New Holland TL100A Tractor Service Repair Manual.pdf
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About This Presentation
service repair manual
Slide Content
TRACTORS
TL70A -- TL80A -- TL90A -- TL100A
SERVICEMANUAL
SECTIONS
GENERAL GUIDELINES 00......................................................
ENGINE 10.....................................................................
CLUTCH 18.....................................................................
TRANSMISSION 21..............................................................
DRIVE LINES 23................................................................
FRONT MECHANICAL TRANSMISSION 25 ........................................
REAR MECHANICAL TRANSMISSION 27 .........................................
POWER TAKE-OFF 31..........................................................
BRAKES 33.....................................................................
HYDRAULIC SYSTEMS 35.......................................................
STEERING 41...................................................................
AXLE AND WHEELS 44..........................................................
CAB AIR CONDITIONING SYSTEM 50 ............................................
ELECTRICAL SYSTEM 55........................................................
PLATFORM, CAB, BODYWORK 90 ...............................................
SERVICE
TL70A -- TL80A -- TL90A -- TL100A
SERVICEMANUAL
SECTIONS
GENERAL GUIDELINES 00......................................................
ENGINE 10.....................................................................
CLUTCH 18.....................................................................
TRANSMISSION 21..............................................................
DRIVE LINES 23................................................................
FRONT MECHANICAL TRANSMISSION 25 ........................................
REAR MECHANICAL TRANSMISSION 27 .........................................
POWER TAKE-OFF 31..........................................................
BRAKES 33.....................................................................
HYDRAULIC SYSTEMS 35.......................................................
STEERING 41...................................................................
AXLE AND WHEELS 44..........................................................
CAB AIR CONDITIONING SYSTEM 50 ............................................
ELECTRICAL SYSTEM 55........................................................
PLATFORM, CAB, BODYWORK 90 ...............................................
SERVICE
INTRODUCTION
◊This manual is divided into sections identified by two--figure numbers and each section has independent page
numbering.
For easy reference, these sections have the same numbers and names as the Repairs Rate Book sections.
◊The different sections can easily be found by consulting the table of contents on the following pages.
◊The document number of the manual and the edition/update dates are given at the bottom of each page.
◊Pages updated in the future will be identified by the same document number followed by a two--figure update
number (e.g., 1
st
Update 603.54.511.01; 2
nd
Update 603.54.511.02; etc.) and by the corresponding issue
date.
These pages will be supplemented by a reprint of the updated contents page.
◊The information contained in this manual was current on the date printed on each section. As NEW HOLLAND
constantly improves its product range, some information may be out of date subsequent to modifications im-
plemented for technical or commercial reasons, or to meet legal requirements in different countries.
In the event of conflicting information, consult the NEW HOLLAND Sales and Service Departments.
IMPORTANT WARNINGS
◊All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND
service technicians, in strict accordance with the instructions given and using any specific tools necessary.
◊Anyone performing the operations described herein without strictly following the instructions is personally re-
sponsible for any eventual injury or damage to property.
◊The Manufacturer and all organisations belonging to the Manufacturer’s distribution network, including but
not restricted to national, regional or local distributors, will accept no responsibility for personal injury or dam-
age to property caused by abnormal function of parts and/or components not approved by the Manufacturer,
including those used for maintenance and/or repair of the product manufactured or marketed by the Manufac-
turer.
In any case, the product manufactured or marketed by the Manufacturer is covered by no guarantee of any
kind against personal injury or damage to property caused by abnormal function of parts and/or components
not approved by the Manufacturer.
TEXT AND ILLUSTRATIONS ARE THE PROPERTY
OF CNH ITALIA S.p.A.
No part of the text or illustrations
may be reproduced
PRINTEDINITALY
CNH ITALIA S.p.A. -- Viale delle Nazioni, 55 -- 41100 MODENA -- Italy
Product Support -- Technical Information
Print No.603.54.511.00-- 03 -- 2006
◊This manual is divided into sections identified by two--figure numbers and each section has independent page
numbering.
For easy reference, these sections have the same numbers and names as the Repairs Rate Book sections.
◊The different sections can easily be found by consulting the table of contents on the following pages.
◊The document number of the manual and the edition/update dates are given at the bottom of each page.
◊Pages updated in the future will be identified by the same document number followed by a two--figure update
number (e.g., 1
st
Update 603.54.511.01; 2
nd
Update 603.54.511.02; etc.) and by the corresponding issue
date.
These pages will be supplemented by a reprint of the updated contents page.
◊The information contained in this manual was current on the date printed on each section. As NEW HOLLAND
constantly improves its product range, some information may be out of date subsequent to modifications im-
plemented for technical or commercial reasons, or to meet legal requirements in different countries.
In the event of conflicting information, consult the NEW HOLLAND Sales and Service Departments.
IMPORTANT WARNINGS
◊All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND
service technicians, in strict accordance with the instructions given and using any specific tools necessary.
◊Anyone performing the operations described herein without strictly following the instructions is personally re-
sponsible for any eventual injury or damage to property.
◊The Manufacturer and all organisations belonging to the Manufacturer’s distribution network, including but
not restricted to national, regional or local distributors, will accept no responsibility for personal injury or dam-
age to property caused by abnormal function of parts and/or components not approved by the Manufacturer,
including those used for maintenance and/or repair of the product manufactured or marketed by the Manufac-
turer.
In any case, the product manufactured or marketed by the Manufacturer is covered by no guarantee of any
kind against personal injury or damage to property caused by abnormal function of parts and/or components
not approved by the Manufacturer.
TEXT AND ILLUSTRATIONS ARE THE PROPERTY
OF CNH ITALIA S.p.A.
No part of the text or illustrations
may be reproduced
PRINTEDINITALY
CNH ITALIA S.p.A. -- Viale delle Nazioni, 55 -- 41100 MODENA -- Italy
Product Support -- Technical Information
Print No.603.54.511.00-- 03 -- 2006
CONTENT 3
603.54.511.00-- 03 -- 2006
CONTENT VOLUME 1
Page Date
00 -- GENERAL GUIDELINES
General instructions..... 1--2 03--06
Safety regulations....... 3--4--5 03--06
Consumables ........... 6 03--06
10 -- ENGINE
Summary............... 1 03--06
General specifications.... 2to4 03--06
Fuel system data........ 5 03--06
Crankshaft and engine
blockdata .............. 6 03--06
Connecting rod data..... 7 03--06
Pistondata ............. 7--8 03--06
Timing gear data........ 8--9 03--06
Cylinder head data...... 9--10 03--06
Tightening Torques...... 11--12 03--06
Tools .................. 13 03--06
View of 4--cylinder engine
mod. TL70A and TL80A . . 14 03--06
View of 4--cylinder engine
mod. TL90A and TL100A . 15 03--06
Engine cooling and lubrica-
tiondiagrams ...........16--17 03--06
Component parts of cylin-
der head mod. TL70A and
TL80A................. 18 03--06
Component parts of cylin-
der head mod. TL90A and
TL100A................ 19 03--06
Component parts of addi-
tional counterweights....20 03--06
Troubleshooting......... 21to24 03--06
Engine removal--installa-
tion ....................25 to 44 03--06
Engine disassembly--as-
sembly ................. 45to78 03--06
Checks and measure-
ments -- cylinder block and
liners .................. 79to81 03--06
Checks and measure-
ments -- crankshaft, bear-
ings and flywheel........ 82to83 03--06
Checks and measure-
ments -- connecting rods . 84 to 85 03--06
Page Date
Checks and measure-
ments--pistons ......... 86to89 03--06
Checks and measure-
ments -- camshaft, tappets
andvalves.............. 90to93 03--06
Checks and measure-
ments -- cylinder head.... 94 03--06
Functional testing on low
engine oil pressure indica-
tor ..................... 95 03--06
Checks and measure-
ments -- cooling system . . 96 03--06
Replacing crankshaft front
seal ................... 97to99 03--06
Replacing crankshaft rear
seal ................... 100to102 03--06
Adjusting tappet, valve and
rockerarmclearance .... 103to105 03--06
Removal--Installation -- in-
jectors ................. 106to108 03--06
Removal -- Installation --
Boschinjectionpump .... 109to113 03--06
Bosch injection pump -- tim-
ing .................... 114to118 03--06
Bosch injection pump -- air
bleeding................ 118 03--06
Removal--Installation --
coolantpump ........... 119--120 03--06
Removal--Installation --
thermostatvalve......... 121--122 03--06
Removal--Installation --
radiator ................
123 to 128 03--06
Coolant pump drive belt ad-
justment................ 129to130 03--06
18 -- CLUTCH
Summary............... 1 03--06
Data ................... 2 03--06
Tightening Torques...... 3 03--06
Tools .................. 3 03--06
Cross--sectional views . . . 4 03--06
Troubleshooting......... 5 03--06
Checks and measure-
ments--clutch .......... 6--7 03--06
Adjustments -- clutch pedal 8 03--06
Removal--Installation --
clutch .................. 9to11 03--06
Clutch Overhaul......... 12to15 03--06
603.54.511.00-- 03 -- 2006
CONTENT VOLUME 1
Page Date
00 -- GENERAL GUIDELINES
General instructions..... 1--2 03--06
Safety regulations....... 3--4--5 03--06
Consumables ........... 6 03--06
10 -- ENGINE
Summary............... 1 03--06
General specifications.... 2to4 03--06
Fuel system data........ 5 03--06
Crankshaft and engine
blockdata .............. 6 03--06
Connecting rod data..... 7 03--06
Pistondata ............. 7--8 03--06
Timing gear data........ 8--9 03--06
Cylinder head data...... 9--10 03--06
Tightening Torques...... 11--12 03--06
Tools .................. 13 03--06
View of 4--cylinder engine
mod. TL70A and TL80A . . 14 03--06
View of 4--cylinder engine
mod. TL90A and TL100A . 15 03--06
Engine cooling and lubrica-
tiondiagrams ...........16--17 03--06
Component parts of cylin-
der head mod. TL70A and
TL80A................. 18 03--06
Component parts of cylin-
der head mod. TL90A and
TL100A................ 19 03--06
Component parts of addi-
tional counterweights....20 03--06
Troubleshooting......... 21to24 03--06
Engine removal--installa-
tion ....................25 to 44 03--06
Engine disassembly--as-
sembly ................. 45to78 03--06
Checks and measure-
ments -- cylinder block and
liners .................. 79to81 03--06
Checks and measure-
ments -- crankshaft, bear-
ings and flywheel........ 82to83 03--06
Checks and measure-
ments -- connecting rods . 84 to 85 03--06
Page Date
Checks and measure-
ments--pistons ......... 86to89 03--06
Checks and measure-
ments -- camshaft, tappets
andvalves.............. 90to93 03--06
Checks and measure-
ments -- cylinder head.... 94 03--06
Functional testing on low
engine oil pressure indica-
tor ..................... 95 03--06
Checks and measure-
ments -- cooling system . . 96 03--06
Replacing crankshaft front
seal ................... 97to99 03--06
Replacing crankshaft rear
seal ................... 100to102 03--06
Adjusting tappet, valve and
rockerarmclearance .... 103to105 03--06
Removal--Installation -- in-
jectors ................. 106to108 03--06
Removal -- Installation --
Boschinjectionpump .... 109to113 03--06
Bosch injection pump -- tim-
ing .................... 114to118 03--06
Bosch injection pump -- air
bleeding................ 118 03--06
Removal--Installation --
coolantpump ........... 119--120 03--06
Removal--Installation --
thermostatvalve......... 121--122 03--06
Removal--Installation --
radiator ................
