Case International 1896-2096 PDF

SHOP MANUAL
CASE/INTERNATIONAL
MODELS
1896-2096
IDENTIFICATION
Tractor model number and identification serial number are located on a plate on right fender of tractors not equipped
with a cab, or on a plate on upper right of cab interior on tractors so equipped. Cab serial number is located on a plate
on upper right of cab Interior. Engine serial number is located on a plate on left side of timing gear housing. Transmission
serial number is on left side of transmission housing. On models so equipped, front-wheel drive serial number is located
on a plate on rear of front drive axle housing.
INDEX (By Starting Paragraph)
Models
1896 2096
Models
1896 2096
AFTER COOLER.......................................... 75
AIR CLEANER SYSTEM.................. 76 76
AXLE, FRONT (TWO
WHEEL DRIVE)
Axle Main Member.......................... 5 5
Front Support.................................. 6 6
Spindles............................................ 2 2
Tie Rod & Tbe-In.............................. 4 4
Wheel Bearings................................ 1 1
BRAKES
Bleed System.................................... 169 169
Brake Cylinders................................ 174 174
Linkage Adjustment........................ 168 168
Power Brake Valve.......................... 167 167
CAB
Remove & Reinstall.......................... 232 232
COOLING SYSTEM
Radiator............................................ 77 77
Thermostat........................................ 78 78
Water Pump...................................... 79 79
FUEL SYSTEM
Bleed System.................................... 59 59
Fuel, Filters & Transfer Pump........ 56 56
Fuel Solenoid Shut-Off.................... 64 64
Iryection Pump................................ 60 60
Ir\jector Nozzle.................................. 65 65
Timing................................................ 61 61
Copyri ght 1990 by Intertec Publ i shing Corp. Printed in the Uni ted States of Ameri ca.
DIFFERENTIAL (REAR)
Overhaul............................................ 161 161
DIFFERENTIAL LOCK
Control Valve.................................... 163 163
ELECTRICAL SYSTEM
Accessory Systems............................ 100 100
Alternator........................................ 87 87
Batteries............................................ 80 80
Cab Fan ............................................ 131 131
Charging System.............................. 82 82
Digital Instrument Cluster.............. 101 101
Heater & Air Conditioning.............. 132 132
Protective Circuits .......................... 98 98
Starting Motor.................................. 94 94
Windshield Wiper............................ 130 130
ENGINE
Cam Followers.................................. 35 35
Camshaft.......................................... 41 41
Connecting Rods & Bearings.......... 47 47
Crankshaft & Bearings.................... 48 48
Cylinder Head.................................. 30 30
Cylinder Sleeves (Service).............. 45 45
Flywheel............................................ 51 51
Main Bearings.................................. 48 48
Oil Pan.............................................. 52 52
Oil Pump .......................................... 53 53
Piston & Rod Removal.................... 43 43
Piston Pins & Bushings.................... 46 46
Pistons & Rings................................ 44 44
INDEX (CONT.)
Models
1896 2096
Models
1896 2096
ENGINE (Cont.)
Removal & Reinstall Engine
Assembly........................................ 29 29
Timing Gear Cover.......................... 36 36
Timing Gears.................................... 37 37
Valve Adjustment............................ 32 32
Valve Guides & Springs .................. 33 33
Valves & Seats.................................. 31 31
FINAL DRIVES
Overhaul............................................ 159 159
FRONT-WHEEL DRIVE
Differential........................................ 10 10
Front Drive Shaft............................ 11 11
Pivot Housing & Axle Shaft............ 9 9
R&R Drive Axle Assy....................... 7 7
Tie Rod & Tbe-In.............................. 14 14
Transfer Gearbox.............................. 12 12
Wheel Hub & Planetary.................. 8 8
HYDRAUUC SYSTEM
Hitch Control Valve.......................... 228 228
Hitch Cylinder.................................. 231 231
Load Check Valve............................ 217 217
Tfesting.............................................. 189 189
Pumps................................................ 200, 200,
201 201
Remote Cyhnder.............................. 218 218
Remote Valves.................................. 213 213
Rockshaft.......................................... 231 231
Sensing Linkage................................ 222 222
System Filters.................................. 209 209
Trouble-shooting.............................. 219 219
PARK HAND BRAKE
Acjjustment........................................ 174A 174A
Renew Brake Pads............................ 174B 174B
PARK LOCK
Overhaul Park L o c k ........................ 165 165
POWER SHIFT
A(^justment........................................ 137 137
Control Valve.................................... 139 139
Power Shift Operation.................... 135 135
R&R & Overhaul.............................. 142 142
POWER TAKE-OFF
Clutch Overhaul.............................. 180 180
Control Valve & Flow Divider........ 177 177
Linkage A(|justment........................ 175 175
R&R Housing & Gears...................... 179 179
POWER STEERING SYSTEM
Fluid, Filters & Bleeding................ 15 15
Hand Pump...................................... 22 22
Oil Cooler.......................................... 27 27
Operational Tssts.............................. 18 18
Steering Column.............................. 28 28
Steering Cyhnder............................ 25,26 25,26
System Pressure .............................. 17 17
TORQUE LIMITER CLUTCH
R&R and Overhaul.......................... 134 134
GEAR TRANSMISSION
Overhaul............................................ 153 153
Shift Forks........................................ 152 152
TURBOCHARGER
Operation.......................................... 72 72
Overhaul............................................ 74 74
DUAL DIMENSIONS
Thi s servi ce manual provides speci fi cati ons in both the U.S. Customary and Metric (SI) system of measurements. The first
specifi cati on is given in the measuri ng system used during manufacture, whi le the second specifi cati ons (gi ven in parenthesis)
is the converted measurement. For instance, a specifi cati on of 0.011 inch (0.279 mm) would indicate that the equi pment was
manufactured using the U.S. system of measurement and the metric equi valent of 0.011 inch is 0.279 mm.
CASE/INTERNATIONAL
CONDENSED SERVICE DATA
Models
1896 2096
GENERAL
Engine Make.......................................................... .................. Consolidated Diesel ---------------
Engine Model........................................................ 6T-590 6TA-590
Cylinders, No. o f .................................................. 6 6
Bore .............................. ........................................ 4.016 in. 4.016 in.
(102 mm) (102 mm)
Stroke .................................................................... 4.724 in. 4.724 in.
(120 mm) (120 mm)
Displacement ........................................................ 359 cu. in. 359 cu. in.
(5.9 L) (5.9 L)
Compression Ratio................................................ 17.5:1 17:1
Main Bearings, No. o f .......................................... 7 7
Cylinder Sleeves .................................................. None None
Forward Speeds.................................................... 12 12
rUNE-UP
Firing Order .......................................................... .......................... 1-5-3-6-2-4 ---------------------
Valve Tkppet Gap, Cold
Intake ................................................................ 0.010 in. 0.010 in.
(0.254 mm) (0.254 mm)
Exhaust ........................................................... 0.020 in. 0.020 in.
(0.508 mm) (0.508 mm)
Ir\jection Pump
Make .................................................................. .......................... Robert Bosch ---------------------
Model .................................................................. ................................. VE ---------------------------
Timing ................................................................ ................................. TDC ---------------------------
Ii\jection Nozzles
Make .................................................................. .................. Robert Bosch 117 mm ---------------
Opening Pressure,
New ................................................................ 3550-3670 psi 3190-3310 psi
(24476-25303 kPa) (21994-22821 kPa)
Used ................................................................ 3200-3625 psi 3120-3260 psi
(22063-24994 kPa) (21511-22476 kPa)
Turbocharger
Make .................................................................. ............................. Holset ------------------------
Engine Governed Speeds (Rpm)
Low Idle ............................................................ ............................. 750-850 ------------------------
High Idle ............................................................ ............................. 2210-2290 ------------------------
Rated Load ........................................................ ................................. 2100 ---------------------------
Battery Terminal Grounded................................ ............................. Negative ------------------------
CAPACITIES
Cooling System...................................................... .......................... 22 U.S. qts. ---------------------
------------------------ (20.8 L) ------------------------
Crankcase (w/fliters) ............................................ .......................... 16 U.S. qts. ---------------------
------------------------ (15.1 L) ------------------------
Transmission & Hydraulic System...................... .......................... 100 U.S. qts. ---------------------
------------------------ (94.6 L) ------------------------
Oil TVpe.............................................................. .......................... Hy-Tran Plus ---------------------
MODELS 1896-2096 Paragraphs 1-3
CONDENSED SERVICE DATA (CONT.)
Models
2096 1896
CAPACITIES (Cont.)
Fuel Tknk . . .................................................................................... 65 U.S. gal. ---------------------
------------------------ (246 L) ------------------------
Front Drive Axle-
Differential (Axle) Housing.............................. ............................. 9 U.S. qts.-------------------------
------------------------ (8.5 L) ------------------------
Oil Type.............................................................. ............................. 85/140 EP------------------------
Planetary (Each Side).......................................... .......................... 1.5 U.S. qts. ---------------------
------------------------ (1.4 L) ------------------------
Oil Type.............................................................. ............................. 85/140 EP------------------------
FRONT AXLE (TWO WHEEL DRIVE)
FRONT WHEEL BEARINGS
All Models
1. Refer to Fig. 1 for typical wheel hub and bear
ing assembly.
The tapered iimer and outer roller bearings are not
interchangeable. Clean and inspect bearing cups and
cones and renew as necessary. Install inner seal (10)
with lip facing spindle flange. Install outer seal (9)
with lip facing away from bearing (8). Fill hub cavity
and pack bearings with No. 2 lithium grease. Coat sur
face of seal lips with grease.
When adjusting wheel bearings, tighten nut (2) un
til drag on hub is felt, then back nut off turn or
until next pin hole lines up. Bearings should have zero
end play. Install cotter pin.
SPINDLES
All Models
2. R&R SPINDLES. Tb remove spindle, lift and
support front of tractor and remove wheel. Discon
nect tie rod ball joint from steering arm (3Fig. 2).
Remove bolt (1) and washer (2) from arm (3). Note
index punch marks on arm and shaft indicating lo
cation of tapered splines for left or right steering arm,
then remove steering arm. Support spindle and re
move snap ring (4) and washer (5), then remove spin
dle (8) from axle extension (7).
Fig. 1Exploded view of wheel hub and bearing assembly
used on al l two-wheel drive tractors.
1. Cap
2. Nut
3. Washer
4. Bearing cone
5. Bearing cup
6. Hub
7. Bearing cup
8. Bearing cone
9. Seal (outer)
10. Seal (inner)
3. SPINDLE BUSHINGS. With spindles removed,
spindle bushings (6Fig. 2) can be removed using a
suitable drift punch. New bushings are presized and
should not require reaming if carefully installed.
Paragraphs 4-5 CASE/INTERNATIONAL
Press new bushings into axle ends until bushing
flange seats against surface of axle ends.
Assemble by reversing disassembly procedure mak
ing sure punch marks on shaft and steering arm align.
Tighten bolt (1) to 200-250 ft.-lbs. (271-339 N-m)
torque. Lubricate through grease fitting with No. 2
lithium grease. Tighten tie rod slotted nut to 100-125
ft.-lbs. (136-168 N-m) torque and install new cotter
pin.
4. TIE RODS AND TOE-IN. Disassembly of tie rod
assembly is obvious after examination of unit and ref
erence to Fig. 3. However, upon reassembly make
sure clamp bolts (5) are installed in same number hole
as axle extension.
Tighten tie rod slotted nuts to a torque of 100-125
ft.-lbs. (136-169 N-m). Install new cotter pins. Tight
en clamp bolt (5) nuts to a torque of 45-54 ft.-lbs. (61-
73 N-m).
Front wheel toe-in must be 1/8-1/2 inch (3.1-12.7
mm), lb adjust toe-in, remove clamp bolt (5) from left
Fig. 2Exploded view of steering spindle used on all two-
wheel drive tractors. Note assembly marks.
1. Cap screw
2. Washer
3. Steering arm
4. Snap ring
5. Washer
6. Bushings
7. Axle extension
8. Spindle
tie rod extension. Loosen jam nut (8), then turn ex
tension (9) in or out until desired toe-in is obtained.
Install clamp bolt (5) and tighten nut to a torque of
45-54 ft.-lbs. (61-73 N-m). Tighten jam nut (8) against
tie rod extension (9).
AXLE MAIN MEMBER
AND PIVOT PIN
All Models
5. Tb remove axle main member, first raise and
support tractor under engine side rails with suitable
jack stands. Disconnect tie rods from steering arms,
then refer to Fig. 3 and disconnect power steering
cylinder (10) from axle main member and tie rod lug.
Secure steering cylinder up and out of the way. Be
careful not to damage hydraulic lines to cylinder.
Refer to Fig. 4 and remove bolt (3), washer and
spacer. Remove front grease fitting and install a slide
hammer to pivot shaft (2). Support axle main mem
ber with a rolling floor jack, then pull pivot shaft out
front of front support (1). Catch thrust washers (4 and
5) as shaft is removed. Lower axle main member
enough to clear front support and roll forward from
tractor.
Fig. 3Exploded view of steering tie rod, cylinder, arms
and related parts used on two-wheel drive tractors.
1. Slotted nuts
2. Dust covers
3. Steering arms
4. Tie rod extension
R.H.
6. Clamp bolts
6. Tie rod tube
7. Tie rod end
8. Jam nut
9. Tie rod extension
L.H.
10. Steering cylinder
11. Axle main
member
12. Axle extension
13. Spacer
14. Locater bolt
Bushings (6) can now be removed using a suitable
drift punch. Drive new bushings into bore of axle
main member until flush to 1/16 inch (1.6 mm) below
outer surface.
When reassembling, coat pivot shaft and bushings
with antiseize compound. Install steel washer (4), ny
lon washer (5), then second steel washer (4) at front
and rear of axle main member. When axle main mem
ber and pivot shaft are installed, install and tighten
spacer, washer and bolt (3) to a torque of 93-112 ft.-
lbs. (126-152 N-m).
If axle extensions (12Fig. 3) have been removed,
reinstall and insert spacers (13Fig. 4) and locater
bolts (14). Install and tighten nuts (15) to a torque of
400-480 ft.-lbs. (542-651 N-m).
FRONT SUPPORT
All Models
6. Tb remove front support (1Fig. 4), first discon
nect headlight wiring, then remove grille, hood and
side panels. Drain coolant from radiator and discon
nect upper and lower radiator hoses. Disconnect air
intake tube, oil cooler lines and air conditioner lines
at quick couplers. Attach a hoist to the radiator, con
denser and oil cooler assembly support brackets, re
move two rear bolts and three front bolts, then lift
off the assembly. Remove front axle assembly as out-
Flg. 4Exploded view of front axle and support used on
two-wheel drive models.
1. Front support
2. Pivot sliaft
3. Bolt
4. Steel washers
5. Nylon washers
6. Bushings
11. Axle main
member
13. Spacer
14. Locater bolt
15. Nut
lined in paragraph 5. Attach a hoist to front support,
then unbolt and remove.
Reinstall by reversing removal procedure. Tighten
side rail to front support bolts to a torque of 380-450
ft.-lbs. (515-610 N-m). Tighten the five cap screws
securing the radiator, condenser and oil cooler sup
port bracket to front support to a torque of 35-42 ft.-
lbs. (48-57 N-m).
FRONT DRIVE AXLE
Models 1896 and 2096 tractors are available with
a ZF front drive axle.
DRIVE AXLE ASSEMBLY AND SUPPORT
Models So Equipped
7. REMOVE AND REINSTALL. To remove the
front drive axle assembly, place transmission in PARK
and securely block rear wheels. Unbolt and remove
drive shaft shield and the front drive shaft assem
bly. Discoimect steering cylinder lines and cap or plug
all openings. Loosen front wheel to hub nuts on both
front wheels. Install a side frame jack CAS-10500-1
or front split stand CAS-10749 on each side of trac
tor. Raise front of tractor until front wheels are off
the ground. Remove wheel nuts and using a hoist,
remove front wheels. Place a floor jack or special axle
carrier CAS-10500-4 under front axle. Remove cap
screw (5Fig. 5), washer (4) and spacer (3). Then,
remove pivot shaft (2) and thrust washers (6 and 9).
Lower axle (floor jack) or raise tractor (axle carrier)
and roll assembly forward from tractor. Inspect bush
ings (7) and renew as necessary. When installing new
bushings, apply a coat of Loctite Anti-Seize to bore
in axle housing. Freeze bushings in dry ice and care
fully install flush to 1/16 inch (1.6 mm) below the face
of axle housing.
Tb remove front support (1Fig. 5), disconnect
headlight wires, then remove grille, hood and side
panels. Drain cooling system, then disconnect upper
and lower radiator hoses. Disconnect air intake tube,
oil cooler lines and air conditioner lines at quick cou
plers. Attach a hoist to the radiator, condenser and
oil cooler assembly support brackets, remove two rear
bolts and three front bolts, then lift off the assem
bly. Attach a hoist to the front support, then unbolt
and remove.
Reinstall by reversing removal procedure. Tighten
side rail to front support bolts to a torque of 380-450
ft.-lbs. (515-610 N-m). Tighten the five cap screws
securing the radiator, condenser and oil cooler sup
port bracket to front support to a torque of 35-42 ft.-
lbs. (48-57 N-m).
Inspect thrust washers (6 and 9) for excessive wear
and renew as necessary. Reinstall axle assembly to
Paragraph 8 CASE/INTERNATIONAL
front support. Make sure nylon thrust washer (9) is
installed between steel thrust washers (6). Use as
many additional steel washers as possible at rear side
of axle housing (8) to shim axle housing forward. Se
cure pivot shaft (2) in place with spacer (3), washer
(4) and cap screw (5), tightened to a torque of 93-112
ft.-lbs. (126-152 N-m). Connect steering cylinder lines
and reinstall drive shaft. Tighten drive shaft bolts and
nuts to a torque of 45-54 ft.-lbs. (61-73 N-m). Install
drive shaft shield. Install front wheels and remove
jacks. Tighten front wheel to hub nuts to a torque
of 115-130 ft.-lbs. (156-176 N-m).
WHEEL HUB AND PLANETARY
Models So Equipped
8. R&R AND OVERHAUL. Tb remove the wheel
hub and planetary, support axle housing and remove
wheel and tire assembly. Rotate wheel hub until
drain plug (9Fig. 6) is at bottom, remove plug and
drain oil. Remove the two socket head screws (8),
then remove planetary carrier (10). Unbolt and re
Flg. 5Fmnt support and axle housing used on models
equipped with front drive axle.
1. Front support
2. Pivot shaft
3. Spacer
4. Washer
5. Cap screw
6. Thrust washers
(steel)
7. Bushings
8. Axle housing
9. Thrust washers
(nylon)
1. Slotted nut
2. Lockplate
3. Ring gear
4. O" ring
5. Bearing cup &
cone (outer)
6. Hub
7. Bearing cup &
cone (inner)
8. Socket head
screw
Fig. 6Exploded view of wheel hub and planetary unit
used on front drive axle.
9. Drain plug
10. Planetary carrier
11. Retaining rings
12. Planetary gear
13. Roller bearing
14. Snap ring
15. Thrust washer
16. Snap ring
17. Sun gear & shaft
18. Splined thrust washer
19. Thrust washer
move lockplate (2). Using a spanner wrench CAS-1762
or equivalent, remove slotted nut (1). Remove ring
gear (3), outer bearing cone (5), hub (6) and inner
bearing cone (7). If necessary, remove bearing cups
(5 and 7), oil seal (1Fig. 7) and dust seal (2) from
hub. Sun gear (17Fig. 6) is secured to axle shaft "U
joint (11Fig. 7) with a snap ring (10). If necessary
to remove sun gear, remove pivot housing (5) as out
lined in paragraph 9.
Tb remove planetary gears (12Fig. 6), remove snap
rings (14) and slide gear and bearing assemblies from
carrier (10). Remove tapered retaining ring (11) and
slide bearing (13) from gear (12). Repeat operation for
other two gears. Remove thrust washer (15) from cen
ter of carrier.
Clean and inspect all parts and renew any show
ing excessive wear or other damage. Remove snap
ring (16) and check condition of splined thrust washer
(18) and thrust washer (19). Renew as necessary and
reassemble on sun gear. Reinstall bearings (13) in
planetary gears (12) and install retaining ring (11) with
wide side of ring toward bearing. Install gear assem
blies and secure with snap rings (14).
MODELS 1896-2096 Paragraph 8 (Cont.)
Tb acyust end play of axle shaft and sun gear, make
sure thrust washer (15) is removed from carrier (10).
Tb determine dimension (AFig. 8) which is the dis
tance from thrust washer seat to mounting flange of
planetary carrier, install special tool CAS-1764 on
thrust washer seat. The length of this tool (dimen
sion B) is stamped in mm on tool. Place special tool
CAS-1765 across mounting flange of planetary carri
er. Using a depth gage through hole in tool CAS-1765,
measure distance (C) to end of tool CAS-1764. Meas
ure diameter of tool CAS-1765 (dimension D). Sub
tract dimension (D) from dimension (C) to obtain
dimension (E). Add dimension (E) to dimension (B)
to obtain dimension (A). Record this dimension. Tb
determine dimension (FFig. 9) which is the distance
from the end of the sun gear shaft to the face of the
mounting flange of the planetary hub, push sun gear
inward as far as possible. Assemble special tool legs
CAS-1763 to tool CAS-1765 and hold against mount
ing flange of planetary hub. The length of this spe
cial tool assembly (dimension G) is stamped in mm
on the legs. Using a depth gage through hole in tool
CAS-1765, measure distance (H) to end of sun gear.
Fig. 7Exploded view of pivot housing and components
used on front drive axle.
1. Oil seal
2. Dust seal
3. Wear ring
4. Pivot pin (lower)
5. Pivot housing
6. Pivot pin (upper)
7. Shim
8. Sleeve bearing
9. Oil seal
10. Snap ring
11. " U " joint assy.
12. Snap ring
13. Axle shaft
14. Oil seal
16. Sleeve bearing
16. "O ring
17. Seal cap
18. Bearing cone
19. Bearing cup
20. Cup plug
21. Axle housing
22. Drain plug
23. Fill & level plug
Fig. 9View of special tools used to determine dimension
(F) from flange of hub to end of sun gear shaft. Refer to
text for procedure.
Subtract dimension (H) from dimension (G) to obtain
dimension (F). Then, subtract dimension (F) from
dimension (AFig. 8) to obtain the total distance axle
and sun gear is free to travel. Correct end play of axle
shaft and sun gear is 0.012-0.024 inch (0.3-0.6 mm).
Fig. 8 View of special tools used to determine dimension
(A) from mounting flange of planetary carrier to seat of
thrust washer. Refer to text for procedure.
Paragraphs 9-10
Subtract correct end play from the predetermined
distance axle shaft and sun gear is free to travel to
determine correct thickness of thrust washer (15-
Fig. 6) to be installed. Thrust washers are available
in thicknesses of 0.059, 0.067, 0.079, 0.087, 0.098 and
0.118 inch (1.5, 1.7, 2.0, 2.2, 2.5 and 3.0 mm).
When reassembling, install new wear ring (3Fig.
7) and bearing cone (7Fig. 6) on pivot housing. If
removed, install bearing cups (5 and 7) in hub (6). In
stall new oil seal (1Fig. 7) and dust seal (2) in hub.
Lubricate seal and install hub and outer bearing cone
(5Fig. 6). Install ring gear (3) and slotted nut (1).
Using a spanner wrench CAS-1762, tighten slotted
nut until a rolling torque of 8.9-13.3 ft.-lbs. (12-18 N*m)
with new bearings or 6.7-8.9 ft.-lbs. (9-12 N-m) with
used bearings, is required to rotate hub. Use special
tool CAS-1768 to check rolling torque. When rolling
torque is correct, secure with lockplate (2) and cap
screws tightened to a torque of 70 ft.-lbs. (96 N-m).
Install new 0 ring (4) on hub (6). Use grease to
stick predetermined thrust washer (15) in place in
carrier (10), then install carrier on hub. Install the two
socket head cap screws (8) and tighten to a torque
of 70 ft.-lbs. (96 N-m). Rotate hub until the filler
(drain) hole is horizontal to center of hub. Fill hub
with GL5 85/140 EP gear oil to filler plug opening.
Capacity is 1.5 U.S. quarts (1.4 L). Install plug (9). In
stall wheel and tire assembly and tighten wheel hub
nuts to a torque of 115-130 ft.-lbs. (156-176 N-m). Low
er tractor to the ground.
PIVOT HOUSING AND AXLE SHAFT
Models So Equipped
9. REMOVE AND REINSTALL. Tb remove the
pivot housing (5Fig. 7), first remove the wheel hub
and planetary as outlined in paragraph 8. Remove
snap ring (16Fig. 6), splined thrust washer (18) and
thrust washer (19) from sun gear (17). Disconnect tie
rod end from arm on pivot housing. Unbolt upper and
lower pivot pins (6 and 4Fig. 7), then remove pivot
pins with 0 rings (16), seal caps (17) and bearing
cones (18). Keep shims (7) with upper pivot pin. Re
move pivot housing (5), then withdraw sun gear, U
joint and axle shaft assembly from axle housing.
Drive out cup plugs (20) and remove bearing cups
(19). Remove bearing cones (18), seal caps (17) and
0 rings (16) from pivot pins. Remove oil seals (9
and 14) and if necessary, remove sleeve bearings (8
and 15).
Loosen snap ring (10) in U joint and remove sun
gear. Loosen snap ring (12) in U joint and remove
axle shaft (13). Clean and inspect all parts and renew
any showing excessive wear or other damage. U
joint (11) is available only as an assembly. Reassem
ble sun gear and axle shaft to "U joint by reversing
disassembly procedure.
CASE/INTERNATIONAL
If removed, install sleeve bearings (8 and 15). In
stall new oil seals (9 and 14) with lips of seals toward
sleeve bearings. Install cup plugs (20) and bearing
cups (19) in axle housing. Lubricate lips of seals (9
and 14), then insert axle shaft into axle housing.
Make certain axle shaft splines engage splines in
differential side gears. Install new O rings (16), seal
caps (17) and bearing cones (18) on pivot pins and
lubricate bearing cones with lithium grease. Carefully
install pivot housing (5) over sun gear and axle hous
ing. Install lower pivot pin assembly with original
shim (7) and cap screws tightened finger tight. Tbrque
bottom cap screws first, then the upper cap screws
to 140 ft.-lbs. (190 N-m.). Check swing resistance with
a torque wrench which should be 16-21 ft.-lbs. (21-
28 N-m) with new bearings or 8-10.5 ft.-lbs. (10.5-14
N-m) for used bearings. Adjust swing resistance by
using alternate shim thickness. Shims are available
in thicknesses of 0.024,0.039, 0.055, 0.063, 0.071 and
0.079 inch (0.6, 1.0, 1.4, 1.6, 1.8 and 2.0 mm).
Install thrust washer (19Fig. 6), splined thrust
washer (18) and snap ring (16). Reinstall wheel hub
and planetary as outlined in paragraph 8. Connect
tie rod end to steering arm on pivot housing and
tighten nut to 100-125 ft.-lbs. (136-169 N-m) torque.
DIFFERENTIAL AND BEVEL GEARS
Models So Equipped
10. R&R AND OVERHAUL. Tb remove the front
differential assembly, place transmission in PARK and
securely block rear wheels. Unbolt and remove drive
shaft shield and front drive shaft. Raise front of trac
tor and support each end of axle housing with jack
stands. Unbolt and remove front wheels. Disconnect
steering cylinder lines and cap or plug all openings.
Disconnect tie rod ends from steering arms on pivot
housings. Remove drain plug (22Fig. 7) and drain
oil from axle housing. Attach a hoist to planetary hub.
Unbolt and remove upper and lower pivot pins (6 and
4) with bearing cones. Keep shim (7) with upper piv
ot pin. Remove planetary hub, pivot housing and axle
shaft from each end of axle housing. Place a floor
jack under differential assembly, remove differential
cap screws and install a guide stud at each side of
differential housing. Separate differential housing
from axle housing and using the floor jack, remove
assembly from tractor.
Tb disassemble, remove lock pins (16Fig. 10) from
acyusting nuts (9 and 15). Remove the adjusting nuts
and bearing cups (10 and 14). Using a suitable puller,
remove bearing cones (11 and 13). Remove cotter pins
(21), then pry off lockplates (26). Remove cap screws
(22 and 25) and separate differential case halves (28
and 40). Remove differential pinions (34), cross pins
(35) and thrust washers (33). Remove ring gear (27)
MODELS 1896-2096
and differential case half (28) assembly first, then re
move differential case half (40) assembly. Remove
side gear (36), thrust disc (37), friction discs (38) and
friction plates (39) from differential case half (40).
Remove side gear (32), thrust disc (31), friction discs
(29) and friction plates (30) from differential case half
(28). Ring gear (27) is secured to differential case half
(28) by four sets of double spring pins (23 and 24).
Use a press to remove case half from ring gear.
Fig. 10Exploded view of limited slip differential and
t>evel drive gears assembly used on front drive axle. Note
steering cylinder Is removed from differential housing.
1. Nut
2. Washer
3. Drive yoke
4. Seal cover
5. OUseal
6. Bearing cone
7. Bearing cup
8. Spacer
9. Ac^justing nut
10. Bearing cup
11. Bearing cone
12. Differential
housing
13. Bearing cone
14. Bearing cup
15. Adjusting nut
16. Lock pin
17. Shim
18. Bearing cup
19. Bearing cone
20. Bevel drive
pinion
21. Cotter pin
22. Cap screw
(drilled head)
23. Spring pin
24. Spring pin
25. Cap screw
26. Lockplate
27. Ring gear
28. Differential case
half
29. FYiction discs
(internal teeth)
30. Friction plates
(external tangs)
31. Thrust disc
32. Side gear
33. Thrust washer (4)
34. Differential
pinion (4)
35. Cross pins
36. Side gear
37. Thrust disc
38. Friction discs
(internal teeth)
39. Friction plates
(external tangs)
40. Differential case
half
Paragraph 10 (Cont.)
Remove nut (1), washer (2) and drive yoke (3) with
seal cover (4). Drive bevel pinion shaft (20) out of
bearing cone (6) and remove pinion with spacer (8)
and bearing cone (19). Remove oil seal (5) and bear
ing cone (6) from differential housing (12). Using a
press, remove bearing cone (19) and spacer (8) from
bevel pinion shaft. Drive bearing cups (7 and 18) from
differential housing, then remove shims (17).
ing excessive wear or other damage. Bevel drive pin
ion (20) and ring gear (27) are available only as a
matched set as are the differential case halves (28
and 40).
Tb install and adjust bevel drive pinion position,
proceed as follows: Install bearing cups (7 and 18)
without shims (17) in differential housing (12). Install
bearing cone (19) over rod end of special tool CAS-
1770 and install in differential housing. Install bear
ing cone (6) on other half of special tool and install
in housing. Tighten tool by hand until bearing cones
are seated in bearing cups (all end play removed). In
stall pilot discs CAS-1771 in carrier bearing bores in
differential housing. Insert special tool CAS-1765
through the pilot discs. Using a feeler gage, measure
the distance between end of tool CAS-1770 and tool
CAS-1765. Add this distance to the metric dimension
stamped on tool CAS-1770, then add Vi the diameter
of tool CAS-1765. Subtract the metric dimension on
end of bevel drive pinion from the previously deter
mined sum to obtain thickness of shim (17) to be in
stalled behind bearing cup (18). Shims are available
in thicknesses of 0.004, 0.008, 0.012 and 0.020 inch
(0.1, 0.2, 0.3 and 0.5 mm). Remove special tools and
bearing cones, then remove bearing cup (18). Install
the previously determined shim pack (17) and rein
stall bearing cup (18). Heat bearing cone (19) to 250
F (120 C) and install on bevel drive pinion (20) until
seated. Install bevel drive pinion and bearing cone
in differential housing and install new spacer (8).
Heat bearing cone (6) to 250 F (120 C) and install
on bevel drive pinion. Install new oil seal (5) with lip
toward bearing cone (6). If bearing cover (4) is dam
aged, press old cover off and a new cover on drive
yoke (3). Install drive yoke and washer (2) on bevel
drive pinion. Apply Loctite to threads of nut (1), then
install and tighten nut until a rolling torque of 1.5-
2.2 ft.-lbs. (2.0-3.0 N*m) is required to rotate bevel
drive pinion.
Tb reassemble the ring gear and differential, pro
ceed as follows: If spring pins (23 and 24) have been
removed or if new differential case is being installed,
refer to Fig. 11 and install spring pins as shown. In
stall large spring pins (24Fig. 10) until seated with
slot in pins aligned with bolt circle. Then, install small
spring pins (23) until flush with top of large pins with
slots 180 degrees from slots in large pins. Heat ring
gear (27) to 400-450 F (204-232 C) and insUll on
Paragraphs 11-12
differential case half. Double spring pins must enter
the four smaller holes in ring gear. Place differential
case half (28) on bench with open side upward. In
stall friction plates (30), friction discs (29), thrust disc
(31) and side gear (32) in the case half. Then, install
cross pins (35), differential pinions (34) and thrust
washers (33) in the case half. Hold three of the
differential pinions in place and using a dial indica
tor, check backlash between fourth pinion and side
gear Correct backlash is 0.008-0.012 inch (0.2-0.3
mm). Acljust backlash by selecting a thicker or thin
ner thrust disc (31). Thrust discs are available in
thicknesses of 0.110, 0.114 and 0.118 inch (2.8, 2.9 and
3.0 mm). Install thrust disc with abrasive side toward
friction plate. Repeat this procedure and adjust back
lash using opposite half of differential (36 through
40).
Install differential case half (40) assembly in
differential housing first, then install differential case
half (28) assembly. Install cross pins (35), pinions (34)
and thrust washers (33) and aligning part numbers
on case halves, assemble differential. Install drilled
head cap screws (22) on each side of spring pins and
install cap screws (25) in remaining holes. Ti^ten cap
screws to a torque of 110 ft.-lbs. (150 N-m). Install
lockplates (26) and use a 19 mm socket to drive plates
over cap screw heads. Install cotter pins (21) in drilled
head cap screws (22).
Heat bearing cones (11 and 13) to 250 F (120 C)
and install on differential case. Install bearing cups
(10 and 14) and adjusting nuts (9 and 15). While main
taining some backlash between ring gear and bevel
drive pinion, tighten adjusting nuts to remove all side
play of differential. Then, tighten one adjusting nut
two notches to obtain a preload of 2.2-2.9 ft.-lbs. (3.0-
4.0 N-m). Check the metric backlash dimension on
rim of ring gear which should be 0.20-0.28 mm. Loos
en one adjusting nut and tighten the other acûsting
Fig. 11Install double spring pins In differential case half
as shown. Refer to text.
CASE/INTERNATIONAL
nut one notch at a time to obtain correct backlash.
Secure acjjusting nuts with lock pins (16).
Clean mounting flanges of differential housing and
axle housing with Loctite Safety Solvent. Apply Loc
tite Gasket Eliminator to mounting flange of axle
housing and install a guide stud at each side of hous
ing opening. Slide differential assembly over guide
studs and into position. Tighten cap screws and nuts
to a torque of 185 ft.-lbs. (250 N-m).
Install new oil seals (14Fig. 7) in each end of axle
housing and carefuUy reinstall pivot housing and
planetary assemblies by reversing disassembly proce
dures. Connect steering lines and tie rod ends and
reinstall front drive shaft and shield. Install front
wheels and lower tractor to ground. Fill front axle
housing to level plug (23) opening with GL5 85/140
EP gear oil. Capacity is 9 U.S. quarts (8.5 L).
FRONT DRIVE SHAFT
Models So Equipped
11. R&R AND OVERHAUL. Tb remove the front
drive shaft, first remove drive shaft shield (15Fig.
12). Remove cap screws (7) and separate cross and
bearing assemblies (6) from front and rear yokes (14
and 1). Remove lube fittings (4). Remove cap screws
(5) and separate cross and bearing assemblies (6) from
drive shaft (8) and slip yoke (12). Unscrew cap (9) and
remove slip yoke from drive shaft.
When reassembling, renew felt washer (10) and seal
ring (11). Flanges on drive shaft and slip yoke (12)
must be parallel. Cross and bearing units are serv
iced only as assemblies. The balance of assembly is
the reverse of disassembly procedure. Tighten cap
screws (5 and 7) to a torque of 45-54 ft.-lbs. (61-73
N-m). Install drive shaft shield (15).
TRANSFER GEARBOX
Models So Equipped
12. R&R AND OVERHAUL. Tb remove the trans
fer gearbox, remove drain plug at bottom of gearbox
and drain oil. Unbolt and remove drive shaft shield
and front drive shaft. If so equipped, unbolt and re
move park hand brake caliper assembly. Remove nut
(3Fig. 12), washer (2) and yoke (1). Disconnect con
trol cable from shift lever (9Fig. 13). Place a floor
jack under gearbox, remove mounting cap screws and
lower gearbox from tractor.
Drive out groove pin (13) and remove shift lever (9).
Unbolt and remove bottom cover (34) and gasket (35).
Drive out roll pins (15) and remove shaft (14) and shift
fork (11) with pads (12). Remove oil seal (10). Unbolt
and remove rear cover (39) with 0 ring (38) and
shims (36 and 37). Unbolt and remove seal retainer
MODELS 1896-2096
(31) and oil seal (32). Install washer and nut on out
put shaft (26). Attach a slide hammer puller and pull
shaft out until bearing cup (30) is free of housing. Us
ing a suitable puller, remove bearing cone (29). Re
move output shaft assembly out through bottom
opening. Remove snap ring (25) and carefully slide
shift collar (23) from shaft.
NOTE: Hold a shop towel around shaft as collar
Is removed to catch detent balls (27) and springs
(28).
Press shaft from gear (22), thrust washer (20) and
bearing cone (19).
Remove nut (6) from idler shaft (2), then press shaft
out of front bearing (7), rear bearing (4) and idler gear
(3). Watch for ball (1) which may fall out of shaft. Re
move bearing cups (5, 8 and 18) from housing, if
necessary.
ing excessive wear or other damage. Bushing (21) is
available only with output gear (22).
When reassembling, install bearing cups (5, 8 and
18), if removed. Install bearing cone (4) in cup (5) and
place idler gear (3) with slot for ball (1) up, in posi
tion on rear bearing. Install idler shaft (2) and press
into gear and bearing until ball hole is just above gear
face. Place ball in position in idler shaft and press
shaft fully into idler gear. Heat bearing cone (7) to
250 F (120 C) and install on idler shaft. Install a
new nut (6) and tighten finger tight. Using a dial in
dicator, measure idler shaft end play. Correct end
play is 0.001-0.004 inch (0.025-0.102 mm). Adjust nut
to obtain correct end play, then lock nut in place by
bending edge of nut into slot in shaft. Use grease to
stick the three springs (28) and balls (27) in holes in
shaft (26). Tighten a worm drive hose clamp around
Fig. 12Exploded view of front drive shaft assembly used with front drive axle.
1. Rear yoke
2. Washer
3. Nut
4. Lube fitting
5. Cap screws
6. Cross & bearing
assy.
7. Cap screws
8. Drive shaft
9. Cap
10. Felt washer
11. Seal ring
12. Slip yoke
13. Lube fitting
14. Front drive yoke
16. Drive shaft shield
Paragraph 13
the shaft to hold detent balls in position. Place shift
collar (23) in position on shaft. Using a plastic ham
mer, drive shift collar into place over the detent balls
and remove hose clamp. Install snap ring (25) in front
of shift collar and place gear (22) and thrust washer
(20) on rear of shaft. Heat bearing cone (19) to 250
F (120 C) and install on shaft. Install shaft assem
bly through bottom cover hole. Heat front bearing
cone (29) to 250 F (120 C) and install on front of
shaft. Install front bearing cup (30). Install new oil
seal (32) in retainer (31) until seal is about 0.125 inch
(3.175 mm) below face of retainer. Apply Loctite 504
Fig. 13Exploded view of transfer gearbox for front drive
axle.
1. Ball
2. Shaft
3. Idler gear
4. Bearing cone
5. Bearing cup
6. Nut
7. Bearing cone
8. Bearing cup
9. Shift lever
10. Oil seal
11. Shift fork
12. Pad (2)
13. Groove pin
14. Shaft
15. Roll pins
16. Dowel ring
17. Housing
18. Bearing cup
19. Bearing cone
20. Thrust washer
21. Bushing
22. Output gear
23. Shift collar
24. Cup plug
25. Snap ring
26. Output shaft
27. Detent ball (3)
28. Detent spring (3)
29. Bearing cone
30. Bearing cup
31. Seal retainer
32. Oil seal
33. Drain plug
34. Bottom cover
35. Gasket
36. Shim. 0.002 in.
(0.05mm)
37. Shim, 0.005 in.
(0.13mm)
38. O" ring
39. Rear cover
CASE/INTERNATIONAL
Gasket Eliminator on front cover, lubricate lip of oil
seal and install retainer. Tighten cap screws to a
torque of 36 ft.-lbs. (49 N-m). Install rear cover (39),
0 ring (38) and original shims (36 and 37). Tight
en cap screws to a torque of 36 ft.-lbs. (49 N-m). Use
a dial indicator to measure output shaft end play.
Correct end play is 0.003-0.(K)5 inch (0.076-0.127 mm).
Add or remove shims (36 and 37) as required to ob
tain correct end play. A 0.002 inch (0.05 mm) thick
shim will change end play about 0.004 inch (0.102
mm).
If necessary to renew cup plug (24), apply a light
coat of Permatex No. 2 to plug and drive plug in un
til flush with outside of housing. Install new oil seal
(10) with hp to inside. Install shift pads (12) in shift
fork (11), then install fork assembly and shaft (14) in
housing. Secure with roll pins (15). Use new gasket
(35) and install bottom cover (34). Tighten cap screws
to a torque of 7 ft.-lbs. (10 N-m). Install shift lever (9)
and secure with groove pin (13).
Apply Loctite 504 Gasket Eliminator on mounting
surface of gearbox. Using a floor jack, raise gearbox
into position. Install mounting cap screws and tight
en to a torque of 106-127 ft.-lbs. (144-172 N-m). Con
nect control cable to shift lever. Install rear yoke (1
Fig. 12), washer (2) and nut (3). Tighten nut to a
torque of 280-340 ft.-lbs. (379-461 N-m). Reinstall
drive shaft and tighten cap screws to a torque of 35-
42 ft.-lbs. (48-57 N-m). Install drive shaft shield. Fill
transmission and transfer gearbox to correct level
with Hy-Tran Plus fluid.
13. R&R AND OVERHAUL INPUT SHAFT. Tb re
move the input shaft for the transfer gearbox, first
split tractor between torque tube and transmission
case as outlined in paragraph 155. Drive a small chisel
under edge of nut (5Fig. 14) to unstake the nut from
slots in shaft. Remove nut from input shaft. Remove
the three cap screws (8) and withdraw input shaft
assembly from torque tube.
Place housing in a press and press shaft from bear
ing cone (6) and housing (9). Remove seal rings (13),
then press shaft from bearing cone (12). If necessary,
use a suitable puller to remove bearing cups (7 and
11) from housing.
ing excessive wear or other damage.
When reassembling, press bearing cups into hous
ing until bottomed. Heat bearing cone (12) to 250
F (120 C) and install on input shaft. Carefully install
seal rings (13) in grooves on shaft, making certain that
the hooked ends are engaged. Place shaft and bear
ing in housing. Heat bearing cone (6) to 250 F (120
C) and install on input shaft. Install new nut (5) and
tighten nut until it is against bearing cone (6). Use
a dial indicator and check input shaft end play. Cor
rect end play is 0.001-0.004 inch (0.025-0.102 mm). Ad-
MODELS 1896-2096
just nut as required to obtain correct end play. Then,
stake edge of nut in slots in shaft.
Install input shaft assembly in the torque tube and
tighten cap screws to a torque of 149-179 ft.-lbs. (201-
243 N*m). Refer to paragraph 157 and reassemble
tractor
TIE RODS AND TOE-IN
Models So Equipped
14. Tbe-in should be 0-3/16 inch (0.0-4.763 mm) and
is adjusted by turning the threaded studs between
steering cylinder rod and tie rod ends. Both sides
must be adjusted equally.
Fig. 14Exploded view of transfer gearbox Input shaft
assembly which Is located In the torque tube.
