New Holland T4040 T4050 Tractor Service Repair Manual-2

T4040 − T4050 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
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
PLATFORM, CAB, BODYWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
T E C H N I C A L S U P P O R T
INTRODUCTION
− This manual is divided into sections identified by two−figure numbers and each section has independent
page numbering.
For easy reference, these sections have the same numbers and names as the Repairs Rate Book sections.
− The different sections can easily be found by consulting the table of contents on the following pages.
− The document number of the manual and the edition/update dates are given at the bottom of each page.
− Pages updated in the future will be identified by the same document number followed by an additional digit:
first edition standard manual 87744428A − 1st update 87744428A1 − 2nd update 87744484A2 − etc.
The update pages can replace or supplement the pages of the standard manual; the information necessary
for the procedure for adding or replacing pages is given on the title page of the update.
The publication will be completed with an appropriate index.
If it is necessary to issue a new updated manual (2nd edition) it will have document number 87744428B, this
indicates that the manual is composed of the standard version 87744484A completed with all the updates:
1st update 87744484A1 − 2nd update 87744428A2 − etc.
− The information contained in this manual was current on the date printed on each section. As
NEW HOLLAND constantly improves its product range, some information may be out of date subsequent
to modifications implemented for technical or commercial reasons, or to meet legal requirements in different
countries.
In the event of conflicting information, consult the NEW HOLLAND Sales and Service Departments.
IMPORTANT WARNINGS
− All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND
service technicians, in strict accordance with the instructions given and using any specific tools necessary.
− Anyone performing the operations described herein without strictly following the instructions is personally
responsible for any eventual injury or damage to property.
− The Manufacturer and all organisations belonging to the Manufacturer’s distribution network, including but
not restricted to national, regional or local distributors, will accept no responsibility for personal injury or dam-
age to property caused by abnormal function of parts and/or components not approved by the Manufacturer,
including those used for maintenance and/or repair of the product manufactured or marketed by the Manu-
facturer.
In any case, the product manufactured or marketed by the Manufacturer is covered by no guarantee of any
kind against personal injury or damage to property caused by abnormal function of parts and/or components
not approved by the Manufacturer.
No part of the text or illustrations

may be reproduced
PRINTED IN FRANCE
CNH GLOBAL N.V.

Print No. 87744428A − 11 − 2007
CONTENTS 3
CONTENTS
Page Date Page Date

Engine disassembly−as-
00 − GENERAL GUIDELINES sembly . . . . . . . . . . . . . . . . . 31−32−33−
General instructions . . . . . 1−2 11−03 34−35−36−
37−38−39−
Safety regulations . . . . . . . 3−4−5 11−03 40−41−42−
Consumables . . . . . . . . . . . 6 11−03 43−44−45−
46−47−48−
10 − ENGINE 49−50−51−
52−53−54−
Summary . . . . . . . . . . . . . . 1 11−07 55−56−57−
58−59−60−
General specifications 2−3−4 11−07 61−62−63−
Fuel system data . . . . . . . . 64 11−07
4 11−07 Checks and measure-
Engine block data . . . . . . . 5 11−07 ments − cylinder block and 65−66−67 11−07
liners . . . . . . . .
Crankshaft data . . . . . . . . .
5 11−07 Checks and measure-
ments − crankshaft, bear-
Connecting rod data . . . . . 6 11−07 ings and flywheel . . . . . . . . 68−69 11−07
Piston data . . 6−7 11−07
Timing gear data . . . . . . . . 7 11−07 Checks and measure-
ments − connecting rods . 70−71 11−07
Cylinder head data . . . . . . 8−9 11−07
Torque Specifications . . . . 10−11 11−07 Checks and measure-
Tools . . . . . . . . . . . . . . . . . . 12 11−07 ments − pistons . . . . . . . . 72−73−74−
75 11−07
Engine diagrams . . . . . . . . 13 11−07
Checks and measure-
ments − camshaft, tappets
Lubrication diagrams . . . . 14 11−07 and valves . . . . . . . . . . . . . 76−77−78−
Engine cooling system dia- 79 11−07
gram . . . . . . . . . . . . . . . . . . 15 11−07 Checks and measure-
Additional counterweight 16 11−07 ments − cylinder head . . . 80 11−07
diagrams . . . . .
Exhaust gas recirculation Checks and measure-
system (EGR) . . . . . . . . . . 17 11−07 ments − lubrication system
81 11−07
Fault diagnosis . . . . . . . . . .
18−19−20− Checks and measure-
21 11−07 ments − cooling system . . 82 11−07
Removal−Installation −
Engine removal−installa- 22−23−24−
crankshaft front seal . . . . .
tion . . . . . . . . . . 25−26−27−
83−84 11−07
28−29−30 11−07
Replacing crankshaft rear
seal 85−86−87 11−07
Valve clearance adjust-
ment . . . . . . . . . . . . . . . . . . . 88−89 11−07
Removal−Installation − in- 90−91−92 11−07
jectors . . . . . . .
Removal − Installation −
Bosch injection pump . . . . 93−94−95 11−07
87744428A − 11 − 2007
4 CONTENTS
Page Date Page Date

Bosch injection pump − tim- Removal−Installation −
ing . . . . . . . . . . 96−97−98 11−07 Rear transmission − gear-
Bosch injection pump − air box casing . . . . . . . . . . . . . 17−18−19−
bleeding . . . . . 98 11−07 20−21−22−
23 11−03
coolant pump . . . . . . . . . . . 99−100 11−07 Disassembly−Assembly −
transmission−gearbox
casing . . . . . . . . . . . . . . . . . 24−25−26−
thermostat valve . . . . . . . . 101−102 11−07
27−28−29−
30−31 11−03
Removal−Installation − 103−104−
radiator . . . . . . 105−106 11−07 Gearbox driving and driven
shafts clearance adjust-
Coolant pump and gener- ment. . . . . . . . . . . . . . . . . . . 32 11−03
ator drive belt . 107−108 11−07
Sealing compound applica-
18 − CLUTCH tion diagram . . . . . . . . . . . . 33 11−03
Data . . . . . . . . . . . . . . . . . . . 1−2 11−03 CHAPTER 2 − Power Shuttle transmission

(16x16)
Tightening torques . . . . . . 2 11−03
Tools . . . . . . . . . . . . . . . . . . 2 11−03 Data . . . . . . . . . . . . . . . . . . . 1−2 11−03
Cross−sectional views . . . 3−4 11−03 Tightening torques . . . . . . 3 11−03
Fault diagnosis . . . . . . . . . . 5 11−03 Tools . . . . . . . . . . . . . . . . . . 4−5−6−7−8 11−03
Removal−Installation − Cross−sectional views . . . 9−10−11−

clutch . . . . . . . . . . . . . . . . . . 6−7−8−9− 12−13 11−03
10 11−03 Clutch control pressure test 12 11−03
Clutch Overhaul . . . . . . . . . 11−12−13− Description and operation 14 11−03
14−15 11−03
Fault diagnosis . . . . . . . . . . 14 11−03
Checks and measure-
ments − clutch . . . . . . . . . . 16−17 11−03 Disassembly−Assembly −
Adjustments − clutch disen- casing . . . . . . . . . . . . . . . . . 15−16 11−03
gagement levers . . . . . . . . 17−18 11−03
Disassembly−Reassembly
Adjustments − clutch pedal 19 11−03 − Power Shuttle control
PTO clutch lever adjust- valve . . . . . . . . . . . . . . . . . . 17−18−19 11−03
ment . . . . . . . . . . . . . . . . . . . 20 11−03 Disassembly−Assembly −
accumulator . . . . . . . . . . . . 20 11−03
21 − TRANSMISSIONS
Gearbox control valve sole-
noid valve. Removal −
CHAPTER 1 − Transmissions and range gear
Installation . . . . . . . . . . . . . 21−22 11−03
(12x12) and (16x16)
Disassembly−Assembly −
Data . . . . . . . . . . . . . . . . . . . 1−2 11−03 clutch casing . . . . . . . . . . . 23−24−25−
Tightening torques . . . . . . 2−3 11−03 26−27 11−03
Tools . . . . . . . . . . . . . . . . . . 4−5−6−7 11−03

