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New Holland TL80A Tractor Service Repair Manual.pdf

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This document is a service manual for tractor models TL70A, TL80A, TL90A and TL100A. It contains sections on general guidelines, the engine, clutch, transmissions, drive lines, brakes, hydraulics and other systems. The engine section includes specifications, diagrams, removal/installation procedures and troubleshooting. Other sections provide similar information for additional components and systems.

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TRACTORS TL70A - - TL80A - - TL90A - - TL100A SERVICE MANUAL SECTIONS GENERAL GUIDELINES 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE LINES 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT MECHANICAL TRANSMISSION 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR MECHANICAL TRANSMISSION 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER TAKE-OFF 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKES 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SYSTEMS 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE AND WHEELS 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAB AIR CONDITIONING SYSTEM 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATFORM, CAB, BODYWORK 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S E R V I C E
INTRODUCTION ◊ This manual is divided into sections identified by two- -figure numbers and each section has independent page numbering. For easy reference, these sections have the same numbers and names as the Repairs Rate Book sections. ◊ 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 a two- -figure update number (e.g., 1st Update 603.54.511.01; 2nd Update 603.54.511.02; etc.) and by the corresponding issue date. These pages will be supplemented by a reprint of the updated contents page. ◊ 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 im- plemented 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 re- sponsible 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 dam- age 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 Manufac- turer. 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. TEXT AND ILLUSTRATIONS ARE THE PROPERTY OF CNH ITALIA S.p.A. No part of the text or illustrations may be reproduced PRINTED IN ITALY CNH ITALIA S.p.A. - - Viale delle Nazioni, 55 - - 41100 MODENA - - Italy Product Support -- Technical Information Print No. 603.54.511.00 -- 03 -- 2006
CONTENT 3 603.54.511.00 -- 03 -- 2006 CONTENT VOLUME 1 Page Date 00 - - GENERAL GUIDELINES General instructions . . . . . 1--2 03--06 Safety regulations . . . . . . . 3--4--5 03--06 Consumables . . . . . . . . . . . 6 03--06 10 - - ENGINE Summary . . . . . . . . . . . . . . . 1 03--06 General specifications . . . . 2 to 4 03--06 Fuel system data . . . . . . . . 5 03--06 Crankshaft and engine block data . . . . . . . . . . . . . . 6 03--06 Connecting rod data . . . . . 7 03--06 Piston data . . . . . . . . . . . . . 7--8 03--06 Timing gear data . . . . . . . . 8--9 03--06 Cylinder head data . . . . . . 9--10 03--06 Tightening Torques . . . . . . 11--12 03--06 Tools . . . . . . . . . . . . . . . . . . 13 03--06 View of 4--cylinder engine mod. TL70A and TL80A . . 14 03--06 View of 4--cylinder engine mod. TL90A and TL100A . 15 03--06 Engine cooling and lubrica- tion diagrams . . . . . . . . . . . 16--17 03--06 Component parts of cylin- der head mod. TL70A and TL80A . . . . . . . . . . . . . . . . . 18 03--06 Component parts of cylin- der head mod. TL90A and TL100A . . . . . . . . . . . . . . . . 19 03--06 Component parts of addi- tional counterweights . . . . 20 03--06 Troubleshooting . . . . . . . . . 21 to 24 03--06 Engine removal--installa- tion . . . . . . . . . . . . . . . . . . . . 25 to 44 03--06 Engine disassembly--as- sembly . . . . . . . . . . . . . . . . . 45 to 78 03--06 Checks and measure- ments -- cylinder block and liners . . . . . . . . . . . . . . . . . . 79 to 81 03--06 Checks and measure- ments -- crankshaft, bear- ings and flywheel . . . . . . . . 82 to 83 03--06 Checks and measure- ments -- connecting rods . 84 to 85 03--06 Page Date Checks and measure- ments -- pistons . . . . . . . . . 86 to 89 03--06 Checks and measure- ments -- camshaft, tappets and valves . . . . . . . . . . . . . . 90 to 93 03--06 Checks and measure- ments -- cylinder head . . . . 94 03--06 Functional testing on low engine oil pressure indica- tor . . . . . . . . . . . . . . . . . . . . . 95 03--06 Checks and measure- ments -- cooling system . . 96 03--06 Replacing crankshaft front seal . . . . . . . . . . . . . . . . . . . 97 to 99 03--06 Replacing crankshaft rear seal . . . . . . . . . . . . . . . . . . . 100 to 102 03--06 Adjusting tappet, valve and rocker arm clearance . . . . 103 to 105 03--06 Removal--Installation -- in- jectors . . . . . . . . . . . . . . . . . 106 to 108 03--06 Removal -- Installation -- Bosch injection pump . . . . 109 to 113 03--06 Bosch injection pump -- tim- ing . . . . . . . . . . . . . . . . . . . . 114 to 118 03--06 Bosch injection pump -- air bleeding . . . . . . . . . . . . . . . . 118 03--06 Removal--Installation -- coolant pump . . . . . . . . . . . 119--120 03--06 Removal--Installation -- thermostat valve . . . . . . . . . 121--122 03--06 Removal--Installation -- radiator . . . . . . . . . . . . . . . . 123 to 128 03--06 Coolant pump drive belt ad- justment . . . . . . . . . . . . . . . . 129 to 130 03--06 18 - - CLUTCH Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 03--06 Tightening Torques . . . . . . 3 03--06 Tools . . . . . . . . . . . . . . . . . . 3 03--06 Cross--sectional views . . . 4 03--06 Troubleshooting . . . . . . . . . 5 03--06 Checks and measure- ments -- clutch . . . . . . . . . . 6--7 03--06 Adjustments -- clutch pedal 8 03--06 Removal--Installation -- clutch . . . . . . . . . . . . . . . . . . 9 to 11 03--06 Clutch Overhaul . . . . . . . . . 12 to 15 03--06
4 CONTENT 603.54.511.00 -- 03 -- 2006 Page Date Adjustments -- clutch disen- gagement levers . . . . . . . . 16 03--06 21 - - TRANSMISSIONS CHAPTER 1 - - Transmission and range gear (12x4) Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 03--06 Tightening Torques . . . . . . 3 03--06 Tools . . . . . . . . . . . . . . . . . . 4--5 03--06 Cross--sectional views . . . 6--7 03--06 Description & Operation . . 8 03--06 Troubleshooting . . . . . . . . . 8 03--06 Transmission longitudinal cutaway section view . . . . 9 03--06 CHAPTER 2 - - Reverser Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 03--06 Tightening Torques . . . . . . 3 03--06 Tools . . . . . . . . . . . . . . . . . . 4 03--06 Cross--sectional views . . . 4--5 03--06 Description & Operation . . 6 03--06 Troubleshooting . . . . . . . . . 6 03--06 Disassembly--Assembly -- clutch casing--reverser . . . 7 to 10 03--06 Transmission longitudinal cutaway section view . . . . 11--12 03--06 CHAPTER 3 - - Dual Command (2 Speed Power Shift) Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2--3 03--06 Tightening Torques . . . . . . 4 03--06 Tools . . . . . . . . . . . . . . . . . . 5 03--06 Cross--sectional views . . . 6 to 8 03--06 Description & Operation . . 10 to 15 03--06 Troubleshooting . . . . . . . . . 16--17 03--06 Removal--Installation -- clutch casing with Dual Command (2 Speed Power Shift) . . . . . . . . . . . . . . . . . . 18 to 26 03--06 Disassembly--Assembly -- clutch casing with Dual Command (2 Speed Power Shift) . . . . . . . . . . . . . . . . . . 27 to 35 03--06 Page Date Control rod adjustments . . 36 03--06 Removal--Installation -- Dual Command (2 Speed Power Shift) solenoid valve 37 to 40 03--06 Working pressure test . . . . 40 03--06 Removal--Installation -- Dual Command (2 Speed Power Shift) control valve 41 to 44 03--06 Disassembly--Assembly -- Dual Command (2 Speed Power Shift) control valve . 45--46 03--06 Transmission longitudinal cutaway section view . . . . 47 03--06 CHAPTER 4 - - Reverser and creeper unit Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 03--06 Tightening torque . . . . . . . . 3 03--06 Tools . . . . . . . . . . . . . . . . . . 4 to 5 03--06 Cross--sectional views . . . 6 to 7 03--06 Description & Operation . . 8 03--06 Troubleshooting . . . . . . . . . 8 03--06 Replacing clutch casing-- reverser and creeper unit . 9 to 13 03--06 End float adjustment be- tween shaft and support . . 14 to 15 03--06 Transmission longitudinal cutaway section view . . . . 16 03--06 CHAPTER 5 - - Power Shuttle tran- smission with Dual Command (2 Speed Power Shift) function Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2--3 03--06 Tightening torque . . . . . . . . 4--5 03--06 Tools . . . . . . . . . . . . . . . . . . 6--7 03--06 Cross--sectional views . . . 8 to 10 03--06 Description & Operation . . 11 to 17 03--06 Range and gear lever posi- tion sensor adjustment 18--19 03--06 Disassembly--Assembly -- clutch casing with power shuttle and Dual Command (2 Speed Power Shift) . . . . 20 to 26 03--06 Disassembly--Assembly -- clutch (A) and (B) . . . . . . . . 27--32 03--06
CONTENT 5 603.54.511.00 -- 03 -- 2006 Page Date Calibrations . . . . . . . . . . . . . 33 03--06 HH MENU access . . . . . . . 33--34 03--06 Clutch calibration H1 menu transmission . . . . . . . . . . . . 35 to 37 03--06 Transmission fault codes . 38 to 40 03--06 23 - - DRIVE LINES Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 03--06 Tightening Torques . . . . . . 3 03--06 Tools . . . . . . . . . . . . . . . . . . 3 03--06 Cross--sectional views . . . 4 03--06 Description & Operation . . 5 03--06 Troubleshooting . . . . . . . . . 6 03--06 Removal--Installation -- ser- vices control valve . . . . . . . 7 to 9 03--06 Disassembly--Assembly -- services control valve . . . . 10 to 11 03--06 Removal--Installation -- drive gear casing . . . . . . . . 12 to 16 03--06 Disassembly--Assembly -- drive gear casing . . . . . . . . 17 to 20 03--06 25 - - FRONT MECHANICAL TRANSMISSION Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 to 4 03--06 Tightening Torques . . . . . . 4--5 03--06 Tools . . . . . . . . . . . . . . . . . . 6 to 8 03--06 Cross--sectional views . . . 9 to 13 03--06 Description & Operation . . 14--15 03--06 Rules for correctly fitting the axle support to the engine 16 03--06 Troubleshooting . . . . . . . . . 17 03--06 Removal--Installation -- front axle . . . . . . . . . . . . . . . 18 to 21 03--06 Disassembly--Assembly -- front axle . . . . . . . . . . . . . . . 22 to 30 03--06 Overhaul -- front differential 31 03--06 Overhaul -- front axle differ- ential with LIM--SLIP . . . . . 32--33 03--06 Overhaul -- differential lock unit . . . . . . . . . . . . . . . . . . . . 34--35 03--06 Disassembly--Assembly -- front epicyclic final drive without brake . . . . . . . . . . . 36 to 38 03--06 Replacing wheel hub seal without brake. . . . . . . . . . . . 39 03--06 Page Date Disassembly--Assembly -- front epicyclic final drive with brake . . . . . . . . . . . . . . 40--41 03--06 Replacing wheel hub seal with brake. . . . . . . . . . . . . . 42 03--06 Replacing steering knuckle pins and bearings . . . . . . . 43 03--06 Stub axle adjustments . . . . 44--45 03--06 Adjustments -- bevel drive 46 to 52 03--06 27 - - REAR MECHANICAL TRANSMISSION Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2--3 03--06 Tightening Torques . . . . . . 3--4 03--06 Tools . . . . . . . . . . . . . . . . . . 5 to 9 03--06 Cross--sectional views . . . 10 to 14 03--06 Description & Operation . . 15 03--06 Troubleshooting . . . . . . . . . 16--17 03--06 Removal--Installation -- transmission--gearbox casing . . . . . . . . . . . . . . . . . 18 to 31 03--06 Disassembly--Assembly -- transmission--gearbox casing . . . . . . . . . . . . . . . . . 32 to 39 03--06 Gearbox driving shaft end float adjustment . . . . . . . . . 40 03--06 Adjustments -- differential lock engagement sleeve position . . . . . . . . . . . . . . . . 41 03--06 Determining the bevel pin- ion positioning adjustment ring . . . . . . . . . . . . . . . . . . . . 42 to 43 03--06 Tapered roller bearings adjustment for pinion shaft 44 03--06 Adjusting the bevel crown wheel bearings and check- ing the clearance between the sides of the bevel drive teeth . . . . . . . . . . . . . . . . . . . 45 to 48 03--06 Differential pinion and side gear backlash adjustment . 49--50 03--06 Differential lock pedal travel adjustment . . . . . . . . . . . . . 51 03--06 Removal--Installation -- final drive . . . . . . . . . . . . . . . 52 to 55 03--06 Disassembly--Assembly -- epicyclic final drive . . . . . . . 55 03--06 Disassembly--Assembly -- drive wheel shaft . . . . . . . . 56--57 03--06
