New Holland T5030 Tractor Service Repair Manual 1 by u1yiuef6

TRACTORS SERVICEMANUAL SECTIONS GENERALGUIDELINES00 ...................................................... ENGINE 10 ..................................................................... CLUTCH 18 ..................................................................... TRANSMISSIONS21 ............................................................ DRIVELINES 23 ................................................................ FRONTMECHANICALTRANSMISSION25 ........................................ REARMECHANICALTRANSMISSION27 ......................................... POWERTAKE-OFF31 .......................................................... BRAKES 33 ..................................................................... HYDRAULICSYSTEMS35 ....................................................... STEERING 41 ................................................................... AXLEANDWHEELS44 .......................................................... CABAIRCONDITIONINGSYSTEM50 ............................................ ELECTRICALSYSTEM55 ........................................................ PLATFORM,CAB,BODYWORK90 ............................................... SERVICE

T5030--T5040--T5050--T5060

GENERALINSTRUCTIONS IMPORTANTNOTICE

AllmaintenanceandrepairworkdescribedinthismanualmustbeperformedexclusivelybyNEWHOLLAND servicetechnicians,instrictaccordancewiththeinstructionsgivenandusinganyspecifictoolsnecessary. Anyoneperformingtheoperationsdescribedhereinwithoutstrictlyfollowingtheinstructionsispersonally responsibleforanyeventualinjuryordamagetoproperty.

SHIMMING

Foreachadjustmentoperation,selectadjustingshimsandmeasureindividuallyusingamicrometer,thenadd uptherecordervalues:Donotrelyonmeasuringtheentireshimmingset,whichmaybeincorrect,ortherated valueindicatedforeachonshim.

ROTATINGSHAFTSEALS

Forcorrectrotatingshaftsealinstallation,proceedasfollows:

--beforeassembly,allowthesealtosoakintheoilitwillbesealingforatleastthirtyminutes;

--thoroughlycleantheshaftandcheckthattheworkingsurfaceontheshaftisnotdamaged;

--positionthesealinglipfacingthefluid;withhydrodynamiclips,takeintoconsiderationtheshaftrotation directionandpositionthegroovessothattheywilldeviatethefluidtowardstheinnersideoftheseal;

--coatthesealinglipwithathinlayeroflubricant(useoilratherthangrease)andfillthegapbetweenthesealing lipandthedustlipondoublelipsealswithgrease;

--insertthesealinitsseatandpressdownusingaflatpunch;donottapthesealwithahammerormallet;

--whilstinsertingtheseal,checkthatitisperpendiculartotheseat;oncesettled,makesurethatitmakes contactwiththethrustelement,ifrequired;

--topreventdamagingtheseallipontheshaft,positionaprotectiveguardduringinstallationoperations.

O--RINGSEALS

LubricatetheO--RINGsealsbeforeinsertingthemintheseats,thiswillpreventthemfromoverturningand twisting,whichwouldjeopardisesealingefficiency.

SEALINGCOMPOUNDS

ApplyoneofthefollowingsealingcompoundsonthematingsurfacesmarkedwithanX:RTVSILMATE, RHODORSILCAF1orLOCTITEPLASTICGASKET.

Beforeapplyingthesealingcompound,preparethesurfacesasfollows:

--removeanyincrustationsusingawirebrush;

--thoroughlyde--greasethesurfacesusingoneofthefollowingcleaningagents:trichlorethylene,petrolora waterandsodasolution.

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BEARINGS

Wheninstallingbearingsitisadvisedto:

--heatthebearingsto80 ÷ 90 °Cbeforefittingontheshafts;

--allowthebearingstocoolbeforeinstallingthem.

SPRINGPINS

Whenfittingsplitsocketelasticpins,ensurethatthepinnotchispositionedinthedirectionoftheforcerequired tostressthepin.

Spiralspringpinsdonotrequirespecialpositioning.

SPAREPARTS

Usesolely genuineparts,whichguaranteethesamequality,durationandsafetyastheoriginalpartsasthey areidenticaltotheonesfittedduringproduction.

Only genuineparts canofferthisguarantee.

Whenorderingspareparts,alwaysprovidethefollowinginformation:

--tractormodel(commercialname)andframenumber;

--enginetypeandnumber;

--partnumberoftheorderedpart,whichcanbefoundinthe“Microfiches”orthe“SparePartsCatalogue”,used fororderprocessing.

NOTESFOREQUIPMENT

ThetoolsthatNEWHOLLANDproposeandillustrateinthismanualare:

--specificallyresearchedanddesignedforusewithNEWHOLLANDvehicles;

--necessarytomakereliablerepair;

--accuratelybuiltandstrictlytestedtoofferefficientandlong--lastingworkingmeans. Byusingthesetools,repairpersonnelwillbenefitfrom:

--operatinginoptimaltechnicalconditions;

--obtainingthebestresults;

--savingtimeandeffort;

--workinginsafeconditions.

IMPORTANTNOTES

Wearlimitvaluesindicatedforcertainpartsarerecommended,butnotbinding.Theterms“front”,“rear”, “right--hand”and“left--hand”(whenreferredtodifferentparts)areintendedasseenfromthedrivingpositionwith thetractorinthenormaldirectionofmovement.

MOVINGTHETRACTORWITHTHEBATTERYREMOVED

Externalpowersupplycablesshouldonlybeconnectedtotherespectivepositiveandnegativecableterminals, usingefficientclampsthatguaranteeadequateandsecurecontact.

