New Holland FR450 TIER 3 Service Manual Download

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Contents

INTRODUCTION

Basic instructions - How to use and navigate through this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Note to the Owner (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Safety rules - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Basic instructions - Chain Wear Tables - Roller Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Conversion factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

General specification System protection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

(*) See content for specific models

47812470 23/02/2015

Find manuals at https://best-manuals.com

Summary of Contents for FR450 TIER 3

Page 1: ... MANUAL FR450 FR500 FR600 FR700 FR850 Forage Harvester Printed in U S A 2015 CNH Industrial Belgium N V All Rights Reserved New Holland is a trademark registered in the United States and many other countries owned by or licensed to CNH Industrial N V its subsidiaries or affiliates ...

Page 2: ...SERVICE MANUAL FR 47812470 23 02 2015 EN Find manuals at https best manuals com ...

Page 3: ...450 FR450 TIER 3 5803 North America F2CE9684U E151 FR500 FR500 TIER 4A North America F3BFE613E A FR600 FR600 TIER 3 5803 North America F3CE0684E E920 FR450 FR450 TIER 4A North America F2CFE613A A FR500 FR500 TIER 3 5803 North America F3BE0684J E919 47812470 23 02 2015 Find manuals at https best manuals com ...

Page 4: ...transmission external controls 21 3 21 100 Mechanical transmission lubrication system 21 4 21 145 Gearbox internal components 21 5 21 182 Differential 21 6 Four Wheel Drive 4WD system 23 23 101 Mechanical control 23 1 23 304 Four Wheel Drive 4WD gearbox 23 2 Front axle system 25 25 100 Powered front axle 25 1 25 102 Front bevel gear set and differential 25 2 25 310 Final drives 25 3 Rear axle syst...

Page 5: ...ters 35 4 35 359 Main control valve 35 5 35 350 Safety and main relief valves 35 6 35 600 High flow hydraulics 35 7 35 410 Header or attachment height system 35 8 35 602 Header or attachment leveling system 35 9 35 514 Upper feed roll gearbox system 35 10 35 516 Cutterhead drive system 35 11 35 530 Spout rotation circuit 35 12 35 532 Spout raising system 35 13 35 534 Spout deflector system 35 14 S...

Page 6: ... oil system 55 8 55 512 Cab controls 55 9 55 640 Electronic modules 55 10 55 610 Ground speed control 55 11 55 019 Hydrostatic drive control system 55 12 55 051 Cab Heating Ventilation and Air Conditioning HVAC controls 55 13 55 050 Heating Ventilation and Air Conditioning HVAC control system 55 14 55 421 Feeding control system 55 15 55 800 Metal detector 55 16 55 820 Chopping and cutting control ...

Page 7: ... 64 100 Cutterhead 64 1 64 106 Drum 64 2 64 130 Drum gearbox 64 3 64 140 Sharpening system 64 4 64 150 Shearbar 64 5 64 160 Crop processor 64 6 64 170 Transition channel concave and lever 64 7 Ejection 70 70 120 Blower 70 1 70 140 Spout 70 2 Platform cab bodywork and decals 90 90 105 Machine shields and guards 90 1 90 150 Cab 90 2 47812470 23 02 2015 Find manuals at https best manuals com ...

Page 8: ...INTRODUCTION 47812470 23 02 2015 1 Find manuals at https best manuals com ...

Page 9: ...gy and the environment 13 Safety rules 14 Personal safety 17 Basic instructions Shop and assembly 18 Torque 20 Basic instructions Chain Wear Tables Roller Chains 22 Conversion factors 24 General specification System protection data 25 Product identification 28 See content for specific models 47812470 23 02 2015 2 Find manuals at https best manuals com ...

Page 10: ...cations the functional data how it works the diagnostic data fault codes and troubleshooting and the service data remove install adjust etc By integrating SAP coding into technical information you will be able to search and retrieve just the right piece of technical information you need to resolve that customer s concern on his machine This is made possible by attaching 3 categories to each piece ...

Page 11: ...g to the main functions or a systems on the machine Each Section is identified by a number 00 35 55 etc The amount of Sections included in the manual will depend on the type and function of the machine that the manual is written for Each Section has a Contents page listed in alphabetic numeric order This table illustrates which Sections could be included in a manual for a particular product PRODUC...

