Sunteți pe pagina 1din 678

TB100, TB110, TB120, TB120 MUDDER

REPAIR MANUAL
COMPLETE CONTENTS
SECTION 00 - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 10 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SECTION 18 - CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION 21 - TRANSMISSION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 23 - FRONT AXLE TRANSFER BOX . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 25 - FRONT AXLE -- FOUR WHEEL DRIVE . . . . . . . . . . . . . . . . . . . 10

SECTION 27 - MECHANICAL REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . 11

SECTION 31 - POWER TAKE-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SECTION 33 - BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SECTION 35 - HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION 41 - STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 44 - FRONT AXLE -- TWO WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . 16

SECTION 55 - ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

The following pages are the collation of the contents pages from each section and
chapter of the TB100, TB110, TB120, and TB120 Mudder Tractor Repair manual.
Complete Repair part # 87046217.

The sections used through out all New Holland product Repair manuals may not be
used for each product. Each Repair manual will be made up of one or several books.
Each book will be labeled as to which sections are in the overall Repair manual and
which sections are in each book.

The sections listed above are the sections utilized for the TB100, TB110, TB120, and
TB120 Mudder Tractors.

© 2004 CNH America LLC 87046220 3/04


Printed In U.S.A.
SECTION 00 - GENERAL
BOOK 1 - 87046218

Chapter 1 -- General
CONTENTS

Description Page
HEALTH AND SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ACIDS AND ALKALIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADHESIVES AND SEALERS -- see Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ANTIFREEZE -- see Fire, Solvents e.g. Isopropanol, Ethylene Glycol, Methanol. . . . . . . . . . . . . . . . . . . . . . . 3
ARC WELDING -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY ACIDS -- see Acids and Alkalis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRAZING -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHEMICAL MATERIALS -- GENERAL -- see Legal Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DO’S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DO NOTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CORROSION PROTECTION MATERIALS -- see Solvents, Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DUSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRIC SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EXHAUST FUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FIBRE INSULATION -- see Dusts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FIRE -- see Welding, Foams, Legal Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FOAMS -- Polyurethane -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUELS -- see Fire, Legal Aspects, Chemicals -- General, Solvents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GAS CYLINDERS -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL WORKSHOP TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LEGAL ASPECTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LUBRICANTS AND GREASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PAINTS -- see Solvents and Chemical Materials -- General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SOLDER -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SOLVENTS -- see Chemical Materials -- General Fuels (Kerosene), Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SUSPENDED LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WELDING -- see Fire, Electric Shock, Gas Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2
SECTION 10 - ENGINE
BOOK 1 - 87046218

Chapter 1 - Diesel Engines


CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Grease and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Crankshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cylinder Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Diesel Engine Strip-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Separating the Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Disassembly and Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Rocker Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Valve and Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Valve Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Rocker Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Engine Front Cover and Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3
SECTION 10 - ENGINE
BOOK 1 - 87046218

Chapter 1 - Diesel Engines (Continued)


CONTENTS

Section Description Page


Connecting Rods, Bearings, Pistons, and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Connecting Rod Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Rear Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Oil Filter Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77, 80
Balancer Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Camshaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84, 85
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84, 86
Engine Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Compression Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Compression Test Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Engine Break-in (Low Hp Application) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Engine Break-in (Other Than Low Hp Application) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

4
SECTION 10 - ENGINE
BOOK 1 - 87046218

Chapter 2 - Engine Cooling System


CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cooling System Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Temperature Warning Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 10 - ENGINE
BOOK 1 - 87046218

Chapter 3 - Air Cleaning System


CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air Cleaner Assembly Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5
SECTION 10 - ENGINE
BOOK 1 - 87046218

Chapter 4 - Fuel System


CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel Injection Pump – Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Maximum No-load Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DP203 Series Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DP203 Series Fuel Injection Pump Shaft Lock Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fuel Injector Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Electric Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6
SECTION 10 - ENGINE
BOOK 1 - 87046218

Chapter 5 - Turbocharger
CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 18 - CLUTCH
BOOK 1 - 87046218

Chapter 1 - Single Clutches


CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

7
SECTION 18 - CLUTCH
BOOK 1 - 87046218

Chapter 2 - Servicing Clutch Associated Parts


CONTENTS

Section Description Page


Clutch Pilot Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 21 - TRANSMISSION SYSTEMS


BOOK 1 - 87046218

Chapter 1 - 8 x 2 Transmission
CONTENTS

Section Description Page


Specifications, Tightening Torques and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8 x 2 Non-synchromesh Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ground Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Introduction to Transmission Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gear Shift Levers and Covers -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Neutral Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission Front End -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Complete Transmission Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

8
SECTION 21 - TRANSMISSION SYSTEMS
BOOK 1 - 87046218

Chapter 2 - 16 x 4 Dual Command (Dual Power) Transmission


CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dual Command Transmission -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Under-Drive Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Planetary Gear Set -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Planetary Gear Set Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SECTION 21 - TRANSMISSION SYSTEMS


BOOK 1 - 87046218

Chapter 3 - Reduction Gearbox Assembly


CONTENTS

Section Description Page


Specifications, Tightening Torques, and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Reduction Gearbox -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Reduction Gearbox Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

9
SECTION 23 - FRONT AXLE TRANSFER BOX
BOOK 1 - 87046218

Chapter 1 - Front Axle Transfer Box


CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clearances and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Shim Thickness Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SECTION 25 - FRONT AXLE--FOUR WHEEL DRIVE


BOOK 1 - 87046218

Chapter 1 - Four Wheel Drive


CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clearances and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Shim Thickness Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Track Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hub and Planetary Reduction Gear Assembly - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Axle Shafts - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Steering Swivel Pin Bearings - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Steering Cylinder and Track Rods – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Front Axle – Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Differential Crown Wheel and Pinion Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . 33
Drive Shaft - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

