Case IH PUMA 130 User manual

PrintedinU.S.A.
Copyright © 2011 CNHAmerica LLC. All Rights Reserved.
Case IHisaregisteredtrademarkofCNH America LLC.
Racine Wisconsin 53404 U.S.A.
PUMA 130 / PUMA 130 CVT
PUMA 145 / PUMA 145 CVT
PUMA 160 / PUMA 160 CVT
Tier 4
Tractor
Part number 84479138A
1st edition English
September 2011
SERVICE MANUAL

Contents
INTRODUCTION
HYDRAULIC,PNEUMATIC,ELECTRICAL,ELECTRONICSYSTEMSA
PRIMARYHYDRAULICPOWERSYSTEM..............................................A.10.A
PRIMARYHYDRAULICPOWERSYSTEMClosedcentermechanicalremotevalve...A.10.B
PRIMARYHYDRAULICPOWERSYSTEMElectro-hydraulicremotevalve.............A.10.C
SECONDARYHYDRAULICPOWERSYSTEM..........................................A.12.A
HYDRAULICCOMMANDSYSTEM......................................................A.14.A
PNEUMATICSYSTEM...................................................................A.20.A
ELECTRICALPOWERSYSTEM........................................................A.30.A
ELECTRONICSYSTEM.................................................................A.50.A
FAULTCODES...........................................................................A.50.A
ENGINEANDPTOIN...................................................................B
ENGINE..................................................................................B.10.A
FUELANDINJECTIONSYSTEM........................................................B.20.A
AIRINTAKESYSTEM....................................................................B.30.A
EXHAUSTSYSTEM......................................................................B.40.A
EXHAUSTSYSTEMEmissionscontrol..................................................B.40.B
ENGINECOOLANTSYSTEM...........................................................B.50.A
TRANSMISSION,DRIVEANDPTOOUT........................................C
TRANSMISSIONSemi-Powershift.......................................................C.20.D
TRANSMISSIONPowershift.............................................................C.20.E
TRANSMISSIONContinuouslyVariableTransmission(CVT)...........................C.20.G
ADDITIONALREDUCERSOverdrive....................................................C.30.D
REARPTOMechanical..................................................................C.40.B
REARPTOHydraulic.....................................................................C.40.C
FRONTPTOHydraulic...................................................................C.42.C
AXLES,BRAKESANDSTEERING.................................................D
FRONTAXLE............................................................................D.10.A
REARAXLE..............................................................................D.12.A
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2WD-4WDSYSTEMHydraulic...........................................................D.14.C
STEERINGHydraulic.....................................................................D.20.C
STEERINGAutoguidance................................................................D.20.E
SERVICEBRAKEHydraulic..............................................................D.30.C
SERVICEBRAKEPneumatic............................................................D.30.E
PARKINGBRAKEMechanical...........................................................D.32.B
PARKINGBRAKEElectronic.............................................................D.32.D
BRAKECONNECTIONHydraulic........................................................D.34.C
SUSPENSIONHydraulic.................................................................D.40.C
WHEELSANDTRACKSWheels.........................................................D.50.C
FRAMEANDCAB........................................................................E
FRAMEPrimaryframe...................................................................E.10.B
SHIELD...................................................................................E.20.A
USERCONTROLSANDSEAT..........................................................E.32.A
USERPLATFORM.......................................................................E.34.A
ENVIRONMENTCONTROLHeating,ventilationandair-conditioning...................E.40.D
HITCHANDWORKINGTOOL.......................................................H
HITCHFronthitch........................................................................H.10.B
HITCHRearhitch.........................................................................H.10.C
HITCHElectronicdraftcontrol............................................................H.10.D
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INTRODUCTION
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Contents
INTRODUCTION
Foreword........................................................................................3
Foreword........................................................................................4
ForewordEcologyandtheEnvironment........................................................9
Safetyrules...................................................................................10
Torque........................................................................................14
Basicinstructions.............................................................................16
Conversionfactors............................................................................18
ConsumablesLubricationsandCoolants.....................................................19
Capacities.....................................................................................21
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INTRODUCTION
Foreword
IMPORTANTINFORMATION
AllrepairandmaintenanceworkslistedinthismanualmustbecarriedoutonlybystaffbelongingtotheCASEIH
Servicenetwork,strictlycomplyingwiththeinstructionsgivenandusing,wheneverrequired,thespecialtools.
Anyonewhocarriesouttheaboveoperationswithoutcomplyingwiththeprescriptionsshallberesponsibleforthe
subsequentdamages.
Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regionalor
localdealers,rejectanyresponsibilityfordamagesduetotheanomalousbehaviorofpartsand/orcomponentsnot
approvedbythemanufacturerhimself,includingthoseusedfortheservicingorrepairoftheproductmanufactured
ormarketedbytheManufacturer.Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedor
marketedbytheManufacturerincaseofdamagesduetoananomalousbehaviorofpartsand/orcomponentsnot
approvedbytheManufacturer.
Noreproduction,thoughpartialoftextandillustrationsallowed.
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INTRODUCTION
Foreword
TechnicalInformation
Thismanualhasbeenproducedbyanewtechnicalinformationsystem.Thisnewsystemisdesignedtodeliver
technicalinformationelectronicallythroughWebdelivery,DVDandinpapermanuals.AcodingsystemcalledICE
hasbeendevelopedtolinkthetechnicalinformationtootherProductSupportfunctionse.g.Warranty.
Technicalinformationiswrittentosupportthemaintenanceandserviceofthefunctionsorsystemsonacustomers
machine.Whenacustomerhasaconcernonhismachineitisusuallybecauseafunctionorsystemonhismachine
isnotworkingatall,isnotworkingefciently,orisnotrespondingcorrectlytohiscommands.Whenyourefertothe
technicalinformationinthismanualtoresolvethatcustomersconcern,youwillndalltheinformationclassiedusing
thenewICEcoding,accordingtothefunctionsorsystemsonthatmachine.Onceyouhavelocatedthetechnical
informationforthatfunctionorsystemthenyouwillndallthemechanical,electricalorhydraulicdevices,compo-
nents,assembliesandsubassembliesforthatfunctionorsystem.Youwillalsondallthetypesofinformationthat
havebeenwrittenforthatfunctionorsystem,thetechnicaldata(specications),thefunctionaldata(howitworks),
thediagnosticdata(faultcodesandtroubleshooting)andtheservicedata(remove,installadjust,etc.).
ByintegratingthisnewICEcodingintotechnicalinformation,youwillbeabletosearchandretrievejusttheright
pieceoftechnicalinformationyouneedtoresolvethatcustomersconcernonhismachine.Thisismadepossibleby
attaching3categoriestoeachpieceoftechnicalinformationduringtheauthoringprocess.
TherstcategoryistheLocation,thesecondcategoryistheInformationTypeandthethirdcategoryistheProduct:
•LOCATION-isthecomponentorfunctiononthemachine,thatthepieceoftechnicalinformationisgoingto
describee.g.Fueltank.
•INFORMATIONTYPE-isthepieceoftechnicalinformationthathasbeenwrittenforaparticularcomponentor
functiononthemachinee.g.CapacitywouldbeatypeofTechnicalDatathatwoulddescribetheamountoffuel
heldbytheFueltank.
•PRODUCT-isthemodelthatthepieceoftechnicalinformationiswrittenfor.
Everypieceoftechnicalinformationwillhavethose3categoriesattachedtoit.Youwillbeabletouseanycombination
ofthosecategoriestondtherightpieceoftechnicalinformationyouneedtoresolvethatcustomersconcernonhis
machine.
Thatinformationcouldbe:
•thedescriptionofhowtoremovethecylinderhead
•atableofspecicationsforahydraulicpump
•afaultcode
•atroubleshootingtable
•aspecialtool
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INTRODUCTION
HowtoUsethisManual
ThismanualisdividedintoSections.EachSectionisthendividedintoChapters.Contentspagesareincludedatthe
beginningofthemanual,theninsideeverySectionandinsideeveryChapter.AnalphabeticalIndexisincludedatthe
endofaChapter.PagenumberreferencesareincludedforeverypieceoftechnicalinformationlistedintheChapter
ContentsorChapterIndex.
EachChapterisdividedintofourInformationtypes:
•TechnicalData(specications)forallthemechanical,electricalorhydraulicdevices,componentsand,assem-
blies.
•FunctionalData(howitworks)forallthemechanical,electricalorhydraulicdevices,componentsandassem-
blies.
•DiagnosticData(faultcodes,electricalandhydraulictroubleshooting)forallthemechanical,electricalorhy-
draulicdevices,componentsandassemblies.
•Servicedata(removedisassembly,assemble,install)forallthemechanical,electricalorhydraulicdevices,
componentsandassemblies.
Sections
Sectionsaregroupedaccordingtothemainfunctionsorasystemsonthemachine.EachSectionisidentiedby
aletterA,B,Cetc.TheamountofSectionsincludedinthemanualwilldependonthetypeandfunctionofthe
machinethatthemanualiswrittenfor.EachSectionhasaContentspagelistedinalphabetic/numericorder.This
tableillustrateswhichSectionscouldbeincludedinamanualforaparticularproduct.
