New Holland Boomer 3040 CVT Compact Tractor Service Repair Manual

SERVICE MANUAL

SERVICE MANUAL Boomer 3040 CVT / Boomer 3045 CVT / Boomer 3050 CVT Compact Tractor TM

TM

TM

Boomer 3040 CVT Boomer 3045 CVT Boomer 3050 CVT Compact Tractor TM

PIN ZCMB11001 and above; PIN ZDMB11925 and above

TM TM

PIN ZCMB11001 and above; PIN ZDMB11925 and above

Part number 48017760

Part number 48017760

Replaces part number 47463786

1st edition English November 2016 Replaces part number 47463786

© 2016 CNH Industrial America LLC. All Rights Reserved.

SERVICE MANUAL Boomer™ 3040 CVT [ZCMB11001 - ], Boomer™ 3040 CVT [ZDMB11925 - ] , Boomer™ 3045 CVT [ZCMB11001 - ] , Boomer™ 3045 CVT [ZDMB11925 - ] , Boomer™ 3050 CVT [ZCMB11001 - ] , Boomer™ 3050 CVT [ZDMB11925 - ]

48017760 14/11/2016 EN

Link Product / Engine Product Boomer™ 3040 CVT [ZCMB11001 -] Boomer™ 3040 CVT [ZDMB11925 -] Boomer™ 3045 CVT [ZCMB11001 -] Boomer™ 3045 CVT [ZDMB11925 -] Boomer™ 3050 CVT [ZCMB11001 -] Boomer™ 3050 CVT [ZDMB11925 -]

Market Product Europe

N844

Europe

N844

Europe

N844L

Europe

N844L

Europe

N844L

Europe

N844L

48017760 14/11/2016

Engine

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

Transmission.............................................................................. 21 [21.504] Continuously Variable Transmission (CVT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1

Four-Wheel Drive (4WD) system .................................................. 23 [23.101] Mechanical control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1

Front axle system ....................................................................... 25 [25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 [25.310] Final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3

Rear axle system........................................................................ 27 [27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 [27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2

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Power Take-Off (PTO) ................................................................. 31 [31.104] Rear electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 [31.110] One-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 [31.120] Central Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3

Brakes and controls .................................................................... 33 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.120] Mechanical service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

Steering..................................................................................... 41 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

Cab climate control ..................................................................... 50 [50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.104] Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3

Electrical systems ....................................................................... 55 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 48017760 14/11/2016

[55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11

Platform, cab, bodywork, and decals ............................................. 90 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.116] Fenders and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4 [90.151] Cab interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5 [90.154] Cab doors and hatches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.6

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INTRODUCTION

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INTRODUCTION

Foreword - Important notice regarding equipment servicing All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel, strictly complying with the instructions given, and using, whenever possible, the special tools.

Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall be responsible for any subsequent damages.

The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manufacturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.

In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer.

The manufacturer reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication but are subject to change without notice.

In case of questions, refer to your NEW HOLLAND Sales and Service Networks.

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INTRODUCTION

Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you.

Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.

Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety.

Information NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.

Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage.

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INTRODUCTION

Safety rules - Ecology and the environment Soil, air, and water quality is important for all industries and life in general. When legislation does not yet rule the treatment of some of the substances that advanced technology requires, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature.

Familiarize yourself with the relative legislation applicable to your country, and make sure that you understand this legislation. Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, anti-freeze, cleaning agents, etc., with regard to the effect of these substances on man and nature and how to safely store, use, and dispose of these substances.

Helpful hints • Avoid the use of cans or other inappropriate pressurized fuel delivery systems to fill tanks. Such delivery systems may cause considerable spillage.

• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of these products contain substances that may be harmful to your health.

• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.

• Avoid spillage when you drain fluids such as used engine coolant mixtures, engine oil, hydraulic fluid, brake fluid, etc. Do not mix drained brake fluids or fuels with lubricants. Store all drained fluids safely until you can dispose of the fluids in a proper way that complies with all local legislation and available resources.

