensor connector (1) .
31. Disconnect the connector cable (1) from the steering sensor
Engine - Engine and crankcase
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32. Carefully clean the area around the connector (1) the hydraulic fluid pressure sensor
Disconnect the connector (1) the hydraulic fluid pressure sensor .
34. Disconnect the connector cable (1) from the hydraulic fluid pressure sensor
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Carefully clean the area around the connector (1) Disconnect connector (1)
Unclamp the connector (1) from the support bracket (2) MOIL16TR01458AA
38. Loosen the screw (1) and remove the collar (2) .
Loosen the sleeve (3) the oil delivery pipe (4)
Carefully clean the area around the two holes (1) the upper side the clutch bell (2)
41. Restore the thread the two holes (1) the upper side the clutch bell (2)
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Engine
Engine -
and crankcase
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Engine - Engine and crankcase
42. Loosen the two screws (1) securing the bracket (2) . Remove the bracket (2) and the cable (3)
Arrange two eyebolts suitable for lifting the
Prepare a hoist and chains / straps that are suitable for lifting the MOIL16TR01461AA
Place a suitable lift under the transmission MOIL16TR01464AA
47. Clean the area around the clutch bell (1) .
Correctly position the two eyebolts (1) , and using the correct lock into the holes the upper face the clutch bell (2)
49. Correctly hook the chains / straps the eyebolts (1) .
Use a suitable tool separate the engine from the
MOIL16TR01465AA
Loosen the four fastening screws (1) the left - hand side the clutch
52. Repeat for the four fastening screws the right - hand side the clutch
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53. Loosen the four retaining nuts (1) the lower side the clutch
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Using a suitable separate the engine from the transmission.
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Place a suitable bracket under the clutch bell the engine
Place a suitable bracket under the clutch bell the engine side.
Place a suitable bracket under the support bracket the front
Place a suitable bracket under the support bracket the front
Unclamp the chains the eyebolts and free the
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MOIL16TR01470AA
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Place a suitable bracket under the clutch bell the transmission
Place a suitable bracket under the clutch bell the transmission side.
Engine - Engine and crankcase
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[10.001]
Engine - Install the transmission
Retrieve the transmission assembly and carefully clean the area around the clutch bell.
Retrieve the front axle and engine assembly and clean the clutch
Arrange two eyebolts suitable for lifting the Prepare a hoist and chains / straps that are suitable for lifting the engine.
Arrange two eyebolts suitable for lifting the Prepare a hoist and chains / straps that are suitable for lifting the
Carefully clean the area around the two holes (1) the upper side the clutch bell (2)
Restore the thread the two holes (1) the upper side the clutch bell (2)
Correctly position the two eyebolts (1) , and using the correct lock into the holes the upper face the clutch bell (2)
Correctly hook the chains / straps the eyebolts (1)
1 Remove any supports positioned under the clutch bell the engine
Engine - Engine and crankcase
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Engine - Engine and crankcase
Remove any supports positioned under the support bracket (1) the front Use a suitable tool fit the transmission the
Apply suitable sealing paste the coupling face (1) the transmission clutch bell.
15. Using a suitable tool, move the engine closer the
16. T ighten the four fastening screws (1) the left - hand side the clutch bell and tighten the prescribed
Repeat for the four fastening screws the right - hand side the clutch bell (1)
T ighten the four retaining nuts (1) the lower side the clutch bell and tighten the prescribed
19. Carefully clean all the parts contaminated any ing paste
Unclamp the chains the eyebolts and free the en-
21. Remove the two eyebolts used lift the engine.
22. Remove any supports positioned under the clutch bell the transmission
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Remove any supports positioned under the sion
24. Retrieve and carefully clean the bracket (1) .
25. Correctly position the cable (2) .
Correctly position the bracket (1) its housing the
T ighten the two screws (3) which fix the bracket (1) place.
