OFCNHITALIAS.p.a.
Nopartofthetextorillustrations maybereproduced
INTRODUCTION
TEXTANDILLUSTRATIONSARETHEPROPERTY
PRINTEDINFRANCE CNHITALIAS.p.a.--VialedelleNazioni,55--41100MODENA--Italia TECHNICALSUPPORT--TechnicalInformation Printno. 87616423 --01--2007
87616423 --01--2007
RepairManual--TDSeriesTractors
GENERALSECTION00 GeneralInstructionsandHealthandSafetyChapter1 SectionDescriptionPage 00000 Generalinstructions1 Notesforspareparts2 ........................................................... Notesforequipment2 Safetyrules 3 Consumables 6 ENGINESECTION10 EngineSystemChapter1 SectionDescriptionPage 10000 Generalspecification2 Injectionpumpcalibrationdata5 ................................................... Generalspecifications16 ........................................................ Tighteningtorques24 Tools 25 Cross--sectionalviews28 Lubricationandcoolingsystemdiagrams32 Faultdiagnosis 35 1000110 Engine Removal--Installation 39 1000154 Engine Benchoverhaul 53 ....................................................... Checks,measurementsandrepairs78 ............................................. 1040610 Radiator Removal--Installation 102 ................................................ 1010270 Crankshaftfrontoilseal removalinstallation 106 1040210 Coolantpump removalinstallation 112 1040230 Coolingsystemthermostat115 1020614 Boschinjectionpump removalinstallation 118 Boschinjectionpump timing 121 Boschinjectionpump airbleeding 123 ............................................. 1021830 Injectors removalinstallation 124 ..................................................
NEW HOLLAND
CONTENTS
87616423 --01--2007 1010612 Valveclearanceadjustment126 1040228 Coolantpumpoverhaul129 ...................................................... 1000130 Compressiontest130 CLUTCHSECTION18 ClutchesChapter1 SectionDescriptionPage 18000 Generalspecifications1 Tighteningtorques4 ............................................................. Tools 5 ......................................................................... Cross--sectionalviews6 ClutchTroubleshooting8 1811010 Removal--Installation9 Overhaul 17 Minimumpermissibledimensionsafterrefacing21 .................................. Adjustments 22 1810040 AdjustmentofthemainandPTOclutchcontrollinkage24 GEARBOXSECTION21 MechanicalTransmission(12x4)Chapter1 SectionDescriptionPage 21000 Maindata 1 ..................................................................... Tighteningtorques2 ............................................................. Tools 3 Sectionviews 3&5 Descriptionandoperation8 Faultdiagnosis 8 ................................................................ 21110 Removal--Refittingseesect27 .................................................. Reverser(12x12)Chapter2 SectionDescriptionPage 21000 Maindata 1 Tighteningtorques2 Tools 3 Sectionviews 3 .................................................................. Descriptionandoperation5 ....................................................... Faultdiagnosis 5 21110 Removal--Refitting6 ReverserandCreeper(20x12)Chapter3 SectionDescriptionPage 21000 Maindata 1 Tighteningtorques2 ............................................................. Tools 3 Sectionviews 3 Descriptionandoperation5 Faultdiagnosis 5 ................................................................ 21110 Removal--Refitting6 ..............................................................
DRIVELINESSECTION23
DriveLinesChapter1
SectionDescriptionPage
23000
Mainspecification1 ..............................................................
TorquesettingsandTools2
Cross--Sectionalviews3 2310126
Transmissionshaftsandguard(Disassembly--Assembly)4 2310140
Drivegearhousingremoved(Disassembly--Assembly)7
Drivegearhousing(Removal--Installation)5 ........................................ 2310142
FRONTAXLEMECHANICALTRANSMISSIONSECTION25
FrontAxleMechanicalTransmissionChapter1
SectionDescriptionPage
25000 Maindata 1 .....................................................................
Tighteningtorques4
Tools 6
Cross--sectionalviews7
Descriptionandoperation9 .......................................................
2510030
2510846--47
Frontaxle.Removal--Installation14
Completefrontaxle.Removal--Installation10 2510038
Steeringknucklebearingpins.Replacement24
Stubaxleadjustment25 .........................................................
Wheelhubbearingadjustment27 .................................................
Beveldriveadjustment29
2510224
2510027
Frontaxledifferential.Overhaul36
FrontaxledifferentialwithLIM--SLIP.Overhaul37 ...................................
FrontaxledifferentialwithNOSPIN.Overhaul39 .................................... 4451180
Leadingdrivewheelstoe--incheck42
REARAXLEANDTRANSMISSIONSECTION27
RearAxleAndTransmissionChapter1
SectionDescriptionPage
27000 Maindata 1
Tighteningtorques3
Specialtools 5
Cross--sectionalviews7 ..........................................................
Descriptionandoperationandtroubleshooting9 21.118.10--12
Transmission--gearboxcasingDisassembly--Overhaul27
Transmission--gearboxcasingRemoval--Installation10 21.118.85
Gearboxdrivenshaftendfloatadjustment35 .......................................
Differentiallockengagementsleeveadjustment36 ..................................