SECTION
A-Hydraulic–Pneumatic–Electrical–ElectronicSystems
B-EngineandPTOIn
C-Transmission,DriveandPTOOut
D-Axles,BrakesandSteering
E-FrameandCab
F-FramePositioning
G-ToolPositioning
H-HitchandWorkingTool
J-ExcavatingandLandscaping
K-CropProcessing
L-FieldProcessing
PRODUCT
TractorsXXXXXXXX
Vehicleswithworkingarms:backhoes,
excavators,skidsteers,.....
XXXXXXXXX
Combines,forageharvesters,balers,....XXXXXXXXXX
Seeding,planting,oating,spraying
equipment,....
XXXXXXXXX
Mountedequipmentandtools,.....XXXX
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INTRODUCTION
SectionContents
SECTIONLETTERDESCRIPTION
HYDRAULIC–
PNEUMATIC–
ELECTRICAL–
ELECTRONIC
SYSTEMS
AThisSectioncoversthemainsystemsthatinteractwithmostof
thefunctionsoftheproduct.Itincludesthecentralpartsofthe
hydraulic,electrical,electronic,pneumatic,lightingandgrease
lubricationsystems.Thecomponentsthatarededicatedtoa
specicfunctionarelistedintheChapterwhereallthetechnical
informationforthatfunctionisincluded.
ENGINEANDPTOINBThisSectioncoversallthefunctionsrelatedtotheproduction
ofpowertomovethemachineandtodrivevariousdevices.
Inthecaseofapulled-typemachine,thisSectioncoversthe
powertake-offfunctionwherepowerisprovidedfromthetowing
machine.
TRANSMISSION,
DRIVEANDPTOOUT
CThisSectioncoversallthefunctionsrelatedtothetransmission
ofpowerfromtheenginetotheaxlesandtointernalorexternal
devices.ThisSectionalsocoversthepowertake-offfunction
wherepowerisprovidedtothepull-typemachineandadditional
ProcessDrivefunctions.
AXLES,BRAKESAND
STEERING
DThisSectioncoversallthefunctionsrelatedtomovingthe
machine,includingtracks,wheels,steeringandbraking.Itcovers
alltheaxles;bothdrivenaxlesandnon-drivenaxles,including
anyaxlesuspension.
FRAMEANDCABEThisSectioncoversallthemainfunctionsandsystemsrelatedto
thestructureandthebodyofthemachine,includingtheframe,
theshields,theoperatorscabandtheplatform.Thefunctions
relatedtothepositioningofthemachineframeareincludedin
SectionF,FramePositioning.
FRAMEPOSITIONINGFThisSectioncoversallthemainfunctionsandsystemsrelatedto
positioningofthemachineframeortopositioningtheattachment
onthesupportingmachineframe.
TOOLPOSITIONINGGThisSectioncoversallthefunctionsrelatedtothenaland/or
automaticpositioningofthetooloncethetoolispositionedusing
theWorkingArmorthemachineframe.
HITCHAND
WORKINGTOOL
HThisSectioncoversallthefunctionsrelatedtothearticulated
orsinglearmsmountedonthefrontorrearofthemachine.A
workingarmcanhavevarioustoolsandquickcouplersmounted
ontoit.ThetoolsandquickcouplersareincludedinSectionJ,
ExcavatingandLandscaping.
EXCAVATINGAND
LANSCAPING
JThisSectioncoversallthefunctionsrelatedtothespecictools
thatmountonthefront,rearorbesidethemachine.Thetools
describedherecanbemountedwiththepositioningsystems
(lifting,sideshift,swing)listedinSectionGToolPositioning.This
Sectioncoversallthequickcouplingsystems,locatedbetween
thetoolandthepositioningsystem.Thetoolsusedforeld
preparation,soilpreparationandtreatment,plantingandseeding
areincluded.
CROPPROCESSINGKThisSectioncoversallthefunctionsrelatedtocropprocessing.
Examplesofcropprocessingincludethreshing,baling,
windrowing,cuttingandconditioning.
FIELDPROCESSINGLThisSectioncoversalltheeldprocessingfunctionsofthe
machine.Examplesofeldprocessincludeseeding,fertilizer
application,seedbedpreparationandchemicalapplication.
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INTRODUCTION
ThismanualcontainsthefollowingSections:
INTRODUCTION
DISTRIBUTIONSYSTEMSA
POWERPRODUCTIONB
POWERTRAINC
TRAVELLINGD
BODYANDSTRUCTUREE
HITCHANDWORKINGTOOLH
Chapters
EachChapterisidentiedbyaletterandnumbercombinatione.g.EngineB.10.ATherstletterisidenticaltothe
Sectionletteri.e.ChapterB.10isinsideSectionB,EngineandPTOIn.