Cross−sectional views . . . 8−9−10−11
−12−13−14 11−03
Description and operation 15 11−03
Fault diagnosis . . . . . . . . . . 15−16 11−03
87744428A − 11 − 2007
CONTENTS 5
Page Date Page Date
23 − DRIVE LINES Disassembly−Assembly −

epicyclic final drive . . . . . . 34−35−36 11−03
Data . . . . . . . . . . . . . . . . . . . 1 11−03
Replacement − wheel hub
Tightening torques . . . . . . 2 11−03 seal . . . . . . . . . . . . . . . . . . . 37 11−03
Tools . . . . . . . . . . . . . . . . . . 3−4 11−03 Replacing steering knuckle
pins and bearings . . . . . . . 38 11−03
Cross−sectional views . . . 5−6−7 11−03
LIM−SLIP self−locking dif-
Description and operation 8−9 11−03
ferential . . . . . . . . . . . . . . . . 39−40 11−03
Fault diagnosis . . . . . . . . . . 9 11−03
Checking leading wheels
Removal−Installation − alignment . . . . . . . . . . . . . . 41 11−03
drive gear casing . . . . . . . . 11−12 11−03
27 − REAR AXLE MECHANICAL
drive gear casing . . . . . . . . 13−14−15− TRANSMISSION
16 11−03
Data . . . . . . . . . . . . . . . . . . . 1−2 11−03
25 − FRONT AXLE MECHANICAL Tightening torques . . . . . . 3−4 11−03
TRANSMISSION
Tools . . . . . . . . . . . . . . . . . . 5−6−7−8 11−03
CHAPTER 1 − Front axle mechanical Cross−sectional views . . . 9−10 11−03

transmission Description and operation 11 11−03
Data . . . . . . . . . . . . . . . . . . . 1−2 11−03 Fault diagnosis . . . . . . . . . . 11 11−03
Tightening torques . . . . . . 3−4 11−03 Disassembly−Assembly −
Tools . . . . . . . . . . . . . . . . . . 5−6 11−03
casing . . . . . . . . . . . . . . . . . 12−13−14−
Cross−sectional views . . . 7−8−9 11−03 15−16−17 11−03
Description and operation 9 11−03 Adjustment − differential
lock engagement sleeve
position . . . . . . . . . . . . . . . . 18 11−03
front axle . . . . . . . . . . . . . . . 10−11−12−
13 11−03 Adjustments − bevel drive 19−20−21−
22−23 11−03
Front axle. Disassembly −
Assembly . . . . . . . . . . . . . . 14−15−16− Adjustment − differential
17−18−19− lock control pedal travel . . 24 11−03
20 11−03
Adjustments − steering side gear casing . . . . . . . . 25−26 11−03
knuckle bearings . . . . . . . . 21−22 11−03
Adjustments − bevel drive 23−24−25− drive wheel shaft . . . . . . . . 27−28 11−03
26−27−28−
29 11−03 Disassembly−Assembly −
epicyclic final drive . . . . . . 29 11−03
Sealing compound applica-
tion diagram . . . . . . . . . . . . 29 11−03
Overhaul − front differential 30 11−03
Disassembly − assembly
epicyclic final drive with
brake . . . . . . . . . . . . . . . . . . 31−32 11−03
Replacement − wheel hub
seal . . . . . . . . . . . . . . . . . . . 33 11−03
87744428A − 11 − 2007
6 CONTENTS
Page Date Fault diagnosis . . . . . . . . . . 16−17 11−03
31 − POWER TAKE−OFF Lift internal controls.

Disassembly − Assembly . 18−19−20−
CHAPTER 1 − Mechanical power take−off 21 11−03
Adjusting the lift . . . . . . . . . 22−23−24−
Data . . . . . . . . . . . . . . . . . . . 1−2−3 11−03
25−26−27−
Tools . . . . . . . . . . . . . . . . . . 4 11−03 28−29−30−
31 11−03
Lift cylinder and arms shaft.
Cross−sectional views . . . 6 11−03
Disassembly − Assembly . 32−33−34−
Description and operation 7−8−9 11−03 35 11−03
Fault diagnosis . . . . . . . . . . 9 11−03 Disassembly−Assembly −
lift control valve . . . . . . . . . 36−37−38−
Disassembly − Assembly − 39 11−03
power take−off . . . . . . . . . . 10−11−12−
13 11−03 Lift pressure relief valve . . 40 11−03
33 − BRAKES CHAPTER 2 − Open centre system auxiliary

control valves
Data . . . . . . . . . . . . . . . . . . . 1−2 11−03
Data . . . . . . . . . . . . . . . . . . . 2 11−03
Tools . . . . . . . . . . . . . . . . . . 2 11−03
Cross−sectional views . . . 3−4−5 11−03
Tools . . . . . . . . . . . . . . . . . . 5−6 11−03
Cross−sectional views . . . 3−4 11−03
Description and operation 6 11−03
Description and operation 5−6−7−8 11−03
Fault diagnosis . . . . . . . . . . 7−8 11−03
Auxiliary control valves.
Removal−Installation − ser- Disassembly − Assembly . 9−10−11 11−03
vice brake . . . . . . . . . . . . . . 9−10 11−03
CHAPTER 3 − Trailer brakes auxiliary control
Removal−Installation − ser- valves
vice brake pump . . . . . . . . 11−12−13−
14−15 11−03 Cross−sectional views . . . 1 11−03
Adjustments − service Description and Operation 1−2−3−4−5
brake pedals travel . . . . . . 16 11−03 −6−7 11−03
Service brake circuit air Fault diagnosis . . . . . . . . . . 8−9−10 11−03
bleeding . . . . . . . . . . . . . . . 16−17−18 11−03
Removal−Installation − trailer brake valve . . . . . . . 11 11−03
parking brake . . . . . . . . . . . 19−20 11−03
CHAPTER 4 − Non−stop flow gear pump
Adjustments − parking
handbrake travel . . . . . . . . 20 11−03 Data . . . . . . . . . . . . . . . . . . . 1−2 11−03
Description and Operation 2 11−03
35 − HYDRAULIC SYSTEMS
Diagrams . . . . . . . . . . . . . . 3 11−03
CHAPTER 1 − Rear mechanical hydraulic lift
Data . . . . . . . . . . . . . . . . . . . 1−2−3 11−03 lift oil pump . . . . . . . . . . . . . 4 11−03
Tightening torques . . . . . . 3−4 11−03
Tools . . . . . . . . . . . . . . . . . . 5−6 11−03
Cross−sectional views . . . 7−8−9−10−
11 11−03
Description and operation 12−13−14−
15 11−03
87744428A − 11 − 2007
CONTENTS 7
Page Date Page Date
41 − STEERING Fault diagnosis . . . . . . . . . . 7 11−03