Determiningthebevelpinionpositioningadjustmentring37
Adjustingthetaperrollerbearingsforthebevelpinionshaft39
Adjustingthebearingsandcheckingthebacklash40 ................................
Differentialpinionandsidegearbacklashadjustment44 ..............................
87616423 --01--2007
87616423 --01--2007 POWERTAKE--OFFSECTION31 MechanicalPowerTake--OffChapter1 SectionDescriptionPage 31000 Mainspecification1 Tools 3 ......................................................................... Torquesettings 4 Sectionaldrawings5 Descriptionandoperation10 ..................................................... Troubleshooting 12 Removal--Refitting13 31101 Benchoverhaul 16
BrakingSystemChapter1 SectionDescriptionPage 33000 Maindata 1 ..................................................................... Tighteningtorques2 Cross--sectionalviews2 .......................................................... Description&Operation9 Tools--Troubleshooting10 33.206 Frontbrakeassemblymod.TD60DandTD70Dremovalandrefitting-overhaulingonthebench11 33.202.60 Servicebrakeremovalandrefitting14 33.202.50 Removal--Refittingoffrontbrakepumps19 33.202.40 Bleedingairfromthefrontbrakingsystem23 ....................................... 33.120.08 Adjustingservicebrakepedalstravel24 33.110.08 Parkingbraketraveladjustment24
RearMechanicalHydraulicLiftChapter1 SectionDescriptionPage 35000 Mainspecification1 Tighteningtorques3 ............................................................ Tools 6 Cross--sectionalviews7 Description&Operation9 ........................................................ Hydrauliccircuit 9 Descriptionandoperationofliftphases10 Faultdiagnosis 13 .............................................................. 35110.30 Hydrauliclift--disassemblyreassembly15 35.110.40--42--46 Hydrauliclift--benchoverhaul21 Adjustingthelift26 .............................................................. 35.110.08 Linkageadjustment32 35.110.30 Pressurereliefvalve--disassemblyreassembly34 .................................. 35.110.32 Pressurereliefvalve--setting34 35.110.14 Liftcontrolvalve--disassemblyassemblyandoverhaulonbench36 35.0101.10 Liftpump 41 ....................................................................
BRAKINGSYSTEMSECTION33
HYDRAULICSYSTEMSECTION35
87616423 --01--2007 OpenCentreSystemAuxiliaryControlValvesChapter2 SectionDescriptionPage 35000 Maindata--Tools 1 Auxiliarycontrolvalves--sectionalviews2 .......................................... Descriptionandoperation3 Faultdiagnosisseechapter1 3520446 Auxiliarycontrolvalves--Assembly--Disassembly7 Spoolbindingtest15 ............................................................ Spoolleakagetest16 Adjustmentoftheautomaticdetentreleasepressure17 TrailerBrakeAuxiliaryControlValveChapter3 SectionDescriptionPage 35000 Sectionviews 1 Descriptionandoperation1 Hydraulicdiagram2 Descriptionandoperationofvalvephases3 Trailerbrakeauxiliarycontrolvalvelinkageadjustment6 STEERINGSECTION41 SteeringChapter1 SectionDescriptionPage 41000 Principaldata 1 Tighteningtorques3 Sectionviews 4 Hydraulicdiagram6 Operation 7 Faultdiagnosis 9 ................................................................ Tools 6 4120430 Hydrostaticsteeringcontrolvalve--Removal--Installation11 4120434 Hydrostaticsteeringcontrolvalve--Disassembly--Assembly14 4120438 Hydrostaticsteeringcontrolvalve--Benchtesting28 ................................ Hydrostaticsteeringoilpump--Disassembly--Assembly30 4121620 Steeringcylinder(two--wheeldriveaxle)--Removal--Refitting32 Steeringcylinder(fourwheeldriveaxle)--Removal--Refitting33 FRONTAXLEANDWHEELSSECTION44 FrontAxleAndWheelsChapter1 SectionDescriptionPage 44000 Principaldata 1 .................................................................. Sectionalviews 3 Torquesettings 3 Equipment--Faultdiagnosis5 ..................................................... 4410130 Removal--Refitting--Overhaul6 4410122 Wheelhubdisassembly--assembly9 4410146 Stubaxleoverhaul16 4410180 Checkingwheelalignment20 .....................................................
