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New holland ts110 a tractor service repair manual

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This document provides repair and maintenance instructions for tractor models TS100A, TS110A, TS115A, TS125A, TS130A, TS135A, T6010, T6020, T6030, T6050, and T6070. It includes sections on general safety, product identification, specifications, dimensions, and minimum hardware tightening torques. Safety precautions are marked as DANGER, WARNING, or CAUTION. Personal protective equipment is recommended when performing any maintenance or repairs.

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87693277 6/07 Replaces 87515329 © 2007 CNH America LLC Printed In U.S.A. TS100A, TS110A, TS115A, TS125A, TS130A AND TS135A REPAIR AND T6010, T6020, T6030, T6050, T6070 REPAIR SECTION 00 - GENERAL 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 01 - SEPARATING THE TRACTOR 3 . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 - ENGINE 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 18 - CLUTCH 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 21 - TRANSMISSION SYSTEMS 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 23 - DRIVE LINES 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 25 - MECHANICAL FRONT AXLE 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 27 - MECHANICAL REAR WHEEL DRIVE 34 . . . . . . . . . . . . . . . . . . . . SECTION 31 - POWER TAKE-OFF 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 33 - BRAKING SYSTEM 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 35 - HYDRAULIC SYSTEMS 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 41 - STEERING 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 44 - FRONT AXLE AND WHEELS 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 50 - AUXILIARY UNITS 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 55 - ELECTRICAL SYSTEM 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The following pages are the collation of the contents pages from each section and chapter of the TS100A, TS110A, TS115A, TS125A, TS130A, TS135A and T6010, T6020, T6030, T6050, T6070 Repair manual. Complete Repair part # 87693272. The sections used through out all New Holland product Repair manuals may not be used for each product. Each Repair manual will be made up of one or several books. Each book will be labeled as to which sections are in the overall Repair manual and which sections are in each book. The sections listed above are the sections utilized for the TSA Series and T6000 Series Tractors.
2 Some sections of this Repair Manual have been revised to include the New T6000 Delta and Plus Series Models T6010, T6020, T6030, T6050, and T6070. Please note the following to locate new T6000 Tractor Model Repair information: For complete engine repair information for the new T6000 Series Tractors use Engine Repair Manual # 87661796. Most all repairs can be carried out by following the Tractor’s systems and specific product configurations in the repair manual. Example; 16 x16 Transmission, Air Conditioning and TSA Standard Series Closed Center Hydraulic System. “TSA Standard” Repair Information also applies to the New T6000 Delta Series Models. Where specific T6000 Tractor Models are not identified use the following TSA to T6000 cross reference: T6000 Tractor Models Use TSA tractor Model T6010 TS100A T6020 TS110A T6030 TS115A T6050 TS125A T6070 TS135A
87693279 6/07 © 2007 CNH America LLC Printed In U.S.A. INFORMATION With the introduction of the T6000 Series Tractors, controller identifications codes have changed. Also, the location of the diagnostic connector has changed. The updated Repair Manual # 87693272 does not contain the new controller ID’s or the new location of the diagnostic connector. This page shows the T6000 Series controller identification codes and the diagnostic connector location. NOTE: Please insert a copy of this page in the front of each Repair Manual Volume for your reference. Models covered are: T6000 DELTA TRACTORS T6020, T6030, T6050 T6000 PLUS SERIES TRACTORS T6010, T6020, T6030, T6050, T6070 CONTROLLER IDENTIFICATION CODES The controller identifiers change with the introduction of the T6000 range of tractors, eg., Controller DA for TS-A will become Controller DR for T6000 range. This is required to be remembered throughout this Repair Manual. See table below: Identifier Identifier Controller Function(s) TS-A T6000 DA DR 24x24 Transmission, Electronic Draft Control, Rear PTO, Differential Lock, Four Wheel Drive DB DS 16x16 Transmission, Electronic Draft Control, Rear PTO, Differential Lock, Four Wheel Drive DD DU (Options) Front PTO, Front Hitch, Front Axle Suspension, Electronic Hydraulic Remotes EDC7 EDC16 Engine Control (Engine Side) HA HJ Enhanced Analogue Digital Instrument Cluster (ADIC) HB HK Basic ADIC GA 12x12 PTO Controller -- Rear PTO, Differential Lock, Four Wheel Drive JA Keypad
CONTROLLER FUNCTIONS Electronic Module Model/Type 24x24 16x16 24x24 16x16 12x12 24x24 16x16 Function DA(DR) DB(DS) DD(DU) GA EDC7 (EDC16) Rear PTO n n n Differential Lock n n n Four Wheel Drive n n n Engine Control (vehicle side) n n Auto Headland Turn Sequence (HTS) n n Electronic Draft Control n n Front Suspension n Front PTO n Front Lift n Electro-Hydraulic Remotes n Transmission 24x24 n Transmission 16x16 n Engine Control (engine side) n The controller type is identified by a code which is attached to each module. The code, for example, ’DB/DS’ identifies it as the module used on a tractor with a 16x16 transmission controlling those functions highlighted in the table above. All the modules on the tractor are linked by the CAN harness and this also links in the instrument cluster, gear display (16x16 only) and diagnostic connector. Refer to the system diagrams in Section 55, Chapter 1 of this repair manual for full controller details and inter connectivity. DIAGNOSTIC CONNECTORS (ADDITIONAL “C” PILLAR LOCATION) A single diagnostic port, 2, located behind the trim under the transmission control levers, or on the right hand “C” pillar, 1, to interrogate all of the controllers is incorporated into the wiring harness. With the aid of special service tool 380000843, the port can be used to gain access to the on-board H-menu diagnostics, see Section 55, Chapter 1 of this Repair Manual for full details, to download software or to connect in more specialized diagnostic equipment such as the E.S.T. (Electronic Service Tool). C277
SECTION 00 - - GENERAL - - CHAPTER 1 1 SECTION 00 - - GENERAL Chapter 1 - - General Information CONTENT Section Description Page 00 000 General Instructions 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautionary Statements 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Health and Safety 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ecology and the Environment 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Identification 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . International Symbols 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications -- Plus/Deluxe Models 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Dimensions 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications -- Standard Models 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Dimensions 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum Hardware Tightening Torques 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SECTION 00 - - GENERAL - - CHAPTER 1 GENERAL INSTRUCTIONS IMPORTANT NOTICE All maintenance and repair operations described in this manual should be carried out exclusively by authorised workshops. All instructions should be carefully observed and special equipment where indicated should be used. Anyone who carries out service operations described without carefully observing these instructions will be directly responsible for any damage caused. NOTES FOR EQUIPMENT Equipment shown in this manual is: -- designed expressly for use on these tractors; -- necessary to make a reliable repair; -- accurately built and strictly tested to offer efficient and long--lasting working life. NOTICES The words “front”, “rear”, “right hand”, and “left hand” refer to the different parts as seen from the operator’s seat oriented to the normal direction of movement of the tractor.
