New Holland TN75FA User manual

TN75FA – TN85FA – TN95FA TRACTORS
SERVICE MANUAL
SECTIONS
GENERAL GUIDELINES 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSIONS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE LINES 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT MECHANICAL TRANSMISSION 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR MECHANICAL TRANSMISSION 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER TAKE–OFF 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKES 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC SYSTEMS 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AXLE AND WHEELS 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAB AIR CONDITIONING SYSTEM 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLATFORM, CAB, BODYWORK 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T E C H N I C A L S U P P O R T

SECTION 10 -- ENGINE -- CHAPTER 1 31
603.54.451.00 -- 01 -- 2004
Op. 10 001 10
ENGINE Removal--Installation
DANGER
Lift and handle all heavy parts using suitable lifting
equipment.
Make sure that assemblies or parts are supported by
means of suitable slings and hooks. Check that no
one is in the vicinity of the load to be lifted.
CAUTION
Always use appropriate tools to align fixing holes.
NEVER USE FINGERS OR HANDS.
1. Remove the cab following the instructions in
Section 90 Chapter 1.
2. Drain the oil from the rear transmission--gearbox
housing.
3. Unscrew the clamps and disconnect the fuel re-
turn hose (1) to the tank (2) and the fuel supply
pump inlet hose.
25659
1
2
7
4. Remove the retaining bolts and detach the rear
guard (1).
25643
1
8
5. Position bracket 380001613 (1) and secure it to
the engine and axle.
25544
1
9

32 SECTION 10 -- ENGINE -- CHAPTER 1
603.54.451.00 -- 01 -- 2004
6. Unscrew the two rear nuts (1) retaining the front
guard. 1
25644
10
7. Position a hydraulic jack under the front guard.
Unscrew the bolts (3) securing the brackets (1
and 2) and the screw retaining the bottom pivot
pin (4). Extract this pin and remove the above--
mentioned bracket (2).
25547
1
234
11
8. Extract the two rear screws and lower the hy-
draulic jack. Retrieve the guard (1) and bracket
(2). 12
25645
12
9. Remove the circlip (2) and move the rear sleeve
forwards (1). 1 2
25646
13

SECTION 10 -- ENGINE -- CHAPTER 1 33
603.54.451.00 -- 01 -- 2004
10. Remove the circlip (2) and move the front sleeve
forwards (1).
25647
1 2
14
11. Unscrew the bolts retaining the bearing support
(1) to the clutch housing and retrieve the drive
shaft together with the support.
25648
1
15
12. Disconnect the service control valve supply pipe
(1) and the front differential locking control pipe
(2).
25660
1
2
16
13. Disconnect the service brake control pipe (1) and
trailer brake valve control pipe (2). 1
2
25661
17

34 SECTION 10 -- ENGINE -- CHAPTER 1
603.54.451.00 -- 01 -- 2004
14. Remove the drain plug (1) and retrieve the diesel
in a suitable container.
25629
1
18
15. Disconnect the trailer brake control pipe (1) and
the pipe (2) connecting the auxiliary control
valves to the lift control valve.
16. Unscrew the clamp and disconnect the hydraulic
pump inlet pipe (1).
25662
1
2
3
19
17. Loosen the clamp and detach the sleeve (1) from
the relevant pipe, which you should then detach
from the front tank and remove.
25630
1
20
18. Unscrew the relevant clamps, detach the ther-
mostarter connections and remove the sleeve
(1) coupling the air filter to the intake manifold. 1
25663
21

SECTION 10 -- ENGINE -- CHAPTER 1 35
603.54.451.00 -- 01 -- 2004
19. Detach the sleeves (1 and 3) from the radiator
and unscrew the bracket (2) securing the radiator
to the engine.
20. Place a fixed stand under the engine, taking care
not to dent the oil sump plating.
25664
1
2
3
22
21. Connect a nylon rope (2) to the axle support and
to the hoist. Tension the rope and detach the
union (1) from the front hydraulic pump.
25665
1
2
23
22. Remove the retaining bolts (1) from both of them
and detach the axle support.
25666
1
24
23. Remove the bolts, retaining clamps and exhaust
silencer assembly (1). 1
25667
25