6 CONTENT 603.54.511.00 -- 03 -- 2006 Page Date 31 - - POWER TAKE- -OFF CHAPTER 1 - - Mechanical power take- -off Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 to 4 03--06 Tools . . . . . . . . . . . . . . . . . . 5 03--06 Tightening Torques . . . . . . 5--6 03--06 Cross--sectional views . . . 7 to 9 03--06 Description & Operation . . 10--11 03--06 Troubleshooting . . . . . . . . . 11 03--06 Removal--Installation -- power take--off . . . . . . . . . . 12 to 14 03--06 Disassembly--Assembly -- power take--off . . . . . . . . . . 15 to 17 03--06 CHAPTER 2 - - Electro- -hydraulic power take- -off Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 to 5 03--06 Tools . . . . . . . . . . . . . . . . . . 5 03--06 Tightening Torques . . . . . . 6 03--06 Cross--sectional views . . . 7 to 12 03--06 Description & Operation . . 13 to 22 03--06 Additional PTO controls for cab--version tractors with Power Shuttle trans- missions . . . . . . . . . . . . . . . 23--24 03--06 Troubleshooting . . . . . . . . . 25 03--06 Replacing the power take-- off brake . . . . . . . . . . . . . . . 26--27 03--06 Removal--Installation -- power take--off . . . . . . . . . . 28 to 31 03--06 Disassembly--Assembly -- power take--off . . . . . . . . . . 32 to 38 03--06 33 - - BRAKES CHAPTER 1 - - Brakes Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 1 03--06 Tightening Torques . . . . . . 2 03--06 Cross--sectional views . . . 3--4 03--06 Tools . . . . . . . . . . . . . . . . . . 4--5 03--06 Description & Operation . . 4 03--06 Page Date Hydraulic diagram -- brakes . . . . . . . . . . . . . . . . . 5 03--06 Pilot valve operation . . . . . 6 03--06 Troubleshooting . . . . . . . . . 7 03--06 Adjustments -- parking handbrake travel . . . . . . . . 8 03--06 Removal--Installation/Dis- assembly--Assembly park- ing brake casing . . . . . . . . . 9 to 11 03--06 Service brake circuit air bleeding . . . . . . . . . . . . . . . . 12 03--06 Removal--Installation -- service brake pump . . . . . . 13--14 03--06 Adjusting the height of the service brake pedals . . . . . 14 03--06 Removal--Installation -- service brake . . . . . . . . . . . 15 to 19 03--06 CHAPTER 2 - - Trailer Air Brakes Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 1 03--06 Tightening Torques . . . . . . 2 03--06 Tools . . . . . . . . . . . . . . . . . . 2 03--06 Cross--sectional views . . . 3 to 6 03--06 Description & Operation . . 6--7 03--06 Operation of single trailer brake circuit components . 8 to 13 03--06 Troubleshooting . . . . . . . . . 14 03--06 Pressure tests . . . . . . . . . . 15 to 19 03--06 35 - - HYDRAULIC SYSTEMS CHAPTER 1 - - Rear mechanical hydraulic lift Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 to 6 03--06 Tightening Torques . . . . . . 7--8 03--06 Tools . . . . . . . . . . . . . . . . . . 9 03--06 Cross--sectional views . . . 10--11 03--06 Description & Operation . . 12 to 15 03--06 Troubleshooting . . . . . . . . . 16--17 03--06 Hydraulic lift pump compo- nents . . . . . . . . . . . . . . . . . . 18--19 03--06 Pump seal kit replacement 19 03--06 Disassembly--Assembly -- LIFT--O--MATIC control . . . 20 03--06 Adjustments -- lift rod mechanism . . . . . . . . . . . . . 21--22 03--06
CONTENT 7 603.54.511.00 -- 03 -- 2006 Page Date LIFT--O--MATIC device up- ward travel adjustment . . . 23 03--06 Disassembly--Assembly -- external lift controls . . . . . . . 24 03--06 Removal--Installation -- lift . 25 to 31 03--06 Disassembly--Assembly -- lift . . . . . . . . . . . . . . . . . . . . . 32 to 36 03--06 Adjusting the lift . . . . . . . . . 37 to 42 03--06 Removal--Installation -- lift control valve . . . . . . . . . . . . 43--44 03--06 Disassembly--Assembly -- lift control valve . . . . . . . . . 45 to 49 03--06 Lift pressure relief valve -- removal/installation and setting . . . . . . . . . . . . . . . . . 50 03--06 CHAPTER 2 - - Open centre system auxiliary control valves Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 1 03--06 Tools . . . . . . . . . . . . . . . . . . 1 03--06 Tightening Torques . . . . . . 2 03--06 Cross--sectional views . . . 3 to 5 03--06 Description & Operation . . 6 to 9 03--06 Disassembly--Assembly -- auxiliary control valves . . . 10--11 03--06 Rod hardening test . . . . . . 11 03--06 Blow--by test . . . . . . . . . . . . 12 03--06 Adjustment of the auto- matic detent release pres- sure . . . . . . . . . . . . . . . . . . . 12 03--06 Removal--Installation -- flow control valve . . . . . . . . 13 03--06 Adjustments -- flow control valve . . . . . . . . . . . . . . . . . . 14--15 03--06 CHAPTER 3 - - Auxiliary control valves (BOSCH) Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 03--06 Tools . . . . . . . . . . . . . . . . . . 2 03--06 Tightening Torques . . . . . . 3 03--06 View of BOSCH auxiliary control valve components . 4 03--06 Description & Operation . . 4--5 03--06 Control valve components 6 to 9 03--06 Description & Operation . . 10 to 18 03--06 Page Date Removal--Installation -- BOSCH auxiliary control valves . . . . . . . . . . . . . . . . . 19 to 21 03--06 Disassembly--Assembly -- BOSCH auxiliary control valves . . . . . . . . . . . . . . . . . 22 to 26 03--06 CHAPTER 4 - - Trailer brake auxiliary control valve Summary . . . . . . . . . . . . . . . 1 03--06 Cross--sectional views . . . 1 03--06 Description & Operation . . 1--9 03--06 Troubleshooting . . . . . . . . . 10 to 12 03--06 CHAPTER 5 - - Supplementary Cylinder Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 1 03--06 Cross--sectional views . . . 1 03--06 Description & Operation . . 1 03--06 Removal--Installation/Dis- assembly--Assembly -- supplementary cylinder . . . 2 03--06 CHAPTER 6 - - Electronic Lift Summary . . . . . . . . . . . . . . . 1 03--06 Precautions . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2--3 03--06 Tightening Torques . . . . . . 4 03--06 Tools . . . . . . . . . . . . . . . . . . 4 03--06 View of electronic lift com- ponents . . . . . . . . . . . . . . . . 5 03--06 Electronic lift control layout 6--7 03--06 Description & Operation . . 8 to 11 03--06 Anti--damping device for implements carried on the lift . . . . . . . . . . . . . . . . . . . . . 12 to 13 03--06 Fault code decoding . . . . . 13 to 14 03--06 Diagnostics . . . . . . . . . . . . . 14 to 54 03--06 Lift electronic control unit . 55 03--06 Removal--Installation -- electronic lift control panel 56 03--06 Lift arm potentiometer re- placement . . . . . . . . . . . . . . 57 03--06 Removal --Installation -- draft sensor . . . . . . . . . . . . . 58--59 03--06 Calibration of the elec- tronic lift arms potentio- meter . . . . . . . . . . . . . . . . . . 60--61 03--06
8 CONTENT 603.54.511.00 -- 03 -- 2006 Page Date Removal--Installation -- electronic lift . . . . . . . . . . . . 62 to 67 03--06 Removal--Installation -- hy- draulic control valve . . . . . . 68--69 03--06 CHAPTER 7 - - Ventral control valves for Walvoil- -type open centre system Summary . . . . . . . . . . . . . . . 1 03--06 Ventral control valve spec- ifications . . . . . . . . . . . . . . . 1 03--06 Tightening Torques . . . . . . 2 03--06 Ventral control valve . . . . . 3--4 03--06 Ventral control valve joy- stick . . . . . . . . . . . . . . . . . . . 5 to 7 03--06 Control valve circuit . . . . . 8 03--06 Hydraulic diagram . . . . . . . 9 03--06 Description and operation of ventral control valve . . . 10 to 18 03--06
CONTENT 1 603.54.511.00 − 03 − 2006 CONTENTS VOLUME 2 Page Date 35 − HYDRAULIC SYSTEMS(*) CHAPTER 8 − Front Loader Summary . . . . . . . . . . . . . . 1 03−06 Specifications . . . . . . . . . . . 2−3 03−06 Maximum permissible front axle weights . . . . . . . . . . . . 3 03−06 Tightening Torques . . . . . . 4 03−06 Diagrams . . . . . . . . . . . . . . 5 to 7 03−06 Ventral control valve spec- ifications . . . . . . . . . . . . . . . 8−9 03−06 Ventral control valve joy- stick . . . . . . . . . . . . . . . . . . . 10 to 12 03−06 System switching full and dipped beam headlights on lights fitted on handrails . . 13 to 16 03−06 Ballasting the tractor for front loader operation . . . . 17 03−06 Loader general description 18 to 27 03−06 Loader installation − re- moval . . . . . . . . . . . . . . . . . . 28 to 32 03−06 Implement installation − re- moval . . . . . . . . . . . . . . . . . . 33 to 36 03−06 Lift arm types and functions 37 to 45 03−06 Smooth ride control . . . . . . 46 to 48 03−06 Multi Quick coupler con- nection − disconnection . . 49 to 60 03−06 Hydraulic functions and flow diagram of loaders . . 61 to 71 03−06 Hydraulic Flow Diagrams . 72 to 88 03−06 Repair instructions . . . . . . 89 to 94 03−06 Hydraulic components . . . 95 to 99 03−06 Troubleshooting . . . . . . . . . 100 to 105 03−06 (*) Chapters prior to section 35 are in volume 1. Page Date 41 − STEERING Summary . . . . . . . . . . . . . . 1 03−06 Data . . . . . . . . . . . . . . . . . . . 2 to 4 03−06 Tightening Torques . . . . . . 5 03−06 View of hydraulic pump components . . . . . . . . . . . . 5 03−06 View of hydrostatic steer- ing control valve compo- nents . . . . . . . . . . . . . . . . . . 6 03−06 Description & Operation . . 7 to 10 03−06 Fault diagnosis . . . . . . . . . . 11−12 03−06 Tools . . . . . . . . . . . . . . . . . . 12 03−06 Removal−Installation − hy- drostatic steering control valve . . . . . . . . . . . . . . . . . . 13 to 17 03−06 Disassembly−Assembly − hydrostatic control valve . . 18 to 31 03−06 Hydrostatic steering con- trol valve bench testing . . . 32−33 03−06 Pressure relief valve test- ing . . . . . . . . . . . . . . . . . . . . 33 03−06 Power steering pump com- ponents . . . . . . . . . . . . . . . . 34−35 03−06 Disassembly − Assembly of hydraulic pump to re- place seal kit . . . . . . . . . . . 35 03−06 Removal−Installation − steering cylinder . . . . . . . . 36−37 03−06 44 − AXLES AND WHEELS Summary . . . . . . . . . . . . . . 1 03−06 Data . . . . . . . . . . . . . . . . . . . 1 03−06 Front wheel track diagram 2 03−06 Cross−sectional views . . . 3 03−06 Tightening Torques . . . . . . 4−5 03−06 Tools . . . . . . . . . . . . . . . . . . 5 03−06 Fault diagnosis . . . . . . . . . . 5 03−06 Disassembly−Assembly − wheel axle hub . . . . . . . . . . 6 to 8 03−06 Removal−Installation − front axle . . . . . . . . . . . . . . . 9 to 11 03−06 Stub axle hub overhaul . . . 12 to 14 03−06 Checking leading wheel alignment . . . . . . . . . . . . . . 15−16 03−06
