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INTRODUCTORY NOTES
- This manual is divided into sections identified by two-figure numbers and each section has independent page numbering.
- The different sections can easily be found by consulting the table of contents on the following pages.
- The document number of the manual and the edition/update dates are given at the bottom of each page.
- Pages updated in the future will be identified by the same document number followed by an additional digit: first edition standard manual 87666787A - 1st update 87666787A1 - 2nd update 87666787A2 - etc. The update pages can replace or supplement the pages of the standard manual; the information necessary for the procedure for adding or replacing pages is given on the title page of the update.
The publication will be completed with an appropriate index.
If it is necessary to issue a new updated manual (2nd edition) it will have document number 87666787B, this indicates that the manual is composed of the standard version 87666787A completed with all the updates: 1st update 87666787A1 - 2nd update 87666787A2 - etc.
- The information contained in this manual was current on the date printed on each section. As NEW HOLLAND constantly improves its product range, some information may be out of date subsequent to modifications implemented for technical or commercial reasons, or to meet legal requirements in different countries.
In the event of conflicting information, consult the NEW HOLLAND Sales and Service Departments.
IMPORTANT WARNINGS
- All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND service technicians, in strict accordance with the instructions given and using any specific tools necessary.
- Anyone performing the operations described herein without strictly following the instructions is personally responsible for any eventual injury or damage to property.
- The Manufacturer and all organisations belonging to the Manufacturer's distribution network, including but not restricted to national, regional or local distributors, will accept no responsibility for personal injury or damage to property caused by abnormal function of parts and/or components not approved by the Manufacturer, including those used for maintenance and/or repair of the product manufactured or marketed by the Manufacturer.
In any case, the product manufactured or marketed by the Manufacturer is covered by no guarantee of any kind against personal injury or damage to property caused by abnormal function of parts and/or components not approved by the Manufacturer.
No part of the text or illustrations may be reproduced PRINTED IN FRANCE
© CNH GLOBAL N.V.
CONTENT
PageDate
00 GENERAL GUIDELINES
General instructions. . . . . 1 211 07
Safety regulations. . . . . . . 3 4 511 07
Tractor refuelling.
10 − ENGINE
Engine disassembly assembly.
. 611 07
CHAPTER 1 Engine T4040 and T4050 models
Summary.
. 111 07
General specifications. . . . 2 3 411 07
Fuel system data. .
Engine block data. . .
Crankshaft data. . . . .
Connecting rod data. .
Piston data .
Timing gear data. . .
411 07
. . . 511 07
. . 511 07
. 611 07
6 711 07
711 07
Cylinder head data. . . . . . 8 911 07
Tightening torques. .
Tools
Engine diagrams. .
Lubrication diagrams.
Cooling diagram.
Additional counterweight diagrams.
Exhaust gas recirculation system (EGR). .
Fault finding.
Engine removal installation.
. 10 1111 07
1211 07
. 1311 07
. 1411 07
1511 07
1611 07
1711 07
18 19 20 2111 07
22 23 24
25 26 27 28 29 30 31 32 11 07 PageDate
Checks and measurements cylinder block and liners
Checks and measurements crankshaft, bearings and flywheel. . . . . . 70 7111 07
Checks and measurements connecting rods. . . . . . . 72 7311 07
Checks and measurements pistons . . . . . 74 75 76 7711 07
Checks and measurements camshaft, tappets and valves. .
Checks and measurements cylinder head8211 07
Checks and measurements lubrication system. . . . . . 8311 07
Checks and measurements cooling system.
8411 07
Removal Installation crankshaft front seal. . . . . 85 8611 07
Replacing crankshaft rear seal.
Valve clearance adjustment
Removal Installation injectors.
87 88 8911 07
90 9111 07
92 93 9411 07
Removal Installation Bosch injection pump. . . . 95 96 9711 07 Bosch injection pump timing.
Bosch injection pump air bleeding.
98 99 10011 07
10011 07
PageDate
Removal Installation coolant pump. . . . . . . . . . . 101 10211 07
Removal Installation thermostat valve. . . . . . . . . 103 10411 07
Removal Installation radiator.
. . 105 106 107 10811 07
Coolant pump and generator drive belt. .
109 11011 07
CHAPTER 2 − Engine T4020 and T4030 models
Summary. . .
. 103 08
General specifications. . . . 2 303 08
Engine removal installation.
4 5 6 7 8 9 10 11 12 13 14 15 16 17 03 08
18 − CLUTCH
Data.
Tightening torques. .
Tools.
Sections. .
Fault finding. .
Removal Installation clutch.
1 211 07
. . 211 07
2 311 07
3 411 07
. 511 07
6 7 8 9 10 11 12 13 14 1511 07
Clutch Overhaul. . . . . . . . . 16 17 18 19 2011 07
Checks and measurements clutch.
Adjustments clutch disengagement levers. .
21 2211 07
. 22 2311 07
Adjustments clutch pedal2411 07
PTO control adjustment. . 2511 07
Sectional view of PTO clutch servo control. . . . . . 2611 07
Description and operation of PTO servo control. . . . . 27 2811 07
PTO servo control adjustment. .
PTO engaged switch adjustment.
21 TRANSMISSIONS
CHAPTER 1 Transmission and range gear (16x16)
Data. . . . . . . . . . . . . . . . . . . 1 211 07
Tightening torques.
