New Holland 3415 Tractor Service Repair Manual

3415REPAIRMANUAL

SECTION1--ENGINESYSTEMS

SECTION2--FUELSYSTEMS

SECTION3--ELECTRICALSYSTEM

SECTION4--CLUTCH

SECTION5--TRANSMISSIONSYSTEMS

SECTION6--POWERTAKE-OFFSYSTEMS

SECTION7--DIFFERENTIAL,REARAXLEANDBRAKES

SECTION8--HYDRAULICSYSTEM

SECTION9--STEERINGSYSTEM

SECTION10--FRONTAXLEANDRELATEDPARTS

SECTION11--WHEELSANDTIRES

SECTION12--SEPARATINGTHETRACTOR

ENGINESYSTEMDESCRIPTIONAND OPERATION

Thischapterdescribesengineoverhaulandrepairs proceduresfortheModel3415tractorengine.

Theengineisafourcylinder,fourcycle,overhead valve,liquidcooledengine,Figures1and2.

Theenginesisidentifiedbyacodenumber,1,cast intothesideofthecylinderblock.

CylinderHeadandValveTrainComponents

Thecylinderheadincorporatesthevalve assemblies,rockerarms,rockershaft,pushrods, andlifters.

Theintakemanifold,1,islocatedonthetopofthe cylinderheadandisseparatefromthevalvecover, 2.

Theexhaustmanifold,3,isboltedtotheleftsideof thecylinderhead.

Thevalverockerarmsandsupportshaft,1,are mountedinaseparatesupportcastingboltedtothe topofthecylinderhead.

CylinderBlockAssembly

NOTE: Thisengineiscertifiedto1999EPAemission legislation.Nooneispermittedtorepairtheengine unlessthefueldeliveryisunchanged,therefore preservingtheemissionsperformance,eg. replacementofblock,shortblockassembly,smoke set,etc.isnotpermitted.Inthatcasepleaseusea longblockassemblyforrepairing.

Thecylinderblockassemblycontainsthepistons, connectingrods,crankshaft,camshaft,timinggears, engineoilpumpanddynamicbalancerassembly.

Theengineisequippedwithstraightconnecting rods.

Thecrankshaftissupportedonfivemainbearings. Thefrontbearingissupportedinaboreinthefront castingofthecylinderblock.

Allremainingbearingsaresplitlinersretainedincast ironholders.

Theengineincorporatesadynamicbalancer assembly,1,thatisboltedtotheundersideofthe blockanddrivenbythecrankshaft.

LubricationSystem

Theoilpumpassemblyislocatedwithintheidlegear atthefrontoftheblockandbelowandtotheleftof thecrankshaftasviewedfromthefront.Theoilpump isdrivenbythecrankshaftgear.

Oilispickedupfromthesumpbytheintaketubeand drawnintothelowersidedrillingintheblocktotheoil pump.Oilfromthepumpflowsthroughpassagesin theblock,pastthereliefvalve,throughtheoilfilter andreturnstothemainoilgalleryintheareaofthe drilledboltlocatedonthesideoftheblock.Oilflow inthemainoilgalleryextendstothemainbearings. Oilflowtothemainbearingspassesthroughdrilled passagesinthecrankshafttotheconnectingrod bearings.

Oilfromthemainoilgallerysuppliespressureoilto thedynamicbalancer,1,throughatube,2, connectedtotheundersideoftheblock.

Pressureoilfromthemainoilgalleryflowsthrougha tube,3,tothefrontofthevalverockershaftto lubricatetherockerarms,valvestems,pushrods andtappets.

Thereliefvalve,4,ismountedinthesideoftheblock andintersectsthemainoilpassage.Whentheoil pressureexceedstheratedpressure,oilisbypassed throughthereliefvalvedirectlytosump.

Thecylinderwalls,pistonsandpistonpinsaresplash lubricatedbythecrankshaft.

SECTION1--ENGINESYSTEMS--CHAPTER1

ENGINEOVERHAUL

CylinderHeadRemoval

1.Openthehood,1,andremovethesidecovers, 2.Disconnecttheheadlightwiring,3.Remove thehoodassembly.

2.Drainthecoolantfromtheradiatorandengine blockthroughtheradiatordraincock,1.

3.Removetheaircleanerassembly,1,alongwith theairinlettube,2,andairoutlettube,3.

4.Removetheupperradiatorhose,4,fromthe cylinderhead.

5.Removetheexhaustmufflerandmanifold assembly,1.

6.Removethefuelinjectionlines,1,andfuel leakoffline,3,andcapallopenings.

7.Removetheinjectorassemblies,2.

8.Removethethermostathousing,2,and thermostat.

9.Removethefueltankandbaffle.

10.Removetheoilpressuresensorswitch,3.

11.Removetheexternaloiltubebanjobolt,2,from thefrontendofthevalverockershaft.

12.Removetheairintakemanifold,1.