ELECTRICALSYSTEMSECTION55
87616423 --01--2007
AuxiliaryUnitsChapter1 SectionDescriptionPage 50000 Safetyinstructions2 .............................................................. Generalcharacteristics3 ......................................................... Equipment 4 .................................................................... Operatingprinciples5 ............................................................ Faultdiagnosis 7 Cabcontrols 11 Use 14 Maincomponentsofthecabairconditioningsystem15 Refrigerantrecovery--recyclingandevacuation--chargingstations20 5020004 Dryingrechargingandcheckingcooling22 5020003 Functionaltestingofairconditioningsystem27 Summaryofthecabair--conditioningsystemchargingoperations28 Checkingforrefrigerantleaksusinganelectronicleakdetector30 Summaryoffaultdiagnosisandmaintenance31 Airconditioningandheatingpipes--Replacement33 5020004--74 Receiver--drier--Replacement36 5020004--72 Condenser--Replacement38 5020004--26 Compressor--Removal--Refitting39 5020010 Compressordrivebelttensionadjustment41
AUXILIARYUNITSSECTION50
InstrumentsChapter1 SectionDescriptionPage 55418 Analogueinstrumentsandintroduction1 Transmitterandswitches4 ........................................................ ComponentsChapter2 SectionDescriptionPage 55500 Introduction 1 Componentdescription1 StartingSystemChapter3 SectionDescription Page 55000 Technicalinformation1 Tighteningtorques1 Descriptionandoperation2 ....................................................... Startingcircuit 3 Systemtests 5 55201 Removalandre--installationofstartermotor8 Servicing 9 ...................................................................... Benchtests 10 .................................................................
--Generaldiagrams(W/Cab)9
--Generaldiagrams(W/OutCab)15
--Analogueinstrumentcircuitandconnectoroverview19
--Start--upcircuitandconnectoroverview21 .................................
--Directionindicator&hazardwarninglightcircuitandconnectoroverview25
--Windscreenandrearwindowwiper/washercircuitandconnectoroverview31
--Brakelightcircuitandconnectoroverview35 ...............................
--Heatingandair--conditioningsystemcircuitandconnectoroverview41
--Worklamp(withoutcabcircuitandconnectoroverview)45
--Worklamp(withoutcabcircuitandconnectoroverview)49
--Sidelights,mainanddippedheadlights,parkinglightcircuitandconnector overview53
BODYWORKANDDRIVERPOSITIONSECTION90
87616423 --01--2007
SectionDescriptionPage
55000 Technicalinformation1 Tighteningtorques1 Descriptionandoperation2 Systemtestingandtrouble--shooting4 55301 Removal,re--installationandservicing10 BatteryChapter5 SectionDescription Page 55000 Technicalinformation1 Descriptionandoperation1
55.301.040 Removalandre--installation2 Batterycheckingandmaintenance3 Chargingthebattery4 Batteryproblems--Frequentcauses7 ElectricalCircuitsChapter6 SectionDescriptionPage SectionDescription Page 55100 Contents 1 Fuses(allversions)2 Symbolsusedinelectricalcircuits4 ................................................ Electricalwirecolourcoding5 Groundlocations 5 Electricaldiagrams...............................................................
ChargingSystemChapter4
..............................................................
.......................................................
90000 Disassembly--Assembly1
BodyworkAndDriverPositionChapter1 SectionDescriptionPage ..............................................................
GENERALINSTRUCTIONS IMPORTANTNOTICE
AllmaintenanceandrepairoperationsdescribedinthismanualshouldbecarriedoutexclusivelybytheNEW HOLLANDauthorisedworkshops.Allinstructionsdetailedshouldbecarefullyobservedandspecialequipment indicatedshouldbeusedifnecessary.
Everyonewhocarriesoutserviceoperationsdescribedwithoutcarefullyobservingtheseprescriptionswillbe directlyresponsibleofderivingdamages.
SHIMMING
Ateachadjustment,selectadjustingshims,measurethemindividuallyusingamicrometerandthensumup recordedvalues.Donotrelyonmeasuringthewholeshimmingset,whichmaybeincorrect,oronratedvalue indicatedforeachshim.
ROTATINGSHAFTSEALS
Tocorrectlyinstallrotatingshaftseals,observethefollowinginstructions:
--Letthesealsoakintothesameoilasitwillsealforatleasthalfanhourbeforemounting;
--Thoroughlycleantheshaftandensurethattheshaftworkingsurfaceisnotdamaged;
--Placethesealingliptowardsthefluid.Incaseofahydrodynamiclip,considertheshaftrotationdirectionand orientgroovesinorderthattheydeviatethefluidtowardstheinnersideoftheseal;
--Coatthesealinglipwithathinlayeroflubricant(oilratherthangrease)andfillwithgreasethegapbetween thesealinglipandthedustlipofdoublelipseals;
--Insertthesealintoitsseatandpressitdownusingaflatpunch.Donotapthesealwithahammeroradrift;
--Takecaretoinsertthesealperpendicularlytoitsseatwhileyouarepressingit.Oncethesealissettled,ensure thatitcontactsthethrustelementifrequired.;
--Topreventdamagingthesealinglipagainsttheshaft,placeasuitableprotectionduringinstallation.
ORINGS
LubricatetheOringsbeforeinsertingthemintotheirseats.ThiswillpreventtheOringsfromrollingoverand twineduringmountingwhichwilljeopardisesealing.
SEALERS
Applyoneofthefollowingsealers:RTVSILMATE,RHODORSILCAF1,orLOCTITEPLASTICGASKETover thematingsurfacesmarkedwithanX.
Beforeapplyingthesealer,preparethesurfaceasfollows:
--removepossiblescalesusingametalbrush;
--thoroughlydegreasethesurfacesusingoneofthefollowingcleaningagent:trichlorethylene,petrolorawater andsodasolution.