Disconnectallservices(lights,windshieldwipers,etc.)beforestartingthevehicle.

Ifthevehicleelectricalsystemrequireschecking,carryoutoperationswiththepowersupplyconnected;once checkingiscompleted,disconnectallservicesandswitchoffthepowersupplybeforedisconnectingthecables.

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SAFETYREGULATIONS

WARNINGANDDANGERSYMBOL

Thiswarningsymbolpointsoutimportantmessagesconcerningyoursafety. Carefullyreadthefollowingsafetyregulationsandobserveadvisedprecautionsin ordertoavoidpotentialhazardsandsafeguardyourhealthandsafety. Inthismanualthesymbolisaccompaniedbythefollowingkey--words:

WARNING --Warningsconcerningunsuitablerepairoperationsthatmayjeopardise thesafetyofRepairpersonnel.

DANGER --Specificwarningsconcerningpotentialhazardsforoperatorsafetyorfor otherpersonsdirectlyorindirectlyinvolved.

TOPREVENT ACCIDENTS

Mostaccidentsorinjuriesthatoccurinworkshopsare theresultofnon--observanceofsimpleand fundamentalsafetyregulations.

Forthisreason,INMOSTCASESTHESE ACCIDENTSCANBEAVOIDED:byforeseeing possiblecausesandconsequentlyactingwiththe necessarycautionandcare.

Accidentsmayoccurwithalltypesofvehicle, regardlessofhowwellitwasdesignedandbuilt.

Acarefulandjudiciousservicetechnicianisthebest guaranteeagainstaccidents.

Preciseobservanceofthemostbasicsafetyruleis normallysufficienttoavoidmanyseriousaccidents.

DANGER. Nevercarryoutanycleaning,lubrication ormaintenanceoperationswhentheengineis running.

SAFETYREGULATIONS

GENERAL

--Carefullyfollowspecifiedrepairandmaintenance procedures.

--Donotwearrings,wristwatches,jewellery, unbuttonedorloosearticlesofclothingsuchas: ties,tornclothing,scarves,openjacketsorshirts withopenzipsthatmayremainentangledin movingparts.

Itisadvisedtowearapprovedsafetyclothing, e.g:non--slipfootwear,gloves,safetygoggles, helmets,etc.

--Donotcarryoutrepairoperationswithsomeone sittinginthedriver’sseat,unlessthepersonisa trainedtechnicianwhoisassistingwiththe operationinquestion.

--Operatethevehicleandusetheimplements exclusivelyfromthedriver’sseat.

--Donotcarryoutoperationsonthevehiclewiththe enginerunning,unlessspecificallyindicated.

--Stoptheengineandensurethatallpressureis relievedfromhydrauliccircuitsbeforeremoving caps,covers,valves,etc.

--Allrepairandmaintenanceoperationsmustbe carriedoutusingextremecareandattention.

--Servicestepsandplatformsusedinaworkshop orinthefieldshouldbebuiltincompliancewith thesafetyrulesinforce.

--Disconnectthebatteriesandlabelallcontrolsto indicatethatthevehicleisbeingserviced.Block themachineandallequipmentwhichshouldbe raised.

--Donotcheckorfillfueltanks,accumulator batteries,norusestartingliquidwhensmokingor nearnakedflames,asthesefluidsare inflammable.

--Brakesareinoperativeifmanuallyreleasedfor repairormaintenancepurposes.

Useblocksorsimilardevicestosecurethe machineintheseconditions.

--Thefuelnozzleshouldalwaysbeincontactwith thefillingaperture.Maintainthispositionuntil fillingoperationsarecompletedinordertoavoid possiblesparkscausedbytheaccumulationof staticelectricity.

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SECTION00--GENERAL--CHAPTER1 3

--Onlyusespecifiedtowingpointsfortowingthe tractor,connectpartscarefully.Makesurethatall pinsand/orlocksaresecuredinpositionbefore applyingtraction.

Neverremainnearthetowingbars,cablesor chainsthatareoperatingunderload.

--Transportvehiclesthatcannotbedrivenusinga traileroralow--loadingplatformtrolley,if available.

--Whenloadingorunloadingthevehiclefromthe trailer(orothermeansoftransport),selectaflat areacapableofsustainingthetrailerortruck wheels,firmlysecurethetractortothetruckor trailerandlockthewheelsintheposition.

--Electricheaters,battery--chargersandsimilar equipmentmustonlybepoweredbyauxiliary powersupplieswithefficientgroundinsulationto avoidelectricalshockhazards.

--Alwaysusesuitablehoistingorliftingdevices whenraisingormovingheavyparts.

--Takeextracareifbystandersarepresent.

--Neverpourgasolineordieseloilintoopen,wide andlowcontainers.

--Neverusegasoline,dieseloilorother inflammableliquidsascleaningagents.Use non--inflammable,nontoxiccommercially availablesolvents.

--Wearsafetygoggleswithsideguardswhen cleaningpartswithcompressedair.

--Limittheairpressuretoamaximumof2.1bar, accordingtolocalregulations.

--Donotruntheengineinconfinedspaceswithout suitableventilation.

--Donotsmoke,usenakedflames,orcause sparksintheareawhenfuelfillingorhandling highlyinflammableliquids.