SECTION 00 - - GENERAL - - CHAPTER 1 3 PRECAUTIONARY STATEMENTS PERSONAL SAFETY Throughout this manual and on machine decals, you will find precautionary statements (“DANGER”, “WARNING”, and “CAUTION”) followed by specific instructions. These precautions are intended for the personal safety of you and those working with you. Please take the time to read them. DANGER This word “DANGER” indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury. The color associated with Danger is RED. WARNING This word “WARNING” indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE. CAUTION This word “CAUTION” indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. FAILURE TO FOLLOW THE “DANGER”, “WARNING”, AND “CAUTION” INSTRUCTIONS MAY RESULT IN SERIOUS BODILY INJURY OR DEATH. MACHINE SAFETY The precautionary statement (“IMPORTANT”) is followed by specific instructions. This statement is intended for machine safety. IMPORTANT: IMPORTANT: The word “IMPORTANT” is used to inform the reader of something he needs to know to prevent minor machine damage if a certain procedure is not followed. INFORMATION NOTE: NOTE: Instructions used to identify and present supplementary information.
4 SECTION 00 - - GENERAL - - CHAPTER 1 IMPORTANT WARNINGS The machine is designed and produced exclusively for agricultural use. All other use will be considered to be contrary to the use specified by CNH AMERICA LLC, who cannot be held liable for damage to property or the machine, or for personal injuries which may result. Persons who risk improper use will therefore assume the responsibility for any consequences arising from such use. Compliance with the instructions for use, maintenance and repairs described in this manual, are the essential preconditions for use specified by CNH AMERICA LLC. The machine must only be used, serviced or repaired by personnel trained in the relevant working methods and safety regulations and who have been authorized to work on the machine. The user must also observe the rules concerning general safety and accident prevention, including the Highway Code when driving on public highways. Any arbitrary modifications made to this machine will release CNH AMERICA LLC from any liability resulting from damage or injury. CNH AMERICA LLC and all its distribution organizations, inclusive of, but not restrict to, national, regional or local distributors, cannot be held liable for damage resulting from the malfunction of parts and/or components not approved by CNH AMERICA LLC. Under no circumstances will a guarantee be issued for products made or sold by CNH AMERICA LLC that are damaged as a result of the malfunction of parts and/or components not approved by CNH AMERICA LLC. TO PREVENT ACCIDENTS Most accidents and personal injuries taking place in workshops are due from non-observance of some essential rules and safety precautions. The possibility that an accident might occur with any type of machines should not be disregarded, no matter how well the machine in question was designed and built. A wise and careful service technician is the best precautions against accidents. Careful observance of this basic precaution would be enough to avoid many severe accidents. DANGER Never carry out any cleaning, lubrication or maintenance operations when the engine is running.
SECTION 00 - - GENERAL - - CHAPTER 1 5 SAFETY RULES Generalities • Carefully follow specified repair and maintenance procedures. • Do not wear rings, wristwatches, jewels, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open jackets or shirts with open zips which could get caught on moving parts. Use approved safety clothing such as anti--slipping footwear, gloves, safety goggles, helmets, etc. • Wear safety glasses with side guards when cleaning parts using compressed air. • Damaged or frayed wires and chains are unreliable. Do not use them for lifting or towing. • Wear suitable protection such as approved eye protection, helmets, special clothing, gloves and footwear whenever welding. All persons standing in the vicinity of the welding process should wear approved eye protection. NEVER LOOK AT THE WELDING ARC IF YOUR EYES ARE NOT SUITABLY PROTECTED. • Never carry out any repair on the machine if someone is sitting on the operator’s seat, except if they are qualified operators assisting in the operation to be carried out. • Never operate the machine or use attachments from a place other than sitting at the operator’s seat or at the side of the machine when operating the fender switches. • Never carry out any operation on the machine when the engine is running, except when specifically indicated. Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps, covers, valves, etc. • All repair and maintenance operations should be carried out with the greatest care and attention. • Disconnect the batteries and label all controls to warn that the tractor is being serviced. Block the machine and all equipment which should be raised. • Never check or fill fuel tanks or batteries, nor use starting liquid if you are smoking or near open flames as such fluids are flammable. • The fuel filling gun should always remain in contact with the filler neck. Maintain this contact until the fuel stops flowing into the tank to avoid possible sparks due to static electricity build--up. • To transfer a failed tractor, use a trailer or a low loading platform trolley if available. • To load and unload the machine from the transportation means, select a flat area providing a firm support to the trailer or truck wheels. Firmly tie the machine to the truck or trailer platform and block wheels as required by the transporter. • Always use lifting equipment of appropriate capacity to lift or move heavy components. • Chains should always be safely fastened. Ensure that fastening device is strong enough to hold the load foreseen. No persons should stand near the fastening point. • The working area should be always kept CLEAN and DRY. Immediately clean any spillage of water or oil. • Never use gasoline, diesel oil or other flammable liquids as cleaning agents. Use non--flammable non--toxic proprietary solvents. • Do not pile up grease or oil soaked rags, as they constitute a great fire hazard. Always place them into a metal container.
