TN55D--TN55S--TN65D--TN65S--TN70D --TN70S--TN75D--TN75STRACTORS SERVICEMANUAL CROSS--SECTIONALVIEWS GENERALGUIDELINES00 ...................................................... ENGINE 10 ..................................................................... CLUTCH 18 ..................................................................... TRANSMISSIONS21 ............................................................ DRIVELINES 23 ................................................................ FRONTMECHANICALTRANSMISSION25 ........................................ REARMECHANICALTRANSMISSION27 ......................................... POWERTAKE-OFF31 .......................................................... BRAKES 33 ..................................................................... HYDRAULICSYSTEMS35 ....................................................... STEERING 41 ................................................................... AXLEANDWHEELS44 .......................................................... CABAIRCONDITIONINGSYSTEM50 ............................................ ELECTRICALSYSTEM55 ........................................................ PLATFORM,CAB,BODYWORK90 ............................................... SERVICE
INTRODUCTION
Thismanualisdividedintosectionsidentifiedbytwo--figurenumbersandeachsectionhasindependent pagenumbering.
Foreasyreference,thesesectionshavethesamenumbersandnamesastheRepairsRateBooksections. Thedifferentsectionscaneasilybefoundbyconsultingthetableofcontentsonthefollowingpages.
Thedocumentnumberofthemanualandtheedition/updatedatesaregivenatthebottomofeachpage.
Pagesupdatedinthefuturewillbeidentifiedbythesamedocumentnumberfollowedbyatwo--figureupdate number(e.g.:1 st Update603.54.350.01;2 nd Update603.54.350.02;etc.)andbythecorrespondingissue date.
Thesepageswillbesupplementedbyareprintoftheupdatedcontentspage.
Theinformationcontainedinthismanualwascurrentonthedateprintedoneachsection.AsNEWHOLLANDconstantlyimprovesitsproductrange,someinformationmaybeoutofdatesubsequenttomodificationsimplementedfortechnicalorcommercialreasons,ortomeetlegalrequirementsindifferentcountries. Intheeventofconflictinginformation,consulttheNEWHOLLANDSalesandServiceDepartments.
IMPORTANTWARNINGS
AllmaintenanceandrepairworkdescribedinthismanualmustbeperformedexclusivelybyNEWHOLLAND servicetechnicians,instrictaccordancewiththeinstructionsgivenandusinganyspecifictoolsnecessary.
Anyoneperformingtheoperationsdescribedhereinwithoutstrictlyfollowingtheinstructionsispersonally responsibleforanyeventualinjuryordamagetoproperty.
TheManufacturerandallorganisationsbelongingtotheManufacturerísdistributionnetwork,includingbut notrestrictedtonational,regionalorlocaldistributors,willacceptnoresponsibilityforpersonalinjuryordamagetopropertycausedbyabnormalfunctionofpartsand/orcomponentsnotapprovedbytheManufacturer, includingthoseusedformaintenanceand/orrepairoftheproductmanufacturedormarketedbytheManufacturer.
Inanycase,theproductmanufacturedormarketedbytheManufactureriscoveredbynoguaranteeofany kindagainstpersonalinjuryordamagetopropertycausedbyabnormalfunctionofpartsand/orcomponents notapprovedbytheManufacturer.
TEXTANDILLUSTRATIONSARETHEPROPERTY OFNEWHOLLANDITALIAS.p.A. Nopartofthetextorillustrations maybereproduced PRINTEDINITALY CNHITALIAS.p.A.--VialedelleNazioni,55--41100MODENA--Italy SERVICE--TechnicalPublications&SpecialTools PrintNo. 603.54.351.01 --03--2002--400
CONTENTS 3 603.54.351.01 --03--2002 CONTENTS PageDate 00--GENERALGUIDELINES Generalinstructions .....1--209--98 Safetyregulations .......3--409--98 Safetyregulations .......503--02 Consumables...........603--02 10--ENGINE Summary...............103--02 Generalspecifications ....2--3--403--02 Fuelsystemdata ........503--02 Fuelsystemdata ........1209--98 Injectionpumpcalibration andengineperformance data...................603--02 Injectionpumpcalibration andengineperformance data...................7--8--9--10-1109--98 Engineblockdata.......1209--98 Crankshaftdata.........13--1409--98 Connectingroddata .....1409--98 Pistondata.............1503--02 Timinggeardata ........1603--02 Timinggeardata ........1709--98 Cylinderheaddata ......1809--98 Lubricationandcooling systemdata ............1903--02 TighteningTorques ......2003--02 Tools..................21--2203--02 Cross--sectionalviewsof engine .................23--2409--98 Lubricationdiagrams .....2509--98 Enginecoolingsystemdiagram...................2609--98 Troubleshooting .........27--28--29-3009--98 EngineRemoval--Installation....................31--3209--98 Compressiontest........3309--98 PageDate EngineDisassembly--Assembly.................34--35--36-37--38--39-40--41--42-43--44--45-46--47--48-49--5009--98 Checksandmeasurements--cylinderblockand liners..................51--5209--98 Checksandmeasure-
Checksandmeasure-
Checksandmeasurements--pistons.........58--59--6009--98 Checksandmeasure-
andvalves..............61--62--6309--98 Checksandmeasure-
Re--facingvalveseats....6503--02 Checksandmeasure-
Checksandmeasure-
Checksandmeasure-
Replacingvalveguides...69--70--7109--98
Boschinjectionpump....8009--98 Removal--Installation Boschinjectionpump....81--8203--02 Boschinjectionpump--tim-
ments--crankshaft,bearingsandflywheel ........53--54--55-5609--98
ments--connectingrods.5709--98
ments--camshaft,tappets
ments--cylinderhead ....6409--98
ments--lubricationsystem6603--02
ments--lubricationsystem6709--98
ments--coolingsystem..6809--98
Replacinginjectorsleeves andsupport .............72--7309--98 Removal--Installation-crankshaftfrontseal.....74--7509--98 Valveclearanceadjustment...................76--7709--98 Removal--Installation--injectors.................78--7909--98 Removal--Installation
ing....................83--8403--02
CONTENTS
PageDate
Boschinjectionpump--air bleeding ................8509--98
Exhaustpipe.Removal-Refitting................8609--98
Removal--Refitting--coolantpump...............8709--98
Coolantpumpoverhaul...8809--98
Removal--Refitting--thermostatvalve............89--9009--98
Removal--Refitting--radiator....................91--92--93-9409--98
Injectionpumpcalibration andengineperformance data...................95--9603--02
18--CLUTCH
Mainspecifications......1--203--02
TighteningTorques ......203--02
Tools..................2--303--02
Cross--sectionalviews...3--403--02
Troubleshooting .........503--02
Removal--Refitting--clutch6--11--12-13--14--1503--02
Removal--Refitting--clutch7--8--9--1009--98
ClutchOverhaul .........1603--02
ClutchOverhaul .........17--18--19-2009--98
Checksandmeasurements--clutch..........21--2209--98
Adjustments--clutchdisengagementlever .........22--2309--98
Adjustments--clutchpedal2409--98
PTOcontroladjustment..2503--02
SectionalviewofPTO clutchservocontrol......2603--02