CONTENTS
TheChapterContentslistsallthetechnicaldata(specications),functionaldata(howitworks),servicedata(remove,
installadjust,etc..)anddiagnosticdata(faultcodesandtroubleshooting)thathavebeenwritteninthatChapterfor
thatfunctionorsystemonthemachine.
Contents
ENGINEANDPTOIN
ENGINE_10.A
TECHNICALDATA
ENGINE-Generalspecication(B.10.A)
FUNCTIONALDATA
ENGINE-Dynamicdescription(B.10.A)
SERVICE
ENGINE-Remove(B.10.A)
DIAGNOSTIC
ENGINE-Troubleshooting(B.10.A)
INDEX
TheChapterIndexlistsinalphabeticalorderallthetypesofinformation(calledInformationUnits)thathavebeen
writteninthatChapterforthatfunctionorsystemonthemachine.
Index
ENGINEANDPTOIN-B
ENGINE
ENGINE-Dynamicdescription(B.10.A)
ENGINE-Generalspecication(B.10.A)
ENGINE-Remove(B.10.A)
ENGINE-Troubleshooting(B.10.A)
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INTRODUCTION
InformationUnitsandInformationSearch
Eachchapteriscomposedofinformationunits.EachinformationunithastheICEcodeshowninparentheseswhich
indicatesthefunctionandthetypeofinformationwritteninthatinformationunit.Eachinformationunithasapageref-
erencewithinthatChapter.Theinformationunitsprovideaquickandeasywaytondjusttherightpieceoftechnical
informationyouarelookingfor.
ExampleinformationunitStackvalve-SectionalView(A.10.A.18)
InformationUnitICEcodeA10.A18
ICEcodeclassicationHydraulic–
Pneumatic–
Electrical–
ElectronicSystems
PrimaryhydraulicpowerStackvalve
CRIL03J033E01A1
Navigatetothecorrectinformationunityouaresearchingforbyidentifyingthefunctionandinformationtype
fromtheICEcode.
•(1)Functionand(2)Informationtype.
•(A)correspondstothesectionsoftherepairmanual.
(B)correspondstothechaptersoftherepairmanual.
(C)correspondstothetypeofinformationlistedinthechaptercontents,TechnicalData,FunctionalData,Diag-
nosticorService.
(A)and(B)arealsoshowninthepagenumberingonthepagefooter.
THERESTOFTHECODINGISNOTLISTEDINALPHANUMERICORDERINTHISMANUAL.
•Youwillndatableofcontentsatthebeginningandendofeachsectionandchapter.
Youwillndanalphabeticalindexattheendofeachchapter.
•Byreferringto(A),(B)and(C)ofthecoding,youcanfollowthecontentsorindex(pagenumbers)andquickly
ndtheinformationyouarelookingfor.
PageHeaderandFooter
Thepageheaderwillcontainthefollowingreferences:
•SectionandChapterdescription
Thepagefooterwillcontainthefollowingreferences:
•PublicationnumberforthatManual,SectionorChapter.
•Versionreferenceforthatpublication.
•Publicationdate
•Section,chapterandpagereferencee.g.A.10.A/9
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INTRODUCTION
ForewordEcologyandtheEnvironment
Soil,air,andwaterarevitalfactorsofagricultureandlifeingeneral.Whenlegislationdoesnotyetrulethetreatment
ofsomeofthesubstanceswhicharerequiredbyadvancedtechnology,commonsenseshouldgoverntheuseand
disposalofproductsofachemicalandpetrochemicalnature.
NOTICE:Thefollowingarerecommendationswhichmaybeofassistance:
•Becomeacquaintedwithandensurethatyouunderstandtherelativelegislationapplicabletoyourcountry.
•Wherenolegislationexists,obtaininformationfromsuppliersofoils,lters,batteries,fuels,antifreeze,cleaning
agents,etc.,withregardtotheireffectonmanandnatureandhowtosafelystore,useanddisposeofthese
substances.
•Agriculturalconsultantswill,inmanycases,beabletohelpyouaswell.
HELPFULHINTS
•Avoidllingtanksusingcansorinappropriatepressurizedfueldeliverysystemswhichmaycauseconsiderable
spillage.
•Ingeneral,avoidskincontactwithallfuels,oils,acids,solvents,etc.Mostofthemcontainsubstanceswhich
maybeharmfultoyourhealth.
•Modernoilscontainadditives.Donotburncontaminatedfuelsandorwasteoilsinordinaryheatingsystems.