--Neverusenakedflamesforlightingwhenworking onthemachineorcheckingforleaks.

--Allmovementsmustbecarriedoutcarefully whenworkingunder,onornearthevehicleand wearprotectiveequipment:helmets,gogglesand specialfootwear.

--Whencarryingoutcheckswiththeengine running,requesttheassistanceofanoperatorin thedriver’sseat.Theoperatormustmaintain visualcontactwiththeservicetechnicianatall times.

--Ifoperatingoutsidetheworkshop,positionthe vehicleonaflatsurfaceandlockinposition.If workingonaslope,lockthevehicleinposition andmovetoaflatareaassoonasissafely possible.

--Damagedorbentchainsorcablesareunreliable. Donotusethemforliftingortowing. Alwaysusesuitableprotectivegloveswhen handlingchainsorcables.

--Chainsshouldalwaysbesafelysecured.Make surethatthehitch--uppointiscapableof sustainingtheloadinquestion.

Keeptheareanearthehitch--uppoint,chainsor cablesfreeofallbystanders.

--Maintenanceandrepairoperationsmustbe carriedoutinaCLEANandDRYarea,eliminate anywateroroilspillageimmediately.

--Donotcreatepilesofoilorgrease--soakedrags astheyrepresentaseriousfirehazard;store theminaclosedmetalcontainer.

Beforestartingthevehicleorimplements,make surethatthedriver’sseatislockedinpositionand alwayscheckthattheareaisfreeofpersonsor obstacles.

--Emptypocketsofallobjectsthatmayfall unobservedintothevehiclepartswhen disassembled.

--Inthepresenceofprotrudingmetalparts,use protectivegogglesorgoggleswithsideguards, helmets,specialfootwearandgloves.

--Whenwelding,useprotectivesafetydevices: tintedsafetygoggles,helmets,specialoveralls, glovesandfootwear.Allpersonspresentinthe areawhereweldingistakingplacemustwear tintedgoggles.

NEVERLOOKDIRECTLYATTHEWELDING ARCWITHOUTSUITABLEEYEPROTECTION.

--Metalcablestendtofraywithrepeateduse. Alwaysusesuitableprotectivedevices(gloves, goggles,etc.)whenhandlingcables.

--Handleallpartscarefully,donotputyourhands orfingersbetweenmovingparts,wearsuitable safetyclothing--safetygoggles,glovesand shoes.

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SECTION10--ENGINE--CHAPTER1 1 87679925A --12--2007 SECTION10--ENGINE Chapter1--Engine CONTENT Description Page Generalspecifications 2 Tighteningtorque 6 Tools 9 ...................................................................................... Engineview 10 ............................................................................... Troubleshooting 11 EngineR.I. 15 Crankshaftfrontseal--Replacement33 Crankshaftrearseal--Replacement36 .......................................................... Valvetappetandrockerarmclearance--Adjustment39 EngineinjectorR.I. 42 BoschinjectionpumpR.I.Timing.Airbleed45 CoolantpumpR.I. 55 ThermostatvalveR.I. 57 RadiatorR.I. 59 Coolantpumpandgeneratordrivebelt.Tensionadjustment66 ......................................

GENERALSPECIFICATIONS 4Cylinders

Engine,technicaltype:

--Model56/76KW/hp--typeF4CE9484A*J600 (BOSCHpump).....................................

--Model63/86KW/hp--typeF4CE9484N*J601 (BOSCHpump).....................................

--Model71/97KW/hp--typeF4CE9484M*J601 (BOSCHpump).....................................

--Model78/106KW/hp--typeF4CE9484L*J600 (BOSCHpump).....................................

Cycle................................................. diesel,4--stroke

Fuelinjection.......................................... Direct

Numberofcylindersinline 4

--Model56/76KW/hp--typeF4CE9484A*J600 (BOSCHpump).....................................

--Model63/86KW/hp--typeF4CE9484N*J601 (BOSCHpump).....................................

--Model71/97KW/hp--typeF4CE9484M*J601 (BOSCHpump).....................................

--Model78/106KW/hp--typeF4CE9484L*J600 (BOSCHpump).....................................

--Maximumtorque:Model56/76KW/hp-typeF4CE9484A*J600(BOSCHpump)

--Maximumtorque:Model63/86KW/hp-typeF4CE9484N*J601(BOSCHpump)

--Maximumtorque:Model71/97KW/hp-typeF4CE9484M*J601(BOSCHpump)

--Maximumtorque:Model78/106KW/hp-typeF4CE9484L*J600(BOSCHpump)

Maximumtorquespeed 1300rpm

Numberofmainbearings 5

Sumppan............................................. structural,castiron (overleaf)

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2 SECTION10--ENGINE--CHAPTER1

104mm Pistonstroke.......................................... 132mm Totaldisplacement:

4485cm3 Compressionratiomod.56/76,63/86,71/97and78/106kW/hp 16,5:1

Pistondiameter --Model56/76,63/86,71/97and78/106KW/hp

--Model56/76,63/86,71/97and78/106KW/hp

MaximumPowerOutput:

56kW(76hp)

63kW(86hp)

71kW(97hp) 78kW(106hp)

Maximumpowerspeed ................................. 2300rpm

324(Nm)

366(Nm)

404(Nm) 425(Nm)

(overleaf)

GENERALSPECIFICATIONS 4Cylinders

Lube forced,withlobepump

Pumpdrive............................................ fromcrankshaft

Enginespeed/oilpumpspeedratio

Oilfiltration............................................ meshscreenonoilpick--upand filtercartridgeindeliveryline Normaloilpressurewithmotorwarmed--up

Cooling coolantcirculation

RadiatoronMod.56/76,63/86,71/97and78/106KW/hp... three--rowverticalpipes

Fan,attachedtothepulley............................... intake,inplasticwith10blades

Coolantpump.......................................... centrifugalvane--type

Coolantthermometer...................................

