New Holland TD5010 TD5020 TD5030 TD5040 TD5050 Tractors Service Manual (84176561B) - PDF Download by www.heydownloads.com

SERVICE MANUAL TD5010 / TD5020 / TD5030 TD5040 / TD5050 Tractors

Print No. 84176561B

TD5010 - TD5020 - TD5030 - TD5040 TD5050 MODEL TRACTORS SERVICE MANUAL SECTIONS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OF MOTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . REAR MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER TAKE-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S

00 10 18 21 23 25 27 31 33 35 41 44 50 55 90

E 84176561 - 03-2008

INTRODUCTION -

This manual is divided into sections identified by two-figure numbers and each section has independent page numbering.

The different sections can easily be found by consulting the table of contents on the following pages.

The document number of the manual and the edition/update dates are given at the bottom of each page.

Pages updated in the future will be identified by the same document number followed by an additional digit: first standard manual edition 84176561A - 1 st update 84176561A1 - 2 nd update 84176561A2 - etc. Updated pages can replace or supplement the pages of the standard manual; the necessary information for the procedure by which to add or replace the pages is given on the frontispiece of the update. An appropriately updated index will complete the publication. If it is necessary to issue a new updated manual (2 nd edition) this will have the document number 84176561B, which indicates that the manual is composed of the standard version 87749051A complete with all the up‐ dates: 1 st update 84176561A1 - 2 nd update 84176561A2 - etc.

The information contained in this manual was current on the date printed on each section. As NEW HOLLAND constantly improves its product range, some information may be out of date subsequent to modifications implemented for technical or commercial reasons, or to meet legal requirements in different countries. In the event of conflicting information, consult the NEW HOLLAND Sales and Service Departments.

IMPORTANT WARNINGS ◊ All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND service technicians in strict accordance with the instructions given and using any specific tools necessary. ◊ Anyone who performs the operations described herein without strictly following the instructions is personally responsible for resulting injury or damage to property. ◊ The Manufacturer and all organisations belonging to the Manufacturer's distribution network, including but not restricted to national, regional or local distributors, will accept no responsibility for personal injury or dam‐ age to property caused by abnormal function of parts and/or components not approved by the Manufacturer, including those used for maintenance and/or repair of the product manufactured or marketed by the Manufac‐ turer. In any case, the product manufactured or marketed by the Manufacturer is covered by no guarantee of any kind against personal injury or damage to property caused by abnormal function of parts and/or components not approved by the Manufacturer.

TEXT AND ILLUSTRATIONS ARE THE PROPERTY OF NEW HOLLAND No part of the text or illustrations may be reproduced

PRINTED IN TURKEY

NEW HOLLAND SERVICE - Technical Publications & Special Tools Part no. 84176561 - 03 - 2008

84176561 - 03-2008

NEW HOLLAND Repair Manual - TD Series Tractors CONTENTS GENERAL

SECTION 00

General Instructions and Health and Safety Section

Chapter 1

Description

00 000

Page

General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Notes for spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Notes for equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ENGINE

SECTION 10

Engine System (F5C) Section

Chapter 1

Description

10 001 10

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Engine System (NEF) Section

10 001 10 10 001 53 10 102 70 10 102 74 10 106 12 10 218 30 10 246 14

Page

Description

Chapter 1 Page

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Lubrication diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Cooling system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine D.A. Checks, measurements and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Crankshaft front seal - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Crankshaft rear seal - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Valve tappet and rocker arm clearance - Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Engine injector R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Bosch injection pump R.I. Timing. Air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 84176561 - 03-2008

10 402 10 10 402 30 10 406 10 10 414 10

Coolant pump R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat valve R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant pump and generator drive belts. Tension adjustment . . . . . . . . . . . . . . . . . . . . . .

CLUTCH

SECTION 18

Clutches Section

Chapter 1

Description

18 000

18 110 10

18 100 40

108 110 112 116

Page

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cross-sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Removal - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Minimum permissible dimensions after refacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Adjustment of the main and PTO clutch control linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

GEARBOX

SECTION 21

Mechanical Transmission (12x4)

Chapter 1

Section

Description

21 000

21 110

Reverser (12x12)

Page

Chapter 2

Section

Description

21 000

21 110

Reverser and Creeper (20x12)

Page

Chapter 3

Section

Description

21 000

84176561 - 03-2008

Page

Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal-Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

21 110

DRIVE LINES Drive Lines

SECTION 23 Chapter 1

Section

Description

23 000

Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque settings and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cross-Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Transmission shafts and guard (Disassembly - Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Drive gear housing (Removal - Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Drive gear housing removed (Disassembly - Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

23 101 26 23 101 40 23 101 42

FRONT AXLE MECHANICAL TRANSMISSION Front Axle Mechanical Transmission

Page

SECTION 25 Chapter 1

Section

Description

25 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cross-sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Complete front axle. Removal - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Front axle. Removal - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Steering knuckle bearing pins. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Stub axle adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Wheel hub bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Bevel drive adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Front axle differential. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Front axle differential with LIM-SLIP. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Front axle differential with NO SPIN. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Leading drive wheels toe-in check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

25 100 30 25 100 38 25 108 46-47

25 102 24 25 100 27 44 511 80

REAR AXLE AND TRANSMISSION Rear Axle And Transmission Section

Description

Page

SECTION 27 Chapter 1 Page

27 000

Gearbox driven shaft end float adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential lock engagement sleeve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Determining the bevel pinion positioning adjustment ring . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the taper roller bearings for the bevel pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the bearings and checking the backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential pinion and side gear backlash adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POWER TAKE-OFF Mechanical Power Take - Off

43 44 45 47 48 52

SECTION 31 Chapter 1

Section

Description

31 000

Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Removal - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

31 101

BRAKING SYSTEM Braking System

Page

SECTION 33 Chapter 1

Section

Description

33 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cross-sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Tools - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Front brake assembly mod. TD60D and TD70D removal and refitting overhauling on the bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Service brake removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Removal-Refitting of front brake pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Bleeding air from the front braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Adjusting service brake pedals travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Parking brake travel adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

33.206 33.202.60 33.202.50 33.202.40 33.120.08 33.110.08

HYDRAULIC SYSTEM Rear Mechanical Hydraulic Lift Section 35 000

Description

Page

SECTION 35 Chapter 1 Page

Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cross-sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84176561 - 03-2008

1 4 7 8

Description & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description and operation of lift phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 110.30 Hydraulic lift - disassembly reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.110.40-42-46 Hydraulic lift - bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.110.08 Linkage adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.110.30 Pressure relief valve - disassembly reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.110.32 Pressure relief valve - setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.110.14 Lift control valve - disassembly assembly and overhaul on bench . . . . . . . . . . . . . . . . . . . 35.0101.10 Lift pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Open Centre System Auxiliary Control Valves

10 10 11 14 16 22 27 33 35 35 37 42

Chapter 2

Section

Description

35 000

Main data - Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Auxiliary control valves - sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see chapter 1 Auxiliary control valves - Assembly-Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Spool binding test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Spool leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Adjustment of the automatic detent release pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

35 204 46

Trailer Brake Auxiliary Control Valve

Page

Chapter 3

Section

Description

Page

35 000

Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and operation of valve phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Trailer brake auxiliary control valve linkage adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

STEERING

SECTION 41

Steering

Chapter 1

Section

Description

41 000

Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Hydrostatic steering control valve - Removal-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydrostatic steering control valve - Disassembly-Assembly . . . . . . . . . . . . . . . . . . . . . . . . 14 Hydrostatic steering control valve - Bench testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Hydrostatic steering oil pump - Disassembly-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Steering cylinder (two-wheel drive axle) - Removal-Refitting . . . . . . . . . . . . . . . . . . . . . . . 32 Steering cylinder (four wheel drive axle) - Removal-Refitting . . . . . . . . . . . . . . . . . . . . . . . 33

41 204 30 41 204 34 41 204 38 41 216 20

FRONT AXLE AND WHEELS Front Axle And Wheels

Page

SECTION 44 Chapter 1 84176561 - 03-2008

Section

Description

44 000

Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Equipment - Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removal-Refitting-Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Wheel hub disassembly-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Stub axle overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Checking wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

44 101 30 44 101 22 44 101 46 44 101 80

AUXILIARY UNITS

Page

SECTION 50

Auxiliary Units

Chapter 1

Section

Description

Page

50 000

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operating principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Main components of the cab air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Refrigerant recovery-recycling and evacuation-charging stations

. . . . . . . . . . . . . . . . . . 20

50 200 04

Drying recharging and checking cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

50 200 03

Functional testing of air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Summary of the cab air-conditioning system charging operations

. . . . . . . . . . . . . . . . . . 28

Checking for refrigerant leaks using an electronic leak detector . . . . . . . . . . . . . . . . . . . . . 30 Summary of fault diagnosis and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Air conditioning and heating pipes - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 50 200 04-74

Receiver-drier - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

50 200 04-72

Condenser - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

50 200 04-26

Compressor - Removal-Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

50 200 10

Compressor drive belt tension adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

ELECTRICAL SYSTEM Instruments

SECTION 55 Chapter 1

Section

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

55 418

Analogue instruments and introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Transmitter and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Components 84176561 - 03-2008

Chapter 2

Section

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

55 500

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Starting System

Chapter 3

Section

Description

55 000

Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Starting circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 System tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removal and re-installation of starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Bench tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

55 201

Charging System

Page

Chapter 4

Section

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

55 000

55 301

Battery

Chapter 5

Section

Description

55 000

Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Removal and re-installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Battery checking and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Battery problems - Frequent causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

55.301.040

Electrical Circuits Section

Page

Chapter 6

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

Section

Description

Page

55 100

Contents . . . . . . . .