Page 12: ...ration 73 Residue handling 74 Cleaning 75 Soil preparation Finishing 76 Secondary cleaning Destemmer 77 Seeding 78 Spraying 79 Planting 80 Crop storage Unloading 82 Front loader and bucket 83 Telescopic single arm 84 Booms dippers and buckets 86 Dozer blade and arm 88 Accessories 89 Tools 90 Platform cab bodywork and decals 47812470 23 02 2015 5 ...

Page 13: ...ation for that function is included Hitches drawbars and implement couplings 37 Frames and ballasting 39 Steering 41 Wheels 44 Steering clutches 46 Tracks and track suspension 48 Cab climate control 50 Electrical systems 55 The Section covers the central parts of the electrical electronic and lighting systems The components that are dedicated to a specific function are listed in the Chapter where ...

Page 14: ...ooms dippers and buckets 84 Dozer blade and arm 86 Accessories 88 Tools 89 Platform cab bodywork and decals 90 This Section covers all the main functions and systems related to the body of the machine including the operators cab and the platform 47812470 23 02 2015 7 ...

Page 15: ...remove install adjust etc and diagnostic data fault codes and troubleshooting that have been written in that Chapter for that function or system on the machine Contents HYDRAULIC SYSTEMS 35 Main control valve 359 FUNCTIONAL DATA Main control valve Sectional view 35 359 C 10 A 30 TECHNICAL DATA Main control valve General specifications 35 359 D 40 A 10 SERVICE Main control valve Remove 35 359 F 10 ...

Page 16: ...e information unit Main control valve Sectional View 35 359 Information Unit SAP code 35 Hydraulic systems SAP code classification 359 Main control valve Page header and footer The page header will contain the following references Section and Chapter description The page footer will contain the following references Publication number for that Manual Section or Chapter Version reference for that pu...

Page 17: ...arts and or components not approved by the manufacturer himself including those used for the servicing or repair of the product manufactured or marketed by the manufacturer In any case no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages due to an anomalous behavior of parts and or components not approved by the manufacturer The informat...

Page 18: ... in your vehicle Fault Code Resolution FCR information For FCR information please refer to the Electronic Service Tool EST or to the information given in the paper or electronic version of this manual Electronic Service Tool EST information The EST information and how to handle Control Modules CM e g resetting of the CM etc is not contained within this manual For EST information please refer to th...

Page 19: ...th or serious injury CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury FAILURE TO FOLLOW DANGER WARNING AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY Machine safety NOTICE Notice indicates a situation that if not avoided could result in machine or property damage Throughout this manual you will find the signal word Notice followed b...

Page 20: ...ot allow coolant mixtures to get into the soil Collect and dispose of coolant mixtures properly The air conditioning system contains gases that should not be released into the atmosphere Consult an air condi tioning specialist or use a special extractor to recharge the system properly Repair any leaks or defects in the engine cooling system or hydraulic system immediately Do not increase the press...

Page 21: ... Do not weld hydraulic pipes when flexible hoses or piping are damaged replace them immediately It is forbidden to modify a hydraulic accumulator by machining welding or any other way Before removing hydraulic accumulators for servicing the liquid pressure in the accumulators must be reduced to zero Pressure check on hydraulic accumulators must be carried out by a method recommended by the accumul...

Page 22: ... raising or moving heavy parts Keep bystanders away Never use gasoline diesel oil or other inflammable liquids as cleaning agents Use non inflammable non toxic commercially available solvents Wear safety goggles with side guards when cleaning parts with compressed air Never use open flames for lighting when working on the machine or checking for leaks When carrying out checks with the engine runni...

Page 23: ...cause damage to the wheel Never cut or weld a rim mounted with an inflated tire Deflate the tire before removing any objects that may be jammed in the tire tread Never inflate tires using inflammable gases as this may result in explosions and injury to bystanders Removal and installation Lift and handle all heavy parts using suitable hoisting equipment Make sure that parts are sustained by appropr...

Page 24: ... in death or serious injury W0086A WARNING Pressurized system Only use the bleed screw to bleed air from the fuel system DO NOT loosen the fuel or injector lines to bleed air Injury or damage can occur Fuel or injector lines are under very high pressure Failure to comply could result in death or serious injury W0285A 47812470 23 02 2015 17 ...