8 9 10 1111 07
Description and operation 1211 07 Fault finding.
Removal Installation rear transmission gearbox casing.
Disassembly Assembly transmission gearbox casing.
Gearbox driving and driven shafts end float adjustment2911 07
Sealing compound application diagram.
3011 07
Gearbox control lever. Removal Installation. . . . . . 3111 07
Range gear control lever. Removal Installation. . . . 3211 07
Shuttle control lever. Removal Installation.
Fuel tank. Removal Installation.
3311 07
34 3511 07
CHAPTER 2 − Mechanical transmission and splitter
Data.
2911 07
. 3011 07
1 211 07
Tightening torques. . . . . . . 211 07 Tools.
Sections.
211 07
3 4 511 07
Description and operation. 611 07 Fault finding.
Splitter device and creeper unit casing, shafts and bearings disassembly.
711 07
8 9 10 11 07
PageDate
CHAPTER 3 Power Shuttle transmission with dual command (2 Speed Power Shift) function
Data. . . . . . . . . . . . . . . . . . . 1 211 07
Tightening torques. . . . . . . 311 07
Tools.
Sections.
4 5 611 07
. 7 8 9 10 1111 07
Clutch control pressure test1011 07
Description and operation. 1211 07
Fault finding.
Disassembly Assembly transmission gearbox casing.
Disassembly Reassembly Power Shuttle control valve. .
Disassembly Assembly accumulator.
Gearbox control valve solenoid valve. Removal Installation.
Disassembly Assembly clutch casing.
. 1211 07
13 1411 07
. 15 16 1711 07
. 1811 07
19 2011 07
. 21 22 23 2411 07
CHAPTER 4 Power Shuttle transmission (16 + 16 and 8 + 8 versions)
Data.
. 111 07
Tightening torques. . . . . . . 211 07
Sections.
3 4 5 611 07
Clutch control pressure test611 07
23 DRIVE LINES
Data. .
111 07
Tightening torques. . . . . . . 211 07
Tools. . . . .
Sections.
3 411 07
. 5 6 711 07
Description and operation. 8 911 07
Fault finding. . . . . . . . . . . . 911 07
Drive shafts and guard.
Disassembly Assembly. . 10 11 1211 07
Removal Installation drive gear casing. . . . . . . . 13 1411 07
PageDate
Disassembly Assembly drive gear casing. . . . . . . . 15 16 17 1811 07
25 FRONT AXLE MECHANICAL TRANSMISSION
CHAPTER 1 − Front mechanical transmission (mod. T4040 Supersteer and T4050 Supersteer)
Data. . . . . . . . . . . . . . . . . . . 1 2 311 07
Tightening torques. . . . . . . 4 5 611 07
10 11 12 1311 07
and operation 13 1411 07 Fault finding. .
Disassembly Assembly front epicyclic final drive with
Disassembly Assembly front epicyclic
07 Wheel hub seal. Renew. . 4311 07
Wheel hub and steering knuckle. Disassembly Assembly.
Adjustments steering knuckle bearings.
Replacing steering knuckle pins and bearings.
Lead drive wheel position check.
PageDate
CHAPTER 2 Front mechanical transmission (mod. T4040 Deluxe and T4050 Deluxe)
Data. . .
. . 1 211 07
Tightening torques. . . . . . . 3 411 07
Tools.
Sections. .
5 611 07
7 811 07
Description and operation 8 911 07
Fault finding.
Removal Installation front axle.
Front axle. Disassembly Assembly.
Overhaul differential lock unit.
Replacing steering knuckle pins and bearings.
Adjustments steering knuckle bearings.
. 1011 07
11 12 13 1411 07
15 16 17 18 19 20 21 22 23 11 07
. 24 2511 07
. 2611 07
. 27 2811 07
Adjustments bevel drive29 30 31 32 33 34 35 11 07
Overhaul front differential3611 07
LIM SLIP self locking differential.
Checking leading wheel alignment.
37 3811 07
3911 07
Disassembly Assembly front epicyclic final drive. . 40 4111 07
Disassembly Assembly front epicyclic final drive with brake.
42 43 4411 07
27 − REAR MECHANICAL TRANSMISSION
Data.
Tightening torques. .
Tools.
Sections.
Adjustments differential lock engagement sleeve position.
. 1 211 07
. 3 411 07
5 6 7 811 07
. 9 1011 07
Description and operation. 11 1211 07 Fault finding. .
Disassembly Assembly transmission gearbox casing. .
. 12 1311 07
. 14 15 16 17 18 19 11 07 PageDate
2011 07
Adjustments bevel drive21 22 23 24 2511 07
Removal Installation final drive casing. . . . . . . . 26 27 28 2911 07
Disassembly Assembly drive wheel shaft. . . .
Disassembly Assembly epicyclic final drive. .
87666787A2 06 2009
. 29 30 3111 07
3111 07
31 POWER TAKE OFF
CHAPTER 1 − Mechanical power take−off
Data. . .
5 611 07
7 811 07
Description and operation. 9 10 1111 07 Fault finding.
Disassembly Assembly power take off.
33 BRAKES
Data.
12 13 14 1511 07
211 07
3 4 511 07
5 611 07
Description and operation. 611 07 Fault finding.
Removal Installation service brake.
Removal Installation service brake pump. . .
7 811 07
9 1011 07
11 12 13 1411 07
Adjustments service brake pedals travel. . . . . . 15 1611 07
Service brake circuit air bleeding.