BEARINGS
Itisadvisabletoheatthebearingsto80to90°Cbeforemountingthemontheirshaftsandcoolthemdownbefore insertingthemintotheirseatswithexternaltapping.
ROLLPINS
Whenfittingstraightrollpins,ensurethatthepinnotchisorientedinthedirectionoftheefforttostressthepin. Coilrollpinscanbeinstalledinanyposition.
87616423 --01--2007
SECTION00--GENERAL--CHAPTER1 1
NOTESFORSPAREPARTS
Useexclusively genuineNEWHOLLANDspareparts,theonlyonesthatguaranteesamequality,life,safety asoriginalcomponentsastheyarethesameasmountedinproduction. Only genuinespareparts canofferthisguarantee.
Allsparepartsordersshouldbecompletewiththefollowingdata:
--tractormodel(commercialname)andframenumber;
--enginetypeandnumber;
--partnumberoftheorderedpart,whichcanbefoundonthe“Microfiches”orthe“SparePartsCatalogue”, whichisthebasefororderprocessing.
NOTESFOREQUIPMENT
EquipmentwhichNEWHOLLANDproposesandshowsinthismanualareasfollows:
--studiedanddesignedexpresslyforuseonNEWHOLLANDtractors;
--necessarytomakeareliablerepair;
--accuratelybuiltandstrictlytestedtoofferefficientandlong--lastingworkingmeans.
WealsoremindtheRepairPersonnelthathavingtheseequipmentmeans:
--workinoptimaltechnicalconditions;
--obtainbestresults;
--savetimeandeffort;
--workmoresafely.
NOTICES
Wearlimitsindicatedforsomedetailsshouldbeintendedasadvised,butnotbindingvalues.Thewords“front”, “rear”,“righthand”,and“lefthand”referredtothedifferentpartsshouldbeintendedasseenfromtheoperator’s seatorientedtothenormalsenseofmovementofthetractor.
HOWTOMOVETHETRACTORWITHTHEBATTERYREMOVED
Cablesfromtheexternalpowersupplyshouldbeconnectedexclusivelytotherespectiveterminalsofthetractor positiveandnegativecablesusingpliersingoodconditionwhichallowproperandsteadycontact.
Disconnectallservices(lights,wind--shieldwipers,etc.)beforestartingthetractor.
Ifitisnecessarytocheckthetractorelectricalsystem,checkitonlywiththepowersupplyconnected.Atcheck end,disconnectallservicesandswitchthepowersupplyoffbeforedisconnectingthecables.
87616423 --01--2007
2 SECTION00--GENERAL--CHAPTER1
SAFETYRULES
PAYATTENTIONTOTHISSYMBOL
Thiswarningsymbolpointsoutimportantmessagesinvolvingpersonalsafety. Carefullyreadthesafetyrulescontainedhereinandfollowadvisedprecautionsto avoidpotentialhazardsandsafeguardyoursafetyandpersonalintegrity.
Inthismanualyouwillfindthissymboltogetherwiththefollowingkey--words:
WARNING --itgiveswarningaboutimproperrepairoperationsandderivingpotential consequencesaffectingtheservicetechnician’spersonalsafety.
DANGER --itgivesspecificwarningaboutpotentialdangersforpersonalsafetyofthe operatororotherpersonsdirectlyorindirectlyinvolved.
TOPREVENTACCIDENTS
Mostaccidentsandpersonalinjuriestakingplacein workshopsareduefromnon--observanceofsome simpleandessentialprudentialruleandsafetyprecautions.Forthisreason,INMOSTCASESTHEY CANBEAVOIDED.Itsufficestoforeseepossible causesandactconsequentlywithnecessarycaution andcare.
Thepossibilitythatanaccidentmightoccurwithany typeofmachinesshouldnotbedisregarded,nomatterhowwellthemachineinquestionwasdesigned andbuilt.
Awiseandcarefulservicetechnicianisthebestprecautionsagainstaccidents.
Carefulobservanceofthisonlybasicprecaution wouldbeenoughtoavoidmanysevereaccidents.
DANGER: Nevercarryoutanycleaning,lubrication ormaintenanceoperationswhentheengineisrunning.
SAFETYRULES GENERALITIES
◊ Carefullyfollowspecifiedrepairandmaintenanceprocedures.
◊ Donotwearrings,wristwatches,jewels,unbuttonedorflappingclothingsuchasties,torn clothes,scarves,openjacketsorshirtswithopen zipswhichcouldgetholdintomovingparts.We advisetouseapprovedsafetyclothingsuchas anti--slippingfootwear,gloves,safetygoggles, helmets,etc.
◊ Nevercarryoutanyrepaironthemachineif someoneissittingontheoperator’sseat,except
iftheyarecertifiedoperatorstoassistinthe operationtobecarriedout.
◊ Neveroperatethemachineoruseattachments fromaplaceotherthansittingattheoperator’s seat.
◊ Nevercarryoutanyoperationonthemachine whentheengineisrunning,exceptwhenspecificallyindicated.