10
SECTION 27 - MECHANICAL REAR WHEEL DRIVE
BOOK 2 - 87046219

Chapter 1 - Rear Axle


CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rear Axle Shaft Bearing Pre-load Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Differential Bearing Pre-load Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clearances and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Maximum Rear Axle Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Final Reduction Gear Assembly (Planetary Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear Axle Shaft Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Planetary Gear Assembly and Axle Housing – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Differential and Differential Lock Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Differential Lock Control Linkage – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Drive Pinion Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Rear Axle Assembly Final Reduction Drop Trumpet (Drop Box) -- Component Overhaul 28
Manual Adjust Rear Wheels (Where Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

11
SECTION 31 - POWER TAKE-OFF
BOOK 2 - 87046219

Chapter 1 - Power Take-Off System


CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clearances and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Shim Thickness Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PTO Clutch -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PTO Shafts and Gears -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Single Speed Shafts and Gears -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Two-speed Shafts and Gears -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SECTION 33 - BRAKING SYSTEM


BOOK 2 - 87046219

Chapter 1 - Braking System


CONTENTS

Section Description Page


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disc Brake Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

12
SECTION 35 - HYDRAULIC SYSTEM
BOOK 2 - 87046219

Chapter 1 - Hydraulic Circuits


CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clearances and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic Component -- General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

SECTION 35 - HYDRAULIC SYSTEM


BOOK 2 - 87046219

Chapter 2 - Hydraulic Pumps


CONTENTS

Section Description Page


Fixed Displacement Transmission Mounted (Tandem Gear) Type Pump . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fixed Displacement Engine Mounted (Single Gear) Type Pump . . . . . . . . . . . . . . . . . . . . . . 11
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

13
SECTION 35 - HYDRAULIC SYSTEM
BOOK 2 - 87046219

Chapter 3 - Remote Control Circuit


CONTENTS

Section Description Page


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Remote Valve Circuit Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remote Control Valve -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Remote Control Valve Coupler -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SECTION 35 - HYDRAULIC SYSTEM


BOOK 2 - 87046219

Chapter 4 - Component Overhaul


CONTENTS

Section Description Page


Oil Cooler -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Pressure Regulating Valve -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Lift Cover -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SECTION 35 - HYDRAULIC SYSTEM


BOOK 2 - 87046219

Chapter 5 - Adjustments and Testing


CONTENTS

Section Description Page


Hydraulic Power Lift (HPL) 3-Point Internal Control Linkage Adjustments . . . . . . . . . . . . . . . 2
Main Draft Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Draft Control Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Position Control Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remote Control Valve External Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Testing Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Low-Pressure and Lubrication Circuit Pressure Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Remote Valve Detent Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

14
SECTION 41 - STEERING SYSTEM
BOOK 2 - 87046219

Chapter 1 - Hydrostatic Steering System


CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION 41 - STEERING SYSTEM


BOOK 2 - 87046219

Chapter 2 - Component Overhaul


CONTENTS

Section Description Page


Steering Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Steering Column Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Steering Cylinder – Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Steering Cylinder – Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Flow Control Valve -- Power Steering Pump (Where Installed) . . . . . . . . . . . . . . . . . . . . . . 25
Transmission Mounted Tandem Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Steering System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

15
SECTION 44 - FRONT AXLE--TWO WHEEL DRIVE
BOOK 2 - 87046219

Chapter 1 - Two Wheel Drive


CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clearances and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Front Axle Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Shim Thickness Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Track Width Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wheel Hub and Bearing - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wheel Spindle - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front Axle Center Beam - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION 55 - ELECTRICAL SYSTEMS


BOOK 2 - 87046219

Chapter 1 - Electrical System and Components


CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Instrument Panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical Components -- Operation and Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

16
SECTION 55 - ELECTRICAL SYSTEMS
BOOK 2 - 87046219

Chapter 2 - Alternator and Charging System


CONTENTS

Section Description Page


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Alternator -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Alternator -- Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 55 - ELECTRICAL SYSTEMS


BOOK 2 - 87046219

Chapter 3 - Starting Motor and System


CONTENTS

Section Description Page


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Starting System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Starting System Circuit Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Starting Motor -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 55 - ELECTRICAL SYSTEMS


BOOK 2 - 87046219

Chapter 4 - Battery, Servicing and Testing


CONTENTS

Section Description Page


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inspection and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

17
18
SECTION 00 -- GENERAL -- CHAPTER 1

GENERAL INSTRUCTIONS

IMPORTANT NOTICE
All maintenance and repair operations described in this manual should be carried out exclusively by New Holland
authorised workshops. All instructions should be carefully observed and special equipment where indicated
should be used.
Anyone who carries out service operations described without carefully observing these prescriptions will be
directly responsible for any damage caused.

NOTES FOR EQUIPMENT


Equipment which NEW HOLLAND proposes and shows in this manual is:

-- studied and designed expressly for use on NEW HOLLAND tractors;


-- necessary to make a reliable repair;
-- accurately built and strictly tested to offer efficient and long--lasting working life.

NOTICES
The words “front”, “rear”, “right hand”, and “left hand” refer to the different parts as seen from the operator’s seat
oriented to the normal direction of movement of the tractor.