Temperaturerangescorrespondingtoeachsection:

--Initialbluesection.....................................

--Middlegreensection(normalworkingconditions)

colouredscaledividedintothreesections

°÷ 60 °

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SECTION10--ENGINE--CHAPTER1 3

atslowidling........................................... NA atfastidling........................................... NA

C 60°÷ 110 °C 110°÷ 120 °C TemperatureControl.................................... viathermostatvalve

2 °C

Intake: --start:BeforeT.D.C................................... NA --end:afterB.D.C. NA Exhaust: --start:beforeB.D.C.................................. NA --end:afterB.D.C. NA EGR (*): --start:BeforeT.D.C................................... NA --end:afterT.D.C. NA Clearancebetweenvalvesandrockerarmswithenginecold: --intake............................................. 0.30

0.05mm --exhaust 0.55

--finalredsection...................................... 0.05mm (overleaf)

--initialopening

ValveTiming

.......................................... overheadvalvesoperatedbytappets,rods androckerarmsviathecamshaftlocated intheengineblock;thecamshaftisdriven bythecrankshaftusingstraight--tooth gears

(overleaf)

GENERALSPECIFICATIONS 4Cylinders

Boostfeeding Withintercooler

Turbochargertype:

--NA NA

Airfiltering............................................. dualcartridgedryairfilter,withclogged filterindicatorwithcentrifugalpre--filter andautomaticdustejector

Fuelpump............................................. withdoublediaphragm

Fuelfiltration........................................... throughwirefilterinfuelsupplypump,and replaceablecartridgeondeliverylineto injectionpump

Camoperated ......................................... viaenginetiming

BOSCHInjectionpump................................. rotatingdistributortype

All--speedgovernor,incorporatedinpump:

BOSCH.............................................. centrifugalcounterweights

Automaticadvanceregulator,incorporatedinpump:

BOSCH............................................... hydraulic

Fixedadvance(pumpsettingonengineforstartofdelivery beforeTDC)...........................................

refertothedatagiveninthetablefor operation14.page53

Type:.................................................

(*) Secondprofileoftheexhaustcamthatpermitspartialopeningoftheexhaustvalvesimultaneouslywiththe intakevalve(exhaustgasrecirculationEGR).

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4 SECTION10--ENGINE--CHAPTER1

Refuelling Engineoilsump 8.9litres Enginesump+filter 9.5litres

Anti--pollutionsystem

Exhaustgasrecirculationsystem EGR

(*)

ENGINER.I.

DANGER

Liftandhandleallheavypartsusingsuitablelifting equipment. Makesurethatassembliesorpartsaresupportedby meansofsuitableslingsandhooks.Ensurethat no--oneisinthevicinityoftheloadtobelifted.

ATTENTION

Usesuitabletoolstoaligntheholes.NEVERUSE FINGERSORHANDS.

1.Removethebonnet(1)asdescribed,see section90.

2.Disconnectthebatterynegativecable.

3.Draintheoilfromthetransmission--gearbox housing.

4.Removetheretainingbolts(1)andtheguard(2) ontheright--handsideofthefan,thenremovethe fourboltsretainingthemechanicalbattery cut--outswitch(1)fromtheguard.

5.Unscrewthecontrolunitmemoryfusepower cable(1)withtherelatedpositivecables(2)from thebatterycut--outswitch.

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16 SECTION10--ENGINE--CHAPTER1

6.Detachthefitting(3)ofthereturnpipe(2)forthe coolantfromthecabheaterradiatorconnectedto theundersideofthecoolantpump(1)anddrain offtheenginecoolant.

7.Removethecatch(2)anddetachthetoolbox(1).

8.Removethesplitpins,retainingpinandfront ballastassembly(1)fromthesupport.

25038 1 6

9.Unscrewthefrontcentralandrearretainingbolts onthefrontaxleshaftguard,thenremovethe guard(1).

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25039 1 2 7

10.Removethecirclip(2)andmovethefrontsleeve (1)inthedirectionindicatedbythearrowuntilit isreleasedfromthegrooveonthefrontaxle.

25040 1 2 8

11.Removethecirclip(2)andmovetherearsleeve (1)inthedirectionindicatedbythearrowuntilit isreleasedfromthegrooveonthedrive.

1 25041 9

12.Removethepropellershaftcentralsupport(1) retainingboltsandextracttheshafttogetherwith thesupport.

13.Removetheretainingbolts(1)ofthedrawpipe (2)oftheliftpump. Onthesamesideofthemachine,ontheleft, unscrewtheunderlyingoilpipesand,ifthereare clampsonthemscrewedontotheframe, unscrewthemtofreethepipesfromtheframe.

--Unscrewthenozzleoildeliverypipeonthe high--pressurepump.

--Onthepowersteeringpump,unscrewtheoil hosedeliveringoiltothepowersteeringcontrol valve.