◊ Stoptheengineandensurethatallpressureis relievedfromhydrauliccircuitsbeforeremoving caps,covers,valves,etc.
◊ Allrepairandmaintenanceoperationsshouldbe carriedoutwiththegreatestcareandattention.
◊ Servicestairsandplatformsusedinaworkshop orinthefieldshouldbebuiltincompliancewith thesafetyrulesinforce.
◊ Disconnectthebatteriesandlabelallcontrolsto warnthatthetractorisbeingserviced.Blockthe machineandallequipmentwhichshouldbe raised.
◊ Nevercheckorfillfueltanksandaccumulator batteries,norusestartingliquidifyouaresmokingornearopenflamesassuchfluidsareflammable.
◊ Brakesareinoperativewhentheyaremanually releasedformaintenancepurposes.Insuch cases,themachineshouldbekeptconstantly undercontrolusingblocksorsimilardevices.
◊ Thefuelfillinggunshouldremainalwaysincontactwiththefillerneck.Maintainthiscontactuntil thefuelstopsflowingintothetanktoavoidpossiblesparksduetostaticelectricitybuildup.
87616423 --01--2007
SECTION00--GENERAL--CHAPTER1 3
SECTION10--ENGINE--CHAPTER1 1 87616423 --01--2007
CONTENTS SectionDescriptionPage 10000 Generalspecification2 Injectionpumpcalibrationdata5 Generalspecifications16 Tighteningtorques24 Tools 25 Cross--sectionalviews28 Lubricationandcoolingsystemdiagrams32 Faultdiagnosis 35 1000110 Engine Removal--Installation 39 1000154 Engine Benchoverhaul 53 ....................................................... Checks,measurementsandrepairs78 ............................................ 1040610 Radiator Removal--Installation 102 ................................................ 1010270 Crankshaftfrontoilseal removalinstallation 106 1040210 Coolantpump removalinstallation 112 1040230 Coolingsystemthermostat115 1020614 Boschinjectionpump removalinstallation 118 Boschinjectionpump timing 121 Boschinjectionpump airbleeding 123 1021830 Injectors removalinstallation 124 1010612 Valveclearanceadjustment126 .................................................. 1040228 Coolantpumpoverhaul129 ...................................................... 1000130 Compressiontest130 ...........................................................
SECTION10--ENGINE Chapter1--Engine
GENERALSPECIFICATIONS 3cylinders 4cylinders
Enginetype:
--mod.TD60Dnormallyaspirated--type8035.05D.939 (BOSCHpump)....................................... seedatapages 6--7
--mod.TD70Dturbocharged--type8035.25C.939 (BOSCHpump).......................................
--mod.TD80Dnormallyaspirated--type8045.05R.939 (BOSCHpump).......................................
--mod.TD90Dturbocharged--type8045.25.939 (BOSCHpump).......................................
--mod.TD95Dturbocharged--type8045.25L.939 (BOSCHpump).......................................
Cycle..................................................
87616423 --01--2007
2 SECTION10--ENGINE--CHAPTER1
seedatapages 8--9
seedatapages 10--11
seedatapages 12--13
seedatapages 14--15
Diesel,4--stroke
................................ 3
Cylinderliners
--mod.TD60D.......................................... 104mm(4.0945in.)
104mm(4.0945in.)
104mm(4.0945in.)
104mm(4.0945in.) --mod.TD95D.......................................... 104mm(4.0945in.) Pistonstroke........................................... 115mm(4.5276in.) Totaldisplacement: --mod.TD60D--TD70D.................................. 2931cm3 (178.8496in.3) --mod.TD80D--TD90D--TD95D........................... 3908cm3 (238.4662in.3) Compressionratio....................................... 17to1normallyaspirated 16.5to1turbocharged Maximumpower2000/25ECat2500rpm: --mod.TD60D.......................................... 43.4kW(59hp) --mod.TD70D.......................................... 50.7kW(69hp) --mod.TD80D.......................................... 58.8kW(80hp) --mod.TD90D.......................................... 65.5kW(89hp) --mod.TD95D.......................................... 69.1kW(94hp) MaximumpowerECER24at2500rpm: --mod.TD60D.......................................... 41.2kW(56hp) --mod.TD70D.......................................... 47.8kW(65hp) --mod.TD80D.......................................... 55.9kW(76hp) --mod.TD90D.......................................... 63.3kW(86hp) --mod.TD95D.......................................... 66.9kW(91hp) Fastidlingspeed ....................................... 2500rpm. Maximumtorque(daNm)at1500rpm:TD60Dmodel 20.7(152.6753ftlb) Maximumtorque(daNm)at1500rpm:TD70Dmodel ........ 25.0(184.3905ftlb) Maximumtorque(daNm)at1500rpm:TD80Dmodel 27.9(205.9778ftlb Maximumtorque(daNm)at1500rpm:TD90Dmodel 32.0(236.0194ftlb) Maximumtorque(daNm)at1500rpm:TD95Dmodel 33.7(248.5584ftlb) Numberofmainbearings ................................. 4 5 Sump.................................................. Structural,castiron
Fuelinjection........................................... Direct Numberofcylindersinline
4
dryforce--fittedin cylinderblock Pistondiameter
--mod.TD70D..........................................
