New Holland 40 Series Operating instructions

Please cut where indicated and insert the label into the plastic pocket on the spine of
the binder.
,---------7
40 SERIES
TRACTOR
SERVICE
5640,6640, 7740, 7840,
8240,8340
Vol.1
40564061
L _________ _J
,---------7
40 SERIES
TRACTOR
SERVICE
5640,6640, 7740, 7840,
8240,8340
Vol.2
40564061
L _________ _J
069008()0

POWERSTAR REPAIR MANUAL
CONTENTS
PART 1 - ENGINE SYSTEM
PART 2 - FUEL SYSTEM
PART 3 - ELECTRICAL SYSTEMS
PART 4 - CLUTCHES
PART 5 - TRANSMISSION SYSTEMS
PART 6 - POWER TAKE-OFF
PART 7 - REAR AXLE AND BRAKES
PART 8 - HYDRAULIC SYSTEMS
PART 9 - STEERING SYSTEMS
PART 10 - FRONT AXLE
PART 11 - CAB
PART 12 - SEPARATING THE TRACTOR
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FOREWORD
Appropriate service methods and correct repair procedures are essential for the safe, reliable
operation ofall equipmentas well as the personal safetyofthe individual performing the repair.
This Repair Manual provides fault finding, overhaul and pressure testing instructions using
recommended procedures and equipment. Following these instructions will ensure the safe,
efficient and timely completion of the service or repair. Anyone who departs from these
instructions should be aware that they do so at the risk of compromising their own personal
safety and the safety of others.
Throughoutthis Manual you will seetext
in italics, preceded by the words NOTE, IMPORTANT
or WARNING. Such text has the following significance.
NOTE: This text stresses a correct operating procedure or technique.
IMPORTANT: This text stresses a correct operating technique
or procedure that, if ignored,
couldresultin damage to the tractor
or equipment.
A WARNING: This text stresses a correct operating technique or procedure that, if
.a ignored, could result in personal injury or death to the Operator or bystanders.
The Manual is divided into Parts, each sub-divided in turn into Chapters. Each Chapter
contains.information on general operating principles, detailed inspection, overhaul and where
applicable, specific trouble shooting, special tools and specifications. Any reference
in this
Manual to right, left, rear, front, top or bottom, is as viewed from the Operator's seat, looking
forward.
All data and illustrations
in this Manual are subject to variations in build specification. This
information was correct at the time of issue, but Ford New Holland policy is one of continuous
improvement and the right to change specifications, equipment
or design at any time, without
notice, is reserved.
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PRODUCTION DATE CODES
AND SERIAL NUMBERS
Series 40 Tractors have an identification plate located under the right-hand hood panel.
Whenever effecting a repair
or overhaul, the relevant information should be noted and used
when referring to Service Bulletins and/or the Parts Catalogue.
TRACTOR IDENTIFICATION PLATE
\8-1
11¥1-rl
Ford New Holland
Limited
358-176
TRACTOR NUMBER
MODEL UNII
TRANSMISSION REAR AXLE
HYDRAULIC PUMP
HYDRAULIC LIFT
FWU·FACTOH
This plate is stamped with the following information:
• TRACTOR NUMBER - • REAR AXLE -
Serial number prefixed by the letters Rear axle production date code.
'BD'.
• MODEL-
Production model code.
• UNIT-
Production unit date code.
• ENGINE-
Serial number and engine production
date code.
• TRANSMISSION -
Transmission production date code.
• HYDRAULIC PUMP -
Hydraulic pump production date code.
• HYDRAULIC LIFT -
Hydraulic power lift production date
code.
• FWD FACTOR -
Four wheel drive factor.
KEY
TO PRODUCTION DATE CODES:-
First Number First Letter Second Number Second Letter
YEAR MONTH DAY
OF MONTH PRODUCTION SHIFT
1-1991
A-Jan. G-July
01 /28/29/30/31
A-Midnight
2-1992
8-Feb. H-Aug. 8-Day
3-1993
C-Mar. J-Sept. C-Afternoon
4-1994
D-Apr. K-Oct.
5-1995 E-May
L-Nov.
F-June
M-Dec.
Example of Production Unit Date Code 2 A O3 B
---
Year of
Production (1992) / ~------
Month of Year ~f Month ShifrPeriod
(January) (Third) (Day)
ii
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CAB, ROPS POST AND FOUR WHEEL DRIVE AXLE IDENTIFICATION PLATES
FORD NEW HOLLAND LTD ENGLAND
OECD APPROVED SAFETY CAB
ODEL NQ _I_·-------' SERIAL NQ ... I ________ _.
TEST STATION I OEC D NQ
T GOOK/NATIONAL APPROVAL
GODKENDT AF DIREKT0REN FOR ARBEJDSTILSYNET
Figure 1
Ford New Holland Inc.
New Holland PA
-
A
~UH l HACTURS ([,Lix Wt lbc,J
5640 (9750) 6640 (11250)
7740 (12750)
COMPLIES OSHA 1928, 53 ASAE S 336 SAE J168
Always Wear Seat Belt with ROPS
FONN-94518N23-EB
Figure 2
The cab/ROPS identification plate, Figure 1 and Figure 2, are located on the left-hand side of
the "Cab" below the windscreen, or the right-hand side "ROPS" post (where fitted).