• Do not allow coolant mixtures to get into the soil. Collect and dispose of coolant mixtures properly.

• The air-conditioning system contains gases that should not be released into the atmosphere. Consult an air-conditioning specialist or use a special extractor to recharge the system properly.

• Repair any leaks or defects in the engine cooling system or hydraulic system immediately.

• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.

• Protect hoses during welding. Penetrating weld splatter may burn a hole or weaken hoses, allowing the loss of oils, coolant, etc.

Battery recycling Batteries and electric accumulators contain several substances that can have a harmful effect on the environment if the batteries are not properly recycled after use. Improper disposal of batteries can contaminate the soil, groundwater, and waterways. NEW HOLLAND strongly recommends that you return all used batteries to a NEW HOLLAND dealer, who will dispose of the used batteries or recycle the used batteries properly. In some countries, this is a legal requirement.

Mandatory battery recycling NOTE: The following requirements are mandatory in Brazil.

Batteries are made of lead plates and a sulfuric acid solution. Because batteries contain heavy metals such as lead, CONAMA Resolution 401/2008 requires you to return all used batteries to the battery dealer when you replace any batteries. Do not dispose of batteries in your household garbage.

Points of sale are obliged to: • Accept the return of your used batteries • Store the returned batteries in a suitable location • Send the returned batteries to the battery manufacturer for recycling

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SERVICE MANUAL Engine Boomer™ 3040 CVT [ZCMB11001 - ], Boomer™ 3040 CVT [ZDMB11925 - ] , Boomer™ 3045 CVT [ZCMB11001 - ] , Boomer™ 3045 CVT [ZDMB11925 - ] , Boomer™ 3050 CVT [ZCMB11001 - ] , Boomer™ 3050 CVT [ZDMB11925 - ]

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10

Engine - Engine and crankcase

Engine - General specification WE WE WE

Boomer™ 3040 CVT Boomer™ 3045 CVT Boomer™ 3050 CVT

Engine Model Number of Cylinders Bore x Stroke Displacement Compression Ratio Rated Speed Muffler Firing Order Low Idle Speed Maximum No-Load Speed Cylinder Arrangement Valve Arrangement Compression Pressure at 200 RPM(cylinder speed) Variation between cylinders

Boomer 3040 ISM N844 4 84 mm x 90 mm ( 3.31 in x 3.54 in) 1995 cm³ ( 121.7 in³) 22.5:1 2600 RPM

Boomer 3045 ISM N844L 4 84 mm x 100 mm ( 3.31 in x 3.94 in) 2216 cm³ ( 135.2 in³) 22.5:1 2600 RPM

1-3-4-2 1050 RPM 2825 RPM In-Line Vertical Overhead 29.4 ± 1.8 bar (427 ± 50 psi)

1-3-4-2 1050 RPM 2825 RPM In-Line Vertical Overhead 29.4 ± 1.8 bar (427 ± 50 psi)

Boomer 3050 ISM N844L 4 84 mm x 100 mm ( 3.31 in x 3.94 in) 2216 cm³ ( 135.2 in³) 22.5:1 2800 RPM Horizontal 1-3-4-2 1050 RPM 3025 RPM In-Line Vertical Overhead 29.4 ± 1.8 bar (427 ± 50 psi)

Engine - Torque WE WE WE

Boomer™ 3040 CVT Boomer™ 3045 CVT Boomer™ 3050 CVT

Engine Model TORQUE SPECIFICATION Connecting Rod Cap Bolts Main Bearing Retaining Bolts Relief Valve Assembly Crankshaft Main Bearing Holder Bolts Rear Main Center Mains Engine Rear Mounting Plate Flywheel Retaining Bolts Engine Front Plate Crankshaft Pulley Nut Cylinder Head Bolts Rocker Arm Assembly Rocker Arm Locknut Oil Tube Banjo Bolt Oil Pressure Switch Rocker Cover Bolts Glow Plugs Cooling Fan Bolts Balancer Retaining Bolts