--mod.TD80D..........................................
--mod.TD90D..........................................
ENGINE
Removal--Installation(Operation1000110)
DANGER
Liftandhandleallheavypartsusingsuitablelifting equipment.
Makesurethatassembliesorpartsaresupportedby meansofsuitableslingsandhooks. Checkthatnooneisinthevicinityoftheloadtobe lifted.
WARNING
Alwaysusesuitabletoolstoalignholesinparts. NEVERUSEFINGERSORHANDS.
39 SECTION10--ENGINE--CHAPTER1
87616423 --01--2007
1. Disconnectthebatterynegativecable.
2. Drainoilfromthetransmission/gearbox.
3. Drainthecoolingsystem.
10 25621 11
1 TRE0601A
4. Unscrewthenut(1)fromtheweightretainingpin.
40 SECTION10--ENGINE--CHAPTER1 87616423 --01--2007 12
1
13
5. Removetheweights(1)fromthefrontsupport.
TRE0602A
1 24872 14
6. Removetheexhaustpipe,attachliftingchainsto thebonnet(1)andattachthechaintothehoist.
1 2 15
7. Disconnecttheelectricalleads(1)from headlamps(2).
24873
1
8. Detachthegasstruts(1)fromthebonnet.
TRE0603A
41 SECTION10--ENGINE--CHAPTER1 87616423 --01--2007 16
1 TRE0604A 17
9. Removethefourbonnethingebolts(1)andlift thebonnetclear.
25028 1 25046 18
10. Removethewiremeshguard(1)fromright-handsideofthefan.
1 19
11. Disconnectthetachometercable(1)and removetheretainingringandsleeve.
1 2 25183
12. Detachthethrottlecontrolspring(1)andremove thethrottlelever(2).
42 SECTION10--ENGINE--CHAPTER1 87616423 --01--2007 20 24892 2 1
21
13. Afterrecoveringtheair--conditionergas(HRC 134a)withthe recoveryandrecyclingstation 294048,disconnectthepipesofthecabair conditioner(1)and(2).
1 2 25411 22
14. Detachthecabheatingpipes(1)and(2).
1 TRE0605A
15. Disconnectthepowersteeringhoses(1).
43 SECTION10--ENGINE--CHAPTER1 87616423 --01--2007 23 1 TRE0606A
24
16. Disconnecttheelectricalconnectors.Detachthe fuseboxbyunscrewingthenut(1).
1
25
17. Disconnectthedeliveryandreturnlines(1)tothe powersteeringcylinders.
TRE0607A
1
18. Removethehose(1)fromtheliftpumpsuction pipe.
TRE0608A
44 SECTION10--ENGINE--CHAPTER1 87616423 --01--2007 26
1
19. Detachtheliftpumpdeliverypipe(1).
27
TRE0609A
20. Detachthefuelpipesfromtheinjectionpump andfuelpumpandthepipeconnectingthetank tothesedimentationfilter.
28
TRE0610A
25035 1
21. Removethefuelfilter(1)completewithitssupport.
45 SECTION10--ENGINE--CHAPTER1 87616423 --01--2007 29
25038 30
22. Removethefront,centreandrearretainingbolts fromthefrontaxledriveshaftguardandremove theguard.
25039 1 2 31
23. Removethecirclip(2)fromthefrontoftheprop shaftandslidethesleeve(1),inthedirection shownbythearrow,untilitisfreeofthesplines onthefrontaxle.
25040 1 2 32
24. Removethecirclip(2)fromtherearoftheprop shaftandslidethesleeve(1),inthedirection shownbythearrow,untilitisfreeofthesplines onthecrankshaft.
25041 1
25. Removethemiddlesupportbolts(1)fromthe propellershaftandremovetheshaftcomplete withsupport.
46 SECTION10--ENGINE--CHAPTER1 87616423 --01--2007 33
1 2 34
26. Withdrawthepinsecuringthedifferentiallock(1) knob,removetheknobandremovethemat(2) fromthefloor. TRE0611A
1 35
27. Unscrewthenuts(1)andtheboltssecuringthe enginetothetransmission.Accessisthrough thetwoslotsinthecabfloor.
TRE0612A
25049 1
28. Unscrewthefourlowerbolts(1)securingthe enginetothetransmission.
47 SECTION10--ENGINE--CHAPTER1 87616423 --01--2007 36 25050 1
37
29. Positionstand 380000236 underneaththetractorandinsertawedge(1),eithersideoftheaxle, topreventtheaxlefrompivoting.
25051 1 38
30. Insertawoodenblockbetweenthestandsand thetractor.
25052 1 39 25055 1
31. Placeafixedstand(1)underneaththedrawbar supportandapplythehandbrake.
32. Unscrewthefourremainingboltssecuringthe enginetothetransmission.
33. Separatetheenginefromthetransmission.
34. Removethespacercollar(1)betweenthe engineandthetransmissionontheTD95D model.
48 SECTION10--ENGINE--CHAPTER1 87616423 --01--2007 40
25056 1 2 41 25057 1 2
35. Placeafixedstand(1)underneaththefront weightsupportandchockthewheelswith woodenwedges(2).
42
36. Insertthepinofkit 380000612 (11”/11”clutch)or thepin 380000292 (12”/12”clutch)(1)intothe centralholeoftheclutch.Unscrewthesixbolts (2)securingtheclutchtotheflywheeland removecompleteclutchassembly.