123 to 128 03--06
Coolant pump drive belt ad-
justment................ 129to130 03--06
18 -- CLUTCH
Summary............... 1 03--06
Data ................... 2 03--06
Tightening Torques...... 3 03--06
Tools .................. 3 03--06
Cross--sectional views . . . 4 03--06
Troubleshooting......... 5 03--06
Checks and measure-
ments--clutch .......... 6--7 03--06
Adjustments -- clutch pedal 8 03--06
Removal--Installation --
clutch .................. 9to11 03--06
Clutch Overhaul......... 12to15 03--06
4 CONTENT
603.54.511.00-- 03 -- 2006
Page Date
Adjustments -- clutch disen-
gagement levers........ 16 03--06
21 -- TRANSMISSIONS
CHAPTER 1 -- Transmission and
range gear (12x4)
Summary............... 1 03--06
Data ................... 2 03--06
Tightening Torques...... 3 03--06
Tools .................. 4--5 03--06
Cross--sectional views . . . 6--7 03--06
Description & Operation . . 8 03--06
Troubleshooting......... 8 03--06
Transmission longitudinal
cutawaysectionview .... 9 03--06
CHAPTER 2 -- Reverser
Summary............... 1 03--06
Data ................... 2 03--06
Tightening Torques...... 3 03--06
Tools .................. 4 03--06
Cross--sectional views . . . 4--5 03--06
Description & Operation . . 6 03--06
Troubleshooting......... 6 03--06
Disassembly--Assembly --
clutch casing--reverser . . . 7 to 10 03--06
Transmission longitudinal
cutawaysectionview .... 11--12 03--06
CHAPTER 3 -- Dual Command
(2 Speed Power Shift)
Summary............... 1 03--06
Data ................... 2--3 03--06
Tightening Torques...... 4 03--06
Tools .................. 5 03--06
Cross--sectional views . . . 6 to 8 03--06
Description & Operation . . 10 to 15 03--06
Troubleshooting......... 16--17 03--06
Removal--Installation --
clutch casing with Dual
Command (2 Speed Power
Shift) .................. 18to26 03--06
Disassembly--Assembly --
clutch casing with Dual
Command (2 Speed Power
Shift) .................. 27to35 03--06
Page Date
Control rod adjustments . . 36 03--06
Removal--Installation --
Dual Command (2 Speed
Power Shift) solenoid valve 37 to 40 03--06
Workingpressuretest .... 40 03--06
Removal--Installation --
Dual Command (2 Speed
Power Shift) control valve 41 to 44 03--06
Disassembly--Assembly --
Dual Command (2 Speed
Power Shift) control valve . 45--46 03--06
Transmission longitudinal
cutawaysectionview .... 47 03--06
CHAPTER 4 -- Reverser and creeper
unit
Summary............... 1 03--06
Data ................... 2 03--06
Tighteningtorque ........ 3 03--06
Tools .................. 4to5 03--06
Cross--sectional views . . . 6 to 7 03--06
Description & Operation . . 8 03--06
Troubleshooting......... 8 03--06
Replacing clutch casing--
reverser and creeper unit . 9 to 13 03--06
End float adjustment be-
tween shaft and support . . 14 to 15 03--06
Transmission longitudinal
cutawaysectionview .... 16 03--06
CHAPTER 5 -- Power Shuttle tran-
smission with Dual
Command (2 Speed
Power Shift) function
Summary............... 1 03--06
Data ................... 2--3 03--06
Tighteningtorque ........ 4--5 03--06
Tools .................. 6--7 03--06
Cross--sectional views . . . 8 to 10 03--06
Description & Operation . . 11 to 17 03--06
Range and gear lever posi-
tion sensor adjustment 18--19 03--06
Disassembly--Assembly --
clutch casing with power
shuttle and Dual Command
(2 Speed Power Shift).... 20to26 03--06
Disassembly--Assembly --
clutch(A)and(B)........ 27--32 03--06
603.54.511.00-- 03 -- 2006
Page Date
Adjustments -- clutch disen-
gagement levers........ 16 03--06
21 -- TRANSMISSIONS
CHAPTER 1 -- Transmission and
range gear (12x4)
Summary............... 1 03--06
Data ................... 2 03--06
Tightening Torques...... 3 03--06
Tools .................. 4--5 03--06
Cross--sectional views . . . 6--7 03--06
Description & Operation . . 8 03--06
Troubleshooting......... 8 03--06
Transmission longitudinal
cutawaysectionview .... 9 03--06
CHAPTER 2 -- Reverser
Summary............... 1 03--06
Data ................... 2 03--06
Tightening Torques...... 3 03--06
Tools .................. 4 03--06
Cross--sectional views . . . 4--5 03--06
Description & Operation . . 6 03--06
Troubleshooting......... 6 03--06
Disassembly--Assembly --
clutch casing--reverser . . . 7 to 10 03--06
Transmission longitudinal
cutawaysectionview .... 11--12 03--06
CHAPTER 3 -- Dual Command
(2 Speed Power Shift)
Summary............... 1 03--06
Data ................... 2--3 03--06
Tightening Torques...... 4 03--06
Tools .................. 5 03--06
Cross--sectional views . . . 6 to 8 03--06
Description & Operation . . 10 to 15 03--06
Troubleshooting......... 16--17 03--06
Removal--Installation --
clutch casing with Dual
Command (2 Speed Power
Shift) .................. 18to26 03--06
Disassembly--Assembly --
clutch casing with Dual
Command (2 Speed Power
Shift) .................. 27to35 03--06
Page Date
Control rod adjustments . . 36 03--06
Removal--Installation --
Dual Command (2 Speed
Power Shift) solenoid valve 37 to 40 03--06
Workingpressuretest .... 40 03--06
Removal--Installation --
Dual Command (2 Speed
Power Shift) control valve 41 to 44 03--06
Disassembly--Assembly --
Dual Command (2 Speed
Power Shift) control valve . 45--46 03--06
Transmission longitudinal
cutawaysectionview .... 47 03--06
CHAPTER 4 -- Reverser and creeper
unit
Summary............... 1 03--06
Data ................... 2 03--06
Tighteningtorque ........ 3 03--06
Tools .................. 4to5 03--06
Cross--sectional views . . . 6 to 7 03--06
Description & Operation . . 8 03--06
Troubleshooting......... 8 03--06
Replacing clutch casing--
reverser and creeper unit . 9 to 13 03--06
End float adjustment be-
tween shaft and support . . 14 to 15 03--06
Transmission longitudinal
cutawaysectionview .... 16 03--06
CHAPTER 5 -- Power Shuttle tran-
smission with Dual
Command (2 Speed
Power Shift) function
Summary............... 1 03--06
Data ................... 2--3 03--06
Tighteningtorque ........ 4--5 03--06
Tools .................. 6--7 03--06
Cross--sectional views . . . 8 to 10 03--06
Description & Operation . . 11 to 17 03--06
Range and gear lever posi-
tion sensor adjustment 18--19 03--06
Disassembly--Assembly --
clutch casing with power
shuttle and Dual Command
(2 Speed Power Shift).... 20to26 03--06
Disassembly--Assembly --
clutch(A)and(B)........ 27--32 03--06
CONTENT 5
603.54.511.00-- 03 -- 2006
Page Date
Calibrations............. 33 03--06
HHMENUaccess ....... 33--34 03--06
Clutch calibration H1 menu
transmission ............ 35to37 03--06
Transmission fault codes . 38 to 40 03--06
23 -- DRIVE LINES
Summary............... 1 03--06
Data ................... 2 03--06
Tightening Torques...... 3 03--06
Tools .................. 3 03--06
Cross--sectional views . . . 4 03--06
Description & Operation . . 5 03--06
Troubleshooting......... 6 03--06
Removal--Installation -- ser-
vicescontrolvalve ....... 7to9 03--06
Disassembly--Assembly --
servicescontrolvalve .... 10to11 03--06
Removal--Installation --
drive gear casing........ 12to16 03--06
Disassembly--Assembly --
drive gear casing........ 17to20 03--06
25 -- FRONT MECHANICAL TRANSMISSION
Summary............... 1 03--06
Data ................... 2to4 03--06
Tightening Torques...... 4--5 03--06
Tools .................. 6to8 03--06
Cross--sectional views . . . 9 to 13 03--06
Description & Operation . . 14--15 03--06
Rules for correctly fitting the
axle support to the engine 16 03--06
Troubleshooting......... 17 03--06
Removal--Installation --
frontaxle ............... 18to21 03--06
Disassembly--Assembly --
frontaxle ............... 22to30 03--06
Overhaul -- front differential 31 03--06
Overhaul -- front axle differ-
entialwithLIM--SLIP ..... 32--33 03--06
Overhaul -- differential lock
unit .................... 34--35 03--06
Disassembly--Assembly --
front epicyclic final drive
without brake........... 36to38 03--06
Replacing wheel hub seal
without brake............ 39 03--06
Page Date
Disassembly--Assembly --
front epicyclic final drive
withbrake .............. 40--41 03--06
Replacing wheel hub seal
withbrake. ............. 42 03--06
Replacing steering knuckle
pins and bearings....... 43 03--06
Stubaxleadjustments.... 44--45 03--06
Adjustments -- bevel drive 46 to 52 03--06
27 -- REAR MECHANICAL TRANSMISSION
Summary............... 1 03--06
Data ................... 2--3 03--06
Tightening Torques...... 3--4 03--06
Tools .................. 5to9 03--06
Cross--sectional views . . . 10 to 14 03--06
Description & Operation . . 15 03--06
Troubleshooting......... 16--17 03--06
Removal--Installation --
transmission--gearbox
casing ................. 18to31 03--06
Disassembly--Assembly --
transmission--gearbox
casing ................. 32to39 03--06
Gearbox driving shaft end
floatadjustment ......... 40 03--06
Adjustments -- differential
lock engagement sleeve
position ................ 41 03--06
Determining the bevel pin-
ion positioning adjustment
ring .................... 42to43 03--06
Tapered roller bearings
adjustment for pinion shaft 44 03--06
Adjusting the bevel crown
wheel bearings and check-
ing the clearance between
the sides of the bevel drive
teeth................... 45to48 03--06
Differential pinion and side
gear backlash adjustment . 49--50 03--06
Differential lock pedal travel
adjustment ............. 51 03--06
Removal--Installation --
finaldrive............... 52to55 03--06
Disassembly--Assembly --
epicyclicfinaldrive....... 55 03--06
Disassembly--Assembly --
drive wheel shaft........ 56--57 03--06
603.54.511.00-- 03 -- 2006
Page Date
Calibrations............. 33 03--06
HHMENUaccess ....... 33--34 03--06
Clutch calibration H1 menu
transmission ............ 35to37 03--06
Transmission fault codes . 38 to 40 03--06
23 -- DRIVE LINES
Summary............... 1 03--06
Data ................... 2 03--06
Tightening Torques...... 3 03--06
Tools .................. 3 03--06
Cross--sectional views . . . 4 03--06
Description & Operation . . 5 03--06
Troubleshooting......... 6 03--06
Removal--Installation -- ser-
vicescontrolvalve ....... 7to9 03--06
Disassembly--Assembly --
servicescontrolvalve .... 10to11 03--06
Removal--Installation --
drive gear casing........ 12to16 03--06
Disassembly--Assembly --
drive gear casing........ 17to20 03--06
25 -- FRONT MECHANICAL TRANSMISSION
Summary............... 1 03--06
Data ................... 2to4 03--06
Tightening Torques...... 4--5 03--06
Tools .................. 6to8 03--06
Cross--sectional views . . . 9 to 13 03--06
Description & Operation . . 14--15 03--06
Rules for correctly fitting the
axle support to the engine 16 03--06
Troubleshooting......... 17 03--06
Removal--Installation --
frontaxle ............... 18to21 03--06
Disassembly--Assembly --
frontaxle ............... 22to30 03--06
Overhaul -- front differential 31 03--06
Overhaul -- front axle differ-
entialwithLIM--SLIP ..... 32--33 03--06
Overhaul -- differential lock
unit .................... 34--35 03--06
Disassembly--Assembly --
front epicyclic final drive
without brake........... 36to38 03--06
Replacing wheel hub seal
without brake............ 39 03--06
Page Date
Disassembly--Assembly --
front epicyclic final drive
withbrake .............. 40--41 03--06
Replacing wheel hub seal
withbrake. ............. 42 03--06
Replacing steering knuckle
pins and bearings....... 43 03--06
Stubaxleadjustments.... 44--45 03--06
Adjustments -- bevel drive 46 to 52 03--06
27 -- REAR MECHANICAL TRANSMISSION
Summary............... 1 03--06
Data ................... 2--3 03--06
Tightening Torques...... 3--4 03--06
Tools .................. 5to9 03--06
Cross--sectional views . . . 10 to 14 03--06
Description & Operation . . 15 03--06
Troubleshooting......... 16--17 03--06
Removal--Installation --
transmission--gearbox
casing ................. 18to31 03--06
Disassembly--Assembly --
transmission--gearbox
casing ................. 32to39 03--06
Gearbox driving shaft end
floatadjustment ......... 40 03--06
Adjustments -- differential
lock engagement sleeve
position ................ 41 03--06
Determining the bevel pin-
ion positioning adjustment
ring .................... 42to43 03--06
Tapered roller bearings
adjustment for pinion shaft 44 03--06
Adjusting the bevel crown
wheel bearings and check-
ing the clearance between
the sides of the bevel drive
teeth................... 45to48 03--06
Differential pinion and side
gear backlash adjustment . 49--50 03--06
Differential lock pedal travel
adjustment ............. 51 03--06
Removal--Installation --
finaldrive............... 52to55 03--06
Disassembly--Assembly --
epicyclicfinaldrive....... 55 03--06
Disassembly--Assembly --
drive wheel shaft........ 56--57 03--06
6 CONTENT
603.54.511.00-- 03 -- 2006
Page Date
3 1 -- P O W E R T A K E -- O F F
CHAPTER 1 -- Mechanical power
take--off
Summary............... 1 03--06
Data ................... 2to4 03--06
Tools .................. 5 03--06
Tightening Torques...... 5--6 03--06
Cross--sectional views . . . 7 to 9 03--06
Description & Operation . . 10--11 03--06
Troubleshooting......... 11 03--06
Removal--Installation --
powertake--off ..........12 to 14 03--06
Disassembly--Assembly --
powertake--off .......... 15to17 03--06
CHAPTER 2 -- Electro--hydraulic
power take--off
Summary............... 1 03--06
Data ................... 2to5 03--06
Tools .................. 5 03--06
Tightening Torques...... 6 03--06
Cross--sectional views . . . 7 to 12 03--06
Description & Operation . . 13 to 22 03--06
Additional PTO controls for
cab--version tractors with
Power Shuttle trans-
missions ............... 23--24 03--06
Troubleshooting......... 25 03--06