Boomer 3040 ISM N844

Boomer 3045 ISM N844L

Boomer 3050 ISM N844L

49 - 54 N·m (36 - 40 lb ft) 49 - 54 N·m (36 - 40 lb ft)

49 - 54 N·m (36 - 40 lb ft) 49 - 54 N·m (36 - 40 lb ft)

49 - 54 N·m (36 - 40 lb ft) 49 - 54 N·m (36 - 40 lb ft)

59 - 69 N·m (43 - 51 lb ft)

59 - 69 N·m (43 - 51 lb ft)

59 - 69 N·m (43 - 51 lb ft)

25 - 29 N·m (18 - 22 lb ft) 49 - 54 N·m (36 - 40 lb ft) 12 - 17 N·m (9 - 12 lb ft) 68 - 78 N·m (51 - 58 lb ft) 9 - 12 N·m (6 - 9 lb ft) 274 - 333 N·m (202 - 246 lb ft) 98 - 103 N·m (72.3 - 76 lb ft) 27 - 39 N·m (20 - 29 lb ft) 11 - 16 N·m (8 - 12 lb ft) 9 - 13 N·m (7 - 9 lb ft) 14 - 20 N·m (10 - 14 lb ft) 7 - 12 N·m (6 - 9 lb ft) 14 - 20 N·m (10 - 14 lb ft) 9 - 13 N·m (7 - 9 lb ft)

25 - 29 N·m (18 - 22 lb ft) 49 - 54 N·m (36 - 40 lb ft) 12 - 17 N·m (9 - 12 lb ft) 68 - 78 N·m (51 - 58 lb ft) 9 - 12 N·m (6 - 9 lb ft) 274 - 333 N·m (202 - 246 lb ft) 98 - 103 N·m (72.3 - 76 lb ft) 27 - 39 N·m (20 - 29 lb ft) 11 - 16 N·m (8 - 12 lb ft) 9 - 13 N·m (7 - 9 lb ft) 14 - 20 N·m (10 - 14 lb ft) 7 - 12 N·m (6 - 9 lb ft) 14 - 20 N·m (10 - 14 lb ft) 9 - 13 N·m (7 - 9 lb ft)

25 - 29 N·m (18 - 22 lb ft) 49 - 54 N·m (36 - 40 lb ft) 12 - 17 N·m (9 - 12 lb ft) 68 - 78 N·m (51 - 58 lb ft) 9 - 12 N·m (6 - 9 lb ft) 274 - 333 N·m (202 - 246 lb ft) 98 - 103 N·m (72.3 - 76 lb ft) 27 - 39 N·m (20 - 29 lb ft) 11 - 16 N·m (8 - 12 lb ft) 9 - 13 N·m (7 - 9 lb ft) 14 - 20 N·m (10 - 14 lb ft) 7 - 12 N·m (6 - 9 lb ft) 14 - 20 N·m (10 - 14 lb ft) 9 - 13 N·m (7 - 9 lb ft)

49 - 53.9 N·m (36 - 39 lb ft) 49 - 53.9 N·m (36 - 39 lb ft) 49 - 53.9 N·m (36 - 39 lb ft)

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Engine - Engine and crankcase