1. Lubrication tube
2. Straight fitting
3. O" ring
4. Elbow fitting
5. Nut
6. Bearing cone
7. Bearing cup
8. Cap screw (3)
9. Housing
10. Dowel ring (3)
11. Bearing cup
12. Bearing cone
13. Seal rings
14. Input shaft
POWER STEERING
SYSTEM
All models are equipped with hydrostatic pow
er steering using a Ross steering unit and an 8
gpm (30.3 L/min.) gear type hydraulic pump as the
power source. One double acting steering cylin
der is used on the standard axle and the ZF front
drive axle.
Paragraphs 14-16
FLUID, FILTERS AND BLEEDING
All Models
15. The transmission and hydraulic system fluid is
used in the power steering system. A dipstick locat
ed at the left rear of the tractor rear housing indi
cates fluid level. Use Hy-Tran Plus fluid in all models.
Refer to CONDENSED SERVICE DATA tables for
reservoir capacity and to HYDRAULIC SYSTEM SEC
TION for additional hydraulic system information.
Steering hydraulic circuit is combined with brake
circuit and dual filter unit is located in right front
side of transmission housing. See Fig. 15 for explod
ed view of filter assembly. Tractors are provided with
a dash mounted warning light and filter elements
should be renewed when TRANS FILTER warning
light flashes. Filters should be 10 to 12 micron rat
ing. Bypass valve (4) should be tightened finger tight
plus V* turn. Filter cover bolts should be tightened
to a torque of 35-42 ft.-lbs. (48-57 N*m).
Tb bleed the steering hydraulic system, run engine
at half throttle and turn steering wheel from lock to
lock several times until steering action is firm. Brake
hydraulic system should be bled as outlined in para
graph 169.
TROUBLE-SHOOTING
All Models
16. Some of the troubles which may occur in the
operation of the power steering system and their pos
sible causes are as follows:
1. No power steering or steers slowly.
a. Binding mechanical linkage.
b. Excessive load on front wheels and/or air pres
sure low in front tires.
c. Steering cylinder piston seal faulty or cylinder
damaged.
d. Faulty power steering supply pump.
e. Faulty hand pump.
2. Will not steer manually.
a. Binding mechanical linkage.
b. Excessive load on front wheels and/or air pres
sure low in front tires.
c. Pumping element in hand pump faulty.
d. Faulty seal in steering cylinder or cylinder
damaged.
3. Hard steering through complete cycle.
a. Low pressure from supply pump.
b. Internal or external leakage.
c. Faulty steering cylinder.
d. Binding mechanical linkage.
e. Excessive load on front wheels and/or air
pressure low in front tires.
f. Cold hydrauhc fluid.
Paragraphs 17-19
4. Momentary hard or lumpy steering,
a. Air in power steering circuit.
SYSTEM OPERATING PRESSURE
AND RELIEF VALVE
All Models
17. The power steering operating pressure is con
trolled by a relief valve contained in the brake regu
lator valve housing. Brake pressure regulator valve
is located below cab floor on left side of torque tube.
Relief pressure should be 2000-2200 psi (13790-15168
kPa).
Tb test steering relief pressure using a CAS-10280
flowmeter or equivalent, install outlet hose from
flowmeter into transmission filler neck. Disconnect
the gear pump outlet hose and install a tee connec
tor. Reinstall pump outlet hose to tee, then install
flowmeter inlet hose to the tee. Close load valve on
flowmeter, start and operate engine at 2000 rpm un
til hydraulic fluid reaches a temperature of approxi
Flg. 15Exploded view of hydraulic system filter as
sembly.
1. Transmission
housing
2. Filter elements
3. Rod
4. Bypass valve
6. Gasket
6. Ck)ver
CASE/INTERNATIONAL
mately 110-120 F (43-49 C). Turn steering wheel
to either left or right lock position and hold. Observe
relief pressure on flowmeter pressure gage. If pres
sure is incorrect, loosen locknut and turn steering
pressure ac^justing screw as required, then tighten
locknut. Turn acûsting screw clockwise to increase
pressure. Steering pressure adjusting screw is the
lower adjusting screw on rear side of brake regula
tor valve. Upper screw is brake pressure adjusting
screw.
OPERATIONAL TESTS
All Models
The following tests are valid only when the power
steering system is void of any air. If necessary, bleed
system as outlined in paragraph 15 before perform
ing tests.
18. HAND PUMP. With power steering supply
pump inoperative (engine not running), attempt to
steer manuaUy in both directions.
NOTE: Manual steering with power steering sup
ply pump Inoperative, will require high steering ef
fort. If manual steering can be accomplished with
supply pump Inoperative, it can be assumed that the
manual steering pump will operate satisfactorily
with the supply pump operating.
19. STEERING WHEEL SLIP (CIRCUIT TEST).
Steering wheel slip is the term used to describe the
inability of the steering wheel to hold a given posi
tion without further steering movement. Wheel slip
is generally due to leakage either internal or exter
nal, or a faulty hand pump or steering cylinder. Some
steering wheel slip, with hydraulic fluid at operat
ing temperature, is normal and permissible. A maxi
mum of one revolution per minute is acceptable.
Tb check for steering wheel slip, install outlet hose
from a CAS-10280 flowmeter or equivalent into trans
mission filler neck. Install a tee connector between
gear pump outlet hose and gear pump. Install inlet
hose of flowmeter to the tee connector Start and op
erate engine until hydraulic fluid is warmed to a tem
perature of 110-120 F(43-49 C). Close load valve
on flowmeter completely. With front wheels straight
ahead and neutral movement on steering wheel, neu
tral steering pressure should not be more than 450
psi (3103 kPa). If pressure is more than 450 psi (3103
kPa), refer to paragraph 24 for pressure adjustment
of steering hand pump.
Shut off engine, then disconnect hose from right
end of steering cylinder Cap and plug hose and cyl
inder port. Close load valve on flowmeter, then start
and operate engine at 1000 rpm. Turn steering wheel
MODELS 1896-2096
counterclockwise and hold tension on wheel while
checking for external leakage at piston rod seal of
cylinder.
Remove center cap and telescopic control cap from
steering wheel and using a torque wrench, turn steer
ing wheel counterclockwise to full lock and hold
pressure. With engine operating at 1000 rpm, steer
ing wheel slip should not exceed 1rpm with 72 in.-
Ibs. (8.14 N*m) pressure on steering wheel. Repeat
test with steering wheel in clockwise direction. If
measured slippage is excessive, steering hand pump
has abnormal internal leakage. Refer to paragraph 22
for service of steering hand pump.
20. STEERE>IG CYLINDER TEST. Reconnect hy
draulic hose to steering cylinder. Start and operate
engine at 1000 rpm until hydraulic fluid temperature
is 110-120 F (43-49 C). Close load valve on flow
meter Using a torque wrench, turn steering wheel
to full lock in either direction and hold pressure. With
engine running at 1000 rpm, steering wheel slip
should not exceed 1 rpm more than that measured
in paragraph 19 in either direction with 72 in.-lbs.
(8.14 N-m) pressure on steering wheel. If measured
slippage is excessive, steering cylinder has more than
normal internal leakage. Refer to paragraph 25 or 26
for service of steering cylinders.
HYDRAULIC PUMP
All Models
21. The power source for the hydrostatic steering
system is an 8 gpm (30.3 L/min.) gear type pump. The
pump is attached to a larger piston type pump which
powers the main hydraulic system. Refer to para
graph 192 for testing, paragraph 201 for removal and
installation and to paragraph 207 for pump overhaul.
HAND PUMP
All Models
22. REMOVE AND REINSTALL. To remove the
steering hand pump, first remove the E rings and
pin from the universal joint that connects the cou
pling to the steering pump. The coupling is located
under the instrument panel. Disconnect the four hy
draulic lines to the steering pump. Cap or plug all
hydraulic openings to prevent contamination of the
hydraulic system. Remove the three bolts securing
steering pump to engine firewall, then remove pump.
Install steering pump by reversing removal proce
dure. Bleed system as outlined in paragraph 15.
Paragraphs 20-23
23. OVERHAUL. Tb disassemble the removed
hand pump refer to Fig. 16 and proceed as follows:
Remove dirt seal, mounting plate and hydraulic fit
tings. Remove and discard outer shaft seal (39), then
remove snap ring (38). Unbolt and remove cover (34),
then remove seal ring (33), seal spacer (37) and in
ner shaft seal (36) from cover Remove thrust wash
er (32), thrust needle bearing (31) and carefully with
draw input shaft assembly (items 18 through 30).
Remove drive link (14) from valve spool (13), then re
move seal ring (15) and washer (12) from valve sleeve
(11) and withdraw valve spool (13) from pump body.
Remove cap (1), remove locknut (2), then push ad
justing screw (5) through pump plug and remove. Re
move pump plug (3) and discard 0 ring (4). Remove
plug (7), discard 0 ring (8) and remove ball (9). Ex-
Flg. 16Exploded view of Ross power steering hand
pump.
1. Cap
2. Locknut
3. Pump plug
4. O" ring
5. Adjusting screw
6. Torsion blades
7. Plug & pin
8. O" ring
9. Ball
10. Pump body
11. Sleeve
12. Washer
13. Spool
14. Drive link
16. Seal assy.
18. Seal assy.
19. Commutator
20. Cap screw
21. Manifold
22. Pin
23. Pin
24. Drive link
25. Spacer
26. Stator
27. Rotor
28. Spring
29. Vane
30. Input shaft
31. Thrust bearing
32. Thrust washer
33. "O ring
34. Cover
35. Cap screw
36. Seal
37. Seal spacer
38. Snap ring
39. Shaft seal
amine sleeve (11) in pump body for excessive wear,
nicks or burrs. Do not remove sleeve from body. If
renewal is necessary, complete body sleeve and spool
assembly must be renewed.
Tb disassemble the rotor assembly (items 18
through 30) first withdraw commutator (19) from link
(items 22 through 24). Remove and discard seal (18).
Unbolt manifold (21), stand rotor assembly on shaft
end, and lift off manifold. Check both sides of mani
fold for excessive wear, scratches or burrs. If renew
al is necessary, manifold (21) and commutator (19)
must be ordered as an assembly. Withdraw drive link
(items 22 through 24) and using a magnet, remove
spacer (25). Remove stator (26) from around rotor as
sembly to prevent rotor vanes (29) and springs (28)
from falling out. Index vanes to rotor before removal
to aid in reassembly.
Inspect rotor and stator for excessive wear, scratch
es or burrs. Rotor and stator must be ordered as a
set if renewal is necessary.
Before reassembling, wash all parts in clean solvent
and air dry. All parts, unless otherwise indicated, are
installed dry. Install two V4inch NF studs into the in
put shaft (30) for aid in assembling. Place stator (26)
onto the input shaft. Place rotor (27) into stator, then
install vanes (29) into rotor
NOTE: If the same vanes are reused, be certain
vanes are Instalied exactly as removed. Thie wear
pattern on the edge of the vanes must ali be rotat
ing t he same direction, if vanes are not correctl y in-
stailed, wear pattern on the vane can be 180 degrees
out of ali gnment.
Check free height of vane springs (28). If free
height is less than 0.08-0.1 inch (2.032-2.540 mm) as
shown in Fig. 17, renew vane spring. Install vane
springs with arched back toward vane.
Check rotor and stator clearance as follows: Posi
tion lobe of rotor in valley of stator shown in Fig. 18.
Center opposite lobe on crown of stator, then using
a feeler gage, measure clearance between rotor tip
and stator crown. If clearance exceeds 0.007 inch
(0.178 mm), rotor and stator assembly must be re
newed. Install spacer (25Fig. 16), then install drive
link with flat sides of pin (22 or 23) aligned with slot
in rotor Install manifold (21) flat side toward rotor-
stator assembly. Place two worm type hose clamps
on input shaft assembly. One clamp spanning the in
put shaft and stator; the other clamp spanning the
stator and manifold as shown in Fig. 19. This ensures
Fig. 17Correct vane spring height Is 0.080-0.100 Inch
(2.032-2.540 mm). Renew springs not meeting required
height.
CASE/INTERNATIONAL
that the manifold and stator have a common center
before cap screws are installed and tightened. Re
move the two V* inch aligning studs, then install and
tighten the seven manifold cap screws to 10-14 ft.-
lbs. (14-19 N-m) torque. Install seal assembly (18Fig.
16), Tfeflon side out, into open end of commutator
(19). Align flat surfaces of drive link with slot in com
mutator and install commutator into manifold, seal
toward drive link.
Install pump plug (3) with new 0 ring (4) into
pump body and tighten to 40-50 ft.-lbs. (54-68 N-m)
torque. Install acyusting screw (5) with new 0 ring
through pump plug (3). Refer to Fig. 20 and install
two torsion blades (6Fig. 16) into valve spool (13).
NOTE: identif ication marl<s on each blade must
be toward outside when instali ed. Marlts may be at
opposite ends or both on one end as shown in Fig.
20. install blades parallel with slot in valve spool and
align top of blades flush with bottom surface of slot.
0.007" Maximum Clearance
Fig. 18With rotor positioned In stator as shown,
clearance must not exceed 0.007 Inch (0.178 mm). Refer
to text.
Fig. 19 View showing positioning of worm gear clamps
to aid In reassembly of Input shaft assembly.
MODELS 1896-2096
Hold adjusting screw in position and install spool
assembly, flat end first, into pump body aligning the
torsion blades in spool with slot in adyusting screw.
Place drive link (14Fig. 16) flat side down into slot
in valve spool. Insert new seal (15) into valve sleeve,
Tfeflon side outward. Carefully install input shaft as
sembly into pump body aligning drive link (14) with
slot in commutator. When correctly installed, input
shaft assembly will be approximately 1/8 (3.175 mm)
below surface of pump body. Place thrust bearing (31)
over shaft, then install original thrust washer, if un
damaged, or new washer of equal thickness. Wash
ers are available in thicknesses from 0.035 to 0.083
inch (0.89 to 2.11 mm) in 0.006 inch (0.15 mm) incre
ments. Install pump cover (34) with new seal ring (33)
and tighten cap .screws to 14-19 ft.-lbs. (19-26 N-m)
torque.
NOTE: Match outside shape of cover to pump
body shape.
Using the CAS-1426 Seal Tbol Kit or equivalent, in
stall input shaft seal as follows: Clean input shaft and
seal bore carefully. Place protective sleeve over in
put shaft; put compressor ring over input shaft and
into upper seal bore. Lubricate seal (36) with petrole
um jelly, place seal into compressor ring, lip side in
ward, and drive seal into pump body with seal driv
er. Driver will set correct seal depth.
Remove seal tools, install spacer (37), snap ring (38)
flat side outward and protective seal (39) into pump
body. Use seal driver to seat seal.
Install locknut (2) on adjusting screw (5) but do not
tighten. Place check ball (9) into pump body. Do not
allow it to fall out port in pump body. Install plug (7)
Torsion Blades
Holes
Aligh Blades With
Bottom Surface of Slot
Holes
Fig. 20Illustration showing correct Installation of torsion
blades In valve spool. Refer to text.
Paragraphs 24-25
with new 0 ring (8) with larger diameter toward
plug, into pump body and tighten to 10-14 ft.-lbs. (14-
19 N-m) torque. Install hydraulic fittings with new
0 rings into pump.
With hydraulic ports upward, pour hydraulic fluid
into intake port and turn pump shaft until fluid ap
pears at outlet port, then plug all ports. Install mount
ing plate so that the two grommets are at the top and
the hydraulic fittings on pump will face left side of
tractor. Install dirt seal on mounting plate.
24. Tb set centering pressure of hand pump, install
a 3000 psi (2100 kPa) gage on each hydraulic steer
ing cylinder line. Start and run tractor at 750 rpm un
til fluid is at operating temperature. Turn pump ad
justing screw (5Fig. 16) until pressure on both gages
is the same, then tighten locknut (2) to 20-25 ft.-lbs.
(27-34 N-m) torque. Bleed power steering system as
outlined in paragraph 15.
STEERING CYLINDER
All Two Wheel Drive Models
25. R&R AND OVERHAUL. Tb remove steering
cylinder, remove cotter pins on cylinder ball joint
nuts. Disconnect hydraulic lines from cylinder and
cap and plug hydraulic openings. Remove ball joint
nuts, then remove cylinder from axle lug and tie rod.
With cylinder removed, move rod back and forth
several times to clear fluid from cylinder. Refer to Fig.
21 and proceed as follows: Loosen jam nut (2) and
unscrew ball joint (3) from cylinder extension tube
(1). Using a spanner wrench, remove extension tube
(1) from cylinder ported tube (10). Loosen jam nut (14)
and unscrew ball joint (13) from rod (11). Remove
gland assembly (items 5 through 9), then withdraw
rod and piston assembly. Remove snap ring (15) and
withdraw gland assembly (items 16 through 20). Re
move retainer ring (21), then remove and discard
wear ring (22), 0 ring (23) and seal ring (24). All
seals, 0 " rings and back-up rings are available for
inspection and renewal as necessary. Check ported
cylinder tube (10) for scoring, grooves or out-of-
roundness. Light scoring can be polished out by us
ing a fine emery cloth and oil, using a rotary motion
while polishing. Heavy scoring, grooving or out-of-
roundness will require renewal of cylinder tube.
Check rod and piston (11) for scoring, grooving and
straightness and renew as necessary.
Renew all O" rings, seals and back-up rings (avail
able in a kit) during reassembly.
Reassemble steering cylinder as follows: Install seal
ring (24) in rear outside groove of piston. Lubricate
0 ring (23) with petroleum jelly and install next
to seal ring (24). Install wear ring (22) in groove in
piston. Place retainer ring (21) in inside of groove of
Paragraph 26
ported cylinder tube (opposite of threaded end). In
stall rod and piston assembly in ported cylinder tube
Fig. 21Exploded view of steering cylinder used on two
wheel drive models.
1. Extension tube
2. Jam nut
3. Ball joint
4. Dust cover
5. Wiper
6. Seal
7. Gland
8. Back-up ring
9. O" ring
10. Cylinder tube
11. Rod & piston
12. Dust cover
13. Ball joint
14. Jam nut
15. Snap ring
16. Back-up ring
17. O" ring
18. Wiper
19. Seal
20. Gland
21. Retainer ring
22. Wear ring
23. O" ring
24. Seal ring
CASE/INTERNATIONAL
(10) with threaded end of rod at end of cylinder with
retainer ring. Install rod seals (6 and 19) into small
end of glands (7 and 20). Install wiper seals (5 and
18) into large end of glands (7 and 20). Using petrole
um jelly, lubricate and install back-up rings (8 and
16) with 0 rings (9 and 17) onto outside groove of
glands (7 and 20) with back-up rings toward large end
of glands. Lubricate insides of glands and slide onto
piston rod, small end of gland inward, at each end
of ported cylinder tube. Install snap ring (15) into
groove in cylinder tube. Apply Loctite 242 or equiva
lent to threads on cylinder extension tube (1) and
tighten extension tube into ported cylinder tube to
a torque of 90-100 ft.-lbs. (122-136 N-m). Screw ball
joints into rod and extension tube until center of ball
joint is correct distance from cylinder at each end as
shown in Fig. 22. Tighten jam nuts (2 and 14Fig.
21) to a torque of 80-100 ft.-lbs. (109-136 N-m).
Install steering cylinder by reversing removal proce
dure. Tighten ball joint slotted nuts to a torque of 180-
200 ft.-lbs. (244-271 N-m). Install hydraulic hoses and
bleed power steering system as outlined in paragraph
15.
All Models Wi th Front Drive Axle
26. OVERHAUL. The steering cylinder tube (14-
Fig. 23) is housed in the front differential housing
(12). Tb disassemble the cylinder, first disconnect tie
rod ends (2) from steering arms and disconnect steer
ing lines at cylinder. Plug or cap line openings. Un
bolt and remove steering stops (5) and spacer plates
(6). Apply heat as necessary to loosen Loctite, then
unscrew tie rod studs (4) from cylinder rod (7). Un
bolt and remove rod guides (11 and 30) and any shims
(29) which are present. Remove O rings ^3 and
15) from cylinder tube (14). Withdraw cylinder tube
and rod assembly from differential housing (12). Slide
piston and rod assembly from cylinder tube. Remove
retaining ring (16), collar ring (18) and split ring (17).
Move piston (21) on rod and remove split ring (24),
spacer (19) and 0 " ring (20), then slide piston off
the rod. Remove Tfeflon rings (26 and 28) and seal ring
Fig. 22Cross-sectional view of two wheel drive steering cylinder showing correct Installation depth of ball joints.
MODELS 1896-2096
(27) from outside of piston and retaining ring (25),
collar ring (23) and spacer (22) from end of piston.
Remove scraper rings (9 and 32) and seal rings (10
and 31) from rod guides (11 and 30).
Clean and inspect all parts. Check cylinder tube,
piston, rod and rod guides for cracks, scoring or oth
er damage. Use all new 0 rings, seals and seal rings
and lubricate with Hy-Tran Plus fluid during reas
sembly.
Reassemble cylinder by reversing disassembly
procedure and acUust steering cylinder tube end play
as follows: Install right rod guide (11) and tighten cap
Fig. 23Exploded view of steering cylinder used on
models equipped with ZF front drive axle. Cylinder tube
(14) Is located In front differential housing (12).
1. Nut
2. Tie rod end
3. Clamp
4. Tie rod stud
5. Stop plate
6. Spacer plate
7. Cylinder rod
8. Cap screw
9. Scraper ring
10. Seal
11. Rod guide
12. Differential housing
13. " O " ring
14. Cylinder tube
15. O ring
16. Retaining ring
17. Split ring
18. Collar ring
19. Spacer
20. O" ring
21. Piston
22. Spacer
23. Collar ring
24. Split ring
25. Retaining ring
26. Teflon ring
27. Seal ring
28. Teflon ring
29. Shim
30. Rod guide
31. Seal
32. Scraper ring
33. Cap screw
Paragraphs 27-28
screws (8) to a torque of 140 ft.-lbs. (190 N*m). Push
cylinder tube (14) inward until seated against rod
guide (11). Using a depth gage, measure distance cyl
inder tube protrudes out left side of differential hous
ing. Then, measure cylinder depth bore in rod guide
(30). The difference between the two measurements
is the correct thickness of shim (29) to be installed
to obtain zero end play of cylinder tube. Shims are
available in thicknesses from 0.039 to 0.071 inch (1.0
to 1.8 mm) in 0.002 inch (0.05 mm) increments. In
stall rod guide (30) with correct shim (29) and tight
en cap screws (33) to a torque of 140 ft.-lbs. (190 N-m).
Apply Loctite 242 to threads of tie rod studs (4) and
tighten in cylinder rod to a torque of 260 ft.-lbs. (350
N*m). Install steering stops and spacer plates (5 and
6) and tighten bolts to 19-23 ft.-lbs. (26-31 N-m)
torque. Connect steering lines and tie rod ends. Tight
en nut (1) to a torque of 148 ft.-lbs. (200 N-m) and
install cotter pins.
Bleed power steering as outlined in paragraph 15
and acyust toe-in, if necessary, as outlined in para
graph 14.
OIL COOLER
All Models
27. An oil cooler is incorporated into the power
steering system. Service of oil cooler involves only
removal and installation or renewal of faulty units.
Removal of oil cooler is obvious after removal of radi
ator grille and hood and examination of the unit.
However, outlet and inlet hoses must be identified
as they are removed from oil cooler pipes so oil cir
cuits will be kept in the proper sequence.
STEERING COLUMN
All Models
28. Figure 24 shows steering column and adjusta
ble parts. Tb remove steering column after manual
pump is removed, proceed as follows: On telescopic
column remove plug (20). Holding lock knob (22) re
move nut (21) then remove lock knob. Remove nut
(23) and using a suitable puller, remove steering
wheel. Remove shroud from steering column. Discon
nect battery and carefully remove all electrical
switches and wiring from steering column panel. Dis
connect tilt return spring (6), unbolt column pivot
bearings (3 and 4) and remove column (2) by push
ing on top of telescoping lock shaft (27). Remove roll
pin securing inner shaft (33) to link (34). Remove in
ternal snap ring and washer (29 and 30) from inside
of outer shaft (25). Separate inner and outer shafts.
Remove friction locks (31), lock keys (28) and stop pin
(32) from inner shaft. Remove locknut (26) and lock
Paragraph 29
shaft (27) from outer shaft. Press bushings (1 and 5)
from column if necessary. Bushings are presized. Re
mainder of disassembly is obvious after examination.
Removal procedure for stationary shaft (items 41
through 46) is similar to removal of telescoping shaft.
When reassembling telescoping shaft, lock keys (28)
must align with slots in locknut (26). Tighten steer
ing wheel nut (23 or 43) to 30-35 ft.-lbs. (41-48 N-m)
torque. Tighten lock knob nut (21) on telescoping
column to 20-25 ft.-lbs. (27-34 N-m) torque.
CASE/INTERNATIONAL
1. Bearing
2. Column
3. Pivot bearing
4. Pivot bearing
5. Bearing
6. Spring
7. Tilt quadrant
8. Brace
9. Support
10. Spacer
11. Brace
12. Latch
13. Spring
14. Pins
15. Rod
17. Pedal
18. Plate
19. Hand pump
20. Plug
21. Nut
22. Knob
23. Nut
24. Steering wheel
25. Shaft cover
26. Nut
27. Shaft
28. Key
29. Washer
30. Snap ring
31. Lock
32. Pin
33. Shaft
34. Coupling
35. U" joint
36. Coupling
37. U" joint
38. Coupling
39. Pin
40. E ring
41. Plug
42. Ring
43. Nut
44. Steering wheel
45. Shaft
46. Bu-shing
Fig. 24Exploded view of typical tilt and telescopic steering shaft and column assembly.
ENGINE AND COMPONENTS
Models 1896 and 2096 are equipped with diesel
engines having a bore of 4.016 inches (102 mm)
and stroke of 4.724 inches (120 mm) and a dis
placement of 359 cubic Inches (5.9 L). Engines are
of a six cylinder design.
Model 1896 is equipped with a turbocharger
while Model 2096 is equipped with a turbocharg
er and an after cooler.
R&R ENGINE ASSEMBLY
All Models
29. Tb remove engine assembly, first split tractor
between engine and torque tube as follows: Place
gear shift lever in PARK position and securely block
rear wheels. Disconnect and remove battery cables
MODELS 1896-2096
from starting motor, then remove batteries and bat
tery box. Remove pin at front of drawbar and pull
drawbar rearward. Remove plugs and drain transmis
sion housing, transfer gearbox if so equipped and
clutch housing. If so equipped, unbolt and remove
front drive shaft. Disconnect self-sealing air condi
tioning couplers. Disconnect throttle cable from
diesel pump. Close the shut-off valve on fuel lift
pump, disconnect and plug supply line. Disconnect
fuel return tube. Close shut-off valves at cylinder
head and water inlet housing and disconnect heater
hoses. Identify and disconnect the four tubes from
power steering hand pump. Disconnect engine wir
ing harness from lower cab harness. Remove pyrom
eter from turbocharger exhaust elbow. Disconnect
neutral start switch wire. Install rear split stand un
der transmission housing and install front split stands
to side rails. Unbolt flywheel housing from clutch
housing and separate tractor.
Drain cooling system, then unbolt and remove front
end weights and weight frame. Discoimect upper and
lower radiator hoses. Disconnect engine wiring har
ness from forward component harness. Remove com
pressor belt from compressor. Unbolt and remove fan,
spacer, compressor drive pulley and compressor drive
belt. Disconnect oil cooler lines below starter and re
move cooler lines. Disconnect wire from air cleaner
restriction switch. Remove turbocharger intake el
bow and the aspirator tube, then unbolt and remove
air cleaner assembly. Remove inner seal clamp, then
unbolt and remove exhaust elbow and extension as
sembly. Remove turbocharger exhaust elbow and
muffler assembly. Unbolt and remove air cleaner and
muffler support, then reinstall rear lifting bracket.
Remove ground speed attachment, if so equipped,
from flywheel housing.
Place a jack stand under front support to prevent
front assembly from tilting forward. Attach a hoist
to front and rear lifting brackets. Unbolt front engine
mounts and side rails from flywheel housing. Lift en
gine from frame.
Reinstall engine by reversing removal procedure.
Tighten engine front mounting bolts to a torque of
93-112 ft.-lbs. (126-152 N-m). Tighten side frame rail
to flywheel housing bolts to a torque of 450-540 ft.-
lbs. (610-732 N-m). When installing exhaust elbow, use
Notches
Fig. 25 View showing cylinder head gasket Identification
notches. Refer to text.
Paragraph 30
a new inner seal and tighten clamp bolts to 50-75 ft.-
lbs. (68-102 N-m) torque. Tighten front weight frame
bolts to 450-540 ft.-lbs. (610-732 N-m) torque.
Clean mounting flanges of flywheel housing and
clutch housing. Apply Loctite 504 Gasket Eliminator
to flange of clutch housing and roll tractor together.
Install connecting bolts and tighten to a torque of
149-179 ft.-lbs. (202-243 N-m). Remove split stands.
The balance of assembly is the reverse of disassem
bly procedure.
CYLINDER HEAD
All Models
cylinder head, disconnect battery cables and drain
cooling system. Disconnect upper radiator hose. Re
move air cleaner, exhaust pipe and muffler. Remove
compressor belt, if so equipped, then lift belt tension-
er and remove fan belt. Unbolt and remove fan,
spacer, compressor drive pulley and fan pulley. Un
bolt and remove fan bracket, belt tensioner and belt
tensioner bracket. Remove alternator and mounting
bracket, then remove thermostat housing with ther
mostat and front lifting bracket. Disconnect oil sup
ply and drain tubes from turbocharger, then unbolt
and remove turbocharger. Remove exhaust manifold
bolts and lift off manifold. Remove ii\jector lines and
fuel leak-off line. Cap or plug all openings. Remove
fuel iryectors from cylinder head. Close shut-off valve
on fuel lift pump, remove fuel inlet and outlet lines
for fuel filters and cover all openings. Remove fuel
filters, then remove retaining nut and lift off filter
housing. Unbolt and remove intake manifold cover
on Model 1896 or after cooler on Model 2096. Then,
on all models, remove valve covers. Remove rocker
arm bolts, then remove rocker arm assemblies and
push rods. Unbolt and lift off cylinder head.
Clean engine block and cyhnder head mating sur
faces, removing carbon or other deposits. Check cyl
inder head for cracks or other signs of damage in the
area of fire ring contact. Using a straightedge and
feeler gage, check cylinder head at each side and be
tween cylinders for warpage. If warpage is more than
0.003 inch (0.0762 mm), cylinder head must be
machined or renewed.
NOTE: After machining, if cyli nder head hei ght is
less than 3.693 Inches (93.80 mm), renew cyli nder
head.
Also, check cylinder block surface for flatness. A
maximum of 0.010 (0.254 mm) may be machined from
cylinder block.
When reassembling, select the correct head gasket
to be installed. Various head gaskets are identified
by notches in edge of gasket as shown in Fig. 25. A
Paragraph 31
gasket with no notches is a standard gasket. A gas
ket with one notch is to be used with 0.040 inch (1.00
mm) oversize bore. A gasket with two notches is to
be used with 0.040 inch (1.00 mm) oversize bore and
0.010 inch (0.254 mm) machined from cylinder head
or from cylinder block. A gasket with three notches
is to be used with 0.040 inch (1.00 mm) oversize bore
and 0.010 inch (0.254 mm) machined from the cylin
der head and 0.010 inch (0.254 mm) from the cylin
der block.
Install head gasket and cylinder head, then lubri
cate bolt threads and install head bolts except for
rocker arm head bolts. Install push rods and rocker
arm assemblies. Lubricate threads and install rocker
arm head bolts and rocker arm bracket bolts. Tight
en head bolts following the sequence shown in Fig.
26. Tighten head bolts in three steps as follows:
Tbrque to 30 ft.-lbs. (41 Nm) in step one, 60 ft.-lbs.
(81 Nm) in step two and 93 ft.-lbs. (126 N-m) in step
three. Tighten rocker arm bracket bolts to a torque
of 18 ft.-lbs. (24 N-m).
Using a new gasket, install intake manifold cover
on Model 1896 or after cooler on Model 2096. Apply
liguid Tfeflon on the retaining cap screws and tighten
to a torque of 18 ft.-lbs. (24 N-m) following sequence
shown in Fig. 27. Refer to paragraph 66 for procedure
on installation of fuel irgectors and to paragraph 73
for installation of turbocharger. Acyust valve tappet
gap as outlined in paragraph 32.
Complete the assembly by reversing the disassem
bly procedure. Other tightening torques are as
follows:
Filter housing nut ............................... 24 ft.-lbs.
(32 N-m)
Thermostat housing bolts .................... 18 ft.-lbs.
(24 N-m)
Exhaust manifold bolts........................ 32 ft.-lbs.
(43 N-m)
Belt tensioner bracket bolts .................18 ft.-lbs.
(24 N-m)
Belt tensioner bolt ..............................32 ft.-lbs.
(43 N-m)
Fan pulley bracket bolts ...................... 18 ft.-lbs.
(24 N-m)
F^n retaining bolts ..............................32 ft.-lbs.
(43 N-m)
Fig. 26 Tighten cylinder head bolts In three steps, using
sequence shown.
CASE/INTERNATIONAL
Valve cover bolts ................................. 18 ft.-lbs.
(24 N-m)
VALVES AND SEATS
All Models
31. Intake and exhaust valves seat directly in the
cylinder head. However, service seat inserts are avail
able for both intake and exhaust valves. Stem seals
are used on all valves. Check valves against the fol
lowing specifications:
INTAKE
Face angle ................................................... 29
Seat angle..................................................... 30
Stem diameter ............................. 0.313-0.314 in.
(7.960-7.980 mm)
Stem to guide
clearance................................. 0.0015-0.003 in.
(0.039-0.079 mm)
Seat width ................................... 0.052-0.076 in.
(1.32-1.92 mm)
Valve tappet gap
(cold) ..................................................0.010 in.
(0.254 mm)
Valve recession from face
of cylinder head (max.)...................... 0.060 in.)
(1.52 mm)
EXHAUST
Pace angle ................................................... 44
Seat angle..................................................... 45
Stem diameter ............................. 0.313-0.314 in.
(7.960-7.980 mm)
Stem to guide
clearance................................. 0.0015-0.003 in.
(0.039-0.079 mm)
Seat width ................................... 0.058-0.081 in.
(1.47-2.09 mm)
BOLT TORQUE SEQUENCE
Fig. 27Bolt torque sequence for Intake manifold cover
on Model 1896 or after cooler on Model 2096.
Fig. 28Bolt torque sequence for exhaust manifold on
all models.
MODELS 1896-2096
Valve tappet gap
(cold) .................................................. 0.020 in.
(0.508 mm)
Valve recession from face
of cylinder head (max.) .................... 0.060 in.
(1.52 mm)
32. VALVE (TAPPET) GAP ADJUSTMENT. The
two position method of tappet gap acUustment is
recommended. DO NOT attempt to adjust valves with
engine operating. Using a flywheel rotating tool CAS-
1690 through opening in flywheel housing, turn fly
wheel in normal direction of rotation while pushing
inward on the lock pin. The timing lock pin is locat
ed in timing gear housing below the fuel iryection
pump. When the lock pin moves forward into the
camshaft gear, engine will be locked with No. 1pis
ton at TDC of compression stroke. At this time, ad
just the six valves indicated in Fig. 29. Disengage the
lock pin and rotate flywheel one complete revolution
and in this position No. 6 piston will be at TDC of
compression stroke. Adjust the remaining six valves
indicated in Fig. 30. Refer to paragraph 31 for valve
tappet gap. Remove flywheel rotating tool.
VALVE GUIDES AND SPRINGS
All Models
33. Valve guides are cast directly in cylinder head.
If ID of guide is worn beyond the limit of 0.381 inch
(8.089 mm), machine guide bore diameter to 0.551-
0.552 inch (13.987-14.013 mm) and install a new serv-
Flg. 29 With No. 1piston at TDC of compression stroke,
adjust the valves Indicated.
Fig. 30With No. 6 piston at TDC of compression stroke,
adjust the valves Indicated.
Paragraphs 32-35
ice guide. New guide will be an interference fit of
0.0005-0.002 inch (0.0127-0.0508 mm) and must be
pressed into cylinder head. Press guide in from top
until top end of guide is 0.448-0.462 inch (11.25-11.75
mm) above guide bore surface in head. Ream in
stalled service guide inside diameter to 0.3155-0.316
inch (8.019-8.039 mm). Stem seals are used on all
valves.
Intake and exhaust valve springs are interchange
able. Renew any spring that is cracked, discolored or
does not meet the following specifications:
Free length ............................................ 2.19 in.
(55.63 mm)
Tfest load .............................................. 64-72 lbs.
(285-321 N)
Tfest length .............................................. 1.94 in.
(49.25 mm)
ROCKER ARMS
All Models
34. Refer to Fig. 31 for exploded view of rocker
arm and shaft assembly used on each cylinder. Tb dis
assemble the removed unit, remove snap rings, thrust
washers and rocker arms. Measure rocker shaft and
if worn to a diameter of less than 0.745 inch (18.938
mm), renew shaft. Measure inside diameter of rock
er arm bore. If rocker arm bore is more than 0.750
inch (19.05 mm), renew rocker arm.
Tighten rocker arm head bolt to a torque of 93 ft.-
lbs. (126 N*m) and rocker arm bracket bolt to a torque
of 18 ft.-lbs. (24 N-m). Adjust valve tappet gap as out
CAM FOLLOWERS
All Models
35. The mushroom type cam followers can be re
moved from below after first removing camshaft and
oil pan as outlined in paragraphs 41 and 52.
Fig. 31Exploded view of rocker arm assembly used on
each cylinder.
Paragraphs 36-40
Measure outside diameter of cam follower stem.
Renew cam followers if outside diameter of stems is
less than 0.627 inch (15.936 mm). Measure inside di
ameter of cam follower bores in cylinder block. Max
imum bore diameter is 0.632 inch (16.055 mm). If
bores exceed the limit, renew cylinder block.
TIMING GEAR COVER
All Models
36. Tb remove the timing gear cover, drain cool
ing system and disconnect front wiring harness. Re
move hood, grille and side panels. Disconnect upper
and lower radiator hoses, air intake tube and air con
ditioner lines at quick couplers. Identify and discon
nect oil cooler lines. Attach a hoist to the radiator,
condenser and oil cooler assembly support brackets.
Remove two rear bolts and three front bolts, then lift
off the assembly.
Remove air conditioner compressor drive belt, if so
equipped, then lift belt tensioner and remove fan
belt. Unbolt and remove fan, spacer, compressor
drive pulley and fan pulley. Remove the four bolts
retaining crankshaft pulley and remove pulley. Un
bolt and remove timing gear cover.
NOTE: Refer to paragraph 49 for front crankshaft
seal Installation and timing gear cover alignment.
When reassembling, use new cover gasket and
tighten cover retaining cap screws to a torque of 18
ft.-lbs. (24 N-m). Tighten crankshaft pulley bolts to
101 ft.-lbs. (137 N-m) torque and fan bolts to 32 ft.-
lbs. (43 N-m) torque. Tighten the five bolts securing
the radiator, condenser and oil cooler assembly sup
port to front support to a torque of 35-42 ft.-lbs. (48-
57 N-m).
TIMING GEARS
All Models
The timing gear train consists of the crankshaft
gear, camshaft gear and ii\jection pump drive gear.
Engine oil pump is mounted on front of engine block
inside the timing gear housing and drives through an
idler gear from crankshaft gear, becoming part of the
gear train. Refer to the appropriate following para
graphs for timing, inspection and overhaul infor
mation.
37. TIMING MARKS. When installing camshaft
gear and crankshaft gear, align single punch mark on
crankshaft gear with double punch mark on cam
shaft gear. When installing iryection pump drive gear,
align the C mark on iryection pump gear with the
CASE/INTERNATIONAL
single timing mark on camshaft gear. Idler gear and
oil pump gear are not marked.
When the timing pin on left rear of timing gear
housing is inserted into hole in camshaft. No. 1 pis
ton is at TDC on compression stroke. Crankshaft pul
ley is not marked.
38. CAMSHAFT GEAR. The camshaft gear is a
shrink fit on the camshaft. Tb remove the camshaft
gear, remove camshaft from engine as outlined in
paragraph 41. With timing gear cover removed and
before removing camshaft, use a dial indicator and
check backlash between camshaft gear and crank
shaft gear. Normal backlash is 0.003-0.013 inch (0.08-
0.33 mm). Maximum backlash is 0.018 inch (0.45 rmn).
Excessive backlash could be caused by gear wear,
shaft wear or camshaft bushing wear; or by a com
bination of factors.
Tb remove camshaft gear after removing camshaft,
press the gear off the shaft. Refer to paragraph 42
and check camshaft bushing and camshaft for exces
sive wear.
When installing camshaft gear on camshaft, heat
gear approximately 45 minutes at a temperature of
250 F (121 C). Install gear with timing marks to the
front and timing pin hole toward the rear.
Reinstall camshaft as outlined in paragraph 41.
39. INJECTION PUMP GEAR. Tb remove the in
jection pump drive gear, first remove the timing gear
cover as outlined in paragraph 36. Using a dial indi
cator, check backlash between iryection pump drive
gear and camshaft gear. Normal backlash is 0.003-
0.013 inch (0.08-0.33 mm). Maximum backlash is 0.018
inch (0.45 mm). Loosen the nut on iryection pump
shaft. Using a flywheel rotating tool CAS-1690
through hole in flywheel housing, turn flywheel in
normal direction of rotation while pushing inward on
the timing lock pin. When lock pin is engaged in hole
in camshaft gear, loosen the iryection pump lock bolt
at the front left side of pump and remove the slot
ted tab. Then, tighten lock bolt to a torque of 22 ft.-
lbs. (30 N-m). Remove nut and lockwasher from pump
shaft. Using a suitable puller, remove the pump gear.
When installing the pump gear, make certain that
the timing letter C is aligned with the single tim
ing mark on camshaft gear. Install nut and lockwash
er on pump shaft and tighten finger tight. Loosen
lock bolt on pump, insert slotted tab, then tighten
lock bolt to a torque of 22 ft.-lbs. (30 N-m). Disengage
timing lock pin from camshaft gear. Then, tighten
pump drive gear nut to a torque of 48 ft.-lbs. (65 N-m).
Refer to paragraph 36 and reinstall timing gear cover.
40. CRANKSHAFT GEAR. Tb remove the crank
shaft gear, first remove timing gear cover. Using a dial
indicator, check backlash between crankshaft gear
MODELS 1896-2096
and camshaft gear. Normal backlash is 0.003-0.013
inch (0.08-0.33 mm). Maximum allowable backlash is
0.018 inch (0.45 mm). Then, remove camshaft as out
lined in paragraph 41 and iryection pump as in para
graph 62. Unbolt and remove timing gear housing
(9Fig. 32) and oil pump assembly. Using a suitable
puller, remove crankshaft gear.
When reassembling, use new crankshaft gear pin
and heat gear for approximately 25 minutes at a tem
perature of 250 F (121 C). Install heated gear on
crankshaft. Align timing marks as outlined in para
graph 37. Use new gasket (8Fig. 32) and install tim
ing gear housing (9). Tighten housing retaining bolts
to a torque of 18 ft.-lbs. (24 N*m). The balance of reas
sembly is the reverse of disassembly.
CAMSHAFT AND BEARINGS
All Models
The camshaft is carried in one (front) renewa
ble bushing and six bores directly in engine block.
However, if the bores in block show excessive
wear, engine must be completely disassembled
and the block line bored for installation of serv
ice bushings.
41. R&R CAMSHAFT. Tb remove the camshaft
and gear assembly, first remove timing gear cover as
Paragraphs 41-42
outlined in paragraph 36. Remove iryection pump
drive gear as outlined in paragraph 39. Unbolt and
remove rocker arm covers, rocker arm assemblies and
push rods. Remove cam follower cover from left side
of engine, pull cam followers upward and hold them
in this position by clipping clothes pins on the stems.
Unbolt and remove fuel lift pump. Working through
the holes in camshaft gear, unbolt and remove the
camshaft thrust plate (5Fig. 33). Withdraw cam
shaft and gear assembly.
Remove camshaft gear as outlined in paragraph 38
if renewal is indicated. Refer to paragraph 42 for
specification data on camshaft and bushings.
When reinstalling camshaft, align timing marks as
in paragraph 37. Then, using a dial indicator, check
camshaft end play. End play is controlled by the
thrust plate (5Fig. 33). Camshaft end play should
be 0.005-0.018 inch (0.13-0.47 mm). If end play is more
than 0.018 inch (0.47 mm), renew thrust plate. Tight
en camshaft thrust plate bolts (6) to a torque of 18
ft.-lbs. (24 N*m). Complete reassembly by reversing
the disassembly procedure. Adjust valve clearance as
42. CAMSHAFT BEARINGS. Desired camshaft
clearance is 0.003-0.006 inch (0.076-0.152 mm). Meas
ure diameter of all camshaft journals which should
be 2.125-2.126 inches (53.987-54.013 mm). If journals
are worn to a diameter of 2.124 inches (53.962 mm),
renew camshaft.