Descriptionandoperation ofPTOservocontrol.....27--2803--02
PTOservocontroladjustment...................2903--02
PTOengagedswitchadjustment................3003--02
21--TRANSMISSIONS
CHAPTER1--Transmissionandrangegear (16x16)
Mainspecifications......1--209--98
TighteningTorques ......2--309--98
Tools..................4--5--6--709--98
Cross--sectionalviews...8--9--10--1109--98
DescriptionandOperation1209--98
Troubleshooting .........12--1309--98
Removal--Refitting--Rear transmission--gearbox casing.................14--15--16-17--18--19-2009--98
Disassembly--Assembly-transmission--gearboxcasing....................21--22--23-24--25--26-27--2809--98
Gearboxdrivinganddriven shaftsclearanceadjustment...................2903--02
Sealingcompoundapplicationdiagram............3003--02 Gearboxcontrollever.Removal--Refitting.........3109--98
Rangegearcontrollever. Removal--Refitting.......3209--98 Shuttlecontrollever. Removal--Refitting.......3309--98 Fueltank.Removal-Refitting................34--3509--98
CHAPTER2--Mechanicaltransmission andsplitter
Mainspecifications......1--209--98
TighteningTorques ......209--98
Tools..................209--98
Cross--sectionalviews...3--4--509--98
DescriptionandOperation609--98
Troubleshooting .........709--98
Splitterdeviceandcreeper unitcasing,shaftsand bearingsdisassembly ....8--9--1009--98
603.54.351.01 --03--2002
4
PageDate
......309--98
.........1209--98
CONTENTS 5 603.54.351.01 --03--2002
Mainspecifications......1--203--02 TighteningTorques
Tools..................4--5--609--98 Cross--sectionalviews...7--8--9--1109--98 Cross--sectionalviews...1003--02 Clutchcontrolpressuretest1003--02 DescriptionandOperation1209--98 Troubleshooting
Disassembly--Assembly--
Disassembly--Reassembly
Disassembly--Assembly--
Gearboxcontrolvalvesole-
ting....................19--2009--98 Disassembly--Assembly-clutchcasing............21--22--23-2409--98 Disassembly--Assembly-clutchcasing............2503--02 Faultscodedecoding....2603--02 Calibration..............27--28--29-30--31--32-33--34--35-36--37--38-39--40--41-42--43--44-4503--02 Firststart--upprocedure..4603--02 Diagnostics
PowerShuttlecontrolunit input/outputwiringdiagram150--151--
Descriptionandoperation ofthecontrolunit........154--155-156--157-15703--02 PageDate CHAPTER4--Mechanicaltransmission
Mainspecifications......109--98 TighteningTorques ......109--98 Tools..................109--98 Cross--sectionalviews...2--3--409--98 CHAPTER4--PowerShuttletransmission
Mainspecifications......109--98 TighteningTorques ......209--98 Cross--sectionalviews...3--4--5--609--98 23--DRIVELINES Mainspecifications......103--02 TighteningTorques ......203--02 Tools..................3--403--02 Cross--sectionalviews...5--6--709--98 DescriptionandOperation8--909--98 Troubleshooting .........909--98 Driveshaftsandguard. Disassembly--Assembly.10--11--1209--98 Removal--Refitting--drive gearcasing .............13--1409--98 Disassembly--Assembly-drivegearcasing ........15--16--17-1809--98 Faultscodedecoding....1903--02 Calibration..............20--21--22-23--24--25-26--2703--02 Firststart--upprocedure..2803--02 Diagnostics .............29to6603--02 PTOcontrolunitinput/outputwiringdiagram.......68--6903--02 25--FRONTMECHANICALTRANSMISSION CHAPTER1--Frontmechanicaltransmission (supersteeraxle) Mainspecifications......1--203--02 Mainspecifications......309--98 TighteningTorques ......4--5--609--98
PageDate CHAPTER3--PowerShuttletransmission with2SpeedPowerShift
transmission--gearboxcasing....................13--1409--98
--PowerShuttlecontrol valve..................15--16--1709--98
accumulator............1809--98
noidvalve.Removal--Refit-
.............47to14803--02
152--15303--02
(8+8NASOversion)
(16+16and8+8versions)
CONTENTS
PageDate
Tools..................7--803--02
Tools..................909--98
Cross--sectionalviews...10--11--12-1309--98
DescriptionandOperation13--1403--02
Troubleshooting .........1509--98
Removal--Refitting--front axle...................16--17--18-1909--98
Removal--Installation-frontaxlebeveldrivesupportanddifferential......20--21--22-2309--98
Overhaul--frontaxlebevel drive...................24--2509--98
Adjustments--beveldrive26--27--28-29--30--3109--98
Overhaul--frontdifferential3209--98
Overhaul--differentiallock unit....................33--34--3509--98
Disassembly--Assembly-frontepicyclicfinaldrive withbrake..............36--37--38-3909--98
Disassembly--Assembly-frontepicyclicfinaldrive..40--4309--98
Disassembly--Assembly-frontepicyclicfinaldrive..41--4203--02
Disassembly--Assembly-wheelhubsandsteering knuckle................4409--98
Adjustments--steering knucklebearings ........4509--98
Replacingsteeringknuckle pinsandbearings .......4609--98
CHAPTER2--Frontmechanicaltransmission
Mainspecifications......1--203--02
Mainspecifications......309--98
TighteningTorques ......3--409--98
Tools..................5--603--02
Cross--sectionalviews...7--803--02
DescriptionandOperation8--909--98
Troubleshooting .........1009--98
Removal--Refitting--front axle...................11--12--13-1409--98
Frontaxle.Disassembly-Assembly..............15--16--17-18--19--20-21--22--2309--98
Overhaul--differentiallock unit....................24--2509--98
Replacingsteeringknuckle pinsandbearings .......2609--98
Adjustments--steering
603.54.351.01 --03--2002
6
PageDate
knucklebearings ........27--2809--98 Adjustments--beveldrive29--3003--02 Adjustments--beveldrive31--32--33-34--3509--98 Overhaul--frontdifferential3609--98 LIM--SLIPself--lockingdifferential................37--3809--98 Checkingleadingwheels alignment..............3903--02 Disassembly--Assembly-frontepicyclicfinaldrive..40--4103--02 Disassembly--Assembly-frontepicyclicfinaldrive withbrake..............42--43--4403--02 27--REARMECHANICAL TRANSMISSION Mainspecifications......1--203--02 TighteningTorques ......3--403--02 Tools..................5--6--7--809--98 Cross--sectionalviews...9--1009--98 DescriptionandOperation11--1209--98 Troubleshooting .........12--1309--98 Disassembly--Assembly-transmission--gearbox casing.................14--15--16-17--18--1909--98 Adjustment--differential lockengagementsleeve position................2009--98 Adjustments--beveldrive21--2203--02 Adjustments--beveldrive23--24--2509--98
Removal--Refitting-sidegearcasing .........26--27--28-2909--98
Disassembly--Assembly-drivewheelshaft ........29--30--3109--98
Disassembly--Assembly-epicyclicreductiongear..3109--98
31--POWERTAKE--OFF
CHAPTER1--Mechanicalpowertake--off Mainspecifications......1--2--303--02
Tools..................3--403--02
TighteningTorques ......5--609--98
Cross--sectionalviews...7--809--98
DescriptionandOperation9--10--1109--98
Troubleshooting .........1109--98
Disassembly--Assembly-powertake--off..........12--13--14-1509--98
33--BRAKES
Mainspecifications......1--209--98
TighteningTorques ......209--98