0
AXLE TYPE SERIAL NUMBER 0
I IL-I---=.,,.,.....,,.--=--"'
REF. NUMBER TOTAL RATIO
...__=---~~__.1 .... 1 -------
INPUT ROT. DIFF. TYPE
..._----------11 ... _________ ,,,_.....
OIL SPECIRC LIT. LOCATION
~====~'CJ l:::::;D;::::IF::;:F.==
lr=J !EPIC.
O...__ ___ ___. O
Figure 3
iii
e
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FUEL INJECTION PUMP
DATE CODES
The fuel injection pumps carry an identification plate with the pumptype number, serial number
and manufacturer's production date code. The date code can be identified
by reference to the
following chart:
MONTH
1991 -1994
CODE
January A
February 8
March C
April D
May E
June F
July G
August H
September J
October K
November L
December M
Example of Fuel Injection Pump Identification Plate:-
Pump Type
Number
3 3 4 2 F 7 7 0
R22564CK
Manufacturer's
Serial Number
iv
YEAR CODE
1991
J
1992 K
1993 L
1994 M
1995 N
1996 0
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FORD
Repair Manual -Series 40 Tractors
HEAL TH AND SAFETY
FOA □
r\EW HOLLAr\D
English
SE4853
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HEALTH AND SAFETY
Contents Page
HEALTH AND SAFETY 1
HEALTH AND SAFETY PRECAUTIONS 1
ADHESIVES AND SEALERS -see Fire 2
ANTIFREEZE -see Fire, Solvents e.g. lsopropanol, Ethylene Glycol, Methanol. 2
ARC WELDING -see Welding. 2
ASBESTOS -see Brake and Clutch Linings and Pads. 2
BATTERY ACIDS -see Acids and Alkalis. 2
BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) -see Fire. 2
BRAKE AND CLUTCH LININGS AND PADS -see Legal Aspects. 2
BRAZING -
see Welding. 3
CHEMICAL MATERIALS -
GENERAL- see Legal Aspects. 3
DO'S 3
DO NOTS 3
CORROSION PROTECTION MATERIALS -see Solvents, Fire. 3
DUSTS 4
ELECTRIC SHOCK 4
EXHAUST FUMES 4
FIBRE INSULATION -see Dusts. 4
FIRE -see Welding, Foams, Legal Aspects. 4
FIRST AID 4
FOAMS -Polyurethane -see Fire. 5
FUELS -see Fire, Legal Aspects, Chemicals -General, Solvents. 5
GAS CYLINDERS -see Fire. 5
GENERALWORKSHOP TOOLS AND EQUIPMENT 6
LEGAL ASPECTS 6
LUBRICANTS AND GREASES 6
PAINTS- see Solvents and Chemical Materials -General. 7
SOLDER -see Welding. 7
SOLVENTS -see Chemical Materials -General Fuels (Kerosene), Fire. 7
SUSPENDED LOADS 8
WELDING -see Fire, Electric Shock, Gas Cylinders. 8
HEAL TH AND SAFETY PRECAUTIONS
Manyofthe procedures associated with vehi-
cle maintenance and repair involve physical
hazards or other risks to health. This section
lists, alphabetically, some of these hazard-
ous operations and the materials and equip-
1
ment associated with them. The precautions
necessary to avoid these hazards are identi-
fied.
The list is not exhaustive and all operations
and procedures and the handling of materi-
als, should be carried out with health and
safety
in mind.
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ACIDS AND ALKALIS -see Battery acids,
e.g. caustic soda, sulphuric acid.
Used
in batteries and cleaning materials.
Irritant and corrosive to the skin, eyes, nose
and throat. Causes burns.
Avoid splashesto the skin, eyes andclothing.
Wearsuitable protective gloves and goggles.
Can destroy oridnary protective clothing. Do
not breathe mists.
Ensure access to water and soap is readily
available for splashing accidents.
ADHESIVES AND SEALERS -see Fire
Highly Flammable, Flammable, combustible.
Generally should be stored in "No Smoking"
areas; cleanliness and tidiness
in use should
be observed, e.g. disposable paper covering
benches; should be dispensed from applica-
tors where possible; containers, including
secondary containers, should be labelled.
Solvent based Adhesives/sealers -See
Solvents.
Follow manufacturers instructions.
Water based Adhesives/Sealers
Those based on polymer emulsions and rub-
ber lattices may contain small amounts of
volatile toxic and harmful chemicals. Skin
and eye contact should be avoided and ade-
quate ventilation provided during use.
Follow manufacturers instructions.
Resin based Adhesives/Sealers -e.g.
epoxide and formaldehyde resin based.
Mixingshouldonlybe carried out
in wellventi-
lated areas as harmful ortoxicvolatile chemi-
cals may be released.
Skin contact with uncured resins and har-
deners can result
in irritation; dermatitis and
absorption of toxic or harmful chemicals
through the skin. Splashes can damage the
eyes.