Page 25: ...allation tool Do not tap the seal with a hammer or mallet 6 While you insert the seal check that the seal is perpendicular to the seat When the seal settles make sure that the seal makes contact with the thrust element if required 7 To prevent damage to the seal lip on the shaft position a protective guard during installation operations O ring seals Lubricate the O ring seals before you insert the...

Page 26: ...battery ground cable from the machine battery The electronic monitoring system and charging system will be damaged if this is not done 5 Remove the battery ground cable Reconnect the cable when you complete welding WARNING Battery acid causes burns Batteries contain sulfuric acid Avoid contact with skin eyes or clothing Antidote external Flush with water Antidote eyes flush with water for 15 minut...

Page 27: ... 3 N m 14 2 lb ft 31 5 N m 23 2 lb ft M10 48 7 N m 35 9 lb ft 26 8 N m 19 8 lb ft 43 8 N m 32 3 lb ft 69 5 N m 51 3 lb ft 38 2 N m 28 2 lb ft 62 5 N m 46 1 lb ft M12 85 N m 62 7 lb ft 46 7 N m 34 4 lb ft 76 5 N m 56 4 lb ft 121 N m 89 2 lb ft 66 5 N m 49 0 lb ft 108 9 N m 80 3 lb ft M14 135 N m 99 6 lb ft 74 2 N m 54 7 lb ft 121 5 N m 89 6 lb ft 193 N m 142 3 lb ft 106 1 N m 78 3 lb ft 173 7 N m 1...

Page 28: ...INTRODUCTION ZEIL06CS0136F0A 2 ZEIL06CS0135F0A 3 47812470 23 02 2015 21 ...

Page 29: ...ts in the drive their speeds the number of teeth and the length of the chain in pitches ZEIL10GH0015A0A 2 Measurement of Chain For Wear Elongation Relatively accurate wear measurements can be made by using the above illustration Measure as closely as possi ble from the center of one pin to the center of another The more pitches pins contained within the measurement increase the accuracy If the mea...

Page 30: ...n 1371 mm 54 0 in 1778 mm 70 0 in 1828 mm 72 0 in 80P 1016 mm 40 0 in 1047 mm 41 2 in 1270 mm 50 0 in 1308 mm 51 5 in 1524 mm 60 0 in 1568 mm 61 7 in 2032 mm 80 0 in 2095 mm 82 5 in 90P 1143 mm 45 0 in 1177 mm 46 3 in 1428 mm 56 2 in 1473 mm 58 0 in 1714 mm 67 5 in 1765 mm 69 5 in 2286 mm 90 0 in 2355 mm 92 7 in 100P 1270 mm 50 0 in 1308 mm 51 5 in 1578 mm 62 1 in 1635 mm 64 4 in 1905 mm 75 0 in 1...

Page 31: ...e 1 litre 1 057 US quart 1 US quart 0 9464 litre 1 cm cc 0 061 in 1 in 16 38 cm cc 1 m 35 31 ft 1 ft 0 028 m 1 ml 0 033 US fl oz 1 US fl oz 29 57 ml Mass 1 kg 2 204 lb 1 lb 0 4536 kg Torque 1 N m 0 7376 lb ft 1 lb ft 1 3558 N m Power 1 kW 1 358 Hp 1 Hp 0 746 kW Pressure 1 bar 100 kPa 1 bar 14 505 psi 1 psi 0 06894 bar Temperature 1 C 1 8 x C 32 F 1 F 0 56 x F 32 C Flow 1 l min 0 2642 US gpm 1 US g...

Page 32: ...n the table below occur NOTICE If it is necessary to move the forage harvester for safety reasons the engine can be re started after an automatic engine shut off Proceed as follows Switch off the ignition key Press and hold down the engine throttle rocker switch At the same time start the engine with the ignition key the engine will shut off after 30 s In this case the operator is responsible for ...

Page 33: ...s ON when pressure low CM does not read pressure value 5 bar 73 psi 0 s 1 s 2 s Engine oil pressure low A2125 CAN message from ECU goes ON when engine oil pressure low CM does not know pressure value Curve speed depen dant Curve speed depen dant Curve speed depen dant 0 s 1 s 7 s Engine coolant temperature high not for FR700 A2123 106 C 223 F 106 C 223 F 104 C 219 F 106 C 223 F 110 C 230 F 110 C 2...