Cross--sectionalviews...3--403--02
Cross--sectionalviews...509--98
Tools..................5--609--98
DescriptionandOperation609--98
Troubleshooting .........7--809--98
Removal--Refitting--servicebrake..............9--1009--98
Removal--Refitting--servicebrakepump.........11--12--13-1409--98
Adjustments--service brakepedalstravel ......15--1609--98
Servicebrakecircuitair bleeding ................16--17--1809--98
Removal--Refitting--parkingbrake...............19--2009--98
Adjustments--parking handbraketravel ........2009--98
35--HYDRAULICSYSTEMS
CHAPTER1--Rearmechanicalhydrauliclift Mainspecifications......1--2--309--98
TighteningTorques ......3--409--98
Tools..................5--609--98
Cross--sectionalviews...7--8--9--10-1109--98
DescriptionandOperation12--13--14-1509--98
Troubleshooting .........1609--98
Troubleshooting .........1703--02
Liftinternalcontrols.Disas-
CONTENTS 7
603.54.351.01 --03--2002 PageDate
PageDate
sembly--Assembly......18--19--20-2103--02 Adjustingthelift.........22--3103--02 Adjustingthelift.........23--24--25-26--27--28-29--3009--98 Liftcylinderandarmsshaft. Disassembly--Assembly.3203--02 Liftcylinderandarmsshaft. Disassembly--Assembly.33--34--3509--98 Disassembly--Assembly-liftcontrolvalve.........36--37--3809--98 Disassembly--Assembly-liftcontrolvalve.........3903--02 Liftpressurereliefvalve..4003--02 CHAPTER2--Opencentresystemauxiliary controlvalves Mainspecifications......203--02 Tools..................203--02 TighteningTorques ......203--02 Cross--sectionalviews...3--4--509--98 DescriptionandOperation5--6--7--809--98 Liftelectroniccontrolunit. Replacement...........909--98 Controlvalves.Disassembly--Assembly..........10--11--1209--98
CONTENTS
PageDate
CHAPTER3--Trailerbrakesauxiliarycontrol valves
Cross--sectionalviews...109--98
DescriptionandOperation1--2--3--4--5 --6--709--98
Troubleshooting .........8--9--1009--98
Removal--Refitting--trailer brakevalve.............1109--98
CHAPTER4--Electronicallycontrolled hydrauliclift
Mainspecifications......2--303--02
TighteningTorques ......409--98
Tools..................4--5--609--98
Cross--sectionalviews...7--8--909--98
Locationofparts........10--1109--98
DescriptionandOperation12--13--14-15--16--17-1809--98
Removal--Installation--lift.19--20--21-22--2309--98
Draftsensorsupport. Removal--Refitting.......2409--98
sor....................28--29--3009--98
Electronicallycontrolled hydrauliclift.Disassembly --Assembly.............31--32--33-34--3509--98
Removal--Installation--hydrauliccontrolvalve......3609--98
Hydrauliccontrolvalve. Disassembly--Assembly.37--3809--98
Hydrauliccontrolvalve. Disassembly--Assembly.3903--02
Liftcalibration...........40--4103--02
603.54.351.01 --03--2002
8
Replacement--controlunit2509--98 Liftarmpotentiometer.Replacement..............26--27
Replacement--draftsen-
09--98
Connectingcalibrationinstrument 294084 tothelift diagnosissocket ........4203--02 Faultscodedecoding....4303--02 PageDate Electronicliftcalibration..44--45--46-47--48--49-50--51--52-53--54--55-5603--02 Firststart--upprocedure..5703--02 Diagnostics .............58to14503--02 Electronicliftcontrolunit input/outputwiringdiagram146--14703--02 CHAPTER5--Non--stopflowgearpump Mainspecifications......2--309--98 Diagrams...............309--98 DescriptionandOperation309--98 Disassembly--Assembly-liftoilpump.............409--98 CHAPTER6--ElectronicliftandfrontPower Take--Off Mainspecificationsoffront lift.....................1--2--303--02 TighteningTorques ......3--4--503--02 Cross--sectionalviewsof implementlinkage.......6--703--02 Cross--sectionalviewsof frontPTO..............8--9--1003--02 DescriptionandOperation11--12--13-14 03--02 Frontlifthydraulicdiagram1503--02 Frontlifttroubleshooting..16--1703--02 Removal--Refitting--Front powertake--offtransmissionshaft...........18--19--20-21--22--23-24--2503--02 Disassembly--Assembly-FrontPTOtransmission shaft...................2603--02 FrontPTOcasingcross-sectionalview ...........2703--02 Removal--Refitting--Front PTOelectromagnetic coupling................28--29--3003--02 Disassembly--Assembly-FrontPTOelectromagnetic coupling................31--32--33-34 03--02
Removal--Refitting--Front liftsupport ..............35--36--3703--02
FrontPTOfaultcodesdecoding.................3803--02
FrontPTOcalibration....39--40--41-42--43--44-45--4603--02
FrontPTOfirststart--up..4703--02
FrontPTOtroubleshooting48to6203--02
Frontelectronicliftcalibration....................63--6403--02
Connectingcalibrationinstrument 294084 tothelift diagnosissocket ........6503--02
Frontliftfaultcodesdecoding....................6603--02 Frontelectronicliftcalibration....................67--68--69-70--71--72-73--74--75-76--77--78-7903--02
Frontelectroniclifttroubleshooting ................81to12603--02
FrontPTOcontrolunit input/outputwiringdiagram128--12903--02
Frontelectronicliftcontrol unitinput/outputwiringdiagram..................130--13103--02
41--STEERING
CHAPTER1--Steering Mainspecifications......209--98
TighteningTorques ......209--98
Tools..................209--98
DescriptionandOperation3--4--509--98
Viewofhydrostaticsteering controlvalvecomponents.609--98
Troubleshooting .........7--809--98
CONTENTS 9 603.54.351.01
--03--2002 PageDate
Replacement--hydrostatic steeringwheel
Removal--Refitting--hydrostaticsteeringcontrolvalve10--11--1209--98 PageDate Disassembly--Assembly-hydrostaticcontrolvalve..13--14--15-16--17--18-19--20--21-22--23--24-25--26--2709--98 Hydrostaticsteeringcontrol valvebenchtesting ......28--2909--98 Pressurereliefvalvetesting3009--98 CHAPTER2--Non--stopflowgearpump Mainspecifications......1--209--98 Diagrams...............309--98 DescriptionandOperation409--98 Disassembly--Assembly-hydrostaticsteeringoil pump..................503--02 44--AXLESANDWHEELS Mainspecifications......1--203--02 Frontwheeltrackdiagram203--02 Cross--sectionalviews...309--98 TighteningTorques ......4--5--609--98 Tools..................6--709--98 Troubleshooting .........709--98 Disassembly--Assembly-wheelaxlehub ..........8--9--1009--98 Removal--Refitting--front axle...................11--12--1309--98 Stubaxlehuboverhaul...14--15--16-1709--98 Checkingleadingwheels alignment..............1809--98 50--CABAIRCONDITIONINGSYSTEM Safetyregulations .......209--98 Mainspecifications......309--98 Tools..................409--98 Operatingprinciples.....509--98 Componentsofcabair conditioningsystem ......6--7--8--9-1009--98 Cabcontrols............11--12--1309--98 Operationcontrolandcooling....................14--1509--98
..........909--98
PageDate
Conditioningsystemmaintenance ................16--1709--98
Troubleshooting .........18--19--20-2109--98
Refrigerantrecovery--recyclingandevacuation-chargingstations........22--2309--98
Dehydration,recharging andrefrigerationcheck...24--25--26-27--28--29-3009--98