2 CONTENT 603.54.511.00 − 03 − 2006 Page Date 50 − SUBSIDIARY PARTS Summary . . . . . . . . . . . . . . 1 03−06 Safety regulations . . . . . . . 2 03−06 Data . . . . . . . . . . . . . . . . . . . 3−4 03−06 Tools . . . . . . . . . . . . . . . . . . 4 03−06 Operating principles . . . . . 5−6 03−06 Conditioning system com- ponents . . . . . . . . . . . . . . . . 7 to 11 03−06 Warnings for air condition- ing system repair oper- ations . . . . . . . . . . . . . . . . . . 11 03−06 Cab controls . . . . . . . . . . . . 12 to 14 03−06 Instructions for use − air conditioning system . . . . . 15 03−06 Air−conditioning system charging and evacuation recovery/recycling station 15 03−06 Leak detector . . . . . . . . . . . 16 03−06 Air conditioning system maintenance . . . . . . . . . . . . 17 03−06 Troubleshooting . . . . . . . . . 18 03−06 Fault diagnosis . . . . . . . . . . 19 to 22 03−06 System functional testing . 23 03−06 Checking for and eliminat- ing gas leaks . . . . . . . . . . . 24 03−06 Compressor drive belt ten- sion adjustment . . . . . . . . . 25−26 03−06 Removal−Installation − compressor . . . . . . . . . . . . . 27 to 29 03−06 Heating and air condition- ing systems piping re- placement . . . . . . . . . . . . . . 30−31 03−06 Air conditioning piping re- placement . . . . . . . . . . . . . . 32 to 37 03−06 Condenser replacement 38 03−06 Dryer filter replacement . . 39−40 03−06 Removal−Installation − heater unit . . . . . . . . . . . . . . 41 to 43 03−06 Replacing the air−condi- tioner evaporator . . . . . . . . 44 to 46 03−06 Removal−Installation − electric fan . . . . . . . . . . . . . 47−48 03−06 55 − ELECTRICAL SYSTEM CHAPTER 1 − Instruments Summary . . . . . . . . . . . . . . 1 03−06 Page Date Control panel . . . . . . . . . . . 2−3 03−06 Analog/digital instruments 4 03−06 Liquid crystal display . . . . . 5 to 7 03−06 Access to the setup menu via keypad . . . . . . . . . . . . . 8−13 03−06 Calling up functions from keypad . . . . . . . . . . . . . . . . . 13 to 16 03−06 Access to the setup menu with the CAL button . . . . . . 17−18 03−06 Calling up functions with the CAL button . . . . . . . . . . 18 03−06 Transmitters, sensors and switches . . . . . . . . . . . . . . . 19−26 03−06 Maintenance . . . . . . . . . . . . 26 03−06 CHAPTER 2 − Components Summary . . . . . . . . . . . . . . 1 03−06 Introduction . . . . . . . . . . . . . 1 03−06 Dashboard controls . . . . . . 2 to 8 03−06 Right mudguard controls . 9 to 11 03−06 In−Cab Controls . . . . . . . . . 12 to 14 03−06 Controls on right−hand cab upright . . . . . . . . . . . . . . . . . 15−16 03−06 External controls . . . . . . . . 17 03−06 Maintenance . . . . . . . . . . . . 18−19 03−06 CHAPTER 3 − Components Summary . . . . . . . . . . . . . . 1 03−06 Technical data . . . . . . . . . . 1 03−06 Tightening Torques . . . . . . 1 03−06 Description and Operation 2 03−06 Fault diagnosis . . . . . . . . . . 3 03−06 Starting and recharging cir- cuit (pre−modification) . . . 4−5 03−06 Starting and recharging cir- cuit (post−modification) . . 6−7 03−06 System testing . . . . . . . . . . 8 to 10 03−06 Starter motor removal, in- stallation and overhaul . . . 10 to 13 03−06 Bench testing . . . . . . . . . . . 13−14 03−06 CHAPTER 4 − Charging system Summary . . . . . . . . . . . . . . 1 03−06 Technical data . . . . . . . . . . 1 03−06 Tightening Torques . . . . . . 1 03−06 Description and Operation 2−3 03−06 System testing and troubleshooting . . . . . . . . . 4 to 9 03−06
CONTENT 3 603.54.511.00 − 03 − 2006 Page Date Removal, Installation and Overhaul . . . . . . . . . . . . . . 10 03−06 Alternator components . . . 11 03−06 Tests . . . . . . . . . . . . . . . . . . 12 to 14 03−06 Disassembly . . . . . . . . . . . . 15 03−06 Electronic voltage regulator 15 to 16 03−06 Inductor winding insulation test . . . . . . . . . . . . . . . . . . . . 16−17 03−06 Overhaul, installation . . . . 17−18 03−06 CHAPTER 5 − Battery Summary . . . . . . . . . . . . . . 1 03−06 Technical data . . . . . . . . . . 1 03−06 Description & Operation . . 1 03−06 Removal−Installation − battery . . . . . . . . . . . . . . . . . 2−3 03−06 Battery maintenance . . . . . 4 to 5 03−06 Battery Charging . . . . . . . . 5−6 03−06 Battery testing . . . . . . . . . . 6 to 8 03−06 Battery problems − fre- quent causes . . . . . . . . . . . 8 03−06 CHAPTER 6 − Electrical circuits (pre−modification) Summary . . . . . . . . . . . . . . 1 03−06 Maxi power fuses box . . . . 2 to 4 03−06 Fuse and relay box . . . . . 4 to 16 03−06 Power sockets . . . . . . . . . . 17 03−06 Operator safety circuit . . . 18 03−06 Grid Heater . . . . . . . . . . . . . 18−19 03−06 Electronic flasher . . . . . . . . 19 03−06 Ground location points . . . 20−21 03−06 How to use the linear wiring diagrams . . . . . . . . . . . . . . . 22 to 24 03−06 Symbols used in electrical circuits . . . . . . . . . . . . . . . . . 25−26 03−06 Electric wire colour code . 26 03−06 Wiring diagram compo- nents . . . . . . . . . . . . . . . . . . 27 to 34 03−06 Power Shuttle cab version 35 to 70 03−06 Dual Command (2 Speed Power Shift) cab version . 71 to 106 03−06 Page Date Power Shuttle ISO deck version . . . . . . . . . . . . . . . . . 107 to 130 03−06 Power Shuttle NASO deck version . . . . . . . . . . . . . . . . . 131 to 154 03−06 Dual Command (2 Speed Power Shift) ISO deck ver- sion . . . . . . . . . . . . . . . . . . . 155 to 178 03−06 Dual Command (2 Speed Power Shift) NASO deck version . . . . . . . . . . . . . . . . . 179 to 202 03−06 Control unit input − output diagrams . . . . . . . . . . . . . . . 203 to 208 03−06 CHAPTER 7 − Electrical circuits (post−modification) Summary . . . . . . . . . . . . . 1 03−06 Maxi power fuses box . . . . 02 to 04 03−06 Fuse and relay box . . . . . 04 to 22 03−06 Power sockets . . . . . . . . . . 23 03−06 Grid Heater . . . . . . . . . . . . . 24 03−06 Electronic flasher . . . . . . . . 24 03−06 How to use the linear wiring diagrams . . . . . . . . . . . . . . . 25 to 27 03−06 Ground location points . . . 28−29 03−06 Electric wire colour code . 30 03−06 Symbols used in electrical circuits . . . . . . . . . . . . . . . . . 31−32 03−06 Wiring diagram compo- nents . . . . . . . . . . . . . . . . . . 33 to 40 03−06 Power Shuttle cab version 41 to 76 03−06 Dual Command (2 Speed Power Shift) cab version . 77 to 112 03−06 Power Shuttle ISO deck version . . . . . . . . . . . . . . . . . 113 to 136 03−06 Power Shuttle NASO deck version . . . . . . . . . . . . . . . . . 137 to 160 03−06 Dual Command (2 Speed Power Shift) ISO deck ver- sion . . . . . . . . . . . . . . . . . . . 161 to 184 03−06 Dual Command (2 Speed Power Shift) NASO deck version . . . . . . . . . . . . . . . . . 185 to 207 03−06 Control unit input − output diagrams . . . . . . . . . . . . . . . 208 to 214 03−06
CONTENT 1 603.54.511.00 -- 03 -- 2006 CONTENTS VOLUME 3 Page Date 55 - - ELECTRICAL SYSTEM (*) CHAPTER 8 - - Connectors Summary . . . . . . . . . . . . . . 1 03--06 Electrical circuits compo- nents . . . . . . . . . . . . . . . . . . 2 to 6 03--06 Wirings (pre--modification) 7 to 26 03--06 Wirings (post--modification) . . . . . . 27 to 46 03--06 List of connectors . . . . . . . . 47 to 94 03--06 CHAPTER 9 - - Components Testing Summary . . . . . . . . . . . . . . . 1 03--06 Tests on switches, sensors and pressure switches . . . 02 to 18 03--06 Removal--Installation wind- screen wiper motor . . . . . . 19 03--06 CHAPTER 10 - - Error codes Summary . . . . . . . . . . . . . . . 1 03--06 Introduction . . . . . . . . . . . . . 2 03--06 Special Attachments . . . . . 3 03--06 Repairing the wiring . . . . . . 3 03--06 Digital multimeter . . . . . . . . 6 to 8 03--06 Electrical test procedures 9--11 03--06 Circuit components . . . . . . 11 to 20 03--06 CAN system . . . . . . . . . . . . 21 03--06 Control unit location . . . . . . 21 03--06 Error code display . . . . . . . 22 to 24 03--06 “H” menu diagnostic mode 24 03--06 Error codes lists . . . . . . . . . 25 to 30 03--06 Error codes charts Calibration U--Codes . . . . . 31 to 34 03--06 2001--3000 (Transmission) . . . . . . . . . . 35 to 280 03--06 5001--6000 (Rear PTO) . . . . . . . . . . . . 281 to 308 03--06 6001--7000 (4WD) . . . . . . . . . . . . . . . . . 309 to 319 03--06 7001--8000 (Differential lock) . . . . . . . . 320 to 335 03--06 Page Date 14001--15000 (Analog-- digital control panel) . . . . . 336 to 404 03--06 Electronically controlled hydraulic lift (EDC) . . . . . . . 405 to 482 03--06 CHAPTER 11 - - HH menu and calibrations Summary . . . . . . . . . . . . . . . 1 03--06 Calibrations . . . . . . . . . . . . . 2 03--06 HH MENU access . . . . . . . 3--4 03--06 HH MENU of the control panel . . . . . . . . . . . . . . . . . . 5 to 11 03--06 HH MENU of the trans- mission . . . . . . . . . . . . . . . . 12 to 25 03--06 HH MENU of the advanced keypad . . . . . . . . 25--26 03--06 90 - - BODYWORK AND DRIVING POSITION Summary . . . . . . . . . . . . . . . 1 03--06 Removal--Installation -- bonnet . . . . . . . . . . . . . . . . . 2--3 03--06 Removal--Installation -- platform . . . . . . . . . . . . . . . . 4 to 11 03--06 Removal--Installation -- driver’s seat . . . . . . . . . . . . 12 03--06 Cab Removal--Installation . 13 to 25 03--06 Removal--Installation -- door . . . . . . . . . . . . . . . . . . . 26 03--06 Replacement of glued cab windows . . . . . . . . . . . . . . . 27--28 03--06 Replacement of cab rear window . . . . . . . . . . . . . . . . 29 to 31 03--06 Replacement of seal on left--hand upright . . . . . . . . 32 03--06 Replacement of seal on right--hand upright . . . . . . . 33--34 03--06 Replacement of fixed pad- ding on right--hand wall . . . 35 to 37 03--06 Replacement of fixed pad- ding on left--hand wall . . . . 38--39 03--06 Replacing hydraulic con- trol lever guard . . . . . . . . . . 40--41 03--06 Replacing cab ceiling fit- tings . . . . . . . . . . . . . . . . . . . 42--43 03--06 (*) Chapters prior to section 55 are in volume 2.
SECTION 00 - - GENERAL GUIDELINES - - CHAPTER 1 1 603.54.511.00 - - 03 - - 2006 GENERAL INSTRUCTIONS IMPORTANT NOTICE 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 re- sponsible for any eventual injury or damage to property. SHIMMING For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value indicated for each shim. ROTATING SHAFT SEALS For correct rotating shaft seal installation, proceed as follows: -- before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes; -- thoroughly clean the shaft and check that the working surface on the shaft is not damaged; -- position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direc- tion and position the grooves so that they will deviate the fluid towards the inner side of the seal; -- coat the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing lip and the dust lip on double lip seals with grease; -- insert the seal in its seat and press down using a flat punch; do not tap the seal with a hammer or mallet; -- whilst inserting the seal, check that it is perpendicular to the seat; once settled, make sure that it makes con- tact with the thrust element, if required; -- to prevent damaging the seal lip on the shaft, position a protective guard during installation operations. “O- -RING” SEALS Lubricate the O--RING seals before inserting them in the seats, this will prevent them from overturning and twist- ing, which would jeopardise sealing efficiency. SEALING COMPOUNDS Apply one of the following sealing compounds on the mating surfaces marked with an X: RTV SILMATE, RHO- DORSIL CAF 1 or LOCTITE PLASTIC GASKET. Before applying the sealing compound, prepare the surfaces as follows: -- remove any incrustations using a wire brush; -- thoroughly de--grease the surfaces using one of the following cleaning agents: trichlorethylene, petrol or a water and soda solution.
2 SECTION 00 - - GENERAL GUIDELINES - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 BEARINGS When installing bearings it is advised to: -- heat the bearings to 80 ÷ 90 °C before fitting on the shafts; -- allow the bearings to cool before installing them. SPRING PINS When fitting split socket spring pins, ensure that the pin notch is positioned in the direction of the force required to stress the pin. Spiral spring pins do not require special positioning. SPARE PARTS Use solely genuine parts, which guarantee the same quality, duration and safety as the original parts as they are identical to the ones fitted during production. Only genuine parts can offer this guarantee. When ordering spare parts, always provide the following information: -- tractor model (commercial name) and frame number; -- engine type and number; -- part number of the ordered part, which can be found in the “Microfiches” or the “Spare Parts Catalogue”, used for order processing. TOOLS The tools that NEW HOLLAND offer and illustrate in this manual are: -- specifically researched and designed for use with NEW HOLLAND vehicles; -- essential for reliable repair operations; -- accurately built and rigorously tested so as to offer efficient and long--lasting operation. By using these tools, repair personnel will benefit from: -- operating in optimal technical conditions; -- obtaining the best results; -- saving time and effort; -- working in safe conditions. IMPORTANT NOTES Wear limit values indicated for certain parts are recommended, but not binding. The terms “front”, “rear”, “right-- hand” and “left--hand” (when referred to different parts) are intended as seen from the driving position with the vehicle in the normal direction of movement. MOVING THE TRACTOR WITH THE BATTERY REMOVED External power supply cables should only be connected to the respective positive and negative cable terminals, using efficient clamps that guarantee adequate and secure contact. Disconnect all services (lights, windshield wipers, etc.) before starting the vehicle. If the vehicle electrical system requires checking, carry out operations with the power supply connected. Once checking is completed, disconnect all services and switch off the power supply before disconnecting the cables.
