New Holland T6.110 Service Manual
New Holland T6.110 is a tractor designed for agricultural tasks in Latin America. It features a powerful F4CE0484 engine and a variety of transmissions, including mechanical and power shuttle options. The T6.110 also boasts a robust 4-wheel drive system, a powerful hydraulic system, and a strong rear three-point hitch for various implements.
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SERVICE MANUAL SERVICE MANUAL T6.110 T6.120 T6.130 T6.110 / T6.120 / T6.130 Tractor Tractor Part number 47705279 Part number 47705279 English September 2014 Copyright © 2014 CNH INDUSTRIAL LATIN AMERICA LTDA.All Rights Reserved. SERVICE MANUAL T6.110 Cabinado , T6.110 Sem cabine , T6.120 Cabinado , T6.120 Sem cabine , T6.130 Cabinado , T6.130 Sem cabine 47705279 11/09/2014 EN Find manuals at https://best-manuals.com Link Product / Engine Product T6.110 Cabinado [HCCZ6110HECS24371 - ] T6.110 Sem cabine [HCCZ6110TECS23550 - ] T6.120 Cabinado [HCCZ6120XECS23550 - ] T6.120 Sem cabine [HCCZ6120HECS24546 - ] T6.130 Cabinado [HCCZ6130LECS24656 - ] T6.130 Sem cabine [HCCZ6130XECS23550 - ] Market Product Latin America Engine F4CE0484C*B601 Latin America F4CE0484C*B601 Latin America F4CE0484A*B605 Latin America F4CE0484A*B605 Latin America F4CE0484B*B602 Latin America F4CE0484B*B602 47705279 11/09/2014 Find manuals at https://best-manuals.com Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 Clutch ....................................................................................... 18 [18.110] Clutch and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1 Transmission.............................................................................. 21 [21.114] Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.112] Power shuttle transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.134] Power shuttle transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 [21.109] Transmission cooler and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 Four-Wheel Drive (4WD) system .................................................. 23 [23.304] Four-Wheel Drive (4WD) gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 [23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2 Front axle system ....................................................................... 25 [25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 [25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 47705279 11/09/2014 Find manuals at https://best-manuals.com Power Take-Off (PTO) ................................................................. 31 [31.114] Two-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 Brakes and controls .................................................................... 33 [33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2 Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 Hitches, drawbars, and implement couplings.................................. 37 [37.110] Rear three-point hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.1 Frames and ballasting ................................................................. 39 [39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1 Steering..................................................................................... 41 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.432] Autoguidance steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 Wheels ...................................................................................... 44 [44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2 Cab climate control ..................................................................... 50 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 Electrical systems ....................................................................... 55 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 47705279 11/09/2014 Find manuals at https://best-manuals.com [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.045] Front axle control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 Platform, cab, bodywork, and decals ............................................. 90 [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.110] Operator platform less cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.114] Operator protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4 [90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.6 [90.102] Engine shields, hood latches, and trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.7 47705279 11/09/2014 Find manuals at https://best-manuals.com 47705279 11/09/2014 Find manuals at https://best-manuals.com INTRODUCTION 47705279 11/09/2014 1 Find manuals at https://best-manuals.com Contents INTRODUCTION Advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 International symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Basic instructions - Shop and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 47705279 11/09/2014 2 Find manuals at https://best-manuals.com INTRODUCTION Advice All repair and maintenance works listed in this manual must be carried out only by qualified dealership personnel, strictly complying with the instructions given; and using, whenever possible, the special tools. Anyone who carries out the above operations without complying with the procedures shall be responsible for the subsequent damages. The manufacturer and all the organizations of it's distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages due to the anomalous behavior of parts 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 information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for continuous improvement. Some information could not be updated due to modifications of a technical or commercial type, as well as to suit the laws and regulations of different countries. In case of questions, refer to your Sales and Service Networks. 47705279 11/09/2014 3 Find manuals at https://best-manuals.com INTRODUCTION International symbols As a guide to the operation of the machine, various universal symbols have been utilized on the instruments, controls, switches, and fuse box. The symbols are shown below with an indication of their meaning. Heater plug for cold start Turning signal Power Take-Off (PTO) Reaction control Alternator charging Activated memory Transmission in neutral Accessories socket Fuel level Turn signals Creeper selection Implement socket Automatic fuel shut-off Turn signals - one trailer Low speed selection Percentage slip Engine speed (rpm x 100) Turn signals - two trailers High speed selection Raising of the hydraulic lift Hour meter Wind shield washer Road speed Rear hitch lower Engine oil pressure Windscreen wash wipe Differential Lock Hydraulic lift height threshold Engine coolant temperature Heating temperature control Rear axle oil temperature Hydraulic lift disabled Coolant level Cab recirculation fan Transmission oil pressure Transmission