Checkingforfluid/gasleaks intheairconditioningsystem....................31--3209--98
Compressordrivebelttensionadjustment.........3309--98
Cabairinfeedvents.Removal--Refitting.........3409--98
Cabheating/air--conditioningsystem.Removal--Refitting..................35--3609--98
Cabheater.Disassembly-Assembly..............3709--98
Cabairconditioningsystem evaporatorunit.Disassembly--Assembly..........3809--98
Cabelectricfanunit.Disassembly--Assembly......3909--98
55--ELECTRICALSYSTEM
CHAPTER1--Instruments
Analoginstruments......1--2--3--409--98
Transmitters,sensorsand switches...............5--6--7--8--9
--1009--98
Transmitters,sensorsand switches...............11--1203--02
ElectronicInstrument Panel ..................13--14--1509--98
603.54.351.01 --03--2002
10
CONTENTS
Maintenance
VersionofframeNo.1269072 Analoginstruments......17--18--1903--02 Transmitters,sensorsand switches...............20--21--22-2303--02 PageDate ElectronicInstrument Panel ..................24--25--2603--02 CHAPTER2--Components Introduction .............109--98 Components ............1--2--3--4--5 --6--7--8--9-10--11--12-13--1409--98 Maintenance ............15--16--1709--98 VersionofframeNo.1269072 Introduction .............1903--02 Components ............20--21--22-23--24--25-26--27--28-29--30--31-32--3303--02 CHAPTER3--StartingSystem Technicaldata..........109--98 TighteningTorques ......109--98 DescriptionandOperation209--98 Electricaldiagram.......309--98 Troubleshooting .........409--98 Systemtesting..........5--6--709--98 Overhaul ...............8--909--98 Startermotortesting.....10--1109--98 VersionofframeNo.1269072 Technicaldata..........1303--02 TighteningTorques ......1303--02 Electricaldiagram.......1403--02 CHAPTER4--Chargingsystem Technicaldata..........109--98 TighteningTorques ......109--98 DescriptionandOperation2--309--98 Systemtesting..........4--5--6--7--8 --909--98 AlternatorRemoval--Refittingandoverhaul ........9--10--11-12--13--14-15--1609--98 CHAPTER5--Battery Technicaldata..........109--98
............1609--98
DescriptionandOperation109--98
BatteryRemoval--Refitting209--98
Batterymaintenance .....309--98 Batteryrecharging.......4--5--609--98
Batterytroubleshooting...609--98
CHAPTER6--Electricalcircuits Contents...............109--98
Index(VersionofframeNo. 1269072) ...............11103--02
CHAPTER7--Cabelectricalcomponents Directionindicatorswitch. Replacement...........209--98
Multi--functioncontrol panel.Removal--Refitting.309--98
Serviceselectroniccontrol unit.Replacement.......409--98
PowerShuttleelectronic controlunit.Replacement.509--98 Fusebox.Replacement...609--98 Fuses--Relays.Replacement...................709--98
Loudspeakers.Removal-Refitting................809--98
Cablampfitting.Removal-Refitting................909--98
Rearwindscreenwiper motor.Removal--Refitting.1009--98
fitting..................409--98 Instrumentpanellower guard.Removal--Refitting.509--98 Platformassembly.Removal--Refitting.........6--7--8--9-10--11--1209--98
Safetyframeroof.Removal--Refitting.........1309--98
Cabassemblywithplatform.Removal--Refitting..14--15--16-17--18--19-20--2109--98 Cabwindows.Replacement...................22--23--2409--98
Right/left--handupright seals.Removal--Refitting.2509--98 Cabceilingfitting.Removal--Refitting.........26--2709--98
CONTENTS 11 603.54.351.01
--03--2002 PageDate
Rearwindscreenwiper
Hoodguard.Removal--Re-
PageDate
motor.Removal--Refitting.1109--98 90--PLATFORM,CAB,BODYWORK CHAPTER1--Cab Hoodopening.Removal-Refitting................209--98 Protectivegrill.Removal-Refitting................309--98
STARTUP
--Neverruntheengineinconfinedspacesthatare notequippedwithadequateventilationforexhaustgasextraction.
--Neverplacethehead,body,limbs,feet,handsor fingersnearfansorrotatingbelts.
ENGINE
--Alwaysloosentheradiatorcapslowlybeforeremovingittoallowanyremainingpressureinthe systemtobedischarged.Fillingupwithcoolant shouldonlybecarriedoutwiththeengine stoppedoridling(ifhot).
--Neverfillupwithfuelwhentheengineisrunning, especiallyifhot,inordertopreventtheoutbreak offireasaresultoffuelspillage.
--Nevercheckoradjustfanbelttensionwhenthe engineisrunning.
Neveradjustthefuelinjectionpumpwhenthevehicleismoving.
--Neverlubricatethevehiclewhentheengineis running.
ELECTRICALSYSTEMS
--Ifitisnecessarytouseauxiliarybatteries,rememberthatbothendsofthecablesmustbe connectedasfollows:(+)with(+)and(--)with(--). Avoidshort--circuitingtheterminals.GASRELEASEDFROMBATTERIESISHIGHLYINFLAMMABLE.Duringcharging,leavethebatterycompartmentuncoveredtoimprove ventilation.Nevercheckthebatterychargeusing ìjumpersî(metalobjectsplacedontheterminals).Avoidsparksorflamesnearthebattery zone.Donotsmoketopreventexplosionhazards.
--Beforeservicingoperations,checkforfuelor currentleaks.Eliminateanyeventualleaksbeforeproceedingwithwork.
--Neverchargebatteriesinconfinedspaces.Make surethatthereisadequateventilationinorderto preventaccidentalexplosionhazardsasaresult oftheaccumulationofgasesreleasedduring chargingoperations.
--Alwaysdisconnectthebatteriesbeforeperforminganykindofservicingontheelectricalsystem.
HYDRAULIC SYSTEMS
--Aliquidleakingfromatinyholemaybealmost invisiblebut,atthesametime,bepowerful
enoughtopenetratetheskin;Therefore,NEVER USEHANDSTOCHECKFORLEAKS.Usea pieceofcardboardorwoodforthispurpose.If anyliquidpenetratesskintissue,callformedical aidimmediately.Failuretotreatthiscondition withcorrectmedicalproceduremayresultinseriousinfectionordermatosis.
--Inordertocheckthepressureinthesystemuse suitableinstruments.
WHEELSANDTYRES
--Makesurethatthetyresarecorrectlyinflatedat thepressurespecifiedbythemanufacturer. Periodicallychecktherimsandtyresfordamage.
--Standawayfrom(atthesideof)thetyrewhen checkinginflationpressure.
--Onlycheckpressurewhenthetractorisunloadedandthetyresarecold,toavoidincorrect readingsasaresultofover--pressure.Donotuse partsofrecoveredwheelsasincorrectwelding brazingorheatingmayweakenandeventually causedamagetothewheel.
--Nevercutorweldarimmountedwithaninflated tyre.
--Toremovethewheels,lockboththefrontand rearvehiclewheels.Afterhavingraisedthevehicle,positionsupportsunderneath,accordingto regulationsinforce.
--Deflatethetyrebeforeremovinganyobjectsthat maybejammedinthetyretread.
--Neverinflatetyresusinginflammablegases;as thismayresultinexplosionsandinjurytobystanders.
REMOVALANDRE--FITTING
--Liftandhandleallheavypartsusingsuitablehoistingequipment.Makesurethatpartsaresustainedbyappropriatehooksandslings.Usethe hoistingeyeboltsforliftingoperations.Extracare shouldbetakenifpersonsarepresentnearthe loadtobelifted.
--Handleallpartscarefully.Donotputyourhands orfingersbetweenparts.Wearsuitablesafety clothing--safetygoggles,glovesandshoes.
--Avoidtwistingchainsormetalcables.Always wearsafetygloveswhenhandlingcablesor chains.