6 SECTION 00 - - GENERAL - - CHAPTER 1 START UP • Never run the engine in confined spaces which are not equipped with adequate ventilation for exhaust gas extraction. • Never bring your head, body, arms, legs, feet, hands, fingers near fans or rotating belts. ENGINE • Always loosen the radiator cap very slowly before removing it to allow pressure in the system to dissipate. Coolant should be topped up only when the engine is stopped. • Do not fill up fuel tank when the engine is running. • Never adjust the fuel injection pump when the tractor is moving. • Never lubricate the tractor when the engine is running. ELECTRICAL SYSTEMS • If it is necessary to use auxiliary batteries, cables must be connected at both sides as follows: (+) to (+) and (--) to (--). Avoid short--circuiting the terminals. GAS RELEASED FROM BATTERIES IS HIGHLY FLAMMABLE. During charging, leave the battery compartment uncovered to improve ventilation. Avoid sparks or flames near the battery area. Do no smoke. • Do not charge batteries in confined spaces. • Always disconnect the batteries before performing any type of service on the electrical system. HYDRAULIC SYSTEMS • Some fluid coming out from a very small port can be almost invisible and be strong enough to penetrate the skin. For this reason, NEVER USE YOUR HANDS TO CHECK FOR LEAKS, but use a piece of cardboard or a piece of wood for this purpose. If any fluid is injected into the skin, seek medical aid immediately. Lack of immediate medical attention may result in serious infections or dermatitis. • Always take system pressure readings using the appropriate gauges. WHEELS AND TYRES • Check that the tyres are correctly inflated at the pressure specified by the manufacturer. Periodically check for possible damage to the rims and tyres. • Stay at the tyre side when inflating. • Check the pressure only when the tractor is unloaded and tyres are cold to avoid wrong readings due to over--pressure. • Never cut, nor weld a rim with the inflated tyre assembled. • To remove the wheels, block both front and rear tractor wheels. Raise the tractor and install safe and stable supports under the tractor in accordance with regulations in force. • Deflate the tyre before removing any object caught into the tyre tread. • Never inflate tyres using flammable gases as they may originate explosions and cause injuries to bystanders. REMOVAL AND INSTALLATION • Lift and handle all heavy components using lifting equipment of adequate capacity. Ensure that parts are supported by appropriate slings and hooks. Use lifting eyes provided to this purpose. Take care of the persons near the loads to be lifted.
SECTION 10 - - ENGINE - - CHAPTER 1 15 DESCRIPTION OF OPERATION COOLING The forced circulation, closed--circuit engine cooling system is composed of the following components: -- Expansion tank: its location, shape and size may change depending on the engine version. -- Radiator, whose job is to dissipate the heat taken by the coolant from the engine. This component, too, is a feature of the version as regards both positioning and engine. -- Viscostatic fan, with the task of increasing the radiator’s dissipating capacity: this, too, belongs to the specific engine version. -- A lubricating oil cooler: this, too, belongs to the specific engine version. -- A centrifugal coolant pump housed at the front of the crankcase. -- A thermostat governing coolant circulation. -- The circuit may also extend to the compressor if the version includes it. 80369 A = TO THE RADIATOR B = FROM THE RADIATOR 8 COOLING SYSTEM DIAGRAM
16 SECTION 10 - - ENGINE - - CHAPTER 1 LUBRICATION Forced--circulation lubrication is accomplished by the oil pump, housed at the front of the crankcase. The lubricating oil is sent from the oil sump to the crankshaft, camshaft and valve control. Lubrication also includes the cooler, turbo--blower and compressor for the compressed air system if there is one. All these components often change according to use and will therefore be covered under the specific heading. 80370 Pressurized oil Oil under gravity 9
SECTION 10 - - ENGINE - - CHAPTER 1 17 LUBRICATION SYSTEM COMPONENTS 80371 10 1. Crankshaft – 2. Balancing weight – 3. Oil sump with suction rose – 4. Suction rose in oil sump – 5. Oil pump – 6. Relief valve.
18 SECTION 10 - - ENGINE - - CHAPTER 1 ENGINE OVERHAUL INTRODUCTION Removal To remove engine from tractor see Section 01 “Separating the Tractor.” DISASSEMBLY Some of the operations described in this section can be carried out directly with the engine fitted on the vehicle, depending on access to the engine bay and on the version. CAUTION The operations for removing the engine, as those for overhaul, must be performed by skilled personnel us- ing specific tools. Fuel System/Preparing Engine to Mount on Rotating Stand To be able to fit the brackets 380001298 (for fixing the engine to the overhaul stand, 380000301) to the crankcase, it is necessary to work from the left--hand side of the engine: 1. Remove the fuel filters (6) from the mounting (1); 2. Disconnect the electrical connection (2) from the mounting (1) and the one to the heater (again located on the filter mounting); 3. Disconnect the fuel pipes (3 -- 4 -- 5) from the mounting (1); 4. Remove the bracket supporting the mounting (1) from the crankcase. CAUTION To disconnect the fuel pipes (3 – 4 – 5, Figure 11) from the relevant fittings, you need to press the clip (1) as shown in Figure 12, B. After disconnecting the piping, put the clip (1) back in its locking position (Figure 12, A) to prevent it getting buckled. 80372 11 5. Disconnect the high--pressure fuel pipe (7, Fig- ure 1) from the rail choke tube and from the high--pressure pump (8) and remove it from the crankcase by taking out the bracket. 6. Disconnect the pipe 9 from the high--pressure pump (8). CAUTION Depending on the high pressure in the piping from the high--pressure pump to the rail and from here to the electro--injectors, never: -- disconnect the pipes with the engine running, -- reuse disconnected pipes. 80628 12
SECTION 10 - - ENGINE - - CHAPTER 1 19 7. Remove the oil filler pipe (3). 8. Unscrew the fixing screws (1) and remove the starter motor (2) from its seat. 80374 13 9. Working from the right--hand side of the engine, disconnect the lubricating pipe (1) from the top of the cooler to the turbo--blower (2). 10. Remove the thermostat body (3) together with the seal. 80373 14 11. Fit brackets 380001298 into the holes (1) and (2) in the crankcase on both sides and, using these brackets, secure the engine to the rotat- ing stand 380000301. Drain off the engine oil by removing the plug from the sump. 80401 15
20 SECTION 10 - - ENGINE - - CHAPTER 1 80375 16 REMOVING COMPONENTS OF THE APPLICATION 1. Connection for electro--injectors -- 2. Engine coolant temperature sensor -- 3. Fuel pressure sensor cable -- 4. Engine oil pressure and temperature sensor -- 5. Crankshaft sensor -- 6. Electro--injector -- 7. Air pressure temperature sensor -- 8. Timing system phase sensor -- 9. Fuel temperature sensor -- 10. Pressure regulator wiring -- 11. EDC7C control unit Electrical Connections 12. Disconnect the engine cable from the connec- tors: (1) electro-injector wiring (6); (7) air pressure/temperature sensor; (3) fuel pressure sensor; (11) EDC control unit; (10 high-pres- sure pump sensor; (8) timing system phase sensor; (2) engine coolant temperature sensor on thermostat; (5) crankshaft speed sensor.