Removal Installation parking brake.
16 17 1811 07
19 2011 07
PageDate
Adjustments parking handbrake travel. . . . . . . . 2111 07
35 HYDRAULIC
SYSTEMS
CHAPTER 1 Rear mechanical hydraulic lift
Data. . . . . . .
Tightening torques. . .
Tools.
Sections.
1 2 311 07
. . . 3 411 07
. 5 611 07
7 8 9 10 1111 07
Description and operation. 12 13 14 1511 07
Fault finding. .
16 1711 07
Lift internal controls. Disassembly Assembly. . . . . . . 18 19 20 2111 07
Adjusting the lift. . . . .
. . . 22 23 24 25 26 27 28 29 30 31 11 07
Lift cylinder and arms shaft. Disassembly Assembly. . 32 33 34 35 11 07
Disassembly Assembly lift control valve.
. 36 37 38 3911 07
Lift pressure relief valve. . 4011 07
CHAPTER 2 Open centre system auxiliary control valves
Data.
Tools. .
Tightening torques. . .
Sections. . . . .
. 211 07
211 07
211 07
. . . . . 3 411 07
Description and operation. 5 6 7 811 07
Lift electronic control unit. Renew.
. 911 07
Auxiliary control valves. Disassembly Assembly. . 10 11 1211 07
CHAPTER 3 − Trailer brakes auxiliary control valves
Sections. . . . . . . . . . . . . . . 111 07
Description and operation. 1 2 3 4 5 6 711 07
Fault finding. . . . . . .
. . 8 9 1011 07
Removal Installation trailer brake valve. . . . . . . 1111 07
CHAPTER 4 Electronically controlled hydraulic lift
2 311 07
Tightening torques. . . . . . . 411 07 Tools. .
4 5 611 07
Sections. . . . . . . . . . . . . . . 7 8 911 07
Location of Components. . 10 11 1211 07
Description and operation. 13 14 15 16 17 1811 07
Removal Installation lift. 19 20 21 22 2311 07
Draft sensor support. Removal Installation. . .
07
Replacement control unit2511 07 Lift arm potentiometer. Renew.
2711 07 Replacement draft sensor
Electronically
28 2911 07
CHAPTER 5 − Constant flow gear pump Data.
Disassembly Assembly lift
CHAPTER 6 Electronic lift and front Power Take−Off Main specifications of front lift.
PageDate
Description and operation. 11 12 13 14 11 07
Front lift hydraulic diagram1511 07 Front lift troubleshooting. . 16 1711 07
Removal Installation Front power take off transmission shaft.
. 18 19 20 21 22 23 24 25 11 07
Disassembly Assembly Front PTO transmission shaft.
Front PTO casing cross sectional view.
Removal Installation Front PTO electromagnetic coupling.
Disassembly Assembly Front PTO electromagnetic coupling.
Removal Installation Front lift support. .
2611 07
2711 07
28 29 3011 07
31 32 33 34 11 07
. 35 36 3711 07
CHAPTER 7 Front lift and power take off (for mod. T4030 Deluxe, T4040 Deluxe and T4050 Deluxe)
Data. .
Tightening torques. .
Sections.
. . 1 203 08
. 3 403 08
5 603 08
Description and operation of front power take off. . . 703 08
Front power take off control adjustment. .
. 803 08
Front power take off control valve. . . .
. . . 903 08
Sectional view of front power take off clutch. . . . 1003 08
Front mechanical lift. . . . . 1103 08
Electronic front lift. . . . . . . 12 13 1403 08
Front electronic lift hydraulic control valve diagram.
. 1503 08
Front electronic lift hydraulic control valve. .
1603 08 PageDate
Description and operation of front electronic lift hydraulic control valve. . . . . . 17 18 19 2003 08
Fault finding. .
Front electronic lift operating instructions.
Front electronic lift calibration. . .
Removal Installation front mechanical/electronic lift.
Removal Installation front power take off. .
Disassembly Assembly front power take off.
Removal Installation front electronic lift control unit.
Removal Installation front electronic lift hydraulic control valve.
code indication.
21 2203 08
23 24 25 2603 08
27 28 2903 08
3103 08
32 3303 08
34 3503 08
08
08
3803 08 Diagnostics.
41 − STEERING
CHAPTER 1 Steering
and operation. 3 4 511 07 View of hydrostatic steering control valve components. 611 07
87666787A2
7 811 07 Replacement hydrostatic steering wheel.
Removal Installation hydrostatic steering control valve.
07
PageDate
Disassembly Assembly hydrostatic control valve. . 13 14 15
16 17 18
19 20 21
22 23 24
25 26 27
28 11 07
Hydrostatic steering control valve bench testing. . . . . . 29 3011 07
Pressure relief valve testing3111 07
Steering control cylinder.
Removal Installation. . . . 32 3311 07
Steering control cylinder.
Disassembly Assembly. . 34 3511 07
CHAPTER 2 Constant flow gear pump
Data. .
Diagrams. .
1 211 07
3 411 07
Description and operation. 411 07
Disassembly Assembly hydrostatic steering oil pump.
511 07
44 AXLES AND WHEELS
. 1 211 07
Front wheel track diagram211 07
Sections. .
Tightening torques.
311 07
Conditioning system components. .
Testing operation and cooling.