TRE0613A 1
37. Removetheradiatormountingbolt(1).
49 SECTION10--ENGINE--CHAPTER1 87616423 --01--2007 43
25060 1 44
38. Attachtheenginetothehoistusingan adjustablechain(1)attachedtothelifting pointsprovidedontheengine.
1 TRE0614A 45
39. Removetheliftpump(1)completewithitsfilter byunscrewingthefourretainingbolts.
1 TRE0615A
40. Disconnectallelectricalconnectorsandremove thecompletewiringharness(1).
50 SECTION10--ENGINE--CHAPTER1 87616423 --01--2007 46
TRE0616A 1 47
41. Slackenofthehoseclampanddetachhose(1) fromtheinletmanifold.
1 TRE0617A 48
42. Removetheleft--handsidefanguard(1).
1 TRE0618B 49
43. Unscrewthebolts(1)securingthesilencertoits bracket.
44. Undothehoseclampanddisconnectthetop radiatorhose(1).
TRE0613B 1
45. Unscrewthethreenutssecuringthesilencerto themanifoldandliftofftheentiresilencerassembly.
Tore--installtheengine,proceedasfollows:
—Attachthethreehooksofanadjustablelifting chaintothethreeeyeboltsontheengine.Raise theenginefromtheplatformandpositionitin frontofthefrontaxlesupport.Jointhetwounits usingthefoursecuringbolts.
—Repositionthemoveablestandfromunderthe frontaxledifferentialhousingtoundertheengine sump,insertingasuitablyshapedblockofwood betweenthestandandthesumppan.
—Attachthetopradiatorhosetothethermostat housingandsecurewithanadjustablehose clamp.
—Connectthebottomradiatorhosetothecoolant pumpandsecureatbothendswithadjustable hoseclamps.
—Refitthefuelpump.
—Detachtheliftingchainfromtheengine.
—Connecttherigidpipefromtheaircleanertothe inletmanifoldandsecurewiththerelativeclamp.
—Reconnectallelectricalleads:thermostart glowplug,coolanttemperaturesensor,‘air filterblocked’sensor,horn,frontaxlesupport earth,enginestoponinjectionpump,leadsto thealternatorandrelay,oilpressuresensor, startermotor,fueldryerfilter.Secureallleads withplasticties.
—Fittheclutchbackonwiththeaidofkit 380000612 (11”/11”clutch)orpin 380000292 (12”/12”clutch).Fixclutchtotheengineflywheelusingthesixretainingbolts.
—Reconnecttheoildeliverypipetothe4WD controlvalve.Tightenthepipeuniononthe anti--cavitationaccumulator;fixthebracketon theleft--handsideneartheengineoilfilter.
—Cleanthedistancecollarandthematingsurfacesoftheoverdriveclutchhousing;scrape awayalltracesofoldsealingcompound.
—ApplyLOCTITEsealingcompoundtothe matingsurfacesofengineanddistancecollar. Fitthedistanceringontheenginestuds.
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46. Usingthehoist,raisetheengineslightlyand positionthemoveablestand(1)underthefront axle.
47. Undothehoseclampanddisconnectthebottom radiatorhose(1).
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48. Unscrewthefourbolts(2)securingtheengineto thefrontaxlesupport,andlowertheengineonto awoodenplatform.
—ApplyLOCTITEsealingcompoundtothemating surfacesoftheoverdriveclutchhousing.
—Removethefixedstandfromunderthefront weightsupport.Removethewoodenwedgesfrom underthefrontwheels.
—Attachtheadjustableliftingchaintotheeyebolts ontheengine.
—Placewoodenwedgesundertherearwheels, checkthatthehandbrakeisfullyonandthatthe fixedandmoveablestandsarefirmlyinplace.
—Detachtheliftingchainfromtheengine.Connect thetwowiresstillattachedtothecabhandrailto thehookofthehoist.Raisethefrontpartofthe cababout6cm.
—Replaceandtightenalltheboltssecuringthe enginetotheoverdriveclutchhousing.
—Boltthebrakepipesupportbrackettotheright-handsideoftheengine.Lowerthehoistanddetachthecablesfromthecabhandrail.
—Lowerthestandsundertheenginesumpandthe clutchhousing.Removetool 380000236 andthe standfromunderthedrawbarsupport.
—Fixthecabinplacewiththetwofrontsecuring bolts.
—Connecttheinjectorleak--offpipe.Connectthe pipestotheglowplugandtothefueldryerfilter.
—Refitthefuelfiltermountingtotheengine.Connect thetwosemi--rigidpipestothemounting.
—Connecttheoilsuctionpipestothepumps; securetherubberhoseswithhoseclamps.