SECTION00--GENERAL--CHAPTER1 5 603.54.351.01 --03--2002
finaldriveswithbrakes TN55D/S(each).......... finaldriveswithoutbrakes
(*)Detergentandanti--freezeto--10 °Cwith50%ofAREXONSDP1 liquid.Fortemperaturesbelow--10 °C) fillonlywithAREXONSDP1 liquid
6 SECTION00--GENERAL--CHAPTER1 603.54.351.01
COMPONENTTOBE FILLEDORTOPPEDUP QUANTITY dm3 gall. (litres) RECOMMENDED NEWHOLLAND PRODUCTS NEWHOLLAND SPECIFICATIONS INTERNATIONAL SPECIFICATIONS Coolingsystem: withoutcab withcab 2.64 (10.0) 3.17 (12.0) Waterand AMBRA AGRIFLU liquid50%+50% NH900A Windscreenwasherbottle. 0.52(2.0) Waterand AREXONSDP1* liquid* Fueltank: 19.81(75) Decantedand filtereddieselfuel Enginesump: withoutfilter: withfilter:................ 1.77 (6.7) 1.98(7.5) AMBRA SUPER GOLD AMBRA SUPER Oil NH324G (SAE10W--30) NH330G (SAE15W--40) NH301C(SAE10W) NH302C(SAE10W) NH303C(SAE10W) NH304C(SAE10W) APICF--4/SG CCMCD4 MIL--L--2104E API CCMCD4 MIL--L--2104C Brakecircuit............ Withfrontbrakes......... 0.18(0.7) 0.13(0.5) AMBRA BRAKE LHMoil NH610A ISO7308 Frontaxle:
--03--2002 CONSUMABLES
axlecasing.............. finaldriveswithoutbrakes TN55D/S(each)..........
TN65,TN70D/STN75D/S
finaldriveswithbrakes TN65,TN70D/STN75D/S (each).................. 1.18 (4.5) 0.21 (0.8) 0.34 (1.3) 0.26(1.0) 0.40 (1.5) AMBRAMULTIG oil NH410B APIGL4 ISO32/46 SAE10W--30
lift,PTOandhydraulic steering:................ 11.09(42) Greasefittings........... AMBRAGR9 grease NH710A NLGI2 Airconditioningsystem --coolant................ --oil.................... 0.21(0.80) 0.04(0.15) R--134a SPA
(each)..................
Reartransmission(bevel drive,finaldrivesand brakes),gearbox,hydraulic
SECTION10--ENGINE--CHAPTER1 1 603.54.351.01 --03--2002 SECTION10--ENGINE
CONTENTS SectionDescription Page 10000 Generalspecifications2 ......................................................... Maindata 5 Torquesettings 20 Tools 21 ....................................................................... Sections 23 Lubricationandcoolingsystemdiagrams25 Troubleshooting27 1000110 Engine.Removal--Installation31 ................................................. 1000130 Compressiontest33 1000154 Engine.Disassembly--Assembly34 1010153 Valveguides.Replacement69 1010160 Injectorsleeve.Replacement72 .................................................. 1010270 Frontengineoilseal.Removal--refitting74 1010612 Valverockerarmclearanceadjustment76 1021830 Engineinjectors.Removal--refitting78 1024614 Boschinjectionpump.Removal--Refittingtimingandairbleedingcheck80 ............. 1025444 Exhaustpipe.Removal--Refitting86 1040211 Coolantpump.Removal--Refittingwithradiatorremoved87 1040228 Coolantpump.Overhaul88 1040230 Thermostat.Removal--Refitting89 ................................................ 1040610 Radiator.Removal--Refitting91 ...................................................
Chapter1--Engine
GENERALSPECIFICATIONS
Engine,technicaltype:
--ModelsTN55DandTN55S--type8035.05B.231/229/529(BOSCHpump) Seedataonpage6--7
--ModelsTN65DandTN65S--type8035.05R.241/239/539(BOSCHpump) Seedataonpage8--9
--ModelsTN70DandTN70S--type8035.25R.220/520(BOSCHpump).. Seedataonpage95--96
--ModelsTN75DandTN75S--type8035.25.231/229/529(BOSCHpump) Seedataonpage10--11
Cycle............................................................... diesel,4--stroke
Injection............................................................. direct Numberofon--linecylinders ........................................... 3
Cylinderliners dryforce--fittedincylinder block Pistondiameter
--ModelsTN65DandTN65S
--ModelsTN70DandTN70S
--ModelsTN75DandTN75S
603.54.351.01 --03--2002
2 SECTION10--ENGINE--CHAPTER1
4.094in.(104mm)
--ModelsTN55DandTN55S .......................................
4.094in.(104mm)
4.094in.(104mm)
4.094in.(104mm) Pistonstroke........................................................ 4.527in.(115mm) Totaldisplacement: --ModelsTN55DandTN55S 2931cm3 --ModelsTN65DandTN65S 2931cm3 --ModelsTN70DandTN70S 2931cm3 --ModelsTN75DandTN75S 2931cm3 CompressionratioforModelsTN55D,TN55S,TN65DandTN65S ........ 17:1normallyaspirated CompressionratioforModelsTN70D,TN70S,TN75DandTN75S 16.5:1turbocharged Maximumpower: --ModelsTN55DandTN55S 37kW(50Hp) --ModelsTN65DandTN65S ........................................ 44kW(60Hp) --ModelsTN70DandTN70S 51kW(70Hp) --ModelsTN75DandTN75S ........................................ 53kW(72Hp) Maximumpowerspeed 2300rpm MaximumtorquespeedforModelsTN55DandTN55S 1400rpm MaximumtorquespeedforModelsTN65DandTN65S 1400rpm MaximumtorquespeedforModelsTN70DandTN70S 1400rpm MaximumtorquespeedforModelsTN75DandTN75S 1400rpm Numberofmainbearings 4 Sumppan........................................................... structural,castiron (continued)
GENERALSPECIFICATIONS
Lubrication forced,withgearpump
Pumpdrive............................................ camshaft
Enginespeed/oilpumpspeedratio 2:1
Oilcleaning meshfilteronoilintakeandfiltering cartridgeondeliveryline
Normaloilpressurewithmotorwarmed--upandrunningat maximumspeed203° to221 °F(95° to105 °C):
ForModelsTN55D/SandTN65D/S 42.06to56.56psi(2.9to3.9bar)
ForModelsTN70D/SandTN75D/S(startoperation) ≥ 29psi(≥ 2bar)
Pressurereliefvalve................................... incorporatedinoilpumphousing
Valveinitialopeningpressure ............................ 50.76psi(3.5bar)
Forfurtherlubricationtechnicaldata...................... seepage19
Coolingsystem coolantcirculation
RadiatoronModelsTN55D/SandTN65D/S 3linesofverticalpipeswithcopperfins
Radiatoronmodel.TN70D/SandTN75D/S 4linesofverticalcopperpipes
Fan,attachedtocoolantpumppulley..................... intake,6--bladeinsheet--metal
SECTION10--ENGINE--CHAPTER1 3
(cont)
603.54.351.01 --03--2002
Coolantpump.......................................... centrifugalvane--type Enginespeed/coolantpumpspeedratio 1:1.25 Temperaturecontrol.................................... thermostat Coolantthermometer................................... colouredscaledividedinto3sections Temperaturerangescorrespondingtoeachsection: --initialwhitesection.................................. 86° to149 °F(30° to65 °C) --middlegreensection(normalworkingconditions) 149° to221 °F(65° to105 °C) --finalredsection..................................... 221° to239 °F(105° to115 °C) Forfurthercoolingsystemtechnicaldata seepage19 Speedometer/tachometer .............................. incorporatedincontrolpanel Operatingsystem ...................................... fromgearoncamshaft Hourcountercalibratedforenginespeedof ................ 1800rpm (continued)
GENERALSPECIFICATIONS