Metric Bolt Torque Specifications Bolt Size

Grade No. 4T

M6

7T 10T 4T

M8

7T 10T 4T

M10

7T 10T 4T

M12

7T 10T 4T

M14

7T 11T 4T

M16

7T 11T 4T

M18

7T 11T 4T

M20

7T 11T

Coarse Thread Fine Thread Pitch Torque 4.9 - 6.9 N·m (3.6 - 5.1 lb ft) 1.0 8.3 - 11.3 N·m (6.1 - 8.3 lb ft) 11.8 - 15.7 N·m (8.7 - 11.6 lb ft) 12.7 - 16.7 N·m (9.4 - 12.3 lb ft) 1.25 22.6 - 28.4 N·m (16.6 - 21.0 lb ft) 28.4 - 36.3 N·m (21.0 - 26.8 lb ft) 25.5 - 33.3 N·m (18.8 - 24.6 lb ft) 1.5 44.1 - 55.9 N·m (32.5 - 41.2 lb ft) 53.9 - 69.6 N·m (39.8 - 51.4 lb ft) 37.3 - 47.1 N·m (27.5 - 34.7 lb ft) 1.75 65.7 - 83.4 N·m (48.5 - 61.5 lb ft) 92.2 - 116 N·m (68.0 - 85.4 lb ft) 62.8 - 80.4 N·m (46.3 - 59.3 lb ft) 2.0 104 - 131 N·m (76.7 - 96.9 lb ft) 139 - 175 N·m (102 - 129 lb ft) 86.3 - 110 N·m (63.6 - 81.0 lb ft) 2.0 140 - 184 N·m (110 - 136 lb ft) 206 - 255 N·m (152 - 188 lb ft) 114 - 141 N·m (83.9 - 104 lb ft) 2.0 196 - 235 N·m (145 - 174 lb ft) 275 - 333 N·m (203 - 246 lb ft) 144 - 179 N·m (106 - 132 lb ft) 2.5 240 - 289 N·m (177 - 213 lb ft) 363 - 441 N·m (268 - 325 lb ft)

Engine - Special tools Boomer™ 3040 CVT Boomer™ 3045 CVT Boomer™ 3050 CVT

WE WE WE

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Fine Thread Pitch Torque

1.0

1.25

1.25

1.5

1.5

1.5

1.5

15.2 - 20.1 N·m (11.2 - 14.8 lb ft) 26.5 - 34.3 N·m (19.5 - 25.3 lb ft) 30.4 - 40.2 N·m (22.4 - 29.7 lb ft) 28.4 - 36.3 N·m (21.0 - 26.8 lb ft) 49.0 - 62.8 N·m (36.2 - 46.3 lb ft) 57.9 - 73.5 N·m (42.7 - 54.2 lb ft) 43.1 - 54.9 N·m (31.8 - 40.5 lb ft) 74.5 - 94.1 N·m (55.0 - 69.4 lb ft) 99.0 - 127 N·m (73.1 - 93.3 lb ft) 69.6 - 87.3 N·m (51.4 - 64.4 lb ft) 117 - 148 N·m (86.1 - 109 lb ft) 147 - 186 N·m (108 - 137 lb ft) 91.2 - 115 N·m (67.3 - 84.6 lb ft) 157 - 192 N·m (116 - 142 lb ft) 221 - 270 N·m (163 - 199 lb ft) 131 - 163 N·m (96.9 - 120 lb ft) 230 - 279 N·m (170 - 206 lb ft) 299 - 368 N·m (221 - 271 lb ft) 172 - 211 N·m (127 - 156 lb ft) 275 - 333 N·m (203 - 246 lb ft) 397 - 485 N·m (293 - 358 lb ft)

Engine - Cylinder heads

Cylinder head - Static description WE WE WE

Boomer™ 3040 CVT Boomer™ 3045 CVT Boomer™ 3050 CVT

Cylinder Head and Valve Train Components The cylinder head incorporates the valve assemblies, rocker arms, rocker shaft, push rods, and lifters. A swirl chamber located between the injector assembly and the main combustion chamber of the cylinders provides improved starting and greater fuel efficiency. Initial combustion starts in the precombustion chamber and as the expansion occurs a strong swirl pattern is created in the main combustion chamber for more complete combustion of the air-fuel mixture. The air intake manifold is separate from the cast aluminum valve cover on all these engines. The exhaust manifold is bolted on the left-hand side of the cylinder head on each of the models. Cylinder heads have integral valve guides. Standard size valves only are used.

The cylinder block assembly contains the pistons, connecting rods, crankshaft, timing gears, and engine oil pump.