When checking front bushing and other five jour
nal bores in block, remove oil pan as in paragraph
Fig. 32Exploded view of timing gear housing, cover and
related parts.
Fig. 33 View of camshaft and related parts. Engines are
equipped with renewable front bushing (4). Service
bushings (1) are available for bores for journals 2 through
6.
1. Retaining ring
2. "O" ring
3. Timing lock pin
4. Lock pin housing
5. Gasket
6. Access plate
7. Gasket
8. Gasket
9. Timing gear
housing
10. Gasket
11. Timing gear
cover
12. Seal ring
13. Access plug
14. Crankshaft seal
1. Service bushings
2. Camshaft
3. Key
4. Front bushing
5. Thrust plate
6. Cap screw (2)
7. Camshaft gear
Paragraphs 43-44
52. Then, measure inside diameter of front bushing
and other journal bores which should be 2.130-2.131
inches (54.107-54.133 mm). If front bushing is worn
to an inside diameter of 2.131 inches (54.133 mm),
renew front bushing. If other five journal bores in
block are worn to an inside diameter of 2.131 inches
(54.133 mm), block must be line bored and service
bushings installed.
ROD AND PISTON UNITS
All Models
43. Connecting rod and piston units are removed
from above after removing cylinder head, oil pan, oil
intake tube and connecting rod caps. Before remov
ing, place a cylinder identification mark at top front
of each piston. If not marked, place cylinder iden
tification mark on connecting rod and cap on side op
posite the camshaft. Remove carbon or wear ring
from top of cylinders, then remove the units.
Reinstall by reversing the removal procedure.
Lubricate threads and tighten connecting rod bolts
evenly to a torque of 74 ft.-lbs. (100 N-m).
Fig. 34View showing connecting rod and piston and
related parts.
1. Service sleeves
2. Top compression
ring
3. Intermediate
compression ring
4. Oil control ring
5. Piston (2096)
6. Piston (1896)
7. Piston pin
8. Retaining ring (2)
9. Bushing
10. Connecting rod
11. Rod cap
12. Connecting rod
bearing
CASE/INTERNATIONAL
PISTONS AND RINGS
All Models
44. Engines are equipped with pistons having two
compression rings and one oil control ring and oper
ate directly in the cylinder block bores. Piston and
ring sets are available in standard size and oversizes
of 0.020 inch (0.5 mm) and 0.040 inch (1.0 mm).
NOTE: If cylinder bores are worn beyond the over
size limits, refer to paragraph 45 for Information on
boring and installing service sleeves.
Check the pistons, pins, rings and cylinder bores
against the following specifications:
Pi.ston Material ........................Aluminum Alloy
Piston Skirt Diameter
0.472 Inch (12.0 mm) From
Bottom, 90 From Pin:
Standard Size Piston ................ 4.010-4.011 in.
(101.873-101.887 mm
Minimum Limit................................. 4.008 in.
0.5 mm Oversize Piston............. 4.030-4.031 in.
(102.373-102.387 mm)
Minimum Limit................................. 4.028 in.
(102.323 mm)
1.0 mm Oversize Pi.ston.............. 4.050-4.051 in.
(102.873-102.887 mm)
Minimum Limit ................................. 4.048 in.
(102.823 mm)
Standard Cylinder Bore ...............4.016-4.017 in.
(102.00-102.04 mm)
Maximum Limit ................................. 4.020 in.
(102.116 mm)
Cylinder Out-Of-Round (max.).............0.0015 in.
(0.038 mm)
Cylinder Tkper (max.) .......................... 0.003 in.
(0.076 mm)
Piston Pin Diameter ................ 1.5747-1.5749 in.
(39.997-40.003 mm)
Clearance In Piston ............... 0.0001-0.0005 in.
(0.003-0.015 mm)
Maximum Limit............................... 0.0014 in.
(0.035 mm)
Clearance In Rod ...................... 0.002-0.003 in.
(0.051-0.076 mm)
Maximum Limit ............................... 0.004 in.
(0.102 mm)
Tbp Compression Ring:
T y p e ............................... Keystone Barrel Face
End Gap .................. ................ 0.016-0.028 in.
(0.40-0.70 mm)
Maximum Limit ............................... 0.032 in.
(0.806 mm)
Side Clearance ........................Not Measurable
MODELS 1896-2096
Intermediate Compression
Ring:
TVpe............................Rectangular Tkper F^ce
End Gap ................................... 0.010-0.022 in.
(0.25-0.55 mm)
Maximum Limit ............................... 0.032 in.
(0.806 mm)
Side Clearance .......................... 0.003-0.005 in.
(0.075-0.120 mm)
Maximum Limit ............................... 0.006 in.
(0.15 mm)
Bottom Oil Control Ring:
TVpe ......... ...................................... Two Piece
End Gap ................................... 0.010-0.022 in.
(0.25-0.55 mm)
Maximum Limit ............................... 0.032 in.
(0.806 mm)
Side Clearance ...................... 0.0025-0.0043 in.
(0.065-0.110 mm)
Maximum Limit ............................. 0.0051 in.
(0.13 mm)
SERVICE CYLINDER SLEEVES
All Models
45. If cylinder bores are worn beyond the oversize
limits, cylinders can be rebored and service sleeves
installed. Completely disassemble block before rebor
ing. Measure up from bottom of cylinder bore 0.250
inch (6.35 mm) and place a mark at this point in bore.
Machine the cylinder bore to this mark to a diame
ter of 4.1142-4.1148 inches (104.500-104.515 mm).
NOTE: Do not bore the cylinder below the Installed
mark.
Freeze cylinder sleeves in dry ice. Install each
sleeve in cylinder bore until sleeve contacts the un
machined ridge at bottom of bore. If the iristalled
sleeves protrude above cylinder block, machine top
of sleeves until flush with top of block. Hone inside
diameter of installed sleeves to 4.016-4.017 inches
(102.00-102.04 mm). Then, install a standard piston
and ring set.
PISTON PINS AND BUSHINGS
All Models
46. The full floating piston pins are retained in pis
ton bosses by snap rings and are available in standard
size only. Outside diameter of new pin is 1.5747-1.5749
inches (39.997-40.003 mm). If pin is worn to a mini
mum service limit of 1.5744 inches (39.990 mm), re
new pin.
Pin bushing inside diameter in connecting rod
should be 1.5769-1.5774 inches (40.053-40.067 mm).
Paragraphs 45-48
If worn to a maximum service limit of 1.5784 inches
(40.092 mm), press old bushing out and new bushing
in using a piloted arbor. Make certain oil holes in rod
and bushing are aligned. Bushing must be finish
honed or reamed after installation.
Measure piston pin bore in piston which should be
1.5750-1.5753 inches (40.006-40.012 mm). If worn be
yond the maximum service limit of 1.5758 inches
(40.025 mm), renew piston.
CONNECTING RODS AND BEARINGS
All Models
47. Connecting rod caps are retained by self-
locking cap screws. Connecting rods are removed as
outlined in paragraph 43. Standard crankpin diame
ter is 2.7154-2.7170 inches (68.987-69.013 mm).
Desired bearing clearance is 0.0015-0.0045 inch
(0.038-0.116 mm) with a maximum allowable clear
ance of 0.005 inch (0.129 mm). Regrind or renew
crankshaft if out-of-round exceeds 0.0019 inch (0.050
mm) or if taper exceeds 0.0005 inch (0.013 mm). Rod
bearings are available in undersizes of 0.010, 0.020,
0.030 and 0.040 inch (0.25, 0.50, 0.75 and 1.0 mm) as
well as standard. Connecting rod side clearance
should be 0.004-0.012 inch (0.1-0.3 mm).
When reinstalling, stamped cylinder numbers on
connecting rods and caps should face opposite cam
shaft side and arrows on top of pistons must be to
ward front of engine. Tighten the self-locking cap
screws to a torque of 74 ft.-lbs. (100 N-m).
CRANKSHAFT AND MAIN BEARINGS
All Models
48. The crankshaft (8Fig. 35) is supported in sev
en main bearings. Crankshaft end play is controlled
by the upper half of flanged No. 4 main bearing
insert.
Standard main journal diameter is 3.2672-3.2682
inches (82.987-83.013 mm). Main bearing caps are
numbered one through seven and caps must be rein
stalled in correct position. Desired main bearing di
ametral clearance is 0.0016-0.0046 inch (0.041-0.119
mm) with a maximum allowable clearance of 0.0055
inch (0.140 mm). Upper and lower bearing liners are
not interchangeable. Make certain the half contain
ing the oil hole is installed in block and that oil holes
properly align.
Desired crankshaft end play is 0.0054-0.0104 inch
(0.137-0.264 mm). If, after installing new main bear
ing liners, end play exceeds 0.013 inch (0.332 mm)
crankshaft must be renewed. Crankshaft renewal re
quires removal of engine assembly as outlined in
paragraph 29.
Paragraphs 49-50
Main bearing liners can be renewed after remov
ing oil pan, oil pump intake tube and bearing caps.
Main bearing liners are available in undersizes of
0.010, 0.020, 0.030 and 0.040 inch (0.25, 0.50, 0.75 and
1.0 mm) as well as standard.
Main bearing cap screws are self-locking type and
can be reused. Tighten main bearing cap screws even
ly to a torque of 129 ft.-lbs. (175 N*m).
CRANKSHAFT SEALS
All Models
49. FRONT. Tb renew the front crankshaft seal
(2Fig. 35), first remove timing gear cover as out
lined in paragraph 36. Then, drive seal from front
cover. Thoroughly clean seal and gasket mounting
surfaces of front cover and timing gear housing.
NOTE: The front seal Is available only In a kit (Part
No. J 904353) which Includes the two Installation
tools.
Install two guide studs in the timing gear cover and
using a new gasket, slide cover in place. Install cov
er retaining bolts but do not tighten at this time. In
stall seal driving tool over crankshaft and into front
Fig. 35View showing crankshaft and related parts.
Center (No. 4) upper l>earlng half controls crankshaft end
play.
1. Crankshaft gear
2. Front oil seal
3. Crankshaft pulley
4. Main bearings
(upper halves)
5. Rear oil seal
6. Seal retainer
7. Gasket
8. Crankshaft
9. Pin
10. Main bearings
(lower halves)
CASE/INTERNATIONAL
cover with the small diameter toward the engine.
This will center the cover with the crankshaft. Tight
en front cover cap screws to a torque of 18 ft.-lbs.
(24 N-m). Remove seal driver tool. Place seal on the
protective sleeve tool. Apply Loctite 277 to outer
edge of seal. Slide protective sleeve and seal on
crankshaft until seal contacts the cover. Remove
sleeve and install seal drive tool. Drive seal inward
until outside diameter of installing tool contacts front
cover. This will be the correct installation depth for
the seal. Remove seal driver tool. If sealing surface
on crankshaft is worn or pitted, a wear ring is avail
able for installation.
For the balance of reassembly, refer to paragraph
36.
50. REAR. Tb renew the rear crankshaft seal (5
Fig. 35), first split tractor between engine and torque
tube as outlined in paragraph 29. Remove screws and
lift out oil baffle plate. Unbolt and remove the torque
limiter from flywheel, then unbolt and remove fly
wheel. Drain oil and remove oil pan. Attach a hoist
to flywheel housing, then unbolt and remove fly
wheel housing. Remove 0 ring from around the
rear seal retainer. Unbolt and remove retainer and
seal, then remove seal from retainer. Clean gasket
mounting surfaces of retainer and crankcase. Use
Loctite safety solvent and clean mounting surface of
retainer seal.
NOTE: The rear crankshaft seal Is available only
In a kit (Part No. J 904354) which Includes two instal
lation tools.
Install two guide studs in rear of crankcase. Using
a new gasket, slide seal retainer in place over guide
studs. Install retainer bolts, remove guide studs, but
do not tighten retainer bolts at this time. Install seal
driver tool into seal retainer with small diameter to
ward the engine. This will center the retainer with
the crankshaft. Tighten seal retainer cap screws to
a torque of 7 ft.-lbs. (9 N-m). Remove the seal drive
tool. Slide protective sleeve tool with seal over crank
shaft until outer diameter of seal contacts seal re
tainer. Remove sleeve and install seal driver tool.
Drive seal inward until outside diameter of install
ing tool contacts seal retainer. This will be the cor
rect installation depth for the seal. Remove seal driv
er tool. If sealing surface on crankshaft flange is worn
or pitted, a wear ring is available for installation.
Install a new 0 ring (8Fig. 36) over seal retain
er. Apply Loctite 504 to sealing surface of flywheel
housing to engine block. Install two guide studs in
engine block, then carefully install flywheel housing.
Install flywheel housing bolts and remove guide
studs. Tighten flywheel housing bolts to a torque of
i45 ft.-lbs. (60 N-m). Install flywheel and tighten bolts
MODELS 1896-2096
to a torque of 101 ft.-lbs. (137 N-m). Install torque
limiter clutch and after applying Loctite 271 to bolt
threads, tighten bolts to a torque of 93-112 ft.-lbs.
(126-152 N-m). Reinstall oil baffle plate.
Refer to paragraph 29 and reconnect tractor.
FLYWHEEL
All Models
51. Tb remove the flywheel (2Fig. 36), first split
tractor between engine and torque tube as outlined
in paragraph 29. Remove torque limiter, then unbolt
and remove flywheel.
The flywheel ring gear is a shrink fit on front of
flywheel. The manufacturer cautions against the use
of a torch or open flame for heating gear. Heat the
new ring gear to 400-450 F (204-232 C) in oil or
in an oven. Install gear on flywheel.
Install flywheel and tighten the retaining cap
screws to a torque of 101 ft.-lbs. (137 N-m). Reassem
ble tractor by reversing disassembly procedure.
OIL PAN AND OIL INLET TUBE
All Models
52. Tb remove the oil pan, remove plug and drain
the oil. On models equipped with front-wheel drive,
remove front drive shaft shield and the drive shaft.
Unbolt and remove the oil pan. Unbolt and remove
oil inlet tube.
Fig. 36Flywheel housing and flywheel used on all
models.
1. Oil baffle plate
2. Flywheel
3. Flywheel housing
4. Seal ring
5. Engine rpm
sensor
6. " O " ring
7. Plug
8. O" ring
9. Dowel
10. O ring
11. Plug
Paragraphs 51-53
Clean all surfaces of foreign material. Using new
gasket, install oil inlet tube. Tighten retaining cap
screws to a torque of 18 ft.-lbs. (24 N-m). Install oil
pan with new pan gasket and tighten bolts to a torque
of 18 ft.-lbs. (24 N-m).
Reinstall front drive shaft and shield as outlined
in paragraph 11. Fill oil pan with new oil to proper
level.
OIL PUMP
All Models
53. Tb remove the oil pump, first remove timing
gear cover as outlined in paragraph 36. With the front
cover removed, unbolt and lift out pump as shown
in Fig. 37. Place oil pump on a bench with gear side
down. Remove rear cover, then using a feeler gage,
measure clearance between lobe on inner rotor and
lobe on outer rotor as shown in Fig. 38. If clearance
exceeds 0.007 inch (0.178 mm), renew pump assem
bly. Oil pump is serviced only as a complete assembly.
Fig. 37With timing gear front cover removed, unbolt and
remove oil pump assembly.
Fig. 38Using a feeler gage, measure clearance between
lobe on Inner rotor and lot)e on outer rotor.
Paragraphs 54-56
When installing oil pump assembly, tighten the four
mounting bolts evenly to a torque of 18 ft.-lbs. (24
N-m) following the sequence shown in Fig. 39. Do not
overtighten. A small clearance will exist between
pump flange and cylinder block.
With pump installed, check backlash between the
pump idler gear and the crankshaft gear. If backlash
exceeds 0.018 inch (0.450 mm), renew pump as
sembly.
Refer to paragraphs 36 and 49 and reassemble
tractor.
OIL PRESSURE REGULATOR
All Models
54. The oil pressure regulator is located in the oil
filter head (6Fig. 40). Remove plug (2), gasket (3),
spring (4) and regulator valve (5). Free length of
spring (4) should be 2.198 inches (55.83 mm). Spring
should test 14.2-17.8 lbs. (63-79 N) when compressed
to a length of 1.77 inches (44.98 mm) and 21.4-25.4
lbs. (95-113 N) when compressed to a length of 1.57
inches (39.98 mm).
When reinstalling, use new gasket (3) and tighten
plug (2) to a torque of 90 ft.-lbs. (120 N-m). Oil pres
sure should be 30-55 psi (207-378 kPa) with engine
warm and operating at 2100 rpm.
OIL COOLER
All Models
55. The engine oil cooler (9Fig. 40) is located in
right side of engine block behind the oil filter head.
Tl) remove the oil cooler, drain cooling system and re
move the oil filter cartridge. Disconnect the tur
bocharger pressure line and remove line fitting from
oil filter head. Unbolt and remove filter head (6) and
gasket (8). Remove oil cooler (9) and gasket (10).
Fig. 39Use tightening sequence shown when Installing
oil pump.
CASE/INTERNATIONAL
Clean all surfaces of foreign material. Cleaning
procedures for the oil cooler consists of flushing the
oil circuit with clean solvent and removing scale or
rust from exterior of cooling plates.
Using new gaskets, reinstall by reversing the
removal procedure. Make certain the cold oil relief
valve (7) is in position in backside of filter header.
Tighten filter head bolts to a torque of 18 ft.-lbs. (24
N-m).
Fig. 40Exploded view of engine oil cooler, oil filter head
and relative components.
1. Filter cartridge
2. Regulator valve
plug
3. Gasket
4. Spring
5. Riegulator valve
6. Filter head
7. Cold oil relief
valve
8. Gasket
9. Oil cooler
10. Gasket
DIESEL FUEL SYSTEM
All models are equipped with a Robert Bosch
Model VE iiyection pump. Robert Bosch multi
hole iivjector nozzles are used on all models.
FUEL, FUEL FILTERS AND TRANSFER
PUMP
All Models
56. FUEL. The manufacturer recommends the use
of a good grade No. 2 diesel fuel having a Cetane rat
ing of 40 or better be used for normal operation. For
MODELS 1896-2096
cold weather operation, Cetane rating should be 45-
55 and fuel pour point should be at least 10 F (-12
C) below lowest expected ambient temperature.
57. TRANSFER PUMP. A diaphragm type fuel
transfer pump (7Fig. 41) is located on left side of
engine block. This unit pumps the fuel through the
two filters and on to the diesel iryection pump. The
transfer pump is operated by a lobe on engine cam
shaft. A hand lever used for bleeding air from fuel
system is located on the transfer pump. The pump
is serviced only as a complete unit.
58. FUEL FILTERS. Filters are the screw-on type
(Fig. 41). Filters are available in a kit which consists
of both units and both should be renewed each 500
hours or when noticeable power loss occurs. Prima
ry filter (PFig. 41 or 42) is equipped with a water
bleed screw (B). Each morning before operating trac
tor, loosen water bleed screw and drain off any wa
ter from primary filter. Retighten screw. There is also
a water drain valve in the bottom center of the main
Fig. 41 -Screw-on type fuel filters are used on all tractors.
Filter head (3) Is secured to flange on cylinder head by
adapter tube (5) and nut (4).
B. Water bleed screw
P. Primary filter
S. Secondary filter
1. " O ring
2. O ring
3. Filter head
4. Nut
5. Adapter tube
6. Gasket
7. Fuel transfer pump
8. Shut-off valve
Paragraphs 57-61
fuel tank. Open valve and drain any accumulated wa
ter from fuel tank each morning.
Tb renew filters, first clean filter head, elements
and surrounding area. Shut off fuel valve (8) at trans
fer pump and remove water bleed screw (B) from pri
mary filter (P). Tb remove the fuel filters, use a clamp
type filter wrench.
Lightly oil gaskets on new units and turn filters on
until gaskets contact filter head. Then, hand tight
en filters A to % of a turn. DO NOT overtighten.
Bleed system as outlined in paragraph 59.
59. BLEED SYSTEM. Tb bleed fuel system, make
certain there is fuel in the tank and that shut-off
valve at transfer pump is open. Loosen air vent screw
(VFig. 42) and operate hand lever on transfer pump
until air free fuel flows from vent screw opening.
Close air vent screw (V) and loosen vent screw on rear
of iiyection pump. Turn ignition switch to ON posi
tion to energize the solenoid shut-off in iryection
pump. Again operate hand lever on transfer pump
until air free fuel flows from vent screw opening.
Close vent screw and operate hand lever several ad
ditional strokes.
INJECTION PUMP
All Models
60. LUBRICATION. The fuel iryection pump is
lubricated with diesel fuel under 5-7 psi (34.48-48.27
kPa) pressure. Excess fuel flows through the return
line where it is joined by iryector leak-off fuel and
returns to the fuel tank.
61. TIMING. Tb check and acyust ii\jection pump
timing, first remove iryection lines. Remove plug from
flywheel housing and insert engine turn over tool
Fig. 42Screw filters on until seals contact filter head,
then hand tighten filters to ^ of a turn.
B. Water bleed screw
P. Primary filter
S. Secondary filter
V. Air vent screw
Paragraph 62
(Fig. 43). Remove vent plug from rear of iryection
pump and install a dial indicator CAS-10066-1A and
adapter CAS-1745 as shown in Fig. 44. Using the turn
over tool, rotate engine counterclockwise until there
is no movement on the dial indicator. Set indicator
dial at zero. Push inward on the timing pin (Fig. 45)
and rotate engine clockwise until timing pin enters
hole in camshaft gear. At this time, the dial indica
tor should read 0.059 inch (1.5 mm) if timing is cor
rect. If reading is not correct, loosen pump rear brace
bolt and the three nuts securing pump to timing gear
housing. Rotate pump until dial indicator reads 0.059
inch (1.5 mm). Then, tighten pump mounting nuts
and brace bolt to a torque of 18 ft.-lbs. (24 N-m).
NOTE; If correct reading cannot be obtained, tim
ing gears are not correctly timed.
Remove dial indicator and adapter from pump. In
stall vent plug and tighten to a torque of 17 ft.-lbs.
(23 N-m). Install fuel iryection lines. Pull timing pin
out of camshaft gear. Remove engine turn over tool
and install plug in flywheel housing. Bleed fuel sys
tem as outlined in paragraph 59.
Fig. 43Install engine turn over tool (CAS-1690) Into
flywheel housing.
Fig. 44Remove vent plug from rear of pump and Install
dial Indicator (CAS-10066-1A) and adapter (CAS-1745).
CASE/INTERNATIONAL
injection pump, first shut off fuel and thoroughly
clean pump, lines, connections and surrounding area.
Remove fuel iryection lines and the inlet line and ex
cess fuel line from pump. Immediately cap or plug
all openings. Remove access plug from left front side
of front cover and remove nut and washer from front
end of pump shaft. Remove plug from flywheel hous
ing and install engine turn over tool CAS-1690. See
Fig. 43. Push inward on timing pin (Fig. 45) while
rotating engine in normal direction of rotation until
timing pin enters hole in camshaft gear. Loosen pump
shaft lock bolt and remove slotted tab (Fig. 46), then
retighten lock bolt to a torque of 22 ft.-lbs. (30 N-m).
Loosen pump rear brace bolt and the three nuts
securing pump to timing gear housing several turns.
Install gear puller CAS-1691 as shown in Fig. 47 and
pull gear from taper on pump shaft. Remove brace
bolt and the three pump mounting nuts. Carefully re
move the injection pump.
CAUTION: If the Woodruff key Is not In the pump
shaft when pump Is removed, engine front cover
must be removed to retrieve the key.
Using a new pump mounting gasket, reinstall pump
by reversing the removal procedure. Before install-
Flg. 45Pushing Inward on timing pin.
Fig. 46Loosen pump shaft lock bolt and remove slotted
tab.
MODELS 1896-2096
ing the iryection lines, set pump timing as outlined
in paragraph 61. Tighten pump drive gear nut to a
torque of 48 ft.-lbs. (56 Nm). When reinstalling slot
ted tab (Fig. 46), tighten lock bolt to a torque of 22
ft.-lbs. (30 N*m). Tighten pump mounting nuts and
brace bolt to a torque of 18 ft.-lbs. (24 N-m).
Use new gaskets on each side of excess fuel line fit
ting and inlet fuel line fitting and tighten baryo fit-
tir\g bolts to a torque of 18 ft.-lbs. (24 N-m). Bleed fuel
system as outlined in paragraph 59.
63. PUMP SPEED ADJUSTMENT. The diesel
governor is an integral part of iryection pump and ex
Flg. 47Using gear puller (CAS-1691) and working
through access hole In front cover, pull gear from pump
shaft.
Fig. 48Diesel Iniectlon pump and Its relative components.
Paragraphs 63-64
cept for minor speed adjustments, governor service
should be done at an authorized diesel service shop.
Recommended governed speeds for all models are
as follows:
Low idle ......................................... 750-850 rpm
High idle (no-load) ...................... 2210-2290 rpm
Rated (loaded) speed............................2100 rpm
Tb adjust governed speeds, first make certain that
throttle cable is correctly acjusted to fully open and
close governor control lever. Turn stop screws (6 and
11Fig. 48) to adjust high and low idle speeds.
64. FUEL SHUT-OFF SOLENOID. Tb remove the
fuel shut-off solenoid (7Fig. 48), disconnect elec
trical wire at connector. Unscrew and remove sole
noid and seal (8). Refer to Fig. 49 and disassemble
solenoid. Inspect plunger and solenoid for scoring or
other damage. Make certain the orifice in plunger is
free of foreign material.
Reassemble solenoid and reinstall unit, using new
0 ring and seal (8Fig. 48). Tighten solenoid to
a torque of 10 ft.-lbs. (15 N-m).
Fig. 49Exploded view of fuel shut-off solenoid.
1. lr\jection pump
2. Pump rear brace
3. Brace bolt
4. Vent plug
5. Gasket
6. High idle stop
screw
7. Fuel shut-off
solenoid
8. Seal
9. Excess fuel bar\jo
bolt
10. Gasket
11. Low idle stop
screw
12. Pump shaft lock
bolt
13. " O " ring
14. Lock bolt tab
15. Woodruff key
16. Gasket
17. Pump drive gear
18. Lockwasher
19. Nut
Paragraphs 65-66
If tractor is equipped with an automatic shutdown
system, and engine oil pressure or transmission oil
pressure is too low or if transmission oil temperature
or coolant temperature is too high, 30 seconds after
alarm sounds, current will shut off to solenoid and
engine will shut down. Refer to appropriate para
graphs under ACCESSORY SYSTEMS.
INJECTOR NOZZLES
All Models
All tractors are equipped with Robert Bosch fuel
iiyectors which are shown in Figs. 50 and 51.
Fig. 50Exploded view of Robert Bosch diesel fuel
Injector.
1. Ii\jector nut
2. Injector body
3. Shims
4. Spring
5. Spring seat
6. Valve stop
7. Valve assy.
8. Cap nut
9. liyector seal
CASE/INTERNATIONAL
65. LOCATING A FAULTY NOZZLE. If rough or
uneven engine operation or misfiring indicate a faulty
iryector, defective unit can usually be located as
follows;
With engine operating at speed where malfunction
is most noticeable (usually slow idle speed), loosen
compression nut on high pressure line at each ii\jec-
tor in turn and listen for change in engine perfor
mance. As in checking spark plugs, faulty unit is one
which, when its line is loosened, least affects engine
operation.
If a faulty nozzle is found and considerable time
has elapsed since iryectors have been serviced, it is
recommended that all nozzles be removed and
checked or that new or reconditioned units be in
stalled. Refer to appropriate following paragraphs for
removal and test procedures.
66. REMOVE AND REINSTALL. Clean the loca
tion around the fuel iryectors. Unbolt and remove the
outer half of iryection lines bracket. Loosen the in
jection line tube nut at pump, then disconnect line
from iryector. Unbolt leak-off line from iryector. Cap
or plug all openings. Using special tool CAS-1066A or
equivalent on iryector nut (1Fig. 50) and a wrench
on the flat surfaces of iryector body (2) to prevent
iryector from turning, unscrew nut and remove in
jector.
Make certain that iryector seal (9) is removed with
iryector. If not, use a suitable tool or wire to remove
the seal from the bore. Remove the remainder of in
jectors using the same procedure. Clean bores for in
jectors using special tool CAS-1694.
Using a small amount of white grease to hold a new
iryector seal in place, reinstall iryector. The ball in the
iryector must align with the slot in the bore. Tighten
iryector nut (1) to a torque of 44 ft.-lbs. (60 N-m). In
stall leak-off line and tighten bolt to a torque of 6
ft.-lbs. (8 N-m). Install and tighten iryection line. Start
engine. If engine fails to start, loosen iryection line
nuts at iryectors. Turn ignition switch on and crank
engine until diesel fuel leaks at loosened connections.
Tighten line nuts and start engine.
Fig. 51Cross-sectional view of diesel fuel Injector assembly.
MODELS 1896-2096
67. TESTING. A complete job of testing and ad
justing an iryector nozzle requires use of special test
equipment such as test stand, part number CAS-
10091 shown in Fig. 52. Only clean diesel fuel or ap
proved testing oil should be used in tester tank. The
nozzle should be tested for opening pressure, seal
leakage and spray pattern. When tested, nozzle
should open with a sharp popping or buzzing sound
and cut off quickly at end of iryection with a mini
mum of seal leakage and a controlled amount of back
leakage. Check as outlined in the following para
graphs.
WARNING: Fuel leaves nozzle tip with sufficient
force to penetrate the skin. Keep hands away from
nozzle tip when testing.
68. OPENING PRESSURE. Before conducting test,
operate tester until fuel flows, then attach iryector
to tester using correct adapter. Close valve to tester
gage and pump tester lever a few quick strokes to be
sure that nozzle is not plugged and that all four spray
holes are open.
Open valve to tester gage and operate tester until
fuel flows, then observe gage reading. Opening pres
sure should be 3200-3625 psi (22063-24994 kPa) on
Model 1896 or 3120-3260 psi (21511-22476 kPa) on
Model 2096.
NOTE: If adjusting a new injector, or a used Injec
tor with a new spring (4Fig. 50), opening pressure
should t>e 3550-3670 psi (24476-25303 kPa) on Model
1896 or 3190-3310 psi (21994-22821 KPa) on Model
2096.
If opening pressure is not as specified, disassem
ble iryector as outlined in paragraph 71 and vary
Fig. 52 CAS-10091 diesel fuel Injection nozzle tester.
Paraqraphs 67-71
shims (3) as required. Shims are available in thirty
thicknesses ranging from 0.039 inch (1.0 mm) to 0.078
inch (1.98 mm). The opening pressure is changed
about 55 psi (379 kPa) for each 0.001 inch (0.0254 mm)
of shim thickness that is added or removed.
NOTE: When testing ail of the Injectors in an en
gine, there must not be more than 150 psi (1034 kPa)
difference between any of the injectors.
69. SPRAY PATTERN. Close the valve to tester
gage and operate tester handle at approximately 60
strokes per minute. Four finely atomized conical
sprays should be emitted from iryector tip. If spray
is solid, streaky or irregular, disassemble and over
haul iryector as outlined in paragraph 71.
70. SEAT LEAKAGE. Point iryector tip downward
and operate tester rapidly to be sure nozzle valve is
seated. Dry iryector tip, then operate tester slowly
to raise gage pressure to within 100 psi (690 kPa) un
der the opening pressure and maintain this pressure
for five seconds. Observe the iryector tip and if noz
zle is in good condition, there should be no fuel ac
cumulation in the five second period although a slight
dampness is permissible. If fuel drips or a visible drop
forms, renew iryector or overhaul as outlined in para
graph 71.
71. OVERHAUL. Soak iryector in a carbon remov
ing solvent and clean outside of iryector thoroughly.
Clamp flats of iryector body (2Fig. 50) in a soft
jawed vise so iryector tip is pointing upward. Use a
box wrench to remove cap nut (8) and BE SURE that
nozzle valve (7) does not turn with cap nut. If nozzle
valve does turn with cap nut, dowels and/or valve
stop (6) will be damaged. Return iryector assembly
to solvent if nozzle valve is stuck to cap nut.
With cap nut removed, nozzle valve (7), valve stop
(6), spring seat (5), spring (4) and shims (3) can be
removed from body (2). Note number and thickness
of shims (3) removed for aid in reassembly. Shims are
available in thirty thicknesses ranging from 0.039
inch (1.0 mm) to 0.078 inch (1.98 mm).
Nozzle valve assembly (7) is a matched set and parts
should never be intermixed. Keep parts for each in
jector separate and immerse in clean diesel fuel or
solvent in a compartmented pan as iryector is disas
sembled.
A brass wire brush can be used to clean exterior
surfaces of nozzle valve (7). Clean nozzle spray
orifices using cleaning wires 0.0005-0.001 inch
(0.0127-0.0254 mm) smaller than orifice holes. Orifice
holes are 0.0114 inch (0.29 mm) on Model 1896 and
0.011 inch (0.28 mm) on Model 2096. Each nozzle con
tains four spray orifices. Use compressed air to clean
ducts in nozzle and a reverse flow of air through tip
end of nozzle is recommended. Clean nozzle valve
Paragraphs 72-73
seat area by using a brush and if necessary to remove
varnish, use solvent and a felt cleaning pad. Make
sure that nozzle valve slides freely in its body. Re
new any parts that are scratched, scored, eroded or
show signs of any other damage.
Reassemble ii\jector as follows: Be sure parts are
wet with diesel fuel and install adjusting shims (3),
spring (4) and spring seat (5) with small diameter side
toward spring. Align dowel pins in valve stop (6) with
dowel holes in body (2) and install valve stop. Install
valve assembly (7) on valve stop, apply Lubriplate to
shoulder only of valve assembly, then install cap nut
(7). Clamp flats of iryector body (2) in a soft jawed
vise and tighten cap nut to a torque of 18 ft.-lbs. (24
N-m).
Recheck iryector opening pressure, and if neces
sary, readjust opening pressure as outlined in para
graph 68.
CASE/INTERNATIONAL
TURBOCHARGER
A Holset turbocharger is used on all models. Refer
to Fig. 53. The unit mounts on exhaust manifold and
uses exhaust pressure to slightly compress the intake
air.
All Models
72. OPERATION. The exhaust manifold is split,
three cylinders porting into each half, minimizing
energy loss due to intermixing. Exhaust gas energy
turns the turbine wheel at a speed which may vary
from a few thousand to 125000 rpm, depending on
engine speed and load. The compressor wheel sup
plies air to the intake manifold (9Fig. 53) on Model
1896 or to the aftercooler (6) on Model 2096 at above
normal atmospheric pressure. The additional air en
tering combustion chamber permits an increase in
amount of fuel burned, and increase power output
over an engine of comparable size not so equipped.
The use of engine exhaust to power the compres
sor increases etigine flexibility, enabling it to perform
with the economy of a small erigine on light loads yet
permitting substantial horsepower increase at full
load. Horsepower loss because of altitude or at
mospheric pressure changes is also largely elimi
nated. TVirbine shaft bearings are floating sleeve type
and unit is lubricated and cooled by a flow of engine
oil under pressure.
All diesel engines operate with an excess of air un
der light loads. In a naturally aspirated engine, most
of the air is used at full load and increasing amount
of fuel results in a higher smoke level with little in
crease in power output. Turbocharging provides a
variation of air delivery and a turbocharged engine
operates with an excess of air up to or beyond de
signed capacity of engine. When more fuel is provid
ed, the turbocharger speed and air delivery increase,
resulting in additional horsepower and heat with lit-
tie change in smoke level. Smoke cannot therefore,
be used as an accurate guide to safe maximum fuel
set ting for a turbocharged engine. Refer to appropri
ate following paragraphs for R&R and overhaul
procedures.
All Models
turbocharger (11Fig. 53), first raise hood and pro
ceed as follows: Disconnect the wire from air clean
er restriction switch. Loosen clamps and remove tur
bocharger intake elbow. Disconnect aspirator tube
from air cleaner and air intake tube from air clean
er. Unbolt and remove air cleaner assembly. Remove
the inner seal clamp and exhaust elbow retaining
bolts. Lift off elbow and exhaust extension. Loosen
clamps on aspirator tube coupling and remove the
tube. Remove muffler mounting bolts and exhau.st el
bow clamp, then remove muffler assembly. Unbolt
and remove air cleaner and muffler support. Remove
pyrometer from exhaust elbow (2), loosen clamping
seal (3), unbolt support (1) and remove elbow assem
bly. On Model 1896, loosen clamps and remove hose
(10), air tube (7) and hose (8) and on Model 2096, loos
en clamp, then unbolt and remove air tube (4) and
hose (10). On all models, disconnect oil supply line
(14) and oil drain line (15) from turbocharger. Unbolt
and remove turbocharger from exhaust manifold (13).
When reinstalling, use new gasket (12) and tighten
turbocharger mounting nuts to a torque of 24 ft.-lbs.
(32 N-m). Install new gasket on oil drain line and
tighten bolts to a torque of 18 ft.-lbs. (24 N-m). In
stall oil supply tube and tighten securely. Complete
installation by reversing the removal procedure.
Turbocharger MUST be primed after installation as
follows: Pull engine stop control out so engine will
not start. Energize starter and crank engine until
MODELS 1896-2096
normal oil pressure green light comes on. (Do not
run starter continuously for more than 30 seconds).
Wait one minute, then start engine. Operate engine
for two minutes at 1000 rpm, then increase to 1800
rpm until normal oil pressure indicator assures proper
lubrication to the turbocharger.
All Models
74. OVERHAUL. With turbocharger removed as
outlined in paragraph 73, place match marks across
compressor housing (1Fig. 54) and back plate (4),
across back plate and center housing (16) and across
center housing and turbine housing (22) for aid in cor
rect assembly.
CAUTION: Do not rest weight of any parts on com
pressor wheel or turbine wheel blades. Weight of
only the turbocharger unit is enough to damage the
blades.
Remove cap screws (12) with washers, remove
clamping plates (13), then lift off compressor hous
ing (1). Straighten tabs of lockplates (24) and remove
cap screws with lockplates and clamping plates (23).
Lift center housing assembly from turbine housing
Paragraph 74
1. Elbow support
2. Exhaust outlet
elbow
3. Clamping seal
4. Air tube
5. Gasket
6. After cooler
7. Air tube
8. Hose
9. Intake manifold
cover
10. Hose
11. Turbocharger
12. Gasket
13. Exhaust manifold
14. Oil supply line
15. Oil drain line
Fig. S3View of turbocharger and relative components. Items 4, 5 and 6 are used on Model 2096 and Items 7, 8 and
9 are used on Model 1896.
(22). Place turbine wheel end of center housing as
sembly in a holding fixture to prevent turbine shaft
from turning and remove nut (2).
NOTE: Use a T handle or a double universal
joint socket to remove the LEFT-HAND THREAD
compressor wheel nut (2).
Remove compressor wheel (3), then remove cen
ter housing from turbine shaft. Remove heat shield
(19) and split ring seal (20) from turbine shaft.
Straighten tabs of lockplates (27), remove cap screws
(26), then remove center housing from back plate.
Remove oil baffle (8) and seal ring (5) from back plate
(4). Remove oil slinger (7) from back plate and split
ring seal (6) from oil slinger. Remove Tbrx head screws
(9), then remove thrust bearing (10) and thrust col
lar (11). Remove outer snap rings (14 and 17) from
each end of center housing and using a wire hook.
pull bearings (15 and 18) from center housing. Re
move inner snap rings (14 and 17) from housing.
Clean all parts in a suitable carbon softening sol
vent. A stiff brush and plastic or wood scraper should
be used after deposits have softened. When clean
ing, use extreme caution to prevent parts from be
ing nicked, scratched or bent.
Inspect turbine housing (22) outlet opening for war
page or cracks. Check compressor housing (1) and
back plate (4) for wheel friction wear. Inspect tur
bine shaft for grooves or scratches and turbine wheel
and compressor wheel for bent or cracked blades or
any other damage. Check heat shield (19) and oil
slinger (7) for damage and center housing (16) bear
ing surfaces for scoring or scratches. If any of these
parts are damaged, renew turbocharger as they are
not serviced separately. A kit consisting of the fol
lowing parts is available for cleaning and servicing
the turbocharger: Nut (2), seal ring (5), split ring seals
CASE/INTERNATIONAL
Fig. 54Exploded view of turbocharger assembly used on all models.
1. Compressor
housing
2. Nut
3. Compressor
wheel
4. Baclc plate
5. Seal ring
6. Split ring seal
7. Oil slinger
8. Oil bafne
9. Screw (3)
10. Thrust bearing
11. Thrust collar
12. Cap screw
13. Clamping plate
14. Snap rings
15. Bearing
16. Center housing
17. Snap rings
18. Bearing
19. Heat shield
20. Split ring seal
21. Turbine wheel &
shaft
22. Turbine housing
23. Clamping plate
24. Lockplate
25. Cap screw
26. Cap screw
27. Lockplate
28. Gasket
75. REMOVE AND REINSTALL, lb remove the
after cooler (7Fig. 55), drain cooling system and re
move air cleaner and muffler. Remove drain plug (8)
and drain after cooler. Loosen clamps (1) on hose (2),
then unbolt and remove air tube (4). Unbolt and re
move the two front and two rear rocker arm covers.
Remove the fuel iryector lines. Immediately cap or
plug all fuel openings. Disconnect coolant hoses (10
and 12), then unbolt and remove after cooler.
1. Clamps
2. Hose connector
3. Cap screw
4. Air tube
5. Gasket
6. Air bleed plug
7. After cooler
8. Drain plug
9. Gasket
10. Inlet hose
11. Inlet tube
12. Return hose
13. Return tube
MODELS 1896-2096
(6 and 20), Tbrx head screws (9), thrust bearing (10),
cap screws (12) with lockwashers, snap rings (14 and
17), bearings (15 and 18), lockplates (24 and 27), cap
screws (25 and 26) and gasket (28).
Lubricate all parts with clean engine oil and reas
semble by reversing the disassembly procedure.
When installing snap rings (14 and 17) make sure
round edge of snap rings face the bearings. When in
stalling nut (2), use a double universal joint socket
and tighten to a torque of 120 in.-lbs. (14 N-m). Oth
er tightening torques are as follows: Center housing
to back plate cap screws (26), 48 in.-lbs. (6 N-m); Tbrx
head screws (9), 36 in.-lbs. (5 N-m); Center housing
to turbine housing cap screws (25), 96 in.-lbs. (11
N*m); Back plate to compressor housing cap screws
(12), 48 in.-lbs. (6 N-m).
With unit reassembled, use a dial indicator and
check turbine shaft horizontal end play which should
be 0.0039-0.0062 inch (0.1-0.16 mm). If shaft end play
exceeds 0.0062 inch (0.16 mm), thrust collar (11)
and/or thrust bearing (10) is worn excessively. End
play of less than 0.0039 inch (0.1 mm) indicates in
complete cleaning (carbon not all removed) or dirty
assembly and unit should be disassembled and
recleaned.
Reinstall turbocharger, then prime turbocharger as
AFTER COOLER
Model 2096
NOTE: If any damage Is shown to after cooler, re
new the complete after cooler assembly.
Clean mounting surfaces of after cooler and cylin
der head of all foreign material. Using a new gasket
(9), install after cooler. Coat threads of cap screws
with Loctite liquid Teflon, then install and tighten
cap screws to a torque of 18 ft.-lbs. (24 N-m). Follow
the tightening sequence shown in Fig. 27. Complete
installation by reversing the removal procedure,
keeping the following points in mind: Use new gas
ket (5Fig. 55) on air tube (4) and tighten cap screws
(3) to a torque of 18 ft.-lbs. (24 N-m). When reinstall
ing rocker arm covers, tighten cap screws to a torque
of 18 ft.-lbs. (24 N-m). When refilling with coolant,
loosen air bleed plug (6) to remove air from after
cooler.
Paragraphs 75-76
AIR CLEANER SYSTEM
All Models
76. FILTERS. All models are equipped with a dry
type air cleaner with a safety filter element (7Fig.
56). This element should be renewed each 1000 hours
of operation. DO NOT attempt to clean safety
element.
Large primary filter element (1) can be cleaned by
directing compressed air into inside of element. Air
pressure must not exceed 100 psi (689.5 kPa). An el
ement cleaning solution, part No. A40910 is availa
ble. Renew primary element after four cleanings.