00-1
SECTION 00 -- GENERAL -- CHAPTER 1

HEALTH AND SAFETY

CONTENTS

Description Page
HEALTH AND SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ACIDS AND ALKALIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADHESIVES AND SEALERS -- see Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ANTIFREEZE -- see Fire, Solvents e.g. Isopropanol, Ethylene Glycol, Methanol. . . . . . . . . . . . . . . . . . . . . . . 3
ARC WELDING -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY ACIDS -- see Acids and Alkalis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRAZING -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHEMICAL MATERIALS -- GENERAL -- see Legal Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DO’S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DO NOTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CORROSION PROTECTION MATERIALS -- see Solvents, Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DUSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRIC SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EXHAUST FUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FIBRE INSULATION -- see Dusts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FIRE -- see Welding, Foams, Legal Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FOAMS -- Polyurethane -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUELS -- see Fire, Legal Aspects, Chemicals -- General, Solvents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GAS CYLINDERS -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL WORKSHOP TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LEGAL ASPECTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LUBRICANTS AND GREASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PAINTS -- see Solvents and Chemical Materials -- General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SOLDER -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SOLVENTS -- see Chemical Materials -- General Fuels (Kerosene), Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SUSPENDED LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WELDING -- see Fire, Electric Shock, Gas Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

HEALTH AND SAFETY PRECAUTIONS precautions necessary to avoid these hazards are
Many of the procedures associated with vehicle identified.
maintenance and repair involve physical hazards or
The list is not exhaustive and all operations and
other risks to health. This section lists, alphabeti-
procedures and the handling of materials, should be
cally, some of these hazardous operations and the
carried out with health and safety in mind.
materials and equipment associated with them. The

00-2
SECTION 00 -- GENERAL -- CHAPTER 1

ACIDS AND ALKALIS -- see Battery acids, e.g. Provide adequate ventilation and avoid skin and eye
caustic soda, sulfuric acid. contact. Follow manufacturers instructions.
Used in batteries and cleaning materials.
Anaerobic, Cyanoacrylate and other Acrylic
Irritant and corrosive to the skin, eyes, nose and Adhesives
throat. Causes burns.
Many are irritant, sensitizing or harmful to the skin.
Some are eye irritants.
Avoid splashes to the skin, eyes and clothing. Wear
suitable protective gloves and goggles. Can destroy
Skin and eye contact should be avoided and the
ordinary protective clothing. Do not breathe mists.
manufacturers instructions followed.
Ensure access to water and soap is readily available
Cyanoacrylate adhesives (super--glues) must not
for splashing accidents.
contact the skin or eyes. If skin or eye tissue is
bonded cover with a clean moist pad and get medical
ADHESIVES AND SEALERS -- see Fire attention. do not attempt to pull tissue apart. Use in
well ventilated areas as vapours can cause irritation
Highly Flammable, Flammable, combustible. of the nose and eyes.
Generally should be stored in “No Smoking” areas; For two--pack systems see Resin based adhesives/
cleanliness and tidiness in use should be observed, sealers.
e.g. disposable paper covering benches; should be
dispensed from applicators where possible; contain-
ers, including secondary containers, should be Isocyanate (Polyurethane) Adhesives/
labelled. Sealers -- see Resin based Adhesives.
Individuals suffering from asthma or respiratory
Solvent based Adhesives/Sealers -- See Solvents. allergies should not work with or near these materials
as sensitivity reactions can occur.
Follow manufacturers instructions.
Any spraying should preferably be carried out in
Water based Adhesives/Sealers
exhaust ventilated booths removing vapours and
Those based on polymer emulsions and rubber spray droplets from the breathing zone. Individuals
lattices may contain small amounts of volatile toxic working with spray applications should wear
and harmful chemicals. Skin and eye contact should supplied air respirators.
be avoided and adequate ventilation provided during
use. ANTIFREEZE -- see Fire, Solvents e.g.
Isopropanol, Ethylene Glycol, Methanol.
Follow manufacturers instructions.
Highly Flammable, Flammable, Combustible.
Resin based Adhesives/Sealers -- e.g. epoxide
and formaldehyde resin based. Used in vehicle coolant systems, brake air pressure
systems, screenwash solutions.
Mixing should only be carried out in well ventilated
areas as harmful or toxic volatile chemicals may be Vapours given off from coolant antifreeze (glycol)
released. arise only when heated.

Skin contact with uncured resins and hardeners can Antifreeze may be absorbed through the skin in toxic
result in irritation; dermatitis and absorption of toxic or harmful quantities. Antifreeze if swallowed is fatal
or harmful chemicals through the skin. Splashes can and medical attention must be found immediately.
damage the eyes.

00-3
SECTION 00 -- GENERAL -- CHAPTER 1

ARC WELDING -- see Welding. The effects of excessive exposure to chemicals may
be immediate or delayed; briefly experienced or
BATTERY ACIDS -- see Acids and Alkalis. permanent; cumulative; superficial; life threatening;
or may reduce life--expectancy.
Gases released during charging are explosive.
Never use naked flames or allow sparks near
charging or recently charged batteries. DO’S
Do remove chemical materials from the skin and
BRAKE AND CLUTCH FLUIDS clothing as soon as practicable after soiling. Change
(Polyalkylene Glycols) -- see Fire. heavily soiled clothing and have it cleaned.
Combustible. Do carefully read and observe hazard and
precaution warnings given on material containers
Splashes to the skin and eyes are slightly irritating. (labels) and in any accompanying leaflets, poster or
Avoid skin and eye contact as far as possible. other instructions. Material health and safety data
Inhalation of vapour hazards do not arise at ambient sheets can be obtained from Manufacturers.
temperatures because of the very low vapour
pressure. Do organise work practices and protective clothing to
avoid soiling of the skin and eyes; breathing
BRAZING -- see Welding. vapours/aerosols/dusts/fumes; inadequate contain-
er labelling; fire and explosion hazards.
CHEMICAL MATERIALS -- GENERAL -- see Do wash before job breaks; before eating, smoking,
Legal Aspects. drinking or using toilet facilities when handling
Chemical materials such as solvents, sealers, chemical materials.
adhesives, paints, resin foams, battery acids,
antifreeze, brake fluids, oils and grease should Do keep work areas clean, uncluttered and free of
always be used with caution and stored and handled spills.
with care. They may be toxic, harmful, corrosive,
Do store according to national and local regulations.
irritant or highly inflammable and give rise to
hazardous fumes and dusts.
Do keep chemical materials out of reach of children.