SECTION 10 - - ENGINE - - CHAPTER 1 1 603.54.511.00 - - 03 - - 2006 SECTION 10 - - ENGINE Chapter 1 - - Engine CONTENTS Operation Description Page General specifications 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening torques 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine views 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication diagram 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling system diagram 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault diagnosis 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 001 10 Engine R.I. 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 001 53 Engine D.A. Checks, measurements and repairs 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 102 70 Crankshaft front seal -- Replacement 97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 102 74 Crankshaft rear seal -- Replacement 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 106 12 Valve tappet and rocker arm clearance -- Adjustment 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 218 30 Engine injector R.I. 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 246 14 Bosch injection pump R.I. Timing. Air bleed 109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 402 10 Coolant pump R.I. 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 402 30 Thermostat valve R.I. 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 406 10 Radiator R.I. 123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 414 10 Coolant pump and generator drive belts. Tension adjustment 129 . . . . . . . . . . . . . . . . . . . . . .
2 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 GENERAL SPECIFICATIONS 4 Cylinders Engine, technical type: -- model TL70A -- type F4CE0404D*D601 (BOSCH pump) . -- -- model TL70A -- type F4CE0404D*D681 (BOSCH pump) . -- -- model TL80A -- type F4CE0404C*D601 (BOSCH pump) . -- -- model TL80A -- type F4CE0404C*D681 (BOSCH pump) . -- -- model TL90A -- type F4CE0454E*D601 (BOSCH pump) . -- -- model TL90A -- type F4CE0454E*D681 (BOSCH pump) . -- -- model TL100A -- type F4CE0454D*D601 (BOSCH pump) -- model TL100A -- type F4CE0454D*D681 (BOSCH pump) -- -- Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diesel, 4--stroke Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . direct Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Piston diameter -- model TL70A -- TL80A -- TL90A -- TL100A . . . . . . . . . . . . . 4.0944 in. (104 mm) Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1968 in. (132 mm) Total displacement: -- model TL70A -- TL80A -- TL90A -- TL100A . . . . . . . . . . . . . 273.67 in3. (4485 cm3) Compression ratio for Models TL70A -- TL80A -- TL90A -- TL100A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5:1 Maximum power: -- model TL70A -- type F4CE0404D*D601 . . . . . . . . . . . . . . . . 53 kW (70 HP) -- model TL70A -- type F4CE0404D*D681 . . . . . . . . . . . . . . . . 53 kW (70 HP) -- model TL80A -- type F4CE0404C*D601 . . . . . . . . . . . . . . . . 60 kW (80 HP) -- model TL80A -- type F4CE0404C*D681 . . . . . . . . . . . . . . . . 60 kW (80 HP) -- model TL90A -- type F4CE0454E*D601 . . . . . . . . . . . . . . . . 67 kW (90 HP) -- model TL90A -- type F4CE0454E*D681 . . . . . . . . . . . . . . . . 67 kW (90 HP) -- model TL100A -- type F4CE0454D*D601 . . . . . . . . . . . . . . . -- model TL100A -- type F4CE0454D*D681 . . . . . . . . . . . . . . . 73,5 kW (100 HP) 73,5 kW (100 HP) Maximum power speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500 rev/min -- Maximum torque: model TL70A -- type F4CE0404D*D601 280 (Nm) -- Maximum torque: model TL70A -- type F4CE0404D*D681 280 (Nm) -- Maximum torque: model TL80A -- type F4CE0404C*D601 320 (Nm) -- Maximum torque: model TL80A -- type F4CE0404C*D681 320 (Nm) -- Maximum torque: model TL90A -- type F4CE0454E*D601 350 (Nm) -- Maximum torque: model TL90A -- type F4CE0454E*D681 350 (Nm) -- Maximum torque: model TL100A -- type F4CE0454D*D601 -- Maximum torque: model TL100A -- type F4CE0454D*D681 370 (Nm) 370 (Nm) Maximum torque speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 rev/min Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . structural, cast iron (continued)
SECTION 10 - - ENGINE - - CHAPTER 1 3 603.54.511.00 - - 03 - - 2006 (cont) GENERAL SPECIFICATIONS 4 Cylinders Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced, with lobe pump Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . camshaft Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . 1:1 Oil cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mesh filter on oil intake and filtering cartridge on delivery line Normal oil pressure with motor warmed--up at slow idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4 psi (1.2 bar) at fast idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 psi (3.8 bar) Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . coolant circulation Radiator on Models TL70A -- TL80A -- TL90A -- TL100A . . . . . 4 lines of vertical pipes with copper fins Fan, attached to the pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . intake, in plastic with 11 blades Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal vane--type Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . . Coolant thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature ranges corresponding to each section: -- Initial blue section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- Middle green section (normal working conditions) . . . . . . . . . -- Final red section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1.977 coloured scale divided into 3 sections 104 to 140 °F (40° to 60 °C) 140 to 230 °F (60° to 110 °C) 230 to 248 °F (110° to 120 °C) Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . via thermostat valve -- initial opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177.0 ± 35.6 °F (81 ± 2 °C) Timing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by tappets, rods and rocker arms via the camshaft located in the engine block; the camshaft is driven by the crankshaft using straight--tooth gears Intake: -- start: before T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10° ± 30’ -- end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10° ± 30’ Exhaust: -- start: before B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64° -- end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26° Valve--rocker arm clearance (with engine cold): -- intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (0.30 ± 0.05 mm) -- exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (0.55 ± 0.05 mm) For further timing system technical data . . . . . . . . . . . . . . . . . . . see page 8 (continued)
4 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 (cont) GENERAL SPECIFICATIONS 4 Cylinders Fuel system Air cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter, with clogged filter indicator with centrifugal pre--filter and automatic dust ejector Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with double diaphragm Fuel filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through wire filter in fuel supply pump, and replaceable cartridge on delivery line to injection pump Minimum fuel flow rate with pump shaft rotating at 1800 rpm . 127.6 l/h Cam operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . engine timing BOSCH injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rotating distributor type All--speed governor, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal counterweights Automatic advance regulator, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydraulic For further fuel system technical data: Fixed advance (pump setting on engine for start of delivery before TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . refer to the data given in the table for operation 14. page 117 Pressure setting -- Injection order, and other information regarding the BOSCH pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . refer to the data given in the table page 5
14 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 MIF1096A 1 View of TL70A tractor engines of 53 kW (70 HP) and TL80A of 60 kW (80 HP)
SECTION 10 - - ENGINE - - CHAPTER 1 15 603.54.511.00 - - 03 - - 2006 MIF1097A model TL90A 2 View of TL90A tractor engines of 67 kW (90 HP) and TL100A of 73.5 kW (100 HP)
16 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 MIF1098A Oil path under pressure Oil return path under gravity 3 Lubrication diagram for engines mod. TL90A and TL100A Forced--circulation lubrication is accomplished by the following components: -- oil pump, housed at the front of the crankcase, driven by the grooved bushing keyed onto the shank of the crankshaft; -- water / oil cooler, housed in the crankcase; -- oil pressure control valve incorporated in the cooler assembly; -- by--pass valve to cut off clogged oil filter, incorpo- rated in the cooler assembly; -- cartridge oil filter. NOTE: Engines mod. TL70A and TL80A do not have a turbocharger lubrication circuit.
SECTION 10 - - ENGINE - - CHAPTER 1 17 603.54.511.00 - - 03 - - 2006 MIF1099A Coolant recirculating in the engine Coolant entering the pump 4 Cooling system diagram The forced circulation, closed--circuit engine cooling system is composed of the following components: -- a lubricating oil cooler; -- a centrifugal coolant pump housed at the front of the crankcase; -- a thermostat valve governing coolant circulation.
18 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 MIF1100A 5 Detail of cylinder head with valve seats fitted in engines mod. TL70A - - TL80A 1. Exhaust manifold 2. Intake manifold 3. Air heater 4. Fitted valve seats 5. Thermostat valve 6. Injector
SECTION 10 - - ENGINE - - CHAPTER 1 19 603.54.511.00 - - 03 - - 2006 MIF1101A 6 Detail of cylinder head with valve seats fitted in engines mod. TL90A - - TL100A 1. Exhaust manifold 2. Intake manifold 3. Air heater 4. Fitted valve seats 5. Thermostat valve 6. Injector
20 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 MIF1102A 7 Additional counterweights 1. Retaining bolts 2. Support 3. Retaining bolts 4. Gear 5. Balancing weight 6. Half bearings 7. Counter--shaft 8. Gear 9. Ring 10. O--Ring
SECTION 10 - - ENGINE - - CHAPTER 1 25 603.54.511.00 - - 03 - - 2006 Op. 10 001 10 ENGINE R.I. DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Check that no one is in the vicinity of the load to be lifted. CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. 1. Remove the bonnet (1) as described in operation 9010022. 2. Disconnect the battery negative lead. 3. Drain the oil from the transmission--gearbox housing. 8 4. Remove the three retaining bolts (1) and the guard (2) on the right--hand side of the fan. 9 5. Detach the fitting (3) of the return pipe (2) for the coolant from the cab heater radiator connected to the underside of the coolant pump (1) and drain off the engine coolant. 10
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26 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 6. Remove the catch (2) and detach the toolbox (1). 11 7. Remove the split pins, retaining pin (3) and front ballast (2) together with the support (1). 12 8. Unscrew the front central and rear retaining bolts on the front axle shaft guard, then remove the guard (1). 25038 1 13 9. Remove the circlip (2) and move the front sleeve (1) in the direction indicated by the arrow until it is released from the groove on the front axle. 25039 1 2 14
SECTION 10 - - ENGINE - - CHAPTER 1 27 603.54.511.00 - - 03 - - 2006 10. Remove the circlip (2) and move the rear sleeve (1) in the direction indicated by the arrow until it is released from the groove on the drive. 25040 1 2 15 11. Remove the propeller shaft central support (1) retaining bolts and extract the shaft together with the support. 1 25041 16 12. Remove the retaining bolts (1) of the draw pipe (2) of the lift pump. 17 13. Detach the fitting (1) of the power steering/four-- wheel drive drain pipe on the left--hand side of the engine. 18
28 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 14. Detach the fitting (1) of the power steering/four-- wheel drive drain pipe on the right--hand side of the engine. 19 15. Take out the bolt (1) retaining the bracket and the power steering/four--wheel drive drain pipe on the right--hand side of the engine (2). 20 16. Remove the two metal clamps (2) and the rigid pipe (1) for drawing oil from the transmission via the pumps of the lift and power steering. 21 17. Remove the fitting (1) of the delivery pipe of the services pump on the right--hand side of the en- gine. 22