Replacing the power take--
offbrake ............... 26--27 03--06
Removal--Installation --
powertake--off .......... 28to31 03--06
Disassembly--Assembly --
powertake--off .......... 32to38 03--06
33 -- BRAKES
CHAPTER 1 -- Brakes
Summary............... 1 03--06
Data ................... 1 03--06
Tightening Torques...... 2 03--06
Cross--sectional views . . . 3--4 03--06
Tools .................. 4--5 03--06
Description & Operation . . 4 03--06
Page Date
Hydraulic diagram --
brakes ................. 5 03--06
Pilot valve operation..... 6 03--06
Troubleshooting......... 7 03--06
Adjustments -- parking
handbrake travel........ 8 03--06
Removal--Installation/Dis-
assembly--Assembly park-
ingbrakecasing......... 9to11 03--06
Service brake circuit air
bleeding................ 12 03--06
Removal--Installation --
servicebrakepump ...... 13--14 03--06
Adjusting the height of the
service brake pedals..... 14 03--06
Removal--Installation --
servicebrake ........... 15to19 03--06
CHAPTER 2 -- Trailer Air Brakes
Summary............... 1 03--06
Data ................... 1 03--06
Tightening Torques...... 2 03--06
Tools .................. 2 03--06
Cross--sectional views . . . 3 to 6 03--06
Description & Operation . . 6--7 03--06
Operation of single trailer
brake circuit components . 8 to 13 03--06
Troubleshooting......... 14 03--06
Pressuretests .......... 15to19 03--06
35 -- HYDRAULIC SYSTEMS
CHAPTER 1 -- Rear mechanical
hydraulic lift
Summary............... 1 03--06
Data ................... 2to6 03--06
Tightening Torques...... 7--8 03--06
Tools .................. 9 03--06
Cross--sectional views . . . 10--11 03--06
Description & Operation . . 12 to 15 03--06
Troubleshooting......... 16--17 03--06
Hydraulic lift pump compo-
nents.................. 18--19 03--06
Pump seal kit replacement 19 03--06
Disassembly--Assembly --
LIFT--O--MATIC control . . . 20 03--06
Adjustments -- lift rod
mechanism............. 21--22 03--06
603.54.511.00-- 03 -- 2006
Page Date
3 1 -- P O W E R T A K E -- O F F
CHAPTER 1 -- Mechanical power
take--off
Summary............... 1 03--06
Data ................... 2to4 03--06
Tools .................. 5 03--06
Tightening Torques...... 5--6 03--06
Cross--sectional views . . . 7 to 9 03--06
Description & Operation . . 10--11 03--06
Troubleshooting......... 11 03--06
Removal--Installation --
powertake--off ..........12 to 14 03--06
Disassembly--Assembly --
powertake--off .......... 15to17 03--06
CHAPTER 2 -- Electro--hydraulic
power take--off
Summary............... 1 03--06
Data ................... 2to5 03--06
Tools .................. 5 03--06
Tightening Torques...... 6 03--06
Cross--sectional views . . . 7 to 12 03--06
Description & Operation . . 13 to 22 03--06
Additional PTO controls for
cab--version tractors with
Power Shuttle trans-
missions ............... 23--24 03--06
Troubleshooting......... 25 03--06
Replacing the power take--
offbrake ............... 26--27 03--06
Removal--Installation --
powertake--off .......... 28to31 03--06
Disassembly--Assembly --
powertake--off .......... 32to38 03--06
33 -- BRAKES
CHAPTER 1 -- Brakes
Summary............... 1 03--06
Data ................... 1 03--06
Tightening Torques...... 2 03--06
Cross--sectional views . . . 3--4 03--06
Tools .................. 4--5 03--06
Description & Operation . . 4 03--06
Page Date
Hydraulic diagram --
brakes ................. 5 03--06
Pilot valve operation..... 6 03--06
Troubleshooting......... 7 03--06
Adjustments -- parking
handbrake travel........ 8 03--06
Removal--Installation/Dis-
assembly--Assembly park-
ingbrakecasing......... 9to11 03--06
Service brake circuit air
bleeding................ 12 03--06
Removal--Installation --
servicebrakepump ...... 13--14 03--06
Adjusting the height of the
service brake pedals..... 14 03--06
Removal--Installation --
servicebrake ........... 15to19 03--06
CHAPTER 2 -- Trailer Air Brakes
Summary............... 1 03--06
Data ................... 1 03--06
Tightening Torques...... 2 03--06
Tools .................. 2 03--06
Cross--sectional views . . . 3 to 6 03--06
Description & Operation . . 6--7 03--06
Operation of single trailer
brake circuit components . 8 to 13 03--06
Troubleshooting......... 14 03--06
Pressuretests .......... 15to19 03--06
35 -- HYDRAULIC SYSTEMS
CHAPTER 1 -- Rear mechanical
hydraulic lift
Summary............... 1 03--06
Data ................... 2to6 03--06
Tightening Torques...... 7--8 03--06
Tools .................. 9 03--06
Cross--sectional views . . . 10--11 03--06
Description & Operation . . 12 to 15 03--06
Troubleshooting......... 16--17 03--06
Hydraulic lift pump compo-
nents.................. 18--19 03--06
Pump seal kit replacement 19 03--06
Disassembly--Assembly --
LIFT--O--MATIC control . . . 20 03--06
Adjustments -- lift rod
mechanism............. 21--22 03--06
CONTENT 7
603.54.511.00-- 03 -- 2006
Page Date
LIFT--O--MATIC device up-
ward travel adjustment . . . 23 03--06
Disassembly--Assembly --
externalliftcontrols ....... 24 03--06
Removal--Installation -- lift . 25 to 31 03--06
Disassembly--Assembly --
lift ..................... 32to36 03--06
Adjustingthelift ......... 37to42 03--06
Removal--Installation -- lift
controlvalve ............ 43--44 03--06
Disassembly--Assembly --
liftcontrolvalve ......... 45to49 03--06
Lift pressure relief valve --
removal/installation and
setting ................. 50 03--06
CHAPTER 2 -- Open centre system
auxiliary control valves
Summary............... 1 03--06
Data ................... 1 03--06
Tools .................. 1 03--06
Tightening Torques...... 2 03--06
Cross--sectional views . . . 3 to 5 03--06
Description & Operation . . 6 to 9 03--06
Disassembly--Assembly --
auxiliary control valves . . . 10--11 03--06
Rod hardening test...... 11 03--06
Blow--bytest ............ 12 03--06
Adjustment of the auto-
matic detent release pres-
sure ................... 12 03--06
Removal--Installation --
flowcontrolvalve ........ 13 03--06
Adjustments -- flow control
valve .................. 14--15 03--06
CHAPTER 3 -- Auxiliary control
valves (BOSCH)
Summary............... 1 03--06
Data ................... 2 03--06
Tools .................. 2 03--06
Tightening Torques...... 3 03--06
View of BOSCH auxiliary
control valve components . 4 03--06
Description & Operation . . 4--5 03--06
Control valve components 6 to 9 03--06
Description & Operation . . 10 to 18 03--06
Page Date
Removal--Installation --
BOSCH auxiliary control
valves ................. 19to21 03--06
Disassembly--Assembly --
BOSCH auxiliary control
valves ................. 22to26 03--06
CHAPTER 4 -- Trailer brake auxiliary
control valve
Summary............... 1 03--06
Cross--sectional views . . . 1 03--06
Description & Operation . . 1--9 03--06
Troubleshooting......... 10to12 03--06
CHAPTER 5 -- Supplementary
Cylinder
Summary............... 1 03--06
Data ................... 1 03--06
Cross--sectional views . . . 1 03--06
Description & Operation . . 1 03--06
Removal--Installation/Dis-
assembly--Assembly --
supplementary cylinder . . . 2 03--06
CHAPTER 6 -- Electronic Lift
Summary............... 1 03--06
Precautions............. 1 03--06
Data ................... 2--3 03--06
Tightening Torques...... 4 03--06
Tools .................. 4 03--06
View of electronic lift com-
ponents................503--06
Electronic lift control layout 6--7 03--06
Description & Operation . . 8 to 11 03--06
Anti--damping device for
implements carried on the
lift ..................... 12to13 03--06
Faultcodedecoding ..... 13to14 03--06
Diagnostics............. 14to54 03--06
Lift electronic control unit . 55 03--06
Removal--Installation --
electronic lift control panel56 03--06
Lift arm potentiometer re-
placement ..............57 03--06
Removal --Installation --
draftsensor.............58--59 03--06
Calibration of the elec-
tronic lift arms potentio-
meter ..................60--61 03--06
603.54.511.00-- 03 -- 2006
Page Date
LIFT--O--MATIC device up-
ward travel adjustment . . . 23 03--06
Disassembly--Assembly --
externalliftcontrols ....... 24 03--06
Removal--Installation -- lift . 25 to 31 03--06
Disassembly--Assembly --
lift ..................... 32to36 03--06
Adjustingthelift ......... 37to42 03--06
Removal--Installation -- lift
controlvalve ............ 43--44 03--06
Disassembly--Assembly --
liftcontrolvalve ......... 45to49 03--06
Lift pressure relief valve --
removal/installation and
setting ................. 50 03--06
CHAPTER 2 -- Open centre system
auxiliary control valves
Summary............... 1 03--06
Data ................... 1 03--06
Tools .................. 1 03--06
Tightening Torques...... 2 03--06
Cross--sectional views . . . 3 to 5 03--06
Description & Operation . . 6 to 9 03--06
Disassembly--Assembly --
auxiliary control valves . . . 10--11 03--06
Rod hardening test...... 11 03--06
Blow--bytest ............ 12 03--06
Adjustment of the auto-
matic detent release pres-
sure ................... 12 03--06
Removal--Installation --
flowcontrolvalve ........ 13 03--06
Adjustments -- flow control
valve .................. 14--15 03--06
CHAPTER 3 -- Auxiliary control
valves (BOSCH)
Summary............... 1 03--06
Data ................... 2 03--06
Tools .................. 2 03--06
Tightening Torques...... 3 03--06
View of BOSCH auxiliary
control valve components . 4 03--06
Description & Operation . . 4--5 03--06
Control valve components 6 to 9 03--06
Description & Operation . . 10 to 18 03--06
Page Date
Removal--Installation --
BOSCH auxiliary control
valves ................. 19to21 03--06
Disassembly--Assembly --
BOSCH auxiliary control
valves ................. 22to26 03--06
CHAPTER 4 -- Trailer brake auxiliary
control valve
Summary............... 1 03--06
Cross--sectional views . . . 1 03--06
Description & Operation . . 1--9 03--06
Troubleshooting......... 10to12 03--06
CHAPTER 5 -- Supplementary
Cylinder
Summary............... 1 03--06
Data ................... 1 03--06
Cross--sectional views . . . 1 03--06
Description & Operation . . 1 03--06
Removal--Installation/Dis-
assembly--Assembly --
supplementary cylinder . . . 2 03--06
CHAPTER 6 -- Electronic Lift
Summary............... 1 03--06
Precautions............. 1 03--06
Data ................... 2--3 03--06
Tightening Torques...... 4 03--06
Tools .................. 4 03--06
View of electronic lift com-
ponents................503--06
Electronic lift control layout 6--7 03--06
Description & Operation . . 8 to 11 03--06
Anti--damping device for
implements carried on the
lift ..................... 12to13 03--06
Faultcodedecoding ..... 13to14 03--06
Diagnostics............. 14to54 03--06
Lift electronic control unit . 55 03--06
Removal--Installation --
electronic lift control panel56 03--06
Lift arm potentiometer re-
placement ..............57 03--06
Removal --Installation --
draftsensor.............58--59 03--06
Calibration of the elec-
tronic lift arms potentio-
meter ..................60--61 03--06
8 CONTENT
603.54.511.00-- 03 -- 2006
Page Date
Removal--Installation --
electroniclift ............62 to 67 03--06
Removal--Installation -- hy-
drauliccontrolvalve......68--69 03--06
CHAPTER 7 -- Ventral control valves
for Walvoil--type open
centre system
Summary............... 1 03--06
Ventral control valve spec-
ifications ...............103--06
Tightening Torques...... 2 03--06
Ventralcontrolvalve ..... 3--4 03--06
Ventral control valve joy-
stick ................... 5to7
03--06
Controlvalvecircuit ..... 8 03--06
Hydraulicdiagram ....... 9 03--06
Description and operation
of ventral control valve . . . 10 to 18 03--06
603.54.511.00-- 03 -- 2006
Page Date
Removal--Installation --
electroniclift ............62 to 67 03--06
Removal--Installation -- hy-
drauliccontrolvalve......68--69 03--06
CHAPTER 7 -- Ventral control valves
for Walvoil--type open
centre system
Summary............... 1 03--06
Ventral control valve spec-
ifications ...............103--06
Tightening Torques...... 2 03--06
Ventralcontrolvalve ..... 3--4 03--06
Ventral control valve joy-
stick ................... 5to7
03--06
Controlvalvecircuit ..... 8 03--06
Hydraulicdiagram ....... 9 03--06
Description and operation
of ventral control valve . . . 10 to 18 03--06
CONTENT 1
603.54.511.00 − 03 − 2006
CONTENTS VOLUME 2
Page Date
35 −HYDRAULIC SYSTEMS
(*)
CHAPTER 8 − Front Loader
Summary . . . . . . . . . . . . . . 1 03−06
Specifications . . . . . . . . . . . 2−303 −06
Maximum permissible front
axle weights . . . . . . . . . . . . 3 03−06
Tightening Torques . . . . . . 4 03 −06
Diagrams . . . . . . . . . . . . . . 5 to 7 03−06
Ventral control valve spec-
ifications . . . . . . . . . . . . . . . 8−903 −06
Ventral control valve joy-
stick . . . . . . . . . . . . . . . . . . . 10 to 12 03−06
System switching full and
dipped beam headlights on
lights fitted on handrails . . 13 to 16 03−06
Ballasting the tractor for
front loader operation . . . . 17 03 −06
Loader general description 18 to 27 03−06
Loader installation − re-
moval . . . . . . . . . . . . . . . . . . 28 to 32 03−06
Implement installation − re-
moval . . . . . . . . . . . . . . . . . . 33 to 36 03−06
Lift arm types and functions 37 to 45 03−06
Smooth ride control . . . . . . 46 to 48 03−06
Multi Quick coupler con-
nection − disconnection . . 49 to 60 03−06
Hydraulic functions and
flow diagram of loaders . . 61 to 71 03−06
Hydraulic Flow Diagrams . 72 to 88 03−06
Repair instructions . . . . . . 89 to 94 03−06
Hydraulic components . . . 95 to 99 03−06
Troubleshooting . . . . . . . . . 100 to 105 03−06
(
*
)
Chapters prior to section 35 are in volume 1.
