New Holland T9.560 [ZCF200001 - ] Tractor Service Repair Manual

SERVICE MANUAL T9.390 / T9.450 / T9.505 / T9.560 / T9.615 / T9.670

SERVICE MANUAL T9.390 / T9.450 / T9.505 / T9.560 / T9.615 / T9.670 Tractor PIN ZCF200001 and above PIN ZDF200001 and above

Tractor

1/4 Part number 47488219

Part number 47488219 English March 2013

Copyright © 2013 CNH America LLC. All Rights Reserved.

SERVICE MANUAL

T9.390 [ZCF200001 - ] , T9.390 [ZDF200001 - ] , T9.450 [ZCF200001 - ] , T9.450 [ZDF200001 - ] , T9.505 [ZCF200001 - ] , T9.505 [ZDF200001 - ] , T9.560 [ZCF200001 - ] , T9.560 [ZDF200001 - ] , T9.615 [ZCF200001 - ] , T9.615 [ZDF200001 - ] , T9.670 [ZCF200001 - ] , T9.670 [ZDF200001 - ]

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Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

Transmission.............................................................................. 21 [21.113] Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.135] Powershift transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.145] Gearbox internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 [21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4

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 system........................................................................ 27 [27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 [27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2 [27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3

Power Take-Off (PTO) ................................................................. 31 [31.104] Rear electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 [31.110] One-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 [31.220] Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3

Brakes and controls .................................................................... 33 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1

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[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.105] Charge pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.220] Auxiliary hydraulic pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7 [35.304] Combination pump units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8 [35.600] High flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9

Hitches, drawbars, and implement couplings.................................. 37 [37.100] Drawbars and towing hitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.1

Frames and ballasting ................................................................. 39 [39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1 [39.110] Drawbar and hitch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2

Steering..................................................................................... 41 [41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 [41.910] Auxiliary steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4

Wheels ...................................................................................... 44 [44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

Cab climate control ..................................................................... 50 [50.104] Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2 [50.300] Cab pressurizing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3

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Electrical systems ....................................................................... 55 [55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.024] Transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.035] Remote control valve electric control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.045] Front axle control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.046] Rear axle control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.048] Rear Power Take-Off (PTO) control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . 55.8 [55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls. . . . . . . . . . . . . . . . . . . 55.9 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.130] Rear three-point hitch electronic control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14 [55.522] Cab Power Take-Off (PTO) controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.16 [55.988] Selective Catalytic Reduction (SCR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . 55.17 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.18

Platform, cab, bodywork, and decals ............................................. 90 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.102] Engine shields, hood latches, and trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4 [90.151] Cab interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5

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INTRODUCTION

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1

Contents INTRODUCTION Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T9.390 [ZCF200001 - ] WE, T9.390 [ZDF200001 - ] WE, T9.390, T9.450 [ZCF200001 - ] WE, T9.450 [ZDF200001 - ] WE, T9.450, T9.505 [ZCF200001 - ] WE, T9.505 [ZDF200001 - ] WE, T9.505, T9.560 [ZCF200001 - ] WE, T9.560 [ZDF200001 - ] WE, T9.560, T9.615 [ZCF200001 - ] WE, T9.615 [ZDF200001 - ] WE, T9.615, T9.670 [ZCF200001 - ] WE, T9.670 [ZDF200001 - ] WE, T9.670

Personal safety - Do not operate tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 T9.390, T9.450, T9.505, T9.560, T9.615, T9.670

Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 T9.390 WE, T9.450 WE, T9.505 WE, T9.560 WE, T9.615 WE, T9.670 WE

Foreword - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 T9.390, T9.450, T9.505, T9.560, T9.615, T9.670

Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . 19 T9.390, T9.450, T9.505, T9.560, T9.615, T9.670

Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 T9.390, T9.450, T9.505, T9.560, T9.615, T9.670

Basic instructions - Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 T9.390 WE, T9.450 WE, T9.505 WE, T9.560 WE, T9.615 WE, T9.670 WE

Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 T9.390, T9.450, T9.505, T9.560, T9.615, T9.670

Torque - Standard torque data for hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 T9.390, T9.450, T9.505, T9.560, T9.615, T9.670

Capacities - Product identification numbers ZCF and before . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 T9.390 [ZCF200001 - ], T9.450 [ZCF200001 - ], T9.505 [ZCF200001 - ], T9.560 [ZCF200001 - ], T9.615 [ZCF200001 ], T9.670 [ZCF200001 - ]