SECTION 10 - - ENGINE - - CHAPTER 1 29 603.54.511.00 - - 03 - - 2006 18. Working on the left--hand side of the engine, take out the retaining bolts (2) and detach the draw pipe (1) of the lift pump. 23 19. Extract the plastic fasteners (2) and detach the diesel recovery pipe (3) and delivery pipe (4) to the diesel pump (1). 24 20. Disconnect the electrical connections (1) and (2) between the cab and the engine. 25 21. Disconnect the electrical connection (1) between the cab and the engine. 26
30 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 22. Disconnect the two power steering oil delivery and return hoses (1). 1 24879 27 23. Remove the four knobs (1) and take off the two right-- and left--hand dashboard panels (2). MDD2562A 1 2 28 24. Extract the differential lock pedal retaining pin from the drive shaft (1), remove the pedal and footboard (2). 25043 1 2 29 25. Remove the four plugs (1) in order to gain access to the engine upper retaining bolts. 30
SECTION 10 - - ENGINE - - CHAPTER 1 31 603.54.511.00 - - 03 - - 2006 26. Remove the retaining clips (1) and detach the flexible cables governing the hand throttle (5) and pedal throttle (4). 27. Remove the retaining clip (3) and detach the throttle control tie--rod (2) connected to the injec- tion pump. 31 28. Detach the fitting (2) and the hose (1) delivering power steering oil to the hydraulic cylinders governing the front wheel steering. 32 29. Detach the clamp (1) and the cab heater delivery pipe (2). 33 30. Detach the clamp (2) and the cab heater return pipe (1). 34

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New Holland TL80A Tractor Service Repair Manual.pdf

  • 1. TRACTORS TL70A - - TL80A - - TL90A - - TL100A SERVICE MANUAL SECTIONS GENERAL GUIDELINES 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE LINES 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT MECHANICAL TRANSMISSION 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR MECHANICAL TRANSMISSION 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER TAKE-OFF 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKES 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SYSTEMS 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE AND WHEELS 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAB AIR CONDITIONING SYSTEM 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATFORM, CAB, BODYWORK 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S E R V I C E
  • 2. INTRODUCTION ◊ This manual is divided into sections identified by two- -figure numbers and each section has independent page numbering. For easy reference, these sections have the same numbers and names as the Repairs Rate Book sections. ◊ 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 a two- -figure update number (e.g., 1st Update 603.54.511.01; 2nd Update 603.54.511.02; etc.) and by the corresponding issue date. These pages will be supplemented by a reprint of the updated contents page. ◊ 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 im- plemented 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 re- sponsible 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 dam- age 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 Manufac- turer. 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. TEXT AND ILLUSTRATIONS ARE THE PROPERTY OF CNH ITALIA S.p.A. No part of the text or illustrations may be reproduced PRINTED IN ITALY CNH ITALIA S.p.A. - - Viale delle Nazioni, 55 - - 41100 MODENA - - Italy Product Support -- Technical Information Print No. 603.54.511.00 -- 03 -- 2006
  • 3. CONTENT 3 603.54.511.00 -- 03 -- 2006 CONTENT VOLUME 1 Page Date 00 - - GENERAL GUIDELINES General instructions . . . . . 1--2 03--06 Safety regulations . . . . . . . 3--4--5 03--06 Consumables . . . . . . . . . . . 6 03--06 10 - - ENGINE Summary . . . . . . . . . . . . . . . 1 03--06 General specifications . . . . 2 to 4 03--06 Fuel system data . . . . . . . . 5 03--06 Crankshaft and engine block data . . . . . . . . . . . . . . 6 03--06 Connecting rod data . . . . . 7 03--06 Piston data . . . . . . . . . . . . . 7--8 03--06 Timing gear data . . . . . . . . 8--9 03--06 Cylinder head data . . . . . . 9--10 03--06 Tightening Torques . . . . . . 11--12 03--06 Tools . . . . . . . . . . . . . . . . . . 13 03--06 View of 4--cylinder engine mod. TL70A and TL80A . . 14 03--06 View of 4--cylinder engine mod. TL90A and TL100A . 15 03--06 Engine cooling and lubrica- tion diagrams . . . . . . . . . . . 16--17 03--06 Component parts of cylin- der head mod. TL70A and TL80A . . . . . . . . . . . . . . . . . 18 03--06 Component parts of cylin- der head mod. TL90A and TL100A . . . . . . . . . . . . . . . . 19 03--06 Component parts of addi- tional counterweights . . . . 20 03--06 Troubleshooting . . . . . . . . . 21 to 24 03--06 Engine removal--installa- tion . . . . . . . . . . . . . . . . . . . . 25 to 44 03--06 Engine disassembly--as- sembly . . . . . . . . . . . . . . . . . 45 to 78 03--06 Checks and measure- ments -- cylinder block and liners . . . . . . . . . . . . . . . . . . 79 to 81 03--06 Checks and measure- ments -- crankshaft, bear- ings and flywheel . . . . . . . . 82 to 83 03--06 Checks and measure- ments -- connecting rods . 84 to 85 03--06 Page Date Checks and measure- ments -- pistons . . . . . . . . . 86 to 89 03--06 Checks and measure- ments -- camshaft, tappets and valves . . . . . . . . . . . . . . 90 to 93 03--06 Checks and measure- ments -- cylinder head . . . . 94 03--06 Functional testing on low engine oil pressure indica- tor . . . . . . . . . . . . . . . . . . . . . 95 03--06 Checks and measure- ments -- cooling system . . 96 03--06 Replacing crankshaft front seal . . . . . . . . . . . . . . . . . . . 97 to 99 03--06 Replacing crankshaft rear seal . . . . . . . . . . . . . . . . . . . 100 to 102 03--06 Adjusting tappet, valve and rocker arm clearance . . . . 103 to 105 03--06 Removal--Installation -- in- jectors . . . . . . . . . . . . . . . . . 106 to 108 03--06 Removal -- Installation -- Bosch injection pump . . . . 109 to 113 03--06 Bosch injection pump -- tim- ing . . . . . . . . . . . . . . . . . . . . 114 to 118 03--06 Bosch injection pump -- air bleeding . . . . . . . . . . . . . . . . 118 03--06 Removal--Installation -- coolant pump . . . . . . . . . . . 119--120 03--06 Removal--Installation -- thermostat valve . . . . . . . . . 121--122 03--06 Removal--Installation -- radiator . . . . . . . . . . . . . . . . 123 to 128 03--06 Coolant pump drive belt ad- justment . . . . . . . . . . . . . . . . 129 to 130 03--06 18 - - CLUTCH Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 03--06 Tightening Torques . . . . . . 3 03--06 Tools . . . . . . . . . . . . . . . . . . 3 03--06 Cross--sectional views . . . 4 03--06 Troubleshooting . . . . . . . . . 5 03--06 Checks and measure- ments -- clutch . . . . . . . . . . 6--7 03--06 Adjustments -- clutch pedal 8 03--06 Removal--Installation -- clutch . . . . . . . . . . . . . . . . . . 9 to 11 03--06 Clutch Overhaul . . . . . . . . . 12 to 15 03--06
  • 4. 4 CONTENT 603.54.511.00 -- 03 -- 2006 Page Date Adjustments -- clutch disen- gagement levers . . . . . . . . 16 03--06 21 - - TRANSMISSIONS CHAPTER 1 - - Transmission and range gear (12x4) Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 03--06 Tightening Torques . . . . . . 3 03--06 Tools . . . . . . . . . . . . . . . . . . 4--5 03--06 Cross--sectional views . . . 6--7 03--06 Description & Operation . . 8 03--06 Troubleshooting . . . . . . . . . 8 03--06 Transmission longitudinal cutaway section view . . . . 9 03--06 CHAPTER 2 - - Reverser Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 03--06 Tightening Torques . . . . . . 3 03--06 Tools . . . . . . . . . . . . . . . . . . 4 03--06 Cross--sectional views . . . 4--5 03--06 Description & Operation . . 6 03--06 Troubleshooting . . . . . . . . . 6 03--06 Disassembly--Assembly -- clutch casing--reverser . . . 7 to 10 03--06 Transmission longitudinal cutaway section view . . . . 11--12 03--06 CHAPTER 3 - - Dual Command (2 Speed Power Shift) Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2--3 03--06 Tightening Torques . . . . . . 4 03--06 Tools . . . . . . . . . . . . . . . . . . 5 03--06 Cross--sectional views . . . 6 to 8 03--06 Description & Operation . . 10 to 15 03--06 Troubleshooting . . . . . . . . . 16--17 03--06 Removal--Installation -- clutch casing with Dual Command (2 Speed Power Shift) . . . . . . . . . . . . . . . . . . 18 to 26 03--06 Disassembly--Assembly -- clutch casing with Dual Command (2 Speed Power Shift) . . . . . . . . . . . . . . . . . . 27 to 35 03--06 Page Date Control rod adjustments . . 36 03--06 Removal--Installation -- Dual Command (2 Speed Power Shift) solenoid valve 37 to 40 03--06 Working pressure test . . . . 40 03--06 Removal--Installation -- Dual Command (2 Speed Power Shift) control valve 41 to 44 03--06 Disassembly--Assembly -- Dual Command (2 Speed Power Shift) control valve . 45--46 03--06 Transmission longitudinal cutaway section view . . . . 47 03--06 CHAPTER 4 - - Reverser and creeper unit Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 03--06 Tightening torque . . . . . . . . 3 03--06 Tools . . . . . . . . . . . . . . . . . . 4 to 5 03--06 Cross--sectional views . . . 6 to 7 03--06 Description & Operation . . 8 03--06 Troubleshooting . . . . . . . . . 8 03--06 Replacing clutch casing-- reverser and creeper unit . 9 to 13 03--06 End float adjustment be- tween shaft and support . . 14 to 15 03--06 Transmission longitudinal cutaway section view . . . . 16 03--06 CHAPTER 5 - - Power Shuttle tran- smission with Dual Command (2 Speed Power Shift) function Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2--3 03--06 Tightening torque . . . . . . . . 4--5 03--06 Tools . . . . . . . . . . . . . . . . . . 6--7 03--06 Cross--sectional views . . . 8 to 10 03--06 Description & Operation . . 11 to 17 03--06 Range and gear lever posi- tion sensor adjustment 18--19 03--06 Disassembly--Assembly -- clutch casing with power shuttle and Dual Command (2 Speed Power Shift) . . . . 20 to 26 03--06 Disassembly--Assembly -- clutch (A) and (B) . . . . . . . . 27--32 03--06
  • 5. CONTENT 5 603.54.511.00 -- 03 -- 2006 Page Date Calibrations . . . . . . . . . . . . . 33 03--06 HH MENU access . . . . . . . 33--34 03--06 Clutch calibration H1 menu transmission . . . . . . . . . . . . 35 to 37 03--06 Transmission fault codes . 38 to 40 03--06 23 - - DRIVE LINES Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 03--06 Tightening Torques . . . . . . 3 03--06 Tools . . . . . . . . . . . . . . . . . . 3 03--06 Cross--sectional views . . . 4 03--06 Description & Operation . . 5 03--06 Troubleshooting . . . . . . . . . 6 03--06 Removal--Installation -- ser- vices control valve . . . . . . . 7 to 9 03--06 Disassembly--Assembly -- services control valve . . . . 10 to 11 03--06 Removal--Installation -- drive gear casing . . . . . . . . 12 to 16 03--06 Disassembly--Assembly -- drive gear casing . . . . . . . . 17 to 20 03--06 25 - - FRONT MECHANICAL TRANSMISSION Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 to 4 03--06 Tightening Torques . . . . . . 4--5 03--06 Tools . . . . . . . . . . . . . . . . . . 6 to 8 03--06 Cross--sectional views . . . 9 to 13 03--06 Description & Operation . . 14--15 03--06 Rules for correctly fitting the axle support to the engine 16 03--06 Troubleshooting . . . . . . . . . 17 03--06 Removal--Installation -- front axle . . . . . . . . . . . . . . . 18 to 21 03--06 Disassembly--Assembly -- front axle . . . . . . . . . . . . . . . 22 to 30 03--06 Overhaul -- front differential 31 03--06 Overhaul -- front axle differ- ential with LIM--SLIP . . . . . 32--33 03--06 Overhaul -- differential lock unit . . . . . . . . . . . . . . . . . . . . 34--35 03--06 Disassembly--Assembly -- front epicyclic final drive without brake . . . . . . . . . . . 36 to 38 03--06 Replacing wheel hub seal without brake. . . . . . . . . . . . 39 03--06 Page Date Disassembly--Assembly -- front epicyclic final drive with brake . . . . . . . . . . . . . . 40--41 03--06 Replacing wheel hub seal with brake. . . . . . . . . . . . . . 42 03--06 Replacing steering knuckle pins and bearings . . . . . . . 43 03--06 Stub axle adjustments . . . . 44--45 03--06 Adjustments -- bevel drive 46 to 52 03--06 27 - - REAR MECHANICAL TRANSMISSION Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2--3 03--06 Tightening Torques . . . . . . 3--4 03--06 Tools . . . . . . . . . . . . . . . . . . 5 to 9 03--06 Cross--sectional views . . . 10 to 14 03--06 Description & Operation . . 15 03--06 Troubleshooting . . . . . . . . . 16--17 03--06 Removal--Installation -- transmission--gearbox casing . . . . . . . . . . . . . . . . . 18 to 31 03--06 Disassembly--Assembly -- transmission--gearbox casing . . . . . . . . . . . . . . . . . 32 to 39 03--06 Gearbox driving shaft end float adjustment . . . . . . . . . 40 03--06 Adjustments -- differential lock engagement sleeve position . . . . . . . . . . . . . . . . 41 03--06 Determining the bevel pin- ion positioning adjustment ring . . . . . . . . . . . . . . . . . . . . 42 to 43 03--06 Tapered roller bearings adjustment for pinion shaft 44 03--06 Adjusting the bevel crown wheel bearings and check- ing the clearance between the sides of the bevel drive teeth . . . . . . . . . . . . . . . . . . . 45 to 48 03--06 Differential pinion and side gear backlash adjustment . 49--50 03--06 Differential lock pedal travel adjustment . . . . . . . . . . . . . 51 03--06 Removal--Installation -- final drive . . . . . . . . . . . . . . . 52 to 55 03--06 Disassembly--Assembly -- epicyclic final drive . . . . . . . 55 03--06 Disassembly--Assembly -- drive wheel shaft . . . . . . . . 56--57 03--06