CHAPTER 1 − Steering wheel axle hub . . . . . . . . . . 8−9−10 11−03
Data . . . . . . . . . . . . . . . . . . . 2 11−03 Removal−Installation −
Tightening torques . . . . . . 2 11−03 front axle . . . . . . . . . . . . . . . 11−12−13 11−03
Tools . . . . . . . . . . . . . . . . . . 2 11−03 Stub axle hub overhaul . . . 14−15−16−
17 11−03
Description and Operation 3−4−5 11−03
Checking leading wheels
View of hydrostatic steering alignment . . . . . . . . . . . . . . 18 11−03
control valve components 6 11−03
Fault diagnosis . . . . . . . . . . 7−8 11−03 55 − ELECTRICAL SYSTEM
Replacement − hydrostatic CHAPTER 1 − Instruments
steering wheel . . . . . . . . . . 9 11−03
Analogue instrumentation 2−3−4−5−6 11−03
Removal−Installation − hy-
drostatic steering control Digital Instrument Cluster . 7−8−9−10−
valve . . . . . . . . . . . . . . . . . . 10−11−12− 11−12 11−03
13−14 11−03 Transmitters, sensors and
switches . . . . . . . . . . . . . . . 13−14−15−
16−17 11−03
hydrostatic control valve . . 15−16−17−
18−19−20− Service . . . . . . . . . . . . . . . . 18−19−20 11−03
21−22−23−
24−25−26− CHAPTER 2 − Starting system
27−28−29− Technical data . . . . . . . . . . 1 11−03
30 11−03
Hydrostatic steering control Fault diagnosis . . . . . . . . . . 3 11−03
valve bench testing . . . . . . 31−32 11−03
System testing . . . . . . . . . . 4−5−6 11−03
Pressure relief valve testing 33 11−03
Removal−Installation
Steering control cylinder. starter motor . . . . . . . . . . . . 6 11−03
Removal − Installation . . . 34−35 11−03
Overhaul − starter motor . 7−8 11−03
Steering control cylinder.
Disassembly − Assembly . 36−37 11−03 Starter motor testing . . . . . 9−10 11−03
CHAPTER 2 − Non−stop flow gear pump CHAPTER 3 − Charging system

Technical data . . . . . . . . . . 1 11−03
Data . . . . . . . . . . . . . . . . . . . 1−2 11−03
Diagrams . . . . . . . . . . . . . . 3−4 11−03
Description and Operation 2−3 11−03
System testing . . . . . . . . . . 4−5−6−7−8
−9 11−03
hydrostatic steering oil
pump . . . . . . . . . . . . . . . . . . 5 11−03 Removal−Installation and
Overhaul − alternator . . . . 9−10−11−
44 − AXLES AND WHEELS 12−13−14−
15−16 11−03
Data . . . . . . . . . . . . . . . . . . . 1−2 11−03
Front wheel track diagram 2 11−03
Cross−sectional views . . . 3 11−03
Tightening torque . . . . . . . 4−5−6 11−03
Tools . . . . . . . . . . . . . . . . . . 6−7 11−03
87744428A − 11 − 2007
8 CONTENTS
Page Date Page Date
CHAPTER 4 − Battery 90 − PLATFORM, CAB, BODYWORK

Technical data . . . . . . . . . . 1 11−03 CHAPTER 1 − Bodywork
Description and Operation 1 11−03 Bonnet. Removal − Installa-
tion . . . . . . . . . . . . . . . . . . . . 2 11−03
Removal−Installation − bat-
tery . . . . . . . . . . . . . . . . . . . . 2 11−03 Protective grill. Removal −
Installation . . . . . . . . . . . . . 3 11−03
Battery maintenance . . . . . 3 11−03
Dashboard. Removal −
Battery charging . . . . . . . . 4−5−6 11−03 Installation . . . . . . . . . . . . . 4−5−6−7 11−03
Battery troubleshooting . . 6 11−03 Removal−Installation fixed
roll bar . . . . . . . . . . . . . . . . . 8−9 11−03
CHAPTER 5 − Electrical circuits (w)
Removal−Installation right
Contents . . . . . . . . . . . . . . . 1 11−03 or left−hand mudguard . . . 10−11 11−03
Replacement − rear guard 12−13−14 11−03
CHAPTER 6 − Connectors
Index . . . . . . . . . . . . . . . . . . 1 11−03
87744428A − 11 − 2007
SECTION 00 − GENERAL GUIDELINES − CHAPTER 1 1
GENERAL INSTRUCTIONS
IMPORTANT NOTICE
All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND
service technicians, in strict accordance with the instructions given and using any specific tools necessary.
Anyone performing the operations described herein without strictly following the instructions is personally re-
sponsible for any eventual injury or damage to property.
BATTERY
Before carrying out any kind of service operation disconnect and isolate the battery negative lead, unless other-
wise requested for specific operations (e.g., operations requiring the engine to be running), after which it is
necessary to disconnect the above−mentioned lead to complete the work.
SHIMMING
For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add
up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated
value indicated for each shim.
ROTATING SHAFT SEALS

For correct rotating shaft seal installation, proceed as follows:
− before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes;
− thoroughly clean the shaft and check that the working surface on the shaft is not damaged;
− position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direc-
tion and position the grooves so that they will deviate the fluid towards the inner side of the seal;
− coat the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing
lip and the dust lip on double lip seals with grease;
− insert the seal in its seat and press down using a flat punch; do not tap the seal with a hammer or mallet;
− whilst inserting the seal, check that the it is perpendicular to the seat; once settled, make sure that it makes
contact with the thrust element, if required;
− to prevent damaging the seal lip on the shaft, position a protective guard during installation operations.
“O−RING” SEALS
Lubricate the O−RING seals before inserting them in the seats, this will prevent them from overturning and twist-
ing, which would jeopardise sealing efficiency.
SEALING COMPOUNDS
Apply one of the following sealing compounds on the mating surfaces marked with an X: LOCTITE 518, LOCTI-
TE 5205, SUPERBOND 559 MASCHERPA or BETABLOCK A272M GURIT ESSEX.
Before applying the sealing compound, prepare the surfaces as follows:
− remove any incrustations using a wire brush;
− thoroughly de−grease the surfaces using one of the following cleaning agents: trichlorethylene, petrol or a
water and soda solution.
BEARINGS
When installing bearings it is advised to:
− heat the bearings to 176 to 194 °C (80 to 90 °C) before fitting on the shafts;
− allow the bearings to cool before installing them from the outside.
87744428A − 11 − 2007
2 SECTION 00 − GENERAL GUIDELINES − CHAPTER 1
SPRING PINS
When fitting split socket elastic pins, ensure that the pin notch is positioned in the direction of the force required
to stress the pin.
Spiral spring pins do not require special positioning.
SPARE PARTS
Use genuine parts only.
Only original spare parts guarantee the same quality, duration and safety as they are the same parts that are
assembled during production.
Only genuine parts can offer this guarantee.
When ordering spare parts, always provide the following information:
− tractor model (commercial name) and frame number;
− engine type and number;
− part number of the ordered part, which can be found in the “Microfiches” or the “Spare Parts Catalogue”, used
for order processing.
TOOLS
The tools that NEW HOLLAND propose and illustrate in this manual are:
− specifically researched and designed for use with NEW HOLLAND vehicles;
− essential for reliable repair operations;
− accurately built and rigorously tested so as to offer efficient and long−lasting operation.
By using these tools, repair personnel will benefit from:
− operating in optimal technical conditions;
− obtaining the best results;
− saving time and effort;
− working in safe conditions.
IMPORTANT NOTES
Wear limit values indicated for certain parts are recommended, but not binding. The terms “front”, “rear”, “right−
hand” and “left−hand” (when referred to different parts) are intended as seen from the driving position with the
vehicle in the normal direction of movement.
MOVING THE TRACTOR WITH THE BATTERY REMOVED

External power supply cables should only be connected to the respective positive and negative cable terminals,
using efficient clamps that guarantee adequate and secure contact.
Disconnect all services (lights, windshield wipers, etc.) before starting the vehicle.
If the vehicle electrical system requires checking, carry out operations with the power supply connected; once
checking is completed, disconnect all services and switch off the power supply before disconnecting the cables.
87744428A − 11 − 2007
SAFETY REGULATIONS
PAY ATTENTION TO THIS SYMBOL
This warning symbol points out important messages
concerning your safety.
Carefully read the following safety regulations and
observe advised precautions in order to avoid poten-
tial hazards and safeguard your health and safety.
In this manual the symbol is accompanied by the fol-
lowing key−words:
CAUTION − Warnings concerning unsuitable repair
operations that may jeopardise the safety of Service
personnel.
DANGER − Specific warnings concerning potential
hazards for operator safety or for other persons di-
rectly or indirectly involved. 1
− Do not carry out repair operations with someone
ACCIDENT PREVENTION sitting in the driver’s seat, unless the person is a
Most accidents or injuries that occur in workshops trained technician who is assisting with the oper-
are the result of non−observance of simple and fun- ation in question.
damental safety regulations. For this reason, IN − Do not operate the vehicle or use any of the im-
MOST CASES THESE ACCIDENTS CAN BE plements from different positions, other than the
AVOIDED by foreseeing possible causes and conse- driver’s seat.
quently acting with the necessary caution and care.
− Do not carry out operations on the vehicle with
Accidents may occur with all types of vehicle, regard-
the engine running, unless specifically indicated.
less of how well it was designed and built.
A careful and judicious service technician is the best − Stop the engine and check that the hydraulic cir-
guarantee against accidents. cuits are pressure−free before removing caps,
covers, valves, etc.
Precise observance of the most basic safety rule is
normally sufficient to avoid many serious accidents. − All repair and maintenance operations must be
carried out using extreme care and attention.
DANGER. Never carry out any cleaning, lubrication
or maintenance operations when the engine is run- − Service steps and platforms used in a workshop
ning. or in the field should be built in compliance with
the safety rules in force.
SAFETY REGULATIONS − Disconnect the batteries and label all controls to