The crankshaft is supported on five main bearings. The front bearing is positioned in a bore in front of the block. The other bearings are split liners located in holders bolted to the block. The camshaft is supported on four ball bearings located in the block.

7607624950

1

Engine models ISM N844 and ISM N844L

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Engine - Cylinder heads

Valve cover - Install WE WE WE

Boomer™ 3040 CVT Boomer™ 3045 CVT Boomer™ 3050 CVT

Prior operation: Valve drive and gears - Clearance (Valves) (10.106).

1. Install a new gasket (1) and position the valve cover (2) over the rocker arms.

2. Install the valve cover retaining bolts (3), and tighten to 12 - 16 N·m (9 - 19 lb ft).

3. Install and tighten the seal washer (4), and cap nuts (5).

76075733A

Next operation: Water pump - Install (with Cooling Fan) (10.400).

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1

Engine - Cylinder heads

Cylinder head - Compression test WE WE WE

Boomer™ 3040 CVT Boomer™ 3045 CVT Boomer™ 3050 CVT

Compression test is performed through the glow plug ports. The test adapter tool (1), is equipped with quick coupler ends for easy installation of the hose and gauge.

The procedures to perform a compression test are as follows: 1. Remove the wire lead from the fuel injection pump solenoid.

2. Remove the glow plug electrical wire and wire connector from top of the glow plugs.

SECT10C01PG17_1

1

SECT10C01PG17_2

2

3. Remove all of the glow plugs.

NOTE: Be sure all the glow plugs are removed before starting the compression tests.

4. Install the adapter Tool No. FNH00120 , hose and gauge assembly OEM1074 (2), in each port and crank the engine until pressure stabilizes. The gauge should read 2944 kPa (427 psi) ) plus or minus 345 kPa (50 psi) .

NOTE: It may be necessary to remove some injector fuel lines to install the adapter tool.

NOTE: There should not be more than 345 kPa (50 psi) variation between the cylinders.

5. When all cylinders have been tested, reinstall the glow plugs and electrical connections.

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Engine - Cylinder heads

Cylinder head - Remove WE WE WE

Boomer™ 3040 CVT Boomer™ 3045 CVT Boomer™ 3050 CVT

Prior operation: Rocker Arm Shaft and Support Bracket - Remove; See: “Engine Disassemble”..

1. Remove the valve stem caps (1), and push rods (2).

2. To remove the cylinder head, remove the cylinder head bolts (3), by alternately loosening a half turn at a time to prevent warping the head.

NOTE: Keep all valve components in separately marked containers for reassembly in their original location.

20093361A

Next operation: Valve Tappet - Removal; See: “Engine Disassemble”.

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Engine - Cylinder heads

Cylinder head - Inspect WE WE WE

Boomer™ 3040 CVT Boomer™ 3045 CVT Boomer™ 3050 CVT

Prior operation: Crankcase gears - Remove - with Camshaft (10.114).

1. Disassembly 1.

Clean the cylinder head and remove any carbon deposits from around the valve heads.

2.

Use a valve spring compressor and remove the valve spring retainer locks (1), spring (2), and spring retainer (3), from each valve (4).

3.

Remove the valves and place the valve components together in separately marked containers for reassembly in their original position.

20093369

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20093370

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2. Inspection and Repair 1.

Clean all carbon deposits from the combustion chamber and valve ports using a wire brush and scraper.

2.

Clean all dirt and residue from the gasket surface using care not to scratch or nick the machined surface.

3.

Clean the cylinder head in solvent and air dry.

4.

Inspect the head for cracks or damage in the following areas: • Valve ports • Valve seats (2).

• Prechamber (3).

• External cracks in the water jackets (1)..

5.

Inspect the gasket surfaces for scratches or nicks, which could cause leakage.

6.

Examine the core hole plugs for rust or signs of leakage. If a plug shows signs of damaging rust or leakage, replace all plugs in the head.

7.

Inspect the prechamber for carbon deposits and looseness. Remove any carbon deposits found.

If prechamber is found to be loose, cylinder head may be warped.