  • 6. 6 CONTENT 603.54.511.00 -- 03 -- 2006 Page Date 31 - - POWER TAKE- -OFF CHAPTER 1 - - Mechanical power take- -off Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 to 4 03--06 Tools . . . . . . . . . . . . . . . . . . 5 03--06 Tightening Torques . . . . . . 5--6 03--06 Cross--sectional views . . . 7 to 9 03--06 Description & Operation . . 10--11 03--06 Troubleshooting . . . . . . . . . 11 03--06 Removal--Installation -- power take--off . . . . . . . . . . 12 to 14 03--06 Disassembly--Assembly -- power take--off . . . . . . . . . . 15 to 17 03--06 CHAPTER 2 - - Electro- -hydraulic power take- -off Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 to 5 03--06 Tools . . . . . . . . . . . . . . . . . . 5 03--06 Tightening Torques . . . . . . 6 03--06 Cross--sectional views . . . 7 to 12 03--06 Description & Operation . . 13 to 22 03--06 Additional PTO controls for cab--version tractors with Power Shuttle trans- missions . . . . . . . . . . . . . . . 23--24 03--06 Troubleshooting . . . . . . . . . 25 03--06 Replacing the power take-- off brake . . . . . . . . . . . . . . . 26--27 03--06 Removal--Installation -- power take--off . . . . . . . . . . 28 to 31 03--06 Disassembly--Assembly -- power take--off . . . . . . . . . . 32 to 38 03--06 33 - - BRAKES CHAPTER 1 - - Brakes Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 1 03--06 Tightening Torques . . . . . . 2 03--06 Cross--sectional views . . . 3--4 03--06 Tools . . . . . . . . . . . . . . . . . . 4--5 03--06 Description & Operation . . 4 03--06 Page Date Hydraulic diagram -- brakes . . . . . . . . . . . . . . . . . 5 03--06 Pilot valve operation . . . . . 6 03--06 Troubleshooting . . . . . . . . . 7 03--06 Adjustments -- parking handbrake travel . . . . . . . . 8 03--06 Removal--Installation/Dis- assembly--Assembly park- ing brake casing . . . . . . . . . 9 to 11 03--06 Service brake circuit air bleeding . . . . . . . . . . . . . . . . 12 03--06 Removal--Installation -- service brake pump . . . . . . 13--14 03--06 Adjusting the height of the service brake pedals . . . . . 14 03--06 Removal--Installation -- service brake . . . . . . . . . . . 15 to 19 03--06 CHAPTER 2 - - Trailer Air Brakes Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 1 03--06 Tightening Torques . . . . . . 2 03--06 Tools . . . . . . . . . . . . . . . . . . 2 03--06 Cross--sectional views . . . 3 to 6 03--06 Description & Operation . . 6--7 03--06 Operation of single trailer brake circuit components . 8 to 13 03--06 Troubleshooting . . . . . . . . . 14 03--06 Pressure tests . . . . . . . . . . 15 to 19 03--06 35 - - HYDRAULIC SYSTEMS CHAPTER 1 - - Rear mechanical hydraulic lift Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 to 6 03--06 Tightening Torques . . . . . . 7--8 03--06 Tools . . . . . . . . . . . . . . . . . . 9 03--06 Cross--sectional views . . . 10--11 03--06 Description & Operation . . 12 to 15 03--06 Troubleshooting . . . . . . . . . 16--17 03--06 Hydraulic lift pump compo- nents . . . . . . . . . . . . . . . . . . 18--19 03--06 Pump seal kit replacement 19 03--06 Disassembly--Assembly -- LIFT--O--MATIC control . . . 20 03--06 Adjustments -- lift rod mechanism . . . . . . . . . . . . . 21--22 03--06
  • 7. CONTENT 7 603.54.511.00 -- 03 -- 2006 Page Date LIFT--O--MATIC device up- ward travel adjustment . . . 23 03--06 Disassembly--Assembly -- external lift controls . . . . . . . 24 03--06 Removal--Installation -- lift . 25 to 31 03--06 Disassembly--Assembly -- lift . . . . . . . . . . . . . . . . . . . . . 32 to 36 03--06 Adjusting the lift . . . . . . . . . 37 to 42 03--06 Removal--Installation -- lift control valve . . . . . . . . . . . . 43--44 03--06 Disassembly--Assembly -- lift control valve . . . . . . . . . 45 to 49 03--06 Lift pressure relief valve -- removal/installation and setting . . . . . . . . . . . . . . . . . 50 03--06 CHAPTER 2 - - Open centre system auxiliary control valves Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 1 03--06 Tools . . . . . . . . . . . . . . . . . . 1 03--06 Tightening Torques . . . . . . 2 03--06 Cross--sectional views . . . 3 to 5 03--06 Description & Operation . . 6 to 9 03--06 Disassembly--Assembly -- auxiliary control valves . . . 10--11 03--06 Rod hardening test . . . . . . 11 03--06 Blow--by test . . . . . . . . . . . . 12 03--06 Adjustment of the auto- matic detent release pres- sure . . . . . . . . . . . . . . . . . . . 12 03--06 Removal--Installation -- flow control valve . . . . . . . . 13 03--06 Adjustments -- flow control valve . . . . . . . . . . . . . . . . . . 14--15 03--06 CHAPTER 3 - - Auxiliary control valves (BOSCH) Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2 03--06 Tools . . . . . . . . . . . . . . . . . . 2 03--06 Tightening Torques . . . . . . 3 03--06 View of BOSCH auxiliary control valve components . 4 03--06 Description & Operation . . 4--5 03--06 Control valve components 6 to 9 03--06 Description & Operation . . 10 to 18 03--06 Page Date Removal--Installation -- BOSCH auxiliary control valves . . . . . . . . . . . . . . . . . 19 to 21 03--06 Disassembly--Assembly -- BOSCH auxiliary control valves . . . . . . . . . . . . . . . . . 22 to 26 03--06 CHAPTER 4 - - Trailer brake auxiliary control valve Summary . . . . . . . . . . . . . . . 1 03--06 Cross--sectional views . . . 1 03--06 Description & Operation . . 1--9 03--06 Troubleshooting . . . . . . . . . 10 to 12 03--06 CHAPTER 5 - - Supplementary Cylinder Summary . . . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 1 03--06 Cross--sectional views . . . 1 03--06 Description & Operation . . 1 03--06 Removal--Installation/Dis- assembly--Assembly -- supplementary cylinder . . . 2 03--06 CHAPTER 6 - - Electronic Lift Summary . . . . . . . . . . . . . . . 1 03--06 Precautions . . . . . . . . . . . . . 1 03--06 Data . . . . . . . . . . . . . . . . . . . 2--3 03--06 Tightening Torques . . . . . . 4 03--06 Tools . . . . . . . . . . . . . . . . . . 4 03--06 View of electronic lift com- ponents . . . . . . . . . . . . . . . . 5 03--06 Electronic lift control layout 6--7 03--06 Description & Operation . . 8 to 11 03--06 Anti--damping device for implements carried on the lift . . . . . . . . . . . . . . . . . . . . . 12 to 13 03--06 Fault code decoding . . . . . 13 to 14 03--06 Diagnostics . . . . . . . . . . . . . 14 to 54 03--06 Lift electronic control unit . 55 03--06 Removal--Installation -- electronic lift control panel 56 03--06 Lift arm potentiometer re- placement . . . . . . . . . . . . . . 57 03--06 Removal --Installation -- draft sensor . . . . . . . . . . . . . 58--59 03--06 Calibration of the elec- tronic lift arms potentio- meter . . . . . . . . . . . . . . . . . . 60--61 03--06
  • 8. 8 CONTENT 603.54.511.00 -- 03 -- 2006 Page Date Removal--Installation -- electronic lift . . . . . . . . . . . . 62 to 67 03--06 Removal--Installation -- hy- draulic control valve . . . . . . 68--69 03--06 CHAPTER 7 - - Ventral control valves for Walvoil- -type open centre system Summary . . . . . . . . . . . . . . . 1 03--06 Ventral control valve spec- ifications . . . . . . . . . . . . . . . 1 03--06 Tightening Torques . . . . . . 2 03--06 Ventral control valve . . . . . 3--4 03--06 Ventral control valve joy- stick . . . . . . . . . . . . . . . . . . . 5 to 7 03--06 Control valve circuit . . . . . 8 03--06 Hydraulic diagram . . . . . . . 9 03--06 Description and operation of ventral control valve . . . 10 to 18 03--06
  • 9. CONTENT 1 603.54.511.00 − 03 − 2006 CONTENTS VOLUME 2 Page Date 35 − HYDRAULIC SYSTEMS(*) CHAPTER 8 − Front Loader Summary . . . . . . . . . . . . . . 1 03−06 Specifications . . . . . . . . . . . 2−3 03−06 Maximum permissible front axle weights . . . . . . . . . . . . 3 03−06 Tightening Torques . . . . . . 4 03−06 Diagrams . . . . . . . . . . . . . . 5 to 7 03−06 Ventral control valve spec- ifications . . . . . . . . . . . . . . . 8−9 03−06 Ventral control valve joy- stick . . . . . . . . . . . . . . . . . . . 10 to 12 03−06 System switching full and dipped beam headlights on lights fitted on handrails . . 13 to 16 03−06 Ballasting the tractor for front loader operation . . . . 17 03−06 Loader general description 18 to 27 03−06 Loader installation − re- moval . . . . . . . . . . . . . . . . . . 28 to 32 03−06 Implement installation − re- moval . . . . . . . . . . . . . . . . . . 33 to 36 03−06 Lift arm types and functions 37 to 45 03−06 Smooth ride control . . . . . . 46 to 48 03−06 Multi Quick coupler con- nection − disconnection . . 49 to 60 03−06 Hydraulic functions and flow diagram of loaders . . 61 to 71 03−06 Hydraulic Flow Diagrams . 72 to 88 03−06 Repair instructions . . . . . . 89 to 94 03−06 Hydraulic components . . . 95 to 99 03−06 Troubleshooting . . . . . . . . . 100 to 105 03−06 (*) Chapters prior to section 35 are in volume 1. Page Date 41 − STEERING Summary . . . . . . . . . . . . . . 1 03−06 Data . . . . . . . . . . . . . . . . . . . 2 to 4 03−06 Tightening Torques . . . . . . 5 03−06 View of hydraulic pump components . . . . . . . . . . . . 5 03−06 View of hydrostatic steer- ing control valve compo- nents . . . . . . . . . . . . . . . . . . 6 03−06 Description & Operation . . 7 to 10 03−06 Fault diagnosis . . . . . . . . . . 11−12 03−06 Tools . . . . . . . . . . . . . . . . . . 12 03−06 Removal−Installation − hy- drostatic steering control valve . . . . . . . . . . . . . . . . . . 13 to 17 03−06 Disassembly−Assembly − hydrostatic control valve . . 18 to 31 03−06 Hydrostatic steering con- trol valve bench testing . . . 32−33 03−06 Pressure relief valve test- ing . . . . . . . . . . . . . . . . . . . . 33 03−06 Power steering pump com- ponents . . . . . . . . . . . . . . . . 34−35 03−06 Disassembly − Assembly of hydraulic pump to re- place seal kit . . . . . . . . . . . 35 03−06 Removal−Installation − steering cylinder . . . . . . . . 36−37 03−06 44 − AXLES AND WHEELS Summary . . . . . . . . . . . . . . 1 03−06 Data . . . . . . . . . . . . . . . . . . . 1 03−06 Front wheel track diagram 2 03−06 Cross−sectional views . . . 3 03−06 Tightening Torques . . . . . . 4−5 03−06 Tools . . . . . . . . . . . . . . . . . . 5 03−06 Fault diagnosis . . . . . . . . . . 5 03−06 Disassembly−Assembly − wheel axle hub . . . . . . . . . . 6 to 8 03−06 Removal−Installation − front axle . . . . . . . . . . . . . . . 9 to 11 03−06 Stub axle hub overhaul . . . 12 to 14 03−06 Checking leading wheel alignment . . . . . . . . . . . . . . 15−16 03−06