filters and hydraulic filters Machine lights Air conditioner Auxiliary Front Wheel Drive (AFWD) operated Remote control valve extension Main beam head Air Filter Restriction Warning! Remote control valve command retraction Low beam Parking brake Danger warning lights Remote control valve flotation Work lamps Brake fluid level Variable control Malfunction! See Operator’s Stop lamp Trailer brake Pressurized! Open carefully Malfunction! (alternative symbol) Klaxon Warning! Corrosive substance Position control Brake fluid level 47705279 11/09/2014 4 INTRODUCTION Foreword Soil, air, and water are vital factors of agriculture and life in general. Where legislation does not yet rule the treatment of some of the substances which are required by advanced technology, common sense should govern the use and disposal of products of a chemical and petrochemical nature. The following are recommendations which may be of assistance: • Become acquainted with and ensure that you understand the relative legislation applicable to your country. • Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning agents, etc., with regard to their effect on man and nature and how to safety store, use and dispose of these substances. Agricultural consultants will, in many cases, be able to help you as well. Helpful Hints • Avoid filling tanks using unsuitable containers or inappropriate pressurized fuel delivery systems that may cause spillages. • If you are exposed to or come in contact with hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolant, etc. required for the function of your machine can be hazardous. They may be attractive and harmful to domestic animals, as well as humans. • Dispose of all fluids, filters, and containers in an environmentally-safe manner and according to local laws and regulations. Check with local environmental and recycling centers or your dealer for correct disposal information. Store fluids and filter in accordance with local laws and regulations. Use only appropriate containers for the storage of chemicals or petrochemical substances. • Modern oils contain additives. Do not burn contaminated fuels and/ or waste oils in ordinary heating systems. • Avoid spillage when draining off used engine coolant mixtures, engine, gear box and hydraulic oils, brake fluids, etc. Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper way to comply with local legislation and available resources. • Modern coolant mixtures, i.e., antifreeze and other additives, should be replaced every two years. They should not be allowed to get into the soil but should be collected and disposed of safely. • The air-conditioning system contains gases that are harmful to the environment when released into the atmosphere. Do not attempt to service or repair the system. Your dealer or air conditioning specialist has a special extractor for this purpose and will be able to recharge the system in any case. • Repair any leaks or defects in the engine cooling or hydraulic system immediately. • Do not increase the pressure in a pressurized circuit as this could cause the components to explode. • Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, causing the loss of oils, coolant, etc. • Keep out of reach of children or other unauthorized persons. Additional precautions are required for applied chemicals. Obtain complete information from the manufacturer or distributor of the chemicals before you use them. 47705279 11/09/2014 5 INTRODUCTION Advice Mandatory recycling The battery is essentially composed of lead plates and sulfuric acid solution. Since the battery contains heavy metals such as lead, CONAMA Resolution 401/2008 orders that all used batteries must be returned to the battery dealer at the time of replacement. Do not dispose of the battery in the garbage. Points of sale are obliged to accept the return of your used battery, and to store it in a suitable place and return it to the manufacturer for recycling. Improper disposal of batteries can contaminate the soil, groundwater and waterways. The consumption of contaminated water can cause high blood pressure, anemia, depression, weakness, leg pain, and drowsiness. Contact of the acid solution with eyes causes chemical conjunctivitis. Contact of the acid solution with skin causes contact dermatitis. In the case of accidental contact with the eyes or skin, immediately wash with running water and seek medical treatment. CUIL13TRO0091AA 47705279 11/09/2014 6 1 INTRODUCTION Safety rules 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. 47705279 11/09/2014 7 INTRODUCTION Safety rules Standard safety precautions Be informed and notify personnel of the laws in force regulating safety, and provide documentation available for consultation. • Keep working areas as clean as possible. • Ensure that working areas are provided with emergency boxes. They must be clearly visible and always contain adequate sanitary equipment. • Fire extinguishers must be properly identified and always be clear of obstructions. Their efficiency must be checked on a regular basis and personnel must be trained on proper interventions and priorities. • Keep all emergency exits free of obstructions and clearly marked. • Smoking in working areas subject to fire danger must be strictly prohibited. Prevention of injury • Wear suitable work attire and safety glasses with no jewelry such as rings and chains when working close to engines and equipment in motion. • Wear safety gloves and goggles when performing the following operations: • Topping off or changing lubrication oils. • Using compressed air or liquids at a pressure greater than 2 bar (29 psi). • Wear a safety helmet when working close to hanging loads or equipment working at head level. • Always wear safety shoes and fitting clothes. • Use protection cream for hands. • Change wet clothes as soon as possible. • In the presence of voltages exceeding 48 - 60 V, verify the efficiency of the ground and mass electrical connections. Ensure that hands and feet are dry and use isolating foot boards. Workers should be properly trained to work with electricity. • Do not smoke or start an open flame close to batteries and any fuel material. • Place soiled rags with oil, diesel fuel or solvents in specially provided anti-fire containers. • Do not use any tool or equipment for any use other than what it was originally intended for. Serious injury may occur. • If running an engine indoors, make sure there is a sufficient exhaust fan in use to eliminate exhaust fumes. During maintenance • Never open the filler cap of the cooling system when the engine is hot. High temperature liquid at operating pressure could result in serious danger and risk of burn. Wait until the temperature decreases under 50 °C (122 °F). • Never add coolant to an overheated engine and use only appropriate liquids. • Always work when the engine is turned off. Certain circumstances require maintenance on a running engine. Be aware of all the risks involved with such an operation. • Always use adequate and safe containers for engine fluids and used oil. • Keep engine clean of any spilled fluids such as oil, diesel fuel, and or chemical solvents. • Use of solvents or detergents during maintenance may emit toxic vapors. Always keep working areas aerated. Wear a safety mask if necessary. • Do not leave soiled rags that may contain any flammable substances close to the engine. • Always use caution when starting an engine after any work has been performed. Be prepared to cut off intake air in case of engine runaway. • Never disconnect the batteries while the engine is running. • Disconnect the batteries prior to performing any work on the equipment. 