Air conditioning system maintenance.
16 1711 07 Fault finding.
Refrigerant recovery recycling and evacuation charging stations. . . . . . . . 22 2311 07
Dehydration, recharging and refrigeration check. . . 24
Checking for and eliminating any gas leaks.
Compressor drive belt tension adjustment.
Cab air infeed vents. Removal Installation. .
Cab heating/air conditioning system. Removal Installation.
Cab heater. Disassembly Assembly. .
07
07
3311 07
. 3411 07
35 3611 07
3711 07
4 5 611 07 Tools.
Fault finding.
Disassembly Assembly wheel axle hub.
Removal Installation front axle. .
6 711 07
711 07
8 9 1011 07
11 12 1311 07
Stub axle hub overhaul. . . 14 15 16 1711 07
Checking leading wheel alignment.
1811 07
50 CAB AIR CONDITIONING SYSTEM
Safety regulations. . . . . . . 211 07
311 07
Cab air conditioning system evaporator unit. Disassembly Assembly.
3811 07
Cab electric fan unit. Disassembly Assembly. . . . . . . 3911 07
55 − ELECTRICAL SYSTEM
CHAPTER 1 Instruments
Analogue instrumentation. 1 2 3 411 07 Digital instrumentation. . . . 5 6 7 8 911 07
Transmitters, sensors and switches.
CHAPTER 2 − Components
. 511 07
411 07 Operating principles. . .
Introduction.
111 07
PageDate
Components. . . . . . . . . . . . 1 2 3 4 5 6 711 07
Service. . . . . . . . .
. . . 8 9 10 11 1211 07
CHAPTER 3 Starting System
Technical data. . . . . . . . . . 111 07
Description and operation. 211 07
Fault finding.
System testing.
View of starter motor components. .
Revision.
311 07
. 4 5 611 07
. 711 07
. . 8 911 07
Starter motor testing. . . . . 9 1011 07
CHAPTER 4 − Charging system
Technical data.
Tightening torques. . .
. 111 07
. . . 111 07
Description and operation. 2 311 07
System testing. . . .
. 4 5 6 7 8 911 07
Removal Installation and Overhaul alternator. . . . 9 10 11 12 13 14 15 16 11 07
CHAPTER 5 − Battery
Technical data. .
. . . 111 07
Description and operation. 111 07
Removal Installation battery.
Battery Service. .
211 07
. . . 311 07
Battery charging. . . . . . . . . 4 5 611 07
Battery troubleshooting. . . 611 07
CHAPTER 6 Electrical circuits for tractors with cab
106 09
CHAPTER 7 Electrical circuits for tractors with platform Index.
CHAPTER 8 Connectors
111 07
111 07
CHAPTER 10 HH Menu and calibrations
09
CHAPTER 11 Front electronic lift (mod. T4030 Deluxe, T4040 Deluxe and T4050Deluxe)
08 Electrical circuit components.
CHAPTER 9 Error codes
106 09
90
−
PLATFORM, CAB, BODYWORK
CHAPTER 1 Cab
Hood. Removal Installation.
Instrument panel lower guard.
Canopy for rops. Removal Installation.
1111 07
Cab assembly with platform. Removal Installation. . . . 12 13 14 15 16 17 18 19 11 07
Cab windows. Renew. . . . 20 21 2211 07
Right/left hand upright seals.
Removal Installation. . . . 2311 07
Cab ceiling fitting.
Removal Installation. . . . 24 2511 07 Sunshade.
Removal Installation. .
. 2611 07
87666787A2
2009
GENERALINSTRUCTIONS
IMPORTANTNOTICE
AllmaintenanceandrepairworkdescribedinthismanualmustbeperformedexclusivelybyNEWHOLLAND servicetechnicians,instrictaccordancewiththeinstructionsgivenandusinganyspecifictoolsnecessary. Anyoneperformingtheoperationsdescribedhereinwithoutstrictlyfollowingtheinstructionsispersonally responsibleforanyeventualinjuryordamagetoproperty.
BATTERY
Beforecarryingoutanykindofserviceoperationdisconnectandisolatethebatterynegativelead,unless otherwiserequestedforspecificoperations(e.g.:operationsthatrequiretheenginerunning).Oncethespecific operationhasbeencompleted,disconnecttheleadinordertocompletetheoperation.
SHIMMING
Foreachadjustmentoperation,selectadjustingshimsandmeasureindividuallyusingamicrometer,thenadd uptherecordervalues:Donotrelyonmeasuringtheentireshimmingset,whichmaybeincorrect,ortherated valueindicatedforeachonshim.
ROTATINGSHAFTSEALS
Forcorrectrotatingshaftsealinstallation,proceedasfollows: --beforeassembly,allowthesealtosoakintheoilitwillbesealingforatleastthirtyminutes; --thoroughlycleantheshaftandcheckthattheworkingsurfaceontheshaftisnotdamaged; --positionthesealinglipfacingthefluid;withhydrodynamiclips,takeintoconsiderationtheshaftrotation directionandpositionthegroovessothattheywilldeviatethefluidtowardstheinnersideoftheseal; --smearthesealinglipwithathinlayeroflubricant(useoilratherthangrease)andfillthegapbetweenthe sealinglipandthedustlipondoublelipsealswithgrease; --insertthesealinitsseatandpressdownusingaflatpunch;donottapthesealwithahammerormallet; --whilstinsertingtheseal,checkthattheitisperpendiculartotheseat;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.