indicate that the vehicle is being serviced. Any
parts that are to be raised must be locked in posi-
GENERAL GUIDELINES
tion.
− Carefully follow specified repair and mainten-
− Do not check or fill fuel tanks, accumulator bat-
ance procedures.
teries, nor use starting liquid when smoking or
− Do not wear rings, wristwatches, jewellery, un- near naked flames, as these fluids are inflam-
buttoned or loose articles of clothing such as: mable.
ties, torn clothing, scarves, open jackets or shirts
with open zips that may remain entangled in − Brakes are inoperative when manually released
moving parts. It is advised to wear approved for repair or maintenance purposes. Use blocks
safety clothing, e.g.: non−slip footwear, gloves, or similar devices to control the machine in these
safety goggles, helmets, etc. conditions.
− The fuel nozzle should always be in contact with
the filling aperture. Maintain this position until fill-
ing operations are completed in order to avoid
possible sparks caused by the accumulation of
static electricity.
87744428A − 11 − 2007
− Only use specified towing points for towing the − When carrying out checks with the engine run-
tractor. Connect parts carefully. Make sure that ning, request the assistance of an operator in the
all pins and/or locks are secured in position be- driver’s seat. The operator must maintain visual
fore applying traction. Never remain near the contact with the service technician at all times.
towing bars, cables or chains that are operating
under load. − If operating outside the workshop, position the
vehicle on a flat surface and lock in position. If
− Transport vehicles that cannot be driven using a working on a slope, lock the vehicle in position.
trailer or a low−loading platform trolley, if avail- Move to a flat area as soon as is safely possible.
able.
− Damaged or bent chains or cables are unreliable.
− When loading or unloading the vehicle from the Do not use them for lifting or towing. Always use
trailer (or other means of transport), select a flat suitable protective gloves when handling chains
area capable of sustaining the trailer or truck or cables.
wheels. Firmly secure the tractor to the truck or
trailer and lock the wheels in the position used by − Chains should always be safely secured. Make
the carrier. sure that the hitch−up point is capable of sustain-
ing the load in question. Keep the area near the
− Electric heaters, battery−chargers and similar hitch−up point, chains or cables free of all by-
equipment must only be powered by auxiliary standers.
power supplies with efficient ground insulation to
avoid electrical shock hazards. − Maintenance and repair operations must be car-
ried out in a CLEAN and DRY area. Eliminate any
− Always use suitable hoisting or lifting devices water or oil spillage immediately.
when raising or moving heavy parts.
− Do not create piles of oil or grease−soaked rags
− Take extra care if bystanders are present. as they represent a serious fire hazard. Always
place them into a metal container.
− Never pour gasoline or diesel oil into open, wide Before starting the tractor or its attachments,
or low containers. check, adjust and block the operator’s seat. Also
check that there are no persons within the tractor
or implement range of action.
− Never use gasoline, diesel oil or other inflam-
mable liquids as cleaning agents. Use non−in-
flammable, non−toxic commercially available − Do not keep into your pockets any object which
solvents. might fall unobserved into the tractor’s inner
compartments.
− Wear safety goggles with side guards when
cleaning parts with compressed air. − In the presence of protruding metal parts, use
protective goggles or goggles with side guards,
helmets, special footwear and gloves.
− Limit the air pressure to a maximum of 30.45 psi
(2.1 bar), according to local regulations.
− When welding, use protective safety devices:
tinted safety goggles, helmets, special overalls,
− Do not run the engine in confined spaces without
gloves and footwear. All persons present in the
suitable ventilation.
area where welding is taking place must wear
tinted goggles. NEVER LOOK DIRECTLY AT
− Do not smoke, use naked flames, or cause THE WELDING ARC WITHOUT SUITABLE
sparks in the area when fuel filling or handling EYE PROTECTION.
highly inflammable liquids.
− Metal cables tend to fray with repeated use. Al-
− Never use naked flames for lighting when work-
ways use suitable protective devices (gloves,
ing on the machine or checking for “leaks”.
goggles, etc.) when handling cables.
− All movements must be carried out carefully
when working under, on or near the vehicle. − Handle all parts carefully. Do not put your hands
Wear protective equipment: helmets, goggles or fingers between moving parts. Wear suitable
and special footwear. safety clothing − safety goggles, gloves and
shoes.
87744428A − 11 − 2007
START UP HYDRAULIC SYSTEMS

− Never run the engine in confined spaces that are − A liquid leaking from a tiny hole may be almost
not equipped with adequate ventilation for ex- invisible but, at the same time, be powerful
haust gas extraction. enough to penetrate the skin; therefore, NEVER
− Never bring your head, body, arms, legs, feet, USE HANDS TO CHECK FOR LEAKS. Use a
hands, fingers near fans or rotating belts. piece of cardboard or wood for this purpose. If
any liquid penetrates skin tissue, call for medical
aid immediately. Failure to treat this condition
with correct medical procedure may result in seri-
ous infection or dermatosis.
− In order to check the pressure in the system use
ENGINE
suitable instruments.
− Always loosen the radiator cap slowly before re-
moving it to allow any remaining pressure in the
system to be discharged. Filling up with coolant
should only be carried out with the engine WHEELS AND TYRES
stopped or idling (if hot). − Check that the tyres are correctly inflated at the
− Never fill up with fuel when the engine is running, pressure specified by the manufacturer.
especially if hot, in order to prevent the outbreak Periodically check possible damages to the rims
of fire as a result of fuel spillage. and tyres.
− Never check or adjust fan belt tension when the − Stand away from (at the side of) the tyre when
engine is running. checking inflation pressure.
Never adjust the fuel injection pump when the ve- − Only check pressure when the tractor is un-
hicle is moving. loaded and the tyres are cold, to avoid incorrect
− Never lubricate the vehicle when the engine is readings as a result of over−pressure. Do not
running. reuse parts of recovered wheels as improper
welding, brazing or heating may weaken the
wheel and make it fail.
− Never cut or weld a rim mounted with an inflated
tyre.
ELECTRICAL SYSTEMS − To remove the wheels, lock both the front and
rear vehicle wheels. After having raised the ve-
− If it is necessary to use auxiliary batteries, re-
hicle, position supports underneath, according to
member that both ends of the cables must be
regulations in force.
connected as follows: (+) with (+) and (−) with (−).
Avoid short−circuiting the terminals. GAS RE- − Deflate the tyre before removing any object
LEASED FROM BATTERIES IS HIGHLY IN- caught in the tyre tread.
FLAMMABLE. During charging, leave the bat- − Never inflate tyres using inflammable gases; as
tery compartment uncovered to improve this may result in explosions and injury to by-
ventilation. Never check the battery charge using standers.
“jumpers” (metal objects placed on the ter-
minals). Avoid sparks or flames near the battery
zone. Do no smoke to prevent explosion haz-
REMOVAL AND INSTALLATION
ards.
− Lift and handle all heavy parts using suitable ho-
− Before servicing operations, check for fuel or
isting equipment. Ensure that parts are sup-
current leaks. Eliminate any eventual leaks be-
fore proceeding with work. ported by appropriate slings and hooks. Use lift-
ing eyes provided to this purpose. Extra care
− Never charge batteries in confined spaces. Make should be taken if persons are present near the
sure that there is adequate ventilation in order to load to be lifted.
prevent accidental explosion hazards as a result
− Handle all parts carefully. Do not put your hands
of the accumulation of gases released during
or fingers between parts. Wear suitable safety
charging operations.
clothing − safety goggles, gloves and shoes.
− Always disconnect the batteries before perform-
− Avoid twisting chains or metal cables. Always
ing any kind of servicing on the electrical system.
wear safety gloves when handling cables or
chains.
87744428A − 11 − 2007
CONSUMABLES
NEW
QUANTITY RECOMMENDED
COMPONENT TO BE HOLLAND INTERNATIONAL
US gal. NEW HOLLAND
FILLED OR TOPPED UP SPECIFICATI SPECIFICATIONS
(litres) PRODUCTS
ONS
Water & liquid