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Engine - Cylinder heads

3. Inspection, Continued • Use a straight edge and a feeler gauge and check the cylinder head for warp lengthwise, crosswise, and diagonally

20093371F

Next operation: Valve drive and gears - Inspect - Valve Seats (10.106).

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3

Engine - Cylinder heads

Cylinder head - Replace (Gasket) WE WE WE

Boomer™ 3040 CVT Boomer™ 3045 CVT Boomer™ 3050 CVT

During assembly, the ultimate engine compression ratio is established by the thickness of the head gasket used. For service replacement, head gaskets of different thickness are available. The correct head gasket must be selected based upon the amount the piston protrudes above the face of the block when at top dead center. The correct head gasket usage is determined as follows:

Head Gasket Selection 1. Position each of the pistons at top dead center and, using a dial indicator, determine the distance each piston projects above the face of the block.

NOTE: Measure each of the pistons while holding a slight down pressure on the piston. Use the dimension taken from the cylinder which has the greatest projection and select a head gasket as indicated in the following chart.

NOTE: The variation in the amount of protrusion among all pistons must be within 0.1 mm (0.004 in).

20002377

Selection Chart Engine Model ISM N844

ISM N844L

Measurement Value Head Gasket Part No. Installed Thickness 0.5 - 0.6 mm 0.0236 in) 0.6 - 0.7 mm 0.02756 in) 0.5 - 0.6 mm 0.0236 in) 0.6 - 0.7 mm 0.02756 in)

(0.0197 (0.0236 (0.0197 (0.0236 -

111147510

1.2 mm (0.0472 in)

111147520

1.3 mm (0.0512 in)

1111477711

1.2 mm (0.0472 in)

111147721

1.3 mm (0.0512 in)

Next operation: Cylinder head - Install (10.101).

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1

Engine - Cylinder heads

Cylinder head - Assemble WE WE WE

Boomer™ 3040 CVT Boomer™ 3045 CVT Boomer™ 3050 CVT

Prior operation: Valve drive and gears - Inspect - Push Rods (10.106).

1. Insert each valve in the guide from which it was removed and lightly lap the valve to be sure of an even seat around the valve face. Remove the valve and remove all traces of lapping compound.

2. Install new intake valve seals on the valve guides using a suitable driver.

3. Using a spring compressor, assemble the valves, springs, retainers, and keepers.

Next operation: Crankcase - Inspect (10.001).

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Engine - Cylinder heads

Cylinder head - Install Prior operation: Cylinder head - Replace (Gasket) (10.101).

1. Install the valve tappets (1).

20093430

1

20002380

2

2. Select the proper head gasket and place it on the block with the side marked with the last four digits of the part code no. up.

3. Tighten the head bolts in the sequence as shown.

Tighten first to half torque value, then to the final torque specification of 98 - 103 N¡m (72.3 - 76 lb ft).

4. Replace the push rods and valve stem caps in their original location.

5. Install the rocker shaft support assembly onto the head and tighten the bolts to 27 - 39 N¡m (20 - 29 lb ft).

Next operation: Valve drive and gears - Clearance (Valves) (10.106).

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Engine - Pan and covers

Timing gear housing - Remove Prior operation: Engine block cover Front - Remove (10.102) 1. Drain the engine crankcase oil.

2. Remove the crankshaft pulley.

3. Loosen the four injection pump mounting bolts (2), and raise the injection pump (3), enough to remove the spring pin (1), and separate the governor link from the control rack. Remove the injection pump.

SECT10C01PG42

1

20002371E

2

76075734B

3

4. Insert a small dowel (1), through the fuel shutoff solenoid hole and slide the control rack (2), in to allow enough clearance to the cylinder block, for the pump to be removed.

5. Remove the through bolts and nuts (1), and remove the steering pump from the front cover. Cap the lines and pump openings.

NOTE: Two of the power steering pump retaining bolts are not shown.