Carefully clean the area around the sleeve (1) the oil delivery pipe (2)
29. T ighten the sleeve (1) the oil delivery pipe (2) .
30. Retrieve the collar (3) and position correctly its
T ighten the fastening screw (4) the collar (2)
Carefully clean the area around the connector (1) the steering sensor
Correctly position the connector cable (1) the ing sensor
Connect the steering sensor connector (1)
Engine - Engine and crankcase
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35. Carefully clean the area around the connector (1) the hydraulic fluid pressure sensor
Correctly position the connector cable (1) the hydraulic fluid pressure sensor .
37. Connect the connector (1) the hydraulic fluid sure sensor
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Carefully clean the area around the connector (1)
Fasten the connector (1) the support bracket (2)
Connect the connector (1)
41. Carefully clean the area around the sleeve (1) the intermediate delivery pipe connected the sion oil filter
Connect the sleeve (1) the intermediate delivery pipe connected the transmission oil filter
T ighten the two screw collars (2) the sleeve (1) the intermediate delivery pipe connected the mission oil filter
T ighten the screw collar (3) fixing the sleeve (1) the intermediate delivery pipe connected the sion oil filter .
Carefully clean the area around the coupling (1) the intermediate delivery pipe connected the sion oil filter
Correctly connect the coupling (1) the intermediate delivery pipe connected the transmission oil filter
T ighten the coupling (1) the intermediate delivery pipe connected the transmission oil filter
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MOIL16TR01457AA
MOIL16TR01456AA
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48. Carefully clean the area around the coupling (1) the intermediate dif ferential oil delivery pipe the left - hand side the
49. Correctly connect the coupling (1) the intermediate dif ferential oil delivery pipe the left - hand side the
T ighten the coupling (1) the intermediate dif ferential oil delivery pipe the left - hand side the MOIL16TR01455AA
Carefully clean the area around the couplings (1) the intermediate delivery and return pipes the transmission oil exchanger
Correctly connect (1) the intermediate delivery and turn pipes the transmission oil exchanger
53. T ighten the couplings (1) the intermediate delivery and return pipes the transmission oil exchanger MOIL16TR01454AA
54. Use a suitable hydraulic lift and position under the oil sump the MOIL16TR01451AA
Use a second suitable hydraulic lift and position under the swinging arm (1) MOIL16TR01452AA
Engine - Engine and crankcase
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Engine - Engine and crankcase
56. Push down the hydraulic lifts and correctly position the half bushes (1) the rear ball joint (2) Position the snap ring fixing the half bushes (1) the rear ball joint (2) the swinging arm (3) .
58. Refit the transmission drive shaft going from the mission the front axle - See Front drive shaft - Install (23.314)
Next operation:
Reattach the cab – See Cab and platform - Install (90.150)
T the transmission oil level - See T ransmission drive housing - Level make (21.1 18) . Refit the front ballast - See Front ballast - Install
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Engine - Remove from transmission
W ARNING
Burn hazard!
very careful avoid contact with hot fluids. fluid extremely hot, allow cool a moderately warm temperature before proceeding.
Failure comply could result death serious injury
W ARNING
Hot surface possible!
W ait for all components cool before performing any
Failure comply could result death serious injury .
CAUTION
Hot area!
Use care when working near hot components. W ear protective gloves.
Failure comply could result minor moderate injury .
W ARNING
Chemical hazard!
W0362A
W0251A
C0034A
When handling fuel, lubricants, and other service chemicals, follow the instructions.
W ear Personal Protective Equipment (PPE) not smoke use open Collect fluids proper containers. Obey all local and environmental regulations when disposing chemicals.
Failure comply could result death serious injury
Prior operation:
Remove the front ballast - See Front ballast - Remove (39.140)
Carefully clean the area around the central drain plug (1) the
Use a suitable container collect the transmission
Loosen the central drain plug (1) the transmission and drain the transmission oil.
Replace the central drain plug (1) the transmission.
