SER VICE MANUAL
TD4020F
TD4030F
TD4040F
Link Product / Engine
TD4020F Europe F5AE5484A
TD4030F Europe F5AE5484A
TD4040F Europe F5AE5484A
Engine
INTRODUCTION
[10.001] Engine and crankcase
Clutch
10] Clutch and components
ransmission
[21.1 14] Mechanical transmission
[21.160] Creeper
[21.162] Reverser
[21.182] Dif ferential
Four-Wheel Drive (4WD) system
control Drive (4WD) gearbox
Front axle system
[25.100] Powered front axle
[25.102] Front bevel gear set and dif ferential
Final drive steering and shafts
Final drives
Rear axle system
Powered rear axle
Rear bevel gear set and dif ferential
[31.101] Rear mechanical control
Brakes and controls
Hydraulic systems
[35.204] Remote control valves
[35.1 14] Three-point hitch control valve
[35.322] Regulated/Low pressure system
Hitches, drawbars, and implement couplings
10] Rear hitch
Steering
Pump
Cylinders
Hydraulic control components
Electrical systems
[55.301] Alternator
[55.201] Engine starting system
[55.051] Cab Heating, V entilation, and Air-Conditioning (HV AC) controls
[55.523] Cab hitch controls .
[55.408] W arning
[55.100]
International symbols
Safety rules
Safety rules
Personal safety
Basic instructions Hardware
T orque Specification T ables
Basic instructions - Shop and Assembly
Capacities
International symbols
a guide the operation the various universal symbols have been utilized the and fuse The symbols are shown below with indication their
Safety rules
IMPORT ANT NOTICE
All maintenance and repair operations described this manual should carried out exclusively authorised All instructions should carefully observed and special equipment where indicated should Anyone who carries out service operations described without carefully observing these instructions will directly responsible for any damage
NOTES FOR EQUIPMENT
Equipment shown this manual is:
• designed expressly for use these tractors;
• necessary make a reliable repair;
• accurately built and strictly tested fer ficient and long - lasting working life.
NOTICES
The words “front”, “rear”, hand”, and refer the dif ferent parts seen from the operator ’ s seat oriented the normal direction movement the tractor
SAFETY RULES
P A Y A TTENTION T O THIS SYMBOL
This warning symbol points out important messages involving personal safety Carefully read the safety rules contained herein and follow advised precautions avoid potential hazards and safeguard your safety this manual you will find this symbol together with the following key - words: W ARNING - gives warning about improper repair operations and potential consequences fecting the service s personal safety DANGER - gives specific warning about potential dangers for personal safety the operator other persons directly indirectly involved the operation.
T O PREVENT ACCIDENTS
Most accidents and personal injuries taking place workshops are due from non - observance some essential rules and safety
The possibility that accident might occur with any type machines should not disregarded, matter how well the machine question was designed and
A wise and careful service technician the best precautions against accidents.
Careful observance this basic precaution would enough avoid many severe
DANGER
Never carry out any cleaning, lubrication maintenance operations when the engine running.
SAFETY RULES
Generalities
• Carefully follow specified repair and maintenance procedures.
• not wear unbuttoned flapping clothing such torn open jackets shirts with open zips which could get caught moving Use approved safety clothing such anti - slipping footwear , safety
• W ear safety glasses with side guards when cleaning parts using compressed air
• Damaged frayed wires and chains are not use them for lifting
• W ear suitable protection such approved eye special gloves and footwear whenever welding. All persons standing the vicinity the welding process should wear approved eye protection. NEVER LOOK A T THE WELDING ARC YOUR EYES ARE NOT SUIT ABL Y
• Never carry out any repair the machine someone sitting the operator ’ s except they are qualified operators assisting the operation carried
• Never operate the machine use attachments from a place other than sitting the operator ’ s seat the side the machine when operating the fender
• Never carry out any operation the machine when the engine except when specifically Stop the engine and ensure that all pressure relieved from hydraulic circuits before removing caps, covers, valves, etc.
• All repair and maintenance operations should carried out with the greatest care and
• Disconnect the batteries and label all controls warn that the tractor being serviced. Block the machine and all equipment which should
• Never check fill fuel tanks nor use starting liquid you are smoking near open flames such fluids are
• The fuel filling gun should always remain contact with the filler Maintain this contact until the fuel stops flowing into the tank avoid possible sparks due static electricity buildup.