Cooling system: AMBRA
NH 900 A −
without cab . . . . . . . . . . . . . . 14,0 AGRIFLU
50% + 50%
Windscreen wash reservoir 2,0 Water & liquid − −
Fuel tank:
Decanted, filtered
− standard model 65 − −
diesel fuel
− with double tank . . . . . . 82
Engine oil sump:

without filter: . . . . . . . . . . . . . 8,9 NH 324H
Oil AMBRA
(SAE 10W−30) API CI−4/CH$
MASTERGOLD
NH 330H ACEA E7/E5
HSP
(SAE 15W−40)
with filter: . . . . . . . . . . . . . . . . 9,5
Brake control circuit . . . . . . 0,7

Oil AMBRA
NH 610 A ISO 7308
BRAKE LHM
With front brakes . . . . . . . . . 1,0
Front axle:
axle casing . . . . . . . . . . . . . . 1.18 (4.5)

final drives without brakes
(each) . . . . . . . . . . . . . . . . . . 0.26 (1.0)
final drives with brakes API GL4
AMBRA MULTI G
(each) . . . . . . . . . . . . . . . . . . 0.39 (1.5) NH 410 B ISO 32/46
oil
SAE 10W−30
Rear transmission (bevel

drive, final drives and bra-
kes), gearbox, hydraulic lift, 11.09
PTO and hydraulic steering: (42)
Grease fittings . . . . . . . . . . . − AMBRA GR9 NH 710 A NLGI 2

grease
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1 1
SECTION 10 − ENGINE
Chapter 1 − Engine
CONTENT
Section Description Page
10 000 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cross−sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Schematic diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
10 001 10 Engine Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
10 001 54 Engine Disassembly − Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10 102 70 Crankshaft front seal − Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10 102 74 Crankshaft rear seal − Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
10 106 12 Valve/rocker arm clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
10 218 30 Engine injectors Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10 246 14 Bosch injection pump Removal−Installation, timing and air bleeding . . . . . . . . . . . . . . . . . 93
10 402 10 Coolant pump Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10 402 30 Thermostatic valve Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10 406 10 Radiator Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10 414 10 Coolant pump and generator drive belts Adjusting tension . . . . . . . . . . . . . . . . . . . . . . . . 107
87744428A − 11 − 2007
2 SECTION 10 − ENGINE − CHAPTER 1
GENERAL SPECIFICATIONS
Engine, technical type:
− Model T4040 type F4CE9484N*J601 (BOSCH pump) . . . .
− Model T4050 − type F4CE9484M*J601 (BOSCH pump) . .
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diesel, 4−stroke
Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct
Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Piston diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 mm
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 mm
Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4485 cm3
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5:1
Maximum Power Output:
− Model T4040 − type F4CE9484N*J601 . . . . . . . . . . . . . . . . . 63 kW (86 Hp)
− Model T4050 − type F4CE0454C*D600/*D603 . . . . . . . . . . 71 kW (97 Hp)
Maximum power speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2300 rpm
− Maximum torque: Model T4040 − type F4CE9484N*J601 . 370 Nm
− Maximum torque: Model T4050 − type F4CE9484M*J601 418 Nm
Maximum torque speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sump pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . structural, cast iron
Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced, with lobe pump
Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . from crankshaft
Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . 1:1
Oil filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mesh screen on oil pick−up and
filter cartridge in delivery line
Normal oil pressure with motor warmed−up
at slow idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 bar
at fast idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 bar

(continued)
87744428A − 11 − 2007
(overleaf)
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . coolant circulation
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 lines of vertical pipes with copper fins
Fan, attached to the pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . intake, in plastic with 11 blades
Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal vane−type
Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . . 1:1.977
Coolant thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . coloured scale divided into three sections
Temperature ranges corresponding to each section:
− Initial blue section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40° ÷ 60 °C
− Middle green section (normal working conditions) . . . . . . . . . 60° ÷ 110 °C
− Final red section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110° ÷ 120 °C
Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . via thermostat valve
− initial opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 ± 2 °C
Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by tappets, rods
and rocker arms via the camshaft located
in the engine block; the camshaft is driven
by the crankshaft using straight−tooth
gears
Intake:
− start: before T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10° ± 30’
− end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10° ± 30’
Exhaust:
− start: before B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64°
− end: after T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26°
Clearance between valves and rocker arms with engine cold:
− intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 ± 0.05 mm
− exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 ± 0.05 mm
Power supply
Air filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter, with clogged
filter indicator with centrifugal pre−filter
and automatic dust ejector
Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with double diaphragm
Fuel filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through wire filter in fuel supply pump, and
replaceable cartridge on delivery line to
injection pump
Minimum fuel flow rate with pump shaft rotating at 1800 rpm . 127.6 l/h
Cam operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . via engine timing
(continued)
87744428A − 11 − 2007
(overleaf)
BOSCH Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rotating distributor type

All−speed governor, incorporated in pump:
BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal counterweights
Automatic advance regulator, incorporated in pump:
BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydraulic
Turbocharger:
− type ........ ..................................... HOLSET HX25
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rotating distributor with speed governor
and advance variator incorporated
BOSCH pump:
− Model T4040 − type F4CE9484N*J601 . . . . . . . . . . . . . . . . . VE 4/12 F1150−2856534
− Model T4050− type F4CE9484M*J601 . . . . . . . . . . . . . . . . . VE 4/12 F1150−2856537
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . anticlockwise
Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−3−4−2 (for all models)
SPECIFICATIONS
BOSCH−type injectors:
F4CE9484N*J601/F4CE9484M*J601 . . . . . . . . . . . . . . . . . 2856255
Number of nozzle holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Nozzle hole diameter mm:
F4CE9484N*J601/F4CE9484M*J601 . . . . . . . . . . . . . . . . . 0.237
Calibration pressure bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 ÷ 274
87744428A − 11 − 2007
ENGINE BLOCK DATA mm
Engine sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cast−iron monobloc with cylinder liners,

crankshaft, camshaft and tappets
Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.000 ÷ 104.024
Oversized cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.400 ÷ 104.424
Main journal half bearing seat diameter external no. 1−5 87.982 ÷ 88.008
internal no. 2−3−4 87.977 ÷ 88.013
Camshaft bushing seat diameter:
− front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.222 ÷ 59.248
− mid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.222 ÷ 59.248
− rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.222 ÷ 59.248
Diameter of standard tappet bores in crankcase . . . . . . . . . . . . . . 16.000 ÷ 16.030
CRANKSHAFT AND BEARINGS DATA mm
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . balanced with integral counterweights