BEARINGS
Wheninstallingbearingsitisadvisedto: --heatthebearingsto80 ÷ 90 0Cbeforefittingontheshafts; --allowthebearingstocoolbeforeinstallingthemfromtheoutside.
SPRINGPINS
Whenfittingsplitsocketelasticpins,ensurethatthepinnotchispositionedinthedirectionoftheforcerequired tostressthepin. Spiralspringpinsdonotrequirespecialpositioning
SPAREPARTS
Usegenuinepartsonly. Onlygenuinesparepartsguaranteethesamequality,durationandsafetyastheyarethesamepartsthatare assembledduringproduction. 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.
SAFETYREGULATIONS
WARNINGANDDANGERSYMBOL
Thiswarningsymbolpointsoutimportantmessages concerningyoursafety.
Carefullyreadthefollowingsafetyregulationsand observeadvisedprecautionsinordertoavoid potentialhazardsandsafeguardyourhealthand safety.
Inthismanualthesymbolisaccompaniedbythe followingkey--words:
WARNING --Warningsconcerningunsuitablerepair operationsthatmayjeopardisethesafetyofRepair personnel.
DANGER --Specificwarningsconcerningpotential hazardsforoperatorsafetyorforotherpersons directlyorindirectlyinvolved.
TOPREVENT ACCIDENTS
Mostaccidentsorinjuriesthatoccurinworkshops aretheresultofnon--observanceofsimpleand fundamentalsafetyregulations.Forthisreason,IN MOSTCASESTHESEACCIDENTSCANBE AVOIDED:byforeseeingpossiblecausesand consequentlyactingwiththenecessarycautionand care.
Accidentsmayoccurwithalltypesofvehicle, regardlessofhowwellitwasdesignedandbuilt.
Acarefulandjudiciousservicetechnicianisthebest guaranteeagainstaccidents.
Preciseobservanceofthemostbasicsafetyruleis normallysufficienttoavoidmanyseriousaccidents.
DANGER. Nevercarryoutanycleaning,lubrication ormaintenanceoperationswhentheengineis running.
SAFETYREGULATIONS
GENERAL
--Carefullyfollowspecifiedrepairand maintenanceprocedures.
--Donotwearrings,wristwatches,jewellery, unbuttonedorloosearticlesofclothingsuchas: ties,tornclothing,scarves,openjacketsorshirts withopenzipsthatmayremainentangledin movingparts.Itisadvisedtowearapproved safetyclothing,e.g.:non--slipfootwear,gloves, safetygoggles,helmets,etc.
--Donotcarryoutrepairoperationswithsomeone sittinginthedriver’sseat,unlessthepersonisa trainedtechnicianwhoisassistingwiththe operationinquestion.
--Donotoperatethevehicleoruseanyofthe implementsfromdifferentpositions,otherthan thedriver’sseat.
--Donotcarryoutoperationsonthevehiclewith theenginerunning,unlessspecificallyindicated.
--Stoptheengineandensurethatallpressureis relievedfromhydrauliccircuitsbeforeremoving caps,covers,valves,etc.
--Allrepairandmaintenanceoperationsmustbe carriedoutusingextremecareandattention.
--Servicestepsandplatformsusedinaworkshop orinthefieldshouldbebuiltincompliancewith thesafetyrulesinforce.
--Disconnectthebatteriesandlabelallcontrolsto indicatethatthevehicleisbeingserviced.Block themachineandallequipmentwhichshouldbe raised.
--Donotcheckorfillfueltanks,accumulator batteries,norusestartingliquidwhensmokingor nearnakedflames,asthesefluidsare inflammable.
--Brakesareinoperativewhenmanuallyreleased forrepairormaintenancepurposes:Useblocks orsimilardevicestocontrolthemachineinthese conditions.
--Thefuelnozzleshouldalwaysbeincontactwith thefillingaperture:Maintainthiscontactuntilthe fuelstopsflowingintothetanktoavoidpossible sparksduetostaticelectricitybuild--up.
Crankshaftrearseal--Replacement87 1010612 Valve/rockerarmclearance90
1021830 EngineinjectorsRemoval--Installation92 1024614 BoschinjectionpumpRemoval--Installation,timingandairbleeding95 1040210 CoolantpumpRemoval--Installation101
1040230 ThermostaticvalveRemoval/Installation103 1040610 RadiatorRemoval--Installation105 1041410 CoolantpumpandgeneratordrivebeltsAdjustingtension109
GENERALSPECIFICATIONS
Engine,technicaltype:
--ModelT4040typeF4CE9484N*J601(BOSCHpump) ....
--ModelT4050--typeF4CE9484M*J601(BOSCHpump)..
Cycle................................................. diesel,4--stroke
Fuelinjection.......................................... Direct
Numberofcylindersinline 4
Pistondiameter........................................