•Avoidspillagewhendrainingoffusedenginecoolantmixtures,engine,gearboxandhydraulicoils,brakeuids,
etc.Donotmixdrainedbrakeuidsorfuelswithlubricants.Storethemsafelyuntiltheycanbedisposedofin
aproperwaytocomplywithlocallegislationandavailableresources.
•Moderncoolantmixtures,i.e.antifreezeandotheradditives,shouldbereplacedeverytwoyears.Theyshould
notbeallowedtogetintothesoilbutshouldbecollectedanddisposedofproperly.
•Donotopentheair-conditioningsystemyourself.Itcontainsgaseswhichshouldnotbereleasedintotheat-
mosphere.YourCASEIHAGRICULTUREdealerorairconditioningspecialisthasaspecialextractorforthis
purposeandwillhavetorechargethesystemproperly.
•Repairanyleaksordefectsintheenginecoolingorhydraulicsystemimmediately.
•Donotincreasethepressureinapressurizedcircuitasthismayleadtoacomponentfailure.
•Protecthosesduringweldingaspenetratingweldsplattermayburnaholeorweakenthem,allowingthelossof
oils,coolant,etc.
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INTRODUCTION
Safetyrules
PRECAUTIONARYSTATEMENTS
PersonalSafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibleinjuryordeath.
Throughoutthismanualandonmachinedecals,youwillndthesignalwordsDANGER,WARNING,andCAUTION
followedbyspecialinstructions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworking
withyou.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGERindicatesahazardoussituationwhich,ifnotavoided,willresultindeathorseriousinjury.The
colorassociatedwithDANGERisRED.
WARNINGindicatesahazardoussituationwhich,ifnotavoided,couldresultindeathorseriousinjury.
ThecolorassociatedwithWARNINGisORANGE.
CAUTION,usedwiththesafetyalertsymbol,indicatesahazardoussituationwhich,ifnotavoided,couldresult
inminorormoderateinjury.ThecolorassociatedwithCAUTIONisYELLOW.
FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT
INDEATHORSERIOUSINJURY.
NOTICE:Installnewdecalsiftheolddecalsaredestroyed,lostpaintedoverorcannotberead.Whenpartsare
replacedthathavedecalsmakesureyouinstallanewdecalwitheachnewpart.
MACHINESAFETY
NOTICE:Noticeindicatesasituationwhich,ifnotavoided,couldresultinmachineorpropertydamage.Thecolor
associatedwithNoticeisBLUE.
ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
INFORMATION
NOTE:Noteindicatesadditionalinformationwhichclariessteps,procedures,orotherinformationinthismanual.
ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or
otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.
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INTRODUCTION
ACCIDENTPREVENTION
WARNING
Avoidinjury!Alwaysdothefollowingbeforelubricating,maintaining,orservicingthemachine.
1.Disengagealldrives.
2.Engageparkingbrake.
3.Lowerallattachmentstotheground,orraiseandengageallsafetylocks.
4.Shutoffengine.
5.Removekeyfromkeyswitch.
6.Switchoffbatterykey,ifinstalled.
7.Waitforallmachinemovementtostop.
Failuretocomplycouldresultindeathorseriousinjury.W0047A
Mostaccidentsorinjuriesthatoccurinworkshopsaretheresultofnoncompliancetosimpleandfundamentalsafety
principles.Forthisreason,INMOSTCASESTHESEACCIDENTSCANBEAVOIDEDbyapplyingthefundamental
safetyprinciples,actingwiththenecessarycautionandcare.
Accidentsmayoccurwithalltypesofmachine,regardlessofhowwellthemachineinquestionwasdesignedand
built.
SAFETYREQUIREMENTSFORFLUIDPOWERSYSTEMSANDCOMPONENTS-HY-
DRAULICS(EUROPEANSTANDARDEN982)
•Flexiblehoseassembliesmustnotbeconstructedfromhoseswhichhavebeenpreviouslyusedaspartofa
hoseassembly.
•Donotweldhydraulicpipes:whenexiblehosesorpipingaredamaged,replacethemimmediately.
•Itisforbiddentomodifyahydraulicaccumulatorbymachining,weldingoranyotherway.
•Beforeremovinghydraulicaccumulatorsforservicing,theliquidpressureintheaccumulatorsmustbereduced
tozero.
•Pressurecheckonhydraulicaccumulatorsmustbecarriedoutbyamethodrecommendedbytheaccumulator
manufacturer.
•Takecarenottoexceedthemaximumallowedpressureoftheaccumulator.Afteranycheckoradjustment,
checkforleakagesorgasinthehosesorpipes.
SAFETYRULES
Generalguidelines
•Carefullyfollowspeciedrepairandmaintenanceprocedures.