Provide adequate ventilation and avoid skin
and eye contact. Follow manufacturers in-
structions.
Anaerobic, Cyanoacrylate and other
Acrylic Adhesives
Manyare irritant, sensitizing orharmful to the
skin. Some are eye irritants.
2
Skin and eye contact should be avoided and
the manufacturers instructions followed.
Cyanoacrylate adhesives (super-glues)
must not contact the skin
or eyes. If skin or
eye tissue is bonded coverwith a clean moist
padandgetmedical attention.
do notattempt
to pull tissue apart. Use in well ventilated ar-
eas as vapours can cause irritation of the
nose and eyes.
For
two-pack systems see Resin based ad-
hesives/sealers.
Isocyanate (Polyurethane) Adhesives/
sealers -see Resin based Adhesives.
Individuals suffering from asthma
or respira-
tory allergies should not work with or near
these materials as sensithdty reactions can
occur.
Anyspraying shouldpreferablybecarried out
in exhaust ventilated booths removing
vapours and spray droplets from the breath-
ing zone. Individuals working with spray ap-
plications should wear supplied air respira-
tors.
ANTIFREEZE -see Fire, Solvents e.g.
lsopropanol, Ethylene Glycol, Methanol.
Highly Flammable, Flammable, Combustible.
Used
in vehicle coolant systems, brake air
pressure systems, screenwash solutions.
Vapours given off from coolant antifreeze
(glycol) arise only when heated.
Antifreeze may be absorbed through the skin
in toxic or harmful quantities. Antifreeze if
swallowed is fatal and medical attention must
be found immediately.
ARC WELDING -see Welding.
ASBESTOS -see Brake and Clutch
Linings and Pads.
BATTERY ACIDS -see Acids and Alkalis.
Gases released during charging are explo-
sive. Neveruse nakedflames orallowsparks
near charging or recently charged batteries.
BRAKE AND CLUTCH FLUIDS
(Polyalkylene Glycols) -see Fire.
Combustible.
Splashes to the skin and eyes are slightly irri-
tating. Avoid skin and eye contact as far as
possible. Inhalation ofvapourhazards
do not
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arise at ambient temperaturesbecause of the
very low vapour pressure.
BRAKE AND CLUTCH LININGS AND
PADS- see Legal Aspects.
These items contain asbestos, which if in-
haled
may cause lung damage and in sc,me
cases, cancer.
The normal handling and fitting ofthese items
should not cause any hazard, but any drilling,
grinding
or filling offriction materials may pro-
duce asbestos dust, and should only be car-
ried
out under strictly controlled conditions.
The dust in brake drums etc., contains very
little asbestos
but care should be taken to
avoid inhalation
of this dust during servicing
of brakes and clutches. The use of drum
cleaning units,
vacuum cleaning or damp
wiping is preferred to the use of air jets for
"blowing-out".
The dust should becollected in a sealed plas-
tic
bag and disposed with, according to local
laws
and regulations.
BRAZING - see Welding.
CHEMICAL MATERIALS - GENERAL -
see Legal Aspects.
Chemical materials such as solvents, seal-
ers, adhesives, paints, resin foams, battery
acids, antifreeze, brake fluids, oils and
grease should always be used with caution
and stored
and handled with care. They may
be toxic, harmful, corrosive, irritant or highly
inflammable and give rise to hazardous
fumes and dusts.
The effects of excessive exposure to chemi-
cals
may be immediate or delayed; briefly ex-
perienced orpermanent; cumulative; superfi-
cial; life threatening;
or may reduce life-ex-
pectancy.
DO'S
Do remove chemical materials from the skin
and clothing as soon as practicable aftersoil-
ing.
Change heavilysoiled clothing and have
it cleaned.
Do carefully read and observe hazard and
precaution warnings given on material con-
tainers (labels) and in
any accompanying
leaflets, poster
or otherinstructions. Material
health and safety
data sheets can be ob-
tained from Manufacturers.
3
Do organise
work practices and protective
clothing to avoid soiling
of the skin and eyes;
breathing vapours/aerosols/dusts/fumes; in-
adequate container labelling; fire
and explo-
sion hazards.
Do wash before
job breaks; before eating,
smoking, drinking
or using toilet facilities
when handling chemical materials.
Do keep
work areas clean, uncluttered and
free
of spills.
Dostore according to national andlocal regu-
lations.
Do
keep chemical materials out of reach of
children.
DO NOTS
Do Not mix chemical materials except under
the manufacturers instructions; some chemi-
cals can form
other toxic or harmful chemi-
cals; giveofftoxic
or harmfulfumes; be explo-
sive
when mixed together.
Do
Not spraychemical materials, particularly
those
based on solvents, in confined spaces
e.g. when people are inside a vehicle.
Do
Not apply heat or flame to chemical mate-
rials except
under the manufacturers' instruc-
tions.
Some are highly inflammable and
some
may release toxic or harmful fumes.
Do
Not leave containers open. Fumes given
off can build up to toxic, harmful
or explosive
concentrations.
Some fumes are heavier
than
air and will accumulate in confined ar-
eas, pits etc.
Do
Not transfer chemical materials to un-
labelled containers.
