New Holland Boomer 54D CVT Tier 4B (final) Compact Tractor Service Repair Manual

SERVICE MANUAL

SERVICE MANUAL

Boomer 54D CVT Tier 4B (final) Compact Tractor

Boomer 54D CVT Tier 4B (final) Compact Tractor

1/2

Part number 48017704

TM

Part number 48017704

TM

1st edition English October 2016

© 2016 CNH Industrial America LLC. All Rights Reserved.

SERVICE MANUAL Boomer™ 54D CVT TIER 4B (FINAL), Cab Boomer™ 54D CVT TIER 4B (FINAL), ROPS

48017704 28/10/2016 EN

Link Product / Engine Product Boomer™ 54D CVT TIER 4B (FINAL), Cab Boomer™ 54D CVT TIER 4B (FINAL), ROPS

Market Product Europe

R 753 IE4

Europe

R 753 IE4

48017704 28/10/2016

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 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.501] Exhaust Gas Recirculation (EGR) exhaust treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15

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 48017704 28/10/2016

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

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 [55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.024] Transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 48017704 28/10/2016

[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11 [55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13 [55.989] Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15

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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1

Contents INTRODUCTION Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety rules - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Basic instructions - Shop and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Torque - Standard torque data for hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Torque Wheel Bolt Torques (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Basic instructions Hardware (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Basic instructions Tire ballast and pressures (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 International symbols (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 General specification wheel tread settings (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 General specification Tire Pressures (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Dimension General (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Weight (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Capacities (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Consumables (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Product identification General information (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

(*) See content for specific models 48017704 28/10/2016

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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™ 54D CVT TIER 4B (FINAL), Cab Boomer™ 54D CVT TIER 4B (FINAL), ROPS

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Engine - Engine and crankcase

Engine and crankcase - Remove : Separating the tractor at the engine - front transmission box WARNING Heavy object!

ALWAYS use a hoist or get assistance to lift the component.

Failure to comply could result in death or serious injury.

W0086A

NOTICE: Drain the engine coolant. The capacity of the cooling system is 9 L (2 US gal) NOTICE: Drain the engine crankcase oil. The capacity of the crankcase is 6.3 L (2 US gal) NOTE: To separate the tractor between the engine and the front transmission box, the hood and cab must be removed.

To accomplish this, see “Platform� Section 90, for removal procedures.

1. Remove the negative (-) battery cable, (1), and the positive (+) battery cable, (2), from the battery.

2. Remove the engine hood.

(90.100).)

(See Hood - Remove

86064532

NOTE: See Cab frame - Remove (90.150) before proceeding.

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1

Engine - Engine and crankcase

NHIL16CT00081FA(1)

2

Components located underneath the tractor that must be disconnected for engine removal (1) Cab wiring harness (2) Transmission cooler outlet

(3) Transmission cooler outlet (4) Wiring harness at the firewall

(5) Rear Front Wheel Drive (7) FWD shaft (FWD) shaft shield (6) Front Front Wheel Drive (8) Oil supply pipe to (FWD) shaft shield hydraulic pump

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Engine - Engine and crankcase

3. Evacuate the air conditioning system. (See Air conditioning - Service instruction - Evacuating the Refrigerant (50.200). ) 4. Disconnect the air conditioning refrigerant lines, see figure 3, (1) and figure 4, (2).

NOTE: Location (1) should have been disconnected at the cab removal.

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5. Remove the hood mounting bracket (1), and hinge (2).

6. Remove the air cleaner (1) , see Air cleaner - Remove (10.202).

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7. Remove the exhaust pipe (1).

8. Remove the M12 x 40, 10.9 bolt (2).

9. Remove the clamp (3).

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10. Remove the Particulate Matter Catalyst (PM CAT) (1), see Particulate Matter (PM) catalyst - Remove (10.501)

11. Disconnect the power steering return hose, (1), from the hydraulic system inlet tube, (2). Remove the hydraulic system inlet tube, (2), from the hydraulic pump, (3).

12. Remove the hydraulic system oil supply tube, (5), to the hydraulic pump, (3).

13. Disconnect the steering lines (6).

14. Disconnect the wire harness, (1), from the starter, (2).

NHIL16CT00054AA

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10

Engine - Engine and crankcase

15. Remove the Front Wheel Drive (FWD) driveshaft shield at the FWD axle (1).

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16. Remove the FWD driveshaft shield at the transmission (2).

