New Holland TT4.80 Service Manual Download

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SERVICE MANUAL

TT4.80 / TT4.90

Tractor

Part number 47866580

edition English

December 2015

Summary of Contents for TT4.80

Page 2: ...SERVICE MANUAL TT4 80 TT4 90 47866580 11 12 2015 EN Find manuals at https best manuals com ...

Page 3: ...ines 10 11 10 250 Turbocharger and lines 10 12 10 254 Intake and exhaust manifolds and muffler 10 13 10 400 Engine cooling system 10 14 10 414 Fan and drive 10 15 10 310 Aftercooler 10 16 10 304 Engine lubrication system 10 17 Clutch 18 18 110 Clutch and components 18 1 Transmission 21 21 114 Mechanical transmission 21 1 21 112 Power shuttle transmission 21 2 21 110 Master clutch housing 21 3 21 1...

Page 4: ...gear set and differential 27 2 27 120 Planetary and final drives 27 3 Power Take Off PTO 31 31 114 Two speed rear Power Take Off PTO 31 1 Brakes and controls 33 33 120 Mechanical service brakes 33 1 33 202 Hydraulic service brakes 33 2 33 110 Parking brake or parking lock 33 3 Hydraulic systems 35 35 000 Hydraulic systems 35 1 35 104 Fixed displacement pump 35 2 35 204 Remote control valves 35 3 3...

Page 5: ... Battery 55 5 55 012 Engine cooling system 55 6 55 404 External lighting 55 7 55 408 Warning indicators alarms and instruments 55 8 Platform cab bodywork and decals 90 90 118 Protections and footboards 90 1 90 114 Operator protections 90 2 90 120 Mechanically adjusted operator seat 90 3 90 100 Engine hood and panels 90 4 90 116 Fenders and guards 90 5 47866580 11 12 2015 Find manuals at https best...

Page 6: ...INTRODUCTION 47866580 11 12 2015 1 Find manuals at https best manuals com ...

Page 7: ...Contents INTRODUCTION Foreword 3 Safety rules 4 Safety rules 5 Safety rules 7 47866580 11 12 2015 2 Find manuals at https best manuals com ...

Page 8: ...ons will be directly responsible for any damage caused Notes for equipment Equipment which NEW HOLLAND proposes and shows in this manual is Studied and designed expressly for use on NEW HOLLAND tractors Necessary to make reliable repair Accurately built and strictly tested to offer efficient and long lasting working life Notice The words front rear right hand side and left hand side refer to the d...

Page 9: ...e operator or other persons directly or indirectly involved in the operation To prevent accidents Most accidents and personal injuries taking place in workshops are due from non observance of some essential rules and safety precautions The possibility that an accident might occur with any type of machines should not be disregarded no matter how well the machine in question was designed and built A...

Page 10: ...uel tanks or batteries nor use starting liquid if you are smoking or near open flames as such fluids are flammable The fuel filling gun should always remain in contact with filler neck Maintain this contact until the fuel stops flowing into the tank to avoid possible sparks due to static electricity build up To transfer a failed tractor use a trailer of a low loading platform trolley if available ...

Page 11: ...tis Always take system pressure readings using the appropriate gauges Wheels and tires Check that the tires are correctly inflated at the pressure specified by the manufacturer Periodically check for possible damage to the rims and tires Stay a the tire side when inflating Check the pressure only when the tractor is unloaded and tires are cold to avoid wrong reading due to over pres sure Never cut...

Page 12: ...ondary containers should be labelled Solvent based adhesive sealers See solvents Follow manufacturer s instructions Water base adhesive sealers Those based on polymer emulsions and rubber lattices may contain small amounts of volatile toxic and harmful chem icals Skin and eye contact should be avoided and adequate ventilation provided during use Follow manufacturers instructions Resin based adhesi...

Page 13: ...teries Brake and clutch fluids polyalkylene glycols See fire combustible Splashes to the skin and eyes are slightly irritating Avoid skin and eye contact as far as possible Inhalation of vapor hazards do not arise at ambient temperatures because of the very low vapor pressure Brazing See welding Chemical materials general See legal aspects Chemical materials such as solvents sealers adhesives pain...

Page 14: ...n Fumes given off can build up to toxic harmful or explosive concentrations Some fumes are heavier than air and will accumulate in confined areas pits etc Do not transfer chemical materials to unlabeled containers Do not clean hands or clothing with chemical materials Chemicals particularly solvents and fuels will dry the skin and may cause irritation with dermatitis Some can be absorbed through t...

Page 15: ...ctricity using dry non conductive material Commence resuscitation if trained to do so Summon medical assistance Exhaust fumes These contain asphyxiating harmful and toxic chemicals and particles such as carbon oxides nitrogen oxides alde hydes lead and aromatic hydrocarbons Engines should only be run under conditions of adequate extraction or general ventilator and not in confined spaces Gasoline ...