Tractor is equipped with an air filter restriction
switch and warning lamp on the digital instrument
cluster which will indicate when primary element
needs service.
Fig. 55View of after cooler and relative parts used on
Model 2096.
Paragraphs 77-78
Fig. 56Exploded view of air cleaner assembly used on
all models.
1. Primary element
2. Cover
3. Seal washer
4. Wing nut
5. Wing nut
6. Seal washer
7. Safety element
8. Air cleaner
housing
9. Hose connector
10. Inlet air duct
11. Air cleaner &
muffler support
12. Bracket
13. Aspirator tube
14. Support
15. Turbocharger air
intake hose
COOLING SYSTEM
RADIATOR
All Models
radiator, drain cooling system and disconnect front
wiring harness. Remove hood, grille and side panels.
Disconnect upper and lower radiator hoses, air intake
duct and air conditioner lines at quick couplers. Iden
tify and disconnect oil cooler lines. Attach a hoist to
the radiator, condenser and oil cooler assembly sup
port brackets. Remove two rear bolts and three front
bolts, then lift off the assembly.
Unbolt and remove the condenser, oil cooler, up
per air baffle and fan shroud. Unbolt sides and bot
tom of radiator and remove radiator.
Reiiistall by reversing the removal procedure. Make
certain that all foam rubber seals are correctly in
stalled in their original positions. Tighten the five
bolts securing the radiator, condenser and oil cooler
a.ssembly support to front support to a torque of 35-
42 ft.-lbs. (48-57 N*m). Refill radiator with coolant.
On Model 2096, loosen plug (6Fig. 55) to bleed air
from after cooler. Coolant capacity on all models is
approximately 22 U.S. quarts (20.8 L).
A 15 psi (103 kPa) radiator cap is used on all models.
CASE/INTERNATIONAL
THERMOSTAT
All Models
thermostat (5Fig. 58), first drain cooling system and
proceed as follows; Raise belt tensioner and remove
fan belt. Remove alternator, then unbolt and remove
alternator mounting bracket (2). Remove upper radi
ator hose from thermostat housing. Remove cap
Fig. 57Exploded view of exhaust pipe and muffler used
on all models.
1. Extension pipe
2. Exhaust elbow
3. Pipe with
aspirator tube
connector
4. Elbow
5. Muffler
6. Muffler retainer
band
7. Air cleaner &
muffler support
8. Bracket
9. Rear lift bracket
MODELS 1896-2096
screws (3 and 8) and lift off thermostat housing (4)
with thermostat (5), seal (6) and engine front lift
bracket (7). Remove lift bracket, seal and thermostat
from housing.
Before installation, test thermostat for correct tem
perature. Thermostat should start to open at approx
imately 181 F (83 C) and be completely open at
203 F (95 C).
Fig. 58View showing thermostat and relative compo
nents.
1. Cap screw (3)
2. Alternator bracket
3. Cap screw (2)
4. Thermostat
housing
5. Thermostat
6. HoiLsing seal
7. Front lift bracket
8. Cap screw
Fig. 59View showing water pump, belt tensioner and
fan with component parts. Items 1, 2 and 3 and Items 8
and 9 are serviced only as assemblies.
1. Bracket
2. Shaft & be2Lring
3. Hub
4. Fan pulley
5. Belt
6. Spacer
7. Fan
8. Water pump
pulley
9. Water pump
10. "O" ring
11. Belt tensioner
12. Bracket
Install thermostat so that tang on thermostat is in
slot of the housing. Install seal (small diameter first)
in housing, then place lift bracket over the seal. In
stall the assembly and tighten cap screws to a torque
of 18 ft.-lbs. (24 N*m). Install alternator bracket (2)
and tighten cap screws (1) to 18 ft.-lbs. (24 N*m)
torque. The balance of installation is the reverse of
removal procedure.
Paragraphs 79-81
WATER PUMP
All Models
water pump assembly (8 and 9Fig. 59), first drain
cooling system and proceed as follows: Raise belt ten
sioner (11) and remove fan belt (5). Remove retain
ing cap screws and withdraw water pump with 0
ring (10).
Water pump (9) and pulley (8) are available only as
an assembly. When reinstalling, use new O ring (10)
and tighten water pump housing cap screws to a
torque of 18 ft.-lbs. (24 N-m).
ELECTRICAL SYSTEM
BATTERIES
All Models
80. Before any electrical system service is per
formed, a thorough check of battery condition, con
dition of cable connections and condition of alterna
tor drive belt should be made.
Batteries should be checked for total voltage and
voltage drop under rated load. If battery voltage is
excessively low, they should be recharged to rated
level using an external battery charger. Failure to do
so can cause alternator to overheat resulting in
premature failure of alternator, regulator or both.
All relative connections should be checked for ex
cessive resistance, using an ohmmeter.
81. BATTERY CURRENT DRAIN TEST. If after
checking, servicing and installing batteries, they re
turn to an undercharged condition when tractor is
not in use, current drain should be suspected. Tb
check, disconnect negative battery cables at starter
ground post and connect an ammeter lead to starter
negative post and the other lead to negative cable
ends. Make sure all electrical systems are off. Any
reading on ammeter indicates current leakage. Check
for lights, radio or accessories being on, or shorted
electrical wiring or components.
Paragraphs 82-86
CHARGING SYSTEM
All Models
82. TESTING. Prior to beginning test, be sure bat
teries are fully charged, all connections are clean and
tight and alternator drive belt is in good condition.
CAUTION: Do not disconnect any wires from al
ternator while engine Is running as damage to al
ternator may result.
Alternator warning light should not come on when
key switch is in OFF position. If light fails to go out
when key is in OFF position, test circuits as outlined
in paragraph 83.
Normal operation of alternator warning light is to
come on only when key switch is in ACC or ON posi
tion, engine NOT running. If engine is started while
throttle is in low idle position, light may stay on un
til engine speed is increased for the first time. Light
should not come on at any time after engine is run
ning and initial engine speed increase was sufficient
to shut light off. If operation of warning light is not
normal, test circuits as outlined in paragraph 83.
83. WARNING LIGHT CIRCUIT TEST. If warning
light fails to go out with key switch in OFF position,
disconnect plug at alternator. If light goes out when
plug is removed from alternator, rectifier bridge in
alternator is defective.
If light stays on after disconnecting plug at alter
nator, there is an electrical short between brown and
red wires at some place in the wiring harness. Check
wire insulation for damage.
If the light fails to come on with the key switch in
ACC or ON position, engine NOT running, disconnect
plug from alternator and connect a jumper wire be
tween brown wire and alternator housing (ground).
CAUTION: Do not connect the red wire to a ground
at any time.
If light comes on at this time, alternator LED warn
ing light and wiring are good and problem is in alter
nator. Check as outlined in pju^graph 84. If light still
fails to come on, check LED warning light, current
supply to socket and wiring from socket to alternator.
If warning light functions normally with engine not
running, but fails to go off when engine is running
at various speeds, check alternator as outlined in
paragraph 84.
84. ALTERNATOR VOLTAGE OUTPUT TEST. Make
certain all wiring connections are in place, then con
nect voltmeter positive lead to BAT terminal of al
ternator and ground negative lead to adequate
ground. Start engine and operate at 2100 rpm. Volt-
meter should read between 13 and 15 volts. If volt
age is less than 13 volts, bypass regulator and check
as in paragraph 85. Voltage in excess of 15 bolts indi
cates either a grounded brush inside the alternator
or a faulty voltage regulator.
CASE/INTERNATIONAL
85. VOLTAGE REGULATOR BYPASS TEST. With
voltmeter connected as in paragraph 84, start and op
erate engine at 2100 rpm. Ground tab on brush holder
to alternator case using a small screwdriver inserted
through test hole in back of alternator case. See Fig.
60. If voltage before bypassing regulator was less than
13 volts, but is between 13 and 15 volts while regu
lator is being bypassed, renew voltage regulator. If
voltage fails to be between 13 and 15 volts while
bypassing regulator, remove alternator and overhaul.
NOTE: Do not Insert the screwdriver more than
one Inch (25.4 mm) Into test hole In back of al
ternator.
86. ALTERNATOR AMPERAGE OUTPUT TEST
Connect an ammeter in alternator output circuit as
shown in Fig. 61. Start and run engine at 2100 rpm.
Turn light switch to ROAD position and connect
a carbon pile across battery terminals. Acyust carbon
pile for maximum current output. Ammeter reading
should be between 95 and 105 amperes. If the read
ing is less than 95 amperes, insert a small screwdriver
through the test hole in back of alternator case (Fig.
60) and ground tab on brush holder to case.
NOTE: Do not Insert the screwdriver more than
one Inch (25.4 mm) Into test hole In back of al
ternator.
If the reading on the ammeter is now 95 to 105 am
peres, renew voltage regulator. If the reading is still
less than 95 amperes, disassemble and test the rotor,
diode trio and rectifier bridge. If these components
test good, renew stator coil assembly.
Fig. 60View of small screwdriver Inserted In test hole
In back of alternator case during regulator bypass test.
MODELS 1896-2096
ALTERNATOR
All Models
87. Delco-Remy 15-SI series alternator is used on
all models. Alternator is equipped with a solid state
regulator internally mounted and has no provisions
for acûstment. Specificatioris are as follows;
Delco-Remy 1105560
Field current at 80 F
(27 C ) -
Volts .............................................................12
Amperes ................................................ 4.0-4.6
Rated cold output at 75 F
(24 O -
Amperes..................................................... 110
Rpm ......................................................... 5000
Rated hot output at 160 F
(71 O -
Amperes .................................................... 105
Rpm ......................................................... 5000
88. DISASSEMBLY AND TESTING. Scribe align
ment marks (MFig. 62) to ensure proper reassem
bly. Remove housing retaining bolts, then separate
Fig. 61Install ammeter In alternator output circuit to
check amperage output. Refer to text.
drive end housing (14) and rotor (10) from rear hous
ing (2) and stator (9). Remove nut (20), washer (19),
tapered retainer (18), pulley (17), fan (16) and spacer
(15) from rotor shaft and withdraw rotor from hous
ing. Remove retainer (12) and ball bearing (13). Re
move the diode trio (6), then disconnect and remove
stator (9). Remove the relay terminal strip (7).
Install and tighten the three terminal nuts on rec
tifier bridge and test rectifier as follows: Connect one
lead from an ohmmeter to the insulated heat sink
(DFig. 63). Connect the other lead to terminal (A)
and record the reading. Reverse the ohmmeter leads
and check the meter reading. If both readings are the
same, rectifier bridge is faulty. Repeat this test be
tween points (D-B) and (D-C), then using ground heat
sink (E), retest at points (E-A), (E-B) and (E-C). The
ohmmeter readings should be high in one direction
and low when leads are reversed. Remove the capac
itor (8Fig. 62) and rectifier bridge. Remove the
brush holder assembly (4) and voltage regulator (3).
Use a pipe to support slip ring end frame (2) around
needle bearing (1) and drive bearing inward until free
of frame (2).
Paragraphs 87-92
89. ROTOR TESTS. Refer to Fig. 64 and touch ohm
meter probes to points (1-2) and (1-3). A reading near
zero will indicate a short circuit to ground. Tbuch
ohmmeter leads to the slip rings (2-3). Ohmmeter
reading should be 2.6 to 3.0 ohms. A higher reading
will indicate an open circuit and a lower reading will
indicate an internal short. If windings are satisfac
tory, mount rotor in a lathe and check runout at slip
rings using a dial indicator. Runout should not exceed
0.002 inch (0.050 mm). Slip ring surfaces can be trued
if runout is excessive or if surfaces are scored. Fin
ish with 400 grit or finer polishing cloth until scratch
es or machine marks are removed.
90. BRUSH HOLDER AND BRUSHES. Brushes
should work freely in holder and have sufficient
spring pressure to maintain brush to slip ring contact.
Brushes, springs and holder are serviced only as an
assembly and should be renewed if brushes are worn
to a length of less than V4inch (6 mm) measured as
shown in Fig. 65.
91. STATOR WINDING TEST. Connect one lead of
an ohmmeter to the stator frame as shown in Fig. 66.
Connect other lead to A , B and then C . If
ohmmeter gives a zero reading for any of the tests,
there is a direct short between stator coils and sta
tor frame. Renew stator assembly.
92. DIODE TRIO TEST. Connect one lead of an
ohmmeter to long connector (DFig. 67) on the di
ode trio. Connect the other lead to cormector (A) and
record the ohmmeter reading. Reverse the leads on
Paragraph 93
(D) and (A) and compare reading with first reading.
If both readings are the same, renew the diode trio.
A good diode will show one high reading and one low
reading on the ohmmeter. Repeat this test between
(D-B) and (D-C).
Connect leads of ohmmeter between (A-B), (A-C)
and then (B-C). There must not be any electrical con
nection between any of these terminals. If any of
these tests show a reading of zero ohms, renew the
diode trio.
93. REASSEMBLY. Reassemble by reversing the
disassembly procedure, keeping the following points
in mind. When installing needle bearing (1Fig. 62),
press bearing in from outside until bearing is flush
with outside of end frame (2). When installing volt-
CASE/INTERNATIONAL
Fig. 63View of Installed rectifier bridge showing
Insulated heat sink (D), grounded heat sink (E) and
Individual diode connectors (A, B and C).
1. Needle bearing
2. Slip ring end
frame
3. Voltage regulator
4. Brush holder
assy.
5. Rectifier bridge
6. Diode trio
7. Relay terminal
8. Capacitor
9. Stator
10. Rotor
11. Collar
12. Bearing retainer
13. Ball bearing
14. Drive end frame
15. Spacer
16. Fan
17. Pulley
18. Tapered retainer
19. Washer
20. Nut
Fig. 62Exploded view of Delco-Remy alternator used with Internal mounted solid state regulator. Note matching marks
(M) on end frames.
age regulator, note position of ground screw (Fig. 68).
Other two screws are insulated. Push brushes against
Fig. 64Removed rotor assembly showing test points
when checking for grounds, shorts and opens. Refer to
text.
Fig. 65Renew brushes If worn to a length of less than
V* Inch (6 mm).
Fig. 66Use an ohmmeter to check for shorts between
stator frame and stator leads (A, B and C).
spring pressure, then insert a plastic pin or toothpick
through holes in brush holder and slip ring end frame
to hold brushes in retracted position. When install
ing drive pulley (17Fig. 62), tighten nut (20) to a
torque of 40-60 ft.-lbs. (54-81 N*m). Align match
marks (M) and assemble housings (2 and 14). Make
certain that pin retaining brushes is removed after
housings are assembled.
Rg. 67View showing ohmmeter being used to test diode
trio. Refer to text.
Fig. 68View showing location of regulator ground
screw. Other two screws are Insulated.
STARTING MOTOR
All Models
94. DISASSEMBU^ AND TESTING. Tb disassem
ble the starting motor, first remove terminal cover
(5Fig. 69), then unbolt and remove terminal con
nector (4), lead wire (14) and magnetic switch (2). Re
move cover (1) and drain tube (3) from magnetic
switch. Remove end cover (34), gasket (33) and 0
ring (24). Remove brush lead screws, pull upward on
brush springs (29), remove brushes (30) from brush
holder, then remove springs. Place match marks
across commutator end frame (31) and field frame
(21) for aid in correct alignment during assembly. Un
bolt and remove end frame (31) and washer (28).
Place an alignment mark across drive housing (8),
center housing (16) and field frame (21). Unbolt and
remove drive housing (8) and O ring (9). Remove
cap screws securii\g center housing (16) to field frame
(21), then remove center housing with drive clutch
(12) and armature (27) from field frame assembly. Re
move 0 ring (20). Unbolt shift lever (13), drive col
lar (11) on armature shaft, then remove snap ring (10)
1. Cover
2. Magnetic switch
3. Switch drain
tube
4. Terminal
connector
5. Terminal cover
6. Bushing
7. Plug
8. Drive housing
9. "O" ring
10. Snap ring
11. Collar
12. Drive clutch
13. Shift lever
14. Lead wire
15. Washer
16. Center housing
17. Lube wicks
18. Center bushing
19. Oil seal
20. "O" ring
21. Field frame
22. Connector
terminal
23. Field insulator
24. "O" ring
25. Pole shoe (4)
26. Field coils
27. Armature
28. Washer
29. Brush spring (4)
30. Brush(4)
31. Connector end
frame
32. End frame
bushing
33. Gasket
34. End cover
35. Brush connector
36. Starting motor
assy.
Fig. 69Exploded view of the NIppondenso starting motor used on all models.
and collar. Slide drive clutch (12) with shift lever (13),
washer (15) and center housing (16) from armature
(27).
Using an ohmmeter, touch one probe to the field
terminal stud and the other probe to the brush lead.
If there is no continuity, field winding has an open
and must be repaired or renewed. Tbuch one ohm
meter probe to field terminal stud and other probe
to the surface of field frame. If there is continuity,
the field coils have a ground and must be repaired
or renewed.
Tbuch one probe of the ohmmeter to a commuta
tor segment and the other probe to the armature
core. If there is continuity, armature has a ground and
must be renewed. Tbuch the two ohmmeter probes
to two commutator segments. If there is no continui
ty, the armature winding has an open circuit and
must be renewed.
Measure the inside diameter of bushings (6, 18 and
32) and the outside diameter of their corresponding
surfaces on armature. Renew bushings if clearance
is more than 0.008 inch (0.2 mm).
Check the length of brushes (30) and renew them
if worn to a length of less than 0.67 inch (17.0 mm).
Inspect the drive clutch (12) to make certain that
the piiuon can rotate freely in direction of starter ro
tation and that it will lock up in opposite direction.
95. REASSEMBLY. When reassembling, install
new oU seal (19-Fig. 69), O rings (9, 20 and 24)
and gasket (33) and reverse disassembly procedure.
Lubricate the lube wicks for bushings with lOW-30
engine oil. Tightening torques are as follows:
Drive housing screws .................... 97-150 in.-lbs.
(11-17 N-m)
Center housing to field
frame screws ............................... 58-93 in.-lbs.
(6.6-10.5 N-m)
Commutator end frame screws . . . . 97-150 in.-lbs.
(11-17 N-m)
Shift lever pivot screw .................. 26-44 ft.-lbs.
(36-60 N-m)
Magnetic switch screws.................. 58-93 in.-lbs.
(6.6-10.5 N-m)
Magnetic switch hex nut ...............71-124 in.-lbs.
(8-14 N-m)
Field terminal stud hex nut ........... 43-60 in.-lbs.
(4.8-6.8 N-m)
MAGNETIC SWITCH
All Models
96. TESTING. Tb test the magnetic switch for
proper operation, connect a 12 V battery as shown
in Fig. 70. Remove terminal connector between field
terminal stud and magnetic switch. When test switch
is closed, the drive clutch and pinion must move out
ward. When test switch is opened, drive clutch and
pinion must move inward. If operation is incorrect,
disconnect battery and wires. With terminal connec
tor removed, connect a multimeter as shown in Fig.
71 and test for continuity. If there is no continuity,
renew magnetic switch.
WIRING
All Models
97. When a problem is suspected in wiring harness
follow an orderly, step by step check of the probleir
circuit. Always check protective circuits (fuses, cir
cuit breaker and diodes) first, then locate the primarj
point of current supply for circuit in question. Ustnf
a 12 volt test light or a voltmeter, check for adequate
voltage at this point. If voltage is present at thii
Fig. 70View showing connections when testing startim
motor magnetic switch.
Fig. 71Use a multimeter as shown to check fc
continuity.
point, continue to check for voltage at appropriate
connections along harness working toward malfunc
tioning unit until problem area is isolated. Harness
connectors (plugs), sockets and connection terminals
being corroded, loose or broken are most often the
cause for interruptions in power supply.
If voltage was not present at primary point of cur
rent supply, check wiring moving toward battery un
til interruption of current is isolated. Repair as
needed.
PROTECTIVE CIRCUITS
All Models
98. FUSES. Fuses are installed in circuits to pro
tect wiring from damage in event of shorted wiring.
When fuse is blown (fuse strip melted), a fuse of the
same size and amperage must be installed after locat
ing and repairing the problem.
99. CIRCUIT BREAKERS. Circuit breakers per
form the same function as fuses, however a circuit
breaker will cut off current flow, breaker will cool
down and reset automatically, ree.stablishing current
flow. Usually used in lighting, cab wiring and gage
circuits, it eliminates complete failure allowing limit
ed use of systems considered necessary for safe op
eration.
Circuit breakers will be in line with red wire con
nected to positive cable connection of magnetic
switch. Under normal operation with voltage at BAT
connection of circuit breaker, voltage should pass
through breaker to remaining terminal.
ACCESSORY SYSTEMS
All Models
Accessory systems include lights, digital instrument
cluster warning systems, windshield wipers, cab ven
tilating, heating and air conditioning system.
100. LIGHTS. Front and rear work lights, tail
lights and warning lights are standard equipment,
however additional front and rear work lights are
available.
Single light failure is usually a bad light bulb, poor
ground or bad current connection. Multiple light fail
ure is usually caused by bad switch or power source
wiring problems. Check fuses and circuit breakers,
then check wiring as outlined in paragraph 97.
101. DIGITAL INSTRUMENT CLUSTER WARN
ING SYSTEMS. Gage and warning systems consist
of three basic components, which are the LCD (liq
uid crystal diode) bar indicators or LED (light emit
ting diode) warning lights, sending units or activat
ing switches and necessary wiring to connect all
components.
102. SYSTEMS NORMAL UGHT. The Systems Nor
mal indicator (1Fig. 72) is a green LED (light emit
ting diode). It works in coryunction with most of the
1. Green systems
normal
2. Turn signals
3. Air filter service
4. Hydraulic
(transmission)
filter
5. Fuel level
6. Coolant level
7. Transmission oil
(pressure &
temperature)
8. Engine oil
pre.ssure
9. Alternator
10. Voltage level
11. Coolant
temperature
12. Exhaust
temperature
13. Park brake
Fig. 72View showing location of Instrument cluster Indicators.
MODELS 1896-2096 Paragraph 103
digital cluster LEDs and LCDs. The Systems Nor
mal green light is usually ON. When it is ON, it in
dicates that the critical tractor systems are function
ing properly and conditions are safe to operate the
tractor.
When a critical condition exists, a red LED warn
ing light comes ON or a LCD bar indicator flashes.
As soon as the critical condition warning appears, the
green Systems Normal light goes OFF. The criti
cal condition LED s and LCDs are the following:
a. Engine oil LED
b. Water level LED
a Alternator LED
d. Transmission oil LED
e. Coolant temperature LCD
f. Exhaust temperature LCD
g. Voltage level LCD
h. Park brake LED
The green LED Systems Normal light will remain
ON when the following less critical system lights
come ON.
a. Air filter LED
b. Transmission filter LED
c. Fuel level LCD
d. Turn signals LED
103. OIL PRESSURE LIGHT. Normal operation of
oil pressure warning light (8Fig. 72) is to light when
key is in ON position, engine not running and to go
out when engine is running and adequate oil pres
sure is reached.
There are two pressure switches that monitor the
engine oil pressure. See Fig. 76. One switch monitors
the oil pressure at idle speed and the other switch
monitors the pressure at 1800 rpm or above. When
engine oil pressure is low at idle speed (800 rpm), low
rpm pressure switch closes and sends a ground sig
nal to pin (10Fig. 73) on instrument cluster. This
causes the following results:
1. The engine oil service monitor (LED) comes ON.
2. The alarm sounds ON and OFF.
3. The green Systems Normal light goes OFF.
4. If tractor is equipped with an automatic shutdown
system, 30 seconds after alarm sounds, the tractor
will shut down.
If oil pressure is low at engine speed of 1800 rpm
or above, the high rpm pressure switch wiU close and
send a ground signal to pin (2) on instrument clus
ter. A ground signal at pin (2) will cause the same four
results as listed for the low rpm switch.
If oil pressure is low and engine rpm is less than
1800, high rpm pressure switch will close sending a
ground signal to pin (2). However, since engine rpm
is less than 1800, ground signal to pin (2) will not
cause the four previously listed results.
If engine oil pressure monitor (warning Ught) comes
on when engine is running, check low rpm pressure
switch as follows: Turn key off and stop engine. Dis
cormect wire (31Fig. 77) from low rpm switch. Mak(
sure wire (31) does not touch any ground on tractor
Turn the key switch ON and check the oil pressurt
warning light which should be OFF. If light is ON
check for grounded circuit between wire (31) and pir
(10). If light is OFF, wiring is good and pressure t(
the switch should be checked. The low rpm switcl
is normally closed and switch opening and closinj
Fig. 73View of sensor pin connections at Instrument cluster.
1. Not used
2. Engine oil 22 psi
(151.7 kPa)
3. Engine shutdown
4. Transmission ( + )
input mph
5. Hand brake
6. Air filter
7. Tractor decode C
8. Instrument
memory
9. Engine rpm ( + )
10. Engine oil 8 psi
(55.2 kPa)
11. Transmission oil
(pressure &
temperature)
12. Not used
13. Not used
14. Fuel level
15. Coolant
temperature
16. Hydraulic
transmission) filter
17. Coolant level
18. Not used
19. Not used
20. Not used
21. Tractor decode A
22. Exhaust
temperature
(yellow +)
23. Alternator
24. Fuse holder
(5 amp)
25. Ground for engine
rpm
26. Not used
27. Not used
28. Fuse holder
(3 amp)
29. Right turn
30. Tractor decode B
31. Chassis ground
32. Ground for
transmission mpl
33. Exhaust
temperature (red
34. Left turn
35. Fuse holder
(20 amp)
36. Not used
37. System ground
pressures are as follows: Low rpm pressure switch
opens at 10 psi (68.9 kPa) on increasing pressure and
closes at 6 psi (41.4 kPa) on decreasing pressure.
Tb check the pressure to the low rpm switch, re
move the switch and install a 0-60 psi (0-414 kPa) hy
draulic test gage. Start tractor and operate at 800
rpm, then check gage pressure. If there is enough en
gine oil pressure, 10 psi (68.9 kPa), to open the low
rpm switch, renew the switch and connect wire (31).
Check to make certain that oil pressure warning light
is OFF at low idle speed.
After renewing low rpm switch, start engine and
operate at 1800 rpm or above. If warning light is on,
disconnect wire (39Fig. 78) from high rpm pressure
switch and make sure wire (39) does not touch any
ground on tractor. Warning light should be OFF. If
light is ON, check for grounded circuit between wire
(39) and pin (2). If light is OFF, wiring is good and
pressure to the high rpm switch should be checked.
Stop engine, remove high rpm switch and install the
0-60 psi (0-414 kPa) pressure test gage. Start engine
and operate at 1800 rpm or above and check test gage
reading. High rpm pressure switch opens at 25 psi
(172 kfti) on increasing pressure and closes at 20 psi
(138 kPa) on decreasing pressure. If test gage reads
25 psi (172 kPa) or higher, renew high rpm pressure
switch.
After renewing high rpm switch, connect wire (39)
and operate engine at 1800 rpm or above. Check to
make sure warning light is OFF. If not, renew instru
ment cluster.
system and tractor is being started in cold tempera
ture of 32 F (0 C) or colder, automatic shutdown
may occur after 30 seconds due to low oil pressure.
Tb prevent shutdown, depress the override switch lo
cated on the steering console.
104. AIR FILTER LIGHT. A vacuum switch moni
tors the condition of the air filter system. The switch
is located on the right front of the air cleaner hous
ing. When air filters need servicing during operation,
the vacuum switch closes sending a ground signal to
pin (6Fig. 73). This ground signal causes air filter
Fig. 75Transmission harness connector located on
lower cab platform showing pin locations.
1. Neutral start
switch
2. Not used
3. Ground for
transmission mph
4. 'I'ransmission ( + )
input mph
5. Transmission
pressure &
temperature
switches
6. Hydraulic
(transmission) oil
filter
7. Implement tail
light connector
8. Differential lock
solenoid
9. Implement left
turn connector
10. Implement right
turn connector
Fig. 74Engine harness firewall connector pin letter location.
AS. Air conditioning compressor clutch
AT. Engine rpm kickup signal (-)
All. Circuit breaker (50 amp)
AV. Circuit breaker (50 amp)
\W. High beam lights (field lights)
AX. Chassis ground
AZ. Front flood light attach
BS. Ether starting attach
BT. Alternator
BU. Circuit breaker (50 amp)
BX. Not used
BY. Not used
BZ. Coolant level sender
CS. Engine shutdown solenoid
CT. Engine rpm pickup signal ( + )
CU. Circuit breaker (50 amp)
ex. Not used
CY. Engine oil pressure 8 psi (55.2 kPa)
CZ. Engine air filter switch
DS. Not used
DT. Circuit breaker (50 amp)
DU. Circuit breaker (50 amp)
DV. Circuit breaker (50 amp)
DW. Low beam lights (road lights)
DX. Not used
DY. Engine oil pressure 22 psi (151.7 kPa)
DZ. Coolant temperature sender
MODELS 1896-2096
Paragraphs 105-106
warning (red LED) light (3Fig. 72) to come ON and
a 3 second alarm sounds. Check filter elements and
renew as necessary.
Start engine and observe warning light. If light
stays on with engine running, stop engine and dis
connect wire from the vacuum switch. Start tractor
and make certain vacuum switch wire is not touch
ing any ground on tractor. Warning light should be
OFF. If not, check wire from vacuum switch to pin
(6Fig. 73) for shorts or grounds. Repair as neces
sary. If warning light is OFF, wire is good.
Ground the end of vacuum switch wire and if light
comes ON, renew the vacuum switch.
Fig. 76View showing location of engine oil low rpm
switch (rear) and high rpm switch (front).
105. COOLANT LEVEL LIGHT. A water probe
monitors the water level. The probe is mounted
through the rear wall of the radiator upper tank.
When end of probe is immersed in water, the water
completes a circuit path to ground and light (6Fig.
72) is OFF. When water level is down to an unsafe
level and probe tip is out of water, there is no cur
rent path to ground. The circuit is open and the re
sistance becomes very high (about 30 K ohms). A f
ter two to three seconds, water level light will come
ON, a 3 second alarm will sound and the green Sys
tems Normal light (1) wiU go OFF.
Check water level in radiator and add coolant tc
proper level. If light stays ON, with key switch ON
and water level correct, check for excessive moisture
at connections. Dry as necessary and reconnect the
connectors.
With key switch OFF, use an ohmmeter and check
resistance between harness pin (17Fig. 73) and
ground. With probe in water, resistance should be
about 10 K ohms. If the resistance is very high (more
than 20 K ohms) or very low (less than 5 K ohms),
water probe is defective and must be renewed.
For a final test, disconnect level probe circuit wire
(57Fig. 79) and turn key switch ON. When end ol
wire (57) is NOT touching a ground, the red LEE
warning light must be ON. When end of wire (57) L
touching ground on tractor, light should be OFF.
106. ALTERNATOR LIGHT. Normal operation ol
the LED alternator warning light is with key switcl
ON and engine not running, light should be ON. Witl
engine operating, light should be OFF. Refer to para
graphs 82 and 83 for tests.
Fig. 77Disconnect wire (31) when checking low rpm
pressure switch. Refer to text.
Fig. 78Disconnect wire (39) when checking high rpn
pressure switch. Refer to text.
107. PARK BRAKE LIGHT. The LED park brake
warning light (13Fig. 72) should be ON when key
switch is ON and park brake is engaged. If not, check
circuits (30F and 35Fig. 80) for loose connections
or broken wires. Also check to make sure the me
chanical switch lever raises when brake lever is up
(applied).
Connect ohmmeter as shown in Fig. 80. Resistance
should be zero ohms with switch lever up and infinite
ohms with switch lever down. If readings are within
these limits, renew instrument cluster. If readings are
not within these limits, touch ohmmeter probes to
switch connectors as shown in Fig. 81. Resistance
should be zero ohms with switch lever up and infinite
ohms with switch lever down. If readings are not
within these limits, renew park brake switch.
108. TRANSMISSION OIL LIGHT Two switches
monitor the transmission oil condition. One is a tem
perature switch and the other a pressure switch.
Fig. 79Disconnect wire (57) when checking coolant level
probe system. Refer to text.
Fig. 80Connect ohmmeter as shown between pin (5)
and ground when checking park brake light.
Both switches are connected to cluster connector pin
(11Fig. 82), so either switch may activate the LED
transmission oil warning light.
The pressure switch is normally closed (engine
stopped). When engine is operating and transmission
oil pressure rises to about 165 psi (1138 kPa), pres
sure switch opens and warning light goes OFF. If pres
sure drops below 130 psi (896 kPa), pressure switch
closes and warning light comes ON.
Fig. 81Touch ohmmeter probes to switch connectors
when checking park brake switch.
Fig. 82Circuits (38) for transmission oil temperature and
(38A) for transmission oil pressure Join together, then
continue on to pin (11).
MODELS 1896-2096 Paragraphs 109-11C
The transmission oil temperature switch is normal
ly open. When engine is operating and oil tempera
ture rises to above 225 F (107 C), temperature
switch closes and warning light comes ON.
When either switch closes (engine operating), a
ground signal is sent to pin (11). After a 7 or 8 sec
ond delay, the ground signal on pin (11) causes the
transmission warning light to come ON, an alarm
sounds ON and OFF and the green "Systems Normal
light goes OFF. If tractor is equipped with an auto
matic shutdown system, 30 seconds after alarm
sounds tractor will shut down.
Tb check the transmission oil pressure switch, with
tractor OFF, disconnect pressure switch wire at
switch. Make certain that wire terminal does not
touch ground. Turn key switch ON and check the
warning light. Since the pressure switch is discon
nected and the temperature switch is normally open,
warning light should be OFF. If light is still ON, check
wiring for shorts or grounds. If light is OFF, the wir
ing is good, but the oil pressure should be checked
as follows: Unscrew the pressure switch and install
a 0-200 psi (0-1380 kPa) hydraulic test gage. Start en
gine and check pressure reading on gage. If gage
reading indicates sufficient pressure of 165 psi (1138
kPa) to open the switch, renew the pressure switch.
After renewing the pressure switch, check the
warning light. If it is still ON, check the transmission
oil temperature switch as follows: Tb check the tem
perature switch, measure the resistance from the
switch input wire terminal to the tractor ground or
to the body of the switch. Since the temperature
switch is normally open at low or safe temperature,
resistance reading should be infinite ohms. If not, re
new the temperature switch.
system and tractor is being started in cold tempera
ture of 32 F (0 C) or colder, automatic shutdown
may occur after 30 seconds due to low transmission
oil pressure. Tb prevent shutdown, depress the over
ride switch located on the steering console.
109. HYDRAULIC (TRANSMISSION) FILTER
LIGHT. The hydraulic (transmission) filter pressure
switch is located in the hydraulic line between the
hydraulic pump and the filter housing.
The pressure switch is a normally closed 15-25 psi
(103-172 kPa) switch. When the pressure at the switch
reaches 22-30 psi (152-207 kPa), the switch should
open. When the pressure drops below 12-18 psi (83-
124 kPa), the switch should close. A closed switch
will send a ground signal to cluster connector pin
(16Fig. 83). After a 7 or 8 second delay, the ground
signal causes the warning light to come ON and a 3
second alarm will sound.
If the hydraulic (transmission) filter LED warning
light (4Fig. 72) comes ON with engine running and
transmission oil at a temperature of at least 120 F
(49 C), check the system as follows: Check trarismis-
sion oil level and filters, then add Hy-Tran Plus oil
and renew filters as required. If warning light stiU
stays ON with engine running, continue the tests.
With tractor OFF, disconnect Dark Blue/Gray wire
at the switch connector. Make certain the wire does
not touch any ground on tractor. Turn the key switcl
to ON position and observe warning light which
should be OFF. If the warning light is ON, the wiring
from connector pin (16Fig. 83) to the pressure
switch should be checked for shorts and grounds. L
the light is OFF, wiring is good. Tb verify the condi
tion of the wiring, connect a jumper wire betweer
connector at end of Dark Blue/Gray wire disconnect
ed from switch and a good ground on tractor. Witl
key switch ON, warning light should be ON. If so, th<
wiring and instrument cluster are good and the pres
sure switch must be checked.
The normally closed pressure switch should b<
open when pressure to it increases to 22-30 psi (152
207 kPa). Unscrew pressure switch and install a 10(
psi (690 kPa) hydraulic test gage. Start engine and op
erate at 2100 rpm. Observe test gage reading. If pres
sure reading is 26-32 psi (179-221 kPa) minimum, re
new the filter pressure switch.
110. TURN SIGNAL SWITCH UGHTS. If the tun
arrows (2Fig. 72) on the cluster panel do not com
ON with key switch ON and the turn signal lever uj
or down, check system as follows: With key switcl
ON, check voltage at switch terminal (2Fig. 84) t<
ground. Reading on voltmeter should be about 11
volts. If there is no voltage, check wiring from switcl
terminal (2) back to the battery for an open circuit
If there is 12 volts at switch terminal (2), there shoulc
Fig. 83The normally closed transmission filter switc
Is connected to cluster pin (16).
Paragraph 111
CASE/INTERNATIONAL
also be 12 volts at terminal (5) when signal lever is
up and 12 volts at terminal (6) when lever is moved
to down position. If there is no voltage at either ter
minal (5 or 6), renew the switch assembly. If there
is voltage at the terminals, check wiring from clus
ter connector terminals (29 and 34) to the switch ter
minals (5 and 6) for an open circuit. Repair as
necessary.
If both turn signal lamps do not come ON, check
upper cab connectors, black ground wire and light
bulbs. If left turn signal lamp does not come ON,
check condition of yellow wire between the turn sig
nal switch and the left turn lamp. If the right turn
signal lamp does not come on, check condition of
light green wire between turn signal switch and the
right turn lamp. Repair as necessary.
111. COOLANT TEMPERATURE BAR GRAPH.
The coolant temperature LCD service monitor (11
Fig. 72) is a 12 segment bar graph. A thermistor is
the sensor for the coolant temperature. As the cool
ant temperature increases, thermistor resistance
decreases and the number of energized segments on
bar graph increases. See Fig. 85. When coolant tem
perature reaches about 230 F (110 C), a 3 second
alarm sounds and bar graph segments one through
eleven flash ON and OFF. The green Systems Nor
mal light goes OFF. If coolant temperature increases
to about 240 F (115 C) all twelve bar graph seg
ments will flash ON and OFF, alarm will sound ON
and OFF, green Systems Normal light will remain
OFF and if tractor is equipped with an automatic
shutdown system, tractor engine will stop.
Fig. 84Wires from terminals (5 and 6) on turn signal
switch connect to connector pins (29 and 34) as shown.
If the bar graph segments one to eleven flash ON
and OFF (indicating too high coolant temperature)
and radiator coolant level is good, check thermistor
and wiring as follows; Disconnect the light green wire
from the thermistor and turn key switch to ON posi
tion. Check coolant temperature bar graph. None of
the segments should be flashing. If any of the seg
ments are flashing, check the wiring from pin (15-
Fig. 86) to the thermistor. If one segment on bar graph
goes ON and OFF, thermistor wire has an open. If all
of the segments go ON and OFF, thermistor wire is
grounded. Repair as required. If none of the seg
ments are flashing, wiring is good and thermistor
THERMISTOR APPROXIMATE ENERGIZED
TEMPERATURE THERMISTOR SEGMENTS
(F) RESISTANCE ON BAR GRAPH
240"? 113 ohms 12
230F 133 ohms 11
223F 149 ohms 10
216F 165 ohms 9
209 F 187 ohms 8
203 F 206 ohms 7
196F 234 ohms 6
189F 265 ohms 5
183 F 296 ohms 4
175F 342 ohms 3
140 F 668 ohms 2
99 F 1635 ohms 1
Fig. 85Chart showing thermistor temperature and
resistance and energized segments on coolant
temperature bar graph. Refer to text.
Fig. 86Wire from thermistor connects to pin (15) on
cluster connector.
MODELS 1896-2096
Paragraphs 112-113
should be checked. For an accurate indication, this
test should be done right after the warning appears.
With thermistor wire connected and key switch in
OFF position, use an ohmmeter to check the resis
tance between connector pin (15) to ground. Check
the chart in Fig. 85 for the amount of resistance this
test should indicate. For example, if segments one to
eleven were flashing, the resistance should read
about 133 ohms. If the resistance reading is not ap
proximately what it should be, as indicated on the
chart, renew the thermistor.
112. FUEL LEVEL BAR GRAPH. The float mech
anism which is a variable resistor is the sensor for
the fuel level bar graph. The two columns in Fig. 87
shows the comparison of the resistance to the ener
gized segments on the bar graph. As the resistance
from float mechanism changes, the signal to pin (14-
Fig. 88) changes and different segments on the bar
graph energize. With a full tank of fuel, all twelve
segments are energized and resistance will be about
81 ohms. When the fuel level decreases to a half tank,
resistance drops to about 37 ohms and orUy six seg
ments are energized. As soon as bar graph segment
two goes out, a 3 second alarm sounds and segment
one flashes ON and OFF until fuel is added.
If the readings on the bar graph are not accurate,
the float mechanism and the wiring should be
checked. If bar graph indicates a full tank, ground
the float mechanism input terminal. Turn key switch
ON and check the bar graph reading. If it does not
read empty, the wirir\g from the input terminal to pin
(14) should be checked for a loose connection or bro
ken wire. If it does read empty, wiring is good and
APPROXIMATE
FLOAT MECHANISM BAR GRAPH
RESISTANCE ENERGIZED SEGMENTS
81 ohms 12
74 ohms 11
67 ohms 10
59 ohms 9
52 ohms S
45 ohms 7
37 ohms 6
30 ohms 5
23 ohms 4
15 ohms 3
8 ohms 2
0 ohms 1
Fig. 87Chart showing float mechanism resistance
compared to energized segments on fuel level bar graph.
Refer to text.
If the fuel level on bar graph indicated an empty
tank, disconnect wire from float input terminal and
make certain the wire does not touch any ground.
Turn key switch ON and check bar graph reading. It
should read full. If not, wiring from input terminal
to pin (14) should be checked for shorts or grounds.
If it does read full, wiring is good and float mecha
nism should be checked.
Remove the float mechanism from the fuel tank.
Check the assembly for damage and renew as neces
sary. Connect an ohmmeter between the terminal
and float body. The resistance should change as the
float arm is raised. If the mechanism is good, the re
sistance should go from zero ohms to 81 ohms as the
float arm is raised. If resistance does not vary as float
arm is moved, renew float mechanism.
If wiring and float mechanism test good, renew dig
ital instrument cluster.
113. EXHAUST TEMPERATURE BAR GRAPH.
The sensor device that measures the exhaust tem
perature is a thermocouple that is screwed into the
turbocharger exhaust elbow. The sensor is a voltage
generating device. When the temperature increases,
the thermocouple generated voltage increases Since
the terminals on thermocouple are connected to pins
(22 and 33Fig. 89), any change in voltage between
the pins will cause different segments of the exhaust
temperature bar graph to energize.
If the exhaust temperature heats to 1250 F (677
C), the thermocouple generates about 28.2 millivolts.
See Fig. 90. When 28.2 millivolts is sensed between
pins (22 and 33Fig. 89), a 3 second alarm sounds,
segments one to eleven flash ON and OFF and the
green Systems Normal light goes OFF. If tempera
ture climbs to 1350 F (732 C), about 30.5 millivolts
Fig. 88Fuel level float mechanism (variable resistor) Is
connected to pin (14) on cluster connector.
Paragraph 114
CASE/ INTERNATIONAL
are generated by the thermocouple and all 12 bar seg
ments flash ON and OFF.
If exhaust temperature bar graph segments one to
twelve are flashing (indicating hot) and engine is
cold, the thermocouple should be checked for an
open circuit. Check the voltage between the wires
at thermocouple with engine operating. Observe the
voltmeter reading and check the bar graph for num
ber of energized segments. Compare with chart in
Fig. 90. If readings are not within specifications, re
new the thermocouple. If readings are within specifi
cations, renew digital instrument cluster.
114. VOLTAGE LEVEL BAR GRAPH. The battery
voltage level on pin (35Fig. 91) is the sensor for the
voltage level bar graph. The voltage level is indicat-
Flg. 89Exhaust temperature thermocouple wires are
corinected to cluster cortnector pins (22 and 33).