17. Remove the roll pins, (1), from the front and rear of the FWD driveshaft, (2), and remove the driveshaft from the tractor.

18. Remove the fuel supply, (1), and return, (2), lines from the fuel filter, (3).

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19. Disconnect the wiring harness under the tractor (1), (See figure 15 ) and at the fire wall (2) (See figure 16).

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20. Disconnect the engine coolant hoses (1), and (2).

21. Attach a chain sling, (1), to the two hoist eyes, (2).and (3), on the engine.

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22. Attach a suitable hoist, (1), to the chain sling, (2).

NOTE: The hoist is used for supporting the engine and axle assembly, not for lifting.

23. Roll a floor jack under the tractor from the rear of the tractor, and place under the front transmission box.

Raise the jack enough to support the drive train.

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19

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24. Remove the nine M10 x 75 buckle-up bolts, (3), that secure the engine, (4), to the front transmission box, (5).

NOTE: The hoist and/or the floor jack may need to be raised or lowered to allow the separation of the engine from the front transmission box.

25. Remove the two M12 x 40 full thread bolts (1).

26. Remove the two M10 nuts (2) from the studs.

27. Carefully roll the drive train away from the engine, using the floor jack for support.

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Engine - Engine and crankcase

Engine and crankcase - Remove the engine from the frame DANGER Heavy objects!

Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.

Failure to comply will result in death or serious injury.

D0076A

1. Use jack stands under the frame rails to support the front frame/engine assembly.

2. Remove the Air Conditioner (A/C) compressor guard, (1), from the tractor.

3. Remove the two M16 flange bolts (2), and loosen the two grommet bolts (3).

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NHIL16CT00010AA

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4. Remove the radiator hose guard (1) from the tractor.

5. Loosen the two grommet bolts (2), and remove the two M16 bolts (3).

6. Drain the coolant from the radiator into a suitable container.

7. Remove the top, (3), and the bottom, (4), radiator hoses.

8. Remove the radiator. See Radiator - Remove (10.400) for more information.

9. Attach a chain sling to the two hoist eyes on the engine.

10. Attach a suitable hoist to the chain sling, and raise the hoist enough to support the engine.

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11. Loosen and remove the ten M12 x 40 engine mounting bolts, (1), on both sides of the frame.

12. Carefully lift the engine from the frame.

13. Attach the engine to a suitable engine stand.

14. With the engine securely attached to the engine stand, remove the chain sling from the two engine hoist eyes.

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Next operation: Engine and crankcase - Install the engine into the frame (10.001)

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Engine - Engine and crankcase

Engine and crankcase - Install the engine into the frame WARNING Heavy objects!

Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.

Failure to comply could result in death or serious injury.

W0398A

Prior operation: Engine and crankcase - Remove the engine from the frame (10.001) 1. Use jack stands under the frame rails to support the front frame/engine assembly.

2. With the engine securely attached to the engine stand, install the chain sling from the two engine hoist eyes.

3. Remove the engine from the engine stand.

4. Carefully lift the engine and install it into the frame.

5. Install and tighten the ten M12 x 40 engine mounting bolts, (1), on both sides of the frame. Torque these bolts to 115 N¡m (85 lb ft).

6. Attach a suitable hoist to the chain sling, and raise the hoist enough to support the engine.

7. Install the radiator, See Radiator - Install (10.400)..

NOTE: This instruction will cover the installation of the radiator, shroud, inter cooler, oil cooler , fuel oil cooler , coolant expansion tank, horn and relay, and the receiver dryer.

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NHIL16CT00031AA

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8. Install the upper radiator hose (1).

9. Install the lower radiator hose (2).

10. Replace the coolant in the cooling system to the specification. The coolant system capacity is 9 L (2 US gal).

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11. Install the radiator hose guard (1) onto the tractor.

12. Tighten the two grommet bolts (2), and install the two M16 bolts (3).

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13. Install the A/C compressor guard, (1), onto the tractor.

14. Install the two M16 flange bolts (2), and tighten the two grommet bolts (3).

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Engine and crankcase - Install Attaching the front transmission box to the engine WARNING Heavy object!

ALWAYS use a hoist or get assistance to lift the component.

Failure to comply could result in death or serious injury.

W0086A

NOTE: The tractor drivetrain is supported by a floor jack from the removal process.

1. Raise the jack enough to support the drive train.

2. Attach a suitable hoist, (1), to the chain sling, (2).

NOTE: The hoist and/or the floor jack may need to be raised or lowered to allow the joining of the engine to the front transmission box.