13.Removethevalvecoverassembly,2.

14.Removethevalverockersupport,1,asan assembly.

NOTE: Alternatelyloosentherockersupportboltsa turnatatimetopreventdistortingtherockershaft.

15.Removethevalvestemcaps,3,andpushrods, 2.

NOTE: Keepallvalvecomponentsinseparately markedcontainersforreassemblyintheiroriginal position.

16.Loosenthecylinderheadboltsgraduallyahalf turnatatimetopreventwarpingofthecylinder headandremovethecylinderhead.

SECTION1--ENGINESYSTEMS--CHAPTER1

CylinderHeadDisassembly

1.Cleanthecylinderheadandremoveanycarbon depositsfromaroundthevalveheads.

2.Usingavalvespringcompressor,1,compress thevalvespring,3,andremovetheretainer locks,5.

3.Releasethevalvespringcompressorand removethevalvespringandretainer,4.

4.Removethevalves,2,fromtheheadandplace inanumberedcontainertofacilitateidentification forinstallingthecomponentsintheiroriginal locationonassembly.

CylinderHeadInspectionandRepair

1.Cleanthevalveportsusingawirebrushand scraper.

2.Cleanalldirtandresiduefromthegasketsurface usingcarenottoscratchornickthemachined surface.

3.Cleanthecylinderheadinsolventandairdry.

4.Checktheheadforcracksordamageinthe followingareas:

• Valveports.

• Valveseats.

• Externalcracksinthewaterjackets.

5.Inspectthegasketsurfacesforscratchesor nickswhichwouldcauseleakage.

6.Examinethecoreholeplugsforrustorsignsof leakage.Ifaplugshowssignsofdamagingrust orleakage,replacealltheplugsinthehead.

7.Useastraightedge,1,andfeelergaugeand checkthecylinderheadforwarpintheareas shown,(A--F).

Resurfaceorreplacetheheadifwarpageis greaterthan0.12mm(0.005″).

8.Checkthepushrodsforstraightness.Replace bentpushrods.Donotattempttostraighten.

ValveSeats

Examinethevalveseatsandrefacetheseatif damaged.

Valveseatgrindingrequiresthattheseatbeground tothecorrectwidthandproperlypositioned.

Avalvethatextendstoodeepintothecombustion areawillresultinvalveburningandifthevalveis recessedtoodeepintotheheaditwillcausearapid build-upofcarbondeposits.

1.Checktheseatforsurfacedefects.Usea45° stoneifnecessarytoreface.Grindawayonly enoughmaterialtoprovideasmoothevenseat.

2.Checktheseatwidth.Ifnecessary,usea15° stonetolowertheseatcontactpointandusea 75° stonetoraisetheseatcontactpoint.

1.CorrectValveSeatWidth:1.7-2.1mm(0.067″ -0.0826″)-Seatmuststrikecenterofvalveface

2.CorrectValveHeadMargin:0.775-1.075mm(0.0305″ -0.0420″)

3.AngleofValveSeat:45_

NOTE: Refacingtheseatshouldalwaysbe coordinatedwithrefacingofthevalvetoassurea compressiontightfit. 150°

1.Seatangle-45° Stone

2.LowerSeatLocation-15° Stone

3.RaiseSeatLocation-75° Stone

Valves

SECTION1--ENGINESYSTEMS--CHAPTER1

1.Cleanalldepositsfromthevalvesusingasoft wirebrush.Inspecttheconditionofthevalveand discardanythatarebadlyburned,crackedor bent.

2.Usingamicrometer,measurethestemdiameter atthreepointsìA,îìB,îandìC.î

Replacevalvesifthestemweardiameterisless thanthefollowingdimensions:

1.MarginTooThin 1920-0.5mm(0.002″)Min. 2120-1.0mm(0.039″)Min.

2.BentValve

3.Pitting

4.Indented

5.WearorNicking

6.Burned

3.Ifinspectionindicatesthatthevalvemaybe reused,thevalveshouldbegroundasshown.

IMPORTANT: Aftergrindingthevalveandseat, checktoassurethattheseatcontactsthecenterof thevalveface.UsingPrussianBlue,lightlycoatthe valveseat,placethevalveinpositionandrotatethe valveslightlywhileholdingalightpressureagainst thevalve.Iftheblueistransferredtothecenterofthe valveface,thecontactiscorrect.

IfPrussianBlueisnotavailable,markthevalveface orseatwithasoftleadpencilasshown.Rotatethe valveslightlyintheseat.Thepenciledlineswillbe brokenattheseatcontactarea.

1.45_ SeatAngle 2.MinimumValveMargin0.5mm(0.002″)

ValveGuides

Thoroughlycleanthevalveguidesbeforeattempting tocheckinternalwear.

1.Usingasmallholegauge,measurethevalve guideboreatthetopandbottomwearpoints,1.