TEM P ERATURE
T F )
r HERMOCOUPLE
V OL TA GE
BAR GRAPH
ENERGI ZED
SEGM ENTS
1350 30. 5 mi l l i vol t s 12
1250 28.2 mi l l i vol t s 11
1150 25.8 mi l l i vol t * 10
1046 23.3 mi l l i vol t * 9
943 20.9 mi l l i vol t s 8
839 18.4 mi l l i vol t s 7
736 16.0 mi l l i vol t s 6
632 13.6 mi l l i vol t s 5
529 11.3 mi l l i vol t s 4
425 8.9 mi l l i vol t s 3
313 6.4 mi l l i vol t * 2
200 3.8 mi l l i vol t s 1
Fig. 90Chart showing exhaust temperature,
thermocouple voltage and energized segments on bar
graph.
ed by the number of energized segments on the bar
graph. See Fig. 92.
If battery voltage at pin (35Fig. 91) drops to 10
volts, the voltage is considered too low for proper op
eration. With a 10 volt signal at pin (35), a 3 second
alarm will sound, segments 1and 2 will flash ON and
OFF and the green Systems Normal light will go
OFF.
If battery voltage at pin (35) climbs to 16 volts, the
voltage is considered too high for proper operation
as system components can be damaged at this level.
With a 16 volt signal at pin (35), a 3 second alarm will
Fig. 91Battery voltage level on pin (35) Is the sensor
for the voltage level bar graph.
B A TTER Y V OL TA GE
A T PI N 35
BAR GRAPH
ENERGI ZED SEGM ENTS
16.0 vol t s 12
15.5 vol t s 11
15.0 vol t s 10
14.5 vol t s 9
14.0 vol t s 8
13.5 vol t * 7
13.0 vol t s 6
12.5 vol t s 5
12.0 vol t s 4
11.5 vol t s 3
10.0 vol t s 2
9.0 vol t s 1
Fig. 92Chart showing battery voltage at pin (35)
compared to energized segments on voltage level bar
graph. Refer to text.
sound, segments one to twelve will flash ON and OFF
and the green Systems Normal" light will go OFF.
If the voltage level bar graph indicates a too high
or too low voltage indication, turn key switch OFF,
and using a voltmeter, check voltage across battery
terminals. Voltage should be 11to 15 volts. If so, bat
teries are good. Turn key switch ON and check the
energized segments on bar graph. The voltmeter
reading should correspond to the energized segments
as shown on chart in Fig. 92. For example, if volt
meter reading was about 12.5 volts, segments 1to 5
should be energized. If readings do not correspond,
check wiring and connections from pin (35Fig. 91)
to batteries.
115. HOURMETER. An hourmeter is used to count
engine hours. This device is electromechanical and
it uses an odometer type display to accumulate en
gine hours. The hourmeter numbers rotate, ac
cumulating hours, only when the engine speed is
above 400 rnm.
116. DIGITAL DISPLAY. The instrument cluster
display is an LCD (liquid crystal diode) which displays
the operators selections and contains several message
legends to indicate the selection. The digital display
(Fig. 93) reads out in either english or metric units.
A switch at the back of the cluster can be set to make
this selection.
The seven function buttons (FFig. 94) on the dig
ital instrument cluster are located as shown. After
programming the cluster, the operator can depress
a function button and the desired information will
be shown on the digital display. Engine rpm and
ground speed function buttons depend upon seasors
for their operation. All other function buttons work
strictly through calculations of a microprocessor chip.
The microprocessor is inside the cluster box.
The five program buttons (P) are located as shown
in Fig. 94. Program buttons are: Tire Size, Attach
Width, Select Digit, Set Digit and Start/Stop. These
buttons actuate the digital display. The operator
feeds information into the digital cluster box us
ing the program buttons. Ground Speed, Area/Hour,
Area Done and Wheel Slip will not indicate accurate
readings until Tire Size and Attach Width are pro
grammed into the cluster.
Refer to the appropriate following paragraphs for
information on operation, tests and programming.
Fig. 94View showing location of the seven function
buttons (F) and the five program buttons (P) on digltai
Instrument cluster.
Fig. 93Digital Instrument cluster showing the digital display.
117. ENGINE RPM FUNCTION. A magnetic sensor
located in the flywheel housing is used to monitor
engine rpm. The sensor is positioned so that it almost
touches the flywheel ring gear. The sensor generates
a magnetic field. As the gear rotates, the gear teeth
cut through this magnetic field. The sensor puts out
one pulse signal for each gear tooth that cuts through
the magnetic field. As the gear rotates more quick
ly, the pulse frequency increases.
The two wire leads from the magnetic sensor con
nect to pins (9 and 25Fig. 96) of the cluster con
nector As the pulse signals change, the varying sig
nals are sent to the cluster. When engine rpm button
is depressed, the engine rpm will appear on the digi
tal display.
The engine rpm warning value is 2500 rpm. If the
rpm is 2500 or higher, the digital display automati
cally changes to display engine rpm. The rpm will
flash ON and OFF on the display. All other buttons
will not operate until engine speed is reduced to less
than 2500 rpm.
If the display shows zero rpm with the engine run
ning, check the following three possible causes;
1. Sensor wires are disconnected.
2. Sensor is acyusted out too far from gear teeth.
3. Sensor is defective.
Check to make sure the sensor is connected and
properly adjusted. If the sensor is acyusted more than
Vi to % turn from the gear, rpm readings will be zero
Fig. 95Using an ohmmeter to check resistance of
engine rpm to magnetic sensor.
or low when rpm is actually maximum. After check
ing these conditions, make any necessary corrections.
If the display readings are still in error, check the
magnetic sensor. Disconnect the wiring plug near the
sensor. Connect an ohmmeter between the two wires
going to sensor as shown in Fig. 95. Resistance read
ing should be between 2500 and 3800 ohms. If resis
tance reading is higher or lower, renew the magnet-
Flg. 96Connect ohmmeter between cluster connector
pins (9 and 25) to check wiring and connections to
magnetic sensor.
Fig. 97Using an ohmmeter to check resistance of
transmission magnetic sensor.
MODELS 1896-2096
Paragraphs 118-119
ic sensor. If the reading is between 2500 and 3800
ohms, reconnect sensor wires and check the wiring
as follows: With the key switch OFF, disconnect the
cluster connector. Connect an ohmmeter between
cluster connector pins (9 and 25) as shown in Fig. 96.
Resistance reading should be between 2500 and 3800
ohms. If not, wiring and/or connections between sen
sor and cluster connector are faulty. Repair as neces
sary. If reading is between 2500 and 3800 ohms, re
new the digital instrument cluster.
118. GROUND SPEED FUNCTION (MAGNETIC
SENSOR). One of two sensors can be used to moni
tor ground speed. One is called the true ground speed
sensor and the other is a transmission magnetic sen
sor. The true ground speed sensor is an option and
is covered in paragraph 119.
The magnetic sensor is mounted in the rear trans
mission top cover It is positioned so that it almost
touches the gear. The sensor generates a magnetic
field. As the gear rotates, the gear teeth cut through
the magnetic field. The sensor puts out one pulse sig
nal for each gear tooth that cuts through the mag
netic field. As the gear rotates more quickly, the
pulse frequency increases.
The two wire leads from the magnetic sensor con
nect to pins (4 and 32Fig. 98) of the cluster con
nector. As the pulse signals change, the varying sig
nals are sent to the cluster to compute the ground
speed. When ground speed button is depressed, the
tractor ground speed will appear on the digital
display.
Fig. 98Connect ohmmeter between cluster connector
pins (4 and 32) to check wiring and connections to
transmission magnetic sensor.
If the display shows zero mph (no display) wher
the tractor is moving, check the following three pos
sible causes.
1. Sensor wires disconnected.
2. Sensor is adjusted out too far from gear teeth.
3. Sensor is defective.
Check to make sure the sensor is connected proper
ly, then adjust the sensor as follows: Loosen the sen
sor locknut and turn the sensor in completely. Turr
the sensor out one full turn. Operate tractor to gel
a mph reading. Stop the tractor and check the dis
play. If there is a mph reading with tractor standing
still, turn the sensor out another */4turn. Tighten the
sensor locknut.
If the display reading is still zero, check the trans
mission magnetic sensor. Disconnect the wiring plug
near the sensor. Connect an ohmmeter between the
two wires going to sensor as shown in Fig. 97. Resis
tance reading should be 2900 to 3600 ohms. If resis
tance reading is higher or lower, renew the magnet
ic sensor. If the reading is between 2900 and 360C
ohms, reconnect sensor wires and check the wiring
as follows: With key switch OFF, disconnect the clus
ter connector. Connect an ohmmeter between clus
ter connector pins (4 and 32) as shown in Fig. 98. Re
sistance reading should be between 2900 and 360C
ohms. If not, wiring and/or connections between sen
sor and cluster cormector are faulty. Repair as neces
sary. If reading is between 2900 and 3600 ohms, re
new the digital instrument cluster.
119. TRUE GROUND SPEED SENSOR. The tru
ground speed sensor is an option. If tractor is nol
equipped with this sensor, then ground speed is moni
tored by the transmission magnetic sensor. The true
ground speed sensor is generally mounted on left side
of tractor between front axle and transmission anc
is set at a 50 degree angle to the rear of the tractor
See Fig. 99.
Fig. 99View of optional true ground speed sensoi
mounted on tractor.
NOTE: The wheel slip button will not function un
less the tractor is equipped with a true ground speed
sensor.
The signal from the true ground speed sensor is
used to compute ground speed, wheel slip, area/hour
and area done. Before these function buttons will in
dicate accurate readings, the true ground speed sen
sor must be calibrated. Calibration is done by driv
ing the tractor on a straight 200 ft. (61 m) course. As
the tractor is moving, the true ground speed sensor
generates a very high frequency wave. This wave
reflects off the ground and bounces back to the sen
sor. The true ground speed sensor compares the
generated wave with the reflected wave. The fre
quency difference is computed and sent to the digi
tal instrument cluster to calculate true ground speed.
True ground speed sensor is not circuited through
the cluster connector as the other sensors are. It has
its own four wire circuit and a four pin connector on
the back panel of the digital instrument cluster.
If the ground speed display reads zero mph when
the tractor is moving, the ground speed sensor should
be checked. First, unplug the true ground speed sen
sor. If the ground speed display still reads zero mph,
check transmission magnetic sensor as outlined in
paragraph 118.
120. PTO RPM FUNCTION. The pto speed is cal
culated from the engine speed. Depressing the pto
rpm button will indicate which pto speed (500 or
1000 rpm) is being monitored. When the button is
released, the actual pto speed will appear on the dis
play. If the pto rpm and engine rpm display readings
seem to be inaccurate, check engine rpm sensor as
121. TIMER FUNCTION. The timer function but
ton works from a clock chip inside the digital clus
ter box. The timer is started and stopped with the
start/stop button. Depressing the timer function but
ton will indicate on the display the actual elapsed
time (ET) the timer has been running.
122. WHEEL SLIP FUNCTION. The wheel sUp
function button will work only if the tractor is
equipped with a true ground speed sensor. If so
equipped, depressing wheel slip button will indicate
the percentage of wheel slip on the display. Percent
age of wheel slip is calculated by the digital cluster.
The cluster compares the transmission magnetic sen
sor signal with the signal from the true ground speed
sensor.
123. AREA/HOUR FUNCTION. Tire size and at
tach width must be programmed into the digital in
strument cluster before the area/hour function but
ton will indicate accurate acreage readings. The
digital cluster calculates the acres per hour from the
ground speed and attachment width.
124. AREA DONE FUNCTION. Tire size and at
tachment width must be programmed into the digi
tal instrument cluster before the area done function
button will indicate accurate readings. Depressing
the area done button will display the accumulation
of acres covered during any time. The digital cluster
calculates the area done from the ground speed and
the attachment width.
Tb zero out the area done, depress button and hold
it in until zero appears on the display.
125. SELECT DIGIT PROGRAM. The select digit
and set digit program buttons are used together.
When programming information into the cluster, one
digit on the display will always be flashing ON and
OFF. The flashing digit indicates the selected digit.
Pushing the select digit program button causes the
next digit to the right to be selected and that digit
will flash ON and OFF.
126. SET DIGIT PROGRAM. Pushing the set digit
program button changes the actual selected digit by
advancing it one count. When a value of nine is
reached, the next advance is to zero.
127. START/STOP PROGRAM. The start/stop but
ton is used in coryunction with the tire size button
and the timer button. The start/stop button, when
used with the timer button, will either start or stop
the timer Each time the start/stop button is pushed,
the status of the timer (either ON or OFF) changes.
A flashing colon on the display indicates the timer
is ON and counting.
128. TIRE SIZE PROGRAM. When programming
the tire size button, check rear tire size, then use the
corresponding code number as shown in Fig. 100. Us
ing program buttons tire size, select digit and set digit,
program the code number into the digital instrument
cluster. Once the tire size code number has been pro
grammed, depressing the ground speed function but
ton will indicate an accurate reading (mph or km/h)
on the digital display.
If the display reads 25 mph and tractor is not run
ning, the probable cause for the readout error is that
the tire size code number has not been programmed
into the cluster. Depress tire size button and check
code number on display. If the code number is incor
rect, reprogram the tire size.
129. ATTACH WIDTH PROGRAM. The attachment
width is programmed into the digital instrument clus
ter by using program buttons attach width, select dig
it and set digit. Once the attachment width and tire
size is programmed into the cluster, depressing the
area/hour and area done function buttons will indi
cate accurate display readouts.
130. WINDSHIELD WIPER. Normal operation of
the windshield wiper is with key switch ON, wiper
should operate when wiper switch is moved to LO
and HI positions. Move wiper switch to OFF position
and wiper should automatically return to PARK po
sition.
If wiper motor does not operate in one or all posi
tions, check cab relay, circuit breaker and fuse. Use
a voltmeter and check for voltage at "B terminal
of wiper switch. If current is present at B" termi
nal, move wiper switch control to LO position and
check for voltage at L terminal. Then, move con
trol to HI position and check for voltage at H ter
minal. If no voltage is found at B terminal, check
wiring, ignition switch and fuses. If voltage reaches
B terminal but does not reach L or H termi
nal as switch is operated, renew wiper switch. If volt
age is present at each terminal and switch is in proper
position, test for voltage in wires as close to wiper
motor as possible. If voltage is present at wiring, but
motor does not run, renew motor. If no voltage is
present, check wiring between switch and motor.
If wiper motor operates but does not return to
PARK position, use voltmeter and with wiper switch
OFF, check for voltage at P terminal of switch. If
voltage is present at P" terminal, check wire to mo
tor and repair or renew motor as necessary. If no volt
age is present at P terminal, renew wiper switch.
131, CAB FAN MOTOR. Cab fan (blower) motor
is used for cab ventilation, heater or air condition
ing system fan as models are equipped.
If motor fails to operate with key switch ON and
blower switch turned to low, high or purge position.
Fig. 100Use code number corresponding to tire size
when programming tire size button.
use a voltmeter and check for voltage at B termi
nal (Fig. 101) of blower switch. If no voltage is pres
ent, check wiring fuses, ignition switch and circuit
breakers. Repair as necessary. If voltage is present
at B terminal, check for voltage at L , H and
P terminals as blower switch is turned to low, high
and purge. If voltage is not present at all locations
with blower switch turned to proper position, renew
blower switch.
If voltage is present at all terminals, unplug resis
tor connector from resistor block. With key switch
ON and blower switch turned to purge position, use
a 12 volt test light and check for current at the pur
ple wire and purple/white wire connector as shown
in Fig. 102. Using the test light, check for current at
yellow/red wire, with switch turned to high position.
Then, turn switch to low position and check for cur
rent at the white wire. If there is no current present
at any of the three tests, check for faulty wires be
tween blower switch and resistor block connector.
Repair as necessary.
If current is present at all of the terminals, recon
nect the resistor connector. If blower will operate in
purge position but not in high or low positions, re
new resistor block. If blower does not operate in any
Fig. 101View showing location of blower switch term
Inals. Refer to text.
Fig. 102Checking for power at blower resistor con
nector, Refer to text.
position, make sure motor ground is good and renew
blower motor as required.
132. HEATER AND AIR CONDITIONING. Heat
er and air conditioner blower motor is the same blow
er as the cab ventilating blower. Refer to paragraph
131 for test procedures. However, the air condition
ing system compressor clutch, high and low pressure
switches and temperature control switch may be
checked as individual units.
Before attempting to diagnose electrical problems
in air conditioning system, make certain compressor
belt is tight, clean condenser and evaporator cores
to ensure maximum air flow and check refrigerant
level at sight glass. Refrigerant level may be checked
after operating system for ten minutes when ambient
temperature is 70 F (21 C) or above. If slow mov
ing bubbles are visible in sight glass, system is nor
mal. If fast moving steady stream of bubbles are visi
ble in sight glass, system needs a small amount of
refrigerant added. Foam in sight glass indicates a very
low refrigerant level. Oil streaks or dark spots on in
side of sight glass indicate no refrigerant in system.
A clear sight glass usually indicates the system is too
full or there is a complete loss of refrigerant. If in
doubt, shut compressor ON and OFF while watching
sight glass. A slight momentary stream of bubbles
should appear in a full system as the compressor
starts.
Slightly low systems should be recharged and
checked for leaks. Extremely low systems need to
have refrigerant oil checked, receiver-dryer renewed
and system evacuated and recharged. Check for
leaks.
133. COMPRESSOR CLUTCH CIRCUIT TEST With
engine running and system recharged, set tempera
ture control switch to coldest position and turn blow
er switch to low or high position. Clutch should en
gage as blower switch is turned ON. If clutch does
not engage, use voltmeter to check for voltage at
compressor clutch. If voltage is present renew com
pressor clutch.
If no voltage is present at clutch, disconnect the
wires at high pressure switch and install a jumper
wire to bypass the switch. If compressor clutch en
gages, check system pressure or renew high pressure
switch as necessary. If clutch still fails to engage, dis
connect wires from low pressure switch located at
receiver-dryer and install jumper wire to bypass the
switch. If clutch engages, check system pressure and
refrigerant level or renew low presure switch as
necessary.
If clutch still fails to engage, use a 12 volt test light
and check for current at temperature control switch.
If light fails to come on at either terminal and blow
er motor is working, check the light blue/yellow wire
from blower switch to temperature control switch.
Repair as necessary.
TORQUE LIMITER
CLUTCH
All Model 1896 and 2096 tractors are equipped
with a slip type torque limiter clutch bolted to
the engine flywheel. The Power Shift transmis
sion receives power through an input shaft from
the torque limiter clutch.
Before overhauling the torque limiter clutch, be
sure problem is in that unit by performing the fol
lowing stall test: With engine running approxi
mately 1200 rpm, shift into 4th range, hold brakes
and slowly release inching pedal. Engine should
stall, unless torque limiter is slipping, which
would allow hydraulic pump drive shaft to stop,
thus losing the oil pressure to power shift. The
torque limiter would then stop slipping since
power shift clutch would slip. The pump would
again be able to deliver pressure to power shift
clutch and torque limiter would again slip, which
would become a bucking action. I f bucking does
not occur, check for a power shift clutch or valve
leakage as outlined in paragraphs 193 through
198.
All Models
134. R&R AND OVERHAUL. Tractor must first be
split between engine and torque tube as follows:
Drive wedge blocks between axle and front support
to prevent sideways tipping. Place gear shift lever in
PARK position and engage the hand brake. Discon
nect headlight wiring, remove hood, side panels and
radiator grille. Disconnect and remove cables from
batteries and starting motor, then remove batteries
and battery box. Remove pin at front of drawbar and
pull drawbar rearward. Remove plugs and drain
transmission housing, transfer gearbox if so
equipped, and torque tube (clutch housing). If so
equipped, unbolt and remove front drive shaft. Dis-
cormect self-sealing air conditioning couplers. Discon
nect throttle cable from diesel pump. Close shut-off
valve on fuel lift pump, disconnect and plug fuel sup
ply line. Disconnect fuel return tube. Close shut-off
valves at cylinder head and water inlet housing and
disconnect heater hoses. Identify and disconnect the
four tubes from power steering hand pump. Discon
nect engine wiring harness from cab firewall connec
tor. Remove pyrometer from turbocharger exhaust el
bow. Disconnect neutral start switch wire. Install rear
split stand under transmission housing and install
front split stands to side rails. Disconnect oil cooler
MODELS 1896-2096
lines below starter. Disconnect, unbolt and remove
true ground speed attachment, if so equipped, from
flywheel housing.
Unbolt engine flywheel housing from torque tube.
Move front half of tractor forward from rear half.
Unbolt and remove the oil baffle plate from fly
wheel housing. Refer to Fig. 103, remove retaining
bolts and Belleville spring retainers, then remove
Belleville spring, steel plates and torque limiter
clutch plates. Remove pto drive shaft sleeve from fly
wheel. Clean and inspect all parts for excessive wear
or other damage and renew as necessary. Check free
height of Belleville spring as shown in Fig. 104. Spring
free height should be 0.454-0.466 inch (11.53-11.84
mm). Renew Belleville spring if the measurement is
less than 0.454 inch (11.53 mm).
When reassembling, use Fig. 103 as a guide, keep
ing the foUowing points in mind: Spring side of torque
limiter clutch plates must face away from each oth
er. Use a pilot shaft made from a planetary output
shaft to align clutch plate splines. Grind diameter of
front of output shaft down about 0.010 inch (0.254
mm) before using. Retainers must engage the half cir
cle notches in steel plates. Dish in Belleville spring
must face outward. Apply Loctite 271 to retainer bolt
threads and tighten bolts evenly to a torque of 93-
112 ft.-lbs. (126-152 N*m). Apply vaseline to the
splines in clutch plates and outer splines of pto drive
shaft sleeve and install the sleeve.
Use Loctite 504 gasket eliminator in the recess in
engine flywheel housing and faces of housings. Then,
install oil baffle plate. Rejoin tractor by reversing the
disassembly procedure.
Fig. 104Invert Belleville spring and measure height of
dish as shown. Free height should be 0.454-0.466 Inch
(11.53-11.84 mm).
POWER SHIFT
TRANSMISSION
All models are equipped with a hydraolically
controlled power shift clutch and planetary drive
unit which provides three forward speeds with
out stopping tractor or interrupting power flow.
The power shift transmission is coupled to a slid
ing gear transmission which can be shifted only
when tractor is at a standstill. Reverse gears can-
Flg. 103Exploded view of torque limiter clutch used on all models.
not be engaged while tractor is moving. The four-
speed gearbox and three-speed power shift unit
provides a total of twelve forward and three re
verse gear speeds.
OPERATION
All Models
135. POWER TRAIN. The power shift unit is an
electric solenoid actuated and hydraulic operated
planetary gear unit shown in Fig. 105.
Control units consist of four clutches which are
hydraulically actuated and released by spring pres
sure when hydraulic flow to clutch is blocked.
The input shaft is driven by the torque limiter
clutch discs on the flywheel. The output shaft speed
and direction of rotation depends upon which
clutches are applied. Refer to Fig. 106 for chart show
ing which clutches are applied for each speed.
Clutches (C-1, C-2, C-3 and C-4) operate as follows:
CLUTCH C-1 when hydraulically engaged, couples
the secondary (reaction) sun gear to carrier housing,
making the sun gear a stationary drive member. Pow
er is transmitted from input shaft and long planet
pinions to short planet pinions which walk around
stationary sun gear driving planet carrier in the same
direction as input shaft but at a slower rate of speed.
Clutch C-1 is the Starting Output clutch for forward
loads and is provided with additional pressurized
lubrication for smooth engagement and long life.
Clutch C-1 is engaged in Low (1) and Intermediate (2)
forward speeds.
the planet carrier to output shaft. Output shaft thus
delivers power to transmission at the same speed and
in same direction as planet carrier turns. Clutch C-2
is engaged in Low (1) and High (3) forward speeds and
in Reverse.
Fig. 105Cutaway view of the three-speed power shift
unit used on Models 1896 and 2096 showing relative
location of major component parts.
the planetary ring gear to output shaft, making the
planetary ring gear the output drive unit. Clutch C-
3 is engaged in Intermediate (2) and High (3) forward
speeds.
the planetary ring gear to carrier housing, making the
planetary ring gear the stationary drive member
Clutch C-4 is engaged in Reverse speed.
The power shift unit is designed to permit selec
tion of any of the forward speeds by moving the pow
er shift lever without stopping the tractor. Tb shift
to reverse, it is necessary to depress the inching ped
al, stop tractor and move reverse lockout lever, be
fore the power shift lever can be moved to reverse
position. This prevents accidental overshifting into
reverse when downshifting in the forward gears. The
inching pedal is also depressed to shift the mechani
cal range transmission shift lever to any of the four
speed ranges or to neutral or park positions. When
inching pedal is depressed, power shift selector le
ver is automatically moved to first (Low) speed posi
tion so that tractor always starts out in lowest pow
er shift speed after selecting a mechanical transmis
sion gear When mechanical (gear) transmission is in
fourth gear, power shift cannot be shifted to reverse
or if power shift is in reverse, gear transmission can
not be shifted to fourth gear.
136. CONTROL SYSTEM. The speed selector
switch is mechanically operated by the power shift
control lever on the console. The switch position de
termines which clutches will engage or disengage.
Each switch position completes circuitry to actuate
two clutches on the power shift. Pressure switches,
relays and solenoid valves are used on the control
system.
The modulating spool in the control valve is
mechanically moved with the inching pedal and is
connected to the C-2 clutch valve. Partial depression
of the inching pedal causes modulating spool to be
partially engaged. In this position, the main oil pas-
Flg. 106Chart Identifying clutches applied for various
speeds on power shift unit.
sage is blocked and oil flows through the 2 gpm (7.57
L/min) orifice and is directed to both the C-2 clutch
and the sump. The C-2 clutch wont engage until the
modulating spool is completely engaged (inching ped
al fully released). The modulating spool disengages
when the inching pedal is completely depressed and
clutch lube oil is directed to the sump. When
modulating spool is engaged, clutch lube oil is direct
ed to the clutch friction plates for cooling.
Hydraulic power to operate the power shift system
is provided by the main hydraulic system 23 gpm (88
L/min.) pump, through a flow divider-pressure regu
lator valve. The flow divider-pressure regulator valve
controls oU pressure at 210 psi (1448 kPa) that is sup
plied to the power shift unit, pto and the differen
tial lock.
ADJUSTMENT
All Models
137. LINKAGE ADJUSTMENT. Tb adjust the
power shift linkage, refer to Figs. 107, 108 and 109
and proceed as follows:
Tb adjust the inching (clutch) pedal, disconnect
clutch cable clevis and reverse interlock cable clevis
from bellcrank at control valve. Acyust upper stop
bolt until distance between floor mat and clutch ped
al is 6.5-6.S inches (165.10-172.72 mm) measured as
shown in Fig. 107. The clutch (modulating) spool in
the power shift valve must be in engaged position
(fully down). Adjust clevis on clutch cable as neces-
Flg. 107Exploded view showing clutch control, shift lever and reverse Interlock used on power shift and Inching pedal
adjustments. Refer to text.
sary and connect clevis to bellcrank. Depress clutch
(inching) pedal until clutch spool has moved up ex
actly 1.03-1.09 inches (26.16-27.69 mm). Acyust low
er stop bolt with clutch pedal held in this position
until stop bolt contacts brake and inching (clutch)
pedal cover. At this time, with pedal depressed, dis
tance between floor mat and pedal should be 1.5-1.8
inches (38.10-45.72 mm) measured as shown in Fig.
107. After pedal is adjusted, remove upper stop bolt.
NOTE: Do not allow Inching (clutch) spool to travel
upward more than 1.09 Inches (27.69 mm) and make
certain the spool Is completely down when pedal Is
In up position.
Tb acUust the reverse interlock cable, make certain
that inching (clutch) cable is acyusted as previously
outlined and proceed as follows: Depress inching ped
al and check to see that reverse interlock cable puUs
power shift control lever to first speed position. If
not, acyust clevis on reverse interlock cable as re
quired.
Refer to Fig. 108 and acyust shift switch as follows:
With switch lever positioned at 45 degrees, connect
Fig. 108Drawing showing power shift selector switch
adjustment.
ball rod assembly to switch lever and power shift
range hand lever. Push power shift hand lever for
ward until the stop screw is against the cam surface
of the interlock lever with interlock in clutch out po
sition as shown in Fig. 108. Move power shift hand
lever to reverse position. At this time, stop screw will
move into the slot of interlock lever. Make certain
that stop screw moves smoothly in the slot. If not,
loosen switch mounting screw and acyust switch po
sition. Make sure that power shift control lever op
eration is smooth and positive in all forward and re
verse ranges.
Tb adjust the two micro switches, refer to Fig. 109,
remove and proceed as follows: Adjust the three wire
C1/C4 swap switch by turning the lower switch ad
justing bolt. Atyust the bolt until the C1/C4 switch
activates when inching pedal is 3/8-5/8 inch (10-16
mm) above the fully down position. Acyust the two
wire declutch switch by turning the upper acyusting
bolt until the declutch switch activates when pedal
is 3/8-5Z8 inch (10-16 mm) below fully up position.
Reinstall switch cover.
138. PRESSURE ADJUSTMENT. The manufac
turer recommends that a Diagnostic Monitor CAS-
1712 be used to test the power shift system. Howev
er, the system pressures can be checked with pres
sure gages. Power shift clutch operating pressure
should be 210 psi (1448 kPa) at 2100 engine rpm.
Operating pressure is controlled by shims (16Fig.
110) located in pto control and flow divider valve
body. Shims are available in thicknesses of 1/64 inch
(0.397 mm) and 3^2 inch (2.3 mm). Add or remove
shims as required to obtain correct pressure.
Fig. 109View showing micro switch adjustment on
power shift Models 1896 and 2096. Refer to text.
MODELS 1896-2096
Paragraphs 139-140
Tb check system pressure, remove transmission
pressure switch from pto control and flow divider
valve and install a 600 psi (4137 kPa) test gage in the
port. With engine operating at 2100 rpm and trans
mission fluid heated to at least 120 F (49 C), pres
sure should be 210 psi (1448 kPa).
Tb check clutch pressures, remove any of the
marked port plugs P-1, P-2, P-3 or P-4 from power
Fig. 110Exploded view of flow divider and pto control
valve.
1. Valve body
2. OUseal
3. Plug
4. O" ring
5. Roll pin
6. Detent ball
7. Guide pin
8. Spring (outer)
9. Spring (inner)
10. "O ring
11. AcUusting screw
12. Connector
13. Pressure
regulator spool
14. Snap ring
15. Spring
16. Shim
17. Plug
18. O" ring
19. Relief valve
20. Spring
21. O ring
22. Plug
23. Pto control spool
24. Spring
25. Modulator poppet
26. Primary spring
27. Washer
28. Secondary spring
29. O" ring
30. Pin
31. Plug
shift valve. With engine operating at 2100 rpm, trans
mission fluid temperature at least 120 F (49 C) and
gear transmission in neutral, move power shift lever
to pressurize the selected clutch as follows:
C-1 (Tb first or second)
C-2 (Tb first, third or reverse)
C-3 (Tb second or third)
C-4 (Tb reverse)
Pressure should be equal for all clutches. A notice
able drop in pressure in a particular clutch port would
probably indicate leakage in that clutch circuit.
Shut off engine and move test gage to the lubrica
tion test port in power shift control valve. Steering
return oil from the oil cooler flows through the
modulating spool for clutch lubrication. Start engine
and check lubrication pressure which should be 210
psi (1448 kPa) with selector lever in any position and
inching pedal fully released. Pressure should drop to
zero when inching pedal is depressed. The system is
also protected by a relief valve (19Fig. 110) located
in the flow divider housing. Relief valve functions
only as a surge relief valve for cold oil starts. Relief
valve should open at 240 psi (1655 kPa).
POWER SHIFT CONTROL VALVE
All Models
power shift control valve (8Fig. I ll), remove nuts
(5), lockwashers and solenoid cover (6). Clean con
trol valve and surrounding area. Identify and discon
nect electrical wires from solenoids and pressure
switches. Disconnect hydraulic tubes as necessary
and linkage from modulating spool. Remove two cap
screws (4) and install two 3/8 x 6 inch guide studs.
Remove four studs (7) and balance of cap screws (4).
Slide control valve from tractor. Remove outer gas
ket (9), plate (10), center gasket (1), manifold (2) and
inner gasket (3).
Reinstall control valve by reversing the removal
procedure, using new gaskets. Tighten cap screws (4)
and studs (7) to a torque of 30-35 ft.-lbs. (41-47 N*m)
using tightening sequence shown in Fig. 112. Refer
to Fig. 113 for view showing location of pressure
switches, pressure check ports and solenoids.
140. OVERHAUL. Refer to Fig. 114 for an explod
ed view of power shift control valve and to Fig. 115
for exploded view of solenoid valves. Disassembly
and reassembly procedures are obvious after exami
nation of units. Oil seal (1Fig. 114) must be installed
with lip toward inside. Tighten modulator spool plug
(11) to a torque of 17-20 ft.-lbs. (23-27 N-m). When
reassembling solenoid (3Fig. 115), lubricate all 0
rings with petroleum jelly. Tighten tube assembly (4)
into valve body to a torque of 90-100 ft.-lbs. (122-163
N-m). Tighten coil retaining nut (1) to a torque of 8-
10 ft.-lbs. (10-13 N-m).
Fig. 111Vlew of powershift control valve removed from
Model 1896 or 2096 tractor.
1. Center gasket
2. Manifold
3. Inner gasket
4. Cap screw (10)
5. Nut (4)
6. Solenoid cover
7. Stud
8. Control valve
assy.
9. Outer gasket
10. Plate
Fig. 112View showing tightening sequence of power
shift control valve retaining bolts.
LUBRICATION RELIEF VALVE
All Models
141. The lubrication relief valve (Fig. 116), is lo
cated on lower right side of transmission housing near
oil filter cover. Valve should be checked if lubrica
tion operating pressure cannot be obtained when
tested as outlined in paragraph 137. All parts of re
lief valve except valve body (2Fig. 116) are availa
ble individually.
OVERHAUL POWER SHIFT UNIT
Tb gain access to power shift unit, tractor must be
split between engine and torque tube housing.
All Models
142. TRACTOR SPLIT. Tb split tractor between
engine and torque tube housing, first remove cab as
outlined in paragraph 232, then follow procedures
NOTE: Cab does not have to be removed If out
put shaft Is not going to be serviced.
143. REMOVAL. With tractor split, remove C-1
clutch lubrication tube (1Fig. 117). Remove C-1 reac
tion plate (2), springs (3), sun gear (5) and clutch
plates (4, 6, 7 and 8). Remove plugs for oil distribu
tion tubes (15) located on top of torque tube, then
remove oil distributor tubes. Unbolt and remove C-1
Fig. 113View showing location of lubrication port, S-1,
S-2 and S-3 pressure switches, P-1, P-2, P-3 and P-4
pressure check ports and C-1, C-2, C-3 and C-4 solenoids.
and C-4 piston carrier (16) and clutch plates and discs
(22, 23 and 25). Remove C-4 clutch return springs
(24). Align holes in planetary input gear with bear
ing carrier retainer screws (28) as shown in Fig. 118,
then remove screws with a 3/16 inch Allen wrench.
Remove drive sleeve from pto/pump drive shaft. Re
move planetary carrier assembly from ring gear. Re
fer to Fig. 117 and remove thrust bearing assembly
(38) and shaft locating snap ring (39). Using three 1/4-
28 X 1-1/2 inch full thread bolts as jack screws, re
move planetary carrier bearing and retainer (40 and
41). Remove pto/pump drive shaft. Loosen C-1 clutch
hub bolts (56), then using a suitable puller, remove
ring gear assembly (46 through 55) and (57 through
69).
Before removal of oil distributor (70), power shift
valve must be removed as outlined in paragraph 140
Fig. 114Exploded view of powershift control valve used
on Models 1896 and 2096 tractors.
1. Oil seal
2. Pressure switch
(3 used)
3. Solenoid valve
(4 used)
4. Spool
6. Retaining ring
6. Modulator poppet
7. Primary spring
8. Washer
9. Secondary spring
10. "O ring
11. Plug
12. Valve body
and the three oil supply tubes (71) must be removed
from oil distributor as shown in Fig. 119. Remove the
three bolts (72Fig. 117) securing oil distributor to
torque tube.
NOTE: With cab removed, remove transmission
top front cover for access to the three oil distribu
tor boits.
Fig. 115Exploded view of solenoid valves used for C~
1, C-2, C-3 and C-4 clutches.
1. Nut
2. CoU
3. Solenoid valve
assy.
4. Tube
5. "O" ring
6. O" ring
7. Spring
8. Plunger
9. Roll pin
10. Spool
11. Cage
12. Retaining ring
13. "O ring
14. -O" ring
Fig. 116Cross-sectional and exploded views of
lubrication relief valve for power shift clutches.
1. Relief valve assy.
2. Body
3. Roll pin
4. Ball
5. Spring
6. Roll pin
7. Shim washer
Remove oil distributor (70) and bearing shield (73),
then withdraw output shaft assembly (74 through
80).
144. OUTPUT SHAFT. Repair of output shaft as
sembly (items 74 through 80Fig. 117) consists of in
spection of gear (79), shaft splines and bearing (75).
If renewal of bearing is necessary, heat new bearing
to 250 F (120 C) and press on with snap ring side
of bearing toward long splined end of output shaft.
If pto shaft bushing (77) inside diameter exceeds
1.358 inches (34.49 mm) renew bushing, using Loc-
quic primer on mating surfaces, then Loctite 271 or
equivalent on bushing outside diameter. Install new
bushing to a depth of 0.300 inch (7.62 mm) below
flush with end of shaft. New bushing installed inside
diameter should be 1.2515-1.2535 inches (31.788-
31.839 mm). Install output gear (79) with recessed
side of gear toward end of shaft.
145. RING GEAR, C-2 AND C-3 CLUTCH. Tb dis
assemble the ring gear, C-2 and C-3 clutch assembly,
refer to Fig. 117. Unbolt and remove C-2 clutch hub
(55), then remove C-2 clutch Belleville springs (53).
1. Lube tube
2. Reaction plate
3. Return springs
4. Disc (C-1)
5. Sun gear (C-1)
6. Disc (C-1)
7. Plate (C-1)
8. Disc (C-1)
9. Seal (outer)
10. " O " ring (outer)
11. Piston (C-1)
12. Seal (inner)
13. " 0 ring
14. Pin
15. Oil tubes & O
rings
16. Piston carrier
(C-1 & C-4)
17. Seal (outer)
18. " O " ring (outer)
19. Seal (inner)
20. O" ring (inner)
21. Piston (C-4)
22. Plate (C-4)
23. Disc (C-4)
24. Return springs
25. Plate (C-4)
26. Pin
27. Input shaft
28. Hex head screw
29. Pin (long
planetary gear)
30. Pin (short
planetary gear)
31. Roll pin
32. Race
33. Roller bearing
34. Roller bearing
35. Long planetary
gear (24 teeth)
36. Race
37. Planetary carrier
38. Thrust washer,
bearing & race
Fig. 117Exploded view of power shift assembly used on Model 2096. Power shift for Model 1896 Is similar.
39. Snap ring
40. Ball bearing
41. Retainer
42. Spacer (short
planetary gear)
43. Short planetary
gear (36 teeth)
44. Roller bearing
45. Race
46. "O" ring
47. Carrier (C-2 &
C-3)
48. Piston (C-2 &
C-3)
49. 0 " ring (inner)
50. Seal (inner)
51. O ring (outer)
52. Seal (outer)
53. Belleville springs
54. Plates & discs
(C-2)
55. Hub (C-2)
56. Ferry head screw
57. Piston (C-2 & C-3)
58. O * ring (inner)
59. Seal (inner)
60. O" ring (outer)
61. Seal (outer)
62. Belleville springs
63. PUtes& discs (C-3)
64. Ring gear
65. Teflon button
66. Snap ring
67. Plates* discs (C-3)
68. Hub (C-3)
69. Oil rings
70. Oil distributor
71. Oil distributor
tubes & O rings
72. Bolt
73. Bearing shield
74. Snap ring
75. Ball bearing
76. Pinion drive shaft
77. Bushing
78. Snap ring
79. Output gear
80. Snap ring
81. Snap ring
82. Roller bearing
83. Snap ring
NOTE: Model 1896 tractors use two Belleville
springs on C-2 and C-3 clutches and Model 2096
tractors use three Belleville springs on C-2 and C-3
clutches.
Remove C-2 clutch plates (54).
NOTE: Model 1896 tractors use three steel plates
and three friction discs on C-2 clutch and Model
2096 tractors use four steel plates and four friction
discs on C-2 clutch.
Remove C-2 and C-3 piston carrier (46 through 52)
and (57 through 61), then lift ring gear (64) off C-3
clutch hub (68). Remove Belleville springs (62) and
lower C-3 clutch plates (67) from clutch hub. Remove
upper C-3 clutch plates (63) from ring gear (64), then
remove internal ring (66) from ring gear (64). Remove
button bearings (65) from ring gear.
146. C-2 AND C-3 PISTON CARRIER. Remove the
four small 0 rings (46Fig. 117) from carrier (47).
Use compressed air to remove the C-2 and C-3 pistons
(48 and 57) from carrier (47). Remove inner and out
er seals and O rings (items 49 through 52) and (58
through 61) from C-2 and C-3 pistons.
Lubricate new inner O rings (49 and 58) with
petroleum jelly and install in both pistons. Lubricate
new inner seal rings (50 and 59), install over inner
0 rings in pistons and seat seals using a smooth
wooden dowel. Install outer O" rings and seal rings
(51, 52, 60 and 61) in both pistons in same manner.
Lubricate edges of both pistons and install flat side
inward into piston carrier. Lubricate the four new
"O rings (46) and install in carrier oil passages.
147. PLANETARY ASSEMBLY. Tb overhaul the re
moved planetary assembly (items 27 through 45-
Fig. 117), drive pins (31) into planet gear shafts as
shown in Fig. 120. This will allow planet shafts (29
and 30Fig. 117), gears (35 and 43), bearings (33, 34
and 44), thrust washers (32, 36 and 45) and spacers
(42) to be removed. Remove input shaft (27). Clean
and inspect all parts and renew any that are ques
tionable.
Reassemble by reversing disassembly procedure
and observe the following: Needle bearings for the
long planetary gears (35) are different lengths. Long
bearings (34) are 1inch (25.4 mm) for Model 1896 and
1-1/4 inches (31.75 mm) for Model 2096 tractors. Short
bearing (33) is % inch (19.05 mm) for Model 1896 and
1inch (25.4 mm) for Model 2096 tractors. Long plane
tary gears (35) must go in holes of carrier that are
closest to outside of planetary shell. Short planetary
gears (43) must go in holes next to inside of plane
tary shell. Thrust races (32, 26 and 45) are aU 0.030-
0.032 inch (0.762-0.813 mm) in thickness. Long nee
dle bearing end of gear (35) must be toward inside
splined end of planetary carrier. Install roU pins (31)
into carrier until flush or recessed 1/32 inch (0.794
mm).
148. C-1 AND C-4 PISTON CARRIER. Tb renew
seals and 0 rings in C-1 and C-4 clutch pistons (11
and 21Fig. 117), follow procedure outhned in para-
Flg. 119View showing oil distributor tutxs after removal
of control valve.
Fig. 118Align hole In planetary Input gear with hex head
screw In bearing retainer. Refer to text.
Fig. 120Drive planetary gear shaft pins Into shafts for
removal of gears and shafts. Refer to text.
graph 146 and install into C-1 and C-4 clutch carrier
(16) as described.
149. REASSEMBUT. Tb reassemble the power
shift clutch first, inspect output shaft rear bearing
(82Fig. 117) and renew if necessary. Install output
shaft assembly (items 74 through 80) into transmis
sion until bearing retaining ring on shaft bearing (75)
seats against transmission case. Coat oil shield (73)
with petroleum jelly, install into oil distributor (70)
with brass side toward outside, then install oil dis
tributor (70) with oil shield toward bearing. Oil shield
must fit over bearing retainer and against bearing.
Install carrier bolts and washers (72) from inside
transmission case and tighten to 35-42 ft.-lbs. (48-57
N'm) torque.
Install oil distributor rings (69) on C-3 clutch hub
(68) making certain hook ends are engaged. Clean
threaded holes in C-3 clutch hub, then use Loctite
Primer NF in threaded holes. Inspect all friction and
steel plates (63 and 67) for wear or warpage and re
new as necessary.
Lubricate all discs and plates with clean Hy-Tran
Plus fluid. Install one friction disc, one steel plate,
one friction disc and one steel plate over clutch hub
(68Fig. 117). Install clutch retaining ring (66) and
button bearings (65) into ring gear (64).
NOTE: Renew button bearings if head thickness
is iess than 0.042 Inch (1.067 mm) as shown in Fig.
121.