• T o transfer a failed tractor , use a trailer a low loading platform trolley
• T o load and unload the machine from the transportation means, select a flat area providing a firm support the trailer truck Firmly tie the machine the truck trailer platform and block wheels required the transporter
• Always use lifting equipment appropriate capacity lift move heavy
• Chains should always safely Ensure that fastening device strong enough hold the load persons should stand near the fastening point.
• The working area should always kept CLEAN and Y Immediately clean any spillage water
• Never use gasoline, diesel oil other flammable liquids cleaning agents. Use non - flammable non - toxic etary
• not pile grease oil soaked they constitute a great fire Always place them into a metal container
ART
• Never run the engine confined spaces which are not equipped with adequate ventilation for exhaust gas
• Never bring your body , fingers near fans rotating
ENGINE
• Always loosen the radiator cap very slowly before removing allow pressure the system Coolant should topped only when the engine
• not fill fuel tank when the engine running.
• Never adjust the fuel injection pump when the tractor
• Never lubricate the tractor when the engine running.
ELECTRICAL SYSTEMS
• necessary use auxiliary batteries, cables must connected both sides follows: (+) (+) and ( ( A void short - circuiting the GAS RELEASED FROM TTERIES HIGHL Y During
leave the battery compartment uncovered improve A void sparks flames near the battery
• not charge batteries confined
• Always disconnect the batteries before performing any type service the electrical
HYDRAULIC SYSTEMS
• Some fluid coming out from a very small port can almost invisible and strong enough penetrate the For this NEVER USE YOUR HANDS T O CHECK FOR but use a piece cardboard a piece wood for this any fluid injected into the seek medical aid immediately Lack immediate medical attention may result serious infections dermatitis.
• Always take system pressure readings using the appropriate
WHEELS AND TYRES
• Check that the tyres are correctly inflated the pressure specified the manufacturer Periodically check for possible damage the rims and
• Stay the tyre side when
• Check the pressure only when the tractor unloaded and tyres are cold avoid wrong readings due over -
• Never nor weld a rim with the inflated tyre
• T o remove the wheels, block both front and rear tractor wheels. Raise the tractor and install safe and stable supports under the tractor accordance with regulations
• Deflate the tyre before removing any object caught into the tyre tread.
• Never inflate tyres using flammable gases they may generate explosions and cause injuries REMOV
AND INST ALLA TION
• Lift and handle all heavy components using lifting equipment adequate capacity Ensure that parts are supported appropriate slings and Use lifting eyes provided this T ake care the persons near the loads
HEAL AND SAFETY PRECAUTIONS
Many the procedures associated with vehicle maintenance and repair involve physical hazards other risks This section alphabetically , some these hazardous operations and the materials and equipment ciated with The precautions necessary avoid these hazards are The list not exhaustive and all operations and procedures and the handling materials, should carried out with health and safety
ACIDS AND ALKALIS
see Battery caustic sulphuric
Used batteries and cleaning
Irritant and corrosive the skin, eyes, nose and throat. Causes burns.
A void splashes the eyes and W ear suitable protective gloves and Can destroy ordinary protective not breathe
Ensure access water and soap readily available for splashing
ADHESIVES AND SEALERS
see Fire Highly Flammable, Flammable, combustible.
Generally should stored areas; cleanliness and tidiness use should able paper covering benches; should dispensed from applicators where possible; including secondary should
Solvent based Adhesives / Sealers
See Follow manufacturers
W ater based Adhesives / Sealers
Those based polymer emulsions and rubber lattices may contain small amounts volatile toxic and harmful icals. Skin and eye contact should avoided and adequate ventilation provided during use. Follow manufacturers
Resin based Adhesives / Sealers
epoxide and formaldehyde resin
Mixing should only carried out well ventilated areas harmful toxic volatile chemicals may Skin contact with uncured resins and hardeners can result irritation; dermatitis and absorption toxic harmful chemicals through the Splashes can damage the
Provide adequate ventilation and avoid skin and eye contact. Follow manufacturers instructions.
Many are irritant, sensitizing harmful the skin. Some are eye irritants.
INTRODUCTION
Skin and eye contact should avoided and the manufacturers instructions Cyanoacrylate adhesives (super - glues) must not contact the skin skin eye tissue bonded cover with a clean moist pad and get medical not attempt pull tissue Use well ventilated areas vapours can cause irritation the nose and For two - pack systems see Resin based adhesives / sealers.
Isocyanate (Polyurethane) Adhesives / Sealers
see Resin based Adhesives.
Individuals suf fering from asthma respiratory allergies should not work with near these materials sensitivity reactions can occur
Any spraying should preferably carried out exhaust ventilated booths removing vapours and spray droplets from the breathing Individuals working with spray applications should wear supplied air
ANTIFREEZE
see Solvents Ethylene
Highly Flammable, Flammable, Combustible.