00-4
SECTION 00 -- GENERAL -- CHAPTER 1

DO NOTS Cutting -- see Welding.


Do Not mix chemical materials except under the De--Waxing -- see Solvents and Fuels (Kerosene).
manufacturers instructions; some chemicals can
form other toxic or harmful chemicals; give off toxic
or harmful fumes; be explosive when mixed together. DUSTS
Powder, dusts or clouds may be irritant, harmful or
Do Not spray chemical materials, particularly those
toxic. Avoid breathing dusts from powdery chemical
based on solvents, in confined spaces e.g. when
materials or those arising from dry abrasion
people are inside a vehicle.
operations. Wear respiratory protection if ventilation
Do Not apply heat or flame to chemical materials is inadequate.
except under the manufacturers’ instructions. Some
are highly inflammable and some may release toxic ELECTRIC SHOCK
or harmful fumes.
Electric shocks can result from the use of faulty
Do Not leave containers open. Fumes given off can electrical equipment or from the misuse of equipment
build up to toxic, harmful or explosive concentrations. even in good condition.
Some fumes are heavier than air and will accumulate
in confined areas, pits etc. Ensure that electrical equipment is maintained in
good condition and frequently tested.
Do Not transfer chemical materials to unlabelled
containers. Ensure that flexes, cables, plugs and sockets are not
frayed, kinked, cut, cracked or otherwise damaged.
Do Not clean hands or clothing with chemical
materials. Chemicals, particularly solvents and fuels Ensure that electric equipment is protected by the
will dry the skin and may cause irritation with correct rated fuse.
dermatitis. Some can be absorbed through the skin
Never misuse electrical equipment and never use
in toxic or harmful quantities.
equipment which is in any way faulty. The results
Do Not use emptied containers for other materials, could be fatal.
except when they have been cleaned under
Use reduced voltage equipment (110 volt) for
supervised conditions.
inspection and working lights where possible.
Do Not sniff or smell chemical materials. Brief
Ensure that the cables of mobile electrical equipment
exposure to high concentrations of fumes can be
cannot get trapped and damaged, such as in a
toxic or harmful.
vehicle hoist.
Clutch Fluids -- see Brake and Clutch Fluids.
Use air operated mobile equipment where possible
Clutch Linings and Pads -- see Brake and Clutch in preference to electrical equipment.
Linings and Pads.
In cases of electrocution:--

CORROSION PROTECTION MATERIALS -- -- switch off electricity before approaching victim


see Solvents, Fire.
-- if this is not possible, push or drag victim from
Highly flammable, flammable. source of electricity using dry non--conductive
material
These materials are varied and the manufacturers
instructions should be followed. They may contain -- commence resuscitation if trained to do so
solvents, resins, petroleum products etc. Skin and
eye contact should be avoided. They should only be -- SUMMON MEDICAL ASSISTANCE
sprayed in conditions of adequate ventilation and not
in confined spaces.

00-5
SECTION 00 -- GENERAL -- CHAPTER 1

EXHAUST FUMES Splashes in the eye should be flushed with clean


water for at least ten minutes.
These contain asphyxiating, harmful and toxic
chemicals and particles such as carbon oxides, Soiled skin should be washed with soap and water.
nitrogen oxides, aldehydes, lead and aromatic
hydrocarbons. Engines should only be run under Inhalation affected individuals should be removed to
conditions of adequate extraction or general fresh air immediately.
ventilation and not in confined spaces.
If swallowed or if effects persist consult a doctor with
Gasolene (Petrol) Engine information (label) on material used.
There may not be adequate warning properties of Do not induce vomiting (unless indicated by
odour or irritation before immediate and delayed manufacturer).
toxic or harmful effects arise.

Diesel Engine FOAMS -- Polyurethane -- see Fire.


Used in sound and noise insulation. Cured foams
Soot, discomfort and irritation usually give adequate
used in seat and trim cushioning.
warning of hazardous fume concentrations.
Follow manufacturers instructions.
FIBRE INSULATION -- see Dusts.
Unreacted components are irritating and may be
Used in noise and sound insulation. harmful to the skin and eyes. Wear gloves and
goggles.
The fibrous nature of surfaces and cut edges can
cause skin irritation. This is usually a physical and Individuals with chronic respiratory diseases,
not a chemical effect. asthma, bronchial medical problems or histories of
allergic diseases should not work with or near
Precautions should be taken to avoid excessive skin uncured materials.
contact through careful organisation of work
practices and the use of gloves. The components, vapours, spray mists can cause
direct irritation, sensitivity reactions and may be toxic
FIRE -- see Welding, Foams, Legal Aspects. or harmful.

Many of the materials found on or associated with the Vapours and spray mists must not be breathed.
repair of vehicles are highly flammable. Some give These materials must be applied with adequate
off toxic or harmful fumes if burnt. ventilation and respiratory protection. Do not remove
respirator immediately after spraying, wait until
Observe strict fire safety when storing and handling vapour/ mists have cleared.
flammable materials or solvents, particularly near
electrical equipment or welding processes. Burning of the uncured components and the cured
foams can generate toxic and harmful fumes.
Ensure before using electrical or welding equipment
but that there is no fire hazard present. Smoking, open flames or the use of electrical
equipment during foaming operations and until
Have a suitable fire extinguisher available when vapours/mists have cleared should not be allowed.
using welding or heating equipment. Any heat cutting of cured foams or partially cured
foams should be conducted with extraction ventila-
tion (see Body Section 44 Legal and Safety Aspects).
FIRST AID
Apart form meeting any legal requirements it is
desirable for someone in the workshop to be trained
in first aid procedures.