T ighten the central drain plug (1) the
Carefully clean all the parts contaminated any ing hydraulic
Remove the operator platform – See Platform - Remove 10)
Remove the transmission drive shaft going from the transmission the front axle - See Front drive shaftRemove (23.314) .
W0371A
Engine - Engine and crankcase
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Use a suitable hydraulic lift and position under the oil sump the
Use a second suitable hydraulic lift and position under the swinging arm (1) .
1 Remove the snap ring fixing the half bushes (1) the rear ball joint (2) the swinging arm (3)
Push down the hydraulic lifts and extract the half bushes (1) the rear ball joint (2)
Carefully clean the area around the couplings (1) the intermediate delivery and return pipes the transmission oil exchanger
Use a suitable container collect the transmission Loosen the couplings (1) the intermediate delivery and return pipes the transmission oil exchanger
Engine - Engine and crankcase
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16. Carefully clean the area around the coupling (1) the intermediate dif ferential oil delivery pipe the left - hand side the
17. Use a suitable container collect the transmission oil.
18. Loosen the coupling (1) the intermediate dif ferential oil delivery pipe the left - hand side the
Carefully clean the area around the coupling (1) the intermediate delivery pipe connected the sion oil filter
Use a suitable container collect the transmission
Loosen the coupling (1) the intermediate delivery pipe connected the transmission oil filter .
22. Carefully clean all the parts contaminated any ing hydraulic
23. Carefully clean the area around the sleeve (1) the intermediate delivery pipe connected the sion oil filter
Use a suitable container collect the transmission
25. Loosen the two screw collars (2) the sleeve (1) the intermediate delivery pipe connected the mission oil filter
Loosen the screw collar (3) fixing the sleeve (1) the intermediate delivery pipe connected the sion oil filter
Disconnect the sleeve (1) the intermediate delivery pipe connected the transmission oil filter
Carefully clean all the parts contaminated any ing hydraulic
Carefully clean the area around the connector (1) the steering sensor
30. Disconnect the steering sensor connector (1) .
31. Disconnect the connector cable (1) from the steering sensor
Engine - Engine and crankcase
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32. Carefully clean the area around the connector (1) the hydraulic fluid pressure sensor
Disconnect the connector (1) the hydraulic fluid pressure sensor .
34. Disconnect the connector cable (1) from the hydraulic fluid pressure sensor
Carefully clean the area around the connector (1) Disconnect connector (1)
Unclamp the connector (1) from the support bracket (2)
38. Loosen the screw (1) and remove the collar (2) .
Loosen the sleeve (3) the oil delivery pipe (4)
Carefully clean the area around the two holes (1) the upper side the clutch bell (2)
41. Restore the thread the two holes (1) the upper side the clutch bell (2)
Engine - Engine and crankcase
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42. Loosen the two screws (1) securing the bracket (2) . Remove the bracket (2) and the cable (3)
Arrange two eyebolts suitable for lifting the
Prepare a hoist and chains / straps that are suitable for lifting the
MOIL16TR01461AA
Place a suitable lift under the transmission
MOIL16TR01464AA
47. Clean the area around the clutch bell (1) .
Correctly position the two eyebolts (1) , and using the correct lock into the holes the upper face the clutch bell (2)
49. Correctly hook the chains / straps the eyebolts (1) .
Use a suitable tool separate the engine from the
MOIL16TR01465AA
Loosen the four fastening screws (1) the left - hand side the clutch
52. Repeat for the four fastening screws the right - hand side the clutch
MOIL16TR01466AA
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Engine - Engine and crankcase
53. Loosen the four retaining nuts (1) the lower side the clutch
MOIL16TR01467AA
Using a suitable separate the engine from the transmission.
MOIL16TR01468AA
Place a suitable bracket under the clutch bell the engine
Place a suitable bracket under the clutch bell the engine side.
Place a suitable bracket under the support bracket the front
Place a suitable bracket under the support bracket the front
Unclamp the chains the eyebolts and free the
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