Fuses (all versions)

............................................................ 2

Symbols used in electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electrical wire colour coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ground locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - General diagrams (W/Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 84176561 - 03-2008

- General diagrams (W/Out Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - Analogue instrument circuit and connector overview . . . . . . . . . . . . . . . . . . . . . . . 19 - Start-up circuit and connector overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 - Direction indicator & hazard warning light circuit and connector overview . . . . . 25 - Windscreen and rear window wiper/washer circuit and connector overview . . . 31 - Brake light circuit and connector overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 - Heating and air-conditioning system circuit and connector overview . . . . . . . . . 41 - Work lamp (without cab circuit and connector overview) . . . . . . . . . . . . . . . . . . . 45 - Work lamp (without cab circuit and connector overview) . . . . . . . . . . . . . . . . . . . 49 - Side lights,main and dipped headlights, parking light circuit and connector overview

BODYWORK AND DRIVER POSITION Bodywork And Driver Position

SECTION 90 Chapter 1

Section

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

90 000

Disassembly-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

84176561 - 03-2008

SECTION 00 - GENERAL - CHAPTER 1

GENERAL INSTRUCTIONS IMPORTANT NOTICE All maintenance and repair operations described in this manual should be carried out exclusively by the NEW HOLLAND authorised workshops. All instructions detailed should be carefully observed and special equipment indicated should be used if necessary. Everyone who carries out service operations described without carefully observing these prescriptions will be directly responsible of deriving damages.

SHIMMING At each adjustment, select adjusting shims, measure them individually using a micrometer and then sum up recorded values. Do not rely on measuring the whole shimming set, which may be incorrect, or on rated value indicated for each shim.

ROTATING SHAFT SEALS To correctly install rotating shaft seals, observe the following instructions: - Let the seal soak into the same oil as it will seal for at least half an hour before mounting; -

Thoroughly clean the shaft and ensure that the shaft working surface is not damaged; Place the sealing lip towards the fluid. In case of a hydrodynamic lip, consider the shaft rotation direction and orient grooves in order that they deviate the fluid towards the inner side of the seal;

Coat the sealing lip with a thin layer of lubricant (oil rather than grease) and fill with grease the gap between the sealing lip and the dust lip of double lip seals; Insert the seal into its seat and press it down using a flat punch. Do no tap the seal with a hammer or a drift;

Take care to insert the seal perpendicularly to its seat while you are pressing it. Once the seal is settled, ensure that it contacts the thrust element if required.; To prevent damaging the sealing lip against the shaft, place a suitable protection during installation.

O RINGS Lubricate the O rings before inserting them into their seats. This will prevent the O rings from rolling over and twine during mounting which will jeopardise sealing.

SEALERS Apply one of the following sealers: RTV SILMATE, RHODORSIL CAF 1, or LOCTITE PLASTIC GASKET over the mating surfaces marked with an X. Before applying the sealer, prepare the surface as follows: -

remove possible scales using a metal brush; thoroughly degrease the surfaces using one of the following cleaning agent: trichlorethylene, petrol or a water and soda solution.

BEARINGS It is advisable to heat the bearings to 80 to 90Â°C before mounting them on their shafts and cool them down before inserting them into their seats with external tapping.

ROLL PINS When fitting straight roll pins, ensure that the pin notch is oriented in the direction of the effort to stress the pin. Coil roll pins can be installed in any position. 84176561- 03 -2008

SECTION 00 - GENERAL - CHAPTER 1 NOTES FOR SPARE PARTS Use exclusively genuine NEW HOLLAND spare parts, the only ones bearing this logo.

Only genuine parts guarantee same quality, life, safety as original components as they are the same as mounted in production. Only the NEW HOLLAND genuine spare parts can offer this guarantee. All spare parts orders should be complete with the following data: - tractor model (commercial name) and frame number; - engine type and number; - part number of the ordered part, which can be found on the “Microfiches” or the “Spare Parts Catalogue”, which is the base for order processing. NOTES FOR EQUIPMENT Equipment which NEW HOLLAND proposes and shows in this manual are as follows: - studied and designed expressly for use on NEW HOLLAND tractors; - necessary to make a reliable repair; - accurately built and strictly tested to offer efficient and long-lasting working means. We also remind the Repair Personnel that having these equipment means: - work in optimal technical conditions; - obtain best results; - save time and effort; - work more safely. NOTICES Wear limits indicated for some details should be intended as advised, but not binding values. The words “front”, “rear”, “right hand”, and “left hand” referred to the different parts should be intended as seen from the operator's seat oriented to the normal sense of movement of the tractor. HOW TO MOVE THE TRACTOR WITH THE BATTERY REMOVED Cables from the external power supply should be connected exclusively to the respective terminals of the tractor positive and negative cables using pliers in good condition which allow proper and steady contact. Disconnect all services (lights, wind-shield wipers, etc.) before starting the tractor. If it is necessary to check the tractor electrical system, check it only with the power supply connected. At check end, disconnect all services and switch the power supply off before disconnecting the cables. 84176561- 03- 2008

SECTION 00 - GENERAL - CHAPTER 1

SAFETY RULES PAY ATTENTION TO THIS SYMBOL This warning symbol points out important messages involving personal safety. Carefully read the safety rules contained herein and follow advised precautions to avoid potential hazards and safeguard your safety and personal integrity. In this manual you will find this symbol together with the following key-words: WARNING - it gives warning about improper repair operations and deriving potential consequences affecting the service technician's personal safety. DANGER - it gives specific warning about potential dangers for personal safety of the operator or other persons directly or indirectly involved. if they are certified operators to assist in the operation to be carried out.

TO PREVENT ACCIDENTS Most accidents and personal injuries taking place in workshops are due from non-observance of some simple and essential prudential rule and safety pre‐ cautions. For this reason, IN MOST CASES THEY CAN BE AVOIDED. It suffices to foresee possible causes and act consequently with necessary caution and care. The possibility that an accident might occur with any type of machines should not be disregarded, no mat‐ ter how well the machine in question was designed and built. A wise and careful service technician is the best pre‐ cautions against accidents. Careful observance of this only basic precaution would be enough to avoid many severe accidents. DANGER: Never carry out any cleaning, lubrication or maintenance operations when the engine is run‐ ning.

◊

Never operate the machine or use attachments from a place other than sitting at the operator's seat.

◊

Never carry out any operation on the machine when the engine is running, except when specifi‐ cally indicated.

◊

Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps, covers, valves, etc.

◊

All repair and maintenance operations should be carried out with the greatest care and attention.

◊

Service stairs and platforms used in a workshop or in the field should be built in compliance with the safety rules in force.

◊

Disconnect the batteries and label all controls to warn that the tractor is being serviced. Block the machine and all equipment which should be raised.

◊

Never check or fill fuel tanks and accumulator batteries, nor use starting liquid if you are smok‐ ing or near open flames as such fluids are flam‐ mable.

◊

Brakes are inoperative when they are manually released for maintenance purposes. In such cases, the machine should be kept constantly under control using blocks or similar devices.

◊

The fuel filling gun should remain always in con‐ tact with the filler neck. Maintain this contact until the fuel stops flowing into the tank to avoid pos‐ sible sparks due to static electricity buildup.

SAFETY RULES GENERALITIES ◊

Carefully follow specified repair and mainte‐ nance procedures.

◊

Do not wear rings, wristwatches, jewels, unbut‐ toned or flapping clothing such as ties, torn clothes, scarves, open jackets or shirts with open zips which could get hold into moving parts. We advise to use approved safety clothing such as anti-slipping footwear, gloves, safety goggles, helmets, etc.

◊

Never carry out any repair on the machine if someone is sitting on the operator's seat, except

84176561- 03 -2008

SECTION 00 - GENERAL - CHAPTER 1

◊

Use exclusively specified towing points for tow‐ ing the tractor. Connect parts carefully. Ensure that foreseen pins and/or locks are steadily fixed before applying traction. Do not stop near towing bars, cables or chains working under load.