SECTION 10 - - ENGINE - - CHAPTER 1 21 Fuel Rail 13. Take off the clamps fastening it to the crankcase and remove it completely. 14. Disconnect the fuel pipes (5) from the rail (2) and from the manifolds (6) for the electro--injec- tors. CAUTION When locking the fittings (4) securing the pipes (6) to the rail (2), using an appropriate wrench, you must prevent the flow limiters, if fitted, (3) from turning. 15. Remove the screws (1) and detach the rail (2). 80376 17 Cylinder Head 16. Disconnect the piping from the fuel return pres- sure limiter (1). 17. Undo the nuts (2) and take off the tappet cover (3). 80377 18 18. Remove the nuts (7) and disconnect the electric cables from the electro--injectors (8). 19. Take out the screws (1) and remove the elec- tro--injector wiring mounting (2) together with its seal. 20. Take out the screws (5), remove the air temper- ature/pressure sensor (6). 21. Remove the nuts (3) and extract the fuel man- ifolds (4). CAUTION Once removed, the fuel manifolds (4) must not be re- used; they must be replaced with new ones. 80591 19
22 SECTION 10 - - ENGINE - - CHAPTER 1 22. Loosen the tappet adjuster fixing nuts (1) and unscrew the adjusters. 23. Take out the screws (2), remove the rocker--arm assembly (3) comprising the mounting (6), rocker arms (4) and spindles (5) then remove the bridges (7) from the valves. 24. Remove the rods (8). 80640 20 25. Take out the screws securing the electro--injec- tors and, using tool 380001099 (1), extract the electro--injectors (2) from the cylinder head. 80686 21 26. Working on the tightener (1), extract the belt (12) from the pulleys of the alternator, coolant pump and snub pulleys. 27. Unscrew the bolt (2) and remove the tightener; 28. Remove the snub pulley (6), unscrew the bolts (7) and remove the pulley (8) from the mounting beneath. 29. Unscrew the bolts (10) and remove the tighten- er mounting. 30. Unscrew the bolts (11) and remove the mount- ing (9) from the crankcase. 31. Unscrew the bolts (3) and remove the coolant pump (4). 32. Unscrew the bolt and remove the engine speed sensor (5) 80378 22
SECTION 10 - - ENGINE - - CHAPTER 1 23 Proceed to remove the turbocharger: 33. Unscrew the ring nut (1) and remove the lu- brication piping of the turbo--blower. 34. Unscrew the nuts (2) securing the turbo--blower on the exhaust manifold (4). 35. Support the turbo--blower (5) and, lifting it, re- move the seal. 36. Unscrew the retaining nuts (3) and remove the exhaust manifold (4). 80315 23 37. From the opposite side, unscrew the bolts se- curing the intake manifold (1) and remove it to- gether with the air heater (2) for cold starts. 80379 24 38. Hook up the brackets, 380001073 (1) with a suitable sling and, using a hoist, remove the cyl- inder head (2) from the crankcase. 80687 25
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24 SECTION 10 - - ENGINE - - CHAPTER 1 Crankcase - - External Components 39. Remove the oil filter (1). 40. Unscrew the retaining bolts and remove the al- ternator (2). 80380 26 41. Unscrew the retaining bolts (1) and remove the pipe fitting (2). 80326 27 42. Disconnect the connector (1) from the oil pres- sure--temperature sensor. 43. Unscrew the bolts (2) and remove the oil pres- sure--temperature sensor (3). 44. Unscrew the bolts (4) and remove the oil filter mounting (5) from the crankcase together with its seals. 45. Remove the cooler from its seat. 80400 28
SECTION 10 - - ENGINE - - CHAPTER 1 25 46. Remove the nuts (1) and detach the high--pres- sure pump (2) together with the feed pump (3). 80381 29 Crank Shaft Seals 47. Install the engine turning / locking tool, 380000988, (1) and 380000732, (2). 48. Loosen the screws fixing the flywheel to the crankshaft. 2 30 49. Unscrew the bolts (1), remove the pulley (2), spacer (3) and pulley (4). 50. The engine flywheel locking tool can help with disassembly of the damper flywheel (2) fitted on the pulley (4). 80382 31
26 SECTION 10 - - ENGINE - - CHAPTER 1 51. Extract the front cover shaft seal. 52. Apply tool 380000665 (4) on the front tang (2) of the crankshaft. 53. Perforate the inner seal (1) with a drill bit (∅ 3.5 mm (0.1378 in.)) through the tool’s guide holes, for a depth of 5 mm (0.1969 in.). 54. Secure the tool to the seal by screwing down the 6 screws supplied. Extract the seal (1) by screwing down the screw (3). 80595 32 55. Use a suitable hooked device (3) with the aid of the lever (4) extract the outer seal (2) from the front cover (1). 80596 33 56. Take out the screws (1) and remove the oil pump (2). CAUTION Note down the assembly position of the screws (1) as they have different lengths. 80330 34
SECTION 10 - - ENGINE - - CHAPTER 1 27 57. Remove two opposing screws (1) where the ex- traction pins are to go in (see figure 36). 58. Unscrew the remaining screws securing the fly- wheel (3) from the crankshaft (2). 59. Remove the tool locking the flywheel (4). 35 60. Screw two screws of suitable length into the holes (4) to sling the flywheel with a lift. 61. Using the two guide pins (2) previously screwed into the holes of the crankshaft (3), guide the ex- traction of the engine flywheel (1) with the aid of a lift. 80356 36 62. Extract the seal, applying tool 380000663 (3) onto the rear tang (5) of the crankshaft. 63. Perforate the inner seal with a drill bit (∅ 3.5 mm (0.1378 in.)) through the tool’s guide holes, for a depth of 5 mm (0.1969 in.). 64. Secure the tool 380000663 (3) to the seal (1) by screwing down the 6 screws supplied (4). Extract the seal (1) by screwing down the screw (2). 65. Using an appropriate hooked device and a le- ver, extract the outer seal from the timing box. 80597 37
28 SECTION 10 - - ENGINE - - CHAPTER 1 Sump 66. Turn the engine over. Take out the screws (2) and remove the oil sump (1). 67. Disconnect the high--pressure pump phase sensor. 68. Unscrew the bolts (3) and remove the timing gear box (4) from the crankcase. 80331 38 Rotating Counter Weights 69. Take out the screws (1) and remove the gear (3) from the camshaft (2). 80397 39 70. Using the pin (1), lock the additional counter- weights (2) at the T.D.C. 71. Unscrew the retaining bolts (3) and remove the additional counterweights (2). 80332 40
SECTION 10 - - ENGINE - - CHAPTER 1 29 80637 41 ROTATING COUNTERWEIGHT COMPONENTS 1. Retaining bolts -- 2. Mounting -- 3. Retaining bolts -- 4. Gear -- 5. Balancing weight -- 6. O--ring -- 7. Ring -- 8. Gear -- 9. Counter--shaft -- 10. Half bearings Crankshaft 72. Take out the screws (1) securing the connecting rod caps (2) and remove them. 73. Extract the pistons together with the connecting rods from the top of the crankcase. CAUTION Keep the half bearings in their respective housings since, if they are used, they must be mounted in the position found upon disassembly. 80598 42

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New holland ts110 a tractor service repair manual

  • 1. 87693277 6/07 Replaces 87515329 © 2007 CNH America LLC Printed In U.S.A. TS100A, TS110A, TS115A, TS125A, TS130A AND TS135A REPAIR AND T6010, T6020, T6030, T6050, T6070 REPAIR SECTION 00 - GENERAL 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 01 - SEPARATING THE TRACTOR 3 . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 - ENGINE 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 18 - CLUTCH 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 21 - TRANSMISSION SYSTEMS 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 23 - DRIVE LINES 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 25 - MECHANICAL FRONT AXLE 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 27 - MECHANICAL REAR WHEEL DRIVE 34 . . . . . . . . . . . . . . . . . . . . SECTION 31 - POWER TAKE-OFF 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 33 - BRAKING SYSTEM 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 35 - HYDRAULIC SYSTEMS 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 41 - STEERING 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 44 - FRONT AXLE AND WHEELS 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 50 - AUXILIARY UNITS 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 55 - ELECTRICAL SYSTEM 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The following pages are the collation of the contents pages from each section and chapter of the TS100A, TS110A, TS115A, TS125A, TS130A, TS135A and T6010, T6020, T6030, T6050, T6070 Repair manual. Complete Repair part # 87693272. The sections used through out all New Holland product Repair manuals may not be used for each product. Each Repair manual will be made up of one or several books. Each book will be labeled as to which sections are in the overall Repair manual and which sections are in each book. The sections listed above are the sections utilized for the TSA Series and T6000 Series Tractors.