Install ring gear (gear teeth up) on C-3 clutch hub
engaging friction disc outside teeth in ring gear. In
stall remaining discs and plates alternating one fric
tion disc and one steel plate on all models.
Check Belleville springs (62Fig. 117) for wear,
rounded comers or scratches and renew as necessary.
If free height is less than 0.167 inch (4.242 mm) as
shown in Fig. 122, renew Belleville spring.
Install Belleville springs (62Fig. 117) into recessed
area of C-3 clutch hub (68). On Model 1896 tractors,
put first spring with inside diameter higher than out
side diameter, and second spring with inside diame
ter contacting high inside diameter of first spring. See
Fig. 123. On Model 2096 tractors, put first spring with
outside diameter higher than inside diameter, second
spring outside diameter contacting outside diameter
of first spring and third spring inside diameter con
tacting inside diameter of second spring See Fig. 123.
Install a 3/8 inch NC x 7 inch stud into bolt hole
of C-3 clutch hub which aligns with timing mark as
shown in Fig. 124. Use Locquic Primer T and Loctite
Fig. 122Renew Belleville springs If free height Is less
than dimension shown.
SET
1896 TRACTORS
TWO BELLEVILLE
SPRINGS
^ M I
2096 TRACTORS
THREE BELLEVILLE
SPRINGS
Fig. 123Cross-sectional drawing showing correct
Installation position of C~2 and C-3 clutch Belleville
springs. Refer to text.
Fig. 121Renew Teflon buttons In ring gear If worn
beyond dimension shown.
Fig. 124View of planetary ring gear showing Installation
of stud aligning with timing mark on C-3 clutch hub.
Epoxy 601 or equivalent on surfaces between C-3
clutch hub and C-2 and C-3 piston carrier assembly
(47-Fig. 117).
NOTE: Do not allow Epoxy to enter pressure or
lube ports of these parts.
Install C-2 and C-3 piston carrier assembly into ring
gear, 0 ring side inward, aligning timing marks on
piston carrier with stud in clutch hub.
Install Belleville springs (53) into piston carrier
recesses. On Model 1896 tractors, install first spring
with inside diameter higher than outside diameter,
then second spring with inside diameter contacting
inside diameter of first spring. On Model 2096 trac
tors, install first spring with inside diameter higher
than outside diameter, then second spring with in
side diameter contacting inside diameter of first
spring and third spring with outside diameter con
tacting outside diameter of second spring. See Fig.
123.
C-2 clutch hub (55Fig. 117) has a timing mark on
inside face which must be transferred to outside face.
Use a dab of paint, or other suitable means, to make
a visibly clear mark. Install discs and plates (54) start
ing with a friction disc and then steel plate, alternat
ing discs and plates, until a total of six plates for Mod
el 1896 tractor or eight plates for Model 2096 tractor
are installed. Install three clutch plate holders (Fig.
125) to aid assembly. Refer to Fig. 126 and install
clutch and hub package, using two 3/8 inch (9.53 mm)
rods as a handle as shown. Be sure timing mark on
hub is aligned with stud in C-3 clutch hub. Use Loc
quic Primer and Loctite 601 or equivalent sealant on
surface of C-2 clutch hub surfaces.
NOTE; Do not allow sealant to enter pressure or
lube ports on hub.
Tb be certain C-2 clutch hub is correctly seated,
measure gap between C-2 clutch hub and C-2 piston.
Gap must be 3/8 inch (9.53 mm) or clutch hub could
be held up on Belleville springs or C-2 clutch plates
are not flat on hub.
Use a pilot shaft to align assembly as shown in Fig.
127, use Locquic and Loctite sealant or equivalent on
cap screws (56Fig. 117), install hardened washers
under cap screws and tighten cap screws only tight
enough to feel Belleville springs starting to compress.
Final tightening must be done after ring gear assem
bly is installed on transmission mainshaft. Remove
clutch plate holder tools and pilot shaft. Lubricate
oil distributor rings (69Fig. 117) on ring gear assem
bly, install pto shaft into output shaft, then install
Fig. 126Align mark on C-2 clutch hub with stud when
Installing assembly.
Fig. 125Drawing of clutch plate holder (A43110)
showing correct dimension of bend for Model 1896. On
Model 2096, use clutch plate holders CAS-1083.
Fig. 127Use pilot shaft to align assembly before cap
screws are tightened.
CASE/INTERNATIONAL
ring gear assembly into torque tube. Tighten C-2
clutch hub cap screws (previously installed) evenly
to 110-120 ft.-lbs. (149-163 N-m). Install bearing retain
er (41), recessed area toward outside. Heat planetary
carrier bearing (40) to 250 F (120 C) and install on
output shaft with retaining ring on bearing toward
inside, then install snap ring (39), sharp edge toward
outside. Install the 0.092-0.095 inch (2.337-2.413 mm)
thick washer against planetary shaft bearing, then
install the one-piece needle bearing and race with
needles facing the thick washer.
Tb install planetary assembly on all models, first in
stall a X 5 inch stud into one of the bearing retain
er holes (41Fig. 117). Install the planetary assem
bly into ring gear assembly aligning bolt holes in
planetary shell with guide stud. Turn ring gear to en
gage C-2 clutch friction plates. Pull ring gear forward
and when faces of short planet gears are flush with,
or 1/8 inch (3.18 mm) below ring gear face, all clutch
plates will be properly engaged. Put Loctite Primer
and Loctite 290 or equivalent on threads of new sock
et head (Jaycock) cap screws (28), then remove guide
stud and install and tighten cap screws to 10-14 ft.-
lbs. (14.6-19 N-m) torque. Install drive shaft sleeve on
pto shaft.
Tb reinstall C-1 and C-4 piston carrier (16Fig. 117),
renew any worn or damaged parts (items 2 through
26). Install seals and 0 rings of C-1 and C-4 pistons
(11 and 21) as outlined for C-2 and C-3 pistons in para
graph 146, then install pistons into carrier (16). In
stall clutch reaction pins (26) into torque tube clutch
housing Lubricate inner and outer return springs (24)
with petroleum jelly and install in recesses of clutch
housing. Install C-4 steel clutch plate (25) aligning
tabs with pins (26). Install C-4 friction disc (23). On
Model 2096 tractors, install another C-4 steel plate
so that tabs align with pins (26), then install another
friction disc. On all models, install clutch plate (22),
with solid tabs, so that notches align with pins (26)
and solid tabs cover return springs as shown in Fig.
128.
Install C-1 and C-4 piston carrier (16Fig. 117) with
oil tube holes up, making certain dowel pins (26) in
housing enter holes in carrier. Install bolts with new
hardened washers and tighten to 80-96 ft.-lbs. (108-
130 N-m).
Install C-1 friction plate (8Fig. 117) on piston car
rier with notched tabs on pins (14) and solid tabs
clockwise from notches. Install C-1 steel plate (7),
friction disc (6), without solid tabs, aligning notches
on pins. Install sun gear (5), engaging splines with sol
id disc (7) and short planetary gears, then install fric
tion disc (4) aligning notches on pins. Lubricate in
ner and outer return springs (3) with petroleum jelly
and install in holes of C-1 reaction plate (2). Install
bolts with new hardened washers, except for bolt
which secures lube tube (1). Install lube tube and
clamp and bolt, then tighten all reaction plate bolts
to 35-42 ft.-lbs. (45-57 N-m) torque.
NOTE: Tip of lube tube (1) must be as near to gap
between planetary input shaft and sun gear as pos
sible without touching.
Install C-1 and C-4 oil distributor tubes (15) with
new 0 rings. End of tube with smallest diameter
must be down. Tighten plugs for oil tubes in top of
clutch housing to 13-15 ft.-lbs. (18-20 N-m) torque.
Install the three oil distributor tubes (71) with new
0 rings. End of tubes with smallest diameter go
into torque tube and engage oil distributor carrier.
See Fig. 129.
Reinstall control valve as outlined in paragraph 139.
Rejoin tractor by reversing split procedure.
Fig. 128Installing C-4 steel clutch plate with notches
on pins and tabs over return springs.
Fig. 129View showing Installation of oil distributor tulies
and "O" rings. Refer to text.
MODELS 1896-2096
Paragraphs 150-151
GEAR TRANSMISSION
ADJUSTMENT
All Models
150. SHIFT LINKAGE, lb adjust the four-speed
gear transmission shift linkage, disconnect control ca
ble yokes (8Fig. 130) from shift levers (9 and 10).
Place shift quadrants (3 and 4) in neutral position,
then place shift levers (9 and 10) in neutral position
(20 degrees above horizontal as shown in insert A
Fig. 130Exploded view of four-speed gear transmission
and park lock linkage.
1. Shift lever 8. Yokes
2. Park lock 9. Shift lever
quadrant (1st & 2nd)
3. 1st & 2nd gear 10. Shift lever
quadrant (3rd & 4th)
4. 3rd & 4th gear 11. Yoke
quadrant 12. Shift lever
5. Shift cable (park lock)
6. Shift cable 13. Reverse lockout
7. Shift rod lever
(park lock) 14. Lockout linkage
Fig. 130). Adjust position of cable yokes (8) so that
yoke holes align with shift lever holes. Install yoke
pins and secure yokes. Quadrant slots should be close
ly aligned.
Reverse lockout linkage (14) should be adjusted to
obtain a distance of 3.00 inches (76.2 mm) between
center of pins as shown in Fig. 131.
151. NEUTRAL START SWITCHES. TbacUust the
neutral start switches, place the four-speed gear
transmission in neutral, disconnect wiring and re
move the two switches (Fig. 132). Remove switch
shims, then reinstall switches without shims. Using
an ohmmeter or suitable continuity light, turn each
switch in until light or meter shows continuity. In
stall shims equal to the gap behind switches. Shims
are available in thicknesses of 0.005 and 0.010 inch
(0.127 and 0.254 mm).
Recheck switch operation by shifting transmission
from neutral to each of the four gear positions.
Switch continuity should break with transmission in
any gear. Continuity should occur only when trans
mission is in neutral position. Rea(ûst as necessary.
Fig. 131Adjust reverse lockout linkage to obtain a
distance of 3.00 Inches (76.2 mm) Ijetween center of pins.
Fig. 132Top cutaway view showing typical Installation
of neutral start switches.
FOUR-SPEED TRANSMISSION SHIFT
FORKS, SHAFTS AND HOUSING
All Models
152. REMOVE AND REINSTALL. Tb remove
shifter forks and shafts for service or renewal, first
drain transmission oil. Then, disconnect shift control
cables from four-speed transmission and park lock
levers. Remove neutral start switch wiring. Remove
rear side access cover and cable bracket. Refer to Fig.
133 and drive out detent roll pins (17) from both forks
(13 and 16), then remove detent springs (19) and balls
(18). Engage park lock, fully clockwise, then drive
roll pin (20) out of shift rail (21) and shift rail bore
in transmission. Disengage park lock, fully counter
clockwise, put transmission in first gear by sliding
rear shift fork (16) rearward. Rotate shift rail until
roll pin (24) can be driven out of shift rail. Separate
shift rail and push rear rail section (25) rearward out
of shifter fork (16), then remove shifter fork. Remove
shifter fork (13) with shift rail (21) and rail connec-
1. Neutral start
switches
2. Shims
3. Snap ring
4. Washer
5. Wave washer
6. Shifter shaft
7. " 0 ring
8. Washer
9. Snap ring
10. Shift fork lever
(1st & 2nd)
11. Roll pin
12. Shift fork lever
(3rd & 4th)
13. Shifter fork
(3rd & 4th)
14. Shift collars
15. Fork finger
(4)
16. Shift fork
(1st & 2nd)
17. Roll pin
Detent ball
Detent springs
20. Roll pin
21. Front rail
22. Roll pin
23. Rail connector
24. Roll pin
26. Rear rail
18.
19.
tor (23) as an assembly. Remove rear section of shift
rail (25) from bore in transmission.
To remove shifter shafts (items 3 through 12), hy
draulic inlet screen must be removed as outlined in
paragraph 212. Remove outer shift levers from four-
speed transmission. Remove snap ring (3Fig. 133)
from shifter shaft (6). Remove flat washer (4) and
wave washer (5). First remove shifter shaft and shift
fork lever (12) for third and fourth gear, then remove
shifter shaft and shift fork lever (10) for first and sec
ond gear. Renew O rings (7) on shifter shafts when
reassembling.
Reassemble by reversing disassembly procedure.
Adjust shift linkage as outlined in paragraph 150,
neutral start switches as in paragraph 151 and park
lock linkage as in paragraph 164.
OVERHAUL GEAR TRANSMISSION
All Models
153. GEAR TRANSMISSION INPUT SHAFT.
Split tractor between engine and torque tube as out
lined in paragraph 134 and remove cab or platform.
Remove power shift clutch assembly as outlined in
paragraph 143. Gear transmission input shaft is also
power shift output shaft and overhaul procedure is
outlined in paragraph 144 of POWER SHIFT section.
Inspect and renew rear input (power shift output)
shaft bearing (2Fig. 134) as necessary by removing
retaining rings (1 and 3).
NOTE: Access to rear snap ring (1Fig. 134) is ob
tained by removal of top transmission access cover.
154. INTERMEDIATE SHAFT. With tractor split
and power shift assembly and pto assembly removed,
disconnect gear transmission shift control cables and
Fig. 134Exploded view of gear transmission Input shaft
and related parts.
1. Snap ring
2. Roller bearing
3. Snap ring
4. Snap ring
5. Output gear
6. Snap ring
7. Bushing
8. Drive shaft
9. Bearing
10. Snap ring
Fig. 133Exploded view of shifter forks and shafts of gear
transmission.
park lock rod. Remove cables from mounting brack
et. Disconnect neutral start switch wiring. Unbolt
and remove rear transmission side access cover and
cable mounting bracket. Refer to Fig. 135 and remove
nut (16) from front end of shaft, then remove input
gear (15). Remove Allen head screws (1) and rear plate
(2), then using a long punch or mild steel rod, drive
intermediate shaft (13) forward out of bearing (4).
Then, while withdrawing shaft from front of trans
mission, remove components (6 through 12) from
shaft through side access opening. Press front bear
ing (14) from shaft. Remove snap rings (3 and 5) and
rear bearing (4) if renewal is indicated.
Clean and inspect all parts for excessive wear or
other damage and renew as necessary. Check bear
ings for free smooth action and renew any bearing
having a loose fit or rough action. Heat front bear
ing (14Fig. 135) to a temperature of 250 F (120
C) for ease of assembly. Rein.stall shaft, gears and
spacers by reversing removal procedures. Use Loctite
271 on threads of Allen head screws (1Fig. 135) and
install plate (2). Tighten screws to a torque of 40 ft.-
Ibs. (54.2 N*m). Install input gear and tighten nut (16)
to a torque of 200 ft.-lbs. (271 N-m), then stake flange
of nut to slot in shaft.
NOTE: Some late models may be equipped with
double taper roller rear bearings In place of double
ball bearings.
Fig. 135Exploded view of Intermediate stiaft and
components of gear transmission.
1. Allen head 8. Gear (2nd)
screws 9. Gear (3rd)
2. Rear plate 10. Spacer
3. Snap ring 11. Gear (4th)
4. Rear bearing 12. Spacer
assy. 13. Shaft
5. Snap ring 14. Front bearing
6. Gear (1st) 15. Input gear
7. Spacer 16. Nut
155. COUNTERSHAFT. For service of counter
shaft, cab or control platform must be removed fron
tractor and torque tube must be removed from trans
mission as follows: With cab or platform removed anc
power shift clutch a.ssembly removed as in paragrapl
143, unbolt cab or platform side mounts from each
side of torque tube. Support torque tube with a suita
ble hoist or rolling floor jack, then unbolt and remov<
torque tube from transmission housing.
Remove rear cab or platform mounts. With trans
mission suitably supported, remove wheels. Remov*
axle housing and final drive assembles as outlined ii
paragraph 158.
Disconnect differential lock oil fitting on right o
transmission then remove oil tube. Remove rear pt<
drive shaft. Unbolt and remove hitch sensing link
age rod and support and remove oil tube from rea
of transmission frame.
Support differential with wood blocks. Removi
differential bearing carriers from both sides of trans
mission. Remove both differential bearing cones
shims and inner halves of brake cylinders from botl
sides of transmission. Attach a suitable chain or slinj
and hoist to differential assembly and remove fron
transmission.
Remove ground speed sensor from top of rea
transmission access cover, then remove cover. Re
move shift rail and shift forks as outlined in para
graph 152.
Bend retainer nut (1Fig. 136) lip from notch ii
countershaft and remove nut and thrust washer (2)
Install a suitable puller and remove front counter
shaft bearing cone (3). Remove snap ring (6) fron
shaft. Push countershaft assembly rearward until ou
of park lock gear (8). Push countershaft rearwan
while removing items (9 through 18) out top of ac
cess opening. Park lock gear cannot be removed un
til fourth, third and second gears are removed. Re
move park lock gear (8), then remove remainder o
items (19 through 23) out top of access opening an<
withdraw countershaft from rear of transmission.
Remove snap ring (5) from behind front Ijeaiing cu)
and drive out cup. Drive out rear bearing cup (25)
Press rear bearing cone from countershaft.
Clean and inspect all parts for damage or excessivi
wear and renew as necessary. Check bearings for frei
smooth action and renew any bearing having a loosi
fit or rough action.
Assemble countershaft as follows: If rear pinioi
bearing cone (26Fig. 136) was removed, heat bear
ing cone to a temperature of 250 F (120 C) and in
stall bearing cone on countershaft with large side to
ward pinion gear. With countershaft standing vertica
with pinion gear down, assemble shaft component
as follows: Install 1/8 inch (3.18 mm) thick thrus
washer from thrust bearing (23), then install needli
bearing and cup washer, cup side down. In.stall firs
CASE/INTERNATIONAL
gear (22) hub gear end up. Install thrust bearing (21)
cup side up. Install pinion shaft hub (19) with V* inch
(6.35 mm) recessed spline side down, then install shift
collar (20). InstaU thrust bearing (18) cup side down;
second gear (17) hub gear end down. Install thrust
bearing (16) cup side down, then third gear (15) hub
gear end up. Install thrust bearing (14) cup side up.
Install pillion hub (12) with V* inch (6.35 mm) recessed
spline side down then install shift collar (13). Install
Fig. 136Exploded view of four-speed gear countershaft
and components.
1. Locknut
2. Washer 16. Thrust bearing
3. Bearing cone 17. Gear (2nd driven)
4. Bearing cup 18. Thrust bearing
6. Snap ring 19. Hub (1st & 2nd)
6. Snap ring 20. Shift collar
8. Park lock gear 21. Thrust bearing
9. Thrust bearing 22. Gear (1st driven)
10. Gear (4th driven) 23. Thrust bearing
11. Thrust bearing 24. Lube tube
12. Hub (3rd & 4th) 25. Bearing cup
13. Shift collar 26. Bearing cone
14. Thrust bearing 27. Pinion shaft
15. Gear (3rd driven) 28. Ring gear
thrust bearing (11) with 1/8 inch (3.18 mm) thrust
washer first and remainder of assembly cup side
down. Install fourth gear (10) with hub gear end
down. Install thrust bearing (9) with cup side up. In
stall park lock gear (8) on shaft. Tkp park lock gear
with hammer to make sure there is no clearance be
tween assembled parts. Install a shim type snap ring
(6) and measure clearance between snap ring and
park lock gear. Install appropriate thickness snap ring
until 0.003-0.011 inch (0.08-0.28 mm) clearance is ob
tained. Snap rings (6) are available in thicknesses of
0.078, 0.088, 0.098, 0.108, 0.118, 0.128 and 0.138 inch
(1.98, 2.24, 2.49, 2.74, 3.0, 3.25 and 3.5 mm). See Fig.
137 for cross-sectional view of assembled counter
shaft. Remove all parts from countershaft for assem
bly into transmission.
If front bearing cup was removed, install snap ring
(5Fig. 136) and press cup (4) into bore against snap
ring. Install countershaft through rear of transmis
sion case assembling parts in order shown in Fig. 137.
Install a bar and bolt as shown in Fig. 138 to hold
countershaft rigid and in correct position for instal
lation of front bearing. Heat front bearing cone (3
Fig. 136) and install on front of countershaft, then
install thrust washer (2) and retainer nut (1).
F\g. 137Cross-sectional view of assembled countershaft
and related parts.
MODELS 1896-2096
Paragraphs 156-159
156. COUNTERSHAFT BEARING PRELOAD. Re
move bar and bolt shown in Fig. 138. Tighten coun
tershaft retainer nut, while rotating countershaft to
remove clearance between countershaft bearing
cones and cups. Loosen nut, then retighten finger
tight. With transmission in neutral, measure rolling
torque with a torque wrench. Tighten retainer nut
until an additional 25-35 in.-lbs. (2.8-4.0 N-m) rolling
torque is obtained for new bearings and 15-25 in.-lbs.
(L7-2.8 Nm) additional rolling torque of original bear
ings is added to the original measurement. After cor
rect preload is obtained, bend edge of retainer nut
into groove in countershaft.
157. Reassemble tractor by reversing disassembly
procedure. Install power shift assembly as outlined
in paragraph 149. Adjust differential bearing preload
and ring gear and pinion backlash as outlined in para
graph 162. Coat all mating surfaces of access cover;
axle housings, transmission halves and pto housing
assembly with Loctite 504 or equivalent prior to as
sembly. Tighten transmission to torque tube nuts to
a torque of 400-500 ft.-lbs. (542-678 N-m). Fill trans
mission to proper level with new Hy-Tran Plus fluid.
Bleed power steering and brake systems as outlined
in paragraphs 15 and 169. Adjust shift linkage as out
lined in paragraphs 137 and 150. Acjjust hitch con
trol and sensing cables as outlined in paragraph 226.
Fig. 138With differential removed. Install jackbolt and
bar to support countershaft for reassembly.
DIFFERENTIAL AND FINAL DRIVE
This section covers the differential and ring
gear, differential lock, planetary final drive and
park lock. Differential can be removed from the
rear, but to remove the bevel pinion gear, tractor
must be split between transmission and torque
tube.
FINAL DRIVE
All Models
158. REMOVE AND REINSTALL. Drain transmis
sion housing, jack up rear of tractor and support both
sides of tractor with stands under the draft arm
mounting brackets. Remove rear tire and wheel as
semblies. Loosen both front platform isolation mount
nuts, support cab or platform with suitable stands,
then remove both rear platform isolation mount re
taining bolts and remove the isolation mounts. Re
move the cab rear mounting brackets. Wrap a chain
around the axle housing, attach a hoist, then remove
all of the axle housing mounting cap screws except
the top one. Install two 5/8 inch guide studs, one on
each side of the axle housing, remove the top cap
screw and pull final drive assembly from transmis
sion housing.
CAUTION: Hang a counterbalance weight on out
er end of axle, or use a pipe over end of axle as a
lever to balance unit as It Is removed. The planetary
end of housing assembly Is much heavier than the
axle end.
When reassembling unit, use the guide studs to
guide unit into mesh with splines. Put Liquid Gasket
or Loctite 504 or equivalent on flanges where axles
mate to transmission housing prior to assembly. It
may be necessary to rotate axle shaft to align splines.
Tighten cap screws to 220-264 ft.-lbs. (298-358 N-m)
torque.
159. OVERHAUL. Remove axle housing as out
lined in paragraph 158. Refer to Fig. 139 as a guide
for disassembly of final drive assembly. Remove sun
gear shaft from planetary assembly. Lock up planet
gears by using a small rod, or other similar object,
and loosen cap screw (16) and pull planetary assem
bly from inner end of axle. Remove ring gear (4) from
axle housing (10) or transmission housing.
Install a 7/8 inch cap screw into tapped hole in in
ner end of axle, place a bar across head of cap screw
and secure bar with two large C" clamps. Keep axle
from turning and push axle shaft and outer seal from
housing by turning cap screw. Remove inner bearing
from housing and oil seal and outer bearing from axle
shaft. Bearing cups can be driven from axle housing
if renewal is required.
Tb disassemble planet carrier, drive roll pins (5) intc
planet gear shafts (14), remove shafts and pull plan
et gears and bearings from carrier. Each planet geai
(8) contains 38 roller bearings (7). Remove retaining
plate (15).
Clean and inspect all parts for pitting, scoring oi
undue wear and renew as necessary. Roller bearing;
Paragraph 160
CASE/INTERNATIONAL
for planet gears are available only in kits of 38 rollers.
Tb reassemble final drive, proceed as follows: If re
moved, install outer bearing cup (18Fig. 139) with
taper facing out and inner bearing cup (11) with ta
per facing in. Heat outer bearing cone (19) and in
stall on axle shaft until it seats against shoulder. In
stall axle and bearing into housing, then heat inner
bearing (12) and install on inner end of axle. Apply
Permatex No. 2 or equivalent, to outer edge of oil seal
(21). Install seal over axle shaft with lip toward in
side and drive oil seal in housing until outer face of
seal is flush with outer edge of housing. Then, place
planet carrier on bench with sphned inner end up.
Drive roll pins from planet gear shafts. Use vaseline,
or equivalent, and install 38 roller bearings (with
spacer between rows of rollers) in planet gears. Place
ONE planet gear and bearing assembly in planet car
rier, align roll pin hole in planet gear shaft with roll
pin hole in carrier and install shaft. Install shaft re
taining roll pin flush with carrier surface.
Fig. 139Exploded view of final drive planetary and
associated parts.
4. Ring gear
5. Roll pin
6. Thrust washer
7. Roller bearings
8. Planet gear
9. Spacer
10. Axle housing
11. Bearing cup
12. Bearing cone
13. Carrier
14. Pinion pin
15. Axle retainer
16. Cap screw
17. Lockplate
18. Bearing cup
19. Bearing cone
20. Short axle shaft
20A. Long axle shaft
21. Seal
22. Key
23. Pin
NOTE: The rear axle retainer (15Fig. 139) must
be installed prior to installing second and third plan
et gears.
Install retainer with recess away from splined hub
of carrier (downward). Install second and third pin
ion gear assemblies following the procedure already
given.
With planet carrier assembled, install splined hub
end on the splined inner end of axle and install re
taining (adjusting) bolt (16) through retainer (15) and
into axle (20). Turn adjusting bolt until it begins to
tighten, then bump outer end of axle and planetary
carrier to seat bearings. Mount a dial indicator against
face of planetary carrier, lightly tap axle and plane
tary assembly back and forth and turn adjusting bolt
as required to obtain axle end play of 0.005-0.015 inch
(0.127-0.381 mm). Using a torque wrench, measure
and record the no-load rolling torque of axle assem
bly, then tighten actjusting bolt until the rolling torque
is 25-50 in.-lbs. (2.8-5.6 N-m) greater than the previ
ously recorded no-load rolling torque. Lightly tap axle
both ways and recheck bearing preload. If rolling
torque (preload) goes above 75 in.-lbs. (8.4 N-m), loos
en and bump a(ûsting bolt only and reacûst as al
ready outlined.
Install lockplate (17) and if points of lockplate do
not align with points of adjusting bolt head, turn
lockplate to another position. If points still do not
align, tighten adjusting bolt to the nearest point that
will align. However, do not tighten bolt more than
necessary as it will affect the preload adjustment.
Reinstall the final drive assembly as outlined in
paragraph 158.
DIFFERENTIAL AND BEVEL RING GEAR
All Models
sion and remove pto assembly, final drive housings
and brake cylinder assemblies. Remove hitch linkage
box oil return tube from inside rear housing. Remove
pto input shaft. Disconnect hitch follow up linkage
from follow up lever and remove as necessary. Sup
port differential assembly on wood blocks and re
move left and right bearing carriers and shims (keep
ing shims with each bearing). Unbolt and remove left
and right inner brake housings. Attach a suitable
chain and hoist and remove differential from trans
mission case.
Reinstall in reverse order of disassembly. Tighten
differential brake housing bolts to 220 ft.-lbs. (298
Nm) torque. Install bearing carriers with same shims
that were removed. Tighten carrier retainer cap
screws to 45 ft.-lbs. (61 N'm) torque. Refer to para
graph 162 for ring gear and pinion backlash ad
justment.
161. OVERHAUL. Remove differential as outlined
in paragraph 160. Place assembly on a bench and re
fer to Fig. 140 as a guide to disassembly. Keep shims
with bearing carriers from which they were removed.
Shims are available in thicknesses of 0.003, 0.007,
0.010 and 0.020 inch (0.08, 0.18, 0.25 and 0.508 mm)
for bearing preload adjustment. Put identification
mark on pinion pin (10) and ring gear cage (3) to en
sure correct reassembly position. Set assembly on
bevel ring gear end and remove two differential lock
seal rings (25 and 26). Remove differential lock cage
retaining cap screws. Remove differential lock cage
(24), spring return plate (18), springs (15) and
differential lock clutch plates (16 and 17) from
differential cage. Remove reaction plate (14), thrust
washer (13) and right side bevel gear (12) from gear
cage (3). Drive roll pin (11) out of pinion, then drive
out pinion pin (10) and remove pinion gears (9) and
Fig. 140Exploded view of differential and lock clutch
assembly.
1. Bearing cone
2. Bearing cup 18. Piston return
3. Cage plate
4. Ring gear 19. Piston
5. Pinion shaft
20. 0" ring (outer)
6. Thrust washer 21. Seal (outer)
7. Left bevel gear 22. " 0 " ring (inner)
8. Thrust washer 23. Seal (inner)
9. Pinion gear
10. Pinion pin cage
n . Roll pin 25. Seal ring
12. Right bevel gear 26. Seal ring
13. Thrust washer
27. Bearing cup
14. Reaction plate 28. Bearing cone
16. Return spring 29. Brake & sun
16. Steel plate shaft
17. Friction disc 30. Snap ring
washers (8). Remove left side gear (7) and thrust
washer (6). Unbolt and remove ring gear (4) from ring
gear cage. If ring gear must be renewed, the bevel
pinion shaft must also be renewed, which will make
it necessary to remove bevel pinion as outlined in
paragraph 155. Drive out bearing cup (2) if renewal
is necessary. Using compressed air in oil slot of
differential lock cage, remove differential lock pis
ton (19). Remove and discard inner and outer seal
rings (items 20 through 23). Use a suitable puller to
remove bearing cup (27) if renewal is necessary.
Clean and inspect all parts for wear, nicks and scor
ing and renew as necessary. Reassemble differential
as follows: Install bearing cups (2 and 27Fig. 140)
until they bottom in cage halves (3 and 24). Install
bevel ring gear (4) and tighten retaining cap screws
with new washers to 220 ft.-lbs. (298 N*m) torque. In
stall thrust washer (6) and side gear (7) into ring gear
cage (3). Install pinion pin (10) through wall of cage
while installing pinion gears (9) and thrust washers
(8) on pinion pin. Be sure pinion pin is in correct in
dex with ring gear cage. Install new roll pin (11) into
pinion pin and ring gear cage until top of roll pin is
1.44 inches (36.58 mm) from top of hole. Lubricate
inner and outer piston seal rings (items 20 through
23) with petroleum jelly and install into inner and
outer grooves of piston (19). Use a smooth wood
dowel or round plastic pen to fit seals into grooves.
Lubricate and install piston, flat side down, into
differential cage half. Install the two seal rings (25
and 26) onto differential lock cage making sure hook
ends of seals are closed. Lubricate seal rings with
petroleum jelly. Install right bevel gear (12) into ring
gear cage, then install thrust washer (13) over side
gear. Install reaction plate (14) flat side up, on ring
gear cage aligning bolt holt >. Install return springs
(15), then alternately instaL a steel clutch plate (16)
and friction disc (17) keeping notches of steel plates
aligned with springs. Install with springs. Install pis
ton return plate (18) with tabs on top of return
springs. Install two */^NC x 6 inch guide studs oppo
site each other in reaction plate, then install differen
tial lock cage (24) over differential ring gear cage
aligning slots in lock cage with springs and clutch
plates. Install retaining bolts with new washers and
tighten bolts to a torque of 110 ft.-lbs. (149 N*m).
Reinstall differential by reversing the removal
procedure, then check and acûst bearing preload
and gear backlash as outlined in paragraph 162.
162. lb check differential bearing preload, instaU
left and right bearing carriers, without shims. Tight
en bolts of right hand carrier to 45 ft.-lbs. (61 N*m)
torque. Install three bolts at 120 degrees from each
other into left hand bearing carrier and tighten,
while turning differential, to 30 in.-lbs. (3.4 N-m)
torque, then tighten, while turning differential, to
50 in.-lbs. (5.6 N-m) torque. Check clearance between
left hand bearing carrier and brake housing using a
feeler gage at three bolt locations. Assemble a set of
shims the same thickness or 0.003 inch (0.076 mm)
greater than the average measurement. Divide the
shims equally and install one set of shims on each
bearing carrier. Install both bearing carriers and tight
en all bolts to 45 ft.-lbs. (61 N*m) torque.
With carrier bearing preload adjusted, check and
acyust backlash between ring gear and pinion shaft
as follows: Locate and record recommended backlash
dimension which will be found etched on outside rim
of bevel ring gear. Mount a dial indicator so it makes
contact with tooth of bevel ring gear and that suffi
cient pressure is on tip to move indicator needle. Tkke
up slack in gears by holding pinion shaft and rotat
ing differential as far as possible in one direction
without moving bevel pinion shaft. Zero the indica
tor and turn differential in opposite direction as far
as possible without moving bevel pinion shaft. Read
dial indicator and compare reading to the backlash
dimension etched on rim of bevel ring gear. If back
lash is too much, remove shims from left hand bear
ing carrier and put the shims on right hand bearing
carrier. If backlash is not enough, remove shims from
the right hand bearing carrier and put the shims on
the left hand carrier.
NOTE: Backlash will change approximately 0.002
Inch (0.051 mm) for every 0.003 Inch (0.076 mm) of
shims that are added or removed. DO NOT change
the total amount of shims as It will affect bearing
preload.
Recheck backlash with dial indicator after each
shim change and when backlash atûstment is com
plete, tighten all bearing retainer cap screws to 45
ft.-lbs. (61 N-m) torque.
DIFFERENTIAL LOCK VALVE
All Models
163. An electric solenoid differential lock control
valve is used on all models. Service on the valve con
sists of renewing solenoid unit (1Fig. 141), 0 rings
(2, 3 and 4) or the complete valve assembly. When
installing solenoid (1) in valve body (5), tighten to a
torque of 18-20 ft.-lbs. (24-27 N-m).
PARK LOCK AND LINKAGE
All Models
164. LINKAGE ADJUSTMENT. Tb acûst park
lock linkage refer to Fig. 142 and disconnect yoke (9)
from lever (10). Place gear shift and park lock quad
rants on console in neutral position. Place park lock
lever (10) in off position approximately 9 degrees be-
Fig. 141View of differential lock solenoid control valve.
1. Solenoid valve
2. "O ring 4. " 0 " ring
3. O" ring 5. Valve body
Fig. 142Schematic view showing adjustment
dimensions and components for park lock lever linkage.
1. Park lock hand
lever
2. Quadrant 6. Locknut
3. Upper rod 7. Lower rod
4. Locknut 8. Locknut
5. Acûstment 9. Yoke
sleeve 10. Park lock lever
low horizontal as shown. Adjust lower yoke (9) so that
distance between center of hole in yoke is approxi
mately 24.4 inches (619.8 mm) from top end of lower
rod, then tighten locknut. Reconnect lower yoke (9)
to lever (10). Loosen locknuts on acyustment sleeve
(5) and align quadrants on the console by turning ad
justment sleeve as necessary. Make sure quadrants
on console are exactly in alignment and that shift le
ver can engage the gear shift quadrants and the park
lock quadrant easily when lever is in neutral po
sitions.
165. PARK LOCK. To service park lock first dis
connect the two shift cables and park lock rod. Re
move cables from mounting bracket. Remove park
lock rod, hitch supply tube and hitch control cables.
Disconnect electrical wires from neutral start switch
es. Unbolt and remove right side rear access cover.
Place transmission in third gear by sliding front shift
fork rearward. Engage park lock by moving detent
lever (15Fig. 143) forward. Remove snap ring (21),
lever (20), key (18) and shims from shaft (17). Remove
set screw (6) from gear stop arm. Push roll pin (12)
out of detent lever as far as possible with an air chisel
and CAS-1605 punch tool. Using a hammer and
punch, continue pushing pin out of detent lever un
til shaft can be removed. Pull shaft (17) out far
Hg. 143Exploded view of Internal park lock mechanism.
1. Spacer
2. Shims 12. Roll pin
3. Gear stop arm 13. Stop bolt
4. Shims 14. Locknut
5. Spacer 15. Detent lever
6. Set screw 16. " 0 ring
7. Bolt 17. Park lock shaft
8. Washer 18. Woodruff key
9. Spacer 19. Shims
10. Detent spring 20. Lever
11. Washer 21. Snap ring
enough to remove spacer (1) and shim(s) (2) on left
side of gear stop arm.
NOTE: If shaft is pulled out completely, all of the
park lock parts will fall to bottom of transmission
case.
Carefully withdraw shaft and remove remainder of
park lock control items. Unbolt and remove detent
spring and related parts (items 7 through 11).
Clean and inspect all parts and renew as necessary.
Compare detent spring (10) to dimensions shown in
Fig. 144.
Tb reassemble, first clean old Loctite from threads
of detent spring bolt (7Fig. 143) and bolt hole. As
semble washers, spacer and detent spring on bolt
making sure straight leg of spring is toward bolt head.
Apply Loctite 271 or equivalent to threads of detent
spring bolt and install into transmission, tightening
bolt to 25-35 ft.-lbs. (34-47 N-m) torque. Insert park
lock shaft (17) into bore of transmission case, with
keyway toward rear of tractor Install detent lever (15)
on shaft with notch toward front of tractor placing
leg of detent spring over detent lever. Install right
side spacer (5), gear stop arm (3) and left side spacer
(1) onto shaft U7). See Fig. 145. Engage stop arm with
park lock gear and install set screw (6Fig. 143),
without Loctite, into stop arm, making sure point of
screw enters hole in shaft.
NOTE; If renewal of park lock gear is necessary,
refer to paragraph 155 for procedure.
Fig. 144Illustration showing detent spring dimensions.
Fig, 145Illustration showing Installation ot spacers on
park lock shaft. Refer to text.
166. ARM SHIM PROCEDURE. Disengage gear
stop arm and push shaft into transmission as far as
possible. Install a dial indicator on end of shaft, pull
shaft out as far as possible to find and record total
end travel. See Fig. 146. Raise right rear tire off the
ground engage the gear stop arm with gear, then ro
tate the right rear tire counterclockwise to remove
backlash in drive train. While pushing the shaft in
as far as possible and pulling the shaft out as far as
possible, record the amount of end travel. See Fig.
147. Subtract 0.150 inch (3.81 mm) from this end trav
el to obtain correct shim pack thickness (4Fig. 143)
for right side of gear stop arm. Tb obtain the correct
shim pack for the left hand side of the gear stop arm,
subtract the right hand side shim pack thickness from
the total end travel found in the first measurement.
See Fig. 148. Remove shaft and related parts, install
proper shim packs for left and right side of gear stop
arm, and reinstall shaft and parts with new O ring
(16Fig. 143). Apply Loctite 271 or equivalent to set
screw (6) on gear stop arm and install and tighten to
15-20 ft.-lbs. (20.4-27.1 N-m) torque. Install roll pin (12)
into detent lever (15). Install key (18), lever (20) and
snap ring (21). Pull park lock lever away from trans
mission as far as possible and measure distance be
tween transmission case and back of lever with feel
Fig. 147Illustration showing procedure for finding right
hand shim pack for park lock shaft. Refer to text.
er gage and record measurement. Remove lever (20)
and add sufficient shims (19) to obtain a clearance
of 0.040-0.100 inch (1.016-2.540 mm) between lever
Fig. 148Illustration showing procedure for finding left
hand shim pack for park lock shaft. Refer to text.
Fig. 149Illustration showing stop bolt for detent lever
travel adjustment.
Fig. 150Adjust stop bolt on detent lever until face of
gear stop arm Is 0.25 Inches (6.35 mm) away from park
lock gear.
Fig. 146Pull shaft out as far as possible to find total end
travel and record measurement. Refer to text.
MODELS 1896-2096
Paragraphs 167-170
and transmission. Disengage park lock and ac^just
stop bolt (13) on detent lever (15) until face of gear
stop arm is 0.25 inch (6.35 mm) away from park lock
gear as shown in Figs. 149 and 150.
Remainder of reassembly is reverse of disassembly.
Adjust shift linkage as outlined in paragraph 150 if
necessary. Adjust park lock rod as outlined in para
graph 164.
BRAKES
All models are equipped with multiple disc
brakes located on the final drive sun gear shafts.
Brake pedals actuate brake valves, which act as
manually operated master cylinders with engine
inoperative and power assisted with engine
running.
POWER BRAKE VALVE
All Models
167. OPERATION. The power brake valve mounts
beneath cab platform and is tapped into the
hydrostatic power steering hydraulic circuit. Filtered
and pressurized fluid from the 8 gpm (30.3 L/min.)
section of main hydraulic pump flows to power brake
valve, through pressure regulating spool to steering
valve; then through oil cooler back to transmission
housing. The return transmission flow lubricates
power shift clutch.
On Models 1896 and 2096, brake valve and regula
tor valve are separate units and are connected by hy
draulic lines.
168. LINKAGE ADJUSTMENT, lb adjust power
brake pedal linkage, refer to Fig. 151 and disconnect
brake push rods from brake pedals. Adjust upper stop
bolts so that distance between floor mat and comer
of each pedal is 6.8 inches (172.72 mm). Reconnect
push rods to pedals and acûst length of push rods
until upper stop bolts just contact brake and clutch
cover. Then, lengthen each push rod one full turn
counterclockwise. Tighten locknuts on push rod to
a torque of 28-35 ft .-lbs. (38-48 N-m). Push each brake
pedal down until push rod travel is 1.25 inches (31.75
mm). At this time, distance between comer of brake
pedal and floor mat should be 1.5 inches (38.1 mm).
Adjust lower stop bolts to this position and tighten
locknuts. Brake pedal free travel should be 0.125 inch
(3.2 mm).
Push both brake pedals down at the same time and
check to see that pedal interlock pin will engage. If
not, adjust highest pedal to height of lower pedal by
acUusting length of push rod.
169. BLEEDING. Power brake system bleed screw
is located at top of each axle housing as shown in Fig.
152. Tb bleed brakes, first operate engine at 1000 to
1500 rpm. Turn the steering wheel all the way to the
left and right several times to flush the steering sys
tem. Open left hand brake bleed screw until fluid
flows out. Permit fluid to flow until bubble free, slow
ly push left hand pedal until pedal is fully down.
Close bleed screw while pedal is fully down. Slowly
release brake pedal until fully up. Repeat procedure
again several times to ensure complete air removal.
Repeat operation for right hand brake.
170. PRESSURE TEST. Tb check system pressure
and flow, refer to paragraph 192 for 8 gpm (30.3
Fig. 151Illustration showing brake pedal linkage and
adjustment dimensions.
Fig. 152View of brake hydraulic air bleed screw (right
side shown).
Paragraphs 171-172
CASE/INTERNATIONAL
L/min.) pump testing. Using a CAS-10280 flowmeter
or equivalent, install outlet hose from flowmeter into
transmission filler neck, then install a tee fitting be
tween outlet hose on gear pump and pump. Install
inlet hose of flowmeter to the connector on pump.
Close load valve on flowmeter, start and run tractor
at 2000 rpm until hydraulic fluid reaches operating
temperature of approximately 110-120 F(43-49
C). Push either left or right brake pedal down with
110 lbs. (489 N) of force. Pressure on flowmeter pres
sure gage must be 1600-1800 psi (11032-12411 kPa).
If pressure is incorrect, adjustment is accomplished
by loosening locknut (17Rg. 153) and turning screw
(16) clockwise to increase pressure or counterclock
wise to decrease pressure. When pressure is correct,
tighten locknut.
power brake master valve and pressure regulator
valve, disconnect brake push rods from pedals. Dis
connect hydraulic lines from brake valve, then un
bolt and remove master brake valve.
Identify and disconnect hydraulic lines as neces
sary. Then, unbolt and remove pressure regulator
valve from left side of torque tube.
Reinstall by reversing removal procedures. Bleed
power steering system as outlined in paragraph 15
and brake system as outlined in paragraph 169. Ad
just brake linkage, if necessary, as outlined in para
graph 168.