00-6
SECTION 00 -- GENERAL -- CHAPTER 1
FUELS -- see Fire, Legal Aspects, Chemicals -- if liquid aspiration into the lungs occurs. Liquid
General, Solvents. contact dries the skin and can cause irritation or
dermatitis. Splashes in the eye may be slightly
Used as fuels and cleaning agents. irritating.

Gasolene (Petrol). In normal circumstances the low volatility does not


give rise to harmful vapours. Exposure to mists and
Highly flammable. vapours from kerosene at elevated temperatures
should be avoided (mists may arise in de--waxing).
Swallowing can result in mouth and throat irritation Avoid skin and eye contact and ensure there is
and absorption from the stomach can result in adequate ventilation.
drowsiness and unconsciousness. Small amounts
can be fatal to children. Aspiration of liquid into the Gas--Oil (Diesel Fuel) -- see Fuels (Kerosene).
lungs, e.g. through vomiting, is a very serious
hazard. Combustible.

Gasolene dries the skin and can cause irritation and Gross or prolonged skin contact with high boiling gas
dermatitis on prolonged or repeated contact. Liquid oils may also cause serious skin disorders including
in the eye causes severe smarting. skin cancer.

Motor gasolene may contain appreciable quantities


of benzene, which is toxic upon inhalation and the GAS CYLINDERS -- see Fire.
concentrations of gasolene vapours must be kept
very low. High concentrations will cause eye, nose Gases such as oxygen, acetylene, carbon dioxide,
and throat irritation, nausea, headache, depression argon and propane are normally stored in cylinders
and symptoms of drunkeness. Very high concentra- at pressures of up to 2000 lb/sq. in. (13,790 kn/m2)
tions will result in rapid loss of consciousness. and great care should be taken in handling these
cylinders to avoid mechanical damage to them or to
Ensure there is adequate ventilation when handling the valve gear attached. The contents of each
and using gasolene. Great care must be taken to cylinder should be clearly identified by appropriate
avoid the serious consequences of inhalation in the markings.
event of vapour build up arising from spillages in
confined spaces. Cylinders should be stored in well ventilated
enclosures, and protected from ice and snow, or
Special precautions apply to cleaning and mainte- direct sunlight. Fuel gases (e.g. acetylene and
nance operations on gasolene storage tanks. propane) should not be stored in close proximity to
oxygen cylinders.
Gasolene should not be used as a cleaning agent.
It must not be siphoned by mouth. Care should be exercised to prevent leaks from gas
cylinders and lines, and to avoid sources of ignition.
Kerosene (Paraffin)
Only trained personnel should undertake work
Used also as heating fuel, solvent and cleaning
involving gas cylinders.
agent.
Gases -- see Gas Cylinders.
Flammable.
Gas Shielded Welding -- see Welding.
Irritation of the mouth and throat may result from
swallowing. The main hazard from swallowing arises Gas Welding -- see Welding.

00-7
SECTION 00 -- GENERAL -- CHAPTER 1

GENERAL WORKSHOP TOOLS AND • The Asbestos Regulations (1969).


EQUIPMENT
• Highly Flammable Liquids and Liquified Petro-
It is essential that all tools and equipment are
leum Gases Regulations (1972).
maintained in good condition and the correct safety
equipment used where required.
• Deposit of Poisonous Waste Act (1972).
Never use tools or equipment for any purpose other
than that for which they were designed. • Control of Pollution Act (1974).

Never overload equipment such as hoists, jacks, • Health and Safety at Work Act (1974).
axle and chassis stands or lifting slings. Damage
caused by overloading is not always immediately • The Packaging and Labelling of Dangerous
apparent and may result in a fatal failure the next time Substances Regulations (1978).
that the equipment is used.
• Control of Lead Regulations (1981).
Do not use damaged or defective tools or equipment,
particularly high speed equipment such as grinding
wheels. A damaged grinding wheel can disintegrate
Workshops should be familiar, in detail, with these
without warning and cause serious injury. and associated laws and regulations. Consult local
factory inspectorate if in any doubt.
Wear suitable eye protection when using grinding,
chiselling or sand blasting equipment.
LUBRICANTS AND GREASES
Wear a suitable breathing mask when using sand Avoid all prolonged and repeated contact with
blasting equipment, working with asbestos based mineral oils, especially used oils. Used oils
materials or using spraying equipment. contaminated during service (e.g. routine service
change sump oils) are more irritating and more likely
Glues -- see Adhesives and Sealers.
to cause serious effects including skin cancer in the
High Pressure Air, Lubrication and Oil Test event of gross and prolonged skin contact.
Equipment -- see Lubricants and Greases.
Wash skin thoroughly after work involving oil.
Always keep high pressure equipment in good Proprietary hand cleaners may be of value provided
condition and regularly maintained, particularly at they can be removed from the skin with water. Do not
joints and unions. use petrol, paraffin or other solvents to remove oil
from the skin.
Never direct a high pressure nozzle at the skin as the
fluid may penetrate to the underlying tissue etc. and Lubricants and greases may be slightly irritating to
cause serious injury. the eyes.

Repeated or prolonged skin contact should be


LEGAL ASPECTS avoided by wearing protective clothing if necessary.
Many laws and regulations make requirements Particular care should be taken with used oils and
relating to health and safety in the use of materials greases containing lead. Do not allow work clothing
and equipment in workshops. Some of these laws to be contaminated with oil. Dry clean or launder such
which apply in the U.K. are listed. Similar laws exist clothing at regular intervals. Discard oil soaked
for other territories:-- shoes.