47705279 11/09/2014 8 INTRODUCTION • Disconnect the batteries to place a load on them with a load tester. • After any work is performed, verify that the battery clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation. • Before disconnecting any pipelines (pneumatic, hydraulic, fuel pipes, etc.), verify that all pressure has been released. Take all necessary precautions bleeding and draining residual pressure. Always wear the proper safety equipment. • Do not alter the lengths of any wires. • Do not connect any electronic service tool to the engine electrical equipment unless specifically approved by NEW HOLLAND. • Do not modify the fuel system or hydraulic system unless approved by NEW HOLLAND. Any unauthorized modification will compromise warranty assistance and may affect engine operation and life span. For engine equipped with an electronic control unit • Do not weld on any part of the equipment without removing the control unit. • Remove the in case of work requiring heating over 80 °C (176 °F). • Do not paint the components and the electronic connections. • Do not alter any data filed in the electronic control unit driving the engine. Any manipulation or alteration of electronic components will void engine warranty assistance and may affect the correct working order and life span of the engine. Respect of the Environment • Respect of the environment should be of primary importance. Take all necessary precautions to ensure personnel's safety and health. • Inform the personnel of the laws regarding the dispensing of used engine fluids. • Handle batteries with care, storing them in a well ventilated environment and within anti-acid container. 47705279 11/09/2014 9 INTRODUCTION Safety rules General safety regulations General Aspects • Strictly follow repair and maintenance procedures. • Do not wear rings, wrist watches, jewelry, accessories, unbuttoned items of clothing, unsecured clothing like ties, torn clothing, scarves, or open jackets or shirts with open zippers that could get caught in moving parts. Use approved safety clothing, such as anti-slip footwear, sleeves, protective goggles, helmets, etc. • Wear safety goggles with side shields when cleaning parts using compressed air. • Worn or damaged cables and chains are not reliable. Do not use these elements in lifting or towing operations. • Use regulation safety equipment, such as approved eye protection, helmets, clothes, sleeves, and special footwear whenever you are welding. All individuals near the welding process must use regulation eye protection. Never look at the welding arc without using suitable eye protection. • Never perform any repairs on the machine if there is someone in the operator seat, except when the person is a qualified operator who is helping with the service to be performed. • Never operate the machine or use accessories from a place other than the operator seat or next to the machine when operating the fender switches. • Never perform any operations on the machine with the engine running, except when specifically instructed to do so. Shut down the engine and release all the pressure from the hydraulic circuits before removing covers, cases, valves, etc. • You must conduct all repair and maintenance operations with the utmost care and attention. • Disconnect the batteries and put warning labels on all of the controls to warn that the machine is being repaired. Lock the machine and all the equipment that you remove. • Never check or fill the fuel tank or batteries or use starting fluid when you are smoking or near a naked flame, because these fluids are flammable. • The fuel filling gun must remain in contact with the filler neck. Maintain the contact until the fuel stops flowing into the tank in order to avoid sparks caused by static electricity build-up. • To transport a faulty machine, use a trailer or a low loader platform trolley, if available. • To load and unload the machine from the mode of transportation, choose a flat area that offers firm support for the wheels of the truck or trailer. Securely fasten the machine to the platform of the trailer or truck, in accordance with the transporter’s requirements. • Always use hoist mechanisms with an appropriate capacity for lifting or moving heavy components. • Chains must always be securely fastened. The fastening device must have sufficient capacity to support the intended load. It is prohibited for bystanders to be near the fastening position. • The work area must always be clean and dry. Clean it immediately if any water or oil is spilled. • Never use gasoline, diesel, or other flammable liquids for cleaning. Use only non-toxic solvents. • Do not allow cloths soaked with oil or grease to accumulate because they can cause a fire risk. Always keep these cloths in a metal container. Starting • Never start the engine in enclosed spaces that are not equipped with a suitable exhaust system or gas-extraction system. • Never bring your head, body, arms, legs, feet, hands, or fingers close to fans or rotating belts. Engine • Always loosen the radiator cap slowly before removing it, in order to dissipate the system pressure. You must top up the coolant with the engine stopped. • Do not fill up the fuel tank when the engine is running. • Never adjust the fuel injection pump when the machine is in motion. 