•Whenappropriate,useP .P .E(PersonalProtectiveEquipment)
•Donotwearrings,wristwatches,jewellery,unbuttonedorloosearticlesofclothingsuchas:ties,tornclothing,
scarves,openjacketsorshirtswithopenzipsthatmayremainentangledinmovingparts.Itisadvisedtowear
approvedsafetyclothing,e.g.:non-slipfootwear,gloves,safetygoggles,helmets,etc.
•Donotcarryoutrepairoperationswithsomeonesittinginthedriver'sseat,unlessthepersonisatrainedtech-
nicianwhoisassistingwiththeoperationinquestion.
•Donotoperatethemachineoruseanyoftheimplementsfromdifferentpositions,otherthanthedriver'sseat.
•Donotcarryoutoperationsonthemachinewiththeenginerunning,unlessspecicallyindicated.
•Bringallhydrauliccylinderstothehomepositions(down,retracted,etc.)beforeengineshutdown.
•Stoptheengineandcheckthatthehydrauliccircuitsarepressure-freebeforeremovingcaps,covers,valves,
etc.
•Allrepairandmaintenanceoperationsmustbecarriedoutusingextremecareandattention.
•Servicestepsandplatformsusedintheworkshoporelsewhereshouldbebuiltaccordingtotheapplicable
standardsandlegislation.
•Disconnectthepowertakeoff(p.t.o).andlabelthecontrolstoindicatethatthemachineisbeingserviced.Any
partsthataretoberaisesmustbelockedinposition.
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INTRODUCTION
•Brakesareinoperativewhenmanuallyreleasedforrepairormaintenancepurposes.Useblocksorsimilarde-
vicestosecurethemachineintheseconditions.
•Onlyusespeciedtowingpointsfortowingthemachine.Connectpartscarefully.Makesurethatallpinsand/or
locksaresecuredinpositionbeforeapplyingtraction.Neverremainnearthetowingbars,cablesorchainsthat
areoperatingunderload.
•Whenloadingorunloadingthemachinefromthetrailer(orothermeansoftransport),selectaatareacapable
ofsustainingthetrailerortruckwheels.Firmlysecurethemachinetothetruckortrailerandlockthewheelsin
thepositionusedbythecarrier.
•Electricheaters,battery-chargersandsimilarequipmentmustonlybepoweredbyauxiliarypowersupplieswith
efcientgroundinsulationtoavoidelectricalshockhazards.
•Alwaysusesuitablehoistingorliftingdeviceswhenraisingormovingheavyparts.
•Keepbystandersaway.
•Neverusegasoline,dieseloilorotherinammableliquidsascleaningagents.Usenon-inammable,nontoxic
commerciallyavailablesolvents.
•Wearsafetygoggleswithsideguardswhencleaningpartswithcompressedair.
•Donotruntheengineinenclosedspaceswithoutsuitableventilationorexhaustextraction.
•Neveruseopenamesforlightingwhenworkingonthemachineorcheckingforleaks.
•Allmovementsmustbecarriedoutcarefullywhenworkingunder,onornearthemachine.Wearpersonalpro-
tectiveequipment(P .P .E.):helmets,gogglesandspecialfootwear.
•Whencarryingoutcheckswiththeenginerunning,requesttheassistanceofanoperatorinthedriver'sseat.
Theoperatormustmaintainvisualcontactwiththeservicetechnicianatalltimes.
•Ifoperatingoutsidetheworkshop,positionthemachineonaatsurfaceandlockinposition.Ifworkingona
slope,lockthemachineinposition.Movetoaatareaassoonasissafelypossible.
•Damagedorbentchainsorcablesareunreliable.Donotusethemforliftingortowing.Alwaysusesuitable
protectivegloveswhenhandlingchainsorcables.
•Chainsshouldalwaysbesafelysecured.Makesurethatthehitch-uppointiscapableofsustainingtheloadin
question.Keeptheareanearthehitch-uppoint,chainsorcablesfreeofallbystanders.
•MaintenanceandrepairoperationsmustbecarriedoutinaCLEANandDRYarea.Cleanupanywateroroil
spillageimmediately.
•Donotcreatepilesofoilorgrease-soakedragsastheyrepresentaseriousrehazard.Alwaysstoreragsina
closedmetalcontainer.
•Beforeengagingthemachine,makesurethattherearenopersonswithinthemachineorimplementrangeof
action.
•Emptyyourpocketsofallobjectsthatmayfallaccidentallyunobservedintothemachineinnercompartments.
•Whenmetalpartsarestickingout,useprotectivegogglesorgoggleswithsideguards,helmets,specialfootwear
andgloves.