Page 16: ...itivity reactions and may be toxic or harmful vapors and spray mists must not be breathed These materials must be applied with adequate ventilation and respi ratory protection Do not remove respirator immediately after spraying wait until vapor mists have cleared Burning of the uncured components and the cured foams can generate toxic and harmful fumes Smoking open flames or the use of electrical ...

Page 17: ...uding skin cancer Gas cylinders See fire Gases such as oxygen acetylene carbon dioxide argon and propane are normally stored in cylinders at pressures of up to 2000 Ib sq in 13 790 kn m2 and great care should be taken in handling these cylinders to avoid mechanical damage to them or to the valve gear attached The contents of each cylinder should be clearly identified by appropriate markings Cylind...

Page 18: ...minated during service e g routine service change sump oils are more irritating and more likely to cause serious effects including 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 re moved from the skin with water Do not use petrol paraffin or other solvents to remove oil from t...

Page 19: ... used Oxy acetylene flames should not be used as they are much hotter and will cause lead fumes to be evolved Some fumes may be produced by the application 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 not produced which can give toxic effects if inhaled Respiratory...

Page 20: ...ded Never work under an unsupported suspended or raised load e g jacked up vehicle suspended engine etc Always ensure that lifting equipment such as jacks hoists axle stands slings etc are adequate and suitable for the job in good condition and regularly maintained Never improvise lifting tackle Underseal See corrosion protection Welding See fire electric shock gas cylinders Welding processes incl...

Page 21: ...ssion is much less than that from arc welding and lighter filters may be used The process itself produces few toxic fumes but such fumes and gases may be produced from coatings on the work particularly during cutting away of damaged body parts and inhalation 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 braz...

Page 22: ...SERVICE MANUAL Engine TT4 80 TT4 90 47866580 11 12 2015 10 ...

Page 23: ...flywheel 10 6 10 110 Balancer and damper 10 7 10 216 Fuel tanks 10 8 10 206 Fuel filters 10 9 10 218 Fuel injection system 10 10 10 202 Air cleaners and lines 10 11 10 250 Turbocharger and lines 10 12 10 254 Intake and exhaust manifolds and muffler 10 13 10 400 Engine cooling system 10 14 10 414 Fan and drive 10 15 10 310 Aftercooler 10 16 10 304 Engine lubrication system 10 17 47866580 11 12 2015...

Page 24: ...Engine 10 Engine and crankcase 001 TT4 80 TT4 90 47866580 11 12 2015 10 1 10 001 1 ...

Page 25: ...e General specification 3 Special tools 4 Crankcase General specification 5 FUNCTIONAL DATA Engine Overview 7 SERVICE Engine Service instruction 11 Remove 12 Install 14 Disassemble 16 Assemble 17 DIAGNOSTIC Engine Troubleshooting 18 47866580 11 12 2015 10 1 10 001 2 ...

Page 26: ...780 54 805 mm 2 157 2 158 in Intermediate 54 280 54 305 mm 2 137 2 138 in Rear 53 780 53 805 mm 2 117 2 118 in Tappet seat bore diameter 15 000 15 018 mm 0 591 0 591 in Tappet oversize 0 100 mm 0 004 in 0 200 mm 0 008 in 0 300 mm 0 012 in Main bearing seat bore diameter 84 200 84 230 mm 3 315 3 316 in Cylinder head Valve guide seat bore diameter in head 13 950 13 983 mm 0 549 0 551 in Valve guide ...

Page 27: ...erence fit in housing cylinder head 0 0050 0 0500 mm 0 0002 0 0020 in Valve guide fitted I D after reaming 8 023 8 043 mm 0 316 0 317 in Valve stem clearance in guide 0 0230 0 0580 mm 0 0009 0 0023 in Maximum wear clearance 0 130 mm 0 005 in Maximum valve stem eccentricity over one revolution with stylus on sealing face 0 030 mm 0 001 in Engine Special tools Sr No Special Tool Description Special ...

Page 28: ...mm 0 007 in Crankshaft thrust washer thickness 3 378 3 429 mm 0 133 0 135 in Thrust washer oversize 0 127 mm 0 005 in 0 254 mm 0 508 in 0 508 mm 0 020 in Width of main bearing housing over thrust washers 31 766 31 918 mm 1 251 1 257 in Length of corresponding main journal 32 000 32 100 mm 1 260 1 264 in Crankshaft end float 0 082 0 334 mm 0 003 0 013 in Maximum wear clearance 0 400 mm 0 016 in Max...