Page 34: ...from ECU goes on when rail pressure low CM does not know pressure value Curve speed depen dant Curve speed depen dant 0 s 1 s 7 s Rail pressure high only valid for FR450 and FR850 A2209 CAN message from ECU goes on when rail pressure high CM does not know pressure value 150 0 bar 21750 psi 1700 bar 24 650 psi 0 s 1 s 7 s Main clutch pressure high A3008 40 bar 580 psi 5 s 10 s 20 s Intake air tempe...

Page 35: ...ndicates the product line CR CX CS CSX Combine Harvesters 1 TC Combine Harvesters 9 Combine Headers 9 Forage Harvesters 5 Grass Pickup 3 Square Balers 4 615 848002 These three digits indicate the batch in which the machine was made 61 5848002 Product line number 5 and batch 848 together form the series number 615848 002 The last 3 digits are a sequential number for each model within a batch Summar...

Page 36: ...SERVICE MANUAL Engine FR 47812470 23 02 2015 10 ...

Page 37: ...Contents Engine 10 10 001 Engine and crankcase 10 1 10 218 Fuel injection system 10 2 10 400 Engine cooling system 10 3 10 414 Fan and drive 10 4 10 418 Rotary screen 10 5 47812470 23 02 2015 10 ...

Page 38: ...Engine 10 Engine and crankcase 001 FR 47812470 23 02 2015 10 1 10 001 1 ...

Page 39: ...Contents Engine 10 Engine and crankcase 001 SERVICE Engine Remove 3 Install 21 See content for specific models 47812470 23 02 2015 10 1 10 001 2 ...

Page 40: ...ble DO NOT work under a vehicle supported by jack stands only Park machine on a level surface Block wheels Support machine with safety stands Failure to comply could result in death or serious injury W0069A NOTE The assistance of a second person is required to perform the below operation 1 Raise the spout to an appropriate height 2 Remove the left hand and right hand side shielding Refer to Side s...

Page 41: ...el tank Collect the fuel in a clean container ZEIL13FR00346AB 4 NOTICE The following operations require the removal of the hydraulic hoses tubes and other hydraulic compo nents Once the hoses tubes or the ports of the hydraulic components are removed cover with protective covers to avoid the ingress of duct contamination and other objects 9 Drain the oil from the reservoir through the hose 16 Refe...

Page 42: ... to the Operator s Manual Engine cooling system Re place 10 400 12 Disconnect the hose 20 21 and 22 from the coolant tank 19 13 Remove the coolant tank 19 ZEIL11FR0031A0B 7 14 Remove the hardware 29 Loosen the clamp 30 15 Remove the exhaust tube 23 from the muffler 24 ZEIL13FR00306AZ 8 16 On the left hand side remove the hardware 1 Re move the sensor bracket 2 ZEIL13FR00305AB 9 47812470 23 02 2015...

Page 43: ...t hand side remove the wire harness 25 attached at the top and at the rear frame ZEIL11FR0033B0Z 10 18 On the left hand side remove the wire harness 27 attached at the top and the rear frame ZEIL11FR0034B0Z 11 47812470 23 02 2015 10 1 10 001 6 ...

Page 44: ...ove the hardware 103 ZEIL13FR00308AB 12 ZEIL13FR00309AB 13 20 On the left hand side of the engine roof assembly 104 remove the hardware 103 ZEIL13FR00310AB 14 21 On the right hand side of the engine roof assembly 104 remove the hardware 103 ZEIL13FR00311AB 15 47812470 23 02 2015 10 1 10 001 7 ...

Page 45: ...in C of a suitable lifting device to the eyebolts and the engine roof assembly 104 26 Lift and remove gradually the engine roof assembly 104 from the machine ZEIL13FR00313AB 18 NOTICE Prevent the rotating coupler from damage during any repair activity 27 On the left hand side remove the rotating coupler 33 NOTICE Use a metallic blank plug to prevent oil leakage Take care of the oil seal in the rot...

Page 46: ... Remove Reverse drive belt 64 130 ZEIL11FR0051A0B 20 31 On the left hand side remove the air intake ducts 35 and 36 ZEIL11FR0038A0B 21 32 On the right hand side loosen the clamps 9 Loosen the last clamp not indicated on the intercooler tube 8 Disconnect the intercooler tube 8 ZEIL13FR00096AA 22 33 On the right hand side loosen the clamps 5 Dis connect the water tube 7 ZEIL13FR00094AA 23 47812470 2...