◊

In case of operations outside the workshop, drive the tractor to a flat area and block it. If working on an incline cannot be avoided, first block the trac‐ tor carefully. Move it to a flat area as soon as pos‐ sible with a certain extent of safety.

◊

To transfer a failed tractor, use a trailer or a low loading platform trolley if available.

◊

To load and unload the machine from the trans‐ portation mean, select a flat area providing a firm support to the trailer or truck wheels. Firmly tie the machine to the truck or trailer platform and block wheels as required by the forwarder.

Ruined or plied cables and chains are unreliable. Do not use them for lifting or trailing. Always han‐ dle them wearing gloves of proper thickness.

◊

Chains should always be safely fastened. Ensure that fastening device is strong enough to hold the load foreseen. No persons should stop near the fastening point, trailing chains or cables.

◊

The working area should be always kept CLEAN and DRY. Immediately clean any spillage of water or oil.

◊

Do not pile up grease or oil soaked rags, as they constitute a great fire hazard. Always place them into a metal container. Before starting the tractor or its attachments, check, adjust and block the operator's seat. Also ensure that there are no persons within the trac‐ tor or attachment operating range.

◊

For electrical heaters, battery-chargers and sim‐ ilar equipment use exclusive auxiliary power supplies with a efficient ground to avoid electrical shock hazard.

◊

Always use lifting equipment and similar of appropriate capacity to lift or move heavy compo‐ nents.

◊

Pay special attention to bystanders.

◊

Never pour gasoline or diesel oil into open, wide and low containers.

◊

Never use gasoline, diesel oil or other flammable liquids as cleaning agents. Use non-flammable non-toxic proprietary solvents.

◊

Do not keep into your pockets any object which might fall unobserved into the tractor's inner compartments.

◊

Wear protection goggles with side guards when cleaning parts using compressed air.

◊

Do not exceed a pressure of 2.1 bar, in accor‐ dance with local regulations.

Whenever there is the possibility of being reached by ejected metal parts or similar, use protection eye mask or goggles with side guards, helmets, special footwear and heavy gloves.

◊

Do not run the engine in a closed building without proper ventilation.

◊

Do not smoke, use open flames, cause sparks in the nearby area when filling fuel or handling highly flammable liquids.

◊

Do not use flames as light sources when working on a machine or checking for leaks.

Wear suitable protection such as tinted eye protection, helmets, special clothing, gloves and footwear whenever it is necessary to carry out welding procedures. All persons standing in the vicinity of the welding process should wear tinted eye protection. NEVER LOOK AT THE WELD‐ ING ARC IF YOUR EYES ARE NOT SUITABLY PROTECTED.

◊

Move with caution when working under a tractor, and also on or near a tractor. Wear proper safety accessories: helmets, goggles and special foot‐ wear.

◊

Metal cables with the use get frayed. Always wear adequate protections (heavy gloves, eye protection, etc.)

◊

During checks which should be carried out with the engine running, ask an assistant to seat at the operator's seat and keep the service technician under visual control at any moment.

Handle all parts with the greatest caution. Keep your hands and fingers far from gaps, moving gears and similar. Always use approved protec‐ tive equipment, such as eye protection, heavy gloves and protective footwear.

84176561- 03- 2008

SECTION 00 - GENERAL - CHAPTER 1 START UP ◊ Never run the engine in confined spaces which are not equipped with adequate ventilation for exhaust gas extraction. ◊ Never bring your head, body, arms, legs, feet, hands, fingers near fans or rotating belts.

ENGINE ◊ Always loosen the radiator cap very slowly before removing it to allow pressure in the system to dis‐ sipate. Coolant should be topped up only when the engine is stopped or idle if hot. ◊ Do not fill up fuel tank when the engine is running, mainly if it is hot, to avoid ignition of fires in case of fuel spilling. ◊ Never check or adjust the fan belt tension when the engine is running. Never adjust the fuel injection pump when the tractor is moving. ◊ Never lubricate the tractor when the engine is run‐ ning.

ELECTRICAL SYSTEMS ◊ If it is necessary to use auxiliary batteries, cables must be connected at both sides as follows: (+) to (+) and (-) to (-). Avoid short-circuiting the termi‐ nals. GAS RELEASED FROM BATTERIES IS HIGHLY FLAMMABLE. During charging, leave the battery compartment uncovered to improve ventilation. Avoid checking the battery charge by means of “jumpers” made by placing metallic objects across the terminals. Avoid sparks or flames near the battery area. Do no smoke to pre‐ vent explosion hazards. ◊ Prior to any service, check for fuel or current leaks. Remove these leaks before going on with the work. ◊ Do not charge batteries in confined spaces. En‐ sure that ventilation is appropriate to prevent acci‐ dental explosion hazard due to build-up of gases releaved during charging. ◊ Always disconnect the batteries before perform‐ ing any type of service on the electrical system.

HYDRAULIC SYSTEMS ◊ Some fluid slowly coming out from a very small port can be almost invisible and be strong enough to penetrate the skin. For this reason, NEVER USE YOUR HANDS TO CHECK FOR LEAKS, but use a piece of cardboard or a piece of wood to this purpose. If any fluid is injected into the skin, seek medical aid immediately. Lack of immediate medical attention, serious infections or dermato‐ sis may result. ◊ Always take system pressure readings using the appropriate gauges. WHEELS AND TYRES ◊ Check that the tyres are correctly inflated at the pressure specified by the manufacturer. Periodi‐ cally check possible damages to the rims and tyres. ◊ Keep off and stay at the tyre side when correcting the inflation pressure. ◊ Check the pressure only when the tractor is unloaded and tyres are cold to avoid wrong read‐ ings due to over-pressure. Do not reuse parts of recovered wheels as improper welding, brazing or heating may weaken the wheel and make it fail. ◊ Never cut, nor weld a rim with the inflated tyre assembled. ◊ To remove the wheels, block both front and rear tractor wheels. Raise the tractor and install safe and stable supports under the tractor in accor‐ dance with regulations in force. ◊ Deflate the tyre before removing any object caught into the tyre tread. ◊ Never inflate tyres using flammable gases as they may originate explosions and cause injuries to bystanders. REMOVAL AND INSTALLATION ◊ Lift and handle all heavy components using lifting equipment of adequate capacity. Ensure that parts are supported by appropriate slings and hooks. Use lifting eyes provided to this purpose. Take care of the persons near the loads to be lifted. ◊ Handle all parts with great care. Do not place your hands or fingers between two parts. Wear approved protective clothing such as safety goggles, gloves and footwear. ◊ Do not twine chains or metal cables. Always wear protection gloves to handle cables or chains. 84176561- 03 -2008

SECTION 00 - GENERAL - CHAPTER 1

CONSUMABLES COMPONENT TO BE FILLED OR TOPPED UP

QUANTITY

RECOMMENDED PRODUCTS

INTERNATIONAL SPECIFICATION

Water & liquid AMBRA AGRIFLU 50% + 50% (NH 900 A)

‐

0.44

Water & cleaning liquid

‐

24.3

19.80

Decanted and filtered diesel fuel

‐

8.5 10.0

2.25 2.64

1.87 2.20

AMBRA MASTERGOLD SAE 15W - 40 (NH 330H)

Brake control circuit . . . . . . . . . . . . .

0.4

0.1

0.09

AMBRA BRAKE LHM Oil (NH 610 A)

ISO 7308

Hydrostatic steering circuit . . . . . . . .

2.0

0.52

0.44

Front axle: ‐ axle housing ‐ final drives (each):

7.0 1.25

1.8 0.3

1.54 0.28

Rear transmission (bevel drive and brakes), gearbox, hydraulic lift and PTO

12.15

10.12

Oil AMBRA MULTI G (NH 410B)

API GL4 ISO 32/46 SAE 10W-30

Rear final drives (each) . . . . . . . . . .

5.3

1.40

1.17

Front wheel hubs . . . . . . . . . . . . . . . .

‐

NLGI 2

Grease fittings . . . . . . . . . . . . . . . . . .

‐

Grease AMBRA GR9 (NH 710A)

US gal

IMP gal

12 14

3.17 3.69

2.64 3.08

14 16

3.69 4.22

3 3.52

Windscreen washer bottle . . . . . . . .

0.53

Fuel tank...........................................