36 SECTION 10 -- ENGINE -- CHAPTER 1
603.54.451.00 -- 01 -- 2004
24. Loosen the clamp (3), unscrew the retaining
bolts (1) and remove the vapour recirculation de-
vice (2).
25668
1 2 3
26
25. Place a fixed stand under the clutch housing.
Connect a chain to the engine and hoist. Tension
the chain. Unscrew the bolts (1) securing the en-
gine to the clutch housing and remove the en-
gine.
26. Refit the engine taking the following into con-
sideration
CAUTION
Always use appropriate tools to align fixing holes.
NEVER USE FINGERS OR HANDS.
25669
1
27
-- Apply the torque settings listed on page 20.
-- Before refitting the engine to the clutch box care-
fully clean the mating surfaces and apply sealing
compound (0.0787 in. (2 mm) diameter), accord-
ing to the diagram shown Section 21, Chapter 1,
page 34.
-- Fit the engine on the clutch casing.
-- Fit the vapour recirculation device.
-- Fit the exhaust silencer assembly.
-- Refit the axle support to the engine and fit the
union on the front hydraulic pump.
-- Connect and secure the sleeves to the radiator.
Lock the bracket securing the radiator to the en-
gine.
-- Fit the sleeve connecting the air filter to the intake
manifold.
-- Fit the fuel tank connection piping.
-- Connect the hydraulic pump inlet piping and the
pipes governing the trailer brake and connecting
the auxiliary control valves to the lift.
-- Fit the fuel tank plug.
-- Connect the service brake and trailer brake valve
control pipes.
-- Connect the differential lock and service control
valve supply pipes.
-- Refit the drive shaft and relevant guards.
-- Remove bracket 380001613 securing the engine
and front axle.
-- Refit the fuel inlet and return pipes.
-- Screw the drain plugs onto the transmission
housing and onto the diesel tank and replenish
them (for the prescribed product and quantity,
see page 6 sect. 00).
-- Refit the cab following the instructions in Sec-
tion 90, Chapter 1.

SECTION 10 -- ENGINE -- CHAPTER 1 37
603.54.451.00 -- 01 -- 2004
Op. 10 001 54
ENGINE Disassembly -- Assembly
CAUTION
Handle all parts carefully.
Do not put your hands or fingers between parts.
Wear the prescribed safety clothing, including
goggles, gloves and safety footwear.
Proceed as follows.
1. Disconnect the pipe (1) from the seat of the ther-
mostatic valve, loosen the bolts securing the al-
ternator and remove the fan drive belt (2). 25670
1
2
28
2. Remove the retaining bolts and retrieve the fan
(1), spacer and driving pulley (2). Detach the re-
turn pipe (3) from the coolant pump.
25671
12
3
29
3. Take out the retaining bolts and remove the cool-
ant pump (1).
25672
1
30
4. Take out the retaining bolts and detach the cool-
ant pump support (1).
25673
1
31

38 SECTION 10 -- ENGINE -- CHAPTER 1
603.54.451.00 -- 01 -- 2004
5. Secure the bracket (1), series 380000313,tothe
engine and lock this on the rotary stand
380000301.
25674
1
32
6. Disconnect the pipes (1 and 2) from the crank-
case and from the hydraulic pump governing the
services.
25675
1
2
33
7. Disconnect the thermostarter supply pipe (1) and
the return pipe (2) from the thermostarter and
from the injectors.
25676
1 2
34
8. Unscrew the unions (2 and 3) from the injection
pump and from the fuel pump. Take out the re-
taining bolts and remove the fuel filter (1) to-
gether with the support and pipes.
25677
1 2
3
35

SECTION 10 -- ENGINE -- CHAPTER 1 39
603.54.451.00 -- 01 -- 2004
9. Unscrew the retaining bolts and remove the ther-
mostatic valve assembly (1). 1
25678
36
10. Unscrew the retaining bolts and remove the al-
ternator (1) together with the support (2).
25679
1
2
37
11. Unscrew the retaining bolts and remove the ex-
haust manifold (1).
12. Unscrew the engine oil filter (2).
25680
12
38
13. Disconnect the pipes (2) from the injection pump
and from the injectors.
14. Unscrew the retaining bolts and remove the inlet
manifold (1).
25681
1
2
39

40 SECTION 10 -- ENGINE -- CHAPTER 1
603.54.451.00 -- 01 -- 2004
15. Unscrew the pump retaining bolts (1).
25682
1
40
16. Remove the cover (1) to access the injection
pump gear compartment.
25683
1
41
17. Unscrew the nut securing the injection pump to
the gear (1).
18. Extract the injection pump driving gear using the
tool 380000322 (2) and retrieve the injection
pump with the Woodruff key.
12
25684
42
19. Unscrew the retaining nuts (1) and retrieve the
fuel pump (2) together with the support.
25685
12
43

SECTION 10 -- ENGINE -- CHAPTER 1 41
603.54.451.00 -- 01 -- 2004
20. Disconnect the piping (1) from the filter, unscrew
the bolts securing the pressure relief valve as-
sembly (2) and remove it.
25686
1 2
44
21. Take out the retaining bolts and detach the hy-
draulic pump (1) along with the oil filter (2).
2
25687
1
45
22. Take out the retaining bolts and remove the lift
hydraulic pump (1).
25688
1
46
23. Take out the retaining bolts and remove the
starter motor (1).
25689
1
47

42 SECTION 10 -- ENGINE -- CHAPTER 1
603.54.451.00 -- 01 -- 2004
24. Remove the injector mounting nuts, the under-
lying spherical washers, then the supports and
the injectors themselves.
25. Remove the retaining bolts (1), washers and
seal, then remove the rocker housing cover (2)
and seal.
25098
2
1
48
26. Remove the rocker shaft retaining bolts (2), then
remove the entire rocker shaft assembly (1).
25099
1 2
49
27. Remove the valve collets (1) and extract the pu-
shrods (2).
25100
2
1
50
28. Unscrew the cylinder head bolts (1) and remove
the head using a hoist and lifting hook
380000216.
29. Remove the cylinder head gasket.
25101 1
51

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