  • 2. 2 Some sections of this Repair Manual have been revised to include the New T6000 Delta and Plus Series Models T6010, T6020, T6030, T6050, and T6070. Please note the following to locate new T6000 Tractor Model Repair information: For complete engine repair information for the new T6000 Series Tractors use Engine Repair Manual # 87661796. Most all repairs can be carried out by following the Tractor’s systems and specific product configurations in the repair manual. Example; 16 x16 Transmission, Air Conditioning and TSA Standard Series Closed Center Hydraulic System. “TSA Standard” Repair Information also applies to the New T6000 Delta Series Models. Where specific T6000 Tractor Models are not identified use the following TSA to T6000 cross reference: T6000 Tractor Models Use TSA tractor Model T6010 TS100A T6020 TS110A T6030 TS115A T6050 TS125A T6070 TS135A
  • 3. 87693279 6/07 © 2007 CNH America LLC Printed In U.S.A. INFORMATION With the introduction of the T6000 Series Tractors, controller identifications codes have changed. Also, the location of the diagnostic connector has changed. The updated Repair Manual # 87693272 does not contain the new controller ID’s or the new location of the diagnostic connector. This page shows the T6000 Series controller identification codes and the diagnostic connector location. NOTE: Please insert a copy of this page in the front of each Repair Manual Volume for your reference. Models covered are: T6000 DELTA TRACTORS T6020, T6030, T6050 T6000 PLUS SERIES TRACTORS T6010, T6020, T6030, T6050, T6070 CONTROLLER IDENTIFICATION CODES The controller identifiers change with the introduction of the T6000 range of tractors, eg., Controller DA for TS-A will become Controller DR for T6000 range. This is required to be remembered throughout this Repair Manual. See table below: Identifier Identifier Controller Function(s) TS-A T6000 DA DR 24x24 Transmission, Electronic Draft Control, Rear PTO, Differential Lock, Four Wheel Drive DB DS 16x16 Transmission, Electronic Draft Control, Rear PTO, Differential Lock, Four Wheel Drive DD DU (Options) Front PTO, Front Hitch, Front Axle Suspension, Electronic Hydraulic Remotes EDC7 EDC16 Engine Control (Engine Side) HA HJ Enhanced Analogue Digital Instrument Cluster (ADIC) HB HK Basic ADIC GA 12x12 PTO Controller -- Rear PTO, Differential Lock, Four Wheel Drive JA Keypad
  • 4. CONTROLLER FUNCTIONS Electronic Module Model/Type 24x24 16x16 24x24 16x16 12x12 24x24 16x16 Function DA(DR) DB(DS) DD(DU) GA EDC7 (EDC16) Rear PTO n n n Differential Lock n n n Four Wheel Drive n n n Engine Control (vehicle side) n n Auto Headland Turn Sequence (HTS) n n Electronic Draft Control n n Front Suspension n Front PTO n Front Lift n Electro-Hydraulic Remotes n Transmission 24x24 n Transmission 16x16 n Engine Control (engine side) n The controller type is identified by a code which is attached to each module. The code, for example, ’DB/DS’ identifies it as the module used on a tractor with a 16x16 transmission controlling those functions highlighted in the table above. All the modules on the tractor are linked by the CAN harness and this also links in the instrument cluster, gear display (16x16 only) and diagnostic connector. Refer to the system diagrams in Section 55, Chapter 1 of this repair manual for full controller details and inter connectivity. DIAGNOSTIC CONNECTORS (ADDITIONAL “C” PILLAR LOCATION) A single diagnostic port, 2, located behind the trim under the transmission control levers, or on the right hand “C” pillar, 1, to interrogate all of the controllers is incorporated into the wiring harness. With the aid of special service tool 380000843, the port can be used to gain access to the on-board H-menu diagnostics, see Section 55, Chapter 1 of this Repair Manual for full details, to download software or to connect in more specialized diagnostic equipment such as the E.S.T. (Electronic Service Tool). C277
  • 5. SECTION 00 - - GENERAL - - CHAPTER 1 1 SECTION 00 - - GENERAL Chapter 1 - - General Information CONTENT Section Description Page 00 000 General Instructions 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautionary Statements 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Health and Safety 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ecology and the Environment 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Identification 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . International Symbols 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications -- Plus/Deluxe Models 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Dimensions 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications -- Standard Models 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Dimensions 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum Hardware Tightening Torques 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • 6. 2 SECTION 00 - - GENERAL - - CHAPTER 1 GENERAL INSTRUCTIONS IMPORTANT NOTICE All maintenance and repair operations described in this manual should be carried out exclusively by authorised workshops. All instructions should be carefully observed and special equipment where indicated should be used. Anyone who carries out service operations described without carefully observing these instructions will be directly responsible for any damage caused. NOTES FOR EQUIPMENT Equipment shown in this manual is: -- designed expressly for use on these tractors; -- necessary to make a reliable repair; -- accurately built and strictly tested to offer efficient and long--lasting working life. NOTICES The words “front”, “rear”, “right hand”, and “left hand” refer to the different parts as seen from the operator’s seat oriented to the normal direction of movement of the tractor.