172. OVERHAUL REGULATOR ASSEMBLY. Re
fer to Fig. 153 for an exploded view of brake valve
regulator assembly and to Fig. 154 for master brake
valve unit. Right and left hand units are identical but
used parts should not be intermixed while unit is dis
assembled. Remove equalizer plug (24Fig. 153),
0 ring (25) and piston assembly (items 26 through
34). Remove snap ring (26) and withdraw internal pin
assembly (items 27 through 31). Remove clips (27 and
29), spring (28) and O ring (31) from pin (30). Re
move and discard 0 ring and seal (33 and 34).
Remove plug (48) and O ring (47), spring (46) and
pressure regulator piston assembly (items 39 through
45). Remove snap ring (45) and disassemble regula
tor piston. Remove and discard 0 ring and seal (39
and 40).
Place index marks on locknut (17) and acûstment
screw (16) of brake pressure relief valve. Remove
locknut and screw together keeping marks aligned.
Remove and discard O ring (18), then remove
spring (19), poppet (20) and using a screwdriver, re
move relief valve seat (22) and remove and discard
0 ring (23).
Index locknut and adjustment screw (1 and 2) of
steering pressure relief valve, and remove screw and
locknut together keeping marks aligned. Using a C
clamp, depress spring housing (4) enough to remove
retaining ring (3), then remove spring housing (4),
spring disc (6), springs (8 and 9), .spring guide (10),
washer (12) and relief ball (13). Loosen and remove
relief valve seat (14). Remove and discard 0 rings
(5, 7, 11 and 15).
Remove connector for sump hose then remove
washer (38), spring (37) and sump poppet (36).
Renew all 0 rings and seals upon reassembly and
renew any parts which are worn, scored, or other-
Fig. 153Exploded view of brake pressure regulator valve
and associated parts.
1. Steering pressure 25. "O ring
screw 26. Snap ring
2. Locknut 27. Washer
3. Snap ring 28. Spring
4. Retainer 29. Washer
5. " 0 " ring 30. Piston pin
6. Spring disc 31. " 0 " ring
7. 0 ring
32. Equalizer piston
8. Spring (outer) 33. 0 ring
9. Spring (inner)
34. Seal ring
10. Guide 35. Valve body
11. " 0 ring
36. Sump poppet
12. Washer
37. Spring
13. Ball 38. Washer
14. Seat 39. Seal ring
16. 0 ring 40. " 0 " ring
16. Brake pressure 41. Regulator piston
screw 42. Spring
17. Locknut 43. Washer
18. 0" ring 44. Spool
19. Spring
45. Retaining ring
20. Poppet 46. Spring
22. Seat
47. O" ring
23. " 0 " ring
48. Plug
24. Plug
49. Roll pin
wise damaged. Use Loctite 242 or equivalent on
threaded seats (14 and 22). Lubricate O rings with
petroleum jelly upon reassembly. Reassemble by
reversing disassembly procedure. Tfest and adjust
steering and brake relief pressures as outlined in
paragraphs 17 and 170.
173. OVERHAUL BRAKE VALVE. With brake
valve removed, drive out pins and remove brake push
rods from piston rods (8Fig. 154). Although left and
Fig. 154Exploded view of master brake valve assembly.
1. Snap ring
2. Wiper seal
3. Piston stop
4. O'* ring
5. Back-up ring
6. O ring
7. Seal retainer
8. Piston rod
9. Seal washer
10. O ring
11. "O" ring
12. Snap ring
13. F*iston
14. Seal ring
15. "O ring
16. Spring
17. Itetaining cup
18. Pin
19. Plug
20. "O" ring
21. Valve body
22. Spring
23. Spool
24. Seal ring
25. "O" ring
26. "O" ring
27. Plug
right hand parts are identical, reused parts should
be installed in their original ports. Remove snap ring
(1) and pull assembly (2 through 7) from brake pis
ton rod (8). Remove and discard 0 rings (4 and 6)
and back-up ring (5). Remove pin (18) from piston rod
(8), then remove cup (17), spring (16) and piston
(items 13 through 15) from piston rod. Remove snap
ring (12) from rod, then remove seal washer (9) and
0 rings (10 and 11) from rod. Remove and discard
O rings (10, 11 and 15) and seal ring (14).
Remove plug (19), spring (22) and boost spool (23).
Remove and discard 0 rings (20 and 25) and seal
ring (24). Renew plug (27) and discard 0 ring (26).
Repeat the removal operation for opposite side of
valve. Clean and inspect all parts and renew any
showing excessive wear or other damage.
When reassembling, renew all *0 rings and seal
rings. Lubricate all " 0 rings with petroleum jelly
during installation. Install wiper seals (2) with lip to
ward outside.
DISC BRAKES
Tractors are equipped with self-adjusting mul
tiple disc brakes, which are located between f i
nal drive housing and transmission case. Refer to
Fig. 155. As pressure is applied to brake piston,
the lined discs are squeezed between notched
steel plates which cannot turn and rotation ol
discs, hub and/or sun gear shaft is stopped, which
prevents planetary gears and axle shafts from
turning. No external service to brakes can be per
formed, other than bleeding, which is outlined in
paragraph 169.
All Models
174. OVERHAUL. Final drive housings must be re
moved as outlined in paragraph 158. Remove brake
fittings (items 6 through 14Fig. 155) and disconnect
and remove the differential lock hydraulic tube (4]
on right side only. Unbolt and remove brake cylin
der (5), containing piston (items 15 through 18),
plates and springs (items 19 through 25). Remove all
brake plates (19, 21 and 22), springs (25), self-adjustei
screws (24) and adjust retainers (20 and 23). Using
compressed air, remove piston (18) from cylinder. Re
move and discard O" rings and seals (15 through 17).
Remove small "O ring (3) from cylinder. Remove aii
removal screw from cylinder.
Inspect all parts for wear, scoring and overheating.
Renew all parts in question and always renew piston
0 rings. Free length of return springs is 1.4 inches
(35.56 mm) and should compress to 1.130 inches (28.7
mm) at 171 lbs. (760 N). Renew all springs as a set
if any one spring fails to meet specifications. Back
up ring (15) must be installed with O ring groove
toward cylinder (5). Coat threads of self-adjust screws
Paragraphs 174A-174B CASE/INTERNATIONAL
with Loctite 601 or equivalent prior to installation.
Lubricate 0 rings on piston and install piston into
cylinder until it bottoms. Install brake plate (19) on
cylinder. Install brake adjuster retainer in holes of
brake plate aligned with self-adjusting screw holes
in cylinder, then install screws (24). Tighten self
adjust screws until retainer (20 and 23) bottoms
against cylinder then loosen screw turn to give a
0.025 inch (0.635 mm) brake plate clearance. Install
differential sun shaft gear into differential, then
starting with a steel plate, install alternate steel and
friction plates on sun shaft gear aligning notches in
steel plates with spring recesses in inner half of brake
housing. Model 1896 tractors use a total of four plates
and discs; Model 2096 tractors use a total of six plates
and discs. Install springs (25), two 5/8 inch NC x 6 inch
studs into inner brake housing, then install cylinder
onto studs making sure brake hydraulic fitting hole
is at top. Install and tighten all brake cylinder bolts
to 220 ft.-lbs. (304 N-m) torque. Install differential
lock hydraulic tube with new 0 rings. Install brake
fitting through top of transmission housing and into
brake cylinder. Place a hydraulic hand pump onto fit
ting at bottom of brake cylinder and fill brake cylin
der with oil until it flows out top fitting, then close
bottom fitting and connect top fitting to supply line.
Remainder of installation is reverse of disassembly.
Bleed brakes as outlined in paragraph 169.
PARK HAND BRAKE
Tractors may be equipped with a park hand brake.
The disc and caliper type brake is attached to the
front of the transfer gearbox. See Fig. 155A. Brake
disc is bolted to rear side of gearbox output shaft
yoke.
Models So Equipped
174A. ADJUSTMENT. Pull hand lever up to the
ON position. Refer to Fig. 155B and measure height
of cable clevis pin in the slot as shown. The bottom
of the pin must be 1-5/16 to 1-3/8 inches (33-35 mm)
above the bottom of the slot. If not, disengage hand
brake lever and rotate knob on brake lever to obtain
correct measurement.
NOTE: Brake lever must always be In the engaged
(ON) position when measuring pin height in slot.
Remove cotter pin (17Fig. 155D) and with brake
lever in disengaged position, acûst nut (16) to obtain
a clearance between brake pad and disc of 0.020-
0.025 inch (0.508-0.635 mm). Use a feeler gage as
shown in Fig. 155C to measure clearance. Back ad
justing nut (16Fig. 155D) off slightly if necessary,
and install cotter pin.
Check the force required to engage the hand brake.
It should take 40-45 lbs. (178-200 N) to engage the
brake. Turn knob on brake lever clockwise to increase
or counterclockwise to decrease the amount of force.
Then once again, with brake disengaged, measure
clt'arance between brake pad and disc. Make sure
clearance is still 0.020-0.025 inch (0.508-0.635 mm).
Remove the brake light switch cover (Fig. 155A).
The brake light switch lever must open the switch
just before the cable clevis pin reaches the bottom
of the slot. If not, loosen switch mounting bolts and
adjust switch in the bracket. Retighten mounting
bolts and reinstall cover.
174B. RENEW BRAKE PADS. Tb renew brake pads
(9Fig. 155D), move brake lever to disengaged posi
tion. Then, disconnect lower end of brake cable. Un
bolt caliper bracket from tractor, then remove brack-
Fig. 155Exploded view of brake cylinder assembly and
related components.
1. Snap ring
2. Sun gear shaft
3. "O" ring
supply tube
5. Cylinder
6. Connector
7. Gasket
8. Fitting
9. Gasket
10. Bleed screw
11. Fitting
12. Grommet
13. Washer
14. "O" ring
15. Back-up ring
16. O" ring
17. O" ring
18. Piston
19. Return plate
20. Retainer
21. Friction disc
22. Steel plate
23. Pin
24. Screw
25. Spring
26. Bearing carrier
27. Shim
28. Housing
MODELS 1896-2096 Paragraph 174B (Cont.)
et and caliper assembly. Remove springs (8 and 10)
and remove pads.
Inspect pads for excessive wear or other damage.
If friction material on either pad is worn thinner than
1/8 inch (3 mm), renew both pads.
Reassemble by reversing the disassembly proce
dure, then readjust brake as outlined in paragraph
174A.
Fig. 155AExploded and schematic view of park hand brake and relative components.
Fig. ISSBWlth brake lever In ON (fully up) position,
cable clevis pin should be 1-5/16 to 1-3/S Inches (33-35
mm) above bottom of slot.
Fig. 155CAdjust clearance of brake pad to disc to 0.020-
0.025 Inch (0.508-0.635 mm).
1. Caliper half
(outer)
2. Caliper half
(inner)
5. Bolt
6. Bolt
13. Actuator pins
14. Cam plate
16. Washer
16. Acijusting nut
17. Cotter pin
POWER TAKE-OFF
All models are equipped with an independent
power take-off which is controlled through a ca
ble operated valve to a hydraulically operated
multiple disc clutch. All models are powered from
a two-piece shaft, coupled at the rear transmis
sion housing and is splined directly to center of
flywheel. Model 1896 and 2096 tractors are avail
able with a two-speed (540 and 1000 rpm) unit.
Pto speeds are based on 2100 rpm engine speeds.
TESTING AND ADJUSTMENT
All Models
175. LINKAGE ADJUSTMENT. No clutch adjust
ment is provided. The pto shift lever and cable can
be a<ûsted to provide the correct movement of con
trol valve spool. Refer to Fig. 156 and proceed as fol
lows: Disconnect control cable yoke from bellcrank
on pto control valve. Make certain that upper cable
yoke is connected to upper hole in hand lever. Move
pto hand lever rearward to the OFF position. Place
pto valve spool in the fully lowered position. Check
to be sure that bellcrank has 0.004-0.008 inch (0.1016-
0.2032 mm) end clearance to prevent binding. Adjust
lower yoke on cable so that yoke pin holes align with
lower hole in bellcrank. Attach yoke to bellcrank
with clip pin.
With engine operating at 750 rpm and oil temper
ature at approximately 120 F (49 C), move hand
lever fully forward to pto engaged position. Press and
release inching pedal and move hitch lever to actu
ate the hitch. Pto must remain engaged. If not, turn
detent acûsting screw (11Fig. 158) inward to in
crease detent pressure. Ac^just screw a maximum of
1/8 turn at a time.
If pto remains engaged in the preceding test, stop
engine. In a short time, pressure will drop and pto
handle should return to disengaged position. If not,
adjusting screw must be backed out slightly to reduce
detent pressure.
176. TESTING, lb connect equipment for testing
the pto flow divider, control valve and pto clutch, dis
connect the pump outlet tube from the piston pump.
Using appropriate fittings, attach flowmeter inlet to
7. Washers
8. Pad retainer
spring
9. Brake pads
10. Pad return spring
(2)
Fig. 1BSDExploded view of hand brake caliper assembly.
MODELS 1896-2096
the pump outlet. Then, connect flowmeter outlet to
piston pump outlet tube. Remove the transmission
pressure switch from the flow divider and pto con
trol valve. Install a 600 psi (4100 kPa) test gage and
hose to pressure switch port on valve.
Tb check pto brake or clutch leakage, start engine
and operate at 750 rpm. Open load valve and flow
valve completely on flowmeter. Make certain that
differential lock is disengaged. Move pto control to
fully engaged position and observe flow on flow
meter. Flowmeter will indicate a flow as soon as con
trol is engaged. Flow reading will decrease as soon
as the engaged pto clutch has filled. A reading of 0-1
gpm (0-3.8 L/min.) is normal. If leakage exceeds 1gpm
(3.8 L/min.), refer to paragraph 180 for pto clutch re
pair procedures.
Tb check pto control and regulator pressure, start
engine and operate at 2100 rpm. Check reading on
600 psi (4100 kPa) test gage. Reading on test gage
must be 210 psi (1448 kPa). If not, add or remove
shims (16Fig. 158) to obtain correct pressure.
Relief valve nominal cracking pressure is 270 psi
(1862 kPa). If correct pressure cannot be obtained,
refer to paragraph 178 for pto control and regulator
valve repair procedures.
Paragraph 177
PTO FLOW DIVIDER CONTROL VALVE
All Models
pto control and flow divider valve, disconnect bell-
crank to pto spool and electrical connectors. Remove
all hydraulic lines from housing and plug or cap all
lines to prevent leakage and contamination. Remove
cap screws securing valve housing to transmission
housing and lift off the valve.
Install by reversing removal procedure, using a new
"O ring. Acûst the installed valve if necessary as
F\g. 156View of pto control valve linkage and related
parts.
1. Pto control
valve/flow
divider
2. "O" ring
3. Fitting
4. To power shift
control valve
5. O ring
6. Fitting
7. From hydraulic
pump
8. To pto clutch
9. Elbow
10. To pto brake
Fig. 157Schematic view of hydraulic system connecting
pto control/flow divider valve.
11. Fitting
12. Pto brake drain
tube
13. O ring
14. Tee
15. To remote
valve(s)
16. To hitch valve
17. Fitting
18. To differential
lock valve
19. Fitting
20. Transmission
pressure sensor
178. OVERHAUL. To disassemble the pto control
and flow-regulator valve, refer to Fig. 158 and remove
connector (12), adjusting screw (11), springs (8 and
9), guide pin (7) and detent ball (6). Remove plug (31)
with pin (30) and 0 ring (29), secondary spring
(28), washer (27), primary spring (26), modulator pop
pet (25), return spring (24) and spool (23). Remove
relief valve plug (22), spring (20) and relief valve (19).
Fig. 158Exploded view of pto control valve and flow
regulator.
Place a C clamp over pressure regulator plug, then
drive out roll pin (5). Loosen C clamp to release
spring pressure from plug (17). Remove plug, shims
(16) and spring (15). Remove plug (3) opposite regu
lator bore and push spool (13) out bottom of bore. Re
move snap ring (14) from spool (13). Remove oil seal
(2) from control spool bore.
When reassembling, renew all O rings. Install
new oil seal (2) with lip toward inside of control spool
bore. Check springs against the following specifi
cations:
Pressure regulator
spring (15)
Free length .......................................... 2.989 in.
(75.92 mm)
Tfest length ............................................ 1.673 in.
(42.49 mm)
Tfest load ........................................ 52.5-64.1 lbs.
(233.4-285.3 N)
Relief valve
spring (20)
Free length .......................................... 2.154 in.
(54.71 mm)
Tfest length ............................................ 1.107 in.
(28.12 mm)
Tfest load ........................................ 27.0-33.0 lbs.
(120.1-146.8 N)
Control spool
return spring (24)
Free length .......................................... 3.201 in.
(81.31 mm)
Tfest length ..............................................1.90 in.
(48.26 mm)
Tfest load ........................................ 10.8-13.2 lbs.
(48.0-58.7 N)
Primary spring (26)
Free length .......................................... 1.868 in.
(47.45 mm)
Tfest length.............................................. 1.40 in.
(35.56 mm)
Tfest load ........................................ 7.38-9.02 lbs.
(32.8-40.1 N)
Secondary spring (28)
Free length .......................................... 0.845 in.
(21.46 mm)
Tfest length ............................................ 0.437 in.
(11.1 mm)
Tfest load ........................................ 0.41-0.51 lbs.
(1.8-2.3 N)
Detent spring,
outer (8)
Free length .......................................... 1.383 in.
(35.13 mm)
1. Valve body
2. Oil seal
3. Plug
4. O" ring
5. Roll pin
6. Detent ball
7. Guide pin
8. Spring (outer)
9. Spring (inner)
10. "O ring
11. Acyusting screw
12. Connector
13. Pressure
regulator spool
14. Snap ring
15. Spring
16. Shims
17. Plug
18. O" ring
19. Relief valve
20. Spring
21. O" ring
22. Plug
23. Pto control spool
24. Spring
25. Modulator poppet
26. Primary spring
27. Washer
28. Secondary spring
29. O" ring
30. Pin
31. Plug
Tfest length .............................................. 0.70 in.
(17.78 mm)
Tfest load ............................................ 5.4-6.6 lbs.
(24.0-29.4 N)
Detent spring,
inner (9)
Free length .......................................... 1.548 in.
(39.32 mm)
Tfest length.............................................. 1.20 in.
(30.48 mm)
Tfest load ............................................ 8.1-9.9 lbs.
(36.0-44.0 N)
Renew any springs which do not meet specifica
tions. Inspect aU parts for wear, scoring or other dam
age and renew as necessary. Valve body (1) and regu
lator spool (13) are not serviced separately. If
regulator spool or body is scored or damaged, renew
complete valve assembly. Shims (16) are available in
thicknesses of 1/64 inch (0.397 mm) and 3/32 inch (2.3
mm). Reassemble by reversing disassembly proce
dure. Adjust overhauled valve assembly and linkage
as outlined in paragraphs 175 and 176.
PTO HOUSING
All Models
sion, remove pto shield and remove the two bolts
from each side of sway bar bracket, then loosen large
third bolt on sway bar bracket. Remove upper lift link
pin and remove upper lift link. Reinstall link pin for
attachment of hoist. Disconnect pto brake tube, pto
clutch tube, pto lube tube and temperature sensor
sender wire. Remove two center pto housing bolts,
install two 5/8 inch NC studs in bolt holes, remove
all remaining nuts and bolts on pto housing. Attach
hoist to upper link pin and remove pto housing as
sembly. Reinstall by reversing removal procedure.
Tighten 5/8 inch mounting bolts to 150-180 ft.-lbs.
(203-244 N-m) torque. Tighten inch mounting bolts
to 80-96 ft.-lbs. (110-130 Nm) torque. Tighten % inch
sway bar bolts to 270-320 ft.-lbs. (366-440 N*m)
torque. Tighten 1inch sway bar bolts to 580-690 ft.-
lbs. (786-935 N*m) torque.
180. PTO DRIVE GEAR AND CLUTCH OVER
HAUL. Remove tube guard (18Fig. 159), shaft re
taining ring (24), then remove shaft (25). Pry out
shaft oil seal (19), remove snap ring (20) and spacer
(21). From front of pto housing, remove snap ring
(42), retaining ring (44) and spring (43). Bump rear
of output shaft to move bearing (40) and cup (41) out
of housing. Remove retaining ring (39) and thrust
washer (38). Drive front roll pin (37) through output
shaft sleeve (30). Separate gears on output shaft
sleeve until shift collar pins (33 and 35) are visible.
Tb remove shift collar pins (33 and 35), install a num
ber 10-24, grade 8, socket head screw with a mini
mum of 1-1/2 inches (38.1 mm) of thread into shift
collar pin. Turn shift collar 180 degrees and remove
second pin in same manner. Tkp front end of output
shaft sleeve to move rear bearing cup (22) out of seat.
Pull output shaft sleeve to rear of housing and re
move 540 rpm output gear (36), shift collar (34) and
1000 rpm output gear (29^ Remove output shaft
Fig. 159Exploded view of dual speed pto gear assembly.
1. Bearing cup
2. Bearing cone
3. Idler gear (1st)
4. Woodruff key
5. Idler shaft (1st)
6. Bearing cone
7. Bearing cup
8. Spacer
9. Snap ring
10. Bearing cup
11. Bearing cone
12. Idler gear (2nd)
13. Woodruff key
14. Idler shaft (2nd]
15. Bearing cone
16. Bearing cup
17. Snap ring
18. Guard
19. Seal
20. Snap ring
21. Spacer
22. f a r i n g cup
23. Bearing cone
24. Snap ring
25. Output shaft
26. Snap ring
27. RoUpin
28. Thrust washer
29. Output gear
(1000 rpm)
30. Outer output
sleeve
31. O" ring
32. Inner output
sleeve
33. Collar pin
34. Shift coUar
35. Collar pin
36. Output gear
(540 rpm)
37. Roll pin
38. Thrust washer
39. Snap ring
40. Bearing cone
41. Bearing cup
42. Snap ring
43. Spring
44. Snap ring
45. Pto housing
Paragraphs 181-186
CASE/INTERNATIONAL
sleeve (30) from rear of pto housing, then remove in
ner sleeve (32). Remove and discard O ring (31).
Press bearing cone (23) from shaft sleeve, then re
move retaining ring (26) and thrust washer (28) from
output shaft sleeve (30).
181. Remove snap ring (17Fig. 159) from lower
idler shaft (14). Install puller into idler shaft until
front bearing cup (16) is removed. Remove idler shaft
(14), lower idler gear (12) and rear bearing cone (11).
Using a suitable puller, remove rear bearing cup (10).
Press front bearing cone (15) from shaft (14).
182. Unbolt and remove pto carrier assembly
(items 6 through 37Fig. 160). Remove needle bear
ing (29), snap ring (31), then using a suitable puller
remove input gear (32) and needle bearing race (30).
Remove snap ring (33) and using a suitable puller re
move input bearing (34). Remove brake carrier (36)
being careful not to lose "O rings (35) and ball (37).
Remove oil control rings (24), retaining back-up ring
(6), clutch hub (5) with back-up and friction plate.
Remove clutch pack (14). Remove snap ring (13),
clutch piston return spring (12), then using com
pressed air in piston supply port, remove clutch pis
ton (items 7 through 11) from carrier (25). Remove
inner and outer seals (8 and 10) and 0 rings (7 and
9) from clutch piston (11). Remove and discard sup
port bushing (27) and thrust washer (26) from carri
er (25).
Remove brake bolts (23), washers (19 and 22),
springs (20) and roll pins (21) from pto brake assem
bly (items 18 and 36). Remove brake friction plate
(18) and using compressed air, remove brake piston
(items 15 through 17). Remove two 0 rings (35).
Remove and discard inner and outer piston **0 ring
seals (15 and 16).
183. Remove snap ring (9Fig. 159) from upper
idler shaft (5) and remove shim (8). Using a suitable
puller in idler shaft, pull front bearing cup (7) from
housing. Remove idler shaft (5) with bearing (6) at
tached, rear bearing (2) and idler gear (3). Using a
suitable puller, remove rear bearing cup (1) and press
bearing cone (6) from shaft (5). Retain Woodruff key
(4).
184. Assemble first idler shaft (items 1 through
9Fig. 159) by reversing disassembly procedure. In
spect and renew any parts showing wear or other
damage. Renew bearing cones and cups as necessary.
Make certain upper idler gear (3) is positioned with
flat side toward front of housing. Measure and instaU
proper width shim (8) between retaining ring (9) and
bearing cup (7) to obtain a clearance of 0.000-0.005
inch (0.000-0.127 mm). Shims (8) are available in
thicknesses of 0.045 to 0.080 inch (1.14 to 2.03 mm)
in 0.005 inch (0.127 mm) increments.
185. Reassemble pto brake (items 15 through 23-
Fig. 160) using new 0 rings (15 and 16) on piston
(17). Lubricate piston with petroleum jelly and install
in carrier (36) flat side up. Install friction plate (18),
washers (19) and roll pins (21). Free length of springs
(20) is 1.54 inches (39.12 mm) and compressed length
of 50 lbs. (68 N) should be 0.500 inch (12.7 mm). Re
new all springs if any one spring fails to meet specifi
cations. Install springs (20), then using Loctite 271 or
equivalent on bolts (23), install bolts and washers (22)
tightening bolts to 18-25 ft.-lbs. (24-34 N*m) torque.
186. Reassemble pto clutch by reversing disassem
bly procedure. Heat bearing (34Fig. 160) before in-
Fig. 160Exploded view of pto clutch and brake
assembly.
1. Pto input shaft
2. Housing
5. Back-up plate,
hub & disc assy.
6. Snap ring
7. O ring
8. Piston seal
9. "O" ring
10. Piston seal
11. Pto clutch piston
12. Spring
13. Snap ring
14. Clutch plates &
discs
15. "O" ring
16. "O" ring
17. Pto brake piston
18. Brake
19. Washer
20. Spring
21. Roll pin
22. Washer
23. Bolt
24. Seal rings
25. Carrier
26. Thrust washer
27. Bushing
29. Needle bearing
30. Race
31. Snap ring
32. Input gear
33. Snap ring
34. Bearing
35. "O" ring
36. Carrier
37. Ball
stallation. Install new thrust washer (26) and press
new bushing (27) to a depth of 0.070 inch (1.778 mm)
below surface of carrier and ream bushing to an ID
of 0.81350.8145 inch (20.663-20.668 mm) as shown
in Fig. 161. Piston return spring (12Fig. 160) should
have a free length of 1.75 inches (44.45 mm) and a
compressed length at 78 lbs. (106 N) of 1.25 inches
(31.8 mm). Renew spring if specifications are not
met. Make certain hooked ends of oil rings (24) con
nect each other. Install new needle bearing for pto
carrier assembly into housing to a depth of 0.094-
0.125 inch (2.388-3.175 mm) as shown in Fig. 162.
Install two new 0 rings (35Fig. 160) into brake
carrier, then install pto carrier assembly onto pto
housing and tighten retaining bolts to 45-54 ft.-lbs.
(61-73 Nm) torque.
187. Install lower idler shaft assembly (items 10
through 17Fig. 159) by reversing disassembly proce
dure. Inspect and renew any parts showing wear or
other damage. Renew bearing cones and cups as
Fig. 161Install carrier bushing as shown. Refer to text.
necessary. Install lower idler gear (12) with flat side
toward front of housing. Measure and install proper
width snap ring (17) to obtain a clearance of 0.001-
0.005 inch (0.0254-0.127 mm) between bearing cup
(16) and snap ring (17). Snap rings (17) are available
in thicknesses of 0.070,0.076,0.081,0.086,0.091,0.096
and 0.101 inch (1.78, 1.93, 2.06, 2.18, 2.31, 2.44 and
2.57 mm).
188. Assembly of output shaft assembly (items 18
through 44Fig. 159) is reverse of disassembly proce
dure. Inspect and renew any parts showing wear or
other damage. Renew any bearing cones and cups as
necessary. Use new O" ring (31) on inner sleeve (32).
Install rear thrust washer (28) with oil grooves fac
ing away from bearing (23). Install 1000 rpm output
gear (29) flat side facing rear of housing. Use new
shift collar pins (33 and 35). Shift spring (43) free
length is 2.330-2.390 inches (59.182-60.706 mm) and
compressed at 41.4 lbs. (56 N) should be 1.277 inches
(32.44 mm). Renew spring if specifications are not
met. Install front roll pin (27) until pin is 0.12 inch
(3.048 mm) above outside diameter of output sleeve.
Install front thrust washer (38) with oil grooves to
inside of pto housing. Install rear roll pin (37) until
pin is 0.12 inch (3.048 mm) above outside diameter
of output sleeve. Measure and install proper thick
ness snap ring (42) to obtain a clearance of 0.001-
0.005 inch (0.0254-0.127 mm) between front bearing
cup (41) and snap ring (42). Snap rings are available
in thicknesses from 0.062-0.103 inch (1.57-2.62 mm)
in 0.005 inch (0.127 mm) increments. Install rear oil
seal (19) with lip inward and seal flush with pto hous
ing. Use Loctite 504 or equivalent on flange of trans
mission and reinstall pto assembly as outlined in para
graph 179.
HYDRAULIC SYSTEM
Fig. 162Install needle bearing Into pto housing to
dimension shown.
The tractor hydraulic system provides power for
steering, brakes, pto clutch and brake, differen
tial lock, power shift clutches and valves, as well
as for hydraulic lift and control of carried and
towed implements. Refer to Fig. 163 for schematic
views showing location of components.
The dual (gear and piston type) hydraulic pump
attaches to left side of transmission housing and
is driven by a shaft extending rearward from en
gine flywheel to pump drive gear train. Charging
pump is mounted behind dual hydraulic pump.
Charging pump is driven by gear train shown in
Fig. 166.
Refer to appropriate following paragraphs for
hydraulic pump and system components.
TESTING
All Models
189. PISTON PUMP AND CHARGE PUMP, lb
test hydraulic pump system, first place outlet hose
to a CAS-10280 or other suitable flowmeter into
transmission filler neck. Disconnect and plug outlet
tube from piston pump, then connect hose from in
let port of flowmeter to outlet port of piston pump.
Disconnect and plug compensator tube on pump
compensator and install */4inch (6.35 mm) hose from
flowmeter to pump compensator. Disconnect electri
cal connector to pressure switch on piston pump in-
Fig. 163Schematic showing location of main hydraulic components.
let tube; remove pressure switch and connect a 100
psi (690 kPa) pressure gage where switch was re
moved. With engine running at 2100 rpm and with
oil at operating temperature of approximately 120
F (49 C) open flow, load and compensator valves on
flowmeter. Charge pump pressure on gage should
read 30 psi (207 kPa) (maximum) and not less than
15 psi (103 kPa).
NOTE: If charge pump pressure reads less than
15 psi (103 kPa), hydraulic oil filters may be clogged
and require renewal or oil Inlet screen may also be
restricted requiring cleaning. Check inlet tube to
pump for restriction or damage. If filters and tube
are In satisfactory condition, charge pump will re
quire removal, inspection and/or repair as outlined
in paragraph 200.
To check piston pump low stand-by pressure, run
engine at 750 rpm and with oil at operating temper
ature of approximately 120 F (49 C) fully open flow
valve on flowmeter, and completely close load and
compensator valve on flowmeter. Pressure on flow
meter pressure gage should read 325-350 psi (2241-
2413 kPa). If not, remove plug (18Fig. 169) and
turn adjusting screw (25) into increase or out to de
crease stand-by pressure.
Tb check piston pump maximum output pressure,
run engine at 2100 rpm, and with oil at operating
temperature of approximately 120 F (49 C) open
flow and compensator valves on flowmeter fully and
close load valve fully. Reading on flowmeter pressure
gage should be 2200-2300 psi (15169-15859 kPa).
NOTE: To adjust piston pump maximum output
pressure, turn adjustment screw on compensator
(Fig. 164) clockwise to increase pressure, counter
clockwise to decrease pressure.
Tb check piston pump efficiency at maximum flow,
with charge pump operating correctly and compen
sator properly adjusted, run engine at 2100 rpm, and
with oil at operating temperature of approximately
120 F (49 C), open flowmeter flow and compensa
tor valves fully. Adjust flowmeter load valve until
flowmeter pressure gage reads 400 psi (2758 kPa).
Flowmeter flow gage must read 22.5 to 24.2 gpm (85
to 92 L/min.). Adjust flowmeter load valve to 2000
psi (13790 kPa). Flow reading must not vary more
than 10 percent. If flow reading is less than required,
piston pump must be overhauled as outlined in para
graph 202.
190. T) check pump flow at 750 (engine) rpm and
at 190 psi (1310 kPa) flowmeter load valve setting,
run engine at 750 rpm, and with oil at operating tem
perature of approximately 120 F (49 C), open flow
meter flow valve fully, and with flowmeter load valve
adjusted to register 190 psi (1310 kPa) on flowmeter
pressure gage, record gpm (L/min.) flow on flowmeter
flow gage for comparison use in later tests.
191. PUMP COMPENSATOR. Tb check pump
compensator operation, run engine at 2100 rpm, and
with oil at operating temperature of approximately
120 F (49 C), fully open flow and compensator
valves on flowmeter. Adjust flowmeter flow valve un
til flowmeter gage reads 10 gpm (37.85 L/min.). Ad
just flowmeter load valve to 500, 1000, 1500 and 2000
psi (3448, 6895, 10342 and 13790 kPa). There must
be 9.5 to 10.5 gpm (36.0 to 39.7 L/min.) on flowmeter
at each of the four settings. If flow is not in the 9.5
to 10.5 gpm (36.0 to 39.7 L/min.) range, the pump
compensator must be overhauled as outlined in para
graph 206. When testing is finished, remove all test
equipment and fittings and reconnect hydraulic
tubes, switches and electrical connections.
192. GEAR PUMP. Tb test the gear pump efficien
cy, disconnect outlet hose from gear pump. Cap or
plug outlet hose. Connect flowmeter inlet hose to
gear pump outlet. ln.sert flowmeter outlet hose in
transmission filler neck. Open flowmeter load valve
completely, then start engine. With engine operat
ing at 2000 rpm and hydraulic oil temperature at 120
F (49 C), flow reading should be 7.2 gpm (27.3
L/min.) minimum. Adjust load valve until flowmeter
pressure gage reads 1750 psi (12066 kPa). At this time,
flow reading must be 6.6 gpm (24.8 L/min.) minimum.
If not, gear pump must be overhauled as outlined in
paragraph 207. Remove flowmeter and hoses and
reconnect pump outlet hose.
LEAKAGE TESTS
193. Tb connect flowmeter for leakage tests, dis
connect outlet tube from piston pump. Using ap
propriate fittings, connect flowmeter inlet hose to
pump outlet port. Connect flowmeter outlet hose to
piston pump outlet tube.
Fig. 164View of pump compensator showing adjusting
screw and plug for shim adjustment. Refer to text.
All Models
194. POWER SHIFT CLUTCHES AND CONTROL
VALVE. With engine operating at 750 rpm and oil
temperature at approximately 120 F (49 C), open
flow and load valves on flowmeter completely. Shift
power shift lever through all power shift positions.
Record flow in each position. Flowmeter will indi
cate a flow as soon as power shift lever is moved to
each position. Flow reading will decrease as soon as
the engaged clutches have filled. A flow reading of
0-1 gpm (0-3.8 L/min.) is normal. If leakage exceeds
1gpm (3.8 L/min.) in one or two of the selected posi
tions, refer to Fig. 165 and check to see which
clutches are applied in the leaking positions. Locate
leaking clutch by process of elimination. Refer to
paragraphs 139 and 140 for control valve overhaul
and to paragraphs 142 through 149 for power shift
unit overhaul.
If excessive leakage is indicated in all of the power
shift positions, differential lock, pto, hitch valve or
remote valves should be suspected of leakage rather
than the power shift.
195. PTO. Check pto for excessive leakage as out
196. DIFFERENTIAL LOCK. With engine oper
ating at 750 rpm and oil at operating temperature,
fully open flow and load valves on flowmeter. Rec
ord flow reading in disengaged position and then in
engaged position. If difference in flow readings is
more than the permitted 1gpm (3.8 L/min.), isolate
differential lock clutch by disconnecting and plug
ging the differential lock line. Recheck flow readings.
If leakage is still present, problem is in differential
lock valve. If no leakage is now present, problem is
in differential lock clutch or oil distributor tube and
0 rings in right brake carrier.
197. REMOTE VALVE. To test for remote valve
leakage in neutral position, fully open flow and load
valves on flowmeter. Isolate remote valves by discon
necting and plugging remote supply line. With engine
operating at 750 rpm and oil at operating tempera
ture of 120 F (49 C), record flow reading on flow
meter. Reconnect remote supply line, then place all
remote levers in neutral position and record flow
reading on flowmeter. If flow reading is 0.5 gpm (1.9
L/min.) or more higher than the reading with valves
isolated, leakage is present in remote valves. Refer
to paragraph 216 for overhaul procedure of remote
valves.
198. HITCH VALVE. Tb test hitch valve for exces
sive leakage, fully open flow and load valves on flow
meter. Isolate hitch valve by disconnecting and plug
ging hitch supply line. With engine operating at 750
rpm and oil at operating temperature, record flow
reading on flowmeter. Reconnect hitch valve supply
line and again check flow reading on flowmeter. If
flow reading is 0.5 gpm (1.9 L/min.) or more higher
than the reading with hitch valve isolated, leakage
is present in hitch valve.
Refer to paragraphs 228 and 229.
PUMP DRIVE
All Models
Fig. 165Chart Identifying clutches applied for various
speeds on power shift unit.
199. REMOVE AND REINSTALL, lb remove hy
draulic pump drive, first remove pto assembly as out
lined in paragraph 179. Remove rear pto drive shaft.
Remove tractor cab. Remove rear transmission top
access cover. Remove hydraulic pump as outlined in
paragraph 201. Remove charge pump as outlined in
paragraph 200. Remove charge pump shims (13Fig.
166), noting number and thickness of shims for rein
stallation. Remove outer drive shaft needle bearing
(7) if necessary and renew as outlined in charge pump
overhaul paragraph 200.
Tb remove pump driven gear (15Fig. 166), trac
tor must be split between torque housing and trans
mission. Remove shim type snap ring (17Fig. 166)
from behind outer bearing (18). Push pump gear drive
assembly (items 21 through 18) rearward and remove
from transmission case by driving front pto shaft (23)
rearward, then pull pto front drive shaft forward
from transmission case. Remove Woodruff key and
pump driven gear (15 and 16) from inside transmis
sion case. Drive needle bearing (14) from trans
mission.
Inspect gears and bearings for wear or other dam
age and renew as necessary. Reassemble by revers
ing disassembly procedure. Install needle bearing (14)
until bearing is approximately 1/16 to 1/8 inch (1.59
to 3.18 mm) below inside surface of transmission case.
Numbers on bearing must face outside of transmis
sion case. Install original pump shim(s), but if origi-
MODELS 1896-2096
nal number and size of shim(s) is not known, refer
to charge pump overhaul paragraph 200 for check
ing and adyusting gear backlash.
Paragraph 200
CHARGE PUMP
All Models
Fig. 166Exploded view of hydraulic charge pump and
drive for both charge and dual hydraulic pumps.
Fig. 167Cross-sectional view of pump drive showing
relative parts.
200. R&R AND OVERHAUL. Tb remove charge
pump, first remove dual hydraulic pump as outlined
in paragraph 201. Refer to Fig. 166, unbolt and re
move charge pump body (items 3 through 10) from
transmission cavity. Remove two-piece gerotor (11)
from drive shaft. Remove shim(s), Woodruff key (16)
and wear plate (12) from cavity. Remove wear plate
(10) from pump body (9). Remove and discard O
ring (8). Remove screws and remove retainer plate
(3), shim(s) (4), outer and inner thrust washers (6) and
thrust bearing (5).
Inspect wear plates (10 and 12) for scoring, bend
ing or other damage. Also renew plates if wear thick
ness measures less than 0.025 inch (0.635 mm). Re
new gerotor (11) if clearance between iruier and outer
apex tips exceeds 0.008 inch (0.203 mm). Inspect and
renew needle bearing (7) as necessary. Install bear
ing with numbers toward outside of pump body.
Clean old sealant from outside of pump body, light
ly rough outside surface of pump body with emery
cloth and apply Loctite Accelerator or equivalent to
pump body and let dry. Repeat procedure to inner
surfaces of pump cavity in transmission. Lubricate
new 0 ring (8Fig. 166) and install in groove of
pump body. Install inner wear plate (10) with tab on
plate fitting in hole of pump body. Install gerotor as
sembly into pump body.
Tb select proper shim pack (13), place outer wear
plate (12) on gerotor, tab of plate facing up. Place a
straightedge across top face of wear plate, measure
gap between straightedge and top face of pump body
with a feeler gage and add 0.0015-0.003 inch (0.038-
0.076 mm) to measurement to obtain correct total
gap. Select number of shims (13) to fill gap correctly.
Blue shims are 0.005 inch (0.127 mm) thick; red shims
are 0.003 inch (0.076 mm) thick. At least one shim
must be installed. Remove plates and gerotor from
pump body. Lubricate 0 ring (8) with petroleum
jelly and install in groove of pump body. Install in
ner wear plate (12) with tab in hole of pump body.
Install gerotor as.sembly (11) in pump body. Install out
er wear plate (12) over drive shaft and with tab on
plate in hole of transmission housing. With groove in
drive shaft up, install Woodruff key (16). Place two
pilot studs in transmission housing and install shim
pack (13). Apply suitable Loctite or equivalent seal
ant to four contact areas of pump housing and trans
mission housing, then aligning Woodruff key and slot
in inner gerotor set, install pump body into transmis
sion housing. One at a time, remove pilot stud and
install retaining bolt, and tighten bolts to 75-89 ft.-
Ibs. (102-121 N-m) torque. Install thrust washers and
bearing (5 and 6), install two 3/8 inch bolts with flat
1. Dual pump
2. Gasket
3. Retainer
4. Shim
6. Needle thrust
bearing
6. Thrust washers
7. Needle bearing
8. "O ring
9. Pump cover
10. Wear plate
11. Gerotor assy.
12. Wear plate
13. Shim
14. Needle bearing
15. Pump drive shaft
16. Woodruff key
17. Snap ring
18. Bearing
19. Spacer
20. Bearing
21. Bevel gear
22. Snap ring
23. Pto & pump
input shaft
washers to secure thrust assembly tightly in mesh
with drive gear and using a depth micrometer, meas
ure distance from outer thrust washer to bottom of
counterbore of pump body. Add sufficient shims (4)
to fill measured gap and to obtain drive gear back
lash of 0.003 to 0.005 inch (0.076-0.127 mm). Shims
are available in 0.003 and 0.010 inch (0.076 and 0.254
mm) thicknesses. Remove 3/8 inch bolts and wash
ers and install desired shim pack (4) and retainer
plate (3). Use Loctite 242 or equivalent on retaining
plate screws and tighten screws to 25-30 ft.-lbs. (34-
41 N*m) torque.
exceed 0.005 inch (0.127 mm). Shoe thickness of pis
ton must not vary more than 0.001 inch (0.0254 mm)
between all piston shoes. Check shoe plate (20) for
excessive wear or cracks and pivot washer (21) for
excessive wear or scratches and renew shoe plate and
pivot washer together if necessary. Check the three
pins (22) for bending and equal length and renew as
necessary. Check each bore of cylinder block (24) for
excessive wear and smoothness of piston travel or ex
cessive looseness in piston travel. Check face of cyl
inder block for excessive wear between ports and for
surface scratches.
DUAL HYDRAULIC PUMP
All Models
201. REMOVE AND REINSTALL. Tb remove dual
hydraulic pump on all models, remove inlet and out
let tubes and hoses from piston and gear pumps. Re
move outlet tube for charge pump. Remove drain
tube for piston pump. Remove both tubes from tee
fitting on pump compensator, then remove nuts and
washers securing pump to transmission and remove
pump.
Reinstall by reversing removal procedure and tight
en nuts to 80-96 ft.-lbs. (108-130 N*m) torque.
202. OVERHAUL PISTON PUMP. Unbolt gear
pump, O ring and splined coupler (items 2, 3 and
4Fig. 170) from piston pump. Unbolt and remove
pump compensator, 0 ring and gasket (1,2 and 3
Fig. 169) from piston pump. Refer to Fig. 168 and re
move *0 ring (44) from control piston guide. Un
bolt and remove valve block (42) from pump hous
ing (9). Remove gasket (32). Remove rear bearing (29)
and spacer (28). Remove cylinder block assembly
(items 19 through 27) from pump housing being care
ful not to allow pistons (19) to fall out. Unbolt and
remove both side bearing covers (3) and shims (4),
keeping shims with respective covers of each side,
" 0 rings (5), spacers (6), bearing cups and cones (7
and 8), then remove cam plate (18) from pump hous
ing. Remove pump shaft (15) with bearing (14), press
ing off bearing cone and renew cup (13) and cone to
gether if necessary. Remove spring (11) and pivot (12).