47705279 11/09/2014 10 INTRODUCTION • Never lubricate the machine when the engine is running. Electrical systems • If it is necessary to use auxiliary batteries, you must connect the cables on both sides as follows: (+) to (+) and (-) to (-). Avoid causing the terminals to short circuit. GAS RELEASED FROM BATTERIES IS HIGHLY FLAMMABLE. During charging, leave the battery compartment open to improve ventilation. Avoid sparks and naked flames near the battery. Do not smoke. • Do not charge the batteries in enclosed spaces. • Always disconnect the batteries before carrying out any type of servicing on the electrical system. Hydraulic system • A little fluid coming out of a small bore could be almost invisible, but strong enough to penetrate the skin. For this reason, NEVER USE YOUR HANDS TO CHECK FOR LEAKS. Instead, use a piece of cardboard or timber. If any fluid penetrates your skin, seek medical assistance immediately. Failure to seek immediate medical assistance could result in serious infections or dermatitis. • Always read the system pressure using suitable gauges. Wheels and Tyres • Make sure that the tires are correctly inflated at the pressure specified by the manufacturer. Inspect the rims and tires regularly for any damage. • Remain next to the tire when filling it with air. • Only check the pressure when the platform is unloaded and the tires are cold, in order to prevent inaccurate readings caused by overpressure. • Never cut or weld a rim with a full tire fitted. • To remove the wheels, lock both the front and rear wheels of the machine. Lift the machine. Install stable and secure supports under the machine, as per the legislation in force. • Deflate the tire before removing any objects that may be caught in the tire tread. • Never inflate tires using flammable gases, as they could cause explosions and injure bystanders. Remove and install • Lift and handle all heavy components using hoist devices of appropriate capacity. You must suspend the parts using suitable hooks and slings. Use the hoist eyes provided for this purpose. Be careful if there are any bystanders near the hoisted load. 47705279 11/09/2014 11 INTRODUCTION Safety rules Health and safety precautions Many of the procedures involved in machine maintenance and repair services involve physical hazards and other health risks. This section lists some of these hazardous procedures and the materials and equipment associated with them. Acids and alkalis Avoid splashing into your eyes and nose, or onto your skin and clothing. Wear suitable sleeves and protective goggles. Irritate and corrode the skin, eyes, nose, and throat. Causes burns. Do not inhale the fumes. Adhesives and sealants These are highly flammable. You must store them in no smoking areas. Use applicators when possible or secondary containers. The containers must be labeled. Resin-based adhesives/sealants Skin contact could result in irritation, dermatitis, and the absorption of toxic or harmful chemicals through the skin. Splashes could cause eye injuries. Ensure that there is adequate ventilation and avoid contact with the skin and the eyes. Follow the manufacturer’s instructions. Ensure that there is adequate ventilation as volatile harmful or toxic chemicals may be released. Anti-freeze These are highly flammable. You must store them in no smoking areas. Anti-freeze can be absorbed through the skin in toxic or harmful quantities. Ingesting anti-freeze can cause death and you must seek medical assistance immediately. Chemicals – General You must always take care when using and handling chemicals such as solvents, sealants, adhesives, paints, foam resins, battery acids, anti-freeze, brake fluid, oils and greases. They may be harmful, toxic, corrosive, irritant, or highly flammable. They may also emit hazardous fumes or dust. Do Remove chemicals from skin and clothing as soon as possible after contact. Change very dirty clothes and make provision for cleaning them. Read and strictly adhere to the safety recommendations on the chemical containers. When working with chemicals, wash before breaks, and before eating, smoking, drinking, or using the bathroom. Keep work areas clean, organized, and free of spillages. Store according to local and national legislation. Keep chemicals out of the reach of children. Do not Do not mix chemicals, except in accordance with the manufacturer's instructions. Some substances could form other chemical substances that are toxic or harmful, emit toxic or harmful fumes, or become explosive after mixing. Do not spray chemicals, especially solvent-based chemicals, in enclosed spaces. Do not apply heat or flames to chemicals, except in accordance with the manufacturer's instructions. Some are highly flammable or could release toxic or harmful fumes. Do not leave containers open. The fumes emitted could accumulate in toxic, harmful, or explosive concentrations. Some fumes are heavier than air and will accumulate in confined areas, trenches, etc. Do not put chemicals in unmarked containers. 47705279 11/09/2014 12 INTRODUCTION Do not clean your hands or clothes with chemicals. Chemicals, particularly solvents and fuels, dry out the skin and can cause irritation and dermatitis. Some can be absorbed through the skin in toxic or harmful quantities. Do not use empty containers to store other chemicals, except when they have been cleaned under supervision. Do not attempt to sniff or inhale chemicals. Rapid exposure to high concentrations of fumes can be toxic or harmful. Anti-corrosive protective material These materials are varied and you must follow the manufacturers' instructions. They may contain solvents, resins, petroleum derivatives, etc. You must avoid contact with the skin and the eyes. You must carry out spraying with adequate ventilation and never in enclosed spaces. Post Dust, powders, or clouds may be irritant, harmful, or toxic. Avoid inhaling the chemical powders or dusts that result from dry abrasion services. Use respiratory protection if ventilation is not adequate. Electric shock Electric shocks result from the use of faulty electrical equipment or from incorrect use. You must keep electrical equipment in good condition and test it frequently. Electrical equipment must be protected by a fuse with an appropriate nominal capacity. Use low-voltage equipment ( 110 volt) for work lights and inspection lights, wherever possible. Use pneumatic equipment instead of electrical equipment wherever possible. In the event of electrocution: • Turn off the electricity before approaching the victim. • If that is not possible, push or pull the victim away from the source of the electricity using a dry, non-conductive material. • If you have been trained, start giving first aid. • Seek medical assistance. Exhaust fumes These fumes contain asphyxiating, toxic or harmful chemical substances. You must only run engines in adequate extraction or general ventilation conditions, and never in enclosed spaces. Fiber insulation The fibrous nature of cut surfaces and edges can cause skin irritation. In general, the effect is physical and not chemical. You must take precautions to avoid excessive skin contact. Take care when organizing your work methods. Wear sleeves. Fire Many materials relating to vehicle repair are highly flammable. Some release toxic or harmful fumes when burned. Scrupulously observe the fire prevention safety recommendations when storing and handling flammable materials or solvents, particularly in the vicinity of electrical equipment or welding processes. Before using any electrical or welding equipment, ensure that there is no risk of fire. Always have an appropriate fire extinguisher nearby when using welding or heating equipment. 