--Againontheleft--handsidebehindthe connectionbetweentheclutchcasingand engine,onthecontrolvalveofthegearbox(if thereisahydraulicgearbox)orontheservices controlvalve,unscrewthedeliveryandreturn pipestothecoolerandthesupplypipetothe controlvalve.

--Stillintheareaofthelatter,unscrewthesecond partofthefrontdifferentiallockpipe.

14.Removethetwometalclamps(2)andtherigid pipe(1)fordrawingoilfromthetransmissionvia thepumpsoftheliftandpowersteering,remove thepipe.

Onthesamesideofthemachine,ontheright, unscrewtheunderlyingoilpipesand,ifthereare clampsonthemscrewedontotheframe, unscrewthemtofreethepipesfromtheframe.

--Highpressureusersupplypipe,removethepipe.

--Onthegearboxfilter,removethedeliverytothe gearboxcontrolvalveandextractthepipe,then removethefiltertoo.

--Againonthegearboxfilter,removethepower steeringoutlethosetothefilter(inthecaseofthe hydraulictransmission)orremovethesupply pipetotheservicescontrolvalve(inthecaseof themechanicaltransmission)thenremovethe pipe.

15.Extracttheplasticfasteners(2)anddetachthe dieselrecoverypipe(3)anddeliverypipe(4)to thedieselpump(1).

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16.Disconnecttheelectricalconnections(1)ofthe enginemaincablefromthecabcable.

17.Disconnectalltheelectricalconnections(1) locatedonthecabmaincableandconnectonthe engineusers.

18.Disconnectthetwopowersteeringoildelivery andreturnhoses(1),removethepipe.

19.Removethefrontdifferentiallockunion(1)and thehose(2)togetherwiththepipedisconnected intheoperation13.

20.Removetheretainingclips(1)anddetachthe flexiblecablesgoverningthehandthrottle(5)and pedalthrottle(4).

21.Removetheretainingclip(3)anddetachthe throttlecontroltie--rod(2)connectedtothe injectionpump.

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20 SECTION10--ENGINE--CHAPTER1

22.Detachtheclamp(1)andthecabheaterdelivery pipe(2).

23.Takeoutthethreeexhaustsilencerrearretaining bolts(1).

24.Removetheclamp(1),theairfilterdustejector pipe(2)andthefournuts(3)securingthe silencertotheexhaustmanifold.

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25.Removethesilencer(2)togetherwiththe exhaustpipe(1).

26.Removethetwoclips(2)forretainingtothe support(3)andthebrakefluidreservoir(1).

27.Removethetworetainingbolts(1)andthe support(2)togetherwiththerelays(3)protecting thesystem.

28.Removethetworetainingbolts(1)andthe supporttogetherwiththefuse--holderbox(2).

32.Disconnectthecloggedfiltersensor,loosenthe clampsanddetachthepipesontheairfilter: --airdeliverytotheturbo(1),(rememberalsoto disconnectthepipeontheoilvapourrecovery filterthatwillremainconnectedtothedelivery pipe)

--pneumaticbrakingcompressorintake(2),(if installed)

--ejector(3)thenrecoveryit takeoutthescrews(4),removetheairfilter.

22 SECTION10--ENGINE--CHAPTER1

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29.Removethefourrearretainingbolts(1)ofthe bonnetsupport(2).

30.Removethethreefrontretainingbolts(1)ofthe bonnetsupport(2).

31.Detachthebonnetsupport(1).

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33.Loosentheairdeliveryretainingclamp(1)onthe turboandextractthepipe.

34.Loosentheairdeliverypipeclamp(1)fromthe turbototheair/airexchanger;performthesame operationontheleft--handairsupplypipe,from thecoolertotheintakemanifold.

35.Loosentheclampontheturbothenextractthe pipe,ontheleft--handsideloosentheoneonthe intakemanifoldrecoveringthepipe.

36.Removethecoolantcompensationboxfromthe support. Unscrewtheretainingbolts(1)ontherightand left,thenremovethecooler.

thesupport(3)togetherwiththedryerfilter(1) andpipes.

section50withoutdetachingpipes(2)and(3)so asnottothenhavetorecover,evacuateand chargethegasintheairconditioningsystem.

24 SECTION10--ENGINE--CHAPTER1

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1 2 3 33

37.Removethetworetainingbolts(2)anddetach

38.Unhookthetoppin(1)retainingthecondenser.

39.Turnthesteeringwheelfullytotheleft,remove theradiatorofthecondenser(1)fromthesame sideofthetractor.

40.Removethecompressor(1)asdescribedin

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41.Removethecondenserradiator(1)thedryer filter(2)withitssupportandthecompressor(3), restingthemalongsidetheright--handrearwheel withtheassociatedpiping.

42.Loosenthecorrespondingretainingclampsand extractthetoppipebetweentheradiatorandthe thermostaticvalveontheengine.

43.Loosentheretainingclamp(2)andextractthe pipe(1)joiningthecoolantpumptothebottomof theradiator.

44.Removethetworetainingbolts(1)andthebrake pipingsupport(2).

45.Removethethreeretainingbolts(2)andthe left--handsideguard(1)oftheenginefan.

46.Workingfromthesideofthestartermotor(1), removetheretainingnut(2)andtheprotective cablehousing(3).