Remove control piston and limit washer (33 and 34)
from guide 35.
Remove wear plate (31) from valve block (42), re
move snap ring (43), then remove control piston guide
(35) from valve block (42).
203. CYLINDER BLOCK. Remove shoe plate and
pistons (19 and 20Fig. 168) from block (24). Remove
pivot washer (21) and three guide pins (22) from block
(24). Check each piston (19) for wear or damage.
Looseness between ball and socket of piston must not
Fig. 168Exploded view of piston type pump section of
dual pump.
1. Pump assy.
2. Whizlock screw
3. Cover
4. Shim
5. O" ring
6. Spacer
7. Bearing cup
8. Bearing cone
9. Housing
10. Dowel
11. Spring
12. Seat
13. Bearing cup
14. Bearing cone
15. Shaft
16. Seat
17. Roll pin
18. Yoke
19. Piston
20. Shoe plate
21. Washer
22. Pin
23. Retainer
24. Cylinder block
25. Spring
26. Washer
27. Snap ring
28. Spacer
29. f a r i n g cone
30. Bearing cup
31. Wafer plate
32. Gasket
33. Piston
34. Limiter ring
35. Rod
36. O" ring
37. Plug
38. Seat
39. Valve
40. Spring
41. Pin
42. Valve block
43. Snap ring
44. "O" ring
45. Plug
46. " O " ring
NOTE: Do not try to remove spring (25), washers
(26) or snap ring (27) because spring Is under high
tension, but Inspect parts for any possible damage
and renew cylinder block assembly (Items 24
through 27) If necessary.
204. Check wafer plate for excessive wear,
scratches or cracks and renew as necessary. Check
piston shoe surface of cam plate (18Fig. 168) for
wear, grooves or scoring and renew as necessary.
Make certain pivot (16) on cam plate is not damaged
and is securely fastened by roll pin (17). Check cam
plate spring (11) for free length of 2.125 inches (53.975
mm) and compression length of 1.4 inches (36.1 mm)
at 65.7 to 80.3 lbs. (292-357 N). Check guide (35) for
scratches and smooth action with control piston (33).
Renew guide and piston as an assembly.
205. Reassemble by reversing disassembly proce
dure. Lubricate all moving parts with clean hydrau
lic oil. Use new 0 rings upon reassembly. If new
bearings, or cam plate have been renewed, acûst
cam plate bearing preload as follows: Using a depth
micrometer, measure distance between top edge of
spacer (6Fig. 168) and flat face of pump housing
at two points 180 degrees apart and average meas
urement. Subtract correct preload of 0.008 inch
(0.203 mm) from averaged depth to obtain correct
shim pack. Shims (4) are available in thicknesses of
Fig. 169Exploded view of pump compensator section
of dual hydraulic pump.
1. Ck)mpensator
assy.
2. "O" ring
3. Gasket
4. Plugs
5. Plug
6. Plug
7. Orifice
8. Body
9. "O" ring
10. Plug
11. Spool (stand-by
pressure)
12. Seat
13. Spring
17. 0 ring
18. Hex socket plug
19. Spool (pressure
limiter)
20. Seat
21. Spring
22. "O" ring
23. A4)usting plug
24. Spring seat
25. Adjusting screw
Fig. 170Exploded view of gear type hydraulic pump
section of dual pump.
1. Ferry head 10. Teflon seal
screw 11. Wear plate
2. Pump assy. 12. Pump body
3. Coupler 13. Drive gear
4. " O " ring 14. Driven gear
5. Front cover 15. "O ring
6. Bushings 16. Bushings
7. Dowels 17. Rear cover
8. "O ring 18. Short screw
9. Rubber seal 19. Long screw
0.003, 0.005 and 0.010 inch (0.076, 0.127 and 0.254
mm). Upper and lower shim packs must not differ
more than 0.020 inch (0.508 mm). Install correct shim
pack and new " 0 ring (5) and tighten cover (3) bolts
to 175-185 in.-lbs. (20-21 N-m) torque.
If any shaft bearings, shaft, valve block or housing
has been renewed, adjust shaft bearing preload as fol
lows; Without installation of valve block, measure
thickness of rear bearing spacer (28) and install,
chamfered side toward inside of housing, on pump
shaft. Install rear bearing (29), tapered end toward
outside of housing, on shaft. Install valve block (42),
without gasket (32) and install and evenly tighten
valve block bolts to 2 in.-lbs. (0.23 N*m) torque while
turning shaft to remove any bearing clearance. Meas
ure gap between pump housing and valve block with
feeler gage at four areas 90 degrees apart and aver
age measurement. Subtract thickness of gasket (32)
which is 0.020 inch (0.508 mm), from averaged meas
urement. This will give shaft bearing preload using
original spacer (28). Shaft bearing preload should be
0.001-0.003 inch (0.025-0.076 mm). If preload exceeds
or is not enough, add or subtract correct preload to
measured preload, and select correct thickness
spacer (28) to obtain desired preload. Spacers (28) are
available in thicknesses ranging from 0.139 to 0.169
inch (3.54 to 4.29 mm) in increments of 0.003 inch
(0.076 mm). After correct spacer is obtained, disas
semble pump housing and valve block then reassem
ble pump assembly. Make certain dowel (41) is pushed
fully into valve block so that wafer plate (31) is com
pletely flat against valve block face. Tighten valve
block to pump housing bolts to 23-26 ft.-lbs. (31-34
N*m) torque.
206. OVERHAUL PUMP COMPENSATOR. Tb dis
assemble pump compensator, remove seal wire from
end of compensator. Refer to Fig. 169. Index high
pressure acûstment plug (23) with body (8) so num
ber of turns needed to remove plug can be recorded
for aid in reassembly. Remove ac^justment plug (23),
spring (21), seat (20) and high pressure spool (19). Re
move plug (18) with "O ring (17) and index screw
(25) with body (8). Count and record number of turns
needed to remove acyusting screw (25). Remove
spring seat (24), spring (13), seat (12) and stand-by
pressure spool (11). Remove cover plug (10), orifice
plug (6) and orifice (7). Remove plugs (4) if necessary.
Check orifice for obstructions or dirt. Clean all
parts and inspect spools and bores for wear, scoring
or other damage. If renewal is necessary, body and
spools must be renewed as an assembly. Free length
of stand-by pressure spring (13) should be 0.966 inch
(24.536 mm) and compressed length should be 0.930
inch (22.860 mm) at 8.8-10.8 lbs. (39.1-48.0 N). Free
length of high pressure spring (21) should be 1.402
inches (35.611 mm) and compressed length should be
1.178 inches (30.0 mm) at 123.3-150.7 lbs. (548.5-670.3
N).
Tighten orifice (7) to 20-25 in.-lbs. (2.3-2.8 N-m)
torque. Use all new O rings and lubricate all mov
ing parts with clean Hy-Tran Plus oil. Install acûst-
ing screw (25) and adjusting plug (23) exact number
of turns recorded during removal. Use new 0 ring
(2) and gasket (3) when installing on piston pump.
Tighten compensator to pump bolts to a torque of 60-
70 in.-lbs. (6.8-7.9 N-m).
207. OVERHAUL GEAR PUMP. Place index
marks across the three sections of pump to aid in
reassembly. Unbolt and remove rear cover (17Fig.
170). Index gear teeth (13 and 14) to retain wear pat
tern, then remove drive (13) and driven (14) gear. Re
move pump body (12) from front cover (5). Remove
wear plate (11), Tfeflon seal (10) and rubber seal (9)
from front cover (5).
Check gears for excessive wear or damage. Check
bushing contact surfaces of gear shafts for excessive
wear and check inside surface of pump body (12)
where gears rotate, for scratches or excessive wear.
Check wear plate (11) and surface of rear cover where
gears contact. If any excessive wear or damage is
found, pump must be renewed as a complete as
sembly.
Use new " 0 rings, rubber seal and Tfeflon seal upon
reassembly. Install wear plate (11) with oil grooves to
ward top. Make sure gear index marks and pump sec
tions align. Tighten retaining bolts (1) to 16-18 ft.-lbs.
(22-24 N-m) torque. Install splined coupler (3) on pis
ton pump and use new *G ring (4) when reassem
bling gear pump to piston pump and tighten mount
ing bolts to 16-18 ft.-lbs. (22-24 N-m) torque.
208. After reinstallation of dual pump on tractor,
run pressure checks and adjustments as outlined in
TEST section, paragraphs 189 through 192.
HYDRAULIC SYSTEM FILTER
All Models
209. DUAL FILTERS. Tb service hydraulic filters
on Model 1896 and 2096 tractors, refer to paragraph
15 in POWER STEERING SYSTEM section.
210. BYPASS RELIEF VALVE. Tb renew the hy
draulic filter bypass relief valve (11Fig. 171), refer
to paragraph 15 in POWER STEERING SYSTEM
section.
211. CHARGE SYSTEM REGULATOR. Tb remove
the charge system pressure regulator valve, first drain
transmission oil. Remove filter manifold to gear pump
tube. Unbolt and remove manifold cover (1Fig. 171)
and gasket (2), then unbolt and remove charge regu
lator valve and gasket (3 and 4).
Reverse the removal procedure and install new
charge regulator valve using new gaskets. Tighten
regulator valve retaining cap screws to a torque of
35-42 ft.-lbs. (48-57 N-m). Tighten manifold cover
bolts to a torque of 35-42 ft.-lbs. (48-57 N-m). Refill
transmission with Hy-Tran Plus oil and bleed system
as outlined in paragraph 15.
212. TRANSMISSION HYDRAULIC OIL
SCREEN. Tb clean or renew transmission hydraulic
oil screen, first drain transmission and remove charge
system relief valve as outlined in paragraph 211. Dis
connect gear and piston pump supply tube and dis
connect electrical wires from filter pressure switch.
Disconnect lube tube, charge pump supply tube and
remote valve supply tube. Unbolt and remove mani
fold (5Fig. 171) and gaskets (6 and 8) along with dual
filter assembly (items 9 through 13). Remove trans
mission hydraulic oil screen (7).
Clean or renew screen and install assembly by
reversing removal procedure. Use new gaskets and
Fig. 171Exploded view of hydraulic filter system used
on all models.
tighten manifold bolts to 35-42 ft.-lbs. (48-57 N-m)
torque. Fill transmission with new Hy-Tran Plus flu
id and bleed power steering and brake systems as out
lined in paragraphs 15 and 169. Check for leaks.
REMOTE HYDRAULIC VALVES
All tractors may be equipped with one to four re
mote valve circuits, located on the left hand side of
the tractor The following removal, installation and
overhaul procedures pertain to a single remote valve
circuit. Multiple circuit procedures are identical. See
Figs. 172 and 173 for linkage and schematic flow dia
gram of remote hydraulic valve system. Some models
may be equipped with a variable flow control for
each remote valve circuit. The control increases or
decreases hydraulic flow to remote couplings from
20 gpm to 3.5 gpm (76.5 to 13.2 L/min.).
213. REMOTE VALVES DETENT RELEASE. Be
fore proceeding with test, disconnect all remote valve
control cables at bellcranks on valves and make cer
tain all cables move freely and smoothly, then recon
nect control cables to bellcranks.
Fig. 172View of remote valve control and flow control
linkage. Single remote valve shown.
1. KnoD
2. Remote valve
lever
3. Bearing
4. Clip
5. Yoke
6. Cable
7. Pin
8. Pins
9. Bellcrank
10. Yoke
11. Eyebolt
12. Locknut
13. Set screw
14. Flow control
knob (models
so equipped)
15. Knob shaft
16. Flexible shaft
17. Pin
18. Set screw
19. Valve knob
20. Remote valve
1. Manifold cover
2. Gasket
3. Charge system
pressure
regulator
4. Gasket
5. Manifold
6. Gasket
7. Transmission &
hydraulic oil
screen
8. Gasket
9. Filter elements
10. Stud
11. Bypass valve
12. Gasket
13. Cover L.H.
Tb check and adjust remote lever release pressure,
connect inlet hose of flowmeter to bottom breaka
way coupling on circuit to be tested. Connect outlet
hose of flowmeter to breakaway coupling on same cir
cuit. Run engine at 2100 rpm, and with oil at operat
ing temperature of approximately 120 F (49 C), ful
ly open flow valve on flowmeter. Move remote lever,
on circuit being tested, to rear detent position. Turn
flow control on circuit being tested until a flow of
15 gpm (57 L/min.) shows on flowmeter. Turn load
valve on flowmeter clockwise while observing flow
meter pressure gage, until remote lever on console
automatically returns to neutral position. Lever
should automatically return to neutral position at
1900 psi (13100 kPa). If lever does not return to neu
tral at this pressure, loosen small locknut on adjust
ment screw (Fig. 174) and turn adjustment screw
clockwise to increase return pressure; counterclock
wise to decrease return pressure. When correct pres
sure is obtained, tighten locknut. Repeat test and ad
justments, if necessary, on all remote levers.
214. REMOTE FLOW CONTROLS. With all previ
ous pump pressures, valve operations and control ad
justments in acceptable conditions, run engine at
2100 rpm, and with oil at operating temperature of
approximately 120 F (49 C), turn flow control valve
on circuit being tested, fully counterclockwise (max
imum flow position). Move and hold remote lever on
same circuit to rear detent position. Adjust load valve
on flowmeter to 1700 psi (11720 kPa). Flow on flow
meter must not be less than 20 gpm (75.7 L/min.).If
flow is less than specified, check and/or overhaul re
mote valve as outlined in paragraph 216.
Fig. 173Schematic view of remote valve hydraulic
component parts. Single remote valve shown.
215. R&R REMOTE VALVE. Tb remove remote
valve, place a container below valve to catch any oil
drainage. Disconnect all hydraulic oil tubes from
valve and end cover. Disconnect lever control link
age by removing pins (7Fig. 172) connecting lever
cables to spool bellcrank. If equipped, discormect ca
bles connecting flow control knob (19). Unbolt and
remove remote valve.
Install by reversing removal procedure. Use new
O rings on all hydraulic fittings. Use new 0 rings
(3Fig. 175) and shims (2) between valves and end
covers. Tighten mounting bolts to 18-20 ft.-lbs. (24-
27 N-m) torque.
216. OVERHAUL. With valve removed from trac
tor as outlined in paragraph 215, remove inlet and
outlet connectors and 0 rings from irUet cover (4
Fig. 175). Remove compensator inlet fitting (5), 0
ring (6), retainer (7), spring (8) and ball (9). Remove
nuts and washers and remove inlet cover (4) from
body. Remove the three metal shims (2) and four O
rings (3) from cover. Remove valve seat (10), if neces
sary, pushing from outside of cover.
Fig. 174view of remote valves showing adjustment
screw to set neutral release pressure. Refer to text.
1. Remote valve
2. Tube from
compensator
3. Remote valve
supply tube
4. Regulator/flow
divider
5. Return tube
6. Coupling supply &
return hoses
7. Coupling
NOTE: If multiple remote valves are being over
hauled, separate valves and remove shims (2) and
"O rings (3) from between each valve.
Remove end cover (11) and remove shims (2) and
0 " rings (3) from remote valve. Remove linkage pins
(8Fig. 172) and bellcrank (9) from eyebolt (11). In
dex eyebolt depth in valve body, loosen locknut (12)
and remove eyebolt (11). Unbolt and remove dust cov
er (42Fig. 176), retainer (44) and felt ring (45) from
body. If equipped, loosen set screw (18Fig. 172) and
remove flow control knob (19). Remove flow control
housing (items 13 through 19Fig. 176), spool (20)
and springs (21 and 22) from body. Remove guide pin
(23) and roll pin (48).
Unbolt detent housing (40), then withdraw detent
housing and valve spool (46). Pull valve spool assem
bly from detent housing. There will be some resis
tance as the detent balls pass over the detent ramps.
Place flat end of spool (46) in a vise, compress cen
tering spring (36) and pull detent shaft (64Fig. 177)
from detent coupler (39Fig. 176). Place a small
punch through hole in coupler (39), unscrew coupler
from spool (46) removing coupler (39), spring retain
ers (35 and 38), spring (36) and spacer (37). Remove
*0 rings (34 and 47) from each end of spool bore
in valve body (24).
Remove secondary shuttle plug (26) with 0 rings
(27 and 38) and ball (29). Unscrew and remove pri
mary shuttle plug (33) with " 0 " rings (30, 31 and 32).
Remove 0 rings (49 and 50Fig. 177) from de
tent housing (52). Hold pressure against plug (73),
then remove snap ring (74) and the plug. Withdraw
spring (72) and push piston (71), balls (66) and wash
er (65) from detent housing. Remove 0 rings (68
and 69) and back-up rings (67 and 70) from piston
Fig. 175When reinstalling, use all new O rings and
Install shims (2) between remote valves and end covers.
(71). Loosen nut (63) and unscrew adjusting plug (62).
Carefully remove the regulator piston (61), back-up
rings (58 and 60), O rings (57 and 59), washer (56),
spring (55) and detent poppet (54).
Clean and inspect all parts for excessive wear or
other damage. Inspect spool (46Fig. 176) and bore
of valve body for wear, scoring or nicks and burrs.
If damage is present, spool and body are not availa
ble separately and must be renewed as an assembly.
Renew other parts as necessary. Use new O rings,
back-up rings and felt washer when reassembling.
Lubricate all 0 rings and back-up rings with
1. Remote valve
13. Nut
14. O" ring
15. Teflon back-up
ring
16. O ring
17. Shaft
18. Roll pin
19. Flow spool
20. Tube
21. Spring (outer)
22. Spring (inner)
23. Spring guide pin
24. Valve body
25. Plug
26. Shuttle plug
27. "O" ring
28. O" ring
29. Ball
30. " O " ring
31. O ring
32. O" ring
33. Primary shuttle
34. " O " ring
35. Spring .seat
36. Centering spring
37. Spacer
38. Spring seat
39. Detent coupler
40. Detent assy.
41. Socket head cap
screw (3)
42. Boot
43. Cap screw (2)
44. Retainer
45. Felt ring
46. Valve spool
47. * 0 " ring
48. Roll pin
1. Remote valve
2. Shims
3. " 0 " rings
4. Inlet ( r i ^ t ) cover
5. Compensator line
fitting
6. "O ring
7. Retainer
8. Spring
9. Ball
10. Seat
11. Front (left) cover
12. Stud (3)
Paragraph 217
CASE/INTERNATIONAL
petroleum jelly and all moving parts with clean Hy-
Tran Plus hydraulic oil.
Reassemble by reversing the disassembly proce
dure, keeping the following points in mind: Check the
springs against the following specifications: Outer
spring (21Fig. 176) should have a free length of 1.57-
1.71 inches (39.878-43.434 mm) and should test 12.75
lbs. (57 N) when compressed to a length of 1.07-1.21
inches (27.178-30.734 mm). Inner spring (22) should
have a free length of 1.94-2.06 inches (49.276-52.324
mm) and should test 13.9 lbs. (62 N) when compressed
to a length of 1.44-1.56 inches (36.576-39.624 mm).
Free length of centering spring (36) is 2.5 inches (63.5
mm) and should test 18-22 lbs. (80-98 N) when com
pressed to a length of 1.375 inches (34.925 mm). Free
1. Remote valve
49. ' 0 " ring
50. * 0 ' rings
51. Orifice
52. Detent housing
53. Seat
54. Poppet
55. Spring
56. Washer
57. O" ring
58. Back-up ring
59. " 0 " ring
60. Back-up ring
61. Piston
62. Adjusting screw
63. Nut
64. Detent shaft
65. Washer
66. Balls (8)
67. Back-up ring
68. "O ring
69. O" ring
70. Back-up ring
71. Piston
72. Spring
73. Plug
74. Snap ring
length of detent relief spring (55Fig. 177) is 1.05
inches (26.67 mm) and should test 8.5-10.5 lbs. (38-
47 N) when compressed to a length of 1.0 inch (25.4
mm). Detent spring (72) should have a free length of
1.7 inches (43.2 mm) and should test 30.4. lbs. (135
N) when compressed to a length of 1.375 inches (34.9
mm).
When installing "O rings (34 and 47Fig. 176), in
stall O ring (47) in bore groove in control end of
valve. Slide spool (46) in from detent end until 0
ring groove at detent end of bore is visible. Install
" 0 ring (34) in this groove. Slide spool back through
this O ring. This method of installation will pre
vent spool lands from cutting 0 rings.
Tighten primary shuttle plug (33) and secondary
shuttle plug (26) to a torque of 5 ft.-lbs. (7 N-m). Use
Loctite 242 on threads of detent coupler (39) and
tighten to a torque of 5 ft.-lbs. (7 N*m). Tighten de
tent housing cap screws to a torque of 8 ft.-lbs. (11
N*m). Tighten flow control nut (23) to 20 ft.-lbs. (27
N*m) torque. Tighten retainer cap screws (43) to 4 ft.-
lbs. (5 N-m) torque.
Reinstall remote valve as outlined in paragraph 215.
Adjust remote valve detent release as outlined in
paragraph 213.
LOAD CHECK VALVE
Tractors may be equipped with a load check valve
on the second or third remote valves. The pressure
operated load check valve will hold the load of a re
mote cylinder until pressure is applied in the oppo
site direction. For example, a raised implement will
not lower during transit until the remote valve is
moved to lower position. When remote valve is
moved to lower position, hydraulic pump pressure
will move the load check spool to open the opposite
(lift) port and allow cylinder to lower.
217. R&R AND OVERHAUL. Tb remove the load
check valve assembly, first clean the lines, valve and
surrounding area. Disconnect hydraulic lines from
valve to remote couplers. Place a match mark across
load check valve and remote valve for aid when reas
sembling. Remove the six socket head cap screws
(88Fig. 178) and lockwjishers. Lift off check valve
assembly and remove O rings (75).
Tb disassemble the load check valve, loosen lock-
nuts (76), then unscrew and remove plugs (77) and
locknuts. Remove spring retainers (78), springs (81)
and poppets (82). Use a thin diameter rod against ei
ther end of spool (84) and push a load check seat (83)
out of housing (87). Push spool (84) out the same end
of housing. Then, use the rod to push opposite load
check seat (83) out the opposite end of housing. Re
move 0 rings (85 and back-up rings (86) from
grooves in housing bore.
Fig. 177Exploded view of remote valve detent
assembly.
MODELS 1896-2096
Paragraph 218
Clean and inspect all parts and renew as necessary.
Springs (81) should have a free length of 1.110 inches
(28.194 mm). Use all new 0 rings and back-up rings
when reassembling. Install back-up rings (86) against
inner shoulders of grooves and install 0 rings (85)
against outer shoulders of grooves. Install one load
check seat (83) in housing until seated. Install spool
(84) in opposite end of housing and follow with the
other load check seat (83) until it is seated. Install
a poppet (82) and spring (81) in each end of housing.
Install a back-up ring (79) and O ring (80) on each
spring retainer (78). " 0 ring must face to inside of
valve. Install spring retainers until they contact load
check seats. Install plugs (77) with locknuts (76).
Tighten plugs to a torque of 50 ft.-lbs. (68 N-m), then
tighten locknuts to a torque of 10-12 ft.-lbs. (14-16
N-m).
Use new "O rings (75) and reinstall load check
valve assembly by reversing removal procedure.
REMOTE CYLINDER
218. OVERHAUL REMOTE WORK CYLINDER.
Refer to Fig. 179 for exploded view of one of the com
monly used cylinders, which may have center beew-
ing (5) renewable separately, or as an integral part
of gland (6). Wiper seal (3) is installed with lip toward
outside. Tighten valve gland (18) to 33-42 ft.-lbs. (44.7-
56.9 N-m) torque. Back-up ring (8) goes over CD of
gland (6), with 0 ring beneath it. Piston seal ring
(10) goes on piston (12) with 0 ring installed un
der it. Install % inch bolt (13) in piston rod (if re
moved) and tighten to 200-220 ft.-lbs. (271-298 N-m)
torque. Gland (6) should be tightened with a span
ner wrench to at least 100-200 ft.-lbs. (136-271 N-m)
torque.
Fig. 178Exploded view of remote valve load check valve
assembly.
1. Remote valve
75. 0 rings
76. Locknut
77. Plug
78. Spring retainer
79. Back-up ring
80. " O " ring
81. Spring
82. Poppet
83. Seat
84. Spool
85. " O " ring
86. Back-up ring
87. Load check
housing
88. Socket head cap
screw (6)
Fig. 179Exploded view of remote cylinder with collar
type hydraulic limit stop.
1. Piston rod
2. Stop collar
3. Wij>er seal
4. Bearing ring
5. Center bearing
6. Gland
7. Piston rod seal
8. Back-up ring
9. O" ring
10. Piston seal ring
11. Wear ring
12. Piston
13. 3/4 inch bolt
14. Cylinder barrel
15. Push rod
16. Spring
17. Sleeve
18. Valve gland
19. Blocking piston
HYDRAULIC HITCH SYSTEM
All tractors may be equipped with a hydraulic 3-
point hitch system. Tractors are equipped with a sin
gle cylinder operated rockshaft arm. Fig. 192. Hy
draulic hitch systems on all models receive hydrau
lic power from the piston type pump after passing
through the regulator/flow divider valve. All models
so equipped have both position and sensing controls.
The hitch position control is used to lift and lower
implements and to select the working depth of soil
entering implements. The sensing control is used to
find sensitivity of implements control of load or draft
on implement due to keep implement at a constant
working depth through variable field conditions.
TROUBLE-SHOOTING HITCH SYSTEM
All Models
219. The following are symptoms which may oc
cur during operation of hydraulic hitch system. By
using this information in conjunction with the Ad
just, R&R and Overhaul information, no trouble
should be encountered in servicing the hydraulic
hitch system.
1. Draft arms will raise and lower but sensing does
not work.
A. Operating procedure incorrect (see Operators
Manual).
B. Incorrect tire pressure.
C. Draft arm height acjjustment incorrect.
D. Incorrect amount of front or wheel weights in
stalled.
E. Sensing linkage not acUusted correctly.
F. Draft spring tension incorrect.
C. Hitch control valve lowering piston not operat
ing correctly.
D. Rockshaft piston and cylinder not operating cor
rectly.
5. Draft arms will not lower.
A. Hitch control cables disconnected or incorrectly
adjusted.
B. Hitch control valve spool control linkage broken
or disconnected.
C. Rockshaft cylinder(s) or hitch control valve not
operating correctly.
D. Lowering piston of hitch control valve not oper
ating correctly.
E. Rockshaft piston and cylinder not operating cor
rectly.
TESTING
All Models
220. HITCH SYSTEM CHECK. Install test fixture
(Fig. 180) (CAS-1455). Install an Owatonna 17-1/2 ton
(158.7 Mg) ram and 0-3000 psi (20000 kPa) pressure
gage (CAS-10117) to testing fixture. Lower draft arms
and pull ser\sing lever (6Fig. 181) to rear for maxi
mum sensing position. Start engine and pull hitch le
ver (1) toward rear until draft arms just start to raise.
At the moment the draft arms move up, hitch lever
(1) should be near center position on console between
full raise and full lower. Slowly pull hitch lever (1)
to rear; lever and draft arms should reach full raise
position simultaneously. If not, acûst hitch lever ca
ble (4) length (paragraph 226) until correct operation
is obtained.
2. Draft arms will raise but do not cancel.
A. Valve lockout linkage incorrectly adjusted.
B. Follow-up linkage incorrectly acyusted.
3. Oscillation of draft arms with engine running or
draft arms lower when engine is stopped.
A. Hitch control valve or rockshaft cyhnder not
operating correctly.
4. Draft arms will not raise.
A. TYactor hydraulic system not operating correctly.
B. Hitch control cables disconnected or incorrectly
ac^justed.
Fig. 180Illustration of CAS-1455 load test fixture used
for hydraulic hitch tests.
Tb check pounds of pull needed to operate the sens
ing mechanism of the hitch, use test fixtures to pull
sensing cross shaft to rear.
NOTE; Tractors have an 800-1000 lbs. (3559-4448
N) spring preload that will need 1000-1200 lbs. (4448-
5338 N) of pull to actuate hitch. Using the Owaton
na 17-1/2 ton (158.7 Mg) ram, 900 lbs. (4003 N) of pull
Is equal to 255 psi (1758 KPa) on gage.
Start engine, lower draft arms and put sensing le
ver to maximum sensing position. Slowly pull the
hitch lever to rear until draft arms just start to raise.
With sensing cross shaft pulled to rear with fixture,
hitch must sense between 227-283 psi (1565-1592
kPa). If draft arms raise slightly then stop, increase
tension on sensing crossbar using fixture. Draft arms
must raise slightly and stop each time pressure is in
creased. When pressure is released, draft arms must
lower. If specified pressures did not obtain accepta
ble operation, sensing linkage wiU have to be adjusted
as outlined in paragraph 222.
ADJUSTMENTS
All Models
221. SENSING SPRING PRELOAD. Set correct
tire pressures. Lower draft arms fully. Distance from
Fig. 181View of hydraulic hitch position and draft
sensing control linkage.
1. Position control
hand lever
2. Quadrant
3. Quadrant stop
knob
4. Cable
5. Position control
valve lever
6. Draft sensing hand
lever
7. Cable
8. Sensing control
valve lever
9. Draft control
housing
ground to center of draft arm balls should be 8 inches
(203.2 mm). A4just if necessary by turning tumbuck-
le(s) on lift links. Remove drawbar. Loosen nuts on
both spring adjusting U-bolts (4Fig. 182). With test
fixture (CAS-1455), hydraulic ram assembly and gage
installed, operate ram until 255 psi (1758 kPa)
registers on gage.
Pull U-bolts (4) rearward until they contact cross
shaft (1). Tighten flange nuts evenly until U-bolts are
snug against cross shaft. Then, tighten locknuts on
each U-bolt to a torque of 200-250 ft.-Ibs. (271-339
N-m) while maintaining 255 psi (1758 kPa) reading on
gage.
All Models
222. SENSING LINKAGE. Place sensing control
hand lever in maximum sensing (fully rearward) po
sition. Drain oil from cover of draft control housing
which should be approximately 1 gallon (3.78 L).
Then remove cover and acûst set screw on sensing
shaft (1Fig. 191) until signal amplifier link in draft
housing is parallel with front of draft control hous
ing. See Fig. 183.
223. DRAFT ARM FULL RAISE, lb adjust the
draft arm full raise position, place sensing hand con
trol to full sensing position, disconnect the hitch con
trol cable (4Fig. 181) from control lever (1) on draft
control console. Refer to Fig. 184 and make certain
timing marks on follow-up cam align with timing
Fig. 182Exploded view of sensing spring mounting
bracket and adjusting U-bolt. One side shown.
1. Cross shaft 8. Spacer
2. Locknut 9. Pin
3. Acûsting nut 10. Nut
4. U-bolt 11. Sensing spring
5. Unk 12. Bolt
6. Washer 13. Lockwasher
7. Snap ring 14. Spacer
mark on housing. If timing marks do not align, follow-
up linkage inside transmission housing must be ad
justed by first removing pto assembly as outlined in
paragraph 179. Refer to Fig. 185 and loosen jam nuts
on acUusting rod for the follow-up lever. Disconnect
lower rod bearing from outer sensing lever. Move out
er sensing lever until timing marks on follow-up cam
and draft control housing are aligned. Adjust lower
rod bearing on adjusting rod as required and recon
nect to outer sensing lever.
On all tractors, start engine, raising draft arms to
fully raised position, then stop engine. Draft arms
must have 1-1/2 to 2 inches (38-51 mm) additional up
ward travel when lifted by hand. If not, turn offset
trunnion (Fig. 186) to move pin of valve lockout link
toward end of slot (rearward) to increase the amount
of draft arm travel; or move trunnion away from end
of slot (forward) to decrease draft arm travel. Recon
nect hitch control cable to control lever on console
and reinstall draft control housing cover.
224. CONTROL SPOOL STROKE. Tb adjust con
trol spool stroke, refer to Figs. 187 and 188, start en
gine and raise draft arms fully, then lower arms about
% the way downward and stop engine. On models
without cover cap screw (19Fig. 187), remove spring
cover (15) and using a depth micrometer, measure
length of valve spool from end of spool to flange of
valve body and record measurement (Fig. 188). Start
engine, move hitch control lever slowly toward raise
Fig. 183With sensing lever In maximum position, adjust
set screw to place signal amplifier arm parallel to front
edge of box.
position until draft arms just start to raise, then stop
arm movement and stop engine. Remeasure spool
length. Subtract first measurement from second
measurement. Difference should be 0.007-0.015 inch
(0.178-0.381 mm). If specifications are not correct.
Fig. 184Timing marks In linkage box should align as
shown. Refer to text.
Fig. 185View showing sensing linkage. Refer to text.
Fig. 186Adjust eccentric nut to change upper limit of
draft arm height. Refer to text for procedure.
support draft arms in raise position, remove cover
(30Fig. 190), and remove lowering piston assembly
(25 through 29). Refer to Fig. 189 and acûst lower
ing piston screw (25Fig. 190) to increase or decrease
lowering spool travel.
225. On models with control spool cover equipped
with cap screw (see insert Fig. 187), start engine. Ful
ly raise draft arms, then lower them to center posi
tion. Remove cap screw (19) from spool cover, install
a 1/4-20 X 3 inch full thread bolt until it just contacts
the valve spool. Set up a dial indicator on the bolt
installed, preload and then zero indicator. Turn bolt
clockwise until draft arms just start to lower and rec
ord reading on dial indicator. Readjust dial indicator
to zero and move hitch control hand lever one inch
(25.4 mm) toward raise position. Turn installed bolt
counterclockwise until draft arms just start to raise
and record reading on dial indicator. Subtract first
reading from second. Difference must not be more
than 0.007-0.015 inch (0.178-0.381 mm). If specifica
tions are not correct, adjust lowering piston screw
(25Fig. 190) as previously outlined in paragraph
224. Recheck and adjust as necessary until correct
control spool travel is obtained. On models with cap
screw in spool cover, renew seal (18Fig. 187) upon
reassembly.
226. CONTROL CABLES. Put hitch control hand
lever (1Fig. 181) to full raise position. Disconnect
clevis pin at draft housing control lever (5). With con
trol lever (5) in full raise position (fully counterclock
wise), acûst cable length until clevis pin hole in ca
ble aligns with control lever (5). Install cotter pins
and tighten jam nuts.
Tb adjust draft cable, lower draft arms fully, dis
connect sensing cable clevis pin from draft control
Measure Wi th Mi cr omet er
Fig. 188Measure control valve spool travel with an
accurate Instrument as shown. Remove lower cover and
lowering piston to measure overall length. Refer to text
for procedure and Fig. 189 for dimensions.
Fig. 187Exploded and schematic view of hydraulic hitch
control valve and related components.
1. Cotter pin
2. Tube
3. Ball
4. Gasket
5. Manifold
6. Plug
7. "O" ring
8. Plug
9. Oil tube
10. Clamp
11. Hose
12. " 0 " ring
13. Control valve
14. Gasket
15. Cover
16. Clamp
17. Cover
18. Washer
19. Bolt
Fig. 189Illustration and graph showing correct
adjustment length of lowering piston.
housing lever (8). Turn draft lever (8) counterclock
wise against the stop, put sensing hand control lever
(6) in fully forward position and adjust cable (7)
length until clevis pin hole aligns with draft control
lever (8). Install clevis pin, cotter pins and tighten
jam nuts.
227. LEVER FRICTION DISCS. Refer to Fig. 181
and tighten locknut on hitch control lever (1) disc un
til an effort of 12-15 ft.-lbs. (53-67 N) of force is need
ed to move lever. Tighten locknut on draft control
lever (6) disc until an effort of 3-7 lbs. (13-31 N) of
force is needed to move lever.
HITCH CONTROL VALVE
All Models
228. REMOVE AND REINSTALL. Refer to Fig.
187, drain transmission oil, disconnect all hydraulic
tubes from manifold (5) and valve (13). Remove
clamps (10) and tube (11) and disconnect spool from
Fig. 190Exploded view of hitch control valve.
valve to draft control housing. Unbolt manifold (5)
and separate from hitch valve body (13).
Reinstall by reversing removal procedure. Use new
0 " rings (12) between manifold and valve. Check
oil return ball and seat for dirt and free action. Tight
en valve to manifold cap screws to 17-20 ft.-lbs. (23-
27 N*m) torque. Use new gasket (4). Tighten control
valve and manifold mounting cap screws to 35-42 ft.-
lbs. (48-57 N-m) torque. Use new O rings on hy
draulic fittings. Fill transmission with new Hy-Tran
Plus fluid.
229. OVERHAUL CONTROL VALVE. With con
trol valve, removed and separated from manifold, dis
assembly of valve will be obvious after removal of
spool cover (15 and 17Fig. 187) and examination of
unit and referral to exploded view of valve in Fig. 190.
Clean and inspect all parts for scratches, burrs or
other damage. Spool (8) and body (1) are not serv
iced separately. Use new 0 rings and seals upon
assembly. Free length of spool return spring should
be 6.36 inches (161.5 mm) and a compressed length
of 4.05 inches (102.9 mm) at 13.5-16.5 lbs. (60-73 N).
Ixjwering poppet piston spring (29) free length is 1.90
inches (48.26 mm) with a compressed length of 1.63
inches (41.4 mm) at 31-39 lbs. (138-174 N). Load check
spring (14) free length is 1.25 inches (31.8 mm) with
a compressed length of 0.750 inch (19.1 mm) at 7.7-
9.4 lbs. (34-42 N). Ball return spring (17) free length
is 0.654 inch (16.6 mm) with a compressed length of
0.450 inch (11.4 mm) at 1.1-1.4 lbs. (5-6 N). Lubricate
all moving parts with clean Hy-Tran Plus fluid upon
reassembly. Check and adjust control spool travel as
All Models
230. OVERHAUL LOWER SENSING LINKAGE.
Figure 191 shows relative positions of sensing link
age in linkage box. Approximately 1 gallon (3.78 L)
of fluid is contained in Iwx. Tb drain box, remove plug
in bottom cover, then remove cover for access to link
age. Most of the linkage can be examined for dam
age or wear without removal. Disassemble only far
enough to renew damaged parts. Valve lockout arm
(7) should not have excessive clearance on eccentric
pivot nut (9). Cam follower roller (14) should be a
good fit on its pivot pin.
For ease of disassembly, remove retaining clip from
pin (12) in valve spool end (11). Spring on control
valve spool will pull spool end forward and release
tension on linkage. Retaining clips on studs and links
can then be removed as necessary. Seals (2) should
be renewed if leaking, or when shafts are removed.
Install seals flush, with lips to inside of box.
When reassembling, be sure linkage is free from
binding and does not interfere with free movement
1. Valve body
2. Snap ring
3. Plug
4. O" ring
5. Pin
6. "O" ring
7. Throttle screi
8. Control spool
9. Spring
10. Washer
11. Snap ring
12. Seat
13. Ball
14. Spring
15. Seal ring
16. Ball
17. Spring
18. "O" ring
19. Connector
20. Ball
21. 0 " ring
22. Back-up washe
23. Sleeve
24. " O " ring
25. Acljusting scre>
26. Back-up ring
28. Piston
29. Spring
30. Cover
31. Spacer
of other linkage. Refer to paragraphs 222 and 223 for
acUustment procedure before bottom cover is rein
stalled.
ROCKSHAFT AND CYLINDER
All Models
231. R&R AND OVERHAUL. Tb remove the hy
draulic hitch rockshaft and work cylinder assembly,
first disconnect lift links from upper lift arms and re
move pto assembly as outlined in paragraph 179. Re
move rear pto shaft. Disconnect draft sensing link-
age bracket from rockshaft (5Fig. 192). Remove
snap rings (1 and 13) from rockshaft ends. Note tim
ing marks on rockshaft ends and lift arms (2) and re
move lift arms. Remove set screws (6) from power arm
(7), unbolt and remove retainer (10), then drive rock
shaft out toward left side of transmission housing,
removing power arm (7). Remove piston rod from pis
ton, then remove snap ring (15) and remove piston
and cylinder liner (items 16 through 23) from trans
mission cavity.
Clean and inspect all parts for excessive wear, scor
ing or other damage and renew as necessary. When
renewing bushings (4 and 11), small ID 2.3805-2.3845
inches (60.465-60.566 mm) bushing (11) installs in
right side of transmission housing. Large ID 2.756-
2.760 inches (70.002-70.102 mm) bushing installs in
Fig. 191Exploded view of sensing linkage In linkage
box.
1. Sensing shaft
2. Seals 15. Cam follower
3. Acûsting screw link
4. Linkage box 16. Pivot Unk
5. Plug 17. Slide trunnion
6. Follow-up cam 18. Manual shaft
7. Valve lockout 19. Pivot block
arm 20. Sensing pivot
8. Valve lockout link
link 21. Stud
9. Eccentric pivot 22. Unk pivot stud
nut 23. Amplifier arm
10. Valve spool link 24. Sensing arm link
11. Valve spool end 25. Pivot block
12. Pin 26. Sensing arm shaft
13. Manual lever 27. Gasket
slide 28. Cover
14. Cam follower 29. Yoke, guide &
roller spring
Fig. 192Exploded view of rockshaft, cylinder and
sensing linkage contained In transmission housing.
1. Snap ring 21. Wear ring
2. Lift arm 22. Cylinder
3. Seal 23. "O ring
4. Bushing 24. Thermal safety
5. Rockshaft valve
6. Set screws 25. Upper rod
7. Power arm bearing
8. Cap screw 26. Locknut
9. Washer 27. Adjusting rod
10. Retainer 28. Locknut
11. Bushing 29. Lower rod
12. Seal bearing
13. Snap ring 30. Shaft
14. Piston rod 31. Outer sensing
15. Snap ring lever
16. Piston 32. Support
17. Wear ring 33. Inner sensing
18. Back-up ring lever
19. O" ring 34. Link
20. Back-up ring 35. Follow-up lever
Paragraph 232
left side of transmission housing. Install new O ring
(19) on piston (16) and the two back-up rings (18 and
20) with concave sides toward "O ring (19). Install
new wear rings (17 and 21) on piston. Use new 0
ring (23) and install cylinder liner (22), small ID first,
into transmission cavity and secure with snap ring
(15). Install new seals (3 and 12) with lips toward in
side. Reinstall rockshaft (5), small end first, through
left side bushing. Make certain all timing marks align
on power arm (7) to rockshaft and lifter arms (2) to
rockshaft. Reinstall draft sensing linkage and adjust
as outhned in ADJUSTMENTS paragraphs of HY
DRAULIC HITCH SYSTEM if necessary. Balance of
reassembly is reverse of removal procedure.
CAB
REMOVE AND REINSTALL
All Models
232. Tb remove the cab assembly, first disconnect
battery cables and remove batteries and carrier. Dis
connect throttle cable from ii\jection pump, shut off
fuel supply valve and disconnect fuel supply line and
return line. Shut off heater valve and disconnect
heater hoses. If so equipped, disconnect cable from
true ground speed sensor. Disconnect air condition
er hoses at quick couplers. Identify and disconnect
the four power steering tubes from steering hand
pump. Disconnect brake drain line and supply line.
Disconnect front-wheel drive shift cable, power shift
wirir\g and differential lock wires, if so equipped. Dis
connect gear shift cables and park lock rod. Discon
nect remote valve cables and hitch control cables.
Identify and disconnect hydraulic remote outlets
from cab panel. Disconnect clutch control cable or
inching pedal cable. Disconnect pto control cable and
left and right brake lines. Disconnect engine wiring
harness from cab wiring harness at front of cab. At
tach a cab lifting bracket and hoist as shown in Fig.
193. Lifting bracket can be fabricated using dimen
sions shown in Fig. 194. Remove bolts from left and
right rear cab mounts and from left and right front
cab mounts. Slowly raise the cab and check to be sure
all wiring, tubes and cables have been disconnected.
Lift off cab assembly.
Reinstall by reversing removal procedures. Install
and tighten rear cab mount bolts to a torque of 80-
96 ft.-lbs. (108-130 N-m). Install front cab mount bolts.
Tighten all % inch bolts to a torque of 80-96 ft.-lbs.
(108-130 N*m) and all 5/8 inch bolts to a torque of 150-
180 ft.-lbs. (203-244 N-m).
Fig. 193View showing cab lifting bracket and hoist
Installed for cab removal.
Fig. 194Cab lifting bracket can be fabricated using
dimensions shown.

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