• The Factories Act (1961).

00-8
SECTION 00 -- GENERAL -- CHAPTER 1
Do not employ used engine oils as lubricants or for Those doing small scale repair work in the open shop
any application where appreciable skin contact is should wear supplied air respirators.
likely to occur. Used oils may only be disposed of in
accordance with local regulations, e.g. in the U.K., Paint Thinners -- see Solvents.
the Control of Pollution Act.
Petrol -- see Fuels (Gasolene).
There are publications describing the problems and
advising on precautionary measures. For the U.K. Pressurised Equipment -- see High Pressure Air,
these include: Lubrication and Oil Test Equipment.

SHW 295: Effects of mineral oil on the Resistance Welding -- see Welding.
skin
SHW 295A: Cancer of the skin caused by Sealers -- see Adhesives and Sealers.
oil
SHW 397: Cautionary notice: Effects of
mineral oil on the skin SOLDER -- see Welding.

Noise Insulation Materials -- see Foams, Fibre Solders are mixtures of metals such that the melting
Insulation. point of the mixture is below that of the constituent
metals (normally lead and tin). Solder application
PAINTS -- see Solvents and Chemical Materials -- does not normally give rise to toxic lead fumes,
General. provided a gas/air flame is used. Oxy--acetylene
flames should not be used, as they are much hotter
Highly Flammable, Flammable. and will cause lead fumes to be evolved.

One Pack. Can contain harmful or toxic pigments, Some fumes may be produced by the application of
driers and other components as well as solvents. any flame to surfaces coated with grease etc. and
Spraying should only be carried out with adequate inhalation of these should be avoided.
ventilation.
Removal of excess solder should be undertaken with
Two Pack. Can also contain harmful and toxic care, to ensure that fine lead dust is not produced,
unreacted resins and resin hardening agents. The which can give toxic effects if inhaled. Respiratory
manufacturers instructions should be followed and protection may be necessary.
the section of page 05--2 on resin based adhesives,
isocyanate containing Adhesives and Foams should Solder spillage and filing should be collected and
be consulted. removed promptly to prevent general air contamina-
tion by lead.
Spraying should preferably be carried out in
exhausted ventilated booths removing vapour and High standards of personal hygiene are necessary in
spray mists from the breathing zone. Individuals order to avoid indigestion of lead or inhalation of
working in booths should wear respiratory protection. solder dust from clothing.

00-9
SECTION 00 -- GENERAL -- CHAPTER 1
SOLVENTS -- see Chemical Materials -- General When the spraying material contains solvents, e.g.
Fuels (Kerosene), Fire. paints, adhesives, coatings, use extraction ventila-
tion or personal respiratory protection in the absence
e.g. Acetone, white spirit, toluene, xylene, of adequate general ventilation.
trichlorethane.
Do not apply heat or flame except under specific and
Used in cleaning materials, de--waxing, paints, detailed manufacturers instructions.
plastics, resins, thinners etc.
Sound Insulation -- see Fibre Insulation, Foams.
Highly Inflammable, Flammable.
Spot Welding -- see Welding.
Skin contact will degrease the skin and may result in
irritation and dematitis following repeated or
prolonged contact. Some can be absorbed through SUSPENDED LOADS.
the skin in toxic or harmful quantities. There is always a danger when loads are lifted or
suspended. Never work under an unsupported
Splashes in the eye may cause severe irritation and suspended or raised load, e.g. jacked up vehicle,
could lead to loss of vision. suspended engine, etc.
Brief exposure to high concentrations of vapours or Always ensure that lifting equipment such as jacks,
mists will cause eye and throat irritation, drowziness, hoists, axle stands, slings, etc. are adequate and
dizziness, headaches and in the worst circum- suitable for the job, in good condition and regularly
stances, unconsciousness. maintained.
Repeated or prolonged exposures to excessive but Never improvise lifting tackle.
lower concentrations of vapours or mists, for which
there might not be adequate warning indications, can Underseal -- see Corrosion Protection.
cause more serious toxic or harmful effects.
WELDING -- see Fire, Electric Shock, Gas Cylinders.
Aspiration into the lungs (e.g. through vomiting) is the
most serious consequence of swallowing. Welding processes include Resistance Welding
(Spot Welding), Arc Welding and Gas Welding.
Avoid splashes to the skin, eyes and clothing. Wear
protective gloves, goggles and clothing if necessary. Resistance Welding

Ensure good ventilation when in use, avoid breathing This process may cause particles of molten metal to
fumes, vapours and spray mists and keep containers be emitted at high velocity and the eyes and skin
tightly sealed. Do not use in confined spaces. must be protected.

00-10
SECTION 00 -- GENERAL -- CHAPTER 1
Arc Welding The process will produce metal spatter and eye and
skin protection is necessary.
This process emits a high level of ultraviolet radiation
which may cause eye and skin burns to the welder The flame is bright and eye protection should be
and to other persons nearby. Gas--shielded welding used, but the ultra--violet emission is much less than
processes are particularly hazardous in this respect. that from arc welding, and lighter filters may be used.
Personal protection must be worn, and screens used
to shield other people. The process itself produces few toxic fumes, but
such fumes and gases may be produced from
Metal spatter will also occur and appropriate eye and coatings on the work, particularly during cutting away
skin protection is necessary. of damaged body parts and inhalation of the fumes
should be avoided.
The heat of the welding arc will produce fumes and
gases from the metals being welded and from any In brazing, toxic fumes may be evolved from the
applied coatings or contamination on the surfaces metals in the brazing rod, and a severe hazard may
being worked on. These gases and fumes may be arise if brazing rods containing cadmium are used.
toxic and inhalation should always be avoided. The In this event particular care must be taken to avoid
use of extraction ventilation to remove the fumes inhalation of fumes and expert advice may be
from the working area may be necessary, particularly required.
in cases where the general ventilation is poor, or
where considerable welding work is anticipated. In SPECIAL PRECAUTIONS MUST BE TAKEN
extreme cases where adequate ventilation cannot be BEFORE ANY WELDING OR CUTTING TAKES
provided, supplied air respirators may be necessary. PLACE ON VESSELS WHICH HAVE CONTAINED
COMBUSTIBLE MATERIALS, E.G. BOILING OR
Gas Welding STEAMING OUT OF FUEL TANKS.