Do
Not clean hands or clothing with chemical
materials. Chemicals, particularly solvents
and fuels will
dry the skin and may cause irri-
tationwithdermatitis.
Some can be absorbed
through the skin in toxic
or harmful quantities.
Do
Not use emptied containers for other ma-
terials, except
when they have been cleaned
under supervised conditions.
Do Not sniff or smell chemical materials.
Brief exposure to high concentrations
of
fumes can be toxic or harmful.
Clutch Flulds- see Brake andClutch Fluids.
Clutch Linings and Pads - see Brake and
Clutch Linings and Pads.

CORROSION PROTECTION MATERIALS
-
see Solvents, Fire ..
Highly flammable, flammable.
These materials are varied and the manufac-
turers instructions should
be followed. They
may contain · solvents, resins, petroleum
products etc. Skin and eyecontactshould
be
avoided. They shouldonlybesprayedin con-
ditions of adequateventilation and not in con-
fined spaces.
Cutting - see Welding.
De-Waxing - see Solvents and Fuels (Kero-
sene).
DUSTS
Powder, dusts or clouds may be irritant,
harmful
or toxic. Avoid breathing dusts from
powdery chemical materials
or those arising
from dry abrasion operations.
Wear respira-
tory protection if ventilation is inadequate.
ELECTRIC
SHOCK
Electric shocks can result from the use of
faultyelectrical equipment or from the misuse
of equipment even in good condition.
Ensure that electrical equipment is main-
tained in
good condition and frequently
tested.
Ensure thatflexes, cables, plugs and sockets
are not frayed, kinked, cut, cracked
or other-
wise damaged.
Ensure that electric equipment is protected
QY the correct rated fuse.
Nevermisuse electrical equipmentand never
use equipment which is in any
way faulty.
The results could be fatal.
Use reduced voltage equipment (11 Ovolt) for
inspection andworking lightswhere possible.
Ensure that the cables of mobile electrical
equipmentcannot
get trapped and damaged,
such as in a vehicle hoist.
Use air operated mobile equipment where
possible in preference to electrical equip-
ment.
In cases of electrocution:-
-switch offelectricitybeforeapproaching vic-
tim
4
- if this is not possible, push or drag victim
from source
of electricity using dry non-con-
ductive material
-commence resuscitation if trained to do so
-SUMMON MEDICAL ASSISTANCE
EXHAUST FUMES
These contain asphyxiating, harmful and
toxic chemicals and particlessuch as carbon
oxides, nitrogen oxides, aldehydes, lead and
aromatichydrocarbons. Engines should only
be run under conditions of adequate extrac-
tion or general ventilation and not in confined
spaces.
Gasolene (Petrol) Engine
There
may not be adequate warning proper-
ties
of odour or irritation before immediate
and delayed toxic
or harmful effects arise.
Diesel Engine
Soot,discomfortand irritation usuallygivead-
quate warning
of hazardous fume concentra-
tions.
FIBRE INSULATION -see Dusts.
Used in noise and sound insulation.
The fibrous nature of surfaces and
cut edges
can cause skin irritation. This is usually a
physical and
not a chemical effect.
Precautions should
be taken to avoid exces-
siveskin contactthrough careful organisation
of work practices and the use of gloves.
FIRE -see Welding, Foams, Legal
Aspects.
Many
of the materials found on or associated
with the repair of vehicles are highly flamma-
ble. Some give off toxic
or harmful fumes if
burnt.
Observe strict fire safety when storing and
handling flammable materials
or solvents,
particularly
near• electrical equipment or
welding processes.
Ensure before using electrical or welding
equipmentbutthatthere is no fire hazardpre-
sent.
Have a suitable fire extinguisher available
when using welding or heating equipment.
FIRST AID
Apart form meeting any legal requirements it
is desirable for someone in the workshop to
be trained in first aid procedures.

Splashes in the eye should be flushed with
clean water for
at least ten minutes.
Soiled skin should be washed with soap and
water.
Inhalation affected individuals should be re-
moved to fresh air immediately.
Ifswallowed
or ifeffects persistconsultadoc-
tor with information (label) on material used.
Do not induce vomiting (unless indicated by
manufacturer).
FOAMS -Polyurethane -see Fire.
Used in sound and noise insulation. Cured
foams used in seat and trim cushioning.
Follow manufacturers instructions.
Unreacted components are irritating and may
be harmful to the skin and eyes. Weargloves
and goggles.
Individuals with chronic respiratory diseases,
asthma, bronchial medical problems
or histo-
ries
of allergic diseases should not work with
or near uncured materials.
The components, vapours, spray mists can
cause direct irritation, sensitivity reactions
and may be toxic or harmful.
Vapours and spray mists must not be
breathed. These materials must be applied
with adequate ventilation and respiratory pro-
tection. Do not remove respirator immedi-
ately after spraying, wait until vapour/ mists
have cleared.
Burning
of the uncured components and the
cured foams can generate toxic and harmful
fumes. ·
Smoking, open flames orthe use of electrical
equipment during foaming operations and
until vapours/mists have cleared should not
be allowed. Any heat cutting of cured foams
orpartially cured foams should be conducted
with extraction ventilation (see Body Section
44 Legal and Safety Aspects).
FUELS-see Fire, Legal Aspects,
Chemicals -General, Solvents.