Used vehicle coolant brake air pressure screenwash V apours given f from coolant antifreeze (glycol) arise only when
Antifreeze may absorbed through the skin toxic harmful
Antifreeze swallowed fatal and medical attention must found immediately
ARC WELDING
see W
TTER Y ACIDS
see Acids and Gases released during charging are explosive.
Never use naked flames allow sparks near charging recently charged
BRAKE AND CLUTCH FLUIDS
see Splashes the skin and eyes are slightly A void skin and eye contact far
(Polyalkylene Glycols)
Inhalation vapour hazards not arise ambient temperatures because the very low vapour pressure.
BRAZING
see W elding.
CHEMICAL TERIALS - GENERAL
see Legal Aspects.
Chemical materials such resin battery brake oils and grease should always used with caution and stored and handled with They may irritant highly inflammable and give rise hazardous fumes and The fects excessive exposure chemicals may immediate delayed; briefly experienced permanent; cumulative; superficial; life threatening; may reduce life - expectancy .
DO’S
remove chemical materials from the skin and clothing soon practicable after soiling. Change heavily soiled clothing and have carefully read and observe hazard and precaution warnings given material containers (labels) and any accompanying poster other Material health and safety data sheets can obtained from
organise work practices and protective clothing avoid soiling the skin and eyes; breathing vapours / aerosols / dusts / fumes; inadequate container labelling; fire and explosion
wash before job breaks; before drinking using toilet facilities when handling chemical keep work areas uncluttered and free
store according national and local regulations. keep chemical materials out reach
NOTS
Not mix chemical materials except under the manufacturers instructions; some chemicals can form other toxic harmful chemicals; give f toxic harmful fumes; explosive when mixed together
Not spray chemical particularly those based confined spaces when people are inside a
Not apply heat flame chemical materials except under the instructions. Some are highly inflammable and some may release toxic harmful
Not leave containers Fumes given f can build harmful explosive Some fumes are heavier than air and will accumulate confined pits
Not transfer chemical materials unlabeled
Not clean hands clothing with chemical particularly solvents and fuels will dry the skin and may cause irritation with Some can absorbed through the skin toxic harmful
Not use emptied containers for other except when they have been cleaned under supervised
Not snif f smell chemical materials. Brief exposure high concentrations fumes can toxic harmful.
Clutch Fluids
see Brake and Clutch Fluids.
Clutch Linings and Pads
see Brake and Clutch Linings and
CORROSION PROTECTION TERIALS
see Highly
These materials are varied and the manufacturers instructions should They may contain petroleum products Skin and eye contact should They should only sprayed conditions adequate ventilation and not confined
Cutting
see W - W axing
see Solvents and Fuels
DUSTS
Powder , dusts clouds may harmful A void breathing dusts from powdery chemical materials those arising from dry abrasion W ear respiratory protection ventilation
ELECTRIC SHOCK
Electric shocks can result from the use faulty electrical equipment from the misuse equipment even good
Ensure that electrical equipment maintained good condition and frequently tested.
Ensure that plugs and sockets are not cracked otherwise
Ensure that electric equipment protected the correct rated
Never misuse electrical equipment and never use equipment which any way faulty The results could Use reduced voltage equipment ( 1 volt ) for inspection and working lights where
Ensure that the cables mobile electrical equipment cannot get trapped and such a vehicle
Use air operated mobile equipment where possible preference electrical cases electrocution: -
• switch f electricity before approaching victim
• this not push drag victim from source electricity using dry non - conductive material
• commence resuscitation trained
• SUMMON MEDICAL ASSIST ANCE
EXHAUST FUMES
These contain harmful and toxic chemicals and particles such carbon nitrogen lead and aromatic Engines should only run under conditions adequate extraction general ventilation and not confined spaces.
Gasolene (Petrol) Engine
There may not adequate warning properties odour irritation before immediate and delayed toxic harmful fects
Diesel Engine
discomfort and irritation usually give adequate warning hazardous fume
FIBRE INSULA TION
see Used noise and sound
The fibrous nature surfaces and cut edges can cause skin
This usually a physical and not a chemical
Precautions should taken avoid excessive skin contact through careful organisation work practices and the use
FIRE
see W Legal
Many the materials found associated with the repair vehicles are highly Some give f toxic harmful fumes
Observe strict fire safety when storing and handling flammable materials particularly near electrical ment welding processes.