Standard journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.99 ÷ 83.01
Journal undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.250 − 0.500
Main journal half bearing thickness . . . . . . . . . . . . . . . . . . . . . . . . . 2.456 ÷ 2.464
Main bearing shell undersizes on internal diameter . . . . . . . . . . . . 0.250 − 0.500
Clearance between bearings and main journal no. 1−5 0.022 ÷ 0.053
no. 2−3−4 0.019 ÷ 0.055
Standard crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.987 ÷ 69.013
Crankpin undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.250 − 0.500
Standard connecting rod half bearing thickness . . . . . . . . . . . . . . . 1.955 ÷ 1.968
Big−end bearing shell undersizes on internal diameter . . . . . . . . . 0.250 − 0.500
Bearing to crankpin clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.019 ÷ 0.058
Standard crankshaft thrust washer width . . . . . . . . . . . . . . . . . . . . 37.280 ÷ 37.380
Width of main bearing for thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.180 ÷ 32.280
Width of corresponding crankshaft journal . . . . . . . . . . . . . . . . . . . 37.475 ÷ 37.550
Crankshaft assembly endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.095 ÷ 0.270
87744428A − 11 − 2007
CONNECTING ROD DATA mm

Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . printed in steel, oblique−cut type
Diameter of small end bushing seat . . . . . . . . . . . . . . . . . . . . . . . . . 40.987 ÷ 41.013
Outside diameter of small end bushing . . . . . . . . . . . . . . . . . . . . . . 41.279 ÷ 41.553
Interference between small end bushing and seat . . . . . . . . . . . . . 0.266 ÷ 0.566
Internal diameter of small end bushing (after press−fitting) . . . . . 38.019 ÷ 38.033
Diameter of seat for bearing shells on connecting rod . . . . . . . . . 72.987 ÷ 73.013
Connecting rod−crankpin end float . . . . . . . . . . . . . . . . . . . . . . . . . . 0.100 ÷ 0.330
PISTON DATA mm
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . light alloy with three compression rings,
including two seal rings and one scra-
per ring
Standard piston diameter, measured at 61 mm from skirt base
and perpendicularly to the gudgeon pin axis . . . . . . . . . . . . . . . . . . 103.714 ÷ 103.732
Piston clearance in cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.268 ÷ 0.310
Spare piston oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,400
Piston protrusion at T.D.C. from cylinder block face . . . . . . . . . . . 0.280 ÷ 0.520
Gudgeon pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.994 ÷ 38.000
Diameter of gudgeon pin seat in piston . . . . . . . . . . . . . . . . . . . . . . 38.010 ÷ 38.016
Gudgeon pin to seat clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 ÷ 0.022
Gudgeon pin to small end bearing clearance . . . . . . . . . . . . . . . . . 0.019 ÷ 0.039
Piston ring seat depth:
− 1st ring (measured on a diameter of 99 mm) . . . . . . . . . . . . . . . 2.705 ÷ 2.735
− 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.440 ÷ 2.460
− 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.030 ÷ 4.050
Piston ring thickness:
− 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.560 ÷ 2.605
− 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.350 ÷ 2.380
− 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.970 ÷ 3.990

(continued)
87744428A − 11 − 2007
(overleaf)
PISTON DATA mm
Piston ring groove clearance (measured vertically):
− 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.100 ÷ 0.175
− 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.060 ÷ 0.110
− 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 ÷ 0.080
Assembly clearance between piston ring ends in cylinder

sleeves:
− 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 ÷ 0.40
− 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 ÷ 0.80
− 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 ÷ 0.55
Spare piston ring oversizing . . . . . . . . . . . . . . . . . ..... ...... 0.400
VALVE TIMING GEAR DATA mm

Internal diameter of camshaft support bushings
(press−fitted and finished in seats):
− front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.083 ÷ 54.147
− mid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.083 ÷ 54.147
− rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.083 ÷ 54.147
Diameter of camshaft journals:
− front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.995 ÷ 54.045
− mid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.995 ÷ 54.045
− rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.995 ÷ 54.045
Clearance between camshaft journals and bushings . . . . . . . . . . 0.038 ÷ 0.152
Camshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.230 ± 0.130
Crankshaft to camshaft teeth clearance . . . . . . . . . . . . . . . . . . . . . 0.076 ÷ 0.280
TAPPET DATA mm
Tappet bore in crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.000 ÷ 16.030
Outside diameter of standard tappets . . . . . . . . . . . . . . . . . . . . . . . 15.929 ÷ 15.959
Tappet running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.041 ÷ 0.101
87744428A − 11 − 2007
ROCKER ARM − VALVE DATA mm

Rocker−arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.963 ÷ 18.975
Rocker−arm shaft seat diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.000 ÷ 19.026
Rocker arm bore to shaft clearance . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 ÷ 0.063
Valve clearance for normal running (engine cold):
− inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 ± 0.05
− exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 ± 0.05
Cam lift:
− inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.045
− exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.239
CYLINDER HEAD DATA mm

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in cast iron with fitted valve seats and
seats for injectors and thermostat valve
Maximum face re−grinding depth. that can be removed from the
cylinder head in the event of reboring . . . . . . . . . . . . . . . . . . . . . . . . . 0.130
Diameter of valve stem seat in cylinder head . . . . . . . . . . . . . . . . . 8.019 ÷ 8.039
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.960 ÷ 7.980
Assembly clearance between valve stem and seat . . . . . . . . . . . . 0.039 ÷ 0.079
Valve seat angle in head:
− inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
− exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Valve face angle:
− inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
− exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Diameter on head for fitting valve seat:
− inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.987 ÷ 47.013
− exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.637 ÷ 43.663
Valve seat insert outside diameter:
− inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.063 ÷ 47.089
− exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.713 ÷ 43.739
Valve stand−in relative to cylinder head face:
− inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 ÷ 1.52
− exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 ÷ 1.52
Interference between valve seat and head:
− inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 ÷ 0.102
− exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 ÷ 0.102
(continued)
87744428A − 11 − 2007
(overleaf)
CYLINDER HEAD DATA mm
Valve head diameter:
− inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.870 ÷ 45.130
− exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.870 ÷ 42.130
Inlet and exhaust valve springs:
− spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.500
− length under load of 329 N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.020
− length under load of 641 N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.200
Injector protrusion relative to head face:
D BOSCH injectors 2856255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not adjustable
87744428A − 11 − 2007
TORQUE SETTINGS WITH ANGLE
Tightening torque
PARTS TO BE TIGHTENED Thread Angle
Nm kgm
Main bearing cap bolts
phase 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 x 1.5 50 ± 6 5.0 ± 0.6 −
phase 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 x 1.5 80 ± 6 8.0 ± 0.6 −
phase 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 x 1.5 − − 90° ± 5°
Big−end cap bolts
phase 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 30 ± 3 3.0 ± 0.3 −
phase 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 60 ± 5 6.0 ± 0.5 −
phase 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 − − 60° ± 5°
Bolts securing cylinder head . . . . . . . . . . . . . . . M 12 x 1.75 x 70 50 ± 5 5.0 ± 0.5 90°
Note: For the tightening sequence, see