Page Date
41 −STEERING
Summary . . . . . . . . . . . . . . 1 03−06
Data . . . . . . . . . . . . . . . . . . . 2 to 4 03−06
Tightening Torques . . . . . . 5 03 −06
View of hydraulic pump
components . . . . . . . . . . . . 5 03−06
View of hydrostatic steer-
ing control valve compo-
nents . . . . . . . . . . . . . . . . . . 6 03−06
Description & Operation . . 7 to 10 03−06
Fault diagnosis . . . . . . . . . . 11−12 03 −06
Tools . . . . . . . . . . . . . . . . . . 12 03−06
Removal−Installation − hy-
drostatic steering control
valve . . . . . . . . . . . . . . . . . . 13 to 17 03−06
Disassembly−Assembly −
hydrostatic control valve . . 18 to 31 03−06
Hydrostatic steering con-
trol valve bench testing . . . 32−33 03 −06
Pressure relief valve test-
ing . . . . . . . . . . . . . . . . . . . . 33 03−06
Power steering pump com-
ponents . . . . . . . . . . . . . . . . 34−35 03 −06
Disassembly − Assembly
of hydraulic pump to re-
place seal kit . . . . . . . . . . . 35 03−06
Removal−Installation −
steering cylinder . . . . . . . . 36−37 03 −06
44 −AXLES AND WHEELS
Summary . . . . . . . . . . . . . . 1 03−06
Data . . . . . . . . . . . . . . . . . . . 1 03−06
Front wheel track diagram 2 03 −06
Cross−sectional views . . . 3 03 −06
Tightening Torques . . . . . . 4−503 −06
Tools . . . . . . . . . . . . . . . . . . 5 03−06
Fault diagnosis . . . . . . . . . . 5 03−06
Disassembly−Assembly −
wheel axle hub . . . . . . . . . . 6 to 8 03−06
Removal−Installation −
front axle . . . . . . . . . . . . . . . 9 to 11 03−06
Stub axle hub overhaul . . . 12 to 14 03−06
Checking leading wheel
alignment . . . . . . . . . . . . . . 15−16 03 −06
603.54.511.00 − 03 − 2006
CONTENTS VOLUME 2
Page Date
35 −HYDRAULIC SYSTEMS
(*)
CHAPTER 8 − Front Loader
Summary . . . . . . . . . . . . . . 1 03−06
Specifications . . . . . . . . . . . 2−303 −06
Maximum permissible front
axle weights . . . . . . . . . . . . 3 03−06
Tightening Torques . . . . . . 4 03 −06
Diagrams . . . . . . . . . . . . . . 5 to 7 03−06
Ventral control valve spec-
ifications . . . . . . . . . . . . . . . 8−903 −06
Ventral control valve joy-
stick . . . . . . . . . . . . . . . . . . . 10 to 12 03−06
System switching full and
dipped beam headlights on
lights fitted on handrails . . 13 to 16 03−06
Ballasting the tractor for
front loader operation . . . . 17 03 −06
Loader general description 18 to 27 03−06
Loader installation − re-
moval . . . . . . . . . . . . . . . . . . 28 to 32 03−06
Implement installation − re-
moval . . . . . . . . . . . . . . . . . . 33 to 36 03−06
Lift arm types and functions 37 to 45 03−06
Smooth ride control . . . . . . 46 to 48 03−06
Multi Quick coupler con-
nection − disconnection . . 49 to 60 03−06
Hydraulic functions and
flow diagram of loaders . . 61 to 71 03−06
Hydraulic Flow Diagrams . 72 to 88 03−06
Repair instructions . . . . . . 89 to 94 03−06
Hydraulic components . . . 95 to 99 03−06
Troubleshooting . . . . . . . . . 100 to 105 03−06
(
*
)
Chapters prior to section 35 are in volume 1.
Page Date
41 −STEERING
Summary . . . . . . . . . . . . . . 1 03−06
Data . . . . . . . . . . . . . . . . . . . 2 to 4 03−06
Tightening Torques . . . . . . 5 03 −06
View of hydraulic pump
components . . . . . . . . . . . . 5 03−06
View of hydrostatic steer-
ing control valve compo-
nents . . . . . . . . . . . . . . . . . . 6 03−06
Description & Operation . . 7 to 10 03−06
Fault diagnosis . . . . . . . . . . 11−12 03 −06
Tools . . . . . . . . . . . . . . . . . . 12 03−06
Removal−Installation − hy-
drostatic steering control
valve . . . . . . . . . . . . . . . . . . 13 to 17 03−06
Disassembly−Assembly −
hydrostatic control valve . . 18 to 31 03−06
Hydrostatic steering con-
trol valve bench testing . . . 32−33 03 −06
Pressure relief valve test-
ing . . . . . . . . . . . . . . . . . . . . 33 03−06
Power steering pump com-
ponents . . . . . . . . . . . . . . . . 34−35 03 −06
Disassembly − Assembly
of hydraulic pump to re-
place seal kit . . . . . . . . . . . 35 03−06
Removal−Installation −
steering cylinder . . . . . . . . 36−37 03 −06
44 −AXLES AND WHEELS
Summary . . . . . . . . . . . . . . 1 03−06
Data . . . . . . . . . . . . . . . . . . . 1 03−06
Front wheel track diagram 2 03 −06
Cross−sectional views . . . 3 03 −06
Tightening Torques . . . . . . 4−503 −06
Tools . . . . . . . . . . . . . . . . . . 5 03−06
Fault diagnosis . . . . . . . . . . 5 03−06
Disassembly−Assembly −
wheel axle hub . . . . . . . . . . 6 to 8 03−06
Removal−Installation −
front axle . . . . . . . . . . . . . . . 9 to 11 03−06
Stub axle hub overhaul . . . 12 to 14 03−06
Checking leading wheel
alignment . . . . . . . . . . . . . . 15−16 03 −06
2 CONTENT
603.54.511.00 − 03 − 2006
Page Date
50 −SUBSIDIARY PARTS
Summary . . . . . . . . . . . . . . 1 03−06
Safety regulations . . . . . . . 2 03−06
Data . . . . . . . . . . . . . . . . . . . 3−403 −06
Tools . . . . . . . . . . . . . . . . . . 4 03−06
Operating principles . . . . . 5−603 −06
Conditioning system com-
ponents . . . . . . . . . . . . . . . . 7 to 11 03−06
Warnings for air condition-
ing system repair oper-
ations . . . . . . . . . . . . . . . . . . 11 03−06
Cab controls . . . . . . . . . . . . 12 to 14 03−06
Instructions for use − air
conditioning system . . . . . 15 03 −06
Air−conditioning system
charging and evacuation
recovery/recycling station 15 03 −06
Leak detector . . . . . . . . . . . 16 03−06
Air conditioning system
maintenance . . . . . . . . . . . . 17 03−06
Troubleshooting . . . . . . . . . 18 03−06
Fault diagnosis . . . . . . . . . . 19 to 22 03−06
System functional testing . 23 03 −06
Checking for and eliminat-
ing gas leaks . . . . . . . . . . . 24 03 −06
Compressor drive belt ten-
sion adjustment . . . . . . . . . 25−26 03 −06
Removal−Installation −
compressor . . . . . . . . . . . . . 27 to 29 03−06
Heating and air condition-
ing systems piping re-
placement . . . . . . . . . . . . . . 30−31 03 −06
Air conditioning piping re-
placement . . . . . . . . . . . . . . 32 to 37 03−06
Condenser replacement 38 03 −06
Dryer filter replacement . . 39−40 03 −06
Removal−Installation −
heater unit . . . . . . . . . . . . . . 41 to 43 03−06
Replacing the air−condi-
tioner evaporator . . . . . . . . 44 to 46 03−06
Removal−Installation −
electric fan . . . . . . . . . . . . . 47−48 03 −06
55 −ELECTRICAL SYSTEM
CHAPTER 1 −Instruments
Summary . . . . . . . . . . . . . . 1 03−06
Page Date
Control panel . . . . . . . . . . . 2−303 −06
Analog/digital instruments 4 03 −06
Liquid crystal display . . . . . 5 to 7 03−06
Access to the setup menu
via keypad . . . . . . . . . . . . . 8−13 03 −06
Calling up functions from
keypad . . . . . . . . . . . . . . . . . 13 to 16 03−06
Access to the setup menu
with the CAL button . . . . . . 17−18 03 −06
Calling up functions with
the CAL button . . . . . . . . . . 18 03−06
Transmitters, sensors and
switches . . . . . . . . . . . . . . . 19−26 03 −06
Maintenance . . . . . . . . . . . . 26 03−06
CHAPTER 2 −Components
Summary . . . . . . . . . . . . . . 1 03−06
Introduction . . . . . . . . . . . . . 1 03−06
Dashboard controls . . . . . . 2 to 8 03−06
Right mudguard controls . 9 to 11 03 −06
In−Cab Controls . . . . . . . . . 12 to 14 03−06
Controls on right−hand cab
upright . . . . . . . . . . . . . . . . . 15−16 03 −06
External controls . . . . . . . . 17 03−06
Maintenance . . . . . . . . . . . . 18−19 03 −06
CHAPTER 3 −Components
Summary . . . . . . . . . . . . . . 1 03−06
Technical data . . . . . . . . . . 1 03−06
Tightening Torques . . . . . . 1 03 −06
Description and Operation 2 03 −06
Fault diagnosis . . . . . . . . . . 3 03−06
Starting and recharging cir-
cuit (pre−modification) . . . 4−503 −06
Starting and recharging cir-
cuit (post−modification) . . 6−703 −06
System testing . . . . . . . . . . 8 to 10 03−06
Starter motor removal, in-
stallation and overhaul . . . 10 to 13 03−06
Bench testing . . . . . . . . . . . 13−14 03 −06
CHAPTER 4 −Charging system
Summary . . . . . . . . . . . . . . 1 03−06
Technical data . . . . . . . . . . 1 03−06
Tightening Torques . . . . . . 1 03 −06
Description and Operation 2−303 −06
System testing and
troubleshooting . . . . . . . . . 4 to 9 03−06
603.54.511.00 − 03 − 2006
Page Date
50 −SUBSIDIARY PARTS
Summary . . . . . . . . . . . . . . 1 03−06
Safety regulations . . . . . . . 2 03−06
Data . . . . . . . . . . . . . . . . . . . 3−403 −06
Tools . . . . . . . . . . . . . . . . . . 4 03−06
Operating principles . . . . . 5−603 −06
Conditioning system com-
ponents . . . . . . . . . . . . . . . . 7 to 11 03−06
Warnings for air condition-
ing system repair oper-
ations . . . . . . . . . . . . . . . . . . 11 03−06
Cab controls . . . . . . . . . . . . 12 to 14 03−06
Instructions for use − air
conditioning system . . . . . 15 03 −06
Air−conditioning system
charging and evacuation
recovery/recycling station 15 03 −06
Leak detector . . . . . . . . . . . 16 03−06
Air conditioning system
maintenance . . . . . . . . . . . . 17 03−06
Troubleshooting . . . . . . . . . 18 03−06
Fault diagnosis . . . . . . . . . . 19 to 22 03−06
System functional testing . 23 03 −06
Checking for and eliminat-
ing gas leaks . . . . . . . . . . . 24 03 −06
Compressor drive belt ten-
sion adjustment . . . . . . . . . 25−26 03 −06
Removal−Installation −
compressor . . . . . . . . . . . . . 27 to 29 03−06
Heating and air condition-
ing systems piping re-
placement . . . . . . . . . . . . . . 30−31 03 −06
Air conditioning piping re-
placement . . . . . . . . . . . . . . 32 to 37 03−06
Condenser replacement 38 03 −06
Dryer filter replacement . . 39−40 03 −06
Removal−Installation −
heater unit . . . . . . . . . . . . . . 41 to 43 03−06
Replacing the air−condi-
tioner evaporator . . . . . . . . 44 to 46 03−06
Removal−Installation −
electric fan . . . . . . . . . . . . . 47−48 03 −06
55 −ELECTRICAL SYSTEM
CHAPTER 1 −Instruments
Summary . . . . . . . . . . . . . . 1 03−06
Page Date
Control panel . . . . . . . . . . . 2−303 −06
Analog/digital instruments 4 03 −06
Liquid crystal display . . . . . 5 to 7 03−06
Access to the setup menu
via keypad . . . . . . . . . . . . . 8−13 03 −06
Calling up functions from
keypad . . . . . . . . . . . . . . . . . 13 to 16 03−06
Access to the setup menu
with the CAL button . . . . . . 17−18 03 −06
Calling up functions with
the CAL button . . . . . . . . . . 18 03−06
Transmitters, sensors and
switches . . . . . . . . . . . . . . . 19−26 03 −06
Maintenance . . . . . . . . . . . . 26 03−06
CHAPTER 2 −Components
Summary . . . . . . . . . . . . . . 1 03−06