  • 7. SECTION 00 - - GENERAL - - CHAPTER 1 3 PRECAUTIONARY STATEMENTS PERSONAL SAFETY Throughout this manual and on machine decals, you will find precautionary statements (“DANGER”, “WARNING”, and “CAUTION”) followed by specific instructions. These precautions are intended for the personal safety of you and those working with you. Please take the time to read them. DANGER This word “DANGER” indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury. The color associated with Danger is RED. WARNING This word “WARNING” indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE. CAUTION This word “CAUTION” indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. FAILURE TO FOLLOW THE “DANGER”, “WARNING”, AND “CAUTION” INSTRUCTIONS MAY RESULT IN SERIOUS BODILY INJURY OR DEATH. MACHINE SAFETY The precautionary statement (“IMPORTANT”) is followed by specific instructions. This statement is intended for machine safety. IMPORTANT: IMPORTANT: The word “IMPORTANT” is used to inform the reader of something he needs to know to prevent minor machine damage if a certain procedure is not followed. INFORMATION NOTE: NOTE: Instructions used to identify and present supplementary information.
  • 8. 4 SECTION 00 - - GENERAL - - CHAPTER 1 IMPORTANT WARNINGS The machine is designed and produced exclusively for agricultural use. All other use will be considered to be contrary to the use specified by CNH AMERICA LLC, who cannot be held liable for damage to property or the machine, or for personal injuries which may result. Persons who risk improper use will therefore assume the responsibility for any consequences arising from such use. Compliance with the instructions for use, maintenance and repairs described in this manual, are the essential preconditions for use specified by CNH AMERICA LLC. The machine must only be used, serviced or repaired by personnel trained in the relevant working methods and safety regulations and who have been authorized to work on the machine. The user must also observe the rules concerning general safety and accident prevention, including the Highway Code when driving on public highways. Any arbitrary modifications made to this machine will release CNH AMERICA LLC from any liability resulting from damage or injury. CNH AMERICA LLC and all its distribution organizations, inclusive of, but not restrict to, national, regional or local distributors, cannot be held liable for damage resulting from the malfunction of parts and/or components not approved by CNH AMERICA LLC. Under no circumstances will a guarantee be issued for products made or sold by CNH AMERICA LLC that are damaged as a result of the malfunction of parts and/or components not approved by CNH AMERICA LLC. TO PREVENT ACCIDENTS Most accidents and personal injuries taking place in workshops are due from non-observance of some essential rules and safety precautions. The possibility that an accident might occur with any type of machines should not be disregarded, no matter how well the machine in question was designed and built. A wise and careful service technician is the best precautions against accidents. Careful observance of this basic precaution would be enough to avoid many severe accidents. DANGER Never carry out any cleaning, lubrication or maintenance operations when the engine is running.
  • 9. SECTION 00 - - GENERAL - - CHAPTER 1 5 SAFETY RULES Generalities • Carefully follow specified repair and maintenance procedures. • Do not wear rings, wristwatches, jewels, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open jackets or shirts with open zips which could get caught on moving parts. Use approved safety clothing such as anti--slipping footwear, gloves, safety goggles, helmets, etc. • Wear safety glasses with side guards when cleaning parts using compressed air. • Damaged or frayed wires and chains are unreliable. Do not use them for lifting or towing. • Wear suitable protection such as approved eye protection, helmets, special clothing, gloves and footwear whenever welding. All persons standing in the vicinity of the welding process should wear approved eye protection. NEVER LOOK AT THE WELDING ARC IF YOUR EYES ARE NOT SUITABLY PROTECTED. • Never carry out any repair on the machine if someone is sitting on the operator’s seat, except if they are qualified operators assisting in the operation to be carried out. • Never operate the machine or use attachments from a place other than sitting at the operator’s seat or at the side of the machine when operating the fender switches. • Never carry out any operation on the machine when the engine is running, except when specifically indicated. Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps, covers, valves, etc. • All repair and maintenance operations should be carried out with the greatest care and attention. • Disconnect the batteries and label all controls to warn that the tractor is being serviced. Block the machine and all equipment which should be raised. • Never check or fill fuel tanks or batteries, nor use starting liquid if you are smoking or near open flames as such fluids are flammable. • The fuel filling gun should always remain in contact with the filler neck. Maintain this contact until the fuel stops flowing into the tank to avoid possible sparks due to static electricity build--up. • To transfer a failed tractor, use a trailer or a low loading platform trolley if available. • To load and unload the machine from the transportation means, select a flat area providing a firm support to the trailer or truck wheels. Firmly tie the machine to the truck or trailer platform and block wheels as required by the transporter. • Always use lifting equipment of appropriate capacity to lift or move heavy components. • Chains should always be safely fastened. Ensure that fastening device is strong enough to hold the load foreseen. No persons should stand near the fastening point. • The working area should be always kept CLEAN and DRY. Immediately clean any spillage of water or oil. • Never use gasoline, diesel oil or other flammable liquids as cleaning agents. Use non--flammable non--toxic proprietary solvents. • Do not pile up grease or oil soaked rags, as they constitute a great fire hazard. Always place them into a metal container.
  • 10. 6 SECTION 00 - - GENERAL - - CHAPTER 1 START UP • Never run the engine in confined spaces which are not equipped with adequate ventilation for exhaust gas extraction. • Never bring your head, body, arms, legs, feet, hands, fingers near fans or rotating belts. ENGINE • Always loosen the radiator cap very slowly before removing it to allow pressure in the system to dissipate. Coolant should be topped up only when the engine is stopped. • Do not fill up fuel tank when the engine is running. • Never adjust the fuel injection pump when the tractor is moving. • Never lubricate the tractor when the engine is running. ELECTRICAL SYSTEMS • If it is necessary to use auxiliary batteries, cables must be connected at both sides as follows: (+) to (+) and (--) to (--). Avoid short--circuiting the terminals. GAS RELEASED FROM BATTERIES IS HIGHLY FLAMMABLE. During charging, leave the battery compartment uncovered to improve ventilation. Avoid sparks or flames near the battery area. Do no smoke. • Do not charge batteries in confined spaces. • Always disconnect the batteries before performing any type of service on the electrical system. HYDRAULIC SYSTEMS • Some fluid coming out from a very small port can be almost invisible and be strong enough to penetrate the skin. For this reason, NEVER USE YOUR HANDS TO CHECK FOR LEAKS, but use a piece of cardboard or a piece of wood for this purpose. If any fluid is injected into the skin, seek medical aid immediately. Lack of immediate medical attention may result in serious infections or dermatitis. • Always take system pressure readings using the appropriate gauges. WHEELS AND TYRES • Check that the tyres are correctly inflated at the pressure specified by the manufacturer. Periodically check for possible damage to the rims and tyres. • Stay at the tyre side when inflating. • Check the pressure only when the tractor is unloaded and tyres are cold to avoid wrong readings due to over--pressure. • Never cut, nor weld a rim with the inflated tyre assembled. • To remove the wheels, block both front and rear tractor wheels. Raise the tractor and install safe and stable supports under the tractor in accordance with regulations in force. • Deflate the tyre before removing any object caught into the tyre tread. • Never inflate tyres using flammable gases as they may originate explosions and cause injuries to bystanders. REMOVAL AND INSTALLATION • Lift and handle all heavy components using lifting equipment of adequate capacity. Ensure that parts are supported by appropriate slings and hooks. Use lifting eyes provided to this purpose. Take care of the persons near the loads to be lifted.