Used as fuels and cleaning agents.
Gasolene (Petrol).
Highly flammable.
Swallowing can resultin mouth andthroatirri-
tation and absorption from the stomach can
5
result in drowsiness and unconsciousness.
Small amounts can be fatal to children. Aspi-
ration of liquid into the lungs, e.g. through
vomiting, is a very serious hazard.
Gasolene dries the skin and can cause irrita-
tion and dermatitis on prolonged
or repeated
contact. Liquid
in the eye causes severe
smarting.
Motor gasolene may contain appreciable
quantities of benzene, which is toxic upon in-
halation and the concentrations
of gasolene
vapours mustbe keptvery low. High concen-
trations will cause eye, nose and throat irrita-
tion, nausea, headache, depression and
symptoms
of drunkeness. Very high concen-
trations will result in rapid loss of conscious-
ness.
Ensure there is adequate ventilation when
handling and using gasolene. Great care
must be taken to avoid the serious conse-
quences of inhalation in the event
of vapour
build up arising from spillages in confined
spaces.
Special precautions apply to cleaning and
maintenance operations on gasolene stor-
age tanks.
Gasolene should not be used as a cleaning
agent. It must not be siphoned
by mouth.
Kerosene (Paraffin)
Used also as heating fuel, solvent and clean-
ing agent.
Flammable.
Irritation
of the mouth and throat may result
from swallowing. The main hazardfrom swal-
lowing arises if liquid aspiration into
the lungs
occurs. Liquid contactdries the skin and can
cause irritation
or dermatitis. Splashes in the
eye may be slightly irritating.
In normal circumstances the low volatility
does notgive rise to harmful vapours. Expo-
sure to mists and vapours from kerosene at
elevated temperatures should be avoided
(mists may arise in de-waxing). Avoid skin
and eye contact and ensure there is ade-
quate ventilation.
Gas-011 (Diesel Fuel) -see Fuels (Kero-
sene).
Combustible.
Gross or prolonged skin contact with high
boiling gas oils may also cause serious skin
disorders including skin cancer.
GAS CYLINDERS -see Fire.
Gases such as oxygen, acetylene, carbon di-
oxide, argon and propane are normally

stored in cylinders at press.ures of up to 2000
lb/sq. in. (13,790 kn/m2) and great care
should be taken in handling these cylindersto
avoid mechanical damage to them or to the
valve gear attached. The contents of each
cylinder should be clearly identified by appro-
priate markings.
Cylinders
should be stored in well ventilated
enclosures,
and protectedfrom ice andsnow,
or direct sunlight. Fuel gases (e.g. acetylene
and propane) should not be stored in close
proximity to oxygen cylinders.
Care shou.ld be exercised to prevent leaks
from
gas cylinders and lines,· and to avoid
sources of ignition.
Only trained personnel should undertake
work involving gas cylinders.
Gases - see Gas Cylinders.
Gas Shellded WeJdJng - se.e Welding.
Gas Weldlng - see Welding.
GENERAL WORKSHOP TOOLS AND
EQUIPMENT
Itis essential that all tools and equipment are
maintained in
good condition and the correct
safety
equipment used where required.
Never use tools or equipment for any purpose
other than that forwhich theywere designed.
Never overload equipment such as hoists,
jacks, axleandchassisstandsorlifting slings.
Damage caused by overloading is not always
immediately
apparent and may result in a fa-
tal failure the
next time that the equipment is
used.
Do not use damaged or defective tools or
equipment, particularly high speed equip-
ment such as grinding wheels. A damaged
grinding wheel can disintegratewithoutwarn-
ing
and cause serious injury.
Wear suitable eye protection when using
grinding, chiselling
or sand blasting equip-
ment.
Wear a suitable breathing mask when using
sand blasting equipment, working with as-
bestos based materials or using spraying
equipment.
Glues - see Adhesives and Sealers.
High Pressure Air, Lubrication and OIi
Test Equipment - see Lubricants and
Greases.
6
Always keep
high pressure equipment in
goodcondition
and regularly maintained,par-
ticularly
at joints and unions.
Never direct a high pressure nozzle at the
skin
as the fluid may penetratetothe underly-
ing tissue etc. and cause serious injury.
LEGAL ASPECTS
Many laws and regulations make require-
ments relating to health and safety in the use
of materials and equipment in workshops.
Some
of these laws which apply in the U.K.
are listed. Similar laws exist
fo.r other territo-
ries:-
• The Factories Act (1961 ).
• The Asbestos Regulations (1969).
• Highly Flammable Liquids and Liquified
Petroleum
Gases Regulations (1972).
• Deposit
of Poisonous Waste Act (1972).
• Control
of Pollution Act (1974).
• Health and Safety
at Work Act (1974).
•
The Packaging and
Dangerous Substances
(1978).
Labelling
of
Regulations
• Centro.I
of Lead Regulations (1981 ).
Workshops should be familiar, in detail, with
these and associated laws and regulations.