Introduction . . . . . . . . . . . . . 1 03−06
Dashboard controls . . . . . . 2 to 8 03−06
Right mudguard controls . 9 to 11 03 −06
In−Cab Controls . . . . . . . . . 12 to 14 03−06
Controls on right−hand cab
upright . . . . . . . . . . . . . . . . . 15−16 03 −06
External controls . . . . . . . . 17 03−06
Maintenance . . . . . . . . . . . . 18−19 03 −06
CHAPTER 3 −Components
Summary . . . . . . . . . . . . . . 1 03−06
Technical data . . . . . . . . . . 1 03−06
Tightening Torques . . . . . . 1 03 −06
Description and Operation 2 03 −06
Fault diagnosis . . . . . . . . . . 3 03−06
Starting and recharging cir-
cuit (pre−modification) . . . 4−503 −06
Starting and recharging cir-
cuit (post−modification) . . 6−703 −06
System testing . . . . . . . . . . 8 to 10 03−06
Starter motor removal, in-
stallation and overhaul . . . 10 to 13 03−06
Bench testing . . . . . . . . . . . 13−14 03 −06
CHAPTER 4 −Charging system
Summary . . . . . . . . . . . . . . 1 03−06
Technical data . . . . . . . . . . 1 03−06
Tightening Torques . . . . . . 1 03 −06
Description and Operation 2−303 −06
System testing and
troubleshooting . . . . . . . . . 4 to 9 03−06
CONTENT 3
603.54.511.00 − 03 − 2006
Page Date
Removal, Installation and
Overhaul . . . . . . . . . . . . . . 10 03−06
Alternator components . . . 11 03 −06
Tests . . . . . . . . . . . . . . . . . . 12 to 14 03−06
Disassembly . . . . . . . . . . . . 15 03−06
Electronic voltage regulator 15 to 16 03−06
Inductor winding insulation
test . . . . . . . . . . . . . . . . . . . . 16−17 03 −06
Overhaul, installation . . . . 17−18 03 −06
CHAPTER 5 −Battery
Summary . . . . . . . . . . . . . . 1 03−06
Technical data . . . . . . . . . . 1 03−06
Description & Operation . . 1 03 −06
Removal−Installation −
battery . . . . . . . . . . . . . . . . . 2−303 −06
Battery maintenance . . . . . 4 to 5 03−06
Battery Charging . . . . . . . . 5−603 −06
Battery testing . . . . . . . . . . 6 to 8 03−06
Battery problems − fre-
quent causes . . . . . . . . . . . 8 03−06
CHAPTER 6 −Electrical circuits
(pre−modification)
Summary . . . . . . . . . . . . . . 1 03−06
Maxi power fuses box . . . . 2 to 4 03−06
Fuse and relay box . . . . . 4 to 16 03−06
Power sockets . . . . . . . . . . 17 03−06
Operator safety circuit . . . 18 03 −06
Grid Heater . . . . . . . . . . . . . 18−19 03 −06
Electronic flasher . . . . . . . . 19 03−06
Ground location points . . . 20−21 03 −06
How to use the linear wiring
diagrams . . . . . . . . . . . . . . . 22 to 24 03−06
Symbols used in electrical
circuits . . . . . . . . . . . . . . . . . 25−26 03 −06
Electric wire colour code . 26 03 −06
Wiring diagram compo-
nents . . . . . . . . . . . . . . . . . . 27 to 34 03−06
Power Shuttle cab version 35 to 70 03−06
Dual Command (2 Speed
Power Shift) cab version . 71 to 106 03−06
Page Date
Power Shuttle ISO deck
version . . . . . . . . . . . . . . . . . 107 to 130 03−06
Power Shuttle NASO deck
version . . . . . . . . . . . . . . . . . 131 to 154 03−06
Dual Command (2 Speed
Power Shift) ISO deck ver-
sion . . . . . . . . . . . . . . . . . . . 155 to 178 03−06
Dual Command (2 Speed
Power Shift) NASO deck
version . . . . . . . . . . . . . . . . . 179 to 202 03−06
Control unit input − output
diagrams . . . . . . . . . . . . . . . 203 to 208 03−06
CHAPTER 7 −Electrical circuits
(post−modification)
Summary . . . . . . . . . . . . . 1 03−06
Maxi power fuses box . . . . 02 to 04 03−06
Fuse and relay box . . . . . 04 to 22 03−06
Power sockets . . . . . . . . . . 23 03−06
Grid Heater . . . . . . . . . . . . . 24 03−06
Electronic flasher . . . . . . . . 24 03−06
How to use the linear wiring
diagrams . . . . . . . . . . . . . . . 25 to 27 03−06
Ground location points . . . 28−29 03 −06
Electric wire colour code . 30 03 −06
Symbols used in electrical
circuits . . . . . . . . . . . . . . . . . 31−32 03 −06
Wiring diagram compo-
nents . . . . . . . . . . . . . . . . . . 33 to 40 03−06
Power Shuttle cab version 41 to 76 03−06
Dual Command (2 Speed
Power Shift) cab version . 77 to 112 03−06
Power Shuttle ISO deck
version . . . . . . . . . . . . . . . . . 113 to 136 03−06
Power Shuttle NASO deck
version . . . . . . . . . . . . . . . . . 137 to 160 03−06
Dual Command (2 Speed
Power Shift) ISO deck ver-
sion . . . . . . . . . . . . . . . . . . . 161 to 184 03−06
Dual Command (2 Speed
Power Shift) NASO deck
version . . . . . . . . . . . . . . . . . 185 to 207 03−06
Control unit input − output
diagrams . . . . . . . . . . . . . . . 208 to 214 03−06
603.54.511.00 − 03 − 2006
Page Date
Removal, Installation and
Overhaul . . . . . . . . . . . . . . 10 03−06
Alternator components . . . 11 03 −06
Tests . . . . . . . . . . . . . . . . . . 12 to 14 03−06
Disassembly . . . . . . . . . . . . 15 03−06
Electronic voltage regulator 15 to 16 03−06
Inductor winding insulation
test . . . . . . . . . . . . . . . . . . . . 16−17 03 −06
Overhaul, installation . . . . 17−18 03 −06
CHAPTER 5 −Battery
Summary . . . . . . . . . . . . . . 1 03−06
Technical data . . . . . . . . . . 1 03−06
Description & Operation . . 1 03 −06
Removal−Installation −
battery . . . . . . . . . . . . . . . . . 2−303 −06
Battery maintenance . . . . . 4 to 5 03−06
Battery Charging . . . . . . . . 5−603 −06
Battery testing . . . . . . . . . . 6 to 8 03−06
Battery problems − fre-
quent causes . . . . . . . . . . . 8 03−06
CHAPTER 6 −Electrical circuits
(pre−modification)
Summary . . . . . . . . . . . . . . 1 03−06
Maxi power fuses box . . . . 2 to 4 03−06
Fuse and relay box . . . . . 4 to 16 03−06
Power sockets . . . . . . . . . . 17 03−06
Operator safety circuit . . . 18 03 −06
Grid Heater . . . . . . . . . . . . . 18−19 03 −06
Electronic flasher . . . . . . . . 19 03−06
Ground location points . . . 20−21 03 −06
How to use the linear wiring
diagrams . . . . . . . . . . . . . . . 22 to 24 03−06
Symbols used in electrical
circuits . . . . . . . . . . . . . . . . . 25−26 03 −06
Electric wire colour code . 26 03 −06
Wiring diagram compo-
nents . . . . . . . . . . . . . . . . . . 27 to 34 03−06
Power Shuttle cab version 35 to 70 03−06
Dual Command (2 Speed
Power Shift) cab version . 71 to 106 03−06
Page Date
Power Shuttle ISO deck
version . . . . . . . . . . . . . . . . . 107 to 130 03−06
Power Shuttle NASO deck
version . . . . . . . . . . . . . . . . . 131 to 154 03−06
Dual Command (2 Speed
Power Shift) ISO deck ver-
sion . . . . . . . . . . . . . . . . . . . 155 to 178 03−06
Dual Command (2 Speed
Power Shift) NASO deck
version . . . . . . . . . . . . . . . . . 179 to 202 03−06
Control unit input − output
diagrams . . . . . . . . . . . . . . . 203 to 208 03−06
CHAPTER 7 −Electrical circuits
(post−modification)
Summary . . . . . . . . . . . . . 1 03−06
Maxi power fuses box . . . . 02 to 04 03−06
Fuse and relay box . . . . . 04 to 22 03−06
Power sockets . . . . . . . . . . 23 03−06
Grid Heater . . . . . . . . . . . . . 24 03−06
Electronic flasher . . . . . . . . 24 03−06
How to use the linear wiring
diagrams . . . . . . . . . . . . . . . 25 to 27 03−06
Ground location points . . . 28−29 03 −06
Electric wire colour code . 30 03 −06
Symbols used in electrical
circuits . . . . . . . . . . . . . . . . . 31−32 03 −06
Wiring diagram compo-
nents . . . . . . . . . . . . . . . . . . 33 to 40 03−06
Power Shuttle cab version 41 to 76 03−06
Dual Command (2 Speed
Power Shift) cab version . 77 to 112 03−06
Power Shuttle ISO deck
version . . . . . . . . . . . . . . . . . 113 to 136 03−06
Power Shuttle NASO deck
version . . . . . . . . . . . . . . . . . 137 to 160 03−06
Dual Command (2 Speed
Power Shift) ISO deck ver-
sion . . . . . . . . . . . . . . . . . . . 161 to 184 03−06
Dual Command (2 Speed
Power Shift) NASO deck
version . . . . . . . . . . . . . . . . . 185 to 207 03−06
Control unit input − output
diagrams . . . . . . . . . . . . . . . 208 to 214 03−06
CONTENT 1
603.54.511.00-- 03 -- 2006
CONTENTS VOLUME 3
Page Date
55 -- ELECTRICAL SYSTEM
(
*
)
CHAPTER 8 -- Connectors
Summary.............. 1 03--06
Electrical circuits compo-
nents.................. 2to6 03--06
Wirings (pre--modification) 7 to 26 03--06
Wirings
(post--modification) ...... 27to46 03--06
List of connectors........ 47to94 03--06
CHAPTER 9 -- Components Testing
Summary............... 1 03--06
Tests on switches, sensors
and pressure switches . . . 02 to 18 03--06
Removal--Installation wind-
screenwipermotor ...... 19 03--06
CHAPTER 10 -- Error codes
Summary............... 1 03--06
Introduction............. 2 03--06
SpecialAttachments ..... 3 03--06
Repairing the wiring...... 3 03--06
Digitalmultimeter ........ 6to8 03--06
Electrical test procedures 9--11 03--06
Circuit components...... 11to20 03--06
CAN system............ 21 03--06
Controlunitlocation...... 21 03--06
Errorcodedisplay ....... 22to24 03--06
“H” menu diagnostic mode 24 03--06
Error codes lists......... 25to30 03--06
Error codes charts
Calibration U--Codes..... 31to34 03--06
2001--3000
(Transmission) .......... 35to280 03--06
5001--6000
(RearPTO) ............ 281to308 03--06
6001--7000
(4WD) ................. 309to319 03--06
7001--8000
(Differentiallock) ........ 320to335 03--06
Page Date
14001--15000 (Analog--
digital control panel)..... 336to404 03--06
Electronically controlled
hydrauliclift(EDC)....... 405to482 03--06
CHAPTER 11 -- HH menu and calibrations
Summary............... 1 03--06
Calibrations............. 2 03--06
HHMENUaccess ....... 3--4 03--06
HH MENU of the control
panel.................. 5to11 03--06
HH MENU of the trans-
mission ................ 12to25 03--06
HH MENU of the
advancedkeypad........ 25--26 03--06
90 -- BODYWORK AND DRIVING POSITION
Summary............... 1 03--06
Removal--Installation --
bonnet................. 2--3 03--06
Removal--Installation --
platform ................ 4to11 03--06
Removal--Installation --
driver’sseat ............ 12 03--06
Cab Removal--Installation . 13 to 25 03--06
Removal--Installation --
door................... 26 03--06
Replacement of glued cab
windows............... 27--28 03--06
Replacement of cab rear
window................ 29to31 03--06
Replacement of seal on
left--hand upright........ 32 03--06
Replacement of seal on
right--hand upright....... 33--34 03--06
Replacement of fixed pad-
ding on right--hand wall . . . 35 to 37 03--06
Replacement of fixed pad-
ding on left--hand wall.... 38--39 03--06
Replacing hydraulic con-
trol lever guard.......... 40--41 03--06
Replacing cab ceiling fit-
tings ................... 42--43 03--06
(
*
)
Chapters prior to section55are involume 2.