Ensure before using electrical welding equipment but that there fire hazard
Have a suitable fire extinguisher available when using welding heating
FIRST AID
Apart from meeting any legal requirements desirable for someone the workshop trained first aid
Splashes the eye should flushed with clean water for least ten
Soiled skin should washed with soap and water .
Inhalation fected individuals should removed fresh air immediately swallowed fects persist consult a doctor with information (label) material not induce vomiting (unless indicated
FOAMS - Polyurethane
see
Used sound and noise
Cured foams used seat and trim
Follow manufacturers instructions.
Unreacted components are irritating and may harmful the skin and W ear gloves and
Individuals with chronic respiratory bronchial medical problems histories allergic diseases should not work with near uncured
The spray mists can cause direct sensitivity reactions and may toxic V apours and spray mists must not These materials must applied with adequate ventilation and piratory protection. not remove respirator immediately after spraying, wait until vapour / mists have cleared. Burning the uncured components and the cured foams can generate toxic and harmful open flames the use electrical equipment during foaming operations and until vapours / mists have cleared should not
Any heat cutting cured foams partially cured foams should conducted with extraction ventilation (see Body Section Legal and Safety Aspects).
FUELS
see Fire, Legal Aspects, ChemicalsGeneral, Solvents.
Used fuels and cleaning
Gasolene (Petrol).
Highly
Swallowing can result mouth and throat irritation and absorption from the stomach can result drowsiness and Small amounts can fatal Aspiration liquid into the through a very serious
Gasolene dries the skin and can cause irritation and dermatitis prolonged repeated contact. Liquid the eye causes severe
Motor gasolene may contain appreciable quantities which toxic upon inhalation and the concentrations gasolene vapours must kept very low . High concentrations will cause eye, nose and throat irritation, nausea, depression and symptoms V ery high concentrations will result rapid loss conscious-
Ensure there adequate ventilation when handling and using Great care must taken avoid the serious consequences inhalation the event vapour build arising from spillages confined
Special precautions apply cleaning and maintenance operations gasolene storage tanks.
Gasolene should not used a cleaning must not siphoned
Kerosene (Paraffin)
Used also heating solvent and cleaning
Irritation the mouth and throat may result from
The main hazard from swallowing arises liquid ration into the lungs Liquid contact dries the skin and can cause irritation Splashes the eye may slightly irritating.
normal circumstances the low volatility does not give rise harmful Exposure mists and vapours from kerosene elevated temperatures should avoided (mists may ariseA void skin and eye contact and ensure there adequate
Gas - Oil (Diesel Fuel)
see Fuels
Gross prolonged skin contact with high boiling gas oils may also cause serious skin disorders including skin cancer .
GAS CYLINDERS
see Fire.
Gases such carbon argon and propane are normally stored cylinders pressures 140 bar ( 2000 / in2 ) and great care should taken handling these cylinders avoid mechanical damage them the valve gear The contents each cylinder should clearly identified appropriate Cylinders should stored well ventilated and protected from ice and snow , direct Fuel gases (e.g. acetylene and propane) should not stored close proximity oxygen cylinders. Care should exercised prevent leaks from gas cylinders and and avoid sources Only trained personnel should undertake work involving gas
Gases
see Gas Cylinders.
Gas Shielded W elding
see W elding.
Gas W elding
see W elding.
GENERAL WORKSHOP T OOLS AND EQUIPMENT
essential that all tools and equipment are maintained good condition and the correct safety equipment used where
Never use tools equipment for any purpose other than that for which they were Never overload equipment such axle and chassis stands lifting Damage caused loading not always immediately apparent and may result a fatal failure the next time that the equipment not use damaged defective tools equipment, particularly high speed equipment such grinding wheels. A damaged grinding wheel can disintegrate without warning and cause serious injury
W ear suitable eye protection when using chiselling sand blasting
W ear a suitable breathing mask when using sand blasting working with asbestos based materials using spraying
Glues
see Adhesives and
High Pressure Air , Lubrication and Oil T est Equipment accordance with local regulations
see Lubricants and Always keep high pressure equipment good condition and regularly maintained, particularly joints and unions. Never direct a high pressure nozzle the skin the fluid may penetrate the underlying tissue and cause serious injury
LEGAL ASPECTS
Many laws and regulations make requirements relating health and safety the use materials and equipment Always conform the laws and regulations applicable the country which you are
W orkshops should familiar , with the associated laws and Consult the local factory inspectorate appropriate authority any doubt.