Oxy--acetylene torches may be used for welding and White Spirit -- see Solvents.
cutting and special care must be taken to prevent
leakage of these gases, with consequent risk of fire
and explosion.

00-11
SECTION 00 -- GENERAL -- CHAPTER 1

FEDERAL EMISSIONS WARRANTY


(North America Only)
(California owner’s emissions warranty is covered elsewhere)
New Holland warrants that your new 1996 and later heavy-duty off-road diesel engine was designed, built, and equipped to conform to
applicable U.S. Environmental Protection Agency regulations for a period of use of five years or 3,000 hours of operation, whichever occurs
first.
The new model year, class of diesel engine, and emission application determination for your engine are identified on the emission control
information label affixed to the top of your engine’s rocker arm cover. The warranty period begins on the date the new equipment is sold to the
first retail purchaser.
Any emission control system parts which are proven defective during normal use will be repaired or replaced during the warranty period. The
warranty repairs and service will be performed by any authorized New Holland dealer at the dealer’s place of business, with no charge for parts
or labor (including diagnosis).
As the engine owner, you are responsible to perform all the required maintenance listed in your owner’s manual. New Holland will not deny an
emission warranty claim solely because you have no record of maintenance; however, a claim may be denied if your failure to perform
maintenance resulted in the failure of a warranted part. Receipts covering regular maintenance should be retained in the event of questions
and these receipts should be passed on to each subsequent owner of the engine.
It is recommended replacement parts used for maintenance or repairs be New Holland Service Parts to maintain the quality originally
designed into your emission certified engine. The use of non-New Holland parts does not invalidate the warranty on other components unless
the use of such parts causes damage to warranted parts.
New Holland wishes to assure the emission control systems warranty is being properly administered. If you believe you have not received the
service entitled to under this warranty, you should contact the nearest New Holland Branch Office for assistance.
Service Department
New Holland North America, Inc.
500 Diller Avenue
New Holland, PA 17557
(717) 355-1121
Please note that the Emission Warranty does not cover:
1. Systems and parts that were not first installed on the new equipment or engine as original equipment by New Holland.
2. Part malfunctions caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or
inadequate maintenance, or use of non-recommended fuels and lubricating oils.
3. Accident caused damage, acts of nature, or other events beyond New Holland’s control.
4. Replacement of expendable items made in connection with scheduled maintenance.
5. Parts requiring replacement, inspection or adjustment maintenance intervals for reasons other than being defective.
6. Parts which are not New Holland Service Parts.
7. Loss of time, inconvenience, loss of use of equipment/engine or commercial loss.
8. Equipment with altered or disconnected hourmeter where the hours cannot be determined.
9. Equipment normally operated outside the United States.
10. Non-defective parts replaced by other than New Holland dealers.
Coverage
This emission control system warranty applies to the following emission control parts.
Fuel Injection Pump
Fuel Injectors
Turbocharger
Intake Manifold
Exhaust Manifold
Boost Pressure Tubing-connection to Aneroid Device ON F.I.P.

00-12
SECTION 00 -- GENERAL -- CHAPTER 1

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT


(North America Only)
(California Only)
Your Warranty Rights and Obligations
The California Air Resources Board and New Holland are pleased to explain the emission control system warranty on your engine. In California,
new 1997 and later heavy-duty off-road engines from 100 to 150 HP must be designed, built, and equipped to meet the State’s stringent
anti-smog standards. New Holland must warrant the emission control system on your engine for the periods of time listed below, provided there
has been no abuse, neglect, or improper maintenance of your engine.
Your emission control system includes parts such as the fuel injection system and the air induction system.
Where a warrantable condition exists, New Holland will repair your heavy-duty off-road engine at no cost to you, including diagnosis, parts, and labor.
Manufacturer’s Warranty Coverage:
The 1997 and later heavy-duty off-road engines are warranted from the original date of delivery for five years or 3,000 hours of operation,
whichever occurs first. If any emission-related part on your engine is defective, the part will be repaired or replaced by New Holland.
Owner’s Warranty Responsibilities:
D As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance listed in your owner’s
manual. New Holland recommends that you retain all receipts covering maintenance on your heavy-duty off-road engine, but New
Holland cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
D As the heavy-duty off-road engine owner, you should, however, be aware that New Holland may deny you warranty coverage if your
heavy-duty off-road engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.
D Your engine is designed to operate on commercially available diesel fuel only. Use of any other fuel may result in your engine no longer
operating in compliance with California’s emissions requirements.
D You are responsible for initiating the warranty process. The ARB suggests that you present your heavy-duty off-road engine to a New
Holland dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible.
If you have questions regarding your warranty rights and responsibilities, you should contact your Branch Office at the address and phone
number listed on the Owner Assistance page of your equipments operator manual.
D Prior to the expiration of the warranty, you must give notice of any failure of an emission control warranted part. Such notice must be given
to New Holland or an authorized dealer, and you must deliver the engine to the repair location.
D You, the owner, are responsible for incidental costs incurred by yourself or your employees as a result of a warrantable failure. Examples
of such costs are communication expenses, meals and lodging.
D The owner is responsible for any business costs or losses, any “downtime” expenses and any “cargo” damage which result from the
failure of a warranted part. New Holland is not responsible for other incidental or consequential damages, including but not limited to fines,
theft, vandalism or collisions.
Parts covered:
This emission control system warranty applies to the following emission control parts.
Fuel Injection Pump
Fuel Injectors
Turbocharger
Intake Manifold
Exhaust Manifold
Boost Pressure Tubing-connection to Aneroid Device ON F.I.P.
Any replacement part, equivalent in performance and durability, may be used in the performance of any maintenance or repairs and must be
provided without charge to the owner. The use of these parts does not reduce the warranty obligations of New Holland. However, New Holland
recommends the use of new, genuine New Holland service parts or New Holland approved rebuilt parts and assemblies. New Holland also
recommends that the engine be serviced by a New Holland authorized dealer.
New Holland Responsibilities
Warranty work will be provided at no charge to the owner at any authorized dealer, using new genuine New Holland service parts or New
Holland approved rebuilt parts or assemblies..
The owner will not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work was
performed at a warranty station.
New Holland is liable for damages to other engine components caused by the failure under warranty of any warranted part.
Warranty Limitations
New Holland is not responsible for failures resulting from abuse or neglect by owner or operator.
New Holland warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built, and equipped so as to
conform with all applicable regulations adopted by the Air Resources Board, and that it is free from defects in materials and workmanship which
cause the failure of a warranted part.
Any warranted part which is not scheduled for replacement as required maintenance, or which is scheduled only for regular inspection to the
effect of “repair or replace as necessary” is warranted for the warranty period.
Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of time prior to the first scheduled
replacement point for that part.
New Holland is liable for damages to other engine components caused by the failure under warranty of any warranted part.