  • 11. SECTION 10 - - ENGINE - - CHAPTER 1 15 DESCRIPTION OF OPERATION COOLING The forced circulation, closed--circuit engine cooling system is composed of the following components: -- Expansion tank: its location, shape and size may change depending on the engine version. -- Radiator, whose job is to dissipate the heat taken by the coolant from the engine. This component, too, is a feature of the version as regards both positioning and engine. -- Viscostatic fan, with the task of increasing the radiator’s dissipating capacity: this, too, belongs to the specific engine version. -- A lubricating oil cooler: this, too, belongs to the specific engine version. -- A centrifugal coolant pump housed at the front of the crankcase. -- A thermostat governing coolant circulation. -- The circuit may also extend to the compressor if the version includes it. 80369 A = TO THE RADIATOR B = FROM THE RADIATOR 8 COOLING SYSTEM DIAGRAM
  • 12. 16 SECTION 10 - - ENGINE - - CHAPTER 1 LUBRICATION Forced--circulation lubrication is accomplished by the oil pump, housed at the front of the crankcase. The lubricating oil is sent from the oil sump to the crankshaft, camshaft and valve control. Lubrication also includes the cooler, turbo--blower and compressor for the compressed air system if there is one. All these components often change according to use and will therefore be covered under the specific heading. 80370 Pressurized oil Oil under gravity 9
  • 13. SECTION 10 - - ENGINE - - CHAPTER 1 17 LUBRICATION SYSTEM COMPONENTS 80371 10 1. Crankshaft – 2. Balancing weight – 3. Oil sump with suction rose – 4. Suction rose in oil sump – 5. Oil pump – 6. Relief valve.
  • 14. 18 SECTION 10 - - ENGINE - - CHAPTER 1 ENGINE OVERHAUL INTRODUCTION Removal To remove engine from tractor see Section 01 “Separating the Tractor.” DISASSEMBLY Some of the operations described in this section can be carried out directly with the engine fitted on the vehicle, depending on access to the engine bay and on the version. CAUTION The operations for removing the engine, as those for overhaul, must be performed by skilled personnel us- ing specific tools. Fuel System/Preparing Engine to Mount on Rotating Stand To be able to fit the brackets 380001298 (for fixing the engine to the overhaul stand, 380000301) to the crankcase, it is necessary to work from the left--hand side of the engine: 1. Remove the fuel filters (6) from the mounting (1); 2. Disconnect the electrical connection (2) from the mounting (1) and the one to the heater (again located on the filter mounting); 3. Disconnect the fuel pipes (3 -- 4 -- 5) from the mounting (1); 4. Remove the bracket supporting the mounting (1) from the crankcase. CAUTION To disconnect the fuel pipes (3 – 4 – 5, Figure 11) from the relevant fittings, you need to press the clip (1) as shown in Figure 12, B. After disconnecting the piping, put the clip (1) back in its locking position (Figure 12, A) to prevent it getting buckled. 80372 11 5. Disconnect the high--pressure fuel pipe (7, Fig- ure 1) from the rail choke tube and from the high--pressure pump (8) and remove it from the crankcase by taking out the bracket. 6. Disconnect the pipe 9 from the high--pressure pump (8). CAUTION Depending on the high pressure in the piping from the high--pressure pump to the rail and from here to the electro--injectors, never: -- disconnect the pipes with the engine running, -- reuse disconnected pipes. 80628 12
  • 15. SECTION 10 - - ENGINE - - CHAPTER 1 19 7. Remove the oil filler pipe (3). 8. Unscrew the fixing screws (1) and remove the starter motor (2) from its seat. 80374 13 9. Working from the right--hand side of the engine, disconnect the lubricating pipe (1) from the top of the cooler to the turbo--blower (2). 10. Remove the thermostat body (3) together with the seal. 80373 14 11. Fit brackets 380001298 into the holes (1) and (2) in the crankcase on both sides and, using these brackets, secure the engine to the rotat- ing stand 380000301. Drain off the engine oil by removing the plug from the sump. 80401 15
  • 16. 20 SECTION 10 - - ENGINE - - CHAPTER 1 80375 16 REMOVING COMPONENTS OF THE APPLICATION 1. Connection for electro--injectors -- 2. Engine coolant temperature sensor -- 3. Fuel pressure sensor cable -- 4. Engine oil pressure and temperature sensor -- 5. Crankshaft sensor -- 6. Electro--injector -- 7. Air pressure temperature sensor -- 8. Timing system phase sensor -- 9. Fuel temperature sensor -- 10. Pressure regulator wiring -- 11. EDC7C control unit Electrical Connections 12. Disconnect the engine cable from the connec- tors: (1) electro-injector wiring (6); (7) air pressure/temperature sensor; (3) fuel pressure sensor; (11) EDC control unit; (10 high-pres- sure pump sensor; (8) timing system phase sensor; (2) engine coolant temperature sensor on thermostat; (5) crankshaft speed sensor.