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Engine - Pan and covers

6. Install and tighten two nuts (1), against each other, onto the retaining studs (2). Remove the studs (2), and the hydraulic pump (3).

76075735

4

7. Remove the retaining nut (1). Pull crankshaft pulley (2), and key (4), off of crankshaft (3).

76075736

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5

Engine - Pan and covers

8. Remove the retaining bolts (1), and lift the cover (2), off the locating dowels.

SECT10C01PG44_2

Next operation: Timing gear housing - Visual inspection (10.102) Next operation: Crankcase gears - Remove - with Camshaft (10.114).

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6

Engine - Pan and covers

Timing gear housing - Visual inspection Prior operation: Engine flywheel - Inspect (10.103).

1. The timing gear housing (3), contains the front oil seal (1), power steering seal (4), and the governor linkage assembly (2). See "Governor Assembly", for governor linkage repair and replacement procedures.

10044360A

1

10044360B

2

Front Oil Seal and Steering Pump Seal Replacement 2. Remove the front oil seal (1), from the timing gear cover (3), and insert a new oil seal in its place.

3. Remove the steering pump seal (4), located on the front of the timing gear cover, and replace with a new seal.

Next operation: Water pump - Inspect (10.400).

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Engine - Pan and covers

Timing gear housing - Install Prior operation: Crankcase gears - Install (Idler Gear, Oil Pump, and Injection Timing) (10.114).

1. Install new cover gasket.

2. Insert the governor linkage through the block.

3. Rotate the oil pump cover to position the spring pin hole (2).

4. Install cover locating pin in the oil pump cover plate.

10044361B

1

SECT10C01PA44_2

2

5. Install the cover retaining bolts (1).

Next operation: Crankshaft - Install (Pulley) (10.103).

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Engine - Pan and covers

Engine block cover Front - Remove 1. Remove the crankcase ventilation system (1). Refer to Crankcase ventilation system - Remove (10.304) for the proper procedure.

NHIL14ENG0610AA

1

NHIL14ENG0611AA

2

NHIL14ENG0612AA

3

2. Remove the crankshaft pulley bolts (2).

3. Remove the crankshaft pulley (3).

4. Remove the connector for the camshaft sensor (1).

5. Remove the cover retaining bolts (1).

NOTE: Take note of the bolt size and location.

6. Remove the front cover (2).

Next operation: Engine block cover Front - Install (10.102)

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Engine - Pan and covers

Engine block cover Front - Install Prior operation: Engine block cover Front - Remove (10.102) 1. Clean the sealing surface (1) of the cover.

NHIL14ENG0614AA

1

NHIL14ENG0613AA

2

NHIL14ENG0616AA

3

NHIL14ENG0615AA

4

2. Clean the sealing surface (1) of timing gear housing.

3. Install the front cover (1) with a new gasket.

4. Loosely install two bolts (2) to hold everything in place.

5. Install the crankcase ventilation drive hub (1).

6. Torque the nut to 80 N¡m (59 lb ft).

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Engine - Pan and covers

7. Install the lower alignment tool 380100280 (2) on the crankshaft.

8. Install the upper alignment tool 380100281 (1) onto the drive hub to align the front cover.

83119829

5

NHIL14ENG0612AA

6

9. Install the remainder of the front cover retaining bolts (1).

10. Torque the front cover retaining bolts (1) to 20 - 30 N¡m (15 - 22 lb ft).

11. Remove the alignment tools.

Next operation: Crankcase ventilation system - Install (10.304)

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Engine - Pan and covers

Engine oil pan - Remove NOTE: Oil pan images may vary depending on your model.

1. Drain the engine oil.

2. Remove the oil pan bolts (3).

3. Remove the oil pan retaining plate (2).

4. Remove the oil pan (1).

NHIL14ENG0605AA

1

NHIL14ENG0606AA

2

5. Remove the pick up tube support bolts (2).

6. Remove the Allen head bolt (1) from the pick up tube.

7. Remove the pick up tube (3) from the engine block.

Next operation: Engine oil pan - Install (10.102)

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Engine - Pan and covers

Engine oil pan - Install Prior operation: Engine oil pan - Remove (10.102) NOTE: Oil pan images may vary depending on your model.