Definition - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 T9.390, T9.450, T9.505, T9.560, T9.615, T9.670

Capacities - Product identification numbers ZDF and after . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 T9.390 [ZDF200001 - ] WE, T9.450 [ZDF200001 - ] WE, T9.505 [ZDF200001 - ] WE, T9.560 [ZDF200001 - ] WE, T9.615 [ZDF200001 - ] WE, T9.670 [ZDF200001 - ] WE

Definition - Machine orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 T9.390 WE, T9.450 WE, T9.505 WE, T9.560 WE, T9.615 WE, T9.670 WE

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INTRODUCTION

Safety rules T9.390 [ZCF200001 - ] WE, T9.390 [ZDF200001 - ] WE, T9.390, T9.450 [ZCF200001 - ] WE, T9.450 [ZDF200001 - ] WE, T9.450, T9.505 [ZCF200001 - ] WE, T9.505 [ZDF200001 - ] WE, T9.505, T9.560 [ZCF200001 - ] WE, T9.560 [ZDF200001 - ] WE, T9.560, T9.615 [ZCF200001 - ] WE, T9.615 [ZDF200001 - ] WE, T9.615, T9.670 [ZCF200001 - ] WE, T9.670 [ZDF200001 - ] WE, T9.670

Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you.

Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation that, if not avoided, could result in death 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 by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety.

Information NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.

Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage.

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SERVICE MANUAL Engine

T9.390 , T9.450 , T9.505 , T9.560 , T9.615 , T9.670

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10

Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 T9.390 , T9.450 , T9.505 , T9.560 , T9.615 , T9.670

[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 T9.390 , T9.450 , T9.505 , T9.560 , T9.615 , T9.670

[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 T9.390 , T9.450 , T9.505 , T9.560 , T9.615 , T9.670

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 T9.390 , T9.450 , T9.505 , T9.560 , T9.615 , T9.670

[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 T9.390 , T9.450 , T9.505 , T9.560 , T9.615 , T9.670

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10

Engine - 10 Engine and crankcase - 001

T9.390 , T9.450 , T9.505 , T9.560 , T9.615 , T9.670

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10.1 [10.001] / 1

Contents Engine - 10 Engine and crankcase - 001

SERVICE Engine Remove - 9 Liter tractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T9.390

Install - 9 Liter tractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 T9.390

Remove - 13L single turbo tractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 T9.450, T9.505, T9.560

Install - 13L single turbo tractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 T9.450, T9.505, T9.560

Remove 13L Two Stage turbocharger tractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 T9.615, T9.670

Install 13L Two Stage turbocharger tractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 T9.615, T9.670

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Engine - Engine and crankcase

Engine - Remove - 9 Liter tractors T9.390

Air conditioning - Evacuate - Air conditioning system (50.200) Prior operation: Hood - Remove - Hood support frame on row crop unit (90.100) 1.

Disconnect air conditioning high and low pressure hoses (1) from compressor. Unplug high pressure sending unit (2).

NOTE: Cap and plug disconnected hoses and ports.

2.

3.

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Cut ties (1) and unplug harness (2).

Loosen fan from hub.

NOTE: Hub has left hand threads.

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Engine - Engine and crankcase

4.

5.

6.

With the help of an assistant turn fan off hub. Remove out the right hand side.

RCPH10FWD011BBC

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Label and disconnect heater hoses (1) and DEF/AdBlueÂŽ solenoid hoses (2).

Disconnect starter connections (1). Remove ground strap from engine block (2).

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Engine - Engine and crankcase

7.

8.

Remove left hand air to air tube (1) and lower radiator hose (2). Loosen upper radiator hose clamp (3).

RCPH10FWD014BBC

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Disconnect alternator cable (1). Disconnect fuel line (2).

NOTE: Plug and cap disconnected fuel line and fitting.

9.

Secure cooling package with support strap (1). Remove right hand air to air tube (2) and upper radiator hose (3).

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Engine - Engine and crankcase

10.

Disconnect fuel return line.

NOTE: Plug and cap disconnected hoses and fittings.

11.

12.

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Disconnect drive shaft from engine.

Remove bracket on both sides over rear engine mounts.

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Engine - Engine and crankcase

13.

14.

Remove front engine mount bracket.