Engine sump: TD 5010, TD 5020, TD5030 : TD 5040, TD5050 :

Cooling system: without cab: TD 5010, TD5020 TD 5030, TD5040, TD5050 with cab: TD 5010, TD5020 TD 5030, TD5040, TD5050

84176561- 03- 2008

liters/dm

API CH‐4 ACEA E5

SECTION 10 - ENGINE - CHAPTER 1

SECTION 10 - ENGINE Chapter 1 - Engine CONTENTS Operation

Description

Page

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 10 001 10

Engine R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1

TOOLS Warning - The operations described in this section can only be carried out with ESSENTIAL tools indi‐ cated by an (X). To work safely and efficiently and obtain the best re‐ sults, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings in‐ cluded in this manual.

List of specific tools required for the various operations described in this Section. 380000569

Movable tool for dismantling tractors with bracket 380000500 and adapter plate 380000844.

84176561- 03-2008

SECTION 10 - ENGINE - CHAPTER 1

ENGINE TROUBLESHOOTING Problems Engine does not start.

Possible Causes 1. Batteries partially discharged.

Solutions Check and recharge batteries. Re‐ place if necessary.

2. Battery terminal connections cor‐ Clean, inspect and tighten terminal roded or loose. nuts. Replace terminals and nuts if excessively corroded.

Engine stalls.

3. Injection pump timing incorrect.

Adjust injection pump timing.

4. Impurities or water in fuel lines.

Disconnect fuel lines from injection pump and clean thoroughly. If necessary clean and dry the fuel tank.

5. No fuel in tank.

Fill tank.

6. Fuel supply pump malfunction.

Check and replace pump if necess‐ ary.

7. Air in fuel system.

Check fuel lines, unions, supply pump, filters and injection pump for air; then bleed the air from the circuit.

8. Starter motor faulty.

Repair or replace starter motor.

9. Thermostarter faulty.

Check and replace thermostarter if necessary.

1. Idle speed too low.

Adjust idle speed.

2. Injection pump delivery irregular. Check injection pump delivery on test bench. 3. Impurities or water in fuel lines.

Disconnect fuel lines from injection pump and clean thoroughly. If necessary clean and dry the fuel tank.

4. Fuel filters clogged.

Replace the filter cartridges.

5. Incorrect valve - rocker arm Adjust the clearance between the clearances. rocker arms and the valves. 6. Burnt or cracked valves.

Replace the valves.

7. Air in fuel system.

Check fuel lines, unions, supply pump, filters and injection pump for air; then bleed the air from the circuit.

8. Injection pump drive mechanism Replace damaged parts. damaged. (continued)

84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1 ENGINE TROUBLESHOOTING (cont)

Problems Engine overheating.

Possible Causes

Solutions

1. Coolant pump malfunction.

Overhaul pump necessary.

and

replace

2. Thermostat faulty.

Replace the thermostat.

3. Radiator inefficient.

Remove internal deposits by flushing. Check for leaks and repair.

4. Deposits in cylinder head and Flush out coolant system. crankcase coolant passages. 5. Coolant pump and fan drive belt Check and adjust belt tension. slack. 6. Coolant level low.

Top up expansion tank with specified coolant mixture.

7. Incorrect engine timing.

Check and adjust engine timing.

8. Injection pump calibration incor‐ Calibrate pump on test bench to va‐ rect - delivering too much or too lues specified in calibration tables. little fuel. 9. Air filter clogged.

Engine lacks power and 1. Injection pump timing incorrect. runs unevenly.

Clean filter unit and replace filter el‐ ement if necessary. Adjust injection pump timing.

2. Auto advance regulator in injec‐ Overhaul injection pump and adjust tion pump damaged. on test bench to values specified in calibration table. 3. Control valve journal worn.

Overhaul injection pump and adjust on test bench to values specified in calibration table.

4. Injection pump delivery irregular. Overhaul injection pump and adjust on test bench to values specified in calibration table. 5. All-speed governor damaged.

Overhaul injection pump and adjust on test bench to values specified in calibration table.

6. Injectors partially obstructed or Clean and overhaul injectors and ad‐ damaged. just pressure setting. 7. Impurities or water in fuel lines.

Disconnect fuel lines from injection pump and clean thoroughly. If necessary clean and dry the fuel tank. (continued)

84176561- 03-2008

SECTION 10 - ENGINE - CHAPTER 1

ENGINE TROUBLESHOOTING (cont)

Problems

Possible Causes 8. Fuel supply pump damaged.

Solutions Replace fuel supply pump.

9. Incorrect valve - rocker arm Adjust the clearance between the clearances. rocker arms and the valves. 10. Cylinder compression low.

Test compression and overhaul en‐ gine if necessary.

11. Air filter clogged.

Clean filter unit and replace filter el‐ ement if necessary.

12. Tie-rod in linkage between accel‐ Adjust to correct length. erator and injection pump incor‐ rectly adjusted. 13. Fast idling speed screw on injec‐ Adjust fast idling speed screw. tion pump incorrectly adjusted. Engine produces abnormal knocking noises.

1. Injectors partially obstructed or Clean and overhaul injectors and ad‐ damaged. just pressure setting. 2. Impurities accumulating in fuel Clean fuel lines and replace severely lines. dented pipes; clean injection pump if necessary. 3. Injection pump timing incorrect.

Adjust injection pump timing.

4. Crankshaft knocking due to ex‐ Re-grind crankshaft journals and cessive play in one or more main crankpins. Fit oversize shell bearings or big-end bearings or excessive and thrust washers. endfloat. 5. Crankshaft out of balance.

Check crankshaft alignment and bal‐ ance; replace if necessary.

6. Flywheel bolts loose.

Replace any bolts that have worked loose and tighten all bolts to the speci‐ fied preliminary and angular torque values.

7. Connecting rod axes not parallel. Straighten connecting rods, check axes parallelism; replace con rods if necessary. 8. Pistons knock due to excessive Rebore cylinder liners and fit oversize wear. pistons. 9. Noise caused by excessive play Fit oversize gudgeon pin, rebore pis‐ of gudgeon pins in small-end and ton seats and small-end bushings. piston bushings. Loose fit of Replace with new bushings. small-end bushing. 10. Excessive tappet / valve noise.

Check for broken springs or excess‐ ive play between valve stems and guides, cam followers and bores; ad‐ just valve clearances. (continued)

84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1 ENGINE TROUBLESHOOTING (cont)

Problems

Possible Causes

Solutions

Engine produces excessive 1. Maximum delivery of injection Calibrate pump on test bench to va‐ black or dark grey smoke. pump too high. lues specified in calibration tables. 2. Injection pump delivery excess‐ Adjust injection pump timing or check ively retarded or automatic ad‐ automatic advance regulator. vance regulator damaged. 3. Injection pump delivery excess‐ Adjust injection pump timing. ively advanced. 4. Injectors partially or totally ob‐ Clean and overhaul injectors and ad‐ structed or incorrectly adjusted. just pressure setting; replace if necessary. 5. Air filter clogged.

Clean filter unit and replace filter el‐ ement if necessary.

6. Loss of engine compression due Replace damaged parts or, if necess‐ to: ary, overhaul the engine. - piston rings sticking; - cylinder liner wear; - worn or incorrectly adjusted valves. 7. High-pressure fuel lines dam‐ Inspect and replace if necessary. aged. Blue, grey-blue or grey-‐ white smoke.

1. Injection pump delivery excess‐ Adjust injection pump timing or check ively retarded or automatic ad‐ automatic advance regulator. vance regulator damaged. 2. Injectors obstructed or damaged. Clean, overhaul and calibrate injec‐ tors, replace if necessary. 3. Oil leaking past piston rings due Replace damaged parts or, if necess‐ to sticking rings or cylinder liner ary, overhaul the engine. wear. 4. Oil leaking through the inlet valve Overhaul cylinder head. guides due to guide or valve stem wear. 5. Engine does not reach correct Replace the thermostat. operating temperature (thermo‐ stat faulty).

Engine runs on after switching off.

1. Engine stop electromagnet dam‐ Replace electromagnet. aged. 2. All-speed governor damaged.

84176561- 03-2008

Overhaul injection pump and adjust on test bench to values specified in calibration table.

SECTION 10 - ENGINE - CHAPTER 1

Op. 10 001 10

ENGINE R.I.

CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. 1. Disconnect the battery negative lead (1). 2. Drain the oil from the transmission-gearbox housing. 3. Drain the cooling system.

1 4. Remove the exhaust pipe, attach lifting chains (2) to the bonnet (1) and attach the chain to the hoist.

2 5. Disconnect the electrical connection (1) of bonnet.

84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1

6. Detach the gas struts (1) from the bonnet.

4 7. Remove the four bonnet hinge bolts (1) and lift the bonnet clear.

5 8. Remove the three retaining bolts (1) and the guard (2) on the right-left hand side of the fan.

6 9. Unscrew the nut (1) from the weight retaining pin. Remove the weights from the front support.