1. Install a new O-ring (1) on the pick up tube.

NHIL14ENG0607AA

1

NHIL14ENG0606AA

2

NHIL14ENG0609AA

3

2. Install the oil pick up tube (3) into the engine block until the O-ring seats.

3. Install the Allen head bolt (1) into the pick up tube.

4. Torque the tube bolt (1) to 10 N¡m (7 lb ft).

5. Install the two M10 x 20 bolts (2) into the pick up tube support.

6. Torque the pick up tube support bolts (2) to 45 N¡m (33 lb ft).

7. Install the new gasket (1) on the oil pan (2).

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Engine - Pan and covers

8. Install the oil pan (1) with the oil pan retaining plate (2).

9. Install the oil pan retaining bolts (3).

10. Torque the bolts (3) as follows: • M10 x 35 = 45 N·m (33 lb ft) • M8 x 35 = 25 N·m (18 lb ft)

NHIL14ENG0605AA

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4

Engine - Crankshaft and flywheel

Engine flywheel - Inspect WE WE WE

Boomer™ 3040 CVT Boomer™ 3045 CVT Boomer™ 3050 CVT

Prior operation: Crankcase gears - Inspect (Camshaft) (10.114).

1. Inspect the ring gear for cracked, broken, chipped, or worn gear teeth. If found damaged, replace the ring gear.

2. If necessary, remove the starter ring gear using a hammer and chisel to crack the ring gear.

20093403

3. To reinstall a new ring gear, heat the new ring gear to 120 - 150 °C (245 - 300 °F) from the inside only.

Be careful not to overheat the ring gear teeth. Use a temperature sensitive crayon to mark the inside of the ring gear. Quench the ring gear quickly to obtain a good shrink fit onto the flywheel.

Next operation: Timing gear housing - Visual inspection (10.102) .

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Engine - Crankshaft and flywheel

Engine flywheel - Install WE WE WE

Boomer™ 3040 CVT Boomer™ 3045 CVT Boomer™ 3050 CVT

Prior operation: Rear Oil Seal and Backplate Install.

1. Fit the flywheel (2), to the crankshaft (1), and align the bolt holes.

2. Install the flywheel retaining bolts and tighten to 69 78 N·m (51 - 57 lb ft).

20093407A

Next operation: Connecting rod and piston - Install (10.105).

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Engine - Crankshaft and flywheel

Engine flywheel - Remove WE WE WE

Boomer™ 3040 CVT Boomer™ 3045 CVT Boomer™ 3050 CVT

Prior operation: Connecting rod and piston - Remove (10.105).

1. Loosen the flywheel retaining bolts.

2. Using a brass drift and hammer, tap the end of the crankshaft (1), to loosen the flywheel (2), from the shaft.

20093407

Next operation: Backplate and Oil Seal - Remove; See: ”Engine Disassemble”..

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Engine - Crankshaft and flywheel

Crankshaft - Inspect (Main Bearing and Thrust Washer) WE WE WE

Boomer™ 3040 CVT Boomer™ 3045 CVT Boomer™ 3050 CVT

Prior operation: Connecting rod and piston - Assemble (10.105).

Removal and Inspection

20044366

1

(1) Holder (2) Upper Main Liner (with oil groove) (3) Thrust Bearing (4) Lower Main Liner (no oil groove)

1. Remove the two retaining bolts from the bearing holders (1).

2. Remove the bearing holders and bearing liners (2).

3. Position a piece of plastigauge across the full width of the bearing liners.

4. Install the bearing holder and tighten the bolts to 49.0 53.9 N·m (36.2 - 39.8 lb ft).

NOTE: Do not permit the bearing holder to rotate, even the slightest amount.

5. Remove the bearing holders and measure the width of the flattened plastigauge using the gauge printed on the plastigauge package.

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