47705279 11/09/2014 13 INTRODUCTION Foams – Polyurethane See fire. Used for soundproofing. Cured foams used in seat cushions and finishes. Follow the manufacturer’s instructions. Components that have not reacted are irritants and could be harmful to the eyes and the skin. Wear sleeves and protective goggles. Individuals with chronic respiratory illnesses, asthma, bronchial problems, or a history of allergic illnesses must not work with or be in proximity to uncured materials. Components, fumes, and aerosol clouds can cause irritation and sensitization reactions, and may be toxic or harmful. You must apply these materials with adequate respiratory protection and adequate ventilation. Do not remove the respirator when you have finished spraying. Keep the respirator on until the fumes and clouds disperse. Burning uncured components and cured foams can generate toxic and harmful fumes. Do not permit smoking, the presence of naked flames, or the use of electrical equipment during the application of foam, and until the fumes/ clouds have dispersed. The hot cutting of cured or partially cured foam must be performed in an environment with a ventilation system with extraction. Kerosene (Paraffin) Ingesting kerosene can cause irritation to the mouth and throat. The greatest danger from ingesting kerosene is the possibility of breathing it into the lungs. Liquid contact dries the skin and can cause irritation or dermatitis. Splashes on the skin and in the eyes cause mild irritation. Avoid contact with the eyes and the skin as far as possible and ensure that there is adequate ventilation. Fuel oil (diesel fuel) When the quantities are large or the exposure period is long, skin contact with fuel oils with a high boiling point can cause serious skin diseases, including skin cancer. Gas cylinders See fire. In general, gases, such as oxygen, carbon dioxide, argon, and propane, are stored in cylinders with pressures of up to 140 bar ( 2000 lb/in2). You need to take sufficient care when handling them to prevent physical damage to the cylinders and the valve accessories. The content of each cylinder must be clearly identified with suitable labels. You must store the cylinders in a well-ventilated room, protected from ice, rain, and direct sunlight. You must not store combustible gases near to oxygen cylinders. Be careful to prevent leaks from the cylinders and the gas lines, and to avoid ignition sources. Only qualified personnel may perform services using the cylinders. General workshop equipment and tools You must keep all equipment and tools in good condition and you must use the correct safety equipment whenever necessary. Never use tools or equipment for any purpose other than that for which they are intended. Never overload equipment such as hoists, jacks, chassis bases and axles, or hoisting slings. The damage caused by overloading does not always appear immediately and could cause a fatal accident the next time that the equipment is used. Do not use faulty or damaged equipment or tools, particularly high-speed equipment, such as emery wheels. A damaged emery wheel can disintegrate suddenly and cause serious injury. Use protective goggles whenever you use equipment for grinding, cutting, polishing, or sandblasting. Oil test equipment, lubrication test equipment, and high-pressure air test equipment, in accordance with local legislation Always keep high-pressure equipment in good condition and carry out regular maintenance, particularly on connections and fittings. Never point a high-pressure nozzle at the skin as the fluid can cause serious injuries. 47705279 11/09/2014 14 INTRODUCTION Legal aspects Various laws and regulations lay down the health and safety requirements for working with materials and equipment in workshops. Always observe the regulations and laws in force in the country in which you are working. Workshops must comply with the relevant regulations and laws. Consult the local supervisory authorities or related government bodies if you are in any doubt. Lubricants and greases Avoid prolonged or recurrent contact with mineral oils, particularly used oils. Thoroughly wash the skin after tasks using oil. Do not use gasoline, paraffin, or other solvents to remove oil from the skin. Lubricants and greases can cause mild eye irritation. You must avoid repeated or prolonged skin contact by wearing protective clothing where necessary. Do not allow your work clothes to become contaminated with oil. Wash or dry clean work clothes regularly. Discard oil-soaked shoes. Do not use used engine oil as a lubricant or for applications where it might come into contact with the skin. Paints You should preferably perform spraying in a ventilated cab with an exhaust system to remove the fumes and spray from the breathing area. Individuals working in cabs must use respiratory protection. Personnel carrying out smallscale repair work must use respirators with an air supply. Solvents Contact dries out the skin, and prolonged or recurrent contact can cause irritation and dermatitis. Some can be absorbed through the skin in toxic or harmful quantities. Splashes into the eyes can cause serious irritation and even lead to blindness. Wear protective sleeves, protective goggles and protective clothing. Ensure that there is good ventilation during use, avoid inhaling smoke, fumes, and spray clouds, and keep containers securely closed. Do not use in enclosed spaces. Do not apply heat or flame, except in accordance with specific and detailed instructions from the manufacturer. Arc welding This process emits a high level of ultraviolet radiation that can burn the eyes and skin of the welder and of other people nearby. Gas-protected welding processes are particularly dangerous in this respect. Personal protection is mandatory. Barriers to protect other people are also necessary. You also need to use suitable eye and skin protection because of metal splashes. The heat of arc welding will produce gases and fumes from the metals that are being melted, and from the coatings applied to or contamination on the worked surfaces. These gases and fumes may be toxic and you must avoid inhaling them. You may need to use ventilation with extraction to remove smoke from the work area, particularly in cases where there is not enough general ventilation or in places where a considerable amount of welding is expected to take place. In extreme cases, where adequate ventilation cannot be guaranteed, you may need to use respirators with an air supply. 