Timingsystem overheadvalvesoperatedbytappets,rods androckerarmsviathecamshaftlocated intheengineblock;thecamshaftisdriven bythecrankshaftusinghelicalgears
Forfurthertimingsystemtechnicaldata ................... seepage16
Fuelsystem
Aircleaning dualcartridgedryairfilter,withclogged filterindicatorwithcentrifugalpre--filter andautomaticdustejector
ChargePump.......................................... doublediaphragm
Fuelfiltering........................................... throughwirefilterinfuelsupplypump,and replaceablecartridgeondeliverylineto injectionpump
Minimumfuelflowratewithpumpshaftrotatingat1600rpm. 100litres/hour
Camoperated enginetiming
BOSCHinjectionpump.................................. rotatingdistributortype
All--speedgovernor,incorporatedinpump:
BOSCH............................................... centrifugalcounterweights
Automaticadvanceregulator,incorporatedinpump:
BOSCH............................................... hydraulic
Forfurtherfuelsystemtechnicaldata:
Fixedadvance(pumpsettingforstartofdeliverybeforeTDC)
--Pressuresetting--Injectionorder,andotherinformation regardingtheBOSCHpump
refertothedatafortherelevantengine typeinthetableonpage2
4 SECTION10--ENGINE--CHAPTER1
(cont)
603.54.351.01 --03--2002
Intake: --start:beforeTDC.................................... 12° --end:afterBDC. ..................................... 31° Drain: --start:beforeBDC.................................... 50° --end:afterTDC. ..................................... 16° Valve--rockerarmclearancefortimingcheck............... 0.0177in.(0.45mm)
--intake............................................. 0.011 ± 0.0019mm(0.30
0.05mm)
0.011
0.0019mm(0.30
0.05mm)
Valve--rockerarmclearance(withenginecold):
±
--exhaust
±
±
SECTION10--ENGINE--CHAPTER1 5 603.54.351.01 --03--2002
--GARRETTtype..................................... T25 Injectionpump......................................... rotatingdistributorwithspeedgovernor andadvancevariatorincorporated BOSCHpump: --ModelsTN55D/S VE3/11F1150L767--99441584 --ModelsTN65D/S VE3/11F1150L766--99441586 --ModelsTN70D/S VE3/11F1150L764--2--500389114-500389115 --ModelsTN75D/S ................................... VE3/11F1150L764--99441587 Directionofrotation..................................... counter--clockwise Injectionorder......................................... 1--2--3 Fuelinjectors: BOSCHtype........................................... 500307714 --Nozzleholdertype.................................. 4791124 --Nozzletype........................................ DLLA132S1320--99469341 Numberofnozzleholes................................. 5 Nozzleholediameter................................... 0.23 Pressuresetting........................................ 3771.18to3945.23psi(260to272bar) DeliverylinesforBOSCHpump --type............................................... 99441952 --Pipedimensions.................................... 6x1.75x540
FUELSYSTEMDATA Turbocharger(ModelsTN70D/SandTN75D/S):
MODELSTN55DANDTN55S--CALIBRATIONDATAFORBOSCHINJECTIONPUMP TYPEVE3/11F1150L767--VE3/11F1150L767--1--99441584--500324953
ASSEMBLYDATA
Pumptimingonengine:deliverystart9°± 0.5° before TDC.ofcylinder1compressionstroke.
Plungerpre--liftfortimingonengine:0.0393in. (1mm)fromBDC.(withtools 291754 291755). CylinderNo.1deliverylineuniononpump:marked withletterA.
ASSEMBLYDIMENSIONS
Plungerpre--liftfromTDC.: mm--
CALIBRATIONTESTCONDITIONS
TestbenchconformingtoISO4008/1 .../2
InjectorsconformingtoISO7440--A61-(1.688.901.027withpad ∅ 0.0196in.(0.5mm)).
Injectorpressuresetting3626.13to5120.10psi (250to353bar).
Fuelsupplypressure: 5.076 ± 0.0725psi(0.35 ± 0.05bar). Deliverypipes(conformingtoISO4093.2): 0.236x0.078x17.71in.(mm6x2x450). ........ Graduatedraintime:30î. .........
Testliquid:ISO4113atatemperatureof 113° ± 33.8 °F(45° ± 1 °C).
1.STARTOFDELIVERY
Pumprotation(viewedfromdriveside): counter--clockwise Injectionorder:1--2--3
2.ADVANCEREGULATORSTROKE
Note:thevaluesshownaboveinbracketsmustbeusedforcheckingpurposesonly.
603.54.351.01 --03--2002
6 SECTION10--ENGINE--CHAPTER1
SYMBOL K MS ya yb in. (mm) 1.515to1.594 (38.5to40.5) 1.685to1.889 (42.8to48.0)
rpm:1200 Advancestroke:in.0.0275to0.0433(mm0.7to1.1)
rpm:1200 Internalpressure:117.41to126.18psi(bar8.1to8.7) 4.FULLLOADDELIVERY rpm:700 Deliveryper1000shots:cm3 59.5to60.5 Spread:cm3 --3.5 5.SPREADGOVERNORATIDLESPEED rpm:325 Deliveryper1000shots:cm3 8.4to12.4 Spread:cm3 6.SPREADGOVERNORATMAXIMUMSPEED rpm:1220 Deliveryper1000shots:cm3 27to33 Spread:-7.DELIVERYATSTARTINGSPEED rpm:100 Deliveryper1000shots:cm3 60to100 8.INJECTIONADVANCEPROGRESSION rpm 1200 1250 Advancestrokein.(mm) 0.0275to0.0433(0.7to1.1) 0.055to0.0708(1.4to1.8) 9.TRANSFERPRESSUREPROGRESSION rpm 1200 400 700 Internalpressurepsi(bar) 117.41to126.18 (8.1to8.7) 46.414to55.117 (3.2to3.8) 68.171to88.477 (4.7to6.1) 10.BACKFLOW rpm 400 1150 Backflowl/h 13to33 25to37 (continued)
3.FUELSUPPLYPUMPPRESSURE
SECTION10--ENGINE--CHAPTER1 15 603.54.351.01 --03--2002 PISTON DATA in (mm) n. mm Pistons................................................. lightalloywiththreecompressionrings, including two seal rings and one nc ngtwosea ngsan scraperring Standardpistondiameter,measuredat2.244in.(57mm)from skirtbaseandperpendicularlytothegudgeonpinaxis ......... 4.0870to4.0876 (103.812to103.826) Pistonclearanceincylinderliner 0.0068to0.0083(0.174to0.212) Maximumpermittedwearclearance......................... 0.0118(0.30) Pistonoversizes.......................................... 0.0157--0.0314(0.4--0.8) PistonprotrusionatTDC.fromcylinderblockface 0.0139to0.0299(0.355to0.761) Gudgeonpindiameter 1.4953to1.4956(37.983to37.990) Diameterofgudgeonpinseatinpiston 1.4957to1.4960(37.993to38.000) Gudgeonpintoseatclearance 0.0001to0.0006(0.003to0.017) Gudgeonpintosmallendbearingclearance ................. 0.0005to0.0012(0.014to0.031) Maximumpermittedwearclearance......................... 0.0023(0.06) Maximumweightdifferencebetweenpistonsinsameengine... 20grams Pistonringgrooveclearance(measuredvertically):........... --1st ring.............................................. 0.0035to0.0048(0.090to0.122) --2nd ring.............................................. 0.0023to0.0036(0.060to0.092) --3rd ring.............................................. 0.0015to0.0029(0.040to0.075) Maximumpermittedwearclearance: --1st ring.............................................. 0.0019(0.50) --2nd and3rd ring....................................... 0.0007(0.20) Assemblyclearancebetweenpistonringendsincylinder sleeves: --1st ring.............................................. 0.0015to0.0025(0.40to0.65) --2nd ring.............................................. 0.0011to0.0021(0.30to0.55) --3rd ring.............................................. 0.0011to0.0023(0.30to0.60) Maximumpermissiblegap(wearlimit)....................... 0.0472(1.20)