47.Removetheretainingnut(1)andtheelectrical cable(2)connectedtothefuse--holderboxand thepositivecablebetweenthemotorandbattery cut--out.

Disconnectalltheconnectionsoftheenginemain cable(onthebrakepumppressureswitches,on thebrakeoilcup,onthecoolanttemperature sensor,enginespeed,engineoilpressure,grid heater, ........)cuttheplasticclampsandremove themetalones,recovertheelectricalsystem.

48.Removethefourknobs(1)andtakeoffthetwo right--andleft--handdashboardpanels(2).

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MDD2562A 1 2 44

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25043 1 2 45

49.Extractthedifferentiallockpedalretainingpin(in thecaseofstandardmachines)fromthedrive shaft(1),removethepedalandfootboard(2).

50.Removethefourplugs(1)inordertogainaccess totheengineupperretainingbolts.

51.Usingthewrench(1),removethetwonutsand twoboltsfasteningtheenginetothe transmission,gainingaccessviathefourslotsin theplatform(2).

52.Hitchtheenginetothehoistwiththechains(1) anchoringittotheattachments(2)ontheengine.

53.Positionafixedstand(2)undertheclutch housing(1)neartheengineattachmentflanging andapplythehandbrake.

54.Positionthemovabletoolfordismantlingtractors 380000569 (2)withthebracket 380000500 and adapterplate 380000844 undertheengineand placeawoodenblock(1)inbetweenthepointsof contactbetweenthetoolandtractor.

transmissiononthetanksideusingthe19mm wrench(1)shownalongside.

thebottomandside.

28 SECTION10--ENGINE--CHAPTER1

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1 2 MODD1771A 50

55.Removethetwoboltsfasteningtheenginetothe

56.Removetheremainingsixretainingbolts(1)at

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25050 1 2 53

57.Separatetheengine(1)fromthetransmission withthetool 380000569 (2).

1 2 25056 54

58.Insertthefixedstand(1)undertheballastsupport andsecurethefrontwheelswithwooden blocks(2).

59.Positionafixedstand(3)underthesupportofthe groove(1)ofthefrontaxledriveplacingawooden plug(2)betweentheparts(3)and(1).

60.Fittheliftingeyelet(1)inthethreadingonthe support(2).

61.Insertthehooksoftheliftingchains(1)inthe eyeletsshowninthefigure,afterwardstensioning thechainswiththehoist.

62.Removethefourbolts(2)fasteningthefrontaxle support(1)totheengine(3).

63.Detachtheengine(2)fromthefrontaxle(3), tryingtoavoidincorrectoperationswiththehoist soasnottolettheenginefandamagethefinsof theradiator(1),leftontheaxle(3).

64.Thenresttheengine(2)onaplatformsupport.

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30 SECTION10--ENGINE--CHAPTER1

65.Torefittheengine,proceedasfollows:

ATTENTION

Usesuitabletoolstoaligntheholes.NEVERUSE FINGERSORHANDS.

--Respectthetighteningtorquesprescribedon page6.

--Insertthethreehooksofthechainintheeyelets ontheengineand,usingthehoist,liftthe assemblyofftheplatformsupport.

--Positiontheengineonthefrontaxle,tryingto avoidincorrectoperationswiththehoistsoasnot tolettheenginefandamagethefinsofthe radiator,thenjointhetwoassembliestogether withthefourretainingbolts.

--Repositionthemovabletoolfordismantling tractors 380000569 undertheengineandplace awoodenblockinbetweenthepointofcontact betweenthetoolandengine.

--Withtheaidofthehoist,placetheengineonthe tool 380000569 andremovetheliftingeyelet previouslyfittedonthefrontoftheengine.

--Removethefixedstandpreviouslypositioned underthesupportofthegrooveofthedriveofthe frontaxleandthewoodenplug.

--RemovethefixedU--boltfittedbeforehandunder theballastsupportandthetwowoodenwedges lockingthefrontwheels.

--Removetheoldsealingpastefromthetwo surfacesbetweentheengineandclutchcasing.

--ApplyLOCTITEsealingcompoundonthe engine/clutchcasingcontactsurfaces.

--Positionwoodenblocksundertherearwheels, makesurethatthehandbrakeisfullyappliedand thatallfixedandmobilestandsaresafely positioned.

--Theinstallationphasedescribedhererequires thepresenceoftwoorthreeworkerstousethe movabletoolfordismantlingtractors 380000569

tomovetheengine/frontaxleassemblycloseto theclutchcasing.

--Inthephaseofinstallingtheengine/frontaxle assemblytotheclutchcasing,itisnecessaryto pushonthefrontwheels,takinggreatcareinthe endphaseofcouplingoverboththepipesandthe cables/electricalconnectionstopreventcrushing betweenthetwobodies.Duringthisphase,itis moreovernecessarytoturnthecrankshaftwith theaidoftheradiatorcoolingfantohelpthe couplingbetweenthesleeveandthedriveshaft.

--Securebothassembliesbytighteningallthebolts lockingtheenginetotheclutchcasing.

--Disconnectthehoistchains,removetheU--bolt previouslyfittedundertheclutchcasingand recoverthemovabletoolfordismantlingtractors 380000569

--Refitthe4plugsontheplatformandrefitthe footboardand,inthecaseofstandardmachines, refitthelockpedal.

--Refitthetwocabinetsundertheinstrumentpanel withthe4knobs.