  • 17. SECTION 10 - - ENGINE - - CHAPTER 1 21 Fuel Rail 13. Take off the clamps fastening it to the crankcase and remove it completely. 14. Disconnect the fuel pipes (5) from the rail (2) and from the manifolds (6) for the electro--injec- tors. CAUTION When locking the fittings (4) securing the pipes (6) to the rail (2), using an appropriate wrench, you must prevent the flow limiters, if fitted, (3) from turning. 15. Remove the screws (1) and detach the rail (2). 80376 17 Cylinder Head 16. Disconnect the piping from the fuel return pres- sure limiter (1). 17. Undo the nuts (2) and take off the tappet cover (3). 80377 18 18. Remove the nuts (7) and disconnect the electric cables from the electro--injectors (8). 19. Take out the screws (1) and remove the elec- tro--injector wiring mounting (2) together with its seal. 20. Take out the screws (5), remove the air temper- ature/pressure sensor (6). 21. Remove the nuts (3) and extract the fuel man- ifolds (4). CAUTION Once removed, the fuel manifolds (4) must not be re- used; they must be replaced with new ones. 80591 19
  • 18. 22 SECTION 10 - - ENGINE - - CHAPTER 1 22. Loosen the tappet adjuster fixing nuts (1) and unscrew the adjusters. 23. Take out the screws (2), remove the rocker--arm assembly (3) comprising the mounting (6), rocker arms (4) and spindles (5) then remove the bridges (7) from the valves. 24. Remove the rods (8). 80640 20 25. Take out the screws securing the electro--injec- tors and, using tool 380001099 (1), extract the electro--injectors (2) from the cylinder head. 80686 21 26. Working on the tightener (1), extract the belt (12) from the pulleys of the alternator, coolant pump and snub pulleys. 27. Unscrew the bolt (2) and remove the tightener; 28. Remove the snub pulley (6), unscrew the bolts (7) and remove the pulley (8) from the mounting beneath. 29. Unscrew the bolts (10) and remove the tighten- er mounting. 30. Unscrew the bolts (11) and remove the mount- ing (9) from the crankcase. 31. Unscrew the bolts (3) and remove the coolant pump (4). 32. Unscrew the bolt and remove the engine speed sensor (5) 80378 22
  • 19. SECTION 10 - - ENGINE - - CHAPTER 1 23 Proceed to remove the turbocharger: 33. Unscrew the ring nut (1) and remove the lu- brication piping of the turbo--blower. 34. Unscrew the nuts (2) securing the turbo--blower on the exhaust manifold (4). 35. Support the turbo--blower (5) and, lifting it, re- move the seal. 36. Unscrew the retaining nuts (3) and remove the exhaust manifold (4). 80315 23 37. From the opposite side, unscrew the bolts se- curing the intake manifold (1) and remove it to- gether with the air heater (2) for cold starts. 80379 24 38. Hook up the brackets, 380001073 (1) with a suitable sling and, using a hoist, remove the cyl- inder head (2) from the crankcase. 80687 25
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  • 21. 24 SECTION 10 - - ENGINE - - CHAPTER 1 Crankcase - - External Components 39. Remove the oil filter (1). 40. Unscrew the retaining bolts and remove the al- ternator (2). 80380 26 41. Unscrew the retaining bolts (1) and remove the pipe fitting (2). 80326 27 42. Disconnect the connector (1) from the oil pres- sure--temperature sensor. 43. Unscrew the bolts (2) and remove the oil pres- sure--temperature sensor (3). 44. Unscrew the bolts (4) and remove the oil filter mounting (5) from the crankcase together with its seals. 45. Remove the cooler from its seat. 80400 28
  • 22. SECTION 10 - - ENGINE - - CHAPTER 1 25 46. Remove the nuts (1) and detach the high--pres- sure pump (2) together with the feed pump (3). 80381 29 Crank Shaft Seals 47. Install the engine turning / locking tool, 380000988, (1) and 380000732, (2). 48. Loosen the screws fixing the flywheel to the crankshaft. 2 30 49. Unscrew the bolts (1), remove the pulley (2), spacer (3) and pulley (4). 50. The engine flywheel locking tool can help with disassembly of the damper flywheel (2) fitted on the pulley (4). 80382 31
  • 23. 26 SECTION 10 - - ENGINE - - CHAPTER 1 51. Extract the front cover shaft seal. 52. Apply tool 380000665 (4) on the front tang (2) of the crankshaft. 53. Perforate the inner seal (1) with a drill bit (∅ 3.5 mm (0.1378 in.)) through the tool’s guide holes, for a depth of 5 mm (0.1969 in.). 54. Secure the tool to the seal by screwing down the 6 screws supplied. Extract the seal (1) by screwing down the screw (3). 80595 32 55. Use a suitable hooked device (3) with the aid of the lever (4) extract the outer seal (2) from the front cover (1). 80596 33 56. Take out the screws (1) and remove the oil pump (2). CAUTION Note down the assembly position of the screws (1) as they have different lengths. 80330 34
  • 24. SECTION 10 - - ENGINE - - CHAPTER 1 27 57. Remove two opposing screws (1) where the ex- traction pins are to go in (see figure 36). 58. Unscrew the remaining screws securing the fly- wheel (3) from the crankshaft (2). 59. Remove the tool locking the flywheel (4). 35 60. Screw two screws of suitable length into the holes (4) to sling the flywheel with a lift. 61. Using the two guide pins (2) previously screwed into the holes of the crankshaft (3), guide the ex- traction of the engine flywheel (1) with the aid of a lift. 80356 36 62. Extract the seal, applying tool 380000663 (3) onto the rear tang (5) of the crankshaft. 63. Perforate the inner seal with a drill bit (∅ 3.5 mm (0.1378 in.)) through the tool’s guide holes, for a depth of 5 mm (0.1969 in.). 64. Secure the tool 380000663 (3) to the seal (1) by screwing down the 6 screws supplied (4). Extract the seal (1) by screwing down the screw (2). 65. Using an appropriate hooked device and a le- ver, extract the outer seal from the timing box. 80597 37
  • 25. 28 SECTION 10 - - ENGINE - - CHAPTER 1 Sump 66. Turn the engine over. Take out the screws (2) and remove the oil sump (1). 67. Disconnect the high--pressure pump phase sensor. 68. Unscrew the bolts (3) and remove the timing gear box (4) from the crankcase. 80331 38 Rotating Counter Weights 69. Take out the screws (1) and remove the gear (3) from the camshaft (2). 80397 39 70. Using the pin (1), lock the additional counter- weights (2) at the T.D.C. 71. Unscrew the retaining bolts (3) and remove the additional counterweights (2). 80332 40
  • 26. SECTION 10 - - ENGINE - - CHAPTER 1 29 80637 41 ROTATING COUNTERWEIGHT COMPONENTS 1. Retaining bolts -- 2. Mounting -- 3. Retaining bolts -- 4. Gear -- 5. Balancing weight -- 6. O--ring -- 7. Ring -- 8. Gear -- 9. Counter--shaft -- 10. Half bearings Crankshaft 72. Take out the screws (1) securing the connecting rod caps (2) and remove them. 73. Extract the pistons together with the connecting rods from the top of the crankcase. CAUTION Keep the half bearings in their respective housings since, if they are used, they must be mounted in the position found upon disassembly. 80598 42