16 SECTION10--ENGINE--CHAPTER1 603.54.351.01 --03--2002 VALVE TIMING GEAR DATA in (mm) n. mm Timinggeartoothbacklash ................................ 0.0062(0.160) Insidediameterofintermediategearbushings (fittedandreamed)....................................... 1.4586to1.4596(37.050to37.075) Diameterofintermediategearjournal 1.4557to1.4566(36.975to37.000) Clearancebetweenpinandrelativebushings................ 0.0019to0.0039(0.050to0.100) Maximumpermittedwearclearance......................... 0.0059(0.15) Bushinginterferencefitinseatinintermediategear 0.0024to0.0055(0.063to0.140) Outsidediameterofcamshaftbearings: --front................................................. 2.1604to2.1625(54.875to54.930) --intermediate.......................................... 2.1407to2.1429(54.375to54.430) --drive................................................ 2.1210to2.1232(53.875to53.930) Interferencebetweenbearingsandseatsincylinderblock ..... 0.0027to0.0059(0.070to0.150) Insidediameterofcamshaftbearings(fittedandreamed): --front................................................. 2.0110to2.0129(51.080to51.130) --intermediate.......................................... 1.9913to1.9933(50.580to50.630) --drive................................................ 1.9716to1.9736(50.080to50.130) Diameterofcamshaftjournals: --front................................................. 2.0066to2.0078(50.970to51.000) --intermediate.......................................... 1.9870to1.9881(50.470to50.500) --drive................................................ 1.9673to1.9685(49.970to50.000) Clearancebetweencamshaftjournalsandbushings.......... 0.0031to0.0062(0.080to0.160) Maximumpermittedwearclearance......................... 0.0078(0.20) Camshaftendfloatbetweenthrustplateandseatoncamshaft.. 0.0027to0.0086(0.070to0.220) Forfurthertimingsystemtechnicaldata seepage4 TAPPET DATA in (mm) TAPPETDATA in.(mm) Tappetboreincrankcase 0.5905to0.5912(15.000to15.018) Outsidediameterofstandardtappet 0.5885to0.5893(14.950to14.970) Tappetrunningclearance 0.0011to0.0026(0.030to0.068) Maximumpermittedwearclearance......................... 0.0059(0.15) Tappetoversizes 0.0039--0.0078--0.118 (0.1--0.2--0.3)
--lengthunderloadof45to49N(10.14to11.02lbs.)(4.6to5kg)
--lengthunderloadof88to94N(19.84to21.16lbs.)(9to9.6kg) 1.2007(30.5)
--springlength(2.fig.149)underloadof127.8to141.2N (286.60to317.46lbs.)(130to144kg).
--springlength(2.fig.149)underloadof233.4to258N (524.70to579.81lbs.)(238to263kg)
SECTION10--ENGINE--CHAPTER1 19 603.54.351.01 --03--2002 in.(mm) LUBRICATIONSYSTEMDATA TN55D/S TN65D/S TN70D/S TN75D/S Assemblyclearancebetweenoilpumpdriveshaftandbushing. 0.0006to0.0021 (0.016to0.055) Clearancebetweenshaftanddrivengear 0.0012to0.0025 (0.033to0.066) Toothbacklashbetweendriveanddrivengears 0.0039(0.100) Radialclearancebetweendriveanddrivengearsandhousing.. 0.0023to0.0066 (0.060to0.170) Thicknessofdriveanddrivengears 1.6126to1.6141 (40.961to41.000) Heightofgearseatinpump 1.6151to1.6175 (41.025to41.087) Endfloatbetweengearsandgearhousinginpump 0.0009to0.0049 (0.025to0.126) Pressurereliefvalvespring --springfreelength 1.7716(45) 1.4133(35.9)
1.4763(37.5)
1.1417(29)
0.9133(23.2)
seepage3 COOLING SYSTEM DATA in (mm) n. mm Interferencefitbetweenpumpimpellerandshaft............. 0.0006to0.0023(0.017to0.059) Interferencefitbetweenfanhubandshaft................... 0.0009to0.0022(0.024to0.058) Interferencefitbetweenfrontsealbushingandimpeller........ 0.0004to0.0022(0.012to0.058) Forfurthercoolingsystemtechnicaldata seepage3
Forfurtherlubricationtechnicaldata........................
603.54.351.01 --03--2002
TORQUESETTINGSWITHANGLE
TORQUESETTINGS
20 SECTION10--ENGINE--CHAPTER1
PARTS TO TIGHTEN Thread Tighteningtorque Angle rea Nm kgm ng Cylinderheadbolts(2,page23) .............. M12x1.25 70 7.1 90° +90° Mainbearingcapbolts(4) M14x1.5 80 8.2 90° Big--endcapbolts(5)....................... M11x1.5 40 4.1 60° Flywheelmountingbolts(3) M12x1.25 40 4.1 60°
PARTS TO TIGHTEN Thread Tighteningtorque rea Nm kgm Rockershaftpedestalbolts(1,page23) M8 25 2.5 Crankshafthubretainingnut(7)............................ M30x1.5 294 30 Fanandalternatorpulleybolts(6).......................... M10x1.25 55 5,6 Additionalcounterweightretainingbolts(1,page24) M12x1.25 110 11.2 Inletmanifoldretainingbolts............................... M8 25 2,6 Alternatorandbelttensionadjustmentnut................... M10x1.25 55 5,6 Coolantpumpretainingbolts............................... M10x1.25 55 5.6 Tappetcovernuts(1.fig.48) M8 15 1.5 Rockershaftpedestalbolts(2.fig.49) ...................... M8 25 2.5 Oilpumpandpumpcoverretainingbolts(1.fig.57)........... M8 25 2.6 Timinggearcaseandcoverbolts(1,fig.61) ................. M8 25 2.6 Intermediateflangedjournalbolts(1,fig.64) M10x1.25 55 5.6 Camshaftthrustplateretainingbolts(2,fig.65)............... M8 35 3.6 Rearcrankcasecoverbolts(2,fig.85)...................... M8 25 2.6 Tappetadjusterlocknuts(1,fig.104) ........................ M8 22 2.2 Nutsforinjectormountingstuds(1,fig.105) M8 25 (*) 2.6 (*) Exhaustmanifoldretainingbolts M8 25 2.6 Injectionpumpmountingbolts M8 25 2.6 Sumppanretainingbolts.................................. M10x1.25 69 7 --Timinggearrearseal,coverandcasing .................. M10x1.25 39to49 4to5 --flywheelhousingcrankcaseandcasing: models.TN55D/SandTN65D/S modelsTN70D/SandTN75D/S M10x1.25 M10x1.25 49to59 49to69 5to6 5to7
(*) Tightenthenutsintwostages--seeoperationsdescribedinfig.105.
TOOLS
Warning-- Theoperationsdescribedinthissection canonlybecarriedoutwith ESSENTIAL toolsindicatedbyan (X)
Toworksafelyandefficientlyandobtainthebestresults,itisalsonecessarytousetherecommended specifictoolslistedbelowandcertainothertools, whicharetobemadeaccordingtothedrawingsincludedinthismanual.
Listofspecifictoolsrequiredforthevarious operationsdescribedinthissection.
290740 Engineliftinghook.
290090 Revolvingengineservicestand.
293860 Enginemountingbracketsforrotating stand 290090
X291309
Compressiontestkit(completewith dummyinjector 293862).
292870 Engineoilpressuretestkit.
293240 Checkset,turbocharger,formodels TN70D/SandTN75D/S).
X291160 Pistonringpliers.
X291048 Clampforfittingpistonsincylinders.
X292248 Protractorforangulartorque measurement.
X291504 Pullerforcrankshaftpulleyhub.
X291883 Wrenchforvalveclearanceadjustment.
X291046 Driftforvalveguideextraction/installation.
X294027 Twistbitforenlargingvalveguide bore.
X294028 Taperedgrinder8° forswagingexhaustvalveguides.