47705279 11/09/2014 15 INTRODUCTION Torque - Minimum tightening torques for normal assembly METRIC NON-FLANGED HARDWARE NOM. SIZE M4 M5 M6 M8 CLASS 8.8 BOLT and CLASS 8 NUT PLATED UNPLATED W/ZnCr CLASS 10.9 BOLT and CLASS 10 NUT PLATED UNPLATED W/ZnCr 2.2 N·m (19 lb in) 4.5 N·m (40 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in) 3.2 N·m (28 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 26 N·m (234 lb in) M10 37 N·m (27 lb ft) M12 64 N·m (47 lb ft) M16 M20 M24 158 N·m (116 lb ft) 319 N·m (235 lb ft) 551 N·m (410 lb ft) 2.9 N·m (26 lb in) 5.9 N·m (52 lb in) 10 N·m (89 lb in) 25 N·m (217 lb in) 49 N·m (36 lb ft) 85 N·m (63 lb ft) 210 N·m (155 lb ft) 425 N·m (313 lb ft) 735 N·m (500 lb ft) 52 N·m (38 lb ft) 91 N·m (67 lb ft) 225 N·m (166 lb ft) 440 N·m (325 lb ft) 762 N·m (560 lb ft) 4.2 N·m (37 lb in) 8.5 N·m (75 lb in) 15 N·m (128 lb in) 35 N·m (311 lb in) 70 N·m (51 lb ft) 121 N·m (90 lb ft) 301 N·m (222 lb ft) 587 N·m (433 lb ft) 1016 N·m (750 lb ft) LOCKNUT CL.8 W/CL8.8 BOLT 2 N·m (18 lb in) 4 N·m (36 lb in) 6.8 N·m (60 lb in) 17 N·m (151 lb in) 33 N·m (25 lb ft) 58 N·m (43 lb ft) 143 N·m (106 lb ft) 290 N·m (214 lb ft) 501 N·m (370 lb ft) LOCKNUT CL.10 W/CL10.9 BOLT 2.9 N·m (26 lb in) 5.8 N·m (51 lb in) 10 N·m (89 lb in) 24 N·m (212 lb in) 48 N·m (35 lb ft) 83 N·m (61 lb ft) 205 N·m (151 lb ft) 400 N·m (295 lb ft) 693 N·m (510 lb ft) NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque specifications are shown in pound-feet. 47705279 11/09/2014 16 INTRODUCTION METRIC FLANGED HARDWARE NOM. SIZE CLASS 8.8 BOLT and CLASS 8 NUT PLATED W/ZnCr UNPLATED M4 M5 M6 M8 2.4 N·m (21 lb in) 4.9 N·m (43 lb in) 8.3 N·m (73 lb in) 20 N·m (179 lb in) M10 40 N·m (30 lb ft) M12 70 N·m (52 lb ft) M16 M20 M24 174 N·m (128 lb ft) 350 N·m (259 lb ft) 607 N·m (447 lb ft) 3.2 N·m (28 lb in) 6.5 N·m (58 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in) 54 N·m (40 lb ft) 93 N·m (69 lb ft) 231 N·m (171 lb ft) 467 N·m (345 lb ft) 809 N·m (597 lb ft) CLASS 10.9 BOLT and CLASS 10 NUT UNPLATED 3.5 N·m (31 lb in) 7.0 N·m (62 lb in) 12 N·m (105 lb in) 29 N·m (257 lb in) 57 N·m (42 lb ft) 100 N·m (74 lb ft) 248 N·m (183 lb ft) 484 N·m (357 lb ft) 838 N·m (618 lb ft) 4.6 N·m (41 lb in) 9.4 N·m (83 lb in) 16 N·m (141 lb in) 39 N·m (343 lb in) 77 N·m (56 lb ft) 134 N·m (98 lb ft) 331 N·m (244 lb ft) 645 N·m (476 lb ft) 1118 N·m (824 lb ft) Metric Hex head and carriage bolts, classes 5.6 and up 1 1. Manufacturer's Identification 2. Property Class Metric Hex nuts and locknuts, classes 05 and up 20083681 2 47705279 11/09/2014 17 LOCKNUT CL.10 W/CL10.9 BOLT 2.2 N·m (19 lb in) 4.4 N·m (39 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in) 3.1 N·m (27 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in) PLATED W/ZnCr IDENTIFICATION 20083680 LOCKNUT CL.8 W/CL8.8 BOLT 37 N·m (27 lb ft) 53 N·m (39 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft) 158 N·m (116 lb ft) 318 N·m (235 lb ft) 552 N·m (407 lb ft) 226 N·m (167 lb ft) 440 N·m (325 lb ft) INTRODUCTION 1. Manufacturer's Identification 2. Property Class 3. Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60 ° apart indicate Class 10 properties, and marks 120 ° apart indicate Class 8. INCH NON-FLANGED HARDWARE NOMINAL SIZE SAE GRADE 5 BOLT and NUT UNPLATED or PLATED SILVER 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 SAE GRADE 8 BOLT and NUT UNPLATED PLATED W/ZnCr or PLATED GOLD SILVER LOCKNUT GrB W/ Gr5 BOLT LOCKNUT GrC W/ Gr8 BOLT PLATED W/ZnCr GOLD 12 N·m 16 N·m 8 N·m (71 lb 11 N·m (97 lb (106 lb in) (142 lb in) in) in) 17 N·m 23 N·m 24 N·m 32 N·m (150 lb in) (204 lb in) (212 lb in) (283 lb in) 40 N·m 43 N·m (31 lb 57 N·m (42 lb 30 N·m (22 lb (30 lb ft) ft) ft) ft) 65 N·m 48 N·m (36 lb 68 N·m (50 lb 91 N·m (67 lb (48 lb ft) ft) ft) ft) 98 N·m 104 N·m 139 N·m 74 N·m (54 lb (73 lb ft) (77 lb ft) (103 lb ft) ft) 107 N·m 142 N·m 150 N·m 201 N·m (79 lb ft) (105 lb ft) (111 lb ft) (148 lb ft) 147 N·m 196 N·m 208 N·m 277 N·m (108 lb ft) (145 lb ft) (153 lb ft) (204 lb ft) 261 N·m 348 N·m 369 N·m 491 N·m (193 lb ft) (257 lb ft) (272 lb ft) (362 lb ft) 420 N·m 561 N·m 594 N·m 791 N·m (310 lb ft) (413 lb ft) (438 lb ft) (584 lb ft) 630 N·m 841 N·m 890 N·m 1187 N·m (465 lb ft) (620 lb ft) (656 lb ft) (875 lb ft) 12.2 N·m (109 lb in) 17.5 N·m (155 lb 25 N·m (220 lb in) in) 8.5 N·m (75 lb in) 31 N·m (23 lb ft) 44 N·m (33 lb ft) 50 N·m (37 lb ft) 71 N·m (53 lb ft) 108 N·m (80 lb ft) 156 N·m (115 lb 111 N·m (82 lb ft) ft) 153 N·m (113 lb 215 N·m (159 lb ft) ft) 271 N·m (200 lb 383 N·m (282 lb ft) ft) 437 N·m (323 lb 617 N·m (455 lb ft) ft) 654 N·m (483 lb 924 N·m (681 lb ft) ft) 76 N·m (56 lb ft) NOTE: For Imperial Units, 1/4 in and 5/16 in hardware torque specifications are shown in pound-inches. 3/8 in through 1 in hardware torque specifications are shown in pound-feet. 47705279 11/09/2014 18 INTRODUCTION INCH FLANGED HARDWARE NOMSAE GRADE 5 BOLT and SAE GRADE 8 BOLT and INAL NUT NUT SIZE UNPLATED PLATED UNPLATED PLATED or PLATED W/ZnCr or PLATED W/ZnCr SILVER GOLD SILVER GOLD 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 9 N·m (80 lb in) 19 N·m (168 lb in) 33 N·m (25 lb ft) 53 N·m (39 lb ft) 81 N·m (60 lb ft) 117 N·m (86 lb ft) 162 N·m (119 lb ft) 287 N·m (212 lb ft) 462 N·m (341 lb ft) 693 N·m (512 lb ft) LOCKNUT GrF W/ Gr5 BOLT 12 N·m (106 lb 13 N·m (115 lb 17 N·m (150 lb 8 N·m (71 lb in) in) in) in) 25 N·m (221 lb 26 N·m (230 lb 35 N·m (310 lb 17 N·m (150 lb in) in) in) in) 44 N·m (33 lb 47 N·m (35 lb 63 N·m (46 lb 30 N·m (22 lb ft) ft) ft) ft) 71 N·m (52 lb 75 N·m (55 lb 100 N·m (74 lb 48 N·m (35 lb ft) ft) ft) ft) 153 N·m 108 N·m (80 lb 115 N·m (85 lb 74 N·m (55 lb ft) (113 lb ft) ft) ft) 156 N·m 165 N·m 221 N·m 106 N·m (78 lb ft) (115 lb ft) (122 lb ft) (163 lb ft) 216 N·m 228 N·m 304 N·m 147 N·m (108 lb (159 lb ft) (168 lb ft) (225 lb ft) ft) 383 N·m 405 N·m 541 N·m 261 N·m (193 lb (282 lb ft) (299 lb ft) (399 lb ft) ft) 617 N·m 653 N·m 871 N·m 421 N·m (311 lb (455 lb ft) (482 lb ft) (642 lb ft) ft) 925 N·m 979 N·m 1305 N·m 631 N·m (465 lb (682 lb ft) (722 lb ft) (963 lb ft) ft) LOCKNUT GrG W/ Gr8 BOLT 12 N·m (106 lb in) 24 N·m (212 lb in) 43 N·m (32 lb ft) 68 N·m (50 lb ft) 104 N·m (77 lb ft) 157 N·m (116 lb ft) 207 N·m (153 lb ft) 369 N·m (272 lb ft) 594 N·m (438 lb ft) 890 N·m (656 lb ft) IDENTIFICATION Inch Bolts and free-spinning nuts 20083682 3 Grade Marking Examples 1 2 3 Grade 2 - No Marks Grade 5 - Three Marks Grade 8 - Five Marks SAE Grade Identification 4 Grade 2 Nut - No Marks 5 Grade 5 Nut - Marks 120 ° Apart 6 Grade 8 Nut - Marks 60 ° Apart 47705279 11/09/2014 19 INTRODUCTION Inch Lock Nuts, All Metal (Three optional methods) 20090268 4 Grade Identification Grade Grade A Grade B Grade C Corner Marking Method (1) No Notches One Circumferential Notch Two Circumferential Notches Flats Marking Method (2) No Mark Letter B Letter C 47705279 11/09/2014 20 Clock Marking Method (3) No Marks Three Marks Six Marks INTRODUCTION Basic instructions - Shop and Assembly SHIMS For each adjustment operation, select adjusting shims and measure separately 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 on 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 direction 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). 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 or seal installation tool. 