7 84176561- 03-2008

SECTION 10 - ENGINE - CHAPTER 1

10. Unscrew the front central and rear retaining bolts on the front axle shaft guard, then remove the guard (1).

1 25038

8 11. Remove the circlip (2) and move the front sleeve (1) in the direction indicated by the arrow until it is released from the groove on the front axle.

25039

9 12. Remove the circlip (2) and move the rear sleeve (1) in the direction indicated by the arrow until it is released from the groove on the drive.

2 25040

10 13. Remove the propeller shaft central support (1) retaining bolts and extract the shaft together with the support.

25041

11 84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1

14. Dicconnect the pressure pipe connection (1) of the lift pump.

12 15. Disconnect the delivery lines of both hydraulic lift pump (1) and hydrostatic steering pump (2).

13 16. Detach the cab heating pipes (1) and (2).

14 17. Detach the cab air-conditioning pipes (1) and (2).

15 84176561- 03-2008

SECTION 10 - ENGINE - CHAPTER 1

18. Extract the plastic fasteners (2) and detach the diesel recovery pipe (3) and delivery pipe (4) to the diesel pump (1).

4 16 19. Remove two metal clamps (1) and the rigid pipe of drawing oil from the transmission housing via lift pump.

17 20. Remove the electrical connection from the brake fluid reservoir and take the brake fluid reservoir (1) from the bracket.

18 21. Disconnect the steering oil delivery and return hoses (1) and (2). Disconnect the steering cylinder lines (3) and (4).

3 4

19 84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1

22. Disconnect the delivery and return lines (1) to the power steering cylinders.

20 23. Disconnect rear brakes connection pipes (1) and (2).

oil

distribution

24. Disconnect brake distributor valve connections (1) and (2).

25. Disconnect A/C compressor inlet (1) and outlet (2) hoses.

84176561- 03-2008

SECTION 10 - ENGINE - CHAPTER 1

26. Remove the fusebox (1) from the bonnet support.

24 27. Remove the electrical oil pressure switch (1).

25 28. Remove the electrical connections of coolant temperature sender (1).

26 29. Remove the electrical connection of pump cut-out solenoid sender (1) and hydrostatic steering pump oil pressure switch (2).

27 84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1

30. Remove the retaining retaining clips (1) and detach the flexible cables governing the hand throttle and pedal throttle. 31. Remove the retaining clip (2) and detach the throttle control tie-rod connected to the injection pump.

28 32. Disconnect the electrical connection (1) between the cab and the engine.

29 33. Disconnect the electrical connections from starter motor (1).

30 34. Disconnect the electrical connections from alternator (1).

31 84176561- 03-2008

SECTION 10 - ENGINE - CHAPTER 1

35. Disconnect the electrical connection of water in fuel sensor (1).

32 36. Disconnect the electrical connections of dryer filter sensor (1).

33 37. Remove the electrical connection (1), air filter clogging sensor (2) and AC compressor electrical connection (3).

34 38. Remove the two retaining bolts and the support together with relays protecting system (1).

35 84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1

39. Remove the two connectors of the brake lights switch (1).

36 40. Loosen the corresponding retaining clamps and extract the pipes (1), (2), (3) and (4).

3 4

37 41. Loosen the corresponding retaining bolts and remove the bracket (1).

38 42. Hitch the engine to the hoist with the chains anchouring it to the attachments on the engine.

39 84176561- 03-2008

SECTION 10 - ENGINE - CHAPTER 1

43. Position the movable tool for dismantling tractors 380000569 with the bracket 380000500 and adapter plate 380000844 under the engine and place a wooden block in between the points of contact between the tool and tractor.

40 44. Extract the differential lock pedal retaining pin from the drive shaft (1), remove the pedal and footboard (2).

2 1

25043

41 45. Unscrew the nuts (1) and the bolts securing the engine to the transmission. Access is through the two slots in the cab floor.

1 42 46. Remove the remaining six retaining bolts at the bottom and side.

43 84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1

47. Seperate the engine from the transmission with the tool 380000569.

2 44

48. Remove the spacer located between the engine and the transmission.

45 49. Insert the fixed under the balast support and secure the front wheels with wooden blocks.

2 46

50. Loosen the corresponding retaining clamp (1) and extract the pipes. And remove the bracket (2).

47 84176561- 03-2008

SECTION 10 - ENGINE - CHAPTER 1

51. Remove the bonnet support (1).

48 52. Loosen the retaining clamp and extract the pipe (1) joining the coolant pump to the bottom of the radiator.

49 53. Position a fixed stand (3) under the support of the groove (1) of the front axle drive placing a wooden plug (2) between the parts (3) and (1).

50 54. Remove the four bolts (2) fastening the front axle support (1) to the engine (3).

51 84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1

55. Insert the hooks of the lifting chains (1) in the eyelets shown in the figure, afterwards tensioning the chains with the hoist.

52 56. Detach the engine (2) from the front axle (3), trying to avoid incorrect operations with the hoist so as not to let the engine fan damage the fins of the radiator (1), left on the axle (3). 57. Then rest the engine on a platform support.

84176561- 03-2008

SECTION 10 - ENGINE - CHAPTER 1 -

Apply LOCTITE sealing compound on the en‐ gine/spacer contact surfaces and fit the spacer on the stud bolts screwed into the engine.

Also apply LOCTITE sealing compound on the clutch overdrive casing surfaces.

Position wooden blocks under the rear wheels, make sure that the handbrake is fully applied and that all fixed and mobile stands are safely posi‐ tioned.

The installation phase described here requires the presence of two or three workers to use the movable tool for dismantling tractors 380000569 to move the engine/front axle assembly close to the overdrive clutch casing.

In the phase of installing the engine/front axle as‐ sembly to the overdrive clutch casing, it is necessary to push on the front wheels, taking great care in the end phase of coupling over both the pipes and the cables/electrical connections to prevent crushing between the two bodies. Dur‐ ing this phase, it is moreover necessary to turn the crankshaft with the aid of the radiator cooling fan to help the coupling between the sleeve and the drive shaft.

Secure both assemblies by tightening all the bolts locking the engine to the overdrive clutch casing.

Remove the U-bolt previously fitted under the clutch casing and recover the movable tool for dismantling tractors 380000569.

Fit the electric cable connected to the fuse-‐ holder box and the retaining nut.

Working from the side of the starter motor, fit the protective cable housing and the retaining nut.

Fit the electrical connections installed on the brake pump and on the brake fluid reservoir.

Refit the power steering piping on the engine and reconnect the electrical connections to the pres‐ sure switch.

Refit the power steering return pipe with its bracket and retaining bolt.

CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.

Apply the torque settings listed at F5C Engines Repair Manual (Print No: 87736548A).

Insert the three hooks of the chain in the eyelets on the engine and, using the hoist, lift the assem‐ bly off the platform support.

Position the engine on the front axle, trying to avoid incorrect operations with the hoist so as not to let the engine fan damage the fins of the radi‐ ator, then join the two assemblies together with the four retaining bolts.

Reposition the movable tool for dismantling trac‐ tors 380000569 under the engine and place a wooden block in between the point of contact be‐ tween the tool and engine.

With the aid of the hoist, place the engine on the tool 380000569 and remove the lifting eyelet previously fitted on the front of the engine.

Remove the fixed stand previously positioned under the support of the groove of the drive of the front axle and the wooden plug.

Refit the pipe joining the coolant pump to the bot‐ tom of the radiator and the associated retaining clamp.

Refit the oil vapour suction pipe, filter/intake manifold connecting pipe and the pipe connect‐ ing the radiator at the top to the thermostat valve, re-installing the associated retaining clamps.

Fit the left-right hand side guard of the engine fan and the three retaining bolts. Remove the fixed U-bolt fitted beforehand under the ballast support and the two wooden wedges locking the front wheels. Remove the old sealing compound from both surfaces of the spacer between the engine and the overdrive clutch housing, and do the same also on the contact surface of the overdrive clutch housing and on that of the engine.

84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1

Refit the brake piping support and the two retain‐ ing bolts.

Refit the two right- and left-hand dashboard panels and the relevant four fixing knobs.

Refit the condenser, air cooler and radiator pipes.

Refit the two power steering cylinder oil delivery and return hoses.

Refit the dryer filter together with its support and piping, tightening the two retaining bolts.

Install the electrical connections between the cab and the engine.

Refit the bonnet support, tightening the retaining bolts.

Reconnect the diesel delivery and return pipes to the diesel pump and install the relevant plastic fasteners.

Refit the support with the fuse-holder box on the bonnet support, tightening the two retaining bolts.

Working on the left-hand side of the engine, in‐ stall the lift pump draw pipe and tighten the re‐ taining bolts.

Refit the support together with the relays protect‐ ing the system on the bonnet support, fitting the two retaining bolts.

Install the delivery pipe of the services pump on the right-hand side of the engine and tighten its fitting.