  • 10. 2 CONTENT 603.54.511.00 − 03 − 2006 Page Date 50 − SUBSIDIARY PARTS Summary . . . . . . . . . . . . . . 1 03−06 Safety regulations . . . . . . . 2 03−06 Data . . . . . . . . . . . . . . . . . . . 3−4 03−06 Tools . . . . . . . . . . . . . . . . . . 4 03−06 Operating principles . . . . . 5−6 03−06 Conditioning system com- ponents . . . . . . . . . . . . . . . . 7 to 11 03−06 Warnings for air condition- ing system repair oper- ations . . . . . . . . . . . . . . . . . . 11 03−06 Cab controls . . . . . . . . . . . . 12 to 14 03−06 Instructions for use − air conditioning system . . . . . 15 03−06 Air−conditioning system charging and evacuation recovery/recycling station 15 03−06 Leak detector . . . . . . . . . . . 16 03−06 Air conditioning system maintenance . . . . . . . . . . . . 17 03−06 Troubleshooting . . . . . . . . . 18 03−06 Fault diagnosis . . . . . . . . . . 19 to 22 03−06 System functional testing . 23 03−06 Checking for and eliminat- ing gas leaks . . . . . . . . . . . 24 03−06 Compressor drive belt ten- sion adjustment . . . . . . . . . 25−26 03−06 Removal−Installation − compressor . . . . . . . . . . . . . 27 to 29 03−06 Heating and air condition- ing systems piping re- placement . . . . . . . . . . . . . . 30−31 03−06 Air conditioning piping re- placement . . . . . . . . . . . . . . 32 to 37 03−06 Condenser replacement 38 03−06 Dryer filter replacement . . 39−40 03−06 Removal−Installation − heater unit . . . . . . . . . . . . . . 41 to 43 03−06 Replacing the air−condi- tioner evaporator . . . . . . . . 44 to 46 03−06 Removal−Installation − electric fan . . . . . . . . . . . . . 47−48 03−06 55 − ELECTRICAL SYSTEM CHAPTER 1 − Instruments Summary . . . . . . . . . . . . . . 1 03−06 Page Date Control panel . . . . . . . . . . . 2−3 03−06 Analog/digital instruments 4 03−06 Liquid crystal display . . . . . 5 to 7 03−06 Access to the setup menu via keypad . . . . . . . . . . . . . 8−13 03−06 Calling up functions from keypad . . . . . . . . . . . . . . . . . 13 to 16 03−06 Access to the setup menu with the CAL button . . . . . . 17−18 03−06 Calling up functions with the CAL button . . . . . . . . . . 18 03−06 Transmitters, sensors and switches . . . . . . . . . . . . . . . 19−26 03−06 Maintenance . . . . . . . . . . . . 26 03−06 CHAPTER 2 − Components Summary . . . . . . . . . . . . . . 1 03−06 Introduction . . . . . . . . . . . . . 1 03−06 Dashboard controls . . . . . . 2 to 8 03−06 Right mudguard controls . 9 to 11 03−06 In−Cab Controls . . . . . . . . . 12 to 14 03−06 Controls on right−hand cab upright . . . . . . . . . . . . . . . . . 15−16 03−06 External controls . . . . . . . . 17 03−06 Maintenance . . . . . . . . . . . . 18−19 03−06 CHAPTER 3 − Components Summary . . . . . . . . . . . . . . 1 03−06 Technical data . . . . . . . . . . 1 03−06 Tightening Torques . . . . . . 1 03−06 Description and Operation 2 03−06 Fault diagnosis . . . . . . . . . . 3 03−06 Starting and recharging cir- cuit (pre−modification) . . . 4−5 03−06 Starting and recharging cir- cuit (post−modification) . . 6−7 03−06 System testing . . . . . . . . . . 8 to 10 03−06 Starter motor removal, in- stallation and overhaul . . . 10 to 13 03−06 Bench testing . . . . . . . . . . . 13−14 03−06 CHAPTER 4 − Charging system Summary . . . . . . . . . . . . . . 1 03−06 Technical data . . . . . . . . . . 1 03−06 Tightening Torques . . . . . . 1 03−06 Description and Operation 2−3 03−06 System testing and troubleshooting . . . . . . . . . 4 to 9 03−06
  • 11. CONTENT 3 603.54.511.00 − 03 − 2006 Page Date Removal, Installation and Overhaul . . . . . . . . . . . . . . 10 03−06 Alternator components . . . 11 03−06 Tests . . . . . . . . . . . . . . . . . . 12 to 14 03−06 Disassembly . . . . . . . . . . . . 15 03−06 Electronic voltage regulator 15 to 16 03−06 Inductor winding insulation test . . . . . . . . . . . . . . . . . . . . 16−17 03−06 Overhaul, installation . . . . 17−18 03−06 CHAPTER 5 − Battery Summary . . . . . . . . . . . . . . 1 03−06 Technical data . . . . . . . . . . 1 03−06 Description & Operation . . 1 03−06 Removal−Installation − battery . . . . . . . . . . . . . . . . . 2−3 03−06 Battery maintenance . . . . . 4 to 5 03−06 Battery Charging . . . . . . . . 5−6 03−06 Battery testing . . . . . . . . . . 6 to 8 03−06 Battery problems − fre- quent causes . . . . . . . . . . . 8 03−06 CHAPTER 6 − Electrical circuits (pre−modification) Summary . . . . . . . . . . . . . . 1 03−06 Maxi power fuses box . . . . 2 to 4 03−06 Fuse and relay box . . . . . 4 to 16 03−06 Power sockets . . . . . . . . . . 17 03−06 Operator safety circuit . . . 18 03−06 Grid Heater . . . . . . . . . . . . . 18−19 03−06 Electronic flasher . . . . . . . . 19 03−06 Ground location points . . . 20−21 03−06 How to use the linear wiring diagrams . . . . . . . . . . . . . . . 22 to 24 03−06 Symbols used in electrical circuits . . . . . . . . . . . . . . . . . 25−26 03−06 Electric wire colour code . 26 03−06 Wiring diagram compo- nents . . . . . . . . . . . . . . . . . . 27 to 34 03−06 Power Shuttle cab version 35 to 70 03−06 Dual Command (2 Speed Power Shift) cab version . 71 to 106 03−06 Page Date Power Shuttle ISO deck version . . . . . . . . . . . . . . . . . 107 to 130 03−06 Power Shuttle NASO deck version . . . . . . . . . . . . . . . . . 131 to 154 03−06 Dual Command (2 Speed Power Shift) ISO deck ver- sion . . . . . . . . . . . . . . . . . . . 155 to 178 03−06 Dual Command (2 Speed Power Shift) NASO deck version . . . . . . . . . . . . . . . . . 179 to 202 03−06 Control unit input − output diagrams . . . . . . . . . . . . . . . 203 to 208 03−06 CHAPTER 7 − Electrical circuits (post−modification) Summary . . . . . . . . . . . . . 1 03−06 Maxi power fuses box . . . . 02 to 04 03−06 Fuse and relay box . . . . . 04 to 22 03−06 Power sockets . . . . . . . . . . 23 03−06 Grid Heater . . . . . . . . . . . . . 24 03−06 Electronic flasher . . . . . . . . 24 03−06 How to use the linear wiring diagrams . . . . . . . . . . . . . . . 25 to 27 03−06 Ground location points . . . 28−29 03−06 Electric wire colour code . 30 03−06 Symbols used in electrical circuits . . . . . . . . . . . . . . . . . 31−32 03−06 Wiring diagram compo- nents . . . . . . . . . . . . . . . . . . 33 to 40 03−06 Power Shuttle cab version 41 to 76 03−06 Dual Command (2 Speed Power Shift) cab version . 77 to 112 03−06 Power Shuttle ISO deck version . . . . . . . . . . . . . . . . . 113 to 136 03−06 Power Shuttle NASO deck version . . . . . . . . . . . . . . . . . 137 to 160 03−06 Dual Command (2 Speed Power Shift) ISO deck ver- sion . . . . . . . . . . . . . . . . . . . 161 to 184 03−06 Dual Command (2 Speed Power Shift) NASO deck version . . . . . . . . . . . . . . . . . 185 to 207 03−06 Control unit input − output diagrams . . . . . . . . . . . . . . . 208 to 214 03−06
  • 12. CONTENT 1 603.54.511.00 -- 03 -- 2006 CONTENTS VOLUME 3 Page Date 55 - - ELECTRICAL SYSTEM (*) CHAPTER 8 - - Connectors Summary . . . . . . . . . . . . . . 1 03--06 Electrical circuits compo- nents . . . . . . . . . . . . . . . . . . 2 to 6 03--06 Wirings (pre--modification) 7 to 26 03--06 Wirings (post--modification) . . . . . . 27 to 46 03--06 List of connectors . . . . . . . . 47 to 94 03--06 CHAPTER 9 - - Components Testing Summary . . . . . . . . . . . . . . . 1 03--06 Tests on switches, sensors and pressure switches . . . 02 to 18 03--06 Removal--Installation wind- screen wiper motor . . . . . . 19 03--06 CHAPTER 10 - - Error codes Summary . . . . . . . . . . . . . . . 1 03--06 Introduction . . . . . . . . . . . . . 2 03--06 Special Attachments . . . . . 3 03--06 Repairing the wiring . . . . . . 3 03--06 Digital multimeter . . . . . . . . 6 to 8 03--06 Electrical test procedures 9--11 03--06 Circuit components . . . . . . 11 to 20 03--06 CAN system . . . . . . . . . . . . 21 03--06 Control unit location . . . . . . 21 03--06 Error code display . . . . . . . 22 to 24 03--06 “H” menu diagnostic mode 24 03--06 Error codes lists . . . . . . . . . 25 to 30 03--06 Error codes charts Calibration U--Codes . . . . . 31 to 34 03--06 2001--3000 (Transmission) . . . . . . . . . . 35 to 280 03--06 5001--6000 (Rear PTO) . . . . . . . . . . . . 281 to 308 03--06 6001--7000 (4WD) . . . . . . . . . . . . . . . . . 309 to 319 03--06 7001--8000 (Differential lock) . . . . . . . . 320 to 335 03--06 Page Date 14001--15000 (Analog-- digital control panel) . . . . . 336 to 404 03--06 Electronically controlled hydraulic lift (EDC) . . . . . . . 405 to 482 03--06 CHAPTER 11 - - HH menu and calibrations Summary . . . . . . . . . . . . . . . 1 03--06 Calibrations . . . . . . . . . . . . . 2 03--06 HH MENU access . . . . . . . 3--4 03--06 HH MENU of the control panel . . . . . . . . . . . . . . . . . . 5 to 11 03--06 HH MENU of the trans- mission . . . . . . . . . . . . . . . . 12 to 25 03--06 HH MENU of the advanced keypad . . . . . . . . 25--26 03--06 90 - - BODYWORK AND DRIVING POSITION Summary . . . . . . . . . . . . . . . 1 03--06 Removal--Installation -- bonnet . . . . . . . . . . . . . . . . . 2--3 03--06 Removal--Installation -- platform . . . . . . . . . . . . . . . . 4 to 11 03--06 Removal--Installation -- driver’s seat . . . . . . . . . . . . 12 03--06 Cab Removal--Installation . 13 to 25 03--06 Removal--Installation -- door . . . . . . . . . . . . . . . . . . . 26 03--06 Replacement of glued cab windows . . . . . . . . . . . . . . . 27--28 03--06 Replacement of cab rear window . . . . . . . . . . . . . . . . 29 to 31 03--06 Replacement of seal on left--hand upright . . . . . . . . 32 03--06 Replacement of seal on right--hand upright . . . . . . . 33--34 03--06 Replacement of fixed pad- ding on right--hand wall . . . 35 to 37 03--06 Replacement of fixed pad- ding on left--hand wall . . . . 38--39 03--06 Replacing hydraulic con- trol lever guard . . . . . . . . . . 40--41 03--06 Replacing cab ceiling fit- tings . . . . . . . . . . . . . . . . . . . 42--43 03--06 (*) Chapters prior to section 55 are in volume 2.
  • 13. SECTION 00 - - GENERAL GUIDELINES - - CHAPTER 1 1 603.54.511.00 - - 03 - - 2006 GENERAL INSTRUCTIONS IMPORTANT NOTICE 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 re- sponsible for any eventual injury or damage to property. SHIMMING For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value indicated for each shim. ROTATING SHAFT SEALS For correct rotating shaft seal installation, proceed as follows: -- before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes; -- thoroughly clean the shaft and check that the working surface on the shaft is not damaged; -- position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direc- tion and position the grooves so that they will deviate the fluid towards the inner side of the seal; -- coat the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing lip and the dust lip on double lip seals with grease; -- insert the seal in its seat and press down using a flat punch; do not tap the seal with a hammer or mallet; -- whilst inserting the seal, check that it is perpendicular to the seat; once settled, make sure that it makes con- tact with the thrust element, if required; -- to prevent damaging the seal lip on the shaft, position a protective guard during installation operations. “O- -RING” SEALS Lubricate the O--RING seals before inserting them in the seats, this will prevent them from overturning and twist- ing, which would jeopardise sealing efficiency. SEALING COMPOUNDS Apply one of the following sealing compounds on the mating surfaces marked with an X: RTV SILMATE, RHO- DORSIL CAF 1 or LOCTITE PLASTIC GASKET. Before applying the sealing compound, prepare the surfaces as follows: -- remove any incrustations using a wire brush; -- thoroughly de--grease the surfaces using one of the following cleaning agents: trichlorethylene, petrol or a water and soda solution.
  • 14. 2 SECTION 00 - - GENERAL GUIDELINES - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 BEARINGS When installing bearings it is advised to: -- heat the bearings to 80 ÷ 90 °C before fitting on the shafts; -- allow the bearings to cool before installing them. SPRING PINS When fitting split socket spring pins, ensure that the pin notch is positioned in the direction of the force required to stress the pin. Spiral spring pins do not require special positioning. SPARE PARTS Use solely genuine parts, which guarantee the same quality, duration and safety as the original parts as they are identical to the ones fitted during production. Only genuine parts can offer this guarantee. When ordering spare parts, always provide the following information: -- tractor model (commercial name) and frame number; -- engine type and number; -- part number of the ordered part, which can be found in the “Microfiches” or the “Spare Parts Catalogue”, used for order processing. TOOLS The tools that NEW HOLLAND offer and illustrate in this manual are: -- specifically researched and designed for use with NEW HOLLAND vehicles; -- essential for reliable repair operations; -- accurately built and rigorously tested so as to offer efficient and long--lasting operation. By using these tools, repair personnel will benefit from: -- operating in optimal technical conditions; -- obtaining the best results; -- saving time and effort; -- working in safe conditions. IMPORTANT NOTES Wear limit values indicated for certain parts are recommended, but not binding. The terms “front”, “rear”, “right-- hand” and “left--hand” (when referred to different parts) are intended as seen from the driving position with the vehicle in the normal direction of movement. MOVING THE TRACTOR WITH THE BATTERY REMOVED External power supply cables should only be connected to the respective positive and negative cable terminals, using efficient clamps that guarantee adequate and secure contact. Disconnect all services (lights, windshield wipers, etc.) before starting the vehicle. If the vehicle electrical system requires checking, carry out operations with the power supply connected. Once checking is completed, disconnect all services and switch off the power supply before disconnecting the cables.