Compressionratio...................................... 16.5:1
MaximumPowerOutput:
--ModelT4040--typeF4CE9484N*J601
--ModelT4050--typeF4CE0454C*D600/*D603
63kW(86Hp)
71kW(97Hp)
Maximumpowerspeed 2300rpm
--Maximumtorque:ModelT4040--typeF4CE9484N*J601. 370Nm
--Maximumtorque:ModelT4050--typeF4CE9484M*J601 418Nm
Maximumtorquespeed 1300rpm
Numberofmainbearings 5
Sumppan............................................. structural,castiron
Lube forced,withlobepump
Pumpdrive............................................ fromcrankshaft
Enginespeed/oilpumpspeedratio 1:1
Oilfiltration............................................ meshscreenonoilpick--upand filtercartridgeindeliveryline Normaloilpressurewithmotorwarmed--up
(continued)
Op.1000110 ENGINERemoval--Installation
DANGER
Liftandhandleallheavypartsusingsuitablelifting equipment. Makesurethatassembliesorpartsaresupportedby meansofsuitableslingsandhooks.Ensurethat no--oneisinthevicinityoftheloadtobelifted.
ATTENTION
Usesuitabletoolstoaligntheholes.NEVERUSE FINGERSORHANDS.
1.Removethebonnetasdescribedinoperation 9010022
2.Extractthefixingpinandremovetheballast(1); unscrewtheretainingscrewsandretrievethe ballastsupport(2).
3.IfthetractorisaT4040SupersteerorT4050 Supersteermodel,positionandsecurethe bracket 380001613 (1)togetherwiththespacers 50162 (4)onthefrontaxle(3)andassociated support(2).
4.Unscrewtheretainingboltsandremovetheside grille(1). Performthisoperationontheothersideofthe tractortoo.
5.Unscrewtherelatedretainingboltandloosenthe guide(1),unhookthecatchandtakeoutthe condenser(2).
6.Disconnecttheelectricalconnectionfromthe compressor(1)andunscrewtherelated retainingbolts.
Removethebracketsfixingthepipesoftheair conditioningsystemandtakethecondenser, compressorandpipesunderthetransmission withoutdisconnectingthepipes.
7.Unscrewthebolts(3)securingtheexhaustpipe (1),unscrewtheexhaustsilencerretainingbolts (2)andremovetheentireassembly.
Unscrewtheretainingboltsandremovetheheat shield.
8.Removetheguard(1)anddisconnectthecables fromthestartermotor(2).
9.Disconnectthepipes(1)ofthecabheating systemanddraintheenginecoolingsystem.
10.Unscrewthepluganddraintheoilfromtherear transmissioncasing(theprescribedquantityis 42litres).
11.Disconnectthepowersteeringpipes(2), unscrewtherelatedretainingboltsandremove thebracket(1).
12.Disconnecttheelectricalconnectionfromthe brakefluidreservoir(1),unscrewtheretaining boltsandremovethereservoirfromthe supportingbracket.
13.Unscrewtheretainingboltsandremovethe bonnetbracket(1).
14.Disconnect:themainelectricalconnections(1), theconnectionofthesteeringsensorandthecab ground,disconnectthethrottlecable(2)fromthe injectionpump.
15.Disconnectthedieselpipes(1)fromtheinjection pump.
Disconnectthepipe(2)fromthepump.
16.Disconnect:thetransmissionoilcoolerpipes(1) andthefrontaxledifferentiallockpipe(2).
17.IfthetractorisaT4040SupersteerorT4050 Supersteermodel,unscrewthefrontandrear retainingbolts,unscrewthefrontpivotpin retainingscrewandremovethebracket(1). Unscrewtherelativeretainingboltsandremove therearguard.
18.IfthetractorisaT4040DeluxeorT4050Deluxe model,unscrewthefront,centralandrear retainingboltsandremovetheguardonthe propellershafts(1).
19.Removethecirclip(2)andmovethefrontsleeve (1)backwardsinordertofreeitfromthegroove onthefrontaxle.
20.Removethecirclip(2)andmovetherearsleeve (1)inordertoreleaseitfromthegrooveonthe drive.
21.Removethepropellershaftcentralsupport(1) retainingboltsandextracttheshafttogetherwith thesupport.
22.Loosentheretainingboltandturnthebracket(1) through90°
23.Formodelsfittedwithbrakesonthefrontaxleit isnecessarytodrainthebrakefluidtankand disconnectthepipes(1,2and3)fromtheblock.
24.Unscrew:theretainingboltsofthepipe(1) deliveringoiltothepumpandtheboltsretaining thepipe(2)tothefiltersupport.
25.Loosentherelatedclampsandremovethe sleeve(2)fromthepipe(1)andremovethe transmissionoilinletpipetogetherwiththe above--mentionedsleeve.
26.Unscrewtheretainingboltsandremovethe guard(1).Dothisonbothsides.
27.Unscrewtheretainingboltsandremovethecab matguard(2). Removetheplasticpedal(1).
28.Unscrewthebolts(1)(onbothsides),extractthe springpin(2)andremovethethrottlepedal(3).
29.Raisethefrontpartofthecabmat;removethe twoplasticplugsand,throughthehole(1), unscrewthefourupperboltssecuringtheengine totheclutchcasing.
30.Placeastandundertheclutchcasing,attachthe rearportionoftheenginetoahoist,usingchains (1).
31.Unscrewtheremainingbolts(1)securingthe enginetotheclutchcasingandseparatethe enginewiththefrontaxlefromtheclutchcasing.
32.Disconnecttheconnections(1)fromtheclogged airfiltersensor.
33.Placeastandundertherearportionofthebevel drivecasing(T4040SupersteerorT4050 Supersteer)ortwostands:oneundertheaxle supportattherearandtheotherunderthefront side.(modelswithstandardfrontaxle). Keepingthechains(1,fig.34)connected,join onechain(5)tothefrontoftheengine. Unscrewtheclampsandremove:theengineoil vapourrecirculationpipe(3),turbochargerintake pipe(2),andtheintakeaircoolerpipes(1and4).