NOTE: The hoist is used for supporting the engine and axle assembly, not for lifting.

3. Carefully roll the drivetrain toward the engine, using the floor jack for support.

76083809N

1

NHIL16CT00009AA

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4. Install the two M12 x 40 full thread bolts (1).

5. Install the two M10 nuts (2) onto the studs.

6. Install the nine M10 x 75 buckle-up bolts, (3), that secure the engine, (4), to the front transmission box, (5).Torque these bolts to 71 N¡m (52 lb ft)

7. Connect the engine coolant hoses (1), and (2).

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NHIL16CT00081FA(1)

4

Components located underneath the tractor that must be connected for engine installation (1) Cab wiring harness (2) Transmission cooler outlet

(3) Transmission cooler outlet (4) Wiring harness at the firewall

(5) Rear Front Wheel Drive (7) FWD shaft (FWD) shaft shield (6) Front Front Wheel Drive (8) Oil supply pipe to (FWD) shaft shield hydraulic pump

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Engine - Engine and crankcase

8. Connect the wiring harness under the tractor (1), (See figure 5 ) and at the fire wall (2) (See figure 6).

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NHIL16CT00053AA

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NHIL15CT00006AA

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20000904N

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9. Install the fuel supply, (1), and return, (2), lines to the fuel filter, (3).

10. Install the FWD drive shaft.

1.

Install the roll pins, (1), from the front and rear of the FWD driveshaft, (2), and remove the driveshaft from the tractor.

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11. Install the Front Wheel Drive (FWD) driveshaft shield at the FWD axle (1).

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12. Install the FWD driveshaft shield at the transmission (2).

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13. Connect the wire harness, (1), on the starter, (2).

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14. Connect the power steering return hose, (1), at the hydraulic system inlet tube, (2). Install the hydraulic system inlet tube, (2), at the hydraulic pump, (3).

15. Connect the steering lines (6).

16. Connect the hydraulic system oil supply tube, (5), to the hydraulic pump, (3).

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17. Install the Particulate Matter Catalyst (PM CAT), see Particulate Matter (PM) catalyst - Install (10.501) 18. Install the exhaust pipe (1).

19. Install the M12 x 40, 10.9 bolt (2).

20. Install the clamp (3).

21. Install the air cleaner (1) , see Air cleaner - Install (10.202) .

NOTE: After the tractor is joined at the engine and the front transmission box, the hood and cab must be installed To accomplish this, see “Platform� Section 90, for removal procedures.

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22. Install the hood mounting bracket (1), and hinge (2).

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NOTE: See Cab frame - Install (90.150) before proceeding.

23. Disconnect the air conditioning refrigerant lines, see figure 17, (1) and figure 18, (2).

NOTE: Location (1) should have been connected after the cab installation..

24. Evacuate the air conditioning system. (See Air conditioning - Service instruction - Evacuating the Refrigerant (50.200).)

25. Charge the air conditioning system. (See Air conditioning - Charging (50.200).)

26. Install the engine oil filter.

27. Fill the engine to specifications.

28. Connect the negative (-) battery cable, (1), and the positive (+) battery cable, (2), from the battery.

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Crankcase - Inspect WE WE WE

Boomer™ 54D CVT TIER 4B (FINAL), Cab Boomer™ 54D CVT TIER 4B (FINAL), ROPS Boomer™ 54D CVT

Prior operation: Cylinder head - Assemble (10.101).

1. Inspect the cylinder block top face for cracks, damage, and warping in the same way as for the cylinder head. Replace the cylinder block if warp is greater than 0.12 mm (0.005 in).

2. Visually inspect the cylinder bore. There should be no scoring, rust, or corrosion.

3. Using a telescoping gauge in line with the crankshaft, measure the inside diameter of the top of the bore (approximately 15 mm (0.59 in) below the top of the block) on all models.

4. Repeat this measurement at right angles to the crankshaft at the same distance.

5. In line with the crankshaft at the bottom of the bore, measure (approximately 117 mm (4.6 in) Model ISM N844, and 127 mm (5 in) Model ISM N844L) from the top of the cylinder.

20093380

6. Repeat this measurement at right angles to the crankshaft at the same distance.

7. If any of the measurements taken indicate worn or damaged cylinder bores, replace engine block with a long block assembly.

NOTE: If the cylinder bore measures 84.2 mm (3.315 in) long replace the block assembly.

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

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