M 12 x 1.75 x 140 40 ± 5 4.0 ± 0.5 180°
page 54, Fig. 120.
M 12 x 1.75 x 180 70 ± 5 7.0 ± 0.5 180°
Bolts securing engine flywheel . . . . . . . . . . . . . M 12 x 1.25 30 ± 4 3.0 ± 0.4 60° ± 5°
87744428A − 11 − 2007
TORQUE WRENCH SETTINGS
Tightening torque
PARTS TO BE TIGHTENED Thread
Nm kgm
Bolts fastening pulley on crankshaft . . . . . . . . . . . . . . . . . . . . . M 12 x 1.75 110 ± 5 11.0 ± 0.5
Flywheel casing retaining bolts . . . . . . . . . . . . . . . . . . . . . . . M 12 x 120 85 ± 10 8.5 ± 1
M 12 x 80 85 ± 10 8.5 ± 1
M 10 x 80 49 ± 5 4.9 ± 0.5
M 10 x 40 49 ± 5 4.9 ± 0.5
Oil sump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 24 ± 4 2.4 ± 0.4
M 8 x 1.50 60 ± 9 6 ± 0.9
Oil sump threaded plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 22 x 1.5 50 ± 5 5 ± 0.5
Rocker arm support retaining bolts . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 24 ± 4 2.4 ± 0.4
Tappet cover retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 24 ± 4 2.4 ± 0.4
Exhaust manifold retaining bolts . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.50 53 ± 6 4.3 ± 0.6
Intake manifold retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 24 ± 4 2.4 ± 0.4
Oil cooler retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 24 ± 4 2.4 ± 0.4
Coolant pump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 24 ± 4 2.4 ± 0.4
Coolant inlet manifold retaining bolts . . . . . . . . . . . . . . . . . . . M 10 x 1.50 24 ± 4 2.4 ± 0.4
Thermostat valve assembly retaining bolts . . . . . . . . . . . . . . M 8 x 1.25 24 ± 4 2.4 ± 0.4
Fan support retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 x 50 10 ± 2 1 ± 0.2
M 10 x 1.50 x 25 43 ± 6 4.3 ± 0.6
Injector fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . − 60 ± 5 6.0 ± 0.5
Fuel pump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 24 ± 4 2.4 ± 0.4
Nuts securing turbine mod. T4050 . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 43 ± 6 4.3 ± 0.5
Alternator retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.50 24 ± 4 2.4 ± 0.4
Starter motor retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.50 49 ± 5 4.9 ± 0.5
Camshaft plate retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 24 ± 4 2.4 ± 0.4
Injection pump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 12 ± 5 1.2 ± 0.5
Oil pump gear casing retaining bolts . . . . . . . . . . . . . . . . . . . M 8 x 1.25 24 ± 4 2.4 ± 0.4
Additional counterweight retaining bolts . . . . . . . . . . . . . . . . . M 10 x 1.5 48 ± 8 4.8 ± 0.8
Bolts securing camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 36 ± 4 3.6 ± 0.4
87744428A − 11 − 2007
SPECIAL TOOLS
X 380000664 Splining tool for fitting rear seal
on crankshaft.
Warning − The operations described in this section
can only be carried out with ESSENTIAL tools X 380000665 Tool to extract crankshaft front
indicated by an (X). seal.
To work safely and efficiently and obtain the best
results, it is also necessary to use the recommended X 380000666 Splining tool for fitting front seal
specific tools listed below and certain other tools, on crankshaft.
which are to be made according to the drawings
included in this manual.
X 380000667 Drift for camshaft bushing
disassembly and reassembly
List of specific tools required for the various (use with 380000668).
operations described in this Section.
380000668 Grip for interchangeable drifts.
X 380000216 Engine removal and installation
tool. X 380000669 Gasket extraction tool.
380000220 Clamp for fitting piston in X 380000670 Tool for cartridge filter
cylinder liner (60−125 mm). disassembly.
X 380000221 Pliers for piston ring 380000671 Injector extraction tool.

disassembly and reassembly
(65−110 mm). 380000975 Box with full set of tools to
regrind valve seats.
380000301 Rotating stand for overhaul
operations (capacity 1000 daN, 380000976 Spring load test appliance.
torque 120 daN/m).
380001003 Complete square to check for
X 380000302 Tool for engine valve connecting rod distortion.
disassembly and reassembly.
380001268 Belt tension gauge.
380000304 Pair of gauges for angular
tightening with 1/2” and 3/4”
square connection. Injection pump bench test.
380000362 Crankshaft lifting tool. 380000228 Dial gauge (0−5 mm).
X 380000364 Dial gauge base for various

measurements (use with X 380000732 Tool for engine flywheel rotation
380000228). (use with 380000988).
380000569 Movable tool for dismantling trac- X 380000914 Dial−gauge holder tool for rotary
tors with bracket 380000500 and injection pump timing (use with
adapter plate 380000844. 380000228).
X 380000661 Engine mounting brackets for X 380000988 Plate for engine flywheel
rotating stand 380000301. rotation tool with flywheel timing
pin (use with 380000732).
X 380000663 Tool to extract crankshaft rear
seal.
87744428A − 11 − 2007
MIF1096A
1
Engine view
87744428A − 11 − 2007
Oil path under pressure

Oil return path under gravity
MIF1098A
2
Engine lubrication diagram
Forced−circulation lubrication is accomplished by − oil pressure control valve incorporated in the

the following components: cooler assembly;
− oil pump, housed at the front of the crankcase, − by−pass valve to cut off clogged oil filter,
driven by the grooved bushing keyed onto the incorporated in the cooler assembly;
shank of the crankshaft; − cartridge oil filter.
− water / oil cooler, housed in the crankcase;
87744428A − 11 − 2007
Coolant recirculating in the engine

Coolant entering the pump
MIF1099A
3
Cooling diagram
The forced circulation, closed−circuit engine cooling − a centrifugal coolant pump housed at the front of
system is composed of the following components: the crankcase;
− a lubricating oil cooler; − a thermostat valve governing coolant circulation.
87744428A − 11 − 2007
MIF1102A
4
Additional counterweight diagram
1. Retaining bolts 6. Half bearings

2. Support 7. Counter−shaft
3. Retaining bolts 8. Gear
4. Gear 9. Ring
5. Balancing weight 10. O−rings
87744428A − 11 − 2007
5
Camshaft view
A. Inlet valve cam. B. Exhaust valve cam.
EXHAUST GAS RECIRCULATION SYSTEM The internal EGR system is not provided with any
(EGR) electronically controlled elements: the system is
always on.
On the TIER 3 version, the exhaust cam profile has
been modified to permit partial opening of the related Its configuration needs no additional elements such
valve during the inlet phase (exhaust gas as control valves, pipes or heat exchangers.
recirculation EGR) with the consequent
re−introduction of some of the exhaust gases into the The exhaust cam (B) in addition to the main lobe has
engine cylinders. another lobe (see sect. A−A, fig. 5) with respect to
The exhaust gases can be partially redirected into the configuration without EGR.
the cylinders in order to reduce the maximum
combustion temperature values which are The additional lobe, during the inlet phase of the
responsible for the production of nitrogen oxide cylinder under examination, permits briefly opening
(NOx). the exhaust valve generating recirculation due to the
The exhaust gas recirculation system (EGR), exhaust gases returning caused by the lower
reducing the temperature of combustion by pressure created in the inlet phase inside the
decreasing the concentration of oxygen in the cylinder.
combustion chamber, is therefore an effective
system to control emissions of NOx.
87744428A − 11 − 2007
TROUBLESHOOTING
Problems Possible Problem Solutions
Engine does not start. 1. Battery partially discharged. Check and recharge batteries.
Replace if necessary.
2. Battery terminal connections Clean, inspect and tighten terminal

corroded or loose. nuts. Replace terminals and nuts if
excessively corroded.
3. Injection pump timing incorrect. Adjust injection pump timing on the

engine.
4. Impurities or water in fuel lines. Disconnect fuel lines from injection

pump and clean thoroughly. If
necessary clean and dry the fuel tank.
5. No fuel in tank. Fill tank.
6. Fuel supply pump malfunction. Check and replace pump if

necessary.
7. Air in fuel system. Check fuel lines, unions, supply

pump, filters and injection pump for
air, then bleed system; then bleed the
air from the circuit.
8. Starter motor faulty. Repair or replace starter motor.
9. Thermostarter faulty. Check and replace thermostarter if

necessary.
Engine stalls. 1. Slow idling speed too low. Adjust slow idling speed.
2. Injection pump delivery irregular. Check delivery on the test bench.