Refit the rigid pipe for drawing oil from the trans‐ mission and the two metal clamps.

Secure the silencer to the exhaust manifold with the four nuts and connect the air filter dust ex‐ tractor pipe to the silencer exhaust, inserting the retaining clamp.

Refit the power steering/four-wheel drive drain pipe on both the left- and right-hand sides of the engine.

Refit the lift pump draw pipe and lock the retain‐ ing bolts.

Refit the three rear retaining bolts of the exhaust silencer.

Refit the propeller shaft with its central support and the retaining bolts.

Fit the cab heater delivery and return pipes and insert the associated clamps.

Refit the front axle drive shaft guard, tightening the front, central and rear retaining bolts.

Refit the front ballast together with the support and insert the retaining pin and the split pins.

Install the fitting of the cab heater radiator coolant return pipe connected to the bottom of the cool‐ ant pump and refill the engine coolant.

Refit the guard on the right-hand side of the fan, tightening the three retaining bolts.

Refill the transmission-gearbox housing with oil.

Install the bonnet. Reconnect the battery nega‐ tive lead.

Refit the brake fluid reservoir onto the support and the two retaining clips. Refit the silencer together with the exhaust pipe.

Refit the fitting of the hose delivering power steering oil to the hydraulic cylinders governing the front wheel steering.

Install the flexible cables governing the hand and pedal throttle, inserting the retaining clips.

Reconnect the throttle control tie-rod to the in‐ jection pump, inserting the retaining clip.

Working from inside the cab, fit the four plugs to gain access to the upper bolts securing the en‐ gine, located at the base of the steering column. Refit the pedal on the differential lock drive shaft, the retaining pin and the footboard.

84176561- 03-2008

SECTION 10 - ENGINE - CHAPTER 1

SECTION 10 - ENGINE Chapter 1 - Engine CONTENTS Operation

Description

Page

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Lubrication diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Cooling system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 10 001 10

Engine R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

10 001 53

Engine D.A. Checks, measurements and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

10 102 70

Crankshaft front seal - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

10 102 74

Crankshaft rear seal - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

10 106 12

Valve tappet and rocker arm clearance - Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

10 218 30

Engine injector R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

10 246 14

Bosch injection pump R.I. Timing. Air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

10 402 10

Coolant pump R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

10 402 30

Thermostat valve R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

10 406 10

Radiator R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

10 414 10

Coolant pump and generator drive belts. Tension adjustment . . . . . . . . . . . . . . . . . . . . . . 116

84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1

GENERAL SPECIFICATIONS

4 Cylinders

Engine, technical type: -

TD 5040 model - type F4CE9487M*J (BOSCH pump)

See data on page

TD 5050 model - type F4CE9487N*J (BOSCH pump)

See data on page

Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

diesel, 4-stroke

Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

direct

Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston diameter -

model TD 5040, TD 5050 . . . . . . . . . . . . . . . . . . . . . . . . .

4.0944 in. (104 mm)

Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1968 in. (132 mm)

Total displacement: -

model TD 5040, TD 5050 . . . . . . . . . . . . . . . . . . . . . . . . .

Compression ratio for Models TD 5040, TD 5050 . . . . . .

273.67 in3. (4485 cm3) 17.5:1

Maximum power: -

model TD 5040 - type F4CE9487M*J . . . . . . . . . . . . . . . . . .

65 kW (88 HP)

model TD 5050 - type F4CE9487N*J . . . . . . . . . . . . . . . . . .

70 kW (95 HP)

Maximum torque: TD 5040 - type F4CE9487M*J . . . . .

375 (Nm)

Maximum torque: TD 5050 - type F4CE9487N*J

390 (Nm)

Maximum torque speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1300 rev/min

Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

structural, cast iron

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

forced, with lobe pump

Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

camshaft

Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . .

1:1

Oil cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mesh filter on oil intake and filtering cartridge on delivery line

Normal oil pressure with motor warmed-up at slow idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.4 psi (1.2 bar)

at fast idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55.1 psi (3.8 bar) (continued)

84176561- 03-2008

SECTION 10 - ENGINE - CHAPTER 1

3 (cont)

GENERAL SPECIFICATIONS Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator on Models TD 5040, TD 5050 . . . . . . . . . . . . .

4 Cylinders coolant circulation 4 lines of vertical pipes with copper fins

Fan, attached to the pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

intake, in plastic with 11 blades

Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

centrifugal vane-type

Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . . Coolant thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature ranges corresponding to each section: - Initial blue section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - Middle green section (normal working conditions) . . . . . . . . . - Final red section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1:1.977 coloured scale divided into 3 sections

Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

via thermostat valve

initial opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104 to 140 °F (40° to 60 °C) 140 to 230 °F (60° to 110 °C) 230 to 248 °F (110° to 120 °C)

177.0 ± 35.6 °F (81 ± 2 °C)

Timing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by tappets, rods and rocker arms via the camshaft located in the engine block; the camshaft is driven by the crankshaft using straight-tooth gears Intake: -

start: before T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10° ± 30'

end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10° ± 30'

Exhaust: -

start: before B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64°

end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26°

Valve-rocker arm clearance (with engine cold): -

intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(0.25 ± 0.05 mm)

exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(0.50 ± 0.05 mm)

For further timing system technical data . . . . . . . . . . . . . . . . . . .

see page 8 (continued)

84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1 (cont)

GENERAL SPECIFICATIONS

4 Cylinders

Fuel system Air cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

dual cartridge dry air filter, with clogged filter indicator with centrifugal pre-filter and automatic dust ejector

Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with double diaphragm

Fuel filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through wire filter in fuel supply pump, and replaceable cartridge on delivery line to injection pump Minimum fuel flow rate with pump shaft rotating at 1800 rpm .

127.6 l/h

Cam operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

engine timing

BOSCH injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rotating distributor type

All- speed governor, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

centrifugal counterweights

Automatic advance regulator, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

hydraulic

For further fuel system technical data: Fixed advance (pump setting for start of delivery before TDC) - Pressure setting - Injection order, and other information regarding the BOSCH pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84176561- 03-2008

refer to the data for the relevant engine type in the table on page 2

SECTION 10 - ENGINE - CHAPTER 1

FUEL SYSTEM DATA Turbo Charger: -

For versions F4CE9487M*J: - type HOLSET HX25W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TB11H/A085BXL

For versions F4CE9487N*J: - type HOLSET HX25W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TB11K/A11CXL

Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rotating distributor with speed governor and advance regulator incorporated

BOSCH pump: -

TD 5040 model - type F4CE9487M*J . . . . . . . . . . . . . . . . . .

VE 4/12 F1250 L2043 (S/N 504218826)

TD 5050 model - type F4CE9487N*J . . . . . . . . . . . . . . . . . .

VE 4/12 F1250 L2023 (S/N 504218827)

Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

anticlockwise

Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3-4-2 (For all models)

TD 5040

TD 5050

504254390 DSLA 145 P 1441

BOSCH-type injectors: -

F4CE9487M*J . . . . . . . . . . . . . . . . . . . . . . . .

F4CE9487N*J . . . . . . . . . . . . . . . . . . . . . . . .

Number of nozzle holes . . . . . . . . . . . . . . . . . . .

504254390 DSLA 145 P 1441

Nozzle hole diameter mm. -

F4CE9487M*J . . . . . . . . . . . . . . . . . . . . . . . .

0.192

F4CE9487N*J . . . . . . . . . . . . . . . . . . . . . . . .

0.192

260 to 272

Calibration pressure bar . . . . . . . . . . . . . . . . . . .

CRANKCASE/CYLINDER BLOCK DATA

in. (mm)

Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

cast-iron monobloc with cylinder liners, crankshaft, camshaft and tappets

Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.09944 to 4.0954 (104.000 to 104.024)

Oversized cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1141 to 4.1151 (104.500 to 104.524)

84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1

Main journal half bearing seat diameter

external no. 1-5

3.4638 to 3.4648 (87.982 to 88.008)

internalno. 2-3-4

3.4636 to 3.4650 (87.977 to 88.013)

Camshaft bushing seat diameter: - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3315 to 2.3325 (59.222 to 59.248)

- intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3315 to 2.3325 (59.222 to 59.248)

- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3315 to 2.3325 (59.222 to 59.248)

Diameter of standard tappet bores in crankcase . . . . . . . . . . . . . .

0.6299 to 0.6311 (16.000 to 16.030)

CRANKSHAFT AND BEARINGS DATA

in. (mm)

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

balanced with integral counterweights

Standard journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2671 to 3.2682 (82.987 to 83.013)

Journal undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0098 to 0.0196 (0.250 - 0.500)

Main journal half bearing thickness . . . . . . . . . . . . . . . . . . . . . . . . .

0.0966 to 0.0970 (2.456 to 2.464)

Main half bearing undersizes (internal diameter) . . . . . . . . . . . . . .

