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

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.

1
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 2
housing.
3. Unscrew the clamps and disconnect the fuel re-
turn hose (1) to the tank (2) and the fuel supply 25659

pump inlet hose. 7

4. Remove the retaining bolts and detach the rear

guard (1).
1

25643

8
5. Position bracket 380001613 (1) and secure it to
the engine and axle.
1

25544

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32 SECTION 10 -- ENGINE -- CHAPTER 1

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 1
and 2) and the screw retaining the bottom pivot
pin (4). Extract this pin and remove the above--
mentioned bracket (2).

4 3 2
25547

11
8. Extract the two rear screws and lower the hy-
draulic jack. Retrieve the guard (1) and bracket 1 2
(2).

25645

12
9. Remove the circlip (2) and move the rear sleeve
forwards (1). 1 2

25646

13

603.54.451.00 - 01 - 2004
 SECTION 10 -- ENGINE -- CHAPTER 1 33

10. Remove the circlip (2) and move the front sleeve
forwards (1). 1 2

25647

14
11. Unscrew the bolts retaining the bearing support
(1) to the clutch housing and retrieve the drive 1
shaft together with the support.

25648

15
12. Disconnect the service control valve supply pipe
(1) and the front differential locking control pipe 1
(2).

2
25660

16
13. Disconnect the service brake control pipe (1) and
trailer brake valve control pipe (2). 1

25661

17

603.54.451.00 - 01 - 2004
34 SECTION 10 -- ENGINE -- CHAPTER 1

14. Remove the drain plug (1) and retrieve the diesel
in a suitable container. 1

25629

18
15. Disconnect the trailer brake control pipe (1) and
the pipe (2) connecting the auxiliary control
1
valves to the lift control valve.
16. Unscrew the clamp and disconnect the hydraulic
pump inlet pipe (1).

3
25662

19
17. Loosen the clamp and detach the sleeve (1) from
the relevant pipe, which you should then detach 1
from the front tank and remove.

25630

20
18. Unscrew the relevant clamps, detach the ther-
mostarter connections and remove the sleeve
1
(1) coupling the air filter to the intake manifold.

25663

21

603.54.451.00 - 01 - 2004
 SECTION 10 -- ENGINE -- CHAPTER 1 35

19. Detach the sleeves (1 and 3) from the radiator

and unscrew the bracket (2) securing the radiator 1
to the engine.
20. Place a fixed stand under the engine, taking care
not to dent the oil sump plating.
2

25664

22
21. Connect a nylon rope (2) to the axle support and
to the hoist. Tension the rope and detach the 1
union (1) from the front hydraulic pump.

25665

23
22. Remove the retaining bolts (1) from both of them
and detach the axle support. 1

25666

24
23. Remove the bolts, retaining clamps and exhaust
silencer assembly (1). 1

25667

25

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36 SECTION 10 -- ENGINE -- CHAPTER 1

24. Loosen the clamp (3), unscrew the retaining

bolts (1) and remove the vapour recirculation de- 1 2 3
vice (2).

25668

26
25. Place a fixed stand under the clutch housing.
Connect a chain to the engine and hoist. Tension 1
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

27
-- Apply the torque settings listed on page 20. -- Connect the hydraulic pump inlet piping and the
-- Before refitting the engine to the clutch box care- pipes governing the trailer brake and connecting
fully clean the mating surfaces and apply sealing the auxiliary control valves to the lift.
compound (0.0787 in. (2 mm) diameter), accord- -- Fit the fuel tank plug.
ing to the diagram shown Section 21, Chapter 1, -- Connect the service brake and trailer brake valve
page 34. control pipes.
-- Fit the engine on the clutch casing. -- Connect the differential lock and service control
-- Fit the vapour recirculation device. valve supply pipes.
-- Fit the exhaust silencer assembly. -- Refit the drive shaft and relevant guards.
-- Refit the axle support to the engine and fit the -- Remove bracket 380001613 securing the engine
union on the front hydraulic pump. and front axle.
-- Connect and secure the sleeves to the radiator. -- Refit the fuel inlet and return pipes.
Lock the bracket securing the radiator to the en- -- Screw the drain plugs onto the transmission
gine. housing and onto the diesel tank and replenish
-- Fit the sleeve connecting the air filter to the intake them (for the prescribed product and quantity,
manifold. see page 6 sect. 00).
-- Fit the fuel tank connection piping. -- Refit the cab following the instructions in Sec-
tion 90, Chapter 1.