603.54.511.00-- 03 -- 2006
CONTENTS VOLUME 3
Page Date
55 -- ELECTRICAL SYSTEM
(
*
)
CHAPTER 8 -- Connectors
Summary.............. 1 03--06
Electrical circuits compo-
nents.................. 2to6 03--06
Wirings (pre--modification) 7 to 26 03--06
Wirings
(post--modification) ...... 27to46 03--06
List of connectors........ 47to94 03--06
CHAPTER 9 -- Components Testing
Summary............... 1 03--06
Tests on switches, sensors
and pressure switches . . . 02 to 18 03--06
Removal--Installation wind-
screenwipermotor ...... 19 03--06
CHAPTER 10 -- Error codes
Summary............... 1 03--06
Introduction............. 2 03--06
SpecialAttachments ..... 3 03--06
Repairing the wiring...... 3 03--06
Digitalmultimeter ........ 6to8 03--06
Electrical test procedures 9--11 03--06
Circuit components...... 11to20 03--06
CAN system............ 21 03--06
Controlunitlocation...... 21 03--06
Errorcodedisplay ....... 22to24 03--06
“H” menu diagnostic mode 24 03--06
Error codes lists......... 25to30 03--06
Error codes charts
Calibration U--Codes..... 31to34 03--06
2001--3000
(Transmission) .......... 35to280 03--06
5001--6000
(RearPTO) ............ 281to308 03--06
6001--7000
(4WD) ................. 309to319 03--06
7001--8000
(Differentiallock) ........ 320to335 03--06
Page Date
14001--15000 (Analog--
digital control panel)..... 336to404 03--06
Electronically controlled
hydrauliclift(EDC)....... 405to482 03--06
CHAPTER 11 -- HH menu and calibrations
Summary............... 1 03--06
Calibrations............. 2 03--06
HHMENUaccess ....... 3--4 03--06
HH MENU of the control
panel.................. 5to11 03--06
HH MENU of the trans-
mission ................ 12to25 03--06
HH MENU of the
advancedkeypad........ 25--26 03--06
90 -- BODYWORK AND DRIVING POSITION
Summary............... 1 03--06
Removal--Installation --
bonnet................. 2--3 03--06
Removal--Installation --
platform ................ 4to11 03--06
Removal--Installation --
driver’sseat ............ 12 03--06
Cab Removal--Installation . 13 to 25 03--06
Removal--Installation --
door................... 26 03--06
Replacement of glued cab
windows............... 27--28 03--06
Replacement of cab rear
window................ 29to31 03--06
Replacement of seal on
left--hand upright........ 32 03--06
Replacement of seal on
right--hand upright....... 33--34 03--06
Replacement of fixed pad-
ding on right--hand wall . . . 35 to 37 03--06
Replacement of fixed pad-
ding on left--hand wall.... 38--39 03--06
Replacing hydraulic con-
trol lever guard.......... 40--41 03--06
Replacing cab ceiling fit-
tings ................... 42--43 03--06
(
*
)
Chapters prior to section55are involume 2.
SECTION 00 -- GENERAL GUIDELINES -- CHAPTER 1 1
603.54.511.00-- 03 -- 2006
GENERAL INSTRUCTIONS
IMPORTANT NOTICE
All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND
service technicians, in strict accordance with the instructions given and using any specific tools necessary.
Anyone performing the operations described herein without strictly following the instructions is personally re-
sponsible for any eventual injury or damage to property.
SHIMMING
For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add
up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated
value indicated for each shim.
ROTATING SHAFT SEALS
For correct rotating shaft seal installation, proceed as follows:
-- before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes;
-- thoroughly clean the shaft and check that the working surface on the shaft is not damaged;
-- position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direc-
tion and position the grooves so that they will deviate the fluid towards the inner side of the seal;
-- coat the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing
lip and the dust lip on double lip seals with grease;
-- insert the seal in its seat and press down using a flat punch; do not tap the seal with a hammer or mallet;
-- whilst inserting the seal, check that it is perpendicular to the seat; once settled, make sure that it makes con-
tact with the thrust element, if required;
-- to prevent damaging the seal lip on the shaft, position a protective guard during installation operations.
“O--RING” SEALS
Lubricate the O--RING seals before inserting them in the seats, this will prevent them from overturning and twist-
ing, which would jeopardise sealing efficiency.
SEALING COMPOUNDS
Apply one of the following sealing compounds on the mating surfaces marked with an X: RTV SILMATE, RHO-
DORSIL CAF 1 or LOCTITE PLASTIC GASKET.
Before applying the sealing compound, prepare the surfaces as follows:
-- remove any incrustations using a wire brush;
-- thoroughly de--grease the surfaces using one of the following cleaning agents: trichlorethylene, petrol or a
water and soda solution.
603.54.511.00-- 03 -- 2006
GENERAL INSTRUCTIONS
IMPORTANT NOTICE
All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND
service technicians, in strict accordance with the instructions given and using any specific tools necessary.
Anyone performing the operations described herein without strictly following the instructions is personally re-
sponsible for any eventual injury or damage to property.
SHIMMING
For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add
up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated
value indicated for each shim.
ROTATING SHAFT SEALS
For correct rotating shaft seal installation, proceed as follows:
-- before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes;
-- thoroughly clean the shaft and check that the working surface on the shaft is not damaged;
-- position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direc-
tion and position the grooves so that they will deviate the fluid towards the inner side of the seal;
-- coat the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing
lip and the dust lip on double lip seals with grease;
-- insert the seal in its seat and press down using a flat punch; do not tap the seal with a hammer or mallet;
-- whilst inserting the seal, check that it is perpendicular to the seat; once settled, make sure that it makes con-
tact with the thrust element, if required;
-- to prevent damaging the seal lip on the shaft, position a protective guard during installation operations.
“O--RING” SEALS
Lubricate the O--RING seals before inserting them in the seats, this will prevent them from overturning and twist-
ing, which would jeopardise sealing efficiency.
SEALING COMPOUNDS
Apply one of the following sealing compounds on the mating surfaces marked with an X: RTV SILMATE, RHO-
DORSIL CAF 1 or LOCTITE PLASTIC GASKET.
Before applying the sealing compound, prepare the surfaces as follows:
-- remove any incrustations using a wire brush;
-- thoroughly de--grease the surfaces using one of the following cleaning agents: trichlorethylene, petrol or a
water and soda solution.
2 SECTION 00 -- GENERAL GUIDELINES -- CHAPTER 1
603.54.511.00-- 03 -- 2006
BEARINGS
When installing bearings it is advised to:
-- heat the bearings to 80÷90°C before fitting on the shafts;
-- allow the bearings to cool before installing them.
SPRING PINS
When fitting split socket spring pins, ensure that the pin notch is positioned in the direction of the force required
to stress the pin.
Spiral spring pins do not require special positioning.
SPARE PARTS
Use solelygenuine parts, which guarantee the same quality, duration and safety as the original parts as they
are identical to the ones fitted during production.
Onlygenuine partscan offer this guarantee.
When ordering spare parts, always provide the following information:
-- tractor model (commercial name) and frame number;
-- engine type and number;
-- part number of the ordered part, which can be found in the “Microfiches” or the “Spare Parts Catalogue”, used
for order processing.
TOOLS
The tools that NEW HOLLAND offer and illustrate in this manual are:
-- specifically researched and designed for use with NEW HOLLAND vehicles;
-- essential for reliable repair operations;
-- accurately built and rigorously tested so as to offer efficient and long--lasting operation.
By using these tools, repair personnel will benefit from:
-- operating in optimal technical conditions;
-- obtaining the best results;
-- saving time and effort;
-- working in safe conditions.
IMPORTANT NOTES
Wear limit values indicated for certain parts are recommended, but not binding. The terms “front”, “rear”, “right--
hand” and “left--hand” (when referred to different parts) are intended as seen from the driving position with the
vehicle in the normal direction of movement.
MOVING THE TRACTOR WITH THE BATTERY REMOVED
External power supply cables should only be connected to the respective positive and negative cable terminals,
using efficient clamps that guarantee adequate and secure contact.
Disconnect all services (lights, windshield wipers, etc.) before starting the vehicle.
If the vehicle electrical system requires checking, carry out operations with the power supply connected. Once
checking is completed, disconnect all services and switch off the power supply before disconnecting the cables.
603.54.511.00-- 03 -- 2006
BEARINGS
When installing bearings it is advised to:
-- heat the bearings to 80÷90°C before fitting on the shafts;
-- allow the bearings to cool before installing them.
SPRING PINS
When fitting split socket spring pins, ensure that the pin notch is positioned in the direction of the force required
to stress the pin.
Spiral spring pins do not require special positioning.
SPARE PARTS
Use solelygenuine parts, which guarantee the same quality, duration and safety as the original parts as they
are identical to the ones fitted during production.
Onlygenuine partscan offer this guarantee.
When ordering spare parts, always provide the following information:
-- tractor model (commercial name) and frame number;
-- engine type and number;
-- part number of the ordered part, which can be found in the “Microfiches” or the “Spare Parts Catalogue”, used
for order processing.
TOOLS
The tools that NEW HOLLAND offer and illustrate in this manual are:
-- specifically researched and designed for use with NEW HOLLAND vehicles;
-- essential for reliable repair operations;
-- accurately built and rigorously tested so as to offer efficient and long--lasting operation.
By using these tools, repair personnel will benefit from:
-- operating in optimal technical conditions;
-- obtaining the best results;
-- saving time and effort;
-- working in safe conditions.
IMPORTANT NOTES
Wear limit values indicated for certain parts are recommended, but not binding. The terms “front”, “rear”, “right--
hand” and “left--hand” (when referred to different parts) are intended as seen from the driving position with the
vehicle in the normal direction of movement.
MOVING THE TRACTOR WITH THE BATTERY REMOVED
External power supply cables should only be connected to the respective positive and negative cable terminals,
using efficient clamps that guarantee adequate and secure contact.
Disconnect all services (lights, windshield wipers, etc.) before starting the vehicle.
If the vehicle electrical system requires checking, carry out operations with the power supply connected. Once
checking is completed, disconnect all services and switch off the power supply before disconnecting the cables.
SECTION 10 -- ENGINE -- CHAPTER 1 1
603.54.511.00-- 03 -- 2006
SECTION 10 -- ENGINE
Chapter 1 -- Engine
CONTENTS
Operation Description Page
General specifications 2.........................................................
Data 5.........................................................................
Tightening torques 11............................................................
Tools 13.......................................................................
Engine views 14................................................................
Lubrication diagram 16..........................................................
Cooling system diagram 17......................................................
Fault diagnosis 21..............................................................
10 001 10 Engine R.I. 25..................................................................
10 001 53 Engine D.A. Checks, measurements and repairs 45.................................
10 102 70 Crankshaft front seal -- Replacement 97...........................................
10 102 74 Crankshaft rear seal -- Replacement 100...........................................
10 106 12 Valve tappet and rocker arm clearance -- Adjustment 103.............................
10 218 30 Engine injector R.I. 106..........................................................
10 246 14 Bosch injection pump R.I. Timing. Air bleed 109.....................................
10 402 10 Coolant pump R.I. 119...........................................................
10 402 30 Thermostat valve R.I. 121........................................................
10 406 10 Radiator R.I. 123................................................................
10 414 10 Coolant pump and generator drive belts. Tension adjustment 129......................