--Refitthespecificelectriccableoftheengine,bind itwiththeplasticclampsandwiththerelated metalclamps,refittherelatedplasticguardson thestartermotortoo.

--Refitthefanguardontheleft--handside.

--Refitthebrakepipesupport.

--Refitthetwocylinderblock/radiatorconnecting pipes,topandbottom,withthemetalclamps.

--Installthecompressorasdescribedinsection50 togetherwiththepipes.

--Refitthecondenserradiatortogetherwiththe pipesandreconnectthetopcondenserretaining pin.

--Refitthedryerfiltertogetherwithitssupportand piping,tighteningthetworetainingbolts.

--Refittheair/aircoolerwiththemetalpipesand sleeves,tighteningthemwiththemetalclamps.

SECTION10--ENGINE--CHAPTER1 31

87679925A --12--2007

--Refittheairfilter,ejectorpipe,deliverypipetothe turbowiththepipeontheoilvapourrecovery filter,andtheairbrakescompressorintakepipe (ifinstalled),tightenthemetalclamps,reconnect theelectricalsystemtothecloggedfiltersensor.

--Refitthebonnetsupport,tighteningtheretaining bolts.

--Refitthesupportwiththefuse--holderboxonthe bonnetsupport,tighteningthetworetainingbolts.

--Refitthesupporttogetherwiththerelays protectingthesystemonthebonnetsupport, fittingthetworetainingbolts.

--Refitthebrakefluidreservoirontothesupport andthetworetainingclips.

--Refitthesilencertogetherwiththeexhaustpipe.

--Securethesilencertotheexhaustmanifoldwith thefournutsandconnecttheairfilterdust extractorpipetothesilencerexhaust,inserting theretainingclamp.

--Refitthethreerearretainingboltsoftheexhaust silencer.

--Fitthecabheaterdeliveryandreturnpipesand inserttheassociatedclamps.

--Installtheflexiblecablesgoverningthehandand pedalthrottle,insertingtheretainingclips.

--Reconnectthethrottlecontroltie--rodtothe injectionpump,insertingtheretainingclip.

--Refitthehosetogetherwiththefrontdifferential lockpipe.

--Reconnecttherightandleftsteeringhosestothe frontaxle.

--Reconnectallthepinsofthecabmainelectrical systemtotheusersontheengine.

--Reconnecttheenginecablemainconnectionto thecab.

--Reconnectthedieselrecoveryanddeliverypipes tothepump.

--Positionandreconnecttheoilpipes(describedin operation14.)ontheright--handside,takingcare totightentheclampstotheframe.

--Positionandreconnecttheoilpipes(describedin operation13.)ontheleft--handside,takingcare totightentheclampstotheframe.

--Refitthepropellershaftwithitscentralsupport andtheretainingbolts.

--Refitthefrontaxledriveshaftguard,tightening thefront,centralandrearretainingbolts.

--Refitthefrontballasttogetherwiththesupport andinserttheretainingpinandthesplitpins.

--Refitthetoolboxandthecatch.

--Refitthepositivecablesandthecontrolunit memorycableonthemechanicalbatterycut--out switch.

--Refitthebatterycut--outswitchontheguardon theright--handsideofthefan,refittheguard tighteningthethreeretainingbolts.

--Refilltheoilfromthetransmission/gearboxand thecoolantintheradiator.

--Installthebonnetasdescribed,seesection90.

--Reconnectthebatterynegativecable.

87679925A --12--2007

32 SECTION10--ENGINE--CHAPTER1

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CRANKSHAFTFRONTSEAL Renew

DANGER

Liftandhandleallheavypartsusingsuitablelifting equipment.

Makesurethatassembliesorpartsaresupportedby meansofsuitableslingsandhooks.Ensurethat no--oneisinthevicinityoftheloadtobelifted.

Toaccesstheseal,proceedasfollows:

1.Removethebonnet(1)asdescribed,see section90,anddisconnectthebatterynegative cable.

2.Removetheradiatorofthecondenser(1),see section50,withouthoweverremovingthe condensergasdelivery/returnpipessoasnotto recover/rechargethesystemrefrigerantgas.

3.Removeradiator(1),asdescribedinthissection onpage59.

SECTION10--ENGINE--CHAPTER1 33

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34 SECTION10--ENGINE--CHAPTER1

87679925A --12--2007

4.Loosenthepivotscrews(2)andlockscrews(1) ofthetightener(3).

5.Loosenthebolt(2)tensioningthebelt(1)and removethebelt.

6.Removethesixretainingbolts(1),thepulley(2) governingtheaccessoryassembliesandthe fan--alternator--coolantpumppulley(3). 7.Applytool 380000665 (4)onthefronttang(2)of thecrankshaft. 8.Perforatetheinnerseal(1)withadrillbit (∅ 3.5mm)throughtheguideholesofthetool 380000665 (4),foradepthof5mm. 9.Securethetool 380000665 (4)totheseal(1)by screwingdownthescrews(3)supplied. 10.Extracttheseal(1)byscrewingdownthescrew (5).

MIF0916A

11.Fitthetierod(3)ofthetool 380000669 tothe outerseal(1)asshowninthefigureandwiththe lever(4),extractitfromthefrontcover(2).