RCPH10FWD021BBC

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Attach 4130 load rotor lifting bale or equivalent. Remove engine from tractor over left hand side rail.

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Engine - Engine and crankcase

Engine - Install - 9 Liter tractors T9.390

1.

Attach load rotor 4130 lifting bale or equivalent to an overhead hoist and the two engine lifting brackets. Install isomounts, lift engine and set into tractor frame.

NOTICE: The engine lifting brackets are for vertical lifting only. Any lifting device that is not vertically in line with the lifting brackets can damage the engine rocker arm cover or cause bracket failure

2.

3.

RCPH10FWD022BBC

1

RCPH10FWD021BBC

2

RCPH10FWD020BBC

3

Install front engine mount bracket. Torque the lower engine mount to frame bolts (1) to 90 - 107 N·m (66 - 79 lb ft). Torque the ISO mount nut (2) to 160 - 220 N·m (118 - 162 lb ft).

Install rear retaining straps to both sides. Torque bolts to 125 - 150 N·m (92 - 111 lb ft). .

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Engine - Engine and crankcase

4.

5.

Connect drive shaft to drive coupler. Torque the bolts to 95 - 108 N¡m (70 - 80 lb ft).

RCPH10FWD018BBC

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6

Connect fuel return line.

NOTE: Remove plug and cap from hose and fitting.

6.

Install upper radiator hose (1) and right hand air to air tube (2). Remove support strap (3).

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Engine - Engine and crankcase

7.

Connect fuel line (1)and alternator cable (2).

NOTE: Remove plug and cap from hose and fitting.

8.

9.

RCPH10FWD015BBC

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RCPH10FWD014BBC

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Tighten upper radiator hose (1). Install lower radiator hose (2), and left hand air to air tube (3).

Secure ground strap to engine block. (1). Connect starter cable and wire (2) to starter.

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Engine - Engine and crankcase

10.

11.

Connect Diesel Emission Fluid/AdBlue® (DEF/AdBlue®) hoses (1) to solenoid and engine tubing.

Connect heater hoses (2) as marked during disassembly.

RCPH10FWD012BBC

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RCPH10FWD011BBC

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Install fan from right hand side of engine with the help of an assistant.

NOTE: Hub has left handed thread.

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Engine - Engine and crankcase

12.

Tighten fan assembly to hub .

NOTE: Hub has left handed thread.

13.

14.

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Plug in harness connector (1) and tie harness lead (2) to bracket.

Attach lifting straps as shown. Use overhead crane to set hood support frame into position.

NOTE: Be sure right hand side air conditioner line is in place while lowering hood support frame into position.

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NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.

Engine - Engine and crankcase

15.

16.

17.

Install and tighten bolts securing hood support frame to tractor frame on both sides.

RCPH10FWD007BBC

15

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Secure hood support frame to cooling package frame with removed hardware.

Connect hose (1). Install clamps (2).

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Engine - Engine and crankcase

18.

19.

Connect hoses (1) and tighten clamps. Install clamp (2) and bracket (3) to hood support frame.

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Assemble intake tube (1) to turbo and air filter housing. Install clamps (2). Plug in harness to sensors (3).

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Engine - Engine and crankcase

20.

21.

Install clamps to hood support frame.

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21

Install clamps to hood support frame.

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Engine - Engine and crankcase

22.

Connect high and low pressure hoses to compressor (1). Plug in high pressure sensor (2) to harness.

NOTE: Install new O-rings and lubricate with clean compressor oil.

23.

24.

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Secure clamp (1). Plug in harness connector (2).

Secure heater hoses and harness with clamps (1).

Plug in connector to DEF/AdBlueÂŽ heater solenoid (2).

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Engine - Engine and crankcase

25.

26.

27.

Loose assemble section of exhaust from muffler/canister with clamps removed during disassembly.

RCPH10FWD994BAC

25

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26

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27

Install exhaust section (1) from turbo to newly installed section. Loose assemble clamps (2).

Assemble clamp at turbo. Adjust sections of exhaust and tighten all clamps.

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Engine - Engine and crankcase

28.

29.

30.

Connect lines for DEF/AdBlueÂŽ (1) and connect harness to sensor (2).

RCPH10FWD991BAC

28

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30

Set air intake duct in position. Loose assemble clamps (1)and bolts (2). Adjust and tighten.

Assemble aspirator tube. Tighten clamps.

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