•Whenwelding,useprotectivesafetydevices:tintedsafetygoggles,helmets,specialoveralls,glovesand
footwear.Allpersonspresentintheareawhereweldingistakingplacemustweartintedgoggles.NEVER
LOOKDIRECTLYATTHEWELDINGARCWITHOUTSUITABLEEYEPROTECTION.
•Alwaysdisconnectbatterygroundterminalwhenwelding.
•Metalcablestendtofraywithrepeateduse.Alwaysusesuitableprotectivedevices(gloves,goggles,etc.)when
handlingcables.
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INTRODUCTION
Machinestart-up.
•Neverruntheengineinconnedspacesthatarenotequippedwithadequateventilationforexhaustgasex-
traction.
•Neverplacethehead,body,limbs,feet,handsorngersnearrotatingandmovingparts.
Hydraulicsystemsandfuelinjectionsystems
•Aliquidleakingfromatinyholemaybealmostinvisiblebut,atthesametime,bepowerfulenoughtopenetrate
theskin.Therefore,NEVERUSEHANDSTOCHECKFORLEAKSbutuseapieceofcardboardorpaperfor
thispurpose.Ifanyliquidpenetratesskintissue,callformedicalaidimmediately.Failuretotreatthiscondition
withcorrectmedicalproceduremayresultinseriousinfectionordeath.
•Inordertocheckthepressureinthesystemusesuitableinstruments.
WheelsandTires
•Makesurethatthetiresarecorrectlyinatedatthepressurespeciedbythemanufacturer.Periodicallycheck
therimsandtiresfordamage.
•Standawayfrom(atthesideof)thetirewhencheckinginationpressure.
•Donotusepartsofrecoveredwheelsasincorrectweldingbrazingorheatingmayweakenandeventuallycause
damagetothewheel.
•Nevercutorweldarimmountedwithaninatedtire.
•Deatethetirebeforeremovinganyobjectsthatmaybejammedinthetiretread.
•Neverinatetiresusinginammablegases,asthismayresultinexplosionsandinjurytobystanders.
RemovalandRe-tting
•Liftandhandleallheavypartsusingsuitablehoistingequipment.Makesurethatpartsaresustainedbyappro-
priatehooksandslings.Usethehoistingeyeboltsforliftingoperations.Extracareshouldbetakenifpersons
arepresentneartheloadtobelifted.
•Handleallpartscarefully.Donotputyourhandsorngersbetweenparts.Wearsuitablesafetyclothing-safety
goggles,glovesandshoes.
•Avoidtwistingchainsormetalcables.Alwayswearsafetygloveswhenhandlingcablesorchains.
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INTRODUCTION
Torque
Minimumhardwaretighteningtorques(inNmorlbin/lbft)fornormalassemblyapplica-
tionsunlessotherwisestated
NOTICE:Shownbelowisthesuggestedinitialtorquetighteningsequencesforgeneralapplications,tighteninse-
quencefromitem1throughtothelastitemofthehardware.
Theminimumhardwaretighteningtorqueondrawings,inspecicationsetc.havepriority.
TheapplicableCNHStandardisENS7001.
df5019-11
Metrichardware
Class8.8inNm(lbinorlbft)Class10.9inNm(lbinorlbft)
Nominal
Size
PlatednutLocknutHardenednutPlatednutLocknutHardenednut
M31.3N·m
(11.5lbin)
0.7N·m
(6.2lbin)
1.2N·m
(10.6lbin)
1.8N·m
(15.9lbin)
0.9N·m
(8.0lbin)
1.6N·m
(14.2lbin)
M42.9N·m
(25.7lbin)
1.6N·m
(14.2lbin)
2.6N·m
(23.0lbin)
4.2N·m
(37.2lbin)
2.3N·m
(20.4lbin)
3.7N·m
(32.7lbin)
M55.9N·m
(52.2lbin)
3.2N·m
(28.3lbin)
5.3N·m
(46.9lbin)
8.5N·m
(75.2lbin)
4.6N·m
(40.7lbin)
7.6N·m
(67.3lbin)
M610.1N·m
(89.4lbin)
5.5N·m
(48.7lbin)
9.1N·m
(80.5lbin)
14.5N·m
(10.7lbft)
7.9N·m
(69.9lbin)
13N·m
(9.6lbft)
M824.5N·m
(18.1lbft)
13.5N·m
(10.0lbft)
22N·m
(16.2lbft)
35.1N·m
(25.9lbft)
19.3N·m