34.Disconnectthelower(1)anduppersleevesfrom theradiator,removethebracket(2)fasteningthe powersteeringpipe.
35.FortheT4040DeluxeorT4050Deluxemodels, insertawoodenwedgeoneachsidebetweenthe axlesupportandtheaxleitself. Forallmodels,unscrewthebolts(1)onboth sidesandseparatetheenginefromthe axle--supportassemblywiththeradiatorand battery.
36.Resttheengineonanadequatesupport.
37.Tore--fittheengine,proceedasfollows.
ATTENTION
Usesuitabletoolstoaligntheholes.NEVERUSE FINGERSORHANDS. --Applythetorquesettingslistedonpage12. --Connecttheengine,withchains,tothehoist.
--Refittheenginetotheaxle--supportassembly withtheradiator,battery,coolers:intakeairand transmissionoil.
--Connecttheupperandlowersleevesofthe radiatortotheengine.
--Securethepowersteeringpipes.
--Beforerefittingtheenginetotheclutchbox carefullycleanthematingsurfacesandapply sealingcompound(2mmdiameter),according tothediagramshownSection21,Chapter1, page30.
--Positiontheengineontheclutchcasingand secureitwiththespecificbolts.
--Fittheplasticplugsonthecabfloor.
--Movethecabmatintotherightpositionand secureitwiththetwoboltsontheupright(dothis onbothsides).
--Fitthethrottlepedalwiththeplasticpart.
--Positionandsecuretheguardofthecabmat(do thisonbothsides).
--Fitthetwolowerguardsofthecontrolpanel(do thisonbothsides).
--Position,connectandsecuretheoildeliverypipe tothelift.
--Position,connectandsecuretheliftcontrol pumpoilinletpipe.
--Formodelsfittedwithbrakesonthefrontaxleit isnecessarytoconnectthepipestotherelated block.
--Positionandsecurethebracketbetweenthe clutchhousingandengine.
--Positionthepropellershaft,securethecentral support,slidethetwofrontandrearsleevesand securethemwiththecirclips.
--IfthetractorisaT4040DeluxeorT4050Deluxe model,positionthepropellershaftguardand secureit.
--IfthetractorisaT4040SupersteerorT4050 Supersteermodel,positionthepropellershaft rearguardandsecureit.
--IfthetractorisaT4040SupersteerorT4050 Supersteermodel,positionthepropellershaft frontguardandsecureit.
--IfthetractorisaT4040SupersteerorT4050 Supersteermodel,unscrewtheretainingbolts andremovethebracket 380001613 withthe spacers 50612.
--Connectthedifferentiallockcontrolpipe.
--Connectthepipestothetransmissionoilcooler pipes.
--Connectthefuelsupplyandreturnlinestothe injectionpump.
--Connectthedeliverypipetothepowersteering pump.
--Connectalltheelectricalconnectionsbetween thecabandengine.
--Positionandsecurethegroundcablebetween thecabandengine.
--Positionandsecurethethrottlecontrolrod.
--Positiontheupperenginebracketwiththeheat guardandsecureit.
--Connectthefrontpipestotherearpipes deliveringcoolanttothecabheater.
--Positionandsecurethebrakefluidtankand connecttheelectricalconnectiontothe above--mentionedpart.
--Connectthesteeringcontrolpipes.
--Connecttheelectriccabletothestartermotor andfittherelevantprotection.
--Positionandsecuretheheatshield,exhaust silencertotheengineandtothecab.
--Positionandsecure:thecompressor,condenser andrelatedpipes.
--Connecttheelectricalconnectiontothe compressor.
--Positionandsecurethesidegrille(dothison bothsides).
--Secure:theradiatorfixingbracket,engineoil vapourrecirculationpipe,inletpipeandintakeair coolerpipes.
--Connectthecloggedairfiltersensorpressure switchandsteeringsensorconnections.
--Formodelsfittedwithbrakesonthefrontaxleit isnecessarytofilltherelevanttank(seesect.00, page6fortheprescribedproductandquantity) andbleedthebrakingsystem(seesect.33).
--Screwtheplugonthereartransmissioncasing andfillupwithoil(seesect.00,page6forthe prescribedproductandquantity).
--Filluptheenginecoolingsystem(seesect.00, page6fortheprescribedproductandquantity).
--Positionandsecuretheballastsupport.
--Positionandsecuretheballast.
--Installthebonnetasdescribedinoperation 9010022
Op.1000154
ENGINEDisassembly--Assembly
ThefiguresrefertotheF4CE9484M*J601versions of71kW(97hp)mod.T4050.Therevisionisto highlightanddescribethespecificpartsofthe versionsF4CE9484N*J601of63kW(86hp)mod. T4040andtheirrespectivevariants.
ATTENTION
Handleallpartscarefully.Donotputyourhandsor fingersbetweenparts.Weartheprescribedsafety clothing,includinggoggles,glovesandsafety footwear.
1.Removetheengineasdescribedinoperation 1000110,proceedasfollows.
2.Drainofftheengineoilbyremovingtheplugfrom thesumpandtheoilfillerplug.
3.Detachthefanunitfromthefanpulley.
