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New Holland 40 Series Repair Manual

New Holland 40 Series
51 pages
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Please cut where indicated and insert the label
into
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,---------7
40 SERIES
TRACTOR
SERVICE
5640,6640, 7740, 7840,
8240,8340
Vol.1
40564061
L
_________
_J
,---------7
40 SERIES
TRACTOR
SERVICE
5640,6640,
7740, 7840,
8240,8340
Vol.2
40564061
L
_________
_J
069008()0
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New Holland 40 Series Specifications

General IconGeneral
ManufacturerNew Holland
CategoryTractor
Series40 Series
Hydraulic SystemOpen Center
PTO Speed540 rpm
Engine TypeDiesel

Summary

Foreword

Production Date Codes and Serial Numbers

Tractor Identification Plate

Details components and stamping of the tractor's identification plate.

Key to Production Date Codes

Provides a chart for decoding production date information based on letters and numbers.

Cab, ROPS Post, and Four Wheel Drive Axle Identification Plates

Fuel Injection Pump Date Codes

Health and Safety

Health and Safety Precautions

Lists hazardous operations and materials, and necessary precautions for safety.

Acids and Alkalis

Details hazards of acids/alkalis and protective measures like gloves and goggles.

Adhesives and Sealers

Discusses flammability, storage, and handling of various adhesives and sealers.

Antifreeze

Covers flammability, usage, absorption hazards, and toxicity of antifreeze.

Brake and Clutch Linings and Pads

Addresses asbestos hazards in linings/pads and safe handling during servicing.

Chemical Materials – General

General precautions for solvents, adhesives, paints, battery acids, etc.

Do's

Lists recommended safety practices when handling chemical materials.

Do Not's

Lists prohibited actions and unsafe practices when handling chemicals.

Corrosion Protection Materials

Details hazards of these materials, spray application, and ventilation.

Dusts

Covers hazards of dusts from chemical materials or abrasion and use of respiratory protection.

Electric Shock

Explains risks of faulty electrical equipment and safety measures.

Exhaust Fumes

Discusses toxic components in exhaust fumes and need for ventilation.

Fibre Insulation

Describes skin irritation from fibrous materials and protective measures.

Fire

Covers flammability of repair materials, toxic fumes, and fire safety.

First Aid

Advises on the need for trained personnel in first aid procedures.

Foams - Polyurethane

Details hazards of uncured foam components, vapours, and fumes.

Fuels

Covers hazards of gasoline, kerosene, and diesel fuel including flammability and toxicity.

Gas Cylinders

Discusses safe handling, storage, and potential hazards of gas cylinders.

General Workshop Tools and Equipment

Emphasizes proper maintenance, use, and inspection of tools and equipment.

Legal Aspects

Lists UK laws and regulations related to health and safety in workshops.

Lubricants and Greases

Covers hazards of prolonged contact with oils, especially used oils, and skin protection.

Paints

Discusses hazards of one-pack and two-pack paints, pigments, solvents, and spraying precautions.

Solder

Addresses hazards of lead fumes from soldering, dust, and personal hygiene.

Solvents

Details skin contact hazards, eye irritation, and vapour inhalation risks from solvents.

Suspended Loads

Warns about dangers of working under suspended loads and ensuring equipment adequacy.

Welding

Covers hazards of welding processes like metal spatter, fumes, radiation, and gas welding risks.

Part 1: Engine Systems

Chapter 1: Diesel Engines

Covers the overall structure and content of the diesel engine chapter.

Diesel Engine Description and Operation

Provides details on engine models, cylinders, bore, stroke, displacement, and general design.

Cylinder Head Assembly

Describes the cylinder head, valves, springs, rocker arm shaft, and manifold mounting.

Crankshaft Assembly

Details crankshaft support, materials, end thrust control, and dynamic balancers.

Connecting Rods

Describes connecting rod design, construction, and attachment to the crankshaft.

Pistons

Explains piston construction, material, and ring arrangement for sealing.

Manifolds

Covers intake and exhaust manifold design, placement, and connection to the engine.

Cylinder Block Assembly

Describes the cylinder block material, water jackets, bore machining, and oil pan.

Timing Gears

Details crankshaft timing gear, camshaft idler gear, and injection pump drive gear meshing.

Lubrication System

Details the engine's oil circulation system and components.

Engine Oil Flow

Explains how engine oil circulates through the pump, filter, gallery, and bearings.

Diesel Engine Stripdown

Outlines procedures for engine removal and disassembly steps.

Fault Finding

Lists common engine problems, their causes, and recommended remedies.

4 & 6 Cylinder Diesel Engine Disassembly and Overhaul

Details the steps for dismantling the engine, including cylinder head and manifold removal.