Page 29: ...m 0 0006 0 0012 in Maximum wear clearance 0 060 mm 0 002 in Maximum weight difference between pistons on same engine 20 00 g 0 71 oz Piston ring clearance in groove Top 0 0900 0 1220 mm 0 0035 0 0048 in 2nd 0 0600 0 0850 mm 0 0024 0 0033 in 3rd 0 0400 0 0750 mm 0 0016 0 0030 in Maximum wear clearance Top 0 500 mm 0 020 in 2nd and 3rd 0 200 mm 0 008 in Piston ring gap Top 0 400 0 650 mm 0 016 0 026...

Page 30: ...ft idler gear which is driven by the crankshaft timing gear Camshaft end thrust is controlled by a thrust plate bolted to the block and located between the camshaft gear and the front camshaft journal A helical gear is integral on rear of cam shaft and drives the engine oil lubrication pump mounted forward of the flywheel Cylinder block assembly The cylinder block is an alloy cast iron with deep c...

Page 31: ...e friction and increase positive seating All rings are located above the piston pin Manifolds The cross flow design aluminium intake and cast iron exhaust manifolds are on opposite sides of the cylinder head This is designed to maintain balanced heat distribution within the cylinder head The configuration of the manifolds also ensures minimum heat transfer to the intake manifold The intake manifol...

Page 32: ...sing on the left hand side of the engine Oil flows from the filter to the main oil gallery which runs the length of the cylinder block which also intersects the camshaft follower chamber The main gallery also supplies oil to the crankshaft main bearings connecting rods both big and small ends and timing gear bushes The underside of the pistons and pins are lubricated by oil pressure jets Timing ge...

Page 33: ...trols the flow of the water as required by tem perature changes NOTE A faulty thermostat may cause the engine to operate at too high hot or low cold on operating temperature If not replaced this could result in a damaged engine or impaired engine performance When the thermostat is closed a recirculating by pass is provided to allow the coolant to recirculate from the head to the block to effort a ...

Page 34: ...phs in the main overhaul procedure Operations or repairs that can be performed with the engine still in the tractor 1 Cylinder head and associated inlet and exhaust components 2 Fuel injection pump and related parts 3 Water pump thermostat and associated compo nents 4 Front timing cover timing gear removal 5 Front pulley Operations or repair that are performed with the engine separated from the fr...

Page 35: ...cal harness 6 Remove the water separator See the Fuel water sep arator filter Remove 10 206 7 Disconnect the Fuel Injection Pump FIP lines See the Injection pump Remove 10 218 8 Disconnect the steering control hoses See the Steer ing control Disconnect 41 101 9 Disconnect the hydraulic hoses See the Pump Re move 35 104 10 Remove the exhaust muffler See the Exhaust muf fler Remove 10 254 11 Use wed...

Page 36: ...rs Failure to comply could result in death or seri ous injury W0398A 1 Disconnect the radiator and turbocharger inlet and out let hoses See the Radiator Remove 10 400 2 Connect the engine to a suitable hoist GNIL15TR00777AB 3 3 Remove the buckle up bolts 1 coupling engine and front axle support Separate it from the front axle GNIL15TR00778AB 4 4 Remove the engine from front axle carefully Mount it...

Page 37: ...e exhaust muffler See the Exhaust muffler Install 10 254 5 Connect the hydraulic hoses See the Pump Install 35 104 6 Connect the steering control hoses See the Steering control Connect 41 101 7 Connect the Fuel Injection Pump FIP lines See the Injection pump Install 10 218 8 Install the water separator See the Fuel water sepa rator filter Install 10 206 9 Connect the electrical harnesses 10 Instal...

Page 38: ... diameter as shown in the figure 3 Due care should be taken in aligning input shaft with clutch plates and pilot bearing as to avoid damage to input shaft and hearing 4 Apply the torque setting listed in tightening torque table 5 Before starting all the fluid levels should be cor rect Start and run the engine until oil and coolant temperature reaches to operating temperature and check for leaks an...

Page 39: ... the turbocharger See the Turbocharger Remove 10 250 2 Remove the exhaust manifold See the Exhaust man ifold Remove 10 254 3 Remove the alternator See the Alternator Remove 55 301 4 Remove the oil cooler See the Engine cooling sys tem Remove Oil cooler 10 400 5 Remove the fuse box See the Fuse and relay box Remove 55 100 6 Remove the fuel filter See the Fuel filters Remove 10 206 47866580 11 12 20...

Page 40: ...e and relay box Install 55 100 3 Install the oil cooler See the Engine cooling system Install Oil cooler 10 400 4 Install the alternator See the Alternator Install 55 301 5 Install the exhaust manifold See the Exhaust mani fold Install 10 254 6 Install the turbocharger See the Turbocharger In stall 10 250 47866580 11 12 2015 10 1 10 001 17 ...

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