Page 47: ...ter tube 7 Refer to figures 22 and 23 ZEIL13FR00314AB 24 36 On the left hand side disconnect the hose 60 from the water tube 59 Remove the water tube 59 ZEIL11FR0050A0Z 25 37 On the left hand side remove the intercooler tube 44 ZEIL11FR0049A0Z 26 38 On the left hand side disconnect the tube 40 from the muffler 24 ZEIL13FR00315AZ 27 47812470 23 02 2015 10 1 10 001 10 ...

Page 48: ...0 ZEIL13FR00316AB 28 40 In the service area remove the cover plate 120 to have access to the batteries ZEIL12FR0203A0Z 29 41 Disconnect all the terminals 42 from the batteries 43 ZEIL13FR00317AB 30 42 On the left hand side disconnect the connector 71 and 72 from the alternator 73 ZEIL11FR0058A0B 31 47812470 23 02 2015 10 1 10 001 11 ...

Page 49: ... from the ECU 52 Discon nect the ECU fuel tube 56 ZEIL13FR00319AB 33 45 On the left hand side disconnect the tube 108 from the engine ZEIL13FR00320AB 34 46 On the right hand side disconnect the connector 17 and other connectors from the feed rolls hydrostatic pump in case of single drive NOTE If installed do the same for the attachment hydro static pump in case of double drive ZEIL13FR00324AZ 35 4...

Page 50: ...Remove the wire harness 113 Disconnect the tube 80 from the lubrication oil cooler ZEIL13FR00326AZ 37 49 On the right hand side disconnect the hose 82 and 83 from the oil filter 84 ZEIL11FR0062A0B 38 50 Above the main gearbox disconnect the main gear box lubrication valve hose 78 and 79 from the tube 80 and 81 ZEIL11FR0061A0B 39 47812470 23 02 2015 10 1 10 001 13 ...

Page 51: ...the idler arm in the upward position Use a strap ZEIL09FR0253A0B 41 If required perform steps 54 55 56 and 57 54 On both sides loosen the hardware 66 from the ra diator fan frame 65 ZEIL13FR00327AB 42 55 Attach a suitable lifting device to the pulley 67 of the radiator fan 56 Carefully remove the hardware from the radiator fan frame 65 Remove the radiator fan assembly ZEIL13FR00328AB 43 47812470 2...

Page 52: ...se 10 from the drain tap ZEIL13FR00323AZ 45 59 On the right hand side disconnect the hose 53 from the filter assembly 54 ZEIL13FR00321AZ 46 60 On the rear of the machine disconnect the hose 55 from the filter assembly 54 61 Remove the bolts 107 Remove the filter assembly 54 from the oil reservoir ZEIL13FR00322AB 47 47812470 23 02 2015 10 1 10 001 15 ...

Page 53: ...30AB 48 63 On the main gearbox disconnect the hose 74 Dis connect and remove the hose 75 ZEIL13FR00331AB 49 64 On the right hand side disconnect the hose 77 from the fitting 76 ZEIL13FR00332AB 50 65 On the right hand side remove the hose 64 111 and 112 66 On the right hand side remove the supports 110 and 109 ZEIL13FR00333AB 51 47812470 23 02 2015 10 1 10 001 16 ...

Page 54: ...gear pump main gearbox lubrication 90 Dis connect the tube 116 from the tube 117 ZEIL13FR00335AB 53 69 On the left hand side disconnect the hose 91 92 and 93 from the filter 94 ZEIL13FR00336AZ 54 70 Disconnect the hose 95 and 96 from the Closed Center Load Sensing CCLS pump on the main gear box NOTE The view shown is from the top side of the main gearbox ZEIL13FR00337AZ 55 47812470 23 02 2015 10 1...

Page 55: ...ble lifting device ZEIL13FR00338AZ 56 72 At the rear remove the tube 58 from the oil reservoir 18 ZEIL11FR0048A0B 57 73 On both sides on the rear of the machine remove the hardware 98 from the engine support ZEIL13FR00339AB 58 74 On the right hand side remove the hardware 99 ZEIL13FR00340AB 59 47812470 23 02 2015 10 1 10 001 18 ...

Page 56: ...ice on the indicated areas of the engine and the main gearbox ZEIL13FR00342AB 61 77 Tilt the rear frame 101 ZEIL13FR00344AB 62 NOTICE Make sure that there are no connections between the engine assembly and the frame of the machine 78 From the left hand side carefully remove the engine and the main gearbox assembly out of the machine as shown ZEIL13FR00343AB 63 47812470 23 02 2015 10 1 10 001 19 ...