LUBRICANTS AND GREASES
A void all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated during service routine service change sump oils) are more irritating and more likely cause serious fects including skin cancer the event gross and prolonged skin
W ash skin thoroughly after work involving Proprietary hand cleaners may value provided they can moved from the skin with water not use paraf fin other solvents remove oil from the Lubricants and greases may slightly irritating the eyes. Repeated prolonged skin contact should avoided wearing protective clothing necessary Particular care should taken with used oils and greases containing not allow work clothing contaminated with Dry clean launder such clothing regular intervals. Discard oil soaked shoes. not employ used engine oils lubricants for any application where appreciable skin contact likely occur Used oils may only disposed accordance with local
Noise Insulation Materials
see Fibre
P AINTS
see Solvents and Chemical MaterialsGeneral.
Highly
One Can contain harmful toxic driers and other components well
Spraying should only carried out with adequate T Can also contain harmful and toxic unreacted resins and resin hardening The manufacturers instructions should followed and the section page 5 resin based adhesives, isocyanate containing Adhesives and Foams should
Spraying should preferably carried out exhausted ventilated booths removing vapour and spray mists from the breathing zone. Individuals working booths should wear respiratory protection. Those doing small scale repair work the open shop should wear supplied air
Paint Thinners
see Petrol
see Fuels
Pressurised Equipment
see High Pressure Air , Lubrication and Oil T est
Resistance W elding
see W
Sealers
see Adhesives and
SOLDER
see W
Solders are mixtures metals such that the melting point the mixture below that the constituent metals mally lead and Solder application does not normally give rise toxic lead provided a gas / air flame
Oxy - acetylene flames should not they are much hotter and will cause lead fumes
Some fumes may produced the application any flame surfaces coated with grease and inhalation these should
Removal excess solder should undertaken with care, ensure that fine lead dust not produced, which can give toxic fects
Respiratory protection may necessary
Solder spillage and filing should collected and removed promptly prevent general air contamination
High standards personal hygiene are necessary order avoid indigestion lead inhalation solder dust from
SOL VENTS
see Chemical Materials - General Fuels
e.g. Acetone, white spirit, toluene, xylene, trichlorethane.
Used cleaning - thinners
Highly
Skin contact will degrease the skin and may result irritation and dermatitis following repeated prolonged contact. Some can absorbed through the skin toxic harmful
Splashes the eye may cause severe irritation and could lead loss
Brief exposure high concentrations vapours mists will cause eye and throat headaches and the worst
Repeated prolonged exposures excessive but lower concentrations vapours mists, for which there might not adequate warning can cause more serious toxic harmful
Aspiration into the lungs through vomiting) the most serious consequence
A void splashes the eyes and W ear protective goggles and clothing necessary
Ensure good ventilation when avoid breathing vapours and spray mists and keep containers tightly not use confined
When the spraying material contains use extraction ventilation personal respiratory protection the absence adequate general ventilation. not apply heat flame except under specific and detailed manufacturers
Sound Insulation
see Fibre
Spot W elding
see W
SUSPENDED LOADS
There always a danger when loads are lifted
Never work under unsupported suspended raised jacked suspended
Always ensure that lifting equipment such axle are adequate and suitable for the good condition and regularly
Never improvise lifting tackle.
Underseal
see Corrosion Protection.
WELDING
see Fire, Electric Shock, Gas Cylinders. W elding processes include Resistance W elding (Spot W Arc W elding and Gas W
Resistance W elding
This process may cause particles molten metal emitted high velocity and the eyes and skin must
Arc W elding
This process emits a high level ultraviolet radiation which may cause eye and skin burns the welder and other persons nearby Gas - shielded welding processes are particularly hazardous this Personal protection must and screens used shield other
Metal spatter will also occur and appropriate eye and skin protection necessary .
The heat the welding arc will produce fumes and gases from the metals being welded and from any applied coatings contamination the surfaces being worked These gases and fumes may toxic and inhalation should always The use extraction ventilation remove the fumes from the working area may necessary , particularly cases where the general ventilation poor , where considerable welding work extreme cases where adequate ventilation cannot provided, supplied air respirators may necessary .
Gas W elding
Oxy - acetylene torches may used for welding and cutting and special care must taken prevent leakage these with consequent risk fire and
The process will produce metal spatter and eye and skin protection necessary
The flame bright and eye protection should used, but the ultra - violet emission much less than that from arc and lighter filters may
The process itself produces few toxic fumes, but such fumes and gases may produced from coatings the work, particularly during cutting away damaged body parts and inhalation the fumes should toxic fumes may evolved from the metals the brazing and a severe hazard may arise brazing rods containing cadmium are this event particular care must taken avoid inhalation fumes and expert advice may
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