Consult local factory inspectorate if in
any
doubt.
LUBRICANTS AND GREASES
Avoid all prolonged and repeated contact
with mineral oils, especially
used oils. Used
oils contaminated during service (e.g, routine
service change
sump oils) are more irritating
and more likely to cause serious effects in-
cluding skin cancer in the event
of gross and
prolonged skin contact.
Wash skin thoroughly after
work involving oil.
Proprietary hand cleaners
may be of value
provided they can be removed from
the skin
with water.
Do not use petrol, paraffin or
other solvents to remove oil from the skin.
Lubricants and
greases may be slightly irritat-
ing to the eyes.
Repeated or prolonged skin contact should
be avoided
by wearing protective clothing if
necessary. Particular care should
be taken

with used oils and greases containing lead.
Do not allow
work clothing to be contami-
nated with oil. Dry clean or launder such
clothing at regular intervals. Discard oil
soaked shoes.
Do not employ used engine oils as lubricants
or for any application where appreciable skin
contact is likely to occur. Used oils may only
be disposed of in accordancewith localregu-
lations, e.g. in the U.K., the Control
of Pollu~
tion Act.
There are publications describing the prob-
lems and advising on precautionary meas-
ures. For the U.K. these include:
SHW 295: Effects of mineral oil on the
skin
SHW 295A: Cancer of the skin caused by
oil
SHW 397: Cautionary notice: Effects of
mineral oil on the skin
Noise Insulation Materials -see Foams,
Fibre Insulation.
PAINTS- see Solvents and Chemical
Materials -General.
Highly Flammable, Flammable.
One Pack. Can contain harmful or toxic pig-
ments, driers and other components as well
as solvents. Spraying should only be carried
out with adequate ventilation.
Two Pack. Can also contain harmful and
toxic unreacted resins and resin hardening
agents. The manufacturers instructions
should be followed and the section of page
05-2 on resin based adhesives, isocyanate
containing Adhesives and Foams should be
consulted.
Spraying should preferably be carried out
in
exhausted ventilated booths removing
vapour and spray mists from the breathing
zone. Individuals working
in booths should
wear respiratory protection. Those doing
small scale repair work in the open shop
should wear supplied air respirators.
Paint Thinners -see Solvents.
Petrol -see Fuels (Gasolene).
Pressurised Equipment -see High Pres-
sure
Air, Lubrication and Oil Test Equipment.
Resistance Welding -see Welding.
Sealers -see Adhesives and Sealers.
7
SOLDER -see Welding.
Solders are mixtures of metals such that the
melting point
of the mixture is below that of
the constituentmetals (normallyleadandtin).
Solderapplication does not normallygive rise
to toxic lead fumes, provided a gas/air flame
is used.
Oxy-acetylene flamesshould not be
used, as they are much hotterand will cause
lead fumes to be evolved.
Some fumes
may be produced by the appli-
cation
of any flame to surfaces coated with
grease etc. and inhalation
of these should be
avoided.
Removal of excess solder should be under-
taken with care, to ensure that fine lead
dust
is notproduced, which can give toxic effectsif
inhaled. Respiratory protection may
be nec-
essary.
Solder spillage and filing should be collected
and removed promptly to prevent general air
contamination
by lead.
High standards of personal hygiene are nec-
essary in orderto avoid indigestion of lead
or
inhalation of solder dust from clothing.
SOLVENTS -see Chemical Materials -
General Fuels (Kerosene), Fire.
e.g. Acetone, white spirit, toluene, xylene,
trichlorethane.
Used in cleaning materials,
de-waxing,
paints, plastics, resins, thinners etc.
Highly Inflammable, Flammable.
Skin contact will degrease the skin and
may
result in irritation and dematitis following re-
peated
or prolonged contact. Some can be
absorbed through the skin in toxic
or harmful
quantities.
Splashes in the eye may cause severe irrita-
tion and could lead to loss of vision.
Brief exposure to high concentrations
of
vapours or mistswill cause eye andthroat irri-
tation, drowziness, dizziness, headaches
and in the worst circumstances, uncon-
sciousness.
Repeated or prolonged exposures to exces-
sive but lower concentrations of vapours
or
mists, for which there might not be adequate
warning indications, can cause more serious
toxic
or harmful effects.
Aspiration into the lungs (e.g. through vomit-
ing) is the mostseriousconsequence ofswal-
lowing. ·

Avoid splashesto the skin, eyes and clothing.
Wear protective gloves, goggles and clothing
if necessary.
Ensure
good ventilation when in use, avoid
breathing fumes, vapours and spray mists
and keep containers tightly sealed. Do not
use in confined spaces.
When the spraying material contains sol-
vents, e.g. paints, adhesives, coatings, use
extraction ventilation
or personal respiratory
protection in the absence of adequate gen-
eral ventilation.
Do
not apply heat or flame except underspe-
cific
and detailed manufacturers instructions.
Sound Insulation - see Fibre Insulation,
Foams.
Spot Welding -see Welding.
SUSPENDED LOADS
There is always a danger when loads are
lifted
or suspended. Never work underan un-
supported suspended
or raised load, e.g.
jacked up vehicle, suspended engine, etc.