0.0098 to 0.0196 (0.250 - 0.500)

Clearance between bearings and main journal

no. 1-5

0.0016 to 0.0046 (0.041 to 0.119)

n. 2-3-4

0.0016 to 0.0040 (0.041 to 0.103)

Standard crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7160 to 2.7170 (68.987 to 69.013)

Crankpin undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0098 to 0.0196 (0.250 - 0.500)

Standard connecting rod half bearing thickness . . . . . . . . . . . . . . .

0.0769 to 0.0774 (1.955 to 1.968)

Connecting rod half bearing undersizes (internal diameter) . . . . .

0.0098 to 0.0196 (0.250 - 0.500)

Bearing to crankpin clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0012 to 0.0016 (0.033 to 0.041)

Standard crankshaft thrust washer width . . . . . . . . . . . . . . . . . . . .

1.4677 to 1.4716 (37.280 to 37.380)

Width of main bearing for thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0228 to 1.0425 (25.980 to 26.480)

Width of corresponding crankshaft journal . . . . . . . . . . . . . . . . . . .

1.4753 to 1.4783 (37.475 to 37.550)

Crankshaft assembly endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0067 to 0.0094 (0.172 to 0.240)

CONNECTING ROD DATA

in. (mm)

Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

printed in steel, oblique-cut type

Diameter of small end bushing seat . . . . . . . . . . . . . . . . . . . . . . . . .

1.6136 to 1.6146 (40.987 to 41.013)

Outside diameter of small end bushing . . . . . . . . . . . . . . . . . . . . . .

1.6251 to 1.6359 (41.279 to 41.553)

84176561- 03-2008

SECTION 10 - ENGINE - CHAPTER 1

Interference between small end bushing and seat . . . . . . . . . . . . .

0.0104 to 0.0222 (0.266 to 0.566)

Inside diameter of small end bushing (measured after fitting) . . .

1.4968 to 1.4973 (38.019 to 38.033)

Diameter of big end bearing seats . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8734 to 2.8745 (72.987 to 73.013)

Connecting rod-crankpin end float . . . . . . . . . . . . . . . . . . . . . . . . .

0.0039 to 0.0129 (0.100 to 0.330)

PISTON DATA Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

in. (mm) TD 5040 - TD 5050 light alloy with three compression rings, including two seal rings and one scraper ring

Standard piston diameter, measured at 2.4015 in. (61 mm) from skirt base and perpendicularly to the gudgeon pin axis . . . . . . . . .

4.0944 to 4.0954 (104.000 to 104.024)

Piston clearance in cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0105 to 0.0122 (0.268 to 0.310)

Piston oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0196 (0.500)

Piston protrusion at T.D.C. from cylinder block face . . . . . . . . . . .

0.0110 to 0.0204 (0.280 to 0.520)

Gudgeon pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4958 to 1.4960 (37.994 to 38.000)

Diameter of gudgeon pin seat in piston . . . . . . . . . . . . . . . . . . . . . .

1.4964 to 1.4966 (38.010 to 38.016)

Gudgeon pin to seat clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0003 to 0.0008 (0.010 to 0.022)

Gudgeon pin to small end bearing clearance . . . . . . . . . . . . . . . . .

0.0007 to 0.0015 (0.019 to 0.039)

Piston ring groove depth: - 1° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.1064 to 0.1076 (2.705 to 2.735)

- 2° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0960 to 0.0968 (2.440 to 2.460)

- 3° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.1586 to 0.1594 (4.030 to 4.050)

Piston ring thickness: - 1° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.1007 to 0.1025 (2.560 to 2.605)

- 2° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0925 to 0.0937 (2.350 to 2.380)

- 3° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.1562 to 0.1570 (3.970 to 3.990) (continued)

84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1 (cont)

PISTON DATA

in. (mm) TD 5040 - TD 5050

Piston ring groove clearance (measured vertically): - 1° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0039 to 0.0068 (0.100 to 0.175)

- 2° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0023 to 0.0043 (0.060 to 0.110)

- 3° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0015 to 0.0028 (0.040 to 0.073)

Assembly clearance between piston ring ends in cylinder sleeves: - 1° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0118 to 0.0157 (0.30 to 0.40)

- 2° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0236 to 0.0314 (0.60 to 0.80)

- 3° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0118 to 0.0216 (0.30 to 0.55)

Spare piston ring oversizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0196 (0.500)

VALVE TIMING GEAR DATA

in. (mm)

Inside diameter of camshaft bearings (fitted and reamed): - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1292 to 2.1317 (54.083 to 54.147)

- intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1292 to 2.1317 (54.083 to 54.147)

- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1292 to 2.1317 (54.083 to 54.147)

Diameter of camshaft journals: - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1257 to 2.1277 (53.995 to 54.045)

- intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1257 to 2.1277 (53.995 to 54.045)

- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1257 to 2.1277 (53.995 to 54.045)

Clearance between camshaft journals and bushings . . . . . . . . . .

0.0014 to 0.0059 (0.038 to 0.152)

Camshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0090 ± 0.0051 (0.230 ± 0.130)

Crankshaft to camshaft teeth clearance . . . . . . . . . . . . . . . . . . . . .

0.0029 to 0.0110 (0.076 to 0.280)

TAPPET DATA

in. (mm)

Tappet bore in crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.6299 to 0.6311 (16.000 to 16.030)

Outside diameter of standard tappet . . . . . . . . . . . . . . . . . . . . . . . .

0.6271 to 0.6283 (15.929 to 15.959)

Tappet running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0016 to 0.0039 (0.041 to 0.101)

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SECTION 10 - ENGINE - CHAPTER 1

ROCKER ARM - VALVE DATA Rocker-arm shaft diameter

in. (mm)

...............................

0.7465 to 0.7470 (18.963 to 18.975)

Rocker-arm shaft seat diameter . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.7480 to 0.7490 (19.000 to 19.026)

Rocker arm bore to shaft clearance . . . . . . . . . . . . . . . . . . . . . . . . .

0.0009 to 0.0024 (0.025 to 0.063)

Valve clearance for normal running (engine cold): - inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0118 to 0.0019 (0.300 to 0.050)

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0216 to 0.0019 (0.550 to 0.050)

Cam lift: - inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.2379 (6.045)

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.2849 (7.239)

CYLINDER HEAD DATA Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

in. (mm) in cast iron with fitted valve seats and seats for injectors and thermostat valve

Maximum face re- grinding depth that can be removed from the cylinder head in the event of reboring . . . . . . . . . . . . . . . . . . . . . . . . .

0.0051 (0.130)

Diameter of valve stem seat in cylinder head . . . . . . . . . . . . . . . . .

0.3157 to 0.3164 (8.019 to 8.039)

Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.3133 to 0.3141 (7.960 to 7.980)

Assembly clearance between valve stem and seat . . . . . . . . . . . .

0.0015 to 0.0031 (0.039 to 0.079)

Valve seat angle in head: -

inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60째

exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45째

Valve face angle: -

inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60째

exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45째

Diameter on head for fitting valve seat: -

inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8498 to 1.8509 (46.987 to 47.013)

exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7178 to 1.7190 (43.637 to 43.663)

Valve seat insert outside diameter: -

inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8528 to 1.8538 (47.063 to 47.089)

exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7209 to 1.7220 (43.713 to 43.739)

Valve stand-in relative to cylinder head face: -

inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0132 to 0.0422 (0.336 to 1.072)

exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0434 to 0.0330 (0.104 to 0.840)

Interference between valve seat and head: -

inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0019 to 0.0040 (0.050 to 0.102)

exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.0019 to 0.0040 (0.050 to 0.102) (continued)

84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1 (cont)

CYLINDER HEAD DATA

in. (mm)

Valve head diameter: - inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7665 to 1.7767 (44.870 to 45.130)

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6484 to 1.6586 (41.870 to 42.130)

Inlet and exhaust valve springs: -

free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4999 (63.500)

length under load of 329 N . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.9299 (49.020)

length under load of 641 N . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5039 (38.200)

Injector protrusion relative to head face: D injectors: BOSCH DLLA 145 P 1338 BOSCH DSLA 145 P 1255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84176561- 03-2008

Not adjustable

SECTION 10 - ENGINE - CHAPTER 1

TIGHTENING TORQUES PARTS TO BE TIGHTENED

Thread

Tightening torque Nm

kgm

M 12 x 1.75 x 100

80 ± 10

8±1

M 16 x 1.50 x 80 M 16 x 1.50 x 100 M 12 x 1.75 x 78

200 ± 20 200 ± 20 80 ± 10

20 ± 2 20 ± 2 8±1

Oil sump retaining bolts (3, fig. 209) . . . . . . . . . . . . . . . . . . . .