2.Determinethestem-to-guideclearanceby subtractingthestemdiameterfromthevalve guide.Replacethevalvesiftheclearanceis morethanthespecifiedlimits: Intake

0.20mm(0.008″) Max

Exhaust

″) Max

3.Replacethecylinderheadifexcessiveclearance isdetermined.SeeìSpecifications.î

ValveSprings

1.Placethevalvespringsonaflatsurface. Measurethefree-lengthofthespringand squareness.

Replacespringsthatdonotmeetthefollowing specifications:

2.Placethespringsinasuitablespringloadtester andmeasurethespringloadrating.Replacethe springsthatdonotmeetthefollowingload specifications:

RockerArmPivotsDisassembly

1.Screwa8Mboltintothefrontendoftherocker shaft,1,andpulltherockershaftoutofthe support.

2.Removethesprings,3,shims,4,androcker arms,2.

RockerArmPivotsInspectionandRepair

1.Inspecttherockerarmsandshaftsforwearof damage.

2.Inspectthevalvestemcontactareaforpittingor wear.Slightwearpatternsmayberemoved usingafinegritstone.

3.Checktheadjustingscrewsfordamagedthreads orexcessivewear.

Replaceanycomponentswhicharevisually wornordamaged.

4.Usingamicrometer,measurethediameterofthe rockerarmshaft,1.

Replacetherockershaftifthewearatanypoint exceedsthefollowingdiameter:

5.Usingaholegauge,measuretheinsidebore diameteroftherockerarm.

Subtracttherockershaftdiameterfromthe rockerarmborediametertoobtainthe shaft-to-armclearance.

Replacetherockerarmand/orshaftassemblyif theclearanceexceedsthefollowing specifications:

PushRods

1.Checkallpushrodsforstraightnessbyrollingon aflatsurface.Replacerodswhicharebent.

2.Inspecttheendsofthepushrodsforexcessive wear.Ifanypushrodisworn,thecorresponding lifterandrockerarmshouldalsobeinspectedfor excessivewear.

CylinderHeadAssembly

1.Inserteachvalveintotheguidefromwhichitwas removedandlightlylapthevalvetobesureofan evensetallaroundthevalveface.

2.Removethevalveandremovealltracesof lappingcompound.

3.Usingaspringcompressor,assemblethe valves,springs,retainersandlocks.

4.Assembletherockerarmsontothepivotshafts andinstallthesnaprings.

CylinderHeadInstallation

Duringassembly,theultimateenginecompression ratioisestablishedbythethicknessofthehead gasketused.Forservicereplacement,headgaskets ofdifferentthicknessesareavailable.Thecorrect headgasketmustbeselectedbaseduponthe positionofthepistontothefaceoftheblockwhenat top-dead-center.

Thecorrectheadgasketusageisdeterminedas follows:

1.Positioneachofthepistonsattop-dead-center andusingadialindicator,determinethedistance ofeachpistontothefaceoftheblock.

NOTE: Measureeachofthepistonswhileholdinga slightdownpressureonthepiston.Usethe dimensiontakenfromthecylinderwhichhasthe greatestgapandselectaheadgasketasindicated inthefollowingchart.

Thevariationbetweenthepistonsmustnotbe greaterthan0.1mm(0.004″).

HEADGASKET

(0.0079″ to0.0118″)

″) From0.3to0.4mm (0.0118″ to0.0157″)

″)

2.Ifremoved,installthetappets.

3.Selecttheproperheadgasketandplaceitonthe blockwiththesidemarkedwiththelastfourdigits ofpartno.code,orìtopîfacingup.

Carefullysetthecylinderheadinpositionwithout disturbingtheheadgasket.

4.Lubricatetheheadboltswithengineoiland installtheboltsloosely.

5.Graduallytightentheheadboltsinstagesin sequenceasshown.

6.Tightenallboltstothespecifiedtorque:

Headbolttorque:98-103N⋅m(73-77ftlbs)

7.Replacethepushrodsandvalvestemcapsin theiroriginallocations.

8.Installtheassembledrockershaft,tightenthe supportboltsinstepstothespecifiedtorque.See ìSpecifications,îChapter3.

9.Positiontheassembledrockerarmandshaft assembliesoverthestudboltsandinstallthe nutsandwashers.

NOTE: Usecaretocarefullypositiontherockerarms overthevalvestemcapsandpushrods.

10.Tightenthenutstothespecifiedtorque:

Rockerpoststud nuttorque:27-39N m(20-29ftlbs)

11.Adjustthevalverockerarmstovalveclearance. Besurethetappetisinitslowestpositionbefore makingtheadjustment.Tobesurethetappetis initslowestposition,bringthepistonto top-dead-centeronthecompressionstroke (bothvalvesclosed).

12.Loosentheadjustingboltlocknut,2,andturnthe adjustingscrewtoobtainthespecified clearance:

″) Max

13.Tightenthelocknut.

″) Max

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