Cylinder Head, Valves and Related Parts

Describes removal of cylinder head, valves, and associated components.

Injector Removal

Details the procedure for removing fuel injectors and associated pipes.

Rocker Shaft Disassembly

Explains how to disassemble the rocker shaft assembly, including bolt removal.

Cylinder Head Disassembly

Outlines the process of dismantling the cylinder head, including valve removal.

Inspection and Repair, Cylinder Head

Covers checking cylinder head core plugs, cleaning gasket surfaces, and inspecting the mating face.

Cylinder Head Flatness

Details how to check cylinder head flatness using a straight edge and feeler gauges.

Valve Inserts

Explains the process of examining, refacing, and installing valve seat inserts.

Valve Seat Specifications

Provides specifications for valve seat angle, width, and head-to-head depth.

Valve Guides

Details how to measure valve guide bore clearance and ream them.

Valve Springs

Explains checking valve spring squareness, length, and retainer condition.

Rocker Shaft Re-Assembly

Covers inspection of rocker shaft for wear and proper re-assembly positioning.

Rocker Shaft Installation

Details inspecting rocker arm screws, push rods, and installing the rocker shaft assembly.

Cylinder Head Re-Assembly

Explains reassembling valves, springs, and push rods into the cylinder head.

Cylinder Head Installation

Describes installing the cylinder head and manifold gaskets, and bolt tightening sequence.

Setting Valve Lash

Details adjusting valve lash for intake and exhaust valves when the engine is cold.

Engine Front Cover and Timing Gear Removal

Explains removing the fan belt, crankshaft pulley, and front cover.

Camshaft End Play Measurement

Details checking camshaft end play and replacing the thrust plate if needed.

Inspection and Repair of Gears

Covers washing gears, examining teeth for wear, and cleaning lubrication holes.

Timing Gear Installation

Details installing camshaft gear, idler gear, fuel injection pump, and front cover.

Oil Pan Removal

Explains draining oil, removing oil pan bolts, and inspecting the sump.

Connecting Rods, Bearings, Pistons and Rings Removal

Describes removing pistons, pins, and rings from the cylinder block.

Piston and Connecting Rod Inspection and Repair

Covers cleaning, inspecting pistons and rods for damage, and checking for distortion.

Connecting Rod Bush

Details the procedure for removing and installing connecting rod bushes.

Connecting Rod Bush Fitment

Explains fitting new bushes using standard tools or specific fixtures.

Cylinder Block Overhaul

Covers changing cylinder block plugs, sensors, and applying sealant.

Cylinder Bore

Details checking cylinder bores for scuffing, wear, taper, and out-of-roundness.

Sleeving - Boring and Honing

Explains measuring cylinder bores, honing, and the process of sleeving bores.

Piston to Cylinder Block Height

Describes checking piston to block height using a dial indicator during re-assembly.

Piston Connecting-Rod Alignment

Details aligning pistons to connecting rods and installing piston pins.

Piston Ring Gap

Explains checking piston ring gap width at various bore positions.

Piston Ring Side Clearance

Details checking the gap between the piston ring and its groove.

Piston Assembly Installation Into Block

Describes installing pistons into the cylinder block, ensuring correct orientation.

Connecting Rod Bearing Side Clearance

Explains checking side clearance of connecting rods to the crankshaft.

Balancer, Main Bearings, Flywheel and Crankshaft

Notes that these components can be overhauled with the engine in the tractor or removed.

Balancer Removal

Details removing the oil pan to expose the balancer and checking backlash.

Balancer Gear Inspection and Repair

Covers measuring shaft/bushing diameters and examining gear teeth for wear.

Balancer Gear Re-Assembly

Explains positioning balancer gears, thrust washers, and checking end float and backlash.

Main Bearing Removal

Describes gaining access to the crankshaft and removing main bearing caps.

Main Bearing Inspection and Repair

Covers cleaning bearing liners, journals, caps and inspecting for wear or damage.

Flywheel Removal

Details separating the engine from the transmission and checking flywheel runout.

Rear Cover Plate Removal

Explains removing the oil pan and rear cover to access engine components.

Rear Crankshaft Oil Seal Installation

Describes installing the rear crankshaft oil seal using tools and ensuring proper fit.

Measuring Crankshaft Seal Runout

Details checking crankshaft seal runout with a dial indicator after installation.

Oil Pump Removal

Explains removing the oil pump after the engine has been partially disassembled.

Oil Pump Inspection and Repair

Covers cleaning pump parts, inspecting for wear, and checking clearances.

Oil Pump Installation

Details cleaning, coating, and assembling oil pump components and installing it.

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