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 contact 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 overturning and twisting, which would jeopardize sealing efficiency. SEALING COMPOUNDS Apply one of the following sealing compounds on the mating surfaces when specified: SILMATE® RTV1473, or LOCTITE® RTV 598™ or LOCTITE® INSTANT GASKET 587 BLUE. Before applying the sealing compound, prepare the surfaces as directed on product container or as follows: • remove any deposits with a wire brush • thoroughly de-grease the surfaces using a locally-approved cleaning agent such as safety solvent or brake parts cleaner. SPARE PARTS Only use "CNH Original Parts" or " NEW HOLLAND Parts". Only genuine spare parts guarantee the same quality, duration and safety as original parts, as they are the same parts that are assembled during standard production. Only "CNH Original Parts" or " NEW HOLLAND Parts" can offer this guarantee. When ordering spare parts, always provide the following information: • machine model (commercial name) and serial number • part number of the ordered part, which can be found in the "Microfiches" or the "Spare Parts Catalogue", used to process orders 47705279 11/09/2014 21 INTRODUCTION PROTECTING THE ELECTRONIC/ ELECTRICAL SYSTEMS DURING CHARGING OR WELDING To avoid damage to the electronic/electrical systems, always observe the following: 1. Never connect or disconnect any part of the charging circuit, including the battery connections, when the engine is running. 2. Never short any of the charging components to earth. 3. Always disconnect the ground cable from the battery before arc welding on the combine or on any header attached to the combine. • position the welder ground clamp as close to the welding area as possible • if welding in close proximity to a computer module, then the module should be removed from the combine • never allow welding cables to lay on, near or across any electrical wiring or electronic component while welding is in progress 4. Always disconnect the negative cable from the battery when charging the battery in the combine with a battery charger. NOTICE: If welding must be performed on the unit, either the combine or the header (if it is attached), the battery ground cable must be disconnected from the combine battery. The electronic monitoring system and charging system will be damaged if this is not done. Remove the battery ground cable. Reconnect the cable when welding is completed. NOTICE: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes, and clothing. Antidote - EXTERNAL: flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call a doctor immediately. EYES: Flush with water for 15 minutes and seek immediate medical attention. TOOLS The tools that NEW HOLLAND suggests and illustrated in this manual have been: • specifically researched and designed for use with NEW HOLLAND machines • 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 NOTE: The terms "front", "rear", "right-hand" and "left-hand" (when referred to different parts) are determined from the rear, facing in the direction of travel of the machine during operation. 47705279 11/09/2014 22 INTRODUCTION Consumables System Cooling system Without cabine With cabine Air Conditioning System Refrigerant Compressor oil Windshield washer reservoir Fuel tank Engine - With filter Front axle Carcaça Final reducers (each) Mechanical transmission Power shuttle transmission Brake system Grease fittings Quantity 15.0 L (4.0 US gal) 18.0 L (4.8 US gal) – 200 cm³ – Recommended fluid Specification NEW HOLLAND International specification NEW HOLLAND AMBRA AGRIFLU NH 900 A ASTM D 6210 type 1-FF – – – – – – – – CNH REFRIGERANT HFC-134A Sandem SP10 Water and AREXONS DP1 liquid 110 models: 150.0 L (39.6 US gal) Diesel oil or Biodiesel B (B5) Other models: 230 L - Brazil (61 US gal) NEW HOLLAND AMBRA MASTERGOLD™ HSP ENGINE OIL SAE 10W-30 10.0 L (2.6 US gal) NEW HOLLAND AMBRA MASTERGOLD™ HSP ENGINE OIL SAE 15W-40 6.2 L (1.6 US gal) NEW HOLLAND AMBRA 1.5 L (0.4 US gal) MULTI G™ HYDRAULIC TRANSMISSION OIL 59.0 L (15.6 US gal) 72.0 L (19.0 US gal) 1.0 - 1.5 L (2.1 - 3.2 US NEW HOLLAND AMBRA pt) BRAKE LHM NEW HOLLAND AMBRA – GR 75 MD 47705279 11/09/2014 23 NH 330 H NH 324 H API CI-4, CH-4, CG-4, CF-4, CF/SL API CH-4, CG-4, CF-4, CF/SL NH 410 B SAE 10W-30, API GL4, ISO VG 32/46 NH 610 A ISO 7308 NH 710 A NLGI 2 INTRODUCTION A decal that states the type of oil that must be used in each machine system is mounted on the rear of the tractor, below the cab. 47359591A 47705279 11/09/2014 24 1 SERVICE MANUAL Engine T6.110 Cabinado [HCCZ6110HECS24371 - ] , T6.110 Sem cabine [HCCZ6110TECS23550 - ] , T6.120 Cabinado [HCCZ6120XECS23550 - ] , T6.120 Sem cabine [HCCZ6120HECS24546 - ] , T6.130 Cabinado [HCCZ6130LECS24656 - ] , T6.130 Sem cabine [HCCZ6130XECS23550 - ] 47705279 11/09/2014 10 Contents Engine - 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 47705279 11/09/2014 10 Engine - 10 Engine and crankcase - 001 T6.110 Cabinado [HCCZ6110HECS24371 - ] , T6.110 Sem cabine [HCCZ6110TECS23550 - ] , T6.120 Cabinado [HCCZ6120XECS23550 - ] , T6.120 Sem cabine [HCCZ6120HECS24546 - ] , T6.130 Cabinado [HCCZ6130LECS24656 - ] , T6.130 Sem cabine [HCCZ6130XECS23550 - ] 47705279 11/09/2014 10.1 [10.001] / 1 Contents Engine - 10 Engine and crankcase - 001 TECHNICAL DATA Engine General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE Engine Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 47705279 11/09/2014 10.1 [10.001] / 2 Engine - Engine and crankcase Engine - General specification T6.110 Number of rolls Loop Injection Aspiration Piston diameter Piston stroke Injection Sequence Engine speeds Idle speed Maximum rotation Rated speed Total cylinder capacity Compression ratio T6.120 4 Diesel, 4 stroke Direct Turbo 104 mm 132 mm 1–3–4–2 T6.130 900 RPM Maximum engine power (SAE J1995) Maximum engine torque at 1400 RPM (SAE J1995) Number of main bearing housings Sump Maximum working inclination - Transversal Maximum working inclination - Longitudinal Rev counter Acionamento Gauge calibrated for engine at Pad Cylinder hole diameter Grinding External diameter oversize Diameter of housing for the main bushings covers Diameter of housings for control shaft bushings: Front Middle Back Diameter of tappet housings Tappet oversize Main bearing seat bore diameter 47705279 11/09/2014 10.1 [10.001] / 3 2375 RPM 2200 RPM 4485 cm³ 17,5:1 82 kW 90 kW 97 kW (111.5 Hp) (122.4 Hp) (131.9 Hp) 528 N·m 550 N·m 583 N·m 5 Cast iron 30 ° 35 ° Incorporated in control panel Originated from the distribution shaft gear 1800 RPM Cast iron monoblock, incorporates housings for distribution shaft / tappet fittings 104.000 - 104.024 mm 87.982 - 88.008 mm 54.089 54.089 59.222 16.000 - 54.139 mm 54.139 mm 59.248 mm 16.030 mm 87.982 - 88.008 mm Engine - Engine and crankcase Engine - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A Prior operation: Drive shaft - Remove (23.314) Prior operation: Exhaust pipes - Remove (10.254) Prior operation: Radiator - Drain fluid (10.400) 1. Disconnect the battery negative (-) cable (1). CUIL14TR00227AA 1 CUIL14TR00801AA 2 LAIL11TL0548A0A 3 2. Disconnect the connections of the existing wire harnesses between the cab and the engine. 