4.Tobeabletofitthebracket 380000661 (forfixing theenginetotheoverhaulstand)tothe crankcase,itisnecessarytoremovethewiring (1)fromtheleft--handsideoftheengine.
5.Tobeabletofitthebracket 380000661 tothe crankcaseontheright--handside,removethe startermotor(5),oilfilter(3),clamp(4),and turbineoilreturnpipe(1).
6.Fixthegearboxtotherotatingstand 380000301 Detachtheoildeliverypipe(2).
7.Removetheintakemanifold(2).
8.Disconnecttheengineoilvapourrecoverypipe fromtheblow--by(3).
9.Removethetappetcovers(1).
10.Removethepipeswiththequick--fitcoupling(6) and(8).
11.RemovethepipingfromtheLDAsystem(5).
12.Removethefuelfilter(7).
13.Removetheheater(4).
14.Removethecontrolunitfortheheater(10).
15.Removethefuelfiltersupport(9).
16.Removetheinjectorfeedpipe(4)fromthe injectionpump(3).
17.Removethebracketsonthecylinderheadofthe pipeassembly(1),(2)and(6).
18.Replacefuelsupplypump(5).
19.Detachthefuelpipeassembly(1)fromthe injectors.
20.Removethefueloutletpipe(2)fromtheinjectors removingthescrew(3)andtheseal(4).
21.Removethescrews(2)andtheturbine(1).
22.Removetheexhaustmanifold(3).
23.Removethebelt(3,fig.46)oftheauxiliary membersbylooseningthetightener.
24.Removethealternator(6),fanpulley(2)andthe tightener(8).Removethesupport(1)ofthe pulley(2)andtheoilcooler(7).
25.Removethecoolantpump(5).
26.Removetheenginecoolingsystemfitting(4) fromthecrankcase.
NOTE: Thecoolantpump(5)cannotbeoverhauled. Itmustbereplacedifthereisanyirregularoperation.
27.Locktheflywheeltostopitturning,removethe fixingscrews(1)fromthepulley(2).
Removingthecrankshaftfrontseal (Op.28. ÷ 32.)
28.Applytool 380000665 (4)onthefronttang(2)of thecrankshaft.
29.Perforatetheinnerseal(1)withadrillbit ( ∅ 3.5mm)throughtheguideholesofthetool 380000665 (4),foradepthof5mm.
30.Securethetool 380000665 (4)totheseal(1)with thescrews(3)provided.
31.Extracttheseal(1)byscrewingdownthescrew (5).
32.Fitthetierod(3)ofthetool 380000669 tothe outerseal(1)asshowninthefigure49andwith thelever(4),extractitfromthefrontcover(2).
33.Turntheengineover,takeoutthescrews(2)and removetheoilsump(1).
34.Takeoutthescrews(2)andremovetheoilpump (1).
NOTE: Theoilpump(1)cannotbeoverhauled. Itmustbereplacedifthereisanyirregularoperation.
35.Usingthepin(1),locktheadditional counterweights(2)attheT.D.C. Unscrewtheretainingbolts(3)andremovethe additionalcounterweights(2).
36.Beforeremovingtheinjectionpump,dothe timingandlocktheengineflywheelwithcylinder no.1atT.D.C.asindicatedonpage8,using tools 380000988 and 380000732.Thenloosen thebolt(2),removethe“L”spacer(1)andlock thescrew(2)inordertokeepthepumpintime withtheengineflywheel.
NOTE: Keepthe”L”spacerwiththepumpcasing.
37.Removethethreenuts(2)(3)(5)securingthe injectionpump(1)tothecrankcase(4)and extractitfromitshousing.
38.Removethescrews(2)fixingtheengineflywheel (1)tothecrankshaft.
39.Screwtwopins(2)oftheappropriatelengthinto theholesinthecrankshaft(3).
40.Extracttheengineflywheel(1)soitcanbeslung withtheliftandputitawayinaspecificcontainer.
Removingthecrankshaftrearseal (Op.41.÷ 44.)
41.Extracttheseal,fittingthetool 380000663 (3)on therearshank(1)ofthecrankshaft.
42.Perforatetheinnerseal(5)withadrillbit ( ∅ ∅ 3.5mm)throughtheguideholesofthetool 380000663 (3),foradepthof5mm.
43.Securethetool 380000663 (3)totheseal(5)by screwingdownthescrews(2)supplied.
44.Extracttheseal(5)byscrewingdownthescrew (4).
45.Takeoutthescrews(2)andremovethetiming gearbox(1),retrievingtheinjectionpumpgear.
NOTE: Notedowntheassemblypositionofthe screws(2)astheyhavedifferentsizes.
46.Takeoutthescrews(1)andremovethegears(3) and(4)fromthecamshaft(2).
47.Takeoutthebolts(1)andremovethehydraulic pumpdrivegear(2).
48.Foreachcylinder,removetherockerarm assembly(1)loosentheadjusternuts(3), unscrewtheadjusters(4)andtakeoutthe screws(2).
49.Extracttheinjectors(2)withtool 380000671 (1).
50.Takeoutthescrews(1)fixingtheheadtothe crankcase.
51.Afterfittingthebrackets(1)and(2)hookthe metalcablesanddetachthecylinderheadfrom thecrankcasewiththehoist.
NOTE: Afterremovingthecylinderhead,removethe brackets(1)and(2).