—Connecttherigidliftcontrolvalvesupplypipetothe relativepump,rememberingtofirstfittheO--ring.
—Securethethreepipeswiththeadjustablehose clamp.
—Connectupalltheelectricalleadstothe connectorsontheverticalsupportbracket.
—Fitthecabheaterpipeunionontheengine/ clutchdistancecollar.Connecttherubberheater hosestotheunionand,ifnecessary,restorethe gasintheair--conditioningsystemwithtool 294030
—Connectthetwoflexiblepowersteeringpipesto theunionontheleft--handsideofthefrontaxle. Securethetwopipeswiththespecialclampand screwtheclamptothetractor.
—Fitthetachometercableandsecurethesleeve withtheretainingring.
—Fitthesilencerontotheexhaustmanifold, rememberingtoreplacethegasseal.Fixthe frontofthesilencertotheverticalsupport bracket.AttachtheflexibleDONASPINpipe.
—Attachthebonnetstaybrackettotheradiator bracket.
—Refitthe4WDpropellershaftandtheguard.
—Re--connectthethrottlecabletotheaccelerator pedal.Itmaybenecessarytoadjustthecableat theinjectionpumpleverend.
—Refittheclutchcabletotheclutchpedal.Fixthe sleevetothetravelstop.
—Replacetheplasticplugsintheholesinthecab floor.Replacethemat.
—Refitthesteeringcolumncoverpanels.
—Replacethewiremeshfanguards.
—Attachslingstothebonnetinthemannerdescribedpreviouslyintheengineremovalinstructions.Screwthebonnethingetoitsbracket.Attachthegasstrut,theelectricalleadstothe headlampsandthenremovetheslings.
—Refitthesecondarybracket(batterysupport)to theoverdriveclutchhousing.Fittherotating bracketwiththebatterytothefixedsupport.
—Refitthefrontweightsandsecurewiththelock pin.
—Refitthetoolboxsupportbracketandthenthe toolbox.
—Fillthetransmission/gearboxandpowersteeringunitwithoil.
—Filltheradiatorwithcoolant.
—Connectthebatterypositiveandnegativeleads. Replacetheplasticbatterycover.
87616423 --01--2007
52 SECTION10--ENGINE--CHAPTER1
.
WARNING
Handleallpartscarefully.Donotputyourhandsor
53 SECTION10--ENGINE--CHAPTER1 87616423 --01--2007 52
Removal--Installation(Operation1000154) 25070
ENGINE
fingersbetweenparts. Wearsuitablesafetyclothing,safetygoggles,gloves andfootwear.
1 53
1. Removethefrontandrearretainingscrewsfrom thebonnetstaybracket(1).
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2. Removethebonnetcatchsupportsideretaining bolts(1)andbackretainingbolts(2)takeoffthe bonnetcatchandthebonnetstaybracket.
3. Loosenthealternatorpivotbolt.
4. Loosenthebelttensionadjustmentbolt(1).
5. Releasethebelttensionadjustmentarmby unscrewingtheretainingnut.
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6. Removethealternatorandcoolantpumpdrive belt.
25073 1
7. Unscrewtheboltssecuringthefan(1)andpulley tothecoolantpump.Removethefanandpulley.
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54 SECTION10--ENGINE--CHAPTER1 87616423 --01--2007 56 25074
1 57
8. Unscrewtheunion(1)fromthewatersupplypipe tothecabheater.
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9. Loosenthehoseclamp(1)anddetachthehose fromthecoolantpump.Removethecurvedhose andflexiblecabheaterhoses.
25077 1 59
10. Removetheunion(1)inordertogainaccessto thepumpretainingbolt.
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11. Unscrewthecoolantpumpretainingbolts(1) andremovethepump.
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1 61 25079 1
12. Unscrewthepumpsupportbolts(1)andthe silencersupportbolt.Removethetwosupports.
3 2 62 25080 1
13. Fitmountingbracket(1)oftheset 380000313 to permitattachmentoftheenginetotherotary stand 380000201
14. Fitaneyebolt(1)onthefrontoftheenginein placeofthesilencersupport.
63
15. Raisetheenginefromthewoodenplatformand moveittotherotarystand 380000301 (2).Secureittothestandbymeansofthebracket(3) oftheset 380000313.
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16. Undothealternatorsupportretainingbolts(1) andremovethecompletealternatorassembly.
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17. Unscrewthebolts(1)securingtheexhaust manifoldtothecylinderheadandremovethe manifold.
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18. Detachthethrottlecontrollever(1)fromthe injectionpump.
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19. Removethethermostathousingretainingbolts (1)andremovethethermostathousing.
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20. Unscrewthehighpressurefuellineunions(1)on theinjectionpumpandremovethefuellines.
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21. Unscrewthebolts(1)securingtheinletmanifold tothecylinderheadandremovethemanifold.
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22. Unscrewtheunions(1)onthefuelsupplypump anddetachthefuellines.
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23. Unscrewthenuts(1)securingtheinjectionpump tothetiminggearcase.
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24. Undoscrews(1)andremovetheinjectionpump drivegearcover.