Always ensure that lifting equipmentsuch as
jacks, hoists, axle stands, slings, etc. are
adequate and suitable for the job,
in good
condition and regularly maintained.
Never improvise lifting tackle.
Undersea! -see Corrosion Protection.
WELDING - see Fire, Electric Shock, Gas
Cylinders.
Welding processes include Resistance
Welding (Spot Welding), Arc Welding and
Gas Welding.
Resistance Welding
This process may cause particles of molten
metal to be emitted
at high velocity and the
eyes
and skin must be protected.
Arc Welding
This process emits a high level of ultraviolet
radiation which
may cause eye and skin
burns to the welder
and to other persons
nearby.
Gas-shielded welding processes
8
are particularly hazardous in this respect.
Personal protection
must be worn, and
screens used to shield other people.
Metal spatter will also occur and appropriate
eye and skin protection is necessary.
The heat
of the welding arc will produce
fumes and gases from the metals being
welded and from anyapplied coatings
or con-
tamination on the surfaces being
worked on.
These
gases and fumes may be toxic and in-
halation should always
be avoided. The use
of extraction ventilation to remove the fumes
from the working
area may be necessary,
particularly
in cases where the general venti-
lation is poor,
or where considerable welding
work is anticipated.
In extreme cases where
adequate ventilation cannot
be provided,
supplied air respirators
may be necessary.
Gas Welding
Oxy-acetylene torches may be used for
welding and cutting and special care must be
taken to preventleakage
of these gases, with
consequent risk
of fire and explosion.
The process will produce metal spatter
and
eye and skin protection is necessary.
The flame is bright and eye protection should
be used,
but the ultra-violet emission is much
less than thatfrom arcwelding, and lighterfil-
ters
may be used.
The process itself produces few toxic fumes,
but such fumes and gases
may be produced
from coatings on the work, particularlyduring
cutting
away of damaged body parts and in-
halation
of the fumes should be avoided.
In brazing, toxic fumes may be evolved from
the metals in the brazing rod, and a severe
hazard
may arise if brazing rods containing
cadmium are used.
In this event particular
care must
be taken to avoid inhalation of
fumes and expert advice may be required.
SPECIALPRECAUTIONS
MUST BE TAKEN
BEFORE ANY WELDING OR CUTTING
TAKES PLACEON VESSELS WHICH HAVE
CONTAINED
COMBUSTIBLE MATERIALS,
E.G. BOILING
OR STEAMING OUT OF
FUEL TANKS.
White Spirit -see Solvents.

FORD
Repair Manual - Series 40 Tractors
ENGINE SYSTEM -
ENGINE & COOLING
Part 1 - Chapters 1 & 2
FDRCJ
• I I
SE 4854
English

PART1
ENGINE SYSTEMS
Chapter 1
DIESEL
ENGINES
Section
A DESCRIPTION AND OPERATION Page
1
B FAULT FINDING 4
C
D
E
DISASSEMBLY AND OVERHAUL
COMPRESSION TEST
SPECIFICATIONS
8
37
38
48 F
SPECIAL TOOLS
A. DIESEL ENGINE - DESCRIPTION AND OPERATION
MODEL
5640 6640
No of Cylinders 4 4
BORE (ins.) 4.4 4.4
(mm) 111.8 111.8
STROKE (ins.) 4.4 5.0
(mm).
111.8 127.0
DISPLACEMENT (cu. in.) 268 304
(cu. cm.) 4393 4983
(T) = Turbocharger
This chapter describes the overhaul and re-
pair
of the new series, direct injection diesel
engines.
These engines are available in 4
or 6 cylinder
naturally aspirated forms, with the 4 cylinder
also being available
in turbocharged form.
As these engines are of similar design and
service procedures are common throughout
the range. The 4 cylinder engines have a de-
sign difference
in thatthey are fitted with a dy-
namic balancer assembly.
All engines feature cross flow cylinder heads,
with the inlet
and exhaust manifolds on oppo-
site sides
of the cylinder head. The fuel and
air combustion process, takes place
in the
specially designed bowl in the crown
of the
pistons.
CYLINDER HEAD ASSEMBLY
The cylinder head incorporates valves and
springs with the valve rocker arm shaft as-
sembly bolted to the cylinder block through
the cylinder head. Cylinder head retaining
bolts are evenly spaced with a six point pat-
tern around each cylinder, this ensures an
even clamping load across the cylinder head
area.
The intake and exhaust manifolds are bolted
to the head.
The intake manifold is mounted
1
7740 (T)
7840 8240 8340
4 6 6 6
4.4 4.4
4.4 4.4
111.8 111.8 111.8
111.8
5.0 4.4 5.0 5.0
127.0 111.8 127.0 127.0
304 401 456 456
4983 6570 7472 7472
on the right hand side of the engine with the
diesel injectors mounted outside the rocker
cover. The exhaust manifold is mounted on
the left hand side
of the engine, water outlet
connections and thermostat being attached
to the front
of the cylinder block directly be-
hind the radiator.