  • 15. SECTION 10 - - ENGINE - - CHAPTER 1 1 603.54.511.00 - - 03 - - 2006 SECTION 10 - - ENGINE Chapter 1 - - Engine CONTENTS Operation Description Page General specifications 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening torques 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine views 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication diagram 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling system diagram 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault diagnosis 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 001 10 Engine R.I. 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 001 53 Engine D.A. Checks, measurements and repairs 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 102 70 Crankshaft front seal -- Replacement 97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 102 74 Crankshaft rear seal -- Replacement 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 106 12 Valve tappet and rocker arm clearance -- Adjustment 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 218 30 Engine injector R.I. 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 246 14 Bosch injection pump R.I. Timing. Air bleed 109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 402 10 Coolant pump R.I. 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 402 30 Thermostat valve R.I. 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 406 10 Radiator R.I. 123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 414 10 Coolant pump and generator drive belts. Tension adjustment 129 . . . . . . . . . . . . . . . . . . . . . .
  • 16. 2 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 GENERAL SPECIFICATIONS 4 Cylinders Engine, technical type: -- model TL70A -- type F4CE0404D*D601 (BOSCH pump) . -- -- model TL70A -- type F4CE0404D*D681 (BOSCH pump) . -- -- model TL80A -- type F4CE0404C*D601 (BOSCH pump) . -- -- model TL80A -- type F4CE0404C*D681 (BOSCH pump) . -- -- model TL90A -- type F4CE0454E*D601 (BOSCH pump) . -- -- model TL90A -- type F4CE0454E*D681 (BOSCH pump) . -- -- model TL100A -- type F4CE0454D*D601 (BOSCH pump) -- model TL100A -- type F4CE0454D*D681 (BOSCH pump) -- -- Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diesel, 4--stroke Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . direct Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Piston diameter -- model TL70A -- TL80A -- TL90A -- TL100A . . . . . . . . . . . . . 4.0944 in. (104 mm) Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1968 in. (132 mm) Total displacement: -- model TL70A -- TL80A -- TL90A -- TL100A . . . . . . . . . . . . . 273.67 in3. (4485 cm3) Compression ratio for Models TL70A -- TL80A -- TL90A -- TL100A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5:1 Maximum power: -- model TL70A -- type F4CE0404D*D601 . . . . . . . . . . . . . . . . 53 kW (70 HP) -- model TL70A -- type F4CE0404D*D681 . . . . . . . . . . . . . . . . 53 kW (70 HP) -- model TL80A -- type F4CE0404C*D601 . . . . . . . . . . . . . . . . 60 kW (80 HP) -- model TL80A -- type F4CE0404C*D681 . . . . . . . . . . . . . . . . 60 kW (80 HP) -- model TL90A -- type F4CE0454E*D601 . . . . . . . . . . . . . . . . 67 kW (90 HP) -- model TL90A -- type F4CE0454E*D681 . . . . . . . . . . . . . . . . 67 kW (90 HP) -- model TL100A -- type F4CE0454D*D601 . . . . . . . . . . . . . . . -- model TL100A -- type F4CE0454D*D681 . . . . . . . . . . . . . . . 73,5 kW (100 HP) 73,5 kW (100 HP) Maximum power speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500 rev/min -- Maximum torque: model TL70A -- type F4CE0404D*D601 280 (Nm) -- Maximum torque: model TL70A -- type F4CE0404D*D681 280 (Nm) -- Maximum torque: model TL80A -- type F4CE0404C*D601 320 (Nm) -- Maximum torque: model TL80A -- type F4CE0404C*D681 320 (Nm) -- Maximum torque: model TL90A -- type F4CE0454E*D601 350 (Nm) -- Maximum torque: model TL90A -- type F4CE0454E*D681 350 (Nm) -- Maximum torque: model TL100A -- type F4CE0454D*D601 -- Maximum torque: model TL100A -- type F4CE0454D*D681 370 (Nm) 370 (Nm) Maximum torque speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 rev/min Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . structural, cast iron (continued)
  • 17. SECTION 10 - - ENGINE - - CHAPTER 1 3 603.54.511.00 - - 03 - - 2006 (cont) GENERAL SPECIFICATIONS 4 Cylinders Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced, with lobe pump Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . camshaft Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . 1:1 Oil cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mesh filter on oil intake and filtering cartridge on delivery line Normal oil pressure with motor warmed--up at slow idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4 psi (1.2 bar) at fast idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 psi (3.8 bar) Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . coolant circulation Radiator on Models TL70A -- TL80A -- TL90A -- TL100A . . . . . 4 lines of vertical pipes with copper fins Fan, attached to the pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . intake, in plastic with 11 blades Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal vane--type Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . . Coolant thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature ranges corresponding to each section: -- Initial blue section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- Middle green section (normal working conditions) . . . . . . . . . -- Final red section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1.977 coloured scale divided into 3 sections 104 to 140 °F (40° to 60 °C) 140 to 230 °F (60° to 110 °C) 230 to 248 °F (110° to 120 °C) Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . via thermostat valve -- initial opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177.0 ± 35.6 °F (81 ± 2 °C) Timing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by tappets, rods and rocker arms via the camshaft located in the engine block; the camshaft is driven by the crankshaft using straight--tooth gears Intake: -- start: before T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10° ± 30’ -- end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10° ± 30’ Exhaust: -- start: before B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64° -- end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26° Valve--rocker arm clearance (with engine cold): -- intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (0.30 ± 0.05 mm) -- exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (0.55 ± 0.05 mm) For further timing system technical data . . . . . . . . . . . . . . . . . . . see page 8 (continued)
  • 18. 4 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 (cont) GENERAL SPECIFICATIONS 4 Cylinders Fuel system Air cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter, with clogged filter indicator with centrifugal pre--filter and automatic dust ejector Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with double diaphragm Fuel filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through wire filter in fuel supply pump, and replaceable cartridge on delivery line to injection pump Minimum fuel flow rate with pump shaft rotating at 1800 rpm . 127.6 l/h Cam operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . engine timing BOSCH injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rotating distributor type All--speed governor, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal counterweights Automatic advance regulator, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydraulic For further fuel system technical data: Fixed advance (pump setting on engine for start of delivery before TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . refer to the data given in the table for operation 14. page 117 Pressure setting -- Injection order, and other information regarding the BOSCH pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . refer to the data given in the table page 5
  • 19. 14 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 MIF1096A 1 View of TL70A tractor engines of 53 kW (70 HP) and TL80A of 60 kW (80 HP)
  • 20. SECTION 10 - - ENGINE - - CHAPTER 1 15 603.54.511.00 - - 03 - - 2006 MIF1097A model TL90A 2 View of TL90A tractor engines of 67 kW (90 HP) and TL100A of 73.5 kW (100 HP)
  • 21. 16 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 MIF1098A Oil path under pressure Oil return path under gravity 3 Lubrication diagram for engines mod. TL90A and TL100A Forced--circulation lubrication is accomplished by the following components: -- oil pump, housed at the front of the crankcase, driven by the grooved bushing keyed onto the shank of the crankshaft; -- water / oil cooler, housed in the crankcase; -- oil pressure control valve incorporated in the cooler assembly; -- by--pass valve to cut off clogged oil filter, incorpo- rated in the cooler assembly; -- cartridge oil filter. NOTE: Engines mod. TL70A and TL80A do not have a turbocharger lubrication circuit.
  • 22. SECTION 10 - - ENGINE - - CHAPTER 1 17 603.54.511.00 - - 03 - - 2006 MIF1099A Coolant recirculating in the engine Coolant entering the pump 4 Cooling system diagram The forced circulation, closed--circuit engine cooling system is composed of the following components: -- a lubricating oil cooler; -- a centrifugal coolant pump housed at the front of the crankcase; -- a thermostat valve governing coolant circulation.
  • 23. 18 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 MIF1100A 5 Detail of cylinder head with valve seats fitted in engines mod. TL70A - - TL80A 1. Exhaust manifold 2. Intake manifold 3. Air heater 4. Fitted valve seats 5. Thermostat valve 6. Injector
  • 24. SECTION 10 - - ENGINE - - CHAPTER 1 19 603.54.511.00 - - 03 - - 2006 MIF1101A 6 Detail of cylinder head with valve seats fitted in engines mod. TL90A - - TL100A 1. Exhaust manifold 2. Intake manifold 3. Air heater 4. Fitted valve seats 5. Thermostat valve 6. Injector
  • 25. 20 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 MIF1102A 7 Additional counterweights 1. Retaining bolts 2. Support 3. Retaining bolts 4. Gear 5. Balancing weight 6. Half bearings 7. Counter--shaft 8. Gear 9. Ring 10. O--Ring
  • 26. SECTION 10 - - ENGINE - - CHAPTER 1 25 603.54.511.00 - - 03 - - 2006 Op. 10 001 10 ENGINE R.I. DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Check that no one is in the vicinity of the load to be lifted. CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. 1. Remove the bonnet (1) as described in operation 9010022. 2. Disconnect the battery negative lead. 3. Drain the oil from the transmission--gearbox housing. 8 4. Remove the three retaining bolts (1) and the guard (2) on the right--hand side of the fan. 9 5. Detach the fitting (3) of the return pipe (2) for the coolant from the cab heater radiator connected to the underside of the coolant pump (1) and drain off the engine coolant. 10
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  • 28. 26 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 6. Remove the catch (2) and detach the toolbox (1). 11 7. Remove the split pins, retaining pin (3) and front ballast (2) together with the support (1). 12 8. Unscrew the front central and rear retaining bolts on the front axle shaft guard, then remove the guard (1). 25038 1 13 9. Remove the circlip (2) and move the front sleeve (1) in the direction indicated by the arrow until it is released from the groove on the front axle. 25039 1 2 14
  • 29. SECTION 10 - - ENGINE - - CHAPTER 1 27 603.54.511.00 - - 03 - - 2006 10. Remove the circlip (2) and move the rear sleeve (1) in the direction indicated by the arrow until it is released from the groove on the drive. 25040 1 2 15 11. Remove the propeller shaft central support (1) retaining bolts and extract the shaft together with the support. 1 25041 16 12. Remove the retaining bolts (1) of the draw pipe (2) of the lift pump. 17 13. Detach the fitting (1) of the power steering/four-- wheel drive drain pipe on the left--hand side of the engine. 18
  • 30. 28 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 14. Detach the fitting (1) of the power steering/four-- wheel drive drain pipe on the right--hand side of the engine. 19 15. Take out the bolt (1) retaining the bracket and the power steering/four--wheel drive drain pipe on the right--hand side of the engine (2). 20 16. Remove the two metal clamps (2) and the rigid pipe (1) for drawing oil from the transmission via the pumps of the lift and power steering. 21 17. Remove the fitting (1) of the delivery pipe of the services pump on the right--hand side of the en- gine. 22
  • 31. SECTION 10 - - ENGINE - - CHAPTER 1 29 603.54.511.00 - - 03 - - 2006 18. Working on the left--hand side of the engine, take out the retaining bolts (2) and detach the draw pipe (1) of the lift pump. 23 19. Extract the plastic fasteners (2) and detach the diesel recovery pipe (3) and delivery pipe (4) to the diesel pump (1). 24 20. Disconnect the electrical connections (1) and (2) between the cab and the engine. 25 21. Disconnect the electrical connection (1) between the cab and the engine. 26
  • 32. 30 SECTION 10 - - ENGINE - - CHAPTER 1 603.54.511.00 - - 03 - - 2006 22. Disconnect the two power steering oil delivery and return hoses (1). 1 24879 27 23. Remove the four knobs (1) and take off the two right-- and left--hand dashboard panels (2). MDD2562A 1 2 28 24. Extract the differential lock pedal retaining pin from the drive shaft (1), remove the pedal and footboard (2). 25043 1 2 29 25. Remove the four plugs (1) in order to gain access to the engine upper retaining bolts. 30
  • 33. SECTION 10 - - ENGINE - - CHAPTER 1 31 603.54.511.00 - - 03 - - 2006 26. Remove the retaining clips (1) and detach the flexible cables governing the hand throttle (5) and pedal throttle (4). 27. Remove the retaining clip (3) and detach the throttle control tie--rod (2) connected to the injec- tion pump. 31 28. Detach the fitting (2) and the hose (1) delivering power steering oil to the hydraulic cylinders governing the front wheel steering. 32 29. Detach the clamp (1) and the cab heater delivery pipe (2). 33 30. Detach the clamp (2) and the cab heater return pipe (1). 34