(14.2lbft)
31.5N·m
(23.2lbft)
M1048.7N·m
(35.9lbft)
26.8N·m
(19.8lbft)
43.8N·m
(32.3lbft)
69.5N·m
(51.3lbft)
38.2N·m
(28.2lbft)
62.5N·m
(46.1lbft)
M1285N·m
(62.7lbft)
46.7N·m
(34.4lbft)
76.5N·m
(56.4lbft)
121N·m
(89.2lbft)
66.5N·m
(49.0lbft)
108.9N·m
(80.3lbft)
M14135N·m
(99.6lbft)
74.2N·m
(54.7lbft)
121.5N·m
(89.6lbft)
193N·m
(142.3lbft)
106.1N·m
(78.3lbft)
173.7N·m
(128.1lbft)
M16210N·m
(154.9lbft)
115.5N·m
(85.2lbft)
189N·m
(139.4lbft)
301N·m
(222lbft)
165.5N·m
(122.1lbft)
270.9N·m
(199.8lbft)
M18299N·m
(220.5lbft)
164.4N·m
(121.3lbft)
269.1N·m
(198.5lbft)
414N·m
(305.4lbft)
227.7N·m
(167.9lbft)
372.6N·m
(274.8lbft)
M20425N·m
(313.5lbft)
233.72N·m
(172.4lbft)
382.5N·m
(282.1lbft)
587N·m
(432.9lbft)
322.8N·m
(238.1lbft)
528.3N·m
(389.7lbft)
M22579N·m
(427lbft)
318.4N·m
(234.8lbft)
521.1N·m
(384.3lbft)
801N·m
(590.8lbft)
440.5N·m
(324.9lbft)
720.9N·m
(531.7lbft)
M24735N·m
(542.1lbft)
404.2N·m
(298.1lbft)
661.5N·m
(487.9lbft)
1016N·m
(749.4lbft)
558.8N·m
(412.1lbft)
914.4N·m
(674.4lbft)
M271073N·m
(791.4lbft)
590.1N·m
(435.2lbft)
967.5N·m
(713.6lbft)
1486N·m
(1096lbft)
817.3N·m
(602.8lbft)
1337N·m
(986.1lbft)
M301461N·m
(1077.6lbft)
803.5N·m
(592.6lbft)
1315N·m
(969.9lbft)
2020N·m
(1489.9lbft)
1111N·m
(819.4lbft)
1818N·m
(1340.9lbft)
84479138A06/06/2011
14

INTRODUCTION
ZEIL06CS0136F0A2
ZEIL06CS0135F0A3
84479138A06/06/2011
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INTRODUCTION
Basicinstructions
SHIMMING
Foreachadjustmentoperation,selectadjustingshimsandmeasureindividuallyusingamicrometer,thenaddup
therecordedvalues.Donotrelyonmeasuringtheentireshimmingset,whichmaybeincorrect,ortheratedvalue
indicatedoneachshim.
ROTATINGSHAFTSEALS
Forcorrectrotatingshaftsealinstallation,proceedasfollows:
•beforeassembly,allowthesealtosoakintheoilitwillbesealingforatleastthirtyminutes
•thoroughlycleantheshaftandcheckthattheworkingsurfaceontheshaftisnotdamaged
•positionthesealinglipfacingtheuid;withhydrodynamiclips,takeintoconsiderationtheshaftrotationdirection
andpositionthegroovessothattheywilldeviatetheuidtowardstheinnersideoftheseal
•coatthesealinglipwithathinlayeroflubricant(useoilratherthangrease)andllthegapbetweenthesealing
lipandthedustlipondoublelipsealswithgrease
•insertthesealinitsseatandpressdownusingaatpunch,donottapthesealwithahammerormallet
•whilstinsertingtheseal,checkthatitisperpendiculartotheseat;oncesettled,makesurethatitmakescontact
withthethrustelement,ifrequired
•topreventdamagingtheseallipontheshaft,positionaprotectiveguardduringinstallationoperations
O-RINGSEALS
LubricatetheO-RINGsealsbeforeinsertingthemintheseats,thiswillpreventthemfromoverturningandtwisting,
whichwouldjeopardizesealingefciency.
SEALINGCOMPOUNDS
Onlyusethesealantswhicharerecommendedinthismanual!Beforeapplyingthesealingcompound,prepare
thesurfacesasfollows:
•removeanyincrustationsusingametalbrush;
•thoroughlyde-greasethesurfacesusingoneofthefollowingcleaningagents:trichlorethylene,petrolorawater
andsodasolution.
COTTERPINS
Whenttingsplitcotterpins,ensurethatthepinnotchispositionedinthedirectionoftheforcerequiredtostressthe
pin.Spiralcotterpinsdonotrequirespecialpositioning.
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