603.54.511.00-- 03 -- 2006
SECTION 10 -- ENGINE
Chapter 1 -- Engine
CONTENTS
Operation Description Page
General specifications 2.........................................................
Data 5.........................................................................
Tightening torques 11............................................................
Tools 13.......................................................................
Engine views 14................................................................
Lubrication diagram 16..........................................................
Cooling system diagram 17......................................................
Fault diagnosis 21..............................................................
10 001 10 Engine R.I. 25..................................................................
10 001 53 Engine D.A. Checks, measurements and repairs 45.................................
10 102 70 Crankshaft front seal -- Replacement 97...........................................
10 102 74 Crankshaft rear seal -- Replacement 100...........................................
10 106 12 Valve tappet and rocker arm clearance -- Adjustment 103.............................
10 218 30 Engine injector R.I. 106..........................................................
10 246 14 Bosch injection pump R.I. Timing. Air bleed 109.....................................
10 402 10 Coolant pump R.I. 119...........................................................
10 402 30 Thermostat valve R.I. 121........................................................
10 406 10 Radiator R.I. 123................................................................
10 414 10 Coolant pump and generator drive belts. Tension adjustment 129......................
2 SECTION 10 -- ENGINE -- CHAPTER 1
603.54.511.00-- 03 -- 2006
GENERAL SPECIFICATIONS 4 Cylinders
Engine, technical type:
-- model TL70A -- type F4CE0404D*D601 (BOSCH pump) . --
-- model TL70A -- type F4CE0404D*D681 (BOSCH pump) . --
-- model TL80A -- type F4CE0404C*D601 (BOSCH pump) . --
-- model TL80A -- type F4CE0404C*D681 (BOSCH pump) . --
-- model TL90A -- type F4CE0454E*D601 (BOSCH pump) . --
-- model TL90A -- type F4CE0454E*D681 (BOSCH pump) . --
-- model TL100A -- type F4CE0454D*D601 (BOSCH pump)
-- model TL100A -- type F4CE0454D*D681 (BOSCH pump)
-- --
Cycle ................................................. diesel, 4--stroke
Fuelinjection .......................................... direct
Number of cylinders in line............................... 4
Piston diameter
-- model TL70A -- TL80A -- TL90A -- TL100A............. 4.0944 in. (104 mm)
Pistonstroke .......................................... 5.1968 in. (132 mm)
Total displacement:
-- model TL70A -- TL80A -- TL90A -- TL100A............. 273.67 in
3
. (4485 cm
3
)
Compression ratio for Models TL70A -- TL80A -- TL90A --
TL100A.............................................. 17.5:1
Maximum power:
-- model TL70A -- type F4CE0404D*D601................ 53 kW (70 HP)
-- model TL70A -- type F4CE0404D*D681................ 53 kW (70 HP)
-- model TL80A -- type F4CE0404C*D601................ 60 kW (80 HP)
-- model TL80A -- type F4CE0404C*D681................ 60 kW (80 HP)
-- model TL90A -- type F4CE0454E*D601................ 67 kW (90 HP)
-- model TL90A -- type F4CE0454E*D681................ 67 kW (90 HP)
-- model TL100A -- type F4CE0454D*D601...............
-- model TL100A -- type F4CE0454D*D681...............
73,5 kW (100 HP)
73,5 kW (100 HP)
Maximum power speed................................. 2500 rev/min
-- Maximum torque: model TL70A -- type F4CE0404D*D601 280 (Nm)
-- Maximum torque: model TL70A -- type F4CE0404D*D681 280 (Nm)
-- Maximum torque: model TL80A -- type F4CE0404C*D601 320 (Nm)
-- Maximum torque: model TL80A -- type F4CE0404C*D681 320 (Nm)
-- Maximum torque: model TL90A -- type F4CE0454E*D601 350 (Nm)
-- Maximum torque: model TL90A -- type F4CE0454E*D681 350 (Nm)
-- Maximum torque: model TL100A -- type F4CE0454D*D601
-- Maximum torque: model TL100A -- type F4CE0454D*D681
370 (Nm) 370 (Nm)
Maximum torque speed................................. 1400 rev/min
Number of main bearings................................ 5
Sump ................................................. structural, cast iron
(continued)
603.54.511.00-- 03 -- 2006
GENERAL SPECIFICATIONS 4 Cylinders
Engine, technical type:
-- model TL70A -- type F4CE0404D*D601 (BOSCH pump) . --
-- model TL70A -- type F4CE0404D*D681 (BOSCH pump) . --
-- model TL80A -- type F4CE0404C*D601 (BOSCH pump) . --
-- model TL80A -- type F4CE0404C*D681 (BOSCH pump) . --
-- model TL90A -- type F4CE0454E*D601 (BOSCH pump) . --
-- model TL90A -- type F4CE0454E*D681 (BOSCH pump) . --
-- model TL100A -- type F4CE0454D*D601 (BOSCH pump)
-- model TL100A -- type F4CE0454D*D681 (BOSCH pump)
-- --
Cycle ................................................. diesel, 4--stroke
Fuelinjection .......................................... direct
Number of cylinders in line............................... 4
Piston diameter
-- model TL70A -- TL80A -- TL90A -- TL100A............. 4.0944 in. (104 mm)
Pistonstroke .......................................... 5.1968 in. (132 mm)
Total displacement:
-- model TL70A -- TL80A -- TL90A -- TL100A............. 273.67 in
3
. (4485 cm
3
)
Compression ratio for Models TL70A -- TL80A -- TL90A --
TL100A.............................................. 17.5:1
Maximum power:
-- model TL70A -- type F4CE0404D*D601................ 53 kW (70 HP)
-- model TL70A -- type F4CE0404D*D681................ 53 kW (70 HP)
-- model TL80A -- type F4CE0404C*D601................ 60 kW (80 HP)
-- model TL80A -- type F4CE0404C*D681................ 60 kW (80 HP)
-- model TL90A -- type F4CE0454E*D601................ 67 kW (90 HP)
-- model TL90A -- type F4CE0454E*D681................ 67 kW (90 HP)
-- model TL100A -- type F4CE0454D*D601...............
-- model TL100A -- type F4CE0454D*D681...............
73,5 kW (100 HP)
73,5 kW (100 HP)
Maximum power speed................................. 2500 rev/min
-- Maximum torque: model TL70A -- type F4CE0404D*D601 280 (Nm)
-- Maximum torque: model TL70A -- type F4CE0404D*D681 280 (Nm)
-- Maximum torque: model TL80A -- type F4CE0404C*D601 320 (Nm)
-- Maximum torque: model TL80A -- type F4CE0404C*D681 320 (Nm)
-- Maximum torque: model TL90A -- type F4CE0454E*D601 350 (Nm)
-- Maximum torque: model TL90A -- type F4CE0454E*D681 350 (Nm)
-- Maximum torque: model TL100A -- type F4CE0454D*D601
-- Maximum torque: model TL100A -- type F4CE0454D*D681
370 (Nm) 370 (Nm)
Maximum torque speed................................. 1400 rev/min
Number of main bearings................................ 5
Sump ................................................. structural, cast iron
(continued)
SECTION 10 -- ENGINE -- CHAPTER 1 3
603.54.511.00-- 03 -- 2006
(cont)
GENERAL SPECIFICATIONS4 Cylinders
Lubrication........................................... forced, with lobe pump
Pumpdrive ............................................ camshaft
Engine speed/oil pump speed ratio....................... 1:1
Oil cleaning............................................ mesh filter on oil intake and filtering
cartridge on delivery line
Normal oil pressure with motor warmed--up
at slow idling speed..................................... 17.4 psi (1.2 bar)
at fast idling speed..................................... 55.1 psi (3.8 bar)
Cooling system....................................... coolant circulation
Radiator on Models TL70A -- TL80A -- TL90A -- TL100A.....4 lines of vertical pipes with copper fins
Fan,attachedtothepulley............................... intake, in plastic with 11 blades
Coolantpump.......................................... centrifugal vane--type
Engine speed/coolant pump speed ratio...................
Coolantthermometer ...................................
Temperature ranges corresponding to each section:
--Initialbluesection.....................................
-- Middle green section (normal working conditions).........
--Finalredsection ......................................
1:1.977
coloured scale divided into 3 sections
104 to 140°F(40°to 60°C)
140 to 230°F(60°to 110°C)
230 to 248°F(110°to 120°C)
Temperaturecontrol .................................... via thermostat valve
-- initial opening....................................... 177.0±35.6°F(81±2°C)
Timing system........................................overhead valves operated by tappets, rods
and rocker arms via the camshaft located
in the engine block; the camshaft is driven
by the crankshaft using straight--tooth
gears
Intake:
-- start:beforeT.D.C. .................................. 10°±30’
-- end: after B.D.C..................................... 10°±30’
Exhaust:
-- start:beforeB.D.C. ................................. 64°
-- end: after B.D.C..................................... 26°
Valve--rocker arm clearance (with engine cold):
-- intake ............................................. (0.30±0.05 mm)
-- exhaust............................................ (0.55±0.05 mm)
For further timing system technical data................... see page 8
(continued)
603.54.511.00-- 03 -- 2006
(cont)
GENERAL SPECIFICATIONS4 Cylinders
Lubrication........................................... forced, with lobe pump
Pumpdrive ............................................ camshaft
Engine speed/oil pump speed ratio....................... 1:1
Oil cleaning............................................ mesh filter on oil intake and filtering
cartridge on delivery line
Normal oil pressure with motor warmed--up
at slow idling speed..................................... 17.4 psi (1.2 bar)
at fast idling speed..................................... 55.1 psi (3.8 bar)
Cooling system....................................... coolant circulation
Radiator on Models TL70A -- TL80A -- TL90A -- TL100A.....4 lines of vertical pipes with copper fins
Fan,attachedtothepulley............................... intake, in plastic with 11 blades
Coolantpump.......................................... centrifugal vane--type
Engine speed/coolant pump speed ratio...................
Coolantthermometer ...................................
Temperature ranges corresponding to each section:
--Initialbluesection.....................................
-- Middle green section (normal working conditions).........
--Finalredsection ......................................
1:1.977
coloured scale divided into 3 sections
104 to 140°F(40°to 60°C)
140 to 230°F(60°to 110°C)
230 to 248°F(110°to 120°C)
Temperaturecontrol .................................... via thermostat valve
-- initial opening....................................... 177.0±35.6°F(81±2°C)
Timing system........................................overhead valves operated by tappets, rods
and rocker arms via the camshaft located
in the engine block; the camshaft is driven
by the crankshaft using straight--tooth
gears
Intake:
-- start:beforeT.D.C. .................................. 10°±30’
-- end: after B.D.C..................................... 10°±30’
Exhaust:
-- start:beforeB.D.C. ................................. 64°
-- end: after B.D.C..................................... 26°
Valve--rocker arm clearance (with engine cold):
-- intake ............................................. (0.30±0.05 mm)
-- exhaust............................................ (0.55±0.05 mm)
For further timing system technical data................... see page 8
(continued)
4 SECTION 10 -- ENGINE -- CHAPTER 1
603.54.511.00-- 03 -- 2006
(cont)
GENERAL SPECIFICATIONS 4 Cylinders
Fuel system
Air cleaning............................................dual cartridge dry air filter, with clogged
filter indicator with centrifugal pre--filter
and automatic dust ejector
Fuelpump............................................. with double diaphragm
Fuelfiltering ...........................................through wire filter in fuel supply pump, and
replaceable cartridge on delivery line to
injection pump
Minimum fuel flow rate with pump shaft rotating at 1800 rpm . 127.6 l/h
Cam operated......................................... engine timing
BOSCHinjectionpump.................................. rotating distributor type
All--speed governor, incorporated in pump:
BOSCH ............................................... centrifugal counterweights
Automatic advance regulator, incorporated in pump:
BOSCH ............................................... hydraulic
For further fuel system technical data:
Fixed advance (pump setting on engine for start of delivery
beforeTDC) ........................................... refer to the data given in the table for
operation 14. page 117
Pressure setting -- Injection order, and other information regarding the BOSCH pump.............................
refer to the data given in the table
page 5
603.54.511.00-- 03 -- 2006
(cont)
GENERAL SPECIFICATIONS 4 Cylinders
Fuel system
Air cleaning............................................dual cartridge dry air filter, with clogged
filter indicator with centrifugal pre--filter
and automatic dust ejector
Fuelpump............................................. with double diaphragm
Fuelfiltering ...........................................through wire filter in fuel supply pump, and
replaceable cartridge on delivery line to
injection pump
Minimum fuel flow rate with pump shaft rotating at 1800 rpm . 127.6 l/h
Cam operated......................................... engine timing
BOSCHinjectionpump.................................. rotating distributor type
All--speed governor, incorporated in pump:
BOSCH ............................................... centrifugal counterweights
Automatic advance regulator, incorporated in pump:
BOSCH ............................................... hydraulic
For further fuel system technical data:
Fixed advance (pump setting on engine for start of delivery
beforeTDC) ........................................... refer to the data given in the table for
operation 14. page 117
Pressure setting -- Injection order, and other information regarding the BOSCH pump.............................
refer to the data given in the table
page 5
14 SECTION 10 -- ENGINE -- CHAPTER 1
603.54.511.00-- 03 -- 2006
MIF1096A
1
View of TL70A tractor engines of 53 kW (70 HP) and TL80A of 60 kW (80 HP)
603.54.511.00-- 03 -- 2006
MIF1096A
1
View of TL70A tractor engines of 53 kW (70 HP) and TL80A of 60 kW (80 HP)
SECTION 10 -- ENGINE -- CHAPTER 1 15
603.54.511.00-- 03 -- 2006
MIF1097A
model TL90A
2
View of TL90A tractor engines of 67 kW (90 HP) and TL100A of 73.5 kW (100 HP)
603.54.511.00-- 03 -- 2006
MIF1097A
model TL90A
2
View of TL90A tractor engines of 67 kW (90 HP) and TL100A of 73.5 kW (100 HP)
16 SECTION 10 -- ENGINE -- CHAPTER 1
603.54.511.00-- 03 -- 2006
MIF1098A
Oil path under pressure
Oil return path under gravity
3
Lubrication diagram for engines mod. TL90A and TL100A
Forced--circulation lubrication is accomplished by the
following components:
-- oil pump, housed at the front of the crankcase,
driven by the grooved bushing keyed onto the
shank of the crankshaft;
-- water / oil cooler, housed in the crankcase;
-- oil pressure control valve incorporated in the
cooler assembly;
-- by--pass valve to cut off clogged oil filter, incorpo-
rated in the cooler assembly;
-- cartridge oil filter.