3. Remove the front ballasts. Consult the procedures in Front ballast - Remove (39.140). 4. Remove the engine hood. Consult the procedures in Hood - Remove (90.100). 5. Remove the engine side shields. Consult the procedures in Side shield - Remove (90.102). 47705279 11/09/2014 10.1 [10.001] / 4 Engine - Engine and crankcase 6. Remove the two clips (1) and disconnect the suction line (2). 7. Remove the bolts (3) and disconnect the pressure tubes (4) and (5). NOTE: After disconnecting each of the tubes, protect the disconnected ends with suitable covers. CUIL14TR00109AA 4 CUIL14TR00794AA 5 CUIL14TR00564AA 6 CUIL14TR00808AA 7 8. Disconnect the two hoses (1) from the steering cylinder. 9. Loosen the throttle cable (1). 10. Disconnect the radiator hose (1). 11. Loosen the expansion tank hose (2). 47705279 11/09/2014 10.1 [10.001] / 5 Engine - Engine and crankcase 12. Disconnect the lower radiator hose (1). 13. Loosen the dust ejector hose (2). CUIL14TR00809AA 8 CUIL14TR00220AA 9 14. Disconnect the fuel supply (1) and return line (2). 15. Disconnect the heater hoses (1) and (2). CUIL14TR00797AA 10 CUIL14TR00554AA 11 16. Loosen the latch (1) that supports the condenser (2). 47705279 11/09/2014 10.1 [10.001] / 6 Engine - Engine and crankcase 17. Remove the electrical connection (2) and loosen the fastening bolts from the filter-drier. LAIL11TL0088A0A 12 CUIL14TR00219AA 13 CUIL14TR00548AA 14 CUIL14TR00559AA 15 18. Loosen the fastening bolts from the air-conditioning compressor (1) and remove the connection to the motor. 19. Move the condenser (1), the filter-drier (2) and the compressor inside the cab without disconnecting the hoses. 20. Remove the intercooler inlet and outlet lines (1). 21. Remove the air filter intake line (2). 47705279 11/09/2014 10.1 [10.001] / 7 Engine - Engine and crankcase 22. Remove the transmission cooler (2) - See the procedures Transmission cooler - Remove (21.109). CUIL14TR00545AA 16 LAIL11TL1133A0A 17 LAIL11TL1134A0A 18 CUIL14TR00803AA 19 23. Place the tool (trolley) under the tractor and put two wedges on the front shaft to prevent swaying. 24. Place a wooden shim (1) on the contact points between the trestles and the tractor. 25. Place a fixed trestle (1) under the draw bar support and pull the parking brake. 26. Remove the fastening bolts (1) between the engine and the transmission. 27. Separate the engine from the transmission, moving the front of the tractor carefully. 47705279 11/09/2014 10.1 [10.001] / 8 Engine - Engine and crankcase 28. Place a fixed trestle (1) under the counterweight cradle and block the front wheels with wooden wedges (2). LAIL11TL1138A0A 20 LAIL11TL0416A0A 21 LAIL11TL1147A0A 22 LAIL11TL1148A0A 23 29. Remove the clutch assembly. Consult the procedures in Clutch - Remove (18.110). 30. Lift the engine slightly and position the mobile trestle (1) under the front axle support. 31. Remove the four bolts (2) securing the engine and remove the engine from the axle support. 47705279 11/09/2014 10.1 [10.001] / 9 Engine - Engine and crankcase 32. Carefully separate the engine from the front axle and place it on the engine stand. LAIL11TT0008A0A 47705279 11/09/2014 10.1 [10.001] / 10 24 Engine - Engine and crankcase Engine - Install DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A WARNING Maintenance hazard! Before performing any maintenance or inspection: -position machine on a firm, level surface -turn off the engine -remove the ignition key -secure the machine (wheels chocked) -disconnect the wiring (unless instructed otherwise) Failure to comply could result in death or serious injury. W1071A 1. Align the front support with the engine. 2. Install the bolts (2) for securing the support to the engine. Tighten to a torque of 380 - 420 N·m (280 - 310 lb ft). LAIL11TL1148A0A 1 CUIL14TR00803AA 2 3. Install the clutch assembly. Consult the procedures in Clutch - Install (18.110). 4. Bring the front axle support assembly and transmission engine together. 5. Install the bolts (1) for securing the engine to the transmission. Tighten to a torque of 265 - 319 N·m (195 235 lb ft). 47705279 11/09/2014 10.1 [10.001] / 11 Engine - Engine and crankcase 6. Install the transmission cooler (2) - See the procedures in Transmission cooler - Install (21.109). CUIL14TR00545AA 3 CUIL14TR00559AA 4 CUIL14TR00797AA 5 CUIL14TR00220AA 6 7. Install the intercooler inlet and outlet lines (1). 8. Install the air filter intake line (2). 9. Connect the heater hoses (1) and (2). 10. Connect the fuel supply (1) and return line (2). 47705279 11/09/2014 10.1 [10.001] / 12 Engine - Engine and crankcase 11. Connect the radiator hose (1). 12. Install the expansion tank hose (2). CUIL14TR00808AA 7 CUIL14TR00809AA 8 CUIL14TR00564AA 9 13. Connect the radiator hose (1). 14. Install the dust ejector hose (2). 15. Install the throttle cable (1). 16. Position the condenser (1), filter-drier (2) and air-conditioning compressor in their housings. CUIL14TR00548AA 47705279 11/09/2014 10.1 [10.001] / 13 10 Engine - Engine and crankcase 17. Connect two steering cylinder hoses (1). CUIL14TR00794AA 11 CUIL14TR00109AA 12 CUIL14TR00801AA 13 CUIL14TR00227AA 14 18. Connect the suction hose (2) and install the two clamps (1). 19. Connect the pressure tubes (4) and (5) and install the bolts (3). 20. Connect the connections of the existing wire harnesses between the cab and the engine. 21. Connect the negative battery cable (1). 22. Fill the hydraulic system with new oil. Consult the procedures in Powered rear axle - Filling (27.100). 47705279 11/09/2014 10.1 [10.001] / 14 Index Engine - 10 Engine and crankcase - 001 Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 47705279 11/09/2014 10.1 [10.001] / 15 47705279 11/09/2014 10.1 [10.001] / 16 Engine - 10 Fuel tanks - 216 T6.110 Cabinado [HCCZ6110HECS24371 - ] , T6.110 Sem cabine [HCCZ6110TECS23550 - ] , T6.120 Cabinado [HCCZ6120XECS23550 - ] , T6.120 Sem cabine [HCCZ6120HECS24546 - ] , T6.130 Cabinado [HCCZ6130LECS24656 - ] , T6.130 Sem cabine [HCCZ6130XECS23550 - ] 47705279 11/09/2014 10.2 [10.216] / 1 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com ">

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Key features
- F4CE0484 engine
- Mechanical and power shuttle transmissions
- Robust 4-wheel drive
- Powerful hydraulic system
- Strong rear three-point hitch
Frequently asked questions
The T6.110 is equipped with an F4CE0484 engine.
The T6.110 offers both mechanical and power shuttle transmission options.
The rear three-point hitch allows you to attach and operate various implements, such as plows, cultivators, and harrows.