X293231 Bushforvalveguideinstallation(with 291046).
X291177 Enginevalveguidereamer.
X291050 Enginevalvespringdisassembly--assemblycompressor.
X293270 Setofgrindingtoolsforregrindinginjectorseat.
X291182 Pullerforcoolantpumpimpeller.
X293280 Driftforinstallationofcoolantpump impellerseal.
293814 Chargerimpellerreactionblock(for modelsTN70D/SandTN75D/S).
293786 Wrenchforinjectionpumpdelivery lineunions.
293671 Injectorcleaningkit.
X293761 Wrenchsetforinjectordismantling (with 295008).
290284 Handpumpforinjectorcalibration test.
Injectionpumpbenchtest
291754 Dialgauge(0.0393/3.937in.) (1/100mm,stroke0.1968in.(5mm), ∅ 1.5748in.(40mm)with 291755).
291755 DeviceforBOSCHinjectionpumptimingonengine(with 291754).
X295042 Pullerforinjectionpumpdrivegear.
SECTION10--ENGINE--CHAPTER1 21 603.54.351.01 --03--2002
Spliningtooltobemanufacturedforassembling thecrankshaftfrontseal(printNo.50138onthe tool--Valuesinmm).
MakeinUNIC40material.
Spliningtooltobemanufacturedforassembling thecrankshaftrearseal(printNo.50139onthe tool--Valuesinmm).
MakeinUNIC40material.
603.54.351.01 --03--2002
22 SECTION10--ENGINE--CHAPTER1
26102 1
26103 2
VALVESEATSINCYLINDERHEAD-Re--facing
ATTENTION
Handleallpartscarefully. Donotputyourhandsorfingersbetweenparts. Wearsuitablesafetyclothing--safetygoggles, glovesandshoes.
Dimensions(mm)ofvalveseatsandvalveguides.
SECTION10--ENGINE--CHAPTER1 65 603.54.351.01 --03--2002
25343 1 101
1.Ifthevalveseatsneedrefacingtoimprovevalve sealing,usetheuniversalvalvegrinder(1)and removeaslittlematerialaspossible.
A.Intake. B.Depthoftaper. S.Drain. 25344 (B) 102
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CHECKS,DIMENSIONSANDREPAIRS-LUBRICATION SYSTEM
ATTENTION
Handleallpartscarefully. Donotputyourhandsorfingersbetweenparts. Wearsuitablesafetyclothing--safetygoggles, glovesandshoes.
Cleanallpartscarefullybeforeproceedingwiththe operationsdescribedbelow.
Toaccesstheoilpump,removethesumppan.
Whenservicingthepump,checkcomponentwear againstthedimensionsspecifiedinthetableon page19.
Incaseofreplacement,notethatthedriveshaft(3) anddrivegeararesuppliedreadyassembled,with thegearhotforce--filledontheshaft.
603.54.351.01 --03--2002
66 SECTION10--ENGINE--CHAPTER1
OILPUMP--Overhaul
Cross--sectionalviewofenginelubricatingoilpump --Models.TN55D,TN55S,TN65DandTN65S
1. Externaldrivegear.
2. Bush.
3. Driveshaftandgear.
4. Drivenshaftandgear.
25354 1 2 3 4 5 103
5. Pressurereliefvalve.
Cross--sectionalviewofenginelubricatingoilpump --Models.TN70D,TN70S,TN75DandTN75S
1. Pressurereliefvalve.
2. Spring.
3. Pumpbody.
26109 1 2 3 4 104
4. Internalgears.
SECTION10--ENGINE--CHAPTER1 81 603.54.351.01 --03--2002
8.Unscrewtheunions:(1)ontheinjectionpump deliverylines,(2)thefuelreturnlinesand(3)the pumpfuelsupplyline.
27757 136
9.DisconnecttheL.D.A.deviceconnectingpipe.to theinletmanifold(onlymodelTN70D/SandTN 75D/S).
1 2 27761 137
10.Checkthatreferencemarkshavebeenmade(2) fortimingtheinjectionpump(1).
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11.Unscrewthebolts(1)securingtheinjection pump.
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12.Unscrewtheinjectionpumpretainingnutfrom thecontrolgear(1).
13.Usingtool 295042 (1)detachtheinjectionpump fromtherelativegearandremovethepumpand controlkey.
14.Torefittheinjectionpump,proceedasfollows.
ATTENTION
Alwaysuseappropriatetoolstoalignfixingholes.NEVERUSEYOURFINGERSORHANDS.
--Respectthetighteningtorquesprescribedon page20.
--Assembletheinjectionpumpcompletewithkey, makingsurethatthereferencemarks(made previously)fortimingoperationscoincide;then fixinpositionbymeansofthebolts.
--Locktheinjectionpumpdrivegearinposition, usingthenut.
--Refittheinjectionpumpdrivegearboxaccess cover.
--AssembletheLDAdeviceconnectionpipetothe inletmanifold(formodelsTN70D/SandTN 75D/S).
--Connectthefuelsupplyandreturnlinestotheinjectionpump.
--Connecttheenginestopelectromagnetcable.
--Connectthefuelsupplylinestotheinjection pump.
--Connectthethrottleleadtotheinjectionpump.
--Closethebonnet.
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BOSCHINJECTIONPUMP Timing
Iftheenginedoesnotrunevenly,ifthetimingmarks (1)arenotvisible,ordoubtsariseconcerningtheir accuracy,timetheinjectionpumpasfollows:
15.Unscrewtheunionsofthefuelsupplylines(1), detachingthemfromtheinjectionpump. Ifnecessary,disconnecttheinjectionpumpsupplyandreturnlines(2and3)and,formodelsTN 70D/SandTN75D/S,theL.D.A.deviceconnectingpipetotheinletmanifold.
16.Removetheflywheelinspectionwindowcover (1).
17.Rotatethecrankshafttobringcylinderno.1to TDC(ofthecompressionstroke).
18.Removethefrontcover.
19.Checkthat4timingmarksongears(1)and(2) arealigned).
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20.Checkthroughtheinspectionwindowthatthe pointerisalignedwithreferencemarks9_ formodelsTN55D/SandTN65D/Sor6_ formodels
21.Withtheinjectionpumpinpositionbutwiththe mountingboltsloose,removetheplug(1)onthe pumphousing.
22.Fitdialgauge 291754 (1)fig.147andrelativetool 291755 (2),pre--loadingtheshaftbyapproximately0.0984in.(2.5mm).
23.Turntheflywheelslowlybackwards,soasto bringtheplungertoBDC.atthestartofthedeliverystroke(thepointatwhichthedialgauge
24.Zero--setthedialgaugeandslowlyturntheflywheelclockwise(asviewedfromthefanendof theengine)untilthepointerlinesupwithreferencemarks9_ formodelsTN55D/SandTN 65D/Sor6_ formodelsTN70D/SandTN75D/S.
25.Checkonthedialgaugethattheplungerhas completedastrokeof1mmuptothispoint,ifnot, slackenoffthepumpmountingbolts.
26.Turnthepumpcounter--clockwiseiftheplunger hascompletedastrokeoflessthan1mm,and clockwiseifthestrokeisgreaterthan1mm,repeatingthetestuntilthecorrectstrokeisobtained.
27.Havingobtainedthecorrectplungerstroke,fix thepumpinpositionbytighteningthemounting nutstothetorquespecifiedonpage20.
28.Stamppumptimingmarks(1,asindicatedinfigure201ontheguard,pumpandinterfacespacer.
29.Removethedialgauge 291754 (1)andrelative tool 291755 (2),andreplacetheplugandtighten toatorqueof8to10Nm(0.8to1kgm).
30.Refitotherpartsinthereverseofthedismantling order.
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