NOTE:Engines mod. TL70A and TL80A do not have
a turbocharger lubrication circuit.
603.54.511.00-- 03 -- 2006
MIF1098A
Oil path under pressure
Oil return path under gravity
3
Lubrication diagram for engines mod. TL90A and TL100A
Forced--circulation lubrication is accomplished by the
following components:
-- oil pump, housed at the front of the crankcase,
driven by the grooved bushing keyed onto the
shank of the crankshaft;
-- water / oil cooler, housed in the crankcase;
-- oil pressure control valve incorporated in the
cooler assembly;
-- by--pass valve to cut off clogged oil filter, incorpo-
rated in the cooler assembly;
-- cartridge oil filter.
NOTE:Engines mod. TL70A and TL80A do not have
a turbocharger lubrication circuit.
SECTION 10 -- ENGINE -- CHAPTER 1 17
603.54.511.00-- 03 -- 2006
MIF1099A
Coolant recirculating in the engine
Coolant entering the pump
4
Cooling system diagram
The forced circulation, closed--circuit engine cooling
system is composed of the following components:
-- a lubricating oil cooler;
-- a centrifugal coolant pump housed at the front of
the crankcase;
-- a thermostat valve governing coolant circulation.
603.54.511.00-- 03 -- 2006
MIF1099A
Coolant recirculating in the engine
Coolant entering the pump
4
Cooling system diagram
The forced circulation, closed--circuit engine cooling
system is composed of the following components:
-- a lubricating oil cooler;
-- a centrifugal coolant pump housed at the front of
the crankcase;
-- a thermostat valve governing coolant circulation.
18 SECTION 10 -- ENGINE -- CHAPTER 1
603.54.511.00-- 03 -- 2006
MIF1100A
5
Detail of cylinder head with valve seats fitted in engines mod. TL70A -- TL80A
1.Exhaust manifold
2.Intake manifold
3.Air heater
4.Fitted valve seats
5.Thermostat valve
6.Injector
603.54.511.00-- 03 -- 2006
MIF1100A
5
Detail of cylinder head with valve seats fitted in engines mod. TL70A -- TL80A
1.Exhaust manifold
2.Intake manifold
3.Air heater
4.Fitted valve seats
5.Thermostat valve
6.Injector
SECTION 10 -- ENGINE -- CHAPTER 1 19
603.54.511.00-- 03 -- 2006
MIF1101A
6
Detail of cylinder head with valve seats fitted in engines mod. TL90A -- TL100A
1.Exhaust manifold
2.Intake manifold
3.Air heater
4.Fitted valve seats
5.Thermostat valve
6.Injector
603.54.511.00-- 03 -- 2006
MIF1101A
6
Detail of cylinder head with valve seats fitted in engines mod. TL90A -- TL100A
1.Exhaust manifold
2.Intake manifold
3.Air heater
4.Fitted valve seats
5.Thermostat valve
6.Injector
20 SECTION 10 -- ENGINE -- CHAPTER 1
603.54.511.00-- 03 -- 2006
MIF1102A
7
Additional counterweights
1.Retaining bolts
2.Support
3.Retaining bolts
4.Gear
5.Balancing weight
6.Half bearings
7.Counter--shaft
8.Gear
9.Ring
10.O--Ring
603.54.511.00-- 03 -- 2006
MIF1102A
7
Additional counterweights
1.Retaining bolts
2.Support
3.Retaining bolts
4.Gear
5.Balancing weight
6.Half bearings
7.Counter--shaft
8.Gear
9.Ring
10.O--Ring
SECTION 10 -- ENGINE -- CHAPTER 1 25
603.54.511.00-- 03 -- 2006
Op. 10 001 10
ENGINE R.I.
DANGER
Lift and handle all heavy parts using suitable lifting
equipment.
Make sure that assemblies or parts are supported by
means of suitable slings and hooks. Check that no
one is in the vicinity of the load to be lifted.
CAUTION
Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
1. Remove the bonnet (1) as described in operation
9010022.
2. Disconnect the battery negative lead.
3. Drain the oil from the transmission--gearbox
housing. 8
4. Remove the three retaining bolts (1) and the
guard (2) on the right--hand side of the fan.
9
5. Detach the fitting (3) of the return pipe (2) for the
coolant from the cab heater radiator connected to
the underside of the coolant pump (1) and drain
off the engine coolant.
10
603.54.511.00-- 03 -- 2006
Op. 10 001 10
ENGINE R.I.
DANGER
Lift and handle all heavy parts using suitable lifting
equipment.
Make sure that assemblies or parts are supported by
means of suitable slings and hooks. Check that no
one is in the vicinity of the load to be lifted.
CAUTION
Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
1. Remove the bonnet (1) as described in operation
9010022.
2. Disconnect the battery negative lead.
3. Drain the oil from the transmission--gearbox
housing. 8
4. Remove the three retaining bolts (1) and the
guard (2) on the right--hand side of the fan.
9
5. Detach the fitting (3) of the return pipe (2) for the
coolant from the cab heater radiator connected to
the underside of the coolant pump (1) and drain
off the engine coolant.
10
26 SECTION 10 -- ENGINE -- CHAPTER 1
603.54.511.00-- 03 -- 2006
6. Remove the catch (2) and detach the toolbox (1).
11
7. Remove the split pins, retaining pin (3) and front
ballast (2) together with the support (1).
12
8. Unscrew the front central and rear retaining bolts
on the front axle shaft guard, then remove the
guard (1).
25038
1
13
9. Remove the circlip (2) and move the front sleeve
(1) in the direction indicated by the arrow until it
is released from the groove on the front axle.
25039
12
14
603.54.511.00-- 03 -- 2006
6. Remove the catch (2) and detach the toolbox (1).
11
7. Remove the split pins, retaining pin (3) and front
ballast (2) together with the support (1).
12
8. Unscrew the front central and rear retaining bolts
on the front axle shaft guard, then remove the
guard (1).
25038
1
13
9. Remove the circlip (2) and move the front sleeve
(1) in the direction indicated by the arrow until it
is released from the groove on the front axle.
25039
12
14
SECTION 10 -- ENGINE -- CHAPTER 1 27
603.54.511.00-- 03 -- 2006
10. Remove the circlip (2) and move the rear sleeve
(1) in the direction indicated by the arrow until it
is released from the groove on the drive.
25040
1
2
15
11. Remove the propeller shaft central support (1)
retaining bolts and extract the shaft together with
the support.
1
25041
16
12. Remove the retaining bolts (1) of the draw pipe
(2) of the lift pump.
17
13. Detach the fitting (1) of the power steering/four--
wheel drive drain pipe on the left--hand side of the
engine.
18
603.54.511.00-- 03 -- 2006
10. Remove the circlip (2) and move the rear sleeve
(1) in the direction indicated by the arrow until it
is released from the groove on the drive.
25040
1
2
15
11. Remove the propeller shaft central support (1)
retaining bolts and extract the shaft together with
the support.
1
25041
16
12. Remove the retaining bolts (1) of the draw pipe
(2) of the lift pump.
17
13. Detach the fitting (1) of the power steering/four--
wheel drive drain pipe on the left--hand side of the
engine.
18
28 SECTION 10 -- ENGINE -- CHAPTER 1
603.54.511.00-- 03 -- 2006
14. Detach the fitting (1) of the power steering/four--
wheel drive drain pipe on the right--hand side of
the engine.
19
15. Take out the bolt (1) retaining the bracket and the
power steering/four--wheel drive drain pipe on the
right--hand side of the engine (2).
20
16. Remove the two metal clamps (2) and the rigid
pipe (1) for drawing oil from the transmission via
the pumps of the lift and power steering.
21
17. Remove the fitting (1) of the delivery pipe of the
services pump on the right--hand side of the en-
gine.
22
603.54.511.00-- 03 -- 2006
14. Detach the fitting (1) of the power steering/four--
wheel drive drain pipe on the right--hand side of
the engine.
19
15. Take out the bolt (1) retaining the bracket and the
power steering/four--wheel drive drain pipe on the
right--hand side of the engine (2).
20
16. Remove the two metal clamps (2) and the rigid
pipe (1) for drawing oil from the transmission via
the pumps of the lift and power steering.
21
17. Remove the fitting (1) of the delivery pipe of the
services pump on the right--hand side of the en-
gine.
22
SECTION 10 -- ENGINE -- CHAPTER 1 29
603.54.511.00-- 03 -- 2006
18. Working on the left--hand side of the engine, take
out the retaining bolts (2) and detach the draw
pipe (1) of the lift pump.
23
19. Extract the plastic fasteners (2) and detach the
diesel recovery pipe (3) and delivery pipe (4) to
the diesel pump (1).
24
20. Disconnect the electrical connections (1) and (2)
between the cab and the engine.
25
21. Disconnect the electrical connection (1) between
the cab and the engine.
26
603.54.511.00-- 03 -- 2006
18. Working on the left--hand side of the engine, take
out the retaining bolts (2) and detach the draw
pipe (1) of the lift pump.
23
19. Extract the plastic fasteners (2) and detach the
diesel recovery pipe (3) and delivery pipe (4) to
the diesel pump (1).
24
20. Disconnect the electrical connections (1) and (2)
between the cab and the engine.
25
21. Disconnect the electrical connection (1) between
the cab and the engine.
26
30 SECTION 10 -- ENGINE -- CHAPTER 1
603.54.511.00-- 03 -- 2006
22. Disconnect the two power steering oil delivery
and return hoses (1).
1
24879
27
23. Remove the four knobs (1) and take off the two
right-- and left--hand dashboard panels (2).
MDD2562A
1 2
28
24. Extract the differential lock pedal retaining pin
from the drive shaft (1), remove the pedal and
footboard (2).
25043
1
2
29
25. Remove the four plugs (1) in order to gain access
to the engine upper retaining bolts.
30
603.54.511.00-- 03 -- 2006
22. Disconnect the two power steering oil delivery
and return hoses (1).
1
24879
27
23. Remove the four knobs (1) and take off the two
right-- and left--hand dashboard panels (2).
MDD2562A
1 2
28
24. Extract the differential lock pedal retaining pin
from the drive shaft (1), remove the pedal and
footboard (2).
25043
1
2
29
25. Remove the four plugs (1) in order to gain access
to the engine upper retaining bolts.
30
SECTION 10 -- ENGINE -- CHAPTER 1 31
603.54.511.00-- 03 -- 2006
26. Remove the retaining clips (1) and detach the
flexible cables governing the hand throttle (5) and
pedal throttle (4).
27. Remove the retaining clip (3) and detach the
throttle control tie--rod (2) connected to the injec-
tion pump.
31
28. Detach the fitting (2) and the hose (1) delivering
power steering oil to the hydraulic cylinders
governing the front wheel steering.
32
29. Detach the clamp (1) and the cab heater delivery
pipe (2).
33
30. Detach the clamp (2) and the cab heater return
pipe (1).
34
603.54.511.00-- 03 -- 2006
26. Remove the retaining clips (1) and detach the
flexible cables governing the hand throttle (5) and
pedal throttle (4).
27. Remove the retaining clip (3) and detach the
throttle control tie--rod (2) connected to the injec-
tion pump.
31
28. Detach the fitting (2) and the hose (1) delivering
power steering oil to the hydraulic cylinders
governing the front wheel steering.
32
29. Detach the clamp (1) and the cab heater delivery
pipe (2).
33
30. Detach the clamp (2) and the cab heater return
pipe (1).
34
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