12.Toassemble,proceedasfollows:

Tofitthefrontsealonthecrankshaft,proceedas follows:

--Fitpart(4)oftool 380000666 onthefrontshank (3)ofthecrankshaft.Secureitwiththescrews(5) andsplinethenewseal(6)ontoit.Positionpart (1)onpart(4),screwdownthenut(7)untilthe seal(6)iscompletelyfittedinthefrontcover(2).

--Fitthefan--alternator--coolantpumppulley,the accessoryassemblypulleyandthesixretaining bolts.

--Refitthetransmissionbeltonthepulleys,adjust itwiththetensioningscrewandlockthetightener, tighteningthetworetainingandpivotscrews.

--Refittheengineradiatorasdescribedinthe operationinthissectiononpage59.

--Refitthecondenserradiator,seesection50.

--Reconnectthebatterynegativecableandclose thebonnet.

SECTION10--ENGINE--CHAPTER1 35 87679925A --12--2007

Usesuitabletoolstoaligntheholes.NEVERUSE FINGERSORHANDS. MIF0917A 67

ATTENTION

MIF1001A 68

CRANKSHAFTREARSEAL Renew DANGER

Liftandhandleallheavypartsusingsuitablelifting equipment.

Makesurethatassembliesorpartsaresupportedby meansofsuitableslingsandhooks.Ensurethat no--oneisinthevicinityoftheloadtobelifted.

Toaccesstheseal,proceedasfollows:

1.Removetheclutchasdescribedinsection18.

87679925A --12--2007

36 SECTION10--ENGINE--CHAPTER1

2.Removetheeightscrews(1)fixingtheengine flywheel(2). 3.Screwtwopins(2)oftheappropriatelengthinto theholesinthecrankshaft(3). Slightlyextracttheengineflywheel(1)soitcanbe slungandthenputdowninaspecificwooden containerwiththehoist.

MIF1116A 4.Applytool 380000663 (3)ontherearshank(1)of thecrankshaft.

5.Perforatetheinnerseal(5)withadrillbit (∅ 3.5mm)throughtheguideholesofthetool 380000663 (3),foradepthof5mm.

6.Securethetool 380000663 (3)totheseal(5)by screwingdownthescrews(2)supplied.

7.Extracttheseal(5)byscrewingdownthescrew (4).

8.Toassemble,proceedasfollows:

ATTENTION

Usesuitabletoolstoaligntheholes.NEVERUSE FINGERSORHANDS.

Tofitthefrontsealonthecrankshaft,proceedas follows:

9.Fitpart(6)oftool 380000664 ontherearshank (3)ofthecrankshaft.Secureitwiththescrews(1) andsplinethenewseal(2)ontoit. Positionpart(5)onpart(6),screwdownthenut (4)untiltheseal(2)iscompletelyfittedinthe flywheelcasing.

10.Withahoistandappropriateslinging,insertthe engineflywheel(1)onthepins(2)described above,pushingitintocontactwiththecrankshaft (3).

SECTION10--ENGINE--CHAPTER1 37 87679925A --12--2007

MIF0927A 72

MIF1145A 73

MIF1116A 74

11.Manuallytightenthebolts(2)retainingthe flywheel(1)tothecrankshaft.

12.Tightenthebolts(1)securingtheengineflywheel (2)intwosuccessivestagesasdescribedon page6:

1st phase,tighteningwithtorquewrenchtoa torqueof30 ± 5Nm;

2nd stage,angleclosed605 ± 5°

NOTE: Angleclosingisperformedwithtool 380001001

13.Installtheclutchasdescribedinsection18.

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38 SECTION10--ENGINE--CHAPTER1

MIF1115A 75

MIF1146A 76

VALVETAPPETANDROCKERARM CLEARANCE Adjustment

ATTENTION

Handleallpartscarefully.Donotputyourhandsor fingersbetweenparts.Weartheprescribedsafety clothing,includinggoggles,glovesandsafety footwear.

1.Removethebonnet(1)asdescribed,see section90.

2.Disconnectthebatterynegativecable.

3.Removetheplasticretainingclamps,fromthe cabheaterwaterdelivery--returnpipes(2)and thoseoftheelectriccables(1),movingthepipes andcablesonthecompressorasdescribedinthe figure.

4.Removetheretainingboltandthefronttappet inspectioncover(1)togetherwiththecoverbase seal.

SECTION10--ENGINE--CHAPTER1 39

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87679925A

5.Removethetworetainingbolts(3)andthecentral tappetinspectioncover(2)togetherwiththe enginevapourintakepipe(1)andthecoverbase seal.

6.Removetheretainingboltandthereartappet inspectioncover(1)togetherwiththecoverbase seal.

7.Aftertakingoffthecovers,adjusttheclearance betweentherockerarmsandvalvesusingan Allenwrench(1),boxwrench(2)andfeelergauge (3).

Theworkingclearanceshouldbe:

=0.25 ± 0.05mm

=0.50 ± 0.05mm.

8.Takethecylinderwheretheclearanceistobe adjustedintotheend--of--compressionphase; thevalvesinthecylinderareclosed,whilstthose onthesymmetricalcylinderarerocking.

--Thesymmetricalcylindersare1--4and3--2.

--FIRINGORDER1--3--4--2

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40 SECTION10--ENGINE--CHAPTER1

inletvalves

exhaustvalves

MIF1016A 82

Balancingvalvesof cylinderno. 1 3 4 2 Adjustvalveclearanceofcylinderno. 4 2 1 3