4. Fuel filters clogged. Replace the filter cartridges.

5. Incorrect valve − rocker arm Adjust the clearance between the
clearances. rocker arms and the valves.
6. Burnt or cracked valves. Replace the valves.
7. Air in fuel system. Check fuel lines, unions, supply
pump, filters and injection pump for
air, then bleed system; then bleed the
air from the circuit.
8. Injection pump drive mechanism Replace damaged parts.

damaged.
(continued)
87744428A − 11 − 2007
(overleaf)

Engine overheating. 1. Coolant pump malfunction. Overhaul pump and replace if
necessary.
2. Thermostat faulty. Replace thermostat.
3. Radiator inefficient. Remove internal deposits by flushing.
Check for leaks and repair.
4. Deposits in cylinder head and Flush out coolant system.
crankcase coolant passages.
5. Coolant pump and fan drive belt Check and adjust belt tension.
slack.
6. Coolant level low. Top up expansion tank with specified
coolant mixture.
7. Incorrect engine timing. Check and adjust engine timing.
8. Injection pump calibration Calibrate pump on test bench to
incorrect − delivering too much or values specified in calibration tables.
too little fuel.
9. Air filter clogged. Clean the assembly and, if
necessary, replace the filtering
element.
Engine lacks power and 1. Injection pump timing incorrect. Adjust injection pump timing on the
runs unevenly. engine.
2. Auto advance regulator in Overhaul injection pump and adjust
injection pump damaged. on test bench to values specified in
calibration table.
3. Control valve journal worn. Overhaul injection pump and adjust
on test bench to values specified in
calibration table.
4. Injection pump delivery irregular. Overhaul injection pump and adjust
calibration table.
5. All−speed governor damaged. Overhaul injection pump and adjust
calibration table.
6. Injectors partially obstructed or Clean, overhaul and calibrate
damaged. injectors.
(continued)
87744428A − 11 − 2007
(overleaf)

8. Fuel supply pump damaged. Replace fuel supply pump.
9. Incorrect valve − rocker arm Adjust the clearance between the
clearances. rocker arms and the valves.
10. Cylinder compression low. Test compression and overhaul
engine if necessary.
element.
12. Tie−rod in linkage between Adjust to correct length.
accelerator and injection pump
incorrectly adjusted.
13. Fast idling speed screw on Adjust fast idling speed screw.
injection pump incorrectly
adjusted.
The engine makes anomal- 1. Injectors partially obstructed or Clean, overhaul and calibrate
ous knocking noises. damaged. injectors.
2. Impurities accumulating in fuel Clean fuel lines and replace severely
lines. dented pipes; clean injection pump if
necessary.
3. Injection pump timing incorrect. Adjust injection pump timing on the
engine.
4. Crankshaft knocking due to Re−grind crankshaft journals and
excessive play in one or more crankpins. Fit oversize shell bearings
main or big−end bearings or and thrust washers.
excessive endfloat.
5. Crankshaft out of balance. Check crankshaft alignment and
balance; replace if necessary.
6. Flywheel bolts loose. Replace any bolts that have worked
loose and tighten all bolts to the
specified torque + angle values.
7. Connecting rod axes not parallel. Straighten connecting rods, check
axes parallelism; replace con rods if
necessary.
8. Pistons knock due to excessive Rebore cylinder liners and fit oversize
wear. pistons.
9. Noise caused by excessive play Fit oversize gudgeon pin, rebore
of gudgeon pins in small−end and piston seats and small−end bushings.
piston bushings. Loose fit of Replace with new bushings.
small−end bushing.
10. Excessive tappet / valve noise. Check for broken springs or
excessive play between valve stems
and guides, tappets and bores; adjust
the clearance between valves and
rocker arms.
(continued)
87744428A − 11 − 2007
(overleaf)

The engine produces 1. Maximum delivery of injection Calibrate pump on test bench to
abnormal smoke: black or pump too high. values specified in calibration tables.
dark grey.
2. Injection pump delivery Adjust injection pump timing or check
excessively retarded or automatic advance regulator.
automatic advance regulator
damaged.
3. Injection pump delivery Adjust injection pump timing on the
excessively advanced. engine.
4. Injectors partially or totally Clean, overhaul and calibrate
obstructed or incorrectly injectors; replace them if necessary.
adjusted.
element.
6. Loss of engine compression due Replace damaged parts or, if
to: necessary, overhaul the engine.
− piston rings sticking;
− cylinder liner wear;
− worn or incorrectly adjusted
valves.
7. High−pressure fuel lines Inspect and replace if necessary.
damaged.
Blue, grey−blue or grey− 1. Injection pump delivery Adjust injection pump timing or check
white smoke. excessively retarded or automatic advance regulator.
automatic advance regulator
damaged.
2. Injectors obstructed or damaged. Clean, overhaul and calibrate
injectors, replace if necessary.
3. Oil leaking past piston rings due Replace damaged parts or, if
to sticking rings or cylinder liner necessary, overhaul the engine.
wear.
4. Oil leaking through the inlet valve Overhaul cylinder head.
guides due to guide or valve stem
wear.
5. Engine does not reach correct Replace thermostat.
operating temperature (thermo-
stat faulty).
Engine runs on after 1. Engine stop electromagnet Replace electromagnet.
switching off. damaged.
2. All−speed governor damaged. Overhaul injection pump and adjust
calibration table.
87744428A − 11 − 2007
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New Holland T4040 T4050 Tractor Service Repair Manual-2

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T4040 − T4050 TRACTORS

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CNH GLOBAL N.V.

Page Date Page Date

Page Date Page Date

Data . . . . . . . . . . . . . . . . . . . 1−2 11−03 CHAPTER 2 − Power Shuttle transmission

Cross−sectional views . . . 3−4 11−03 Tightening torques . . . . . . 3 11−03

Fault diagnosis . . . . . . . . . . 5 11−03 Tools . . . . . . . . . . . . . . . . . . 4−5−6−7−8 11−03

Removal−Installation − Cross−sectional views . . . 9−10−11−

Tools . . . . . . . . . . . . . . . . . . 4−5−6−7 11−03

Page Date Page Date

23 − DRIVE LINES Disassembly−Assembly −

CHAPTER 1 − Front axle mechanical Cross−sectional views . . . 9−10 11−03

Page Date Fault diagnosis . . . . . . . . . . 16−17 11−03

31 − POWER TAKE−OFF Lift internal controls.

33 − BRAKES CHAPTER 2 − Open centre system auxiliary

Page Date Page Date

41 − STEERING Fault diagnosis . . . . . . . . . . 7 11−03

CHAPTER 2 − Non−stop flow gear pump CHAPTER 3 − Charging system

Page Date Page Date

CHAPTER 4 − Battery 90 − PLATFORM, CAB, BODYWORK

ROTATING SHAFT SEALS

MOVING THE TRACTOR WITH THE BATTERY REMOVED

SAFETY REGULATIONS − Disconnect the batteries and label all controls to

START UP HYDRAULIC SYSTEMS

Water & liquid

Windscreen wash reservoir 2,0 Water & liquid − −

Engine oil sump:

Brake control circuit . . . . . . 0,7

axle casing . . . . . . . . . . . . . . 1.18 (4.5)

Rear transmission (bevel

Grease fittings . . . . . . . . . . . − AMBRA GR9 NH 710 A NLGI 2

Section Description Page

10 000 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

at fast idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 bar

BOSCH Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rotating distributor type

Number of nozzle holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Nozzle hole diameter mm:

Calibration pressure bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 ÷ 274

ENGINE BLOCK DATA mm

Engine sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cast−iron monobloc with cylinder liners,

Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.000 ÷ 104.024

Oversized cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.400 ÷ 104.424

internal no. 2−3−4 87.977 ÷ 88.013

Camshaft bushing seat diameter:

− front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.222 ÷ 59.248

− mid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.222 ÷ 59.248

− rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.222 ÷ 59.248

Diameter of standard tappet bores in crankcase . . . . . . . . . . . . . . 16.000 ÷ 16.030

CRANKSHAFT AND BEARINGS DATA mm

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . balanced with integral counterweights

CONNECTING ROD DATA mm

Diameter of small end bushing seat . . . . . . . . . . . . . . . . . . . . . . . . . 40.987 ÷ 41.013

Outside diameter of small end bushing . . . . . . . . . . . . . . . . . . . . . . 41.279 ÷ 41.553

Interference between small end bushing and seat . . . . . . . . . . . . . 0.266 ÷ 0.566

Internal diameter of small end bushing (after press−fitting) . . . . . 38.019 ÷ 38.033

Diameter of seat for bearing shells on connecting rod . . . . . . . . . 72.987 ÷ 73.013

Connecting rod−crankpin end float . . . . . . . . . . . . . . . . . . . . . . . . . . 0.100 ÷ 0.330