Valve guides are integral in the cylinder head
and valves with oversize stems are available
in service. Special replaceable cast alloy
valve seats are pressed into each valve port
during manufacture, with oversize valve
seats also available
in service.
All valves are fitted with positive valve rota-
tors, with both Intake and exhaust valves us-
ing umbrellatype oil seals. Valve lash is main-
tained
by adjustment of the self locking ad-
justing screw, mounted
in each of the rocker
arms.
CAMSHAFT ASSEMBLY
The camshaft runs in replaceable bearings,
with 3 fitted in the 4 cylinderand 5 fitted in the
6 cylinder. Thecamshaftdrive
gear is in mesh
with, and driven
by the camshaft idler gear
and crankshaft timing gear.
Camshaft end thrust is controlled
by a thrust
plate bolted to the blockand locatedbetween
the camshaft
gear and the front camshaft
journal.
A helical
gear is mounted on the rear of the
camshaftand drivesthe engine oil lubrication
pump mounted forward of the flywheel.

---------- PART 1 - ENGINE SYSTEMS----------
CRANKSHAFT ASSEMBLY
The crankshaft is supported in the cylinder
block
by 5 main bearingson the 4 cylinderen-
gine and 7 main bearings, on the 6 cylinder
engine.
Two types of material are used in the manu-
facture
of the crankshafts:-
Nodular Iron, that has rough cast crank
webbs, forthe 5640 & 6640 models and Steel
Crankshafts,· that have machine finished
crank webbs,0for the larger models. ·
End thrust is controlled
by a thrustbearing in-
corporated in the centre main bearing of the
crankshaft.
A crankshaft driven dynamic balancer is in-
stalled on the 4 cylinder engines to ensure
smooth running performance during their
working life.
The balancer assembly is bolted
to the bottom of the cylinder block and con-
tainstwo meshingweightedgears. These are
driven and timed from a
gear heat shrunk to
the crankshaft.
In addition to the internal balancer, a damper
is also fitted externally to the crankshaft pul-
ley. The six cylinder engine requires onlythis
external
damper to ensure smooth running
operation. Front and rear crankshaft oil se~l-
ing is effected
by one piece seals that are de-
signed for long and durable service life.
CONNECTING RODS
Connecting rods "Teepee" (wedge) shaped
at the small end have been designed to re-
duce the reciprocating weight at the piston
end. The connecting rods are
of a heavy
beam construction and are assembled as a
matched set to each engine, attached to the
crankshaft,
by means of insert-type copper/
lead or aluminium tin alloy bearings.
They are retained in position by the connect-
ing rod big end cap and secured by two bolts
per rod. The small end of the connecting rod
is fitted with a replaceable bronze bushing,
through which the free floating piston pin is fit-
ted.
The steel pin being held in place within
the piston
by two snap rings.
PISTONS
Pistons of increasedweightand strength, are
constructed
of an aluminium silicon alloy with
an iron insertforthe top ring. The combustion
chamber being recessed into the piston
crowns.
Each piston has two compression rings and
one oil control ring, to reduce friction and in-
crease positive sealing. All rings are located
above the·piston pin.
2
MANIFOLDS
The cross flow design aluminium intake, and
cast iron exhaust manifolds, are on opposite
sides ofthe cylinderhead. This is designed to
maintain balanced heatdistribution withinthe
cylinder head. The configuration of the mani-
folds also ensures minimum heat transfer to
the intake manifold.
The intake manifold is connected through
tubing to the aircleanerand in the rear end of
the manifold a tapped hole is provided for in-
stallation of a thermostart
or an ether cold
starting aid.
NOTE: On tractors where
cold start
equipment is not installed ensure the plug in
the intake manifold is kept tight at all times.
Considerable
damage to the cylinder bores,
may be incurred by entry of grit or other
foreign material if the plug is left loose or
missing. Also dirt and grit may be drawn
through the air cleanerconnections if they are
not properly secured.
CYLINDER BLOCK ASSEMBLY
The cylinder block is an alloy cast iron with
deep cylinder skirts, and water jackets for
cooling the cylinders. The cylinder bores are
machined integral with the cylinder block,
during the manufacturing process.
Cylinders are
in line and vertical and num-
bered from 1 to 4
or 6, from the front to the
rear of the engine. They can be bored over-
size for the fitment of sleeves or oversize pis-
tons, which are available in service.
The oil pan which is attached to the bottom of
the cylinder block, is the reservoir for the en-
gine oil lubrication system. An aluminium en-
ginefrontcoverisattachedto the front engine
adapterplateandcovers all ofthe timing gear
assembly.
TIMING GEARS
The crankshaft timing
gear is heated and
pressfitted on to the front ofthe crankshaft, to
a high degreeofaccuracyduring manufactur-
ing. This enables precise timing being main-
tained during the life of the engine.
The crankshaft
gear drives the camshaft idler
gearwhich is attachedto the frontof the cylin-
der block. The idler gear then drives the cam-
shaftand the injection pumpviameshing heli-
cal gears.
The camshaft
gear is bolted to the front of the
camshaft, and is keyed to maintain position of
the
gear on the camshaft. All gears can be
checked for timing by observing the punch
marks on the gears.