Page 57: ...ssembly on the wooden blocks W ZEIL13FR00345AB 64 80 Remove the hardware 121 from the engine flange Separate the main gearbox assembly from the engine NOTICE Main gearbox assembly is heavy Use a suitable lifting device ZEIL09FR0271A0Z 65 47812470 23 02 2015 10 1 10 001 20 ...

Page 58: ...ands can slip or fall over Dropping tipping or slipping of machine or its components is pos sible DO NOT work under a vehicle supported by jack stands only Park machine on a level surface Block wheels Support machine with safety stands Failure to comply could result in death or serious injury W0069A NOTE The assistance of a second person is required to perform the below operation 1 Remove the stee...

Page 59: ...ice 4 From the left hand side carefully install the assembly on the machine frame as shown ZEIL13FR00342AB 2 ZEIL13FR00343AB 3 5 Position the engine and the main gearbox assembly on the machine frame Align the holes to install the hardware 6 On the left hand side install all the hardware 100 In stall the hardware 100 on the inner side of the bracket also ZEIL13FR00341AZ 4 7 On the right hand side ...

Page 60: ... At the rear of the machine install the tube 58 on the oil reservoir 18 ZEIL11FR0048A0B 7 10 Bring the rear frame 101 into his original position ZEIL13FR00344AB 8 11 Use a suitable lifting device to lift the muffler 24 In stall the muffler 24 on the engine frame with the hard ware 97 ZEIL13FR00338AZ 9 47812470 23 02 2015 10 1 10 001 23 ...

Page 61: ...0337AZ 10 13 On the left hand side connect the hose 91 92 and 93 to the filter 94 ZEIL13FR00336AZ 11 14 On the main gearbox connect the tube 89 to the gear pump main gearbox lubrication 90 Connect the tube 116 to the tube 117 ZEIL13FR00335AB 12 15 On the right hand side connect the hose 85 to the tube 86 Connect the hose 87 to the tube 88 ZEIL13FR00334AB 13 47812470 23 02 2015 10 1 10 001 24 ...

Page 62: ...3FR00333AB 14 18 On the right hand side connect the hose 77 to the fitting 76 ZEIL13FR00332AB 15 19 On the right hand side connect the hose 74 and 75 to the main gearbox ZEIL13FR00331AB 16 20 On the main gearbox connect the hose 62 and 63 Connect the hose 69 to the gear pump steering ZEIL13FR00330AB 17 47812470 23 02 2015 10 1 10 001 25 ...

Page 63: ...18 23 On the right hand side connect the hose 53 to the filter assembly 54 ZEIL13FR00321AZ 19 24 On the rear of the engine install the hose 10 on the drain tap ZEIL13FR00323AZ 20 If the radiator fan assembly is removed earlier perform steps 25 26 27 and 28 25 Behind the radiator install the support 68 as shown ZEIL13FR00329AB 21 47812470 23 02 2015 10 1 10 001 26 ...

Page 64: ...e ZEIL13FR00328AB 22 28 Install the radiator fan assembly 65 on the machine On both sides use the hardware 66 ZEIL13FR00327AB 23 29 Cut the strap Move the idler arm back to the original position 30 Install the fan drive belt Refer to Belt Install 10 414 ZEIL09FR0253A0D 24 31 On the left hand side connect the tube 119 to the suction filter 118 ZEIL13FR00078AR 25 47812470 23 02 2015 10 1 10 001 27 ...

Page 65: ...FR0061A0B 26 33 On the right hand side install the hose 82 and 83 on the oil filter 84 ZEIL11FR0062A0B 27 34 On the right hand side connect the tube 80 Install the wire harness 113 as shown Connect the con nector 115 ZEIL13FR00326AZ 28 35 On the oil reservoir 18 connect the hose 62 63 and 64 ZEIL13FR00325AB 29 47812470 23 02 2015 10 1 10 001 28 ...

Page 66: ... pump in case of double drive ZEIL13FR00324AZ 30 37 On the left hand side connect the tube 108 to the engine ZEIL13FR00320AB 31 38 On the left hand side connect the Engine Control Unit ECU fuel tube 56 Connect the ECU connector 51 to the ECU 52 ZEIL13FR00319AB 32 39 On the right hand side connect the air conditioning hose 48 and 49 from the air conditioning pump 50 ZEIL13FR00318AB 33 47812470 23 0...