M 10 x 1.50 x 45 M 10 x 1.50

50 ± 5 70 ± 5

5 ± 0.5 7 ± 0.5

Oil sump threaded plugs (2, fig. 209) . . . . . . . . . . . . . . . . . . .

M 22 x 1.5

50 ± 5

5 ± 0.5

Rocker arm support retaining bolts (2, fig. 186) . . . . . . . . . .

M 8 x 1.25

25 ± 5

2.5 ± 0.5

Tappet cover retaining bolts (1, fig. 224 - 225) . . . . . . . . . . .

M 8 x 1.25

25 ± 5

2.5 ± 0.5

Exhaust manifold retaining bolts (3, fig. 221) . . . . . . . . . . . .

M 10 x 1.50

53 ± 5

5.3 ± 0.5

Intake manifold retaining bolts (2, fig. 224 - 225) . . . . . . . .

M 8 x 1.25

25 ± 5

2.5 ± 0.5

Oil cooler retaining bolts (4, fig. 216) . . . . . . . . . . . . . . . . . . .

M 8 x 1.25

25 ± 5

2.5 ± 0.5

Coolant pump retaining bolts (2, fig. 214) . . . . . . . . . . . . . . .

M 8 x 1.25

25 ± 5

2.5 ± 0.5

Coolant inlet manifold retaining bolts (2, fig. 212) . . . . . . . .

M 10 x 1.50

45 ± 10

4.5 ± 1

Thermostat valve assembly retaining bolts (3, fig. 175) . . .

M 8 x 1.25

25 ± 5

2.5 ± 0.5

Fan support retaining bolts (3, fig. 215) . . . . . . . . . . . . . . . . .

M 8 x 1.25 x 50 M 10 x 1.50 x 25

25 ± 5 45 ± 5

2.5 ± 0.5 4.5 ± 0.5

Injector fastener (1, fig. 184) . . . . . . . . . . . . . . . . . . . . . . . . . .

60 ± 5

6.0 ± 0.5

Fuel pump retaining bolts (5, fig. 223) . . . . . . . . . . . . . . . . . .

M 8 x 1.25

25 ± 5

2.5 ± 0.5

Nuts securing turbine mod. (2, fig. 221) .

M 8 x 1.25

25 ± 5

2.5 ± 0.5

Alternator retaining bolts (3, fig. 217) . . . . . . . . . . . . . . . . . . .

M 10 x 1.50

45 ± 5

4.5 ± 0.5

Starter motor retaining bolts (5, fig. 228) . . . . . . . . . . . . . . . .

M 10 x 1.50

55 ± 5

5 ± 0.5

Camshaft plate retaining bolts (3, fig. 151) . . . . . . . . . . . . . .

M 8 x 1.25

25 ± 5

2.5 ± 0.5

Injection pump retaining bolts (3, fig. 195) . . . . . . . . . . . . . . .

M 8 x 1.25

12 ± 5

1.2 ± 0.5

Oil pump gear casing retaining bolts (2, fig. 208) . . . . . . . . .

M 8 x 1.25

25 ± 5

2.5 ± 0.5

Additional counterweight retaining bolts (3, fig. 199) . . . . . .

M 10 x 1.5

48 ± 8

4.8 ± 0.8

Camshaft gear retaining bolts (1, fig. 190) . . . . . . . . . . . . . . . .

M 8 x 1.25

36 ± 4

3.6 ± 0.4

Flywheel casing retaining bolts (2, fig. 202) . . . . . . . . . . . . .

84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1 TORQUE SETTINGS WITH ANGLE Tightening torque PARTS TO BE TIGHTENED

Thread

kgm

Angle

Main bearing cap bolts (1, fig. 159) phase 1

M 12 x 1.5

50 ± 6

5.0 ± 0.6

phase 2

M 12 x 1.5

80 ± 6

8.0 ± 0.6

phase 3

M 12 x 1.5

90° ± 5°

phase 1

M 10 x 1.25

30 ± 5

3.0 ± 0.5

phase 2

M 10 x 1.25

50 ± 5

5.0 ± 0.5

phase 3

M 10 x 1.25

60° ± 5°

M 12 x 1.75 x 70

50 ± 5

5.0 ± 0.5

90°

M 12 x 1.75 x 140

40 ± 5

4.0 ± 0.5

180°

M 12 x 1.75 x 180

70 ± 5

7.0 ± 0.5

180°

Bolts fastening pulley on crankshaft (1, fig. 211) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

50 ± 5

5.0 ± 0.5

90° ± 5°

Engine flywheel retaining bolts (1, fig. 207) . . .

M 12 x 1.25

30 ± 5

3.0 ± 0.5

60° ± 5°

Big end cap bolts (1, fig. 171)

Cylinder head bolts (1, fig. 191) . . . . . . . . . . . . Note:

For the tightening sequence, see page 60, fig. 192.

84176561- 03-2008

SECTION 10 - ENGINE - CHAPTER 1

TOOLS

X 380000663

Tool to extract crankshaft rear seal.

Warning - The operations described in this section can only be carried out with ESSENTIAL tools indi‐ cated by an (X). To work safely and efficiently and obtain the best re‐ sults, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings in‐ cluded in this manual.

X 380000664

Splining tool for fitting rear seal on crankshaft.

X 380000665

Tool to extract crankshaft front seal.

X 380000666

Splining tool for fitting front seal on crankshaft.

X 380000667

Drift for camshaft bushing dis‐ assembly and reassembly (use with 380000668).

List of specific tools required for the various operations described in this Section. 380000668 X 380000216

Engine removal and installation tool.

380000220

Clamp for fitting piston in cylin‐ der liner 2.3622-4.9212 in. (60-125 mm).

X 380000221

380000301

X 380000302

X 380000670

Tool for cartridge filter disas‐ sembly.

Pliers for piston ring disassem‐ bly and reassembly 2.5590-4.3307 in. (65-1 10 mm).

380000975

Box with full set of tools to re‐ grind valve seats.

380000976

Spring load test appliance.

Rotating stand for overhaul operations (capacity 1000 daN, torque 120 daN/m).

380001003

Complete square to check for connecting rod distortion.

380001268

Belt tension gauge.

Tool for engine valve disassem‐ bly and reassembly.

380000362

Crankshaft lifting tool.

X 380000661

Gasket extraction tool.

Injector extraction tool.

Pair of gauges for angular tightening with 1/2” and 3/4” square connection.

380000569

X 380000669

380000671

380000304

X 380000364

Grip for interchangeable drifts.

Injection pump bench test. 380000228

Dial gauge 0-019.68 in. (0-5 mm).

Dial gauge base for various measurements (use with 380000228).

X 380000914

Dial-gauge holder tool for rotary injection pump timing (use with 380000228).

Movable tool for dismantling tractors with bracket 380000500 and adapter plate 380000844.

X 380000732

Tool for engine flywheel rotation (use with 380000988).

X 380000988

Plate for engine flywheel rota‐ tion tool with flywheel timing pin (use with 380000732).

Engine mounting brackets for rotating stand 380000301.

84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1

MIF1097A

54 View of TD 5040 tractor engines of 65 kW (88 HP) and TD 5050 of 70 kW (95 HP)

84176561- 03-2008

SECTION 10 - ENGINE - CHAPTER 1

Oil path under pressure Oil return path under gravity MIF1098A

55 Lubrication diagram for engines mod.TD 5040 and TD 5050

Forced-circulation lubrication is accomplished by the following components: - oil pump, housed at the front of the crankcase, driven by the grooved bushing keyed onto the shank of the crankshaft; - water / oil cooler, housed in the crankcase;

oil pressure control valve incorporated in the cooler assembly; by-pass valve to cut off clogged oil filter, incorpoâ&#x20AC;? rated in the cooler assembly; cartridge oil filter.

84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1

Coolant recirculating in the engine Coolant entering the pump MIF1099A

56 Cooling system diagram

The forced circulation, closed-circuit engine cooling system is composed of the following components: - a lubricating oil cooler;

84176561- 03-2008

a centrifugal coolant pump housed at the front of the crankcase; a thermostat valve governing coolant circulation.

SECTION 10 - ENGINE - CHAPTER 1

MIF1101A

57 Detail of cylinder head with valve seats fitted in engines mod. TD 5040, TD 5050

1. Exhaust manifold 2. Intake manifold 3. Air heater

4. Fitted valve seats 5. Thermostat valve 6. Injector

84176561 - 03-2008

SECTION 10 - ENGINE - CHAPTER 1

MIF1102A

58 Additional counterweights

1. 2. 3. 4. 5.

Retaining bolts Support Retaining bolts Gear Balancing weight

84176561- 03-2008

6. 7. 8. 9. 10.

Half bearings Counter-shaft Gear Ring O-Ring