603.54.451.00 - 01 - 2004
 SECTION 10 -- ENGINE -- CHAPTER 1 37

Op. 10 001 54
ENGINE Disassembly -- Assembly 1
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. 2

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

28
2. Remove the retaining bolts and retrieve the fan
(1), spacer and driving pulley (2). Detach the re- 2
1
turn pipe (3) from the coolant pump.

25671

29
3. Take out the retaining bolts and remove the cool-
ant pump (1). 1

25672

30
4. Take out the retaining bolts and detach the cool-
ant pump support (1).
1

25673

31

603.54.451.00 - 01 - 2004
38 SECTION 10 -- ENGINE -- CHAPTER 1

5. Secure the bracket (1), series 380000313, to the

engine and lock this on the rotary stand 1
380000301.

25674

32
6. Disconnect the pipes (1 and 2) from the crank-
case and from the hydraulic pump governing the
1
services.

25675

33
7. Disconnect the thermostarter supply pipe (1) and
the return pipe (2) from the thermostarter and 1 2
from the injectors.

25676

34
8. Unscrew the unions (2 and 3) from the injection
pump and from the fuel pump. Take out the re-
1 2
taining bolts and remove the fuel filter (1) to-
gether with the support and pipes.
3

25677

35

603.54.451.00 - 01 - 2004
 SECTION 10 -- ENGINE -- CHAPTER 1 39

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).
1

25679

37
11. Unscrew the retaining bolts and remove the ex-
haust manifold (1). 1 2
12. Unscrew the engine oil filter (2).

25680

38
13. Disconnect the pipes (2) from the injection pump
and from the injectors. 1
14. Unscrew the retaining bolts and remove the inlet
manifold (1).

25681

39

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40 SECTION 10 -- ENGINE -- CHAPTER 1

15. Unscrew the pump retaining bolts (1).

1

25682

40
16. Remove the cover (1) to access the injection
pump gear compartment. 1

25683

41
17. Unscrew the nut securing the injection pump to
the gear (1). 1 2
18. Extract the injection pump driving gear using the
tool 380000322 (2) and retrieve the injection
pump with the Woodruff key.

25684

42
19. Unscrew the retaining nuts (1) and retrieve the
fuel pump (2) together with the support. 2
1

25685

43

603.54.451.00 - 01 - 2004
 SECTION 10 -- ENGINE -- CHAPTER 1 41

20. Disconnect the piping (1) from the filter, unscrew

the bolts securing the pressure relief valve as- 1 2
sembly (2) and remove it.

25686

44
21. Take out the retaining bolts and detach the hy-
draulic pump (1) along with the oil filter (2). 1

25687

45
22. Take out the retaining bolts and remove the lift
hydraulic pump (1). 1

25688

46
23. Take out the retaining bolts and remove the
starter motor (1). 1

25689

47

603.54.451.00 - 01 - 2004
42 SECTION 10 -- ENGINE -- CHAPTER 1

24. Remove the injector mounting nuts, the under-

lying spherical washers, then the supports and 1
the injectors themselves.
25. Remove the retaining bolts (1), washers and
seal, then remove the rocker housing cover (2)
and seal.

25098

48
26. Remove the rocker shaft retaining bolts (2), then
remove the entire rocker shaft assembly (1).

1 2

25099

49
27. Remove the valve collets (1) and extract the pu-
shrods (2). 1 2

25100

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

603.54.451.00 - 01 - 2004
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