Page 67: ...EIL11FR0058A0B 34 41 In the service area connect all the terminals 42 to the batteries ZEIL13FR00317AB 35 42 Install the cover plate 120 ZEIL12FR0203A0Z 36 43 On the right hand side install the tube 40 Connect one end near the turbocharger Use the clamp 41 ZEIL13FR00316AB 37 47812470 23 02 2015 10 1 10 001 30 ...

Page 68: ... 24 ZEIL13FR00315AZ 38 45 On the left hand side install the intercooler tube 44 ZEIL11FR0049A0Z 39 46 On the left hand side install the water tube 59 on the hose 60 ZEIL11FR0050A0Z 40 47 On the right hand side install the water tube 7 Use the clamps 5 ZEIL13FR00094AA 41 47812470 23 02 2015 10 1 10 001 31 ...

Page 69: ...On the left hand side install the reverse drive belt 32 Refer to Drum gearbox Belt drive Install Reverse drive belt 64 130 51 Install the hose 34 on the tube 61 ZEIL11FR0051A0B 44 52 Install the main drive belt 31 Refer to Drum gear box Belt drive Install Main drive belt 64 130 53 Remove the blank plug and install the rotating coupler 33 NOTE During installation of the rotating coupler the hose sh...

Page 70: ...the engine roof assembly 104 on the machine ZEIL13FR00313AB 46 57 On the left hand side of the radiator fan plastic cover 102 install the hardware 103 on the engine roof assembly 104 ZEIL13FR00312AZ 47 58 On the engine roof assembly 104 install the plate 125 Use the hardware 70 ZEIL13FR00101AZ 48 59 On the right hand side of the engine roof assembly 104 install the hardware 103 ZEIL13FR00311AB 49 ...

Page 71: ...hand side of the engine roof assembly 104 install the hardware 103 ZEIL13FR00310AB 50 61 On both sides of the rear of the engine roof assembly 104 install the hardware 103 ZEIL13FR00308AB 51 ZEIL13FR00309AB 52 47812470 23 02 2015 10 1 10 001 34 ...

Page 72: ... hand side route the wiring harness 27 as shown at the top and the rear frame ZEIL11FR0034B0Z 53 63 On the right hand side route the wiring harness 25 as shown at the top and the rear frame ZEIL11FR0033B0Z 54 47812470 23 02 2015 10 1 10 001 35 ...

Page 73: ... 68 Connect the hose 20 21 and 22 to the coolant tank 19 69 Check if all the coolant lines are connected and tight ened 70 Refill the coolant in the cooling system Refer to the Operator s Manual Engine cooling system Replace 10 400 ZEIL11FR0031A0B 57 71 Near the coolant tank connect the connectors in volved Connect the coolant level sensor wire 105 attached at the top ZEIL13FR00307AB 58 72 Check a...

Page 74: ...ition 76 Tighten the nut 12 until the worm 14 is on the worm wheel 15 77 Adjust the backlash between the worm and the worm wheel Refer to Worm Worm wheel Backlash 70 140 78 Tighten the lock nut 13 79 Calibrate the spout home position Refer to the Oper ator s Manual ZEIL07FR0417A0Z 60 80 Reinstall the rear shielding 3 as follows A Lift the rear shielding 3 and position it on the machine Use a suita...

Page 75: ...install the indicated plate ZEIL12FR0204A0Z 62 83 Install the left hand and right hand side shielding Re fer to Side shields Install side shieldings 90 105 84 Bleed the fuel system Refer to the Operator s Man ual 47812470 23 02 2015 10 1 10 001 38 ...

Page 76: ...Index Engine 10 Engine and crankcase 001 Engine Install 21 Engine Remove 3 See content for specific models 47812470 23 02 2015 10 1 10 001 39 ...

Page 77: ...47812470 23 02 2015 10 1 10 001 40 ...

Page 78: ...Engine 10 Fuel injection system 218 FR 47812470 23 02 2015 10 2 10 218 1 ...

Page 79: ...Contents Engine 10 Fuel injection system 218 FUNCTIONAL DATA Fuel injection system Overview 4 47812470 23 02 2015 10 2 10 218 2 ...

Page 80: ...47812470 23 02 2015 10 2 10 218 3 ...

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