00-13
SECTION 00 -- GENERAL -- CHAPTER 1

CALIFORNIA
Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known


to the State of California to cause cancer, birth defects, and
other reproductive harm.

Battery posts, terminals and related accessories contain lead


and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.

00-14
SECTION 00 -- GENERAL -- CHAPTER 1

PRECAUTIONARY
STATEMENTS
PERSONAL SAFETY
Throughout this manual and on machine decals, you will find precautionary statements (“DANGER”,
“WARNING”, and “CAUTION”) followed by specific instructions. These precautions are intended for the personal
safety of you and those working with you. Please take the time to read them.

DANGER
This word “DANGER” indicates an immediate hazardous situation that, if not avoided, will result in death
or serious injury. The color associated with Danger is RED.

WARNING
This word “WARNING” indicates a potentially hazardous situation that, if not avoided, could result in
death or serious injury. The color associated with Warning is ORANGE.

CAUTION
This word “CAUTION” indicates a potentially hazardous situation that, if not avoided, may result in minor
or moderate injury. It may also be used to alert against unsafe practices. The color associated with
Caution is YELLOW.

FAILURE TO FOLLOW THE “DANGER”, “WARNING”, AND “CAUTION” INSTRUCTIONS MAY RESULT IN
SERIOUS BODILY INJURY OR DEATH.

MACHINE SAFETY
The precautionary statement (“IMPORTANT”) is followed by specific instructions. This statement is intended for
machine safety.

IMPORTANT: The word “IMPORTANT” is used to inform the reader of something he needs to know to prevent
minor machine damage if a certain procedure is not followed.

INFORMATION
NOTE: Instructions used to identify and present supplementary information.

00-15
SECTION 00 -- GENERAL -- CHAPTER 1

SAFETY
PRECAUTIONARY STATEMENTS
A careful operator is the best operator. Most accidents can be avoided by observing certain precautions. To help
prevent accidents, read the following precautions before operating this equipment. Equipment should be
operated only by those who are responsible and instructed to do so.

Carefully review the procedures given in this manual with all operators. It is important that all operators be familiar
with and follow safety precautions.

THE TRACTOR 5. Use extreme caution and avoid hard application


of the tractor brakes when towing heavy loads at
1. Read the Operator’s Manual carefully before road speeds.
using the tractor. Lack of operating knowledge
can lead to accidents. 6. Any towed vehicle whose total weight exceeds
that of the towing tractor must be equipped with
2. Only allow properly trained and qualified persons brakes for safe operation.
to operate the tractor.
7. Never apply the differential lock when turning.
3. To prevent falls, use the handrails and step plates When engaged, the differential lock will prevent
when getting on and off the tractor. Keep steps the tractor from turning.
and platform clear of mud and debris.
8. Always check overhead clearance, specifically
4. Do not permit anyone but the operator to ride on when transporting the tractor. Watch where you
the tractor unless a passenger seat is fitted. are going, especially at low overhanging
There is no safe place for extra riders otherwise. obstacles.
5. Replace all missing, illegible or damaged safety 9. Use extreme caution when operating on steep
decals. slopes.
6. Keep safety decals free of dirt or grime. 10. To avoid overturns, drive the tractor with care and
7. Do not modify or alter or permit anyone else to at speeds compatible with safety, especially
modify or alter the tractor or any of its when operating over rough ground, when
components or any tractor function without first crossing ditches or slopes and when turning
consulting your dealer. overturning.
8. Tractor wheels are very heavy. Handle with care 11. If the tractor becomes stuck or the tires are frozen
and ensure, when stored, that they cannot fall. to the ground, reverse the tractor out to prevent
corners.
DRIVING THE TRACTOR
12. Keep the tractor in the same gear when going
1. Always sit in the drivers seat while starting or downhill as would be used when going uphill. Do
driving the tractor. not coast or freewheel down hills.
2. When driving on public roads, have considera- OPERATING THE TRACTOR
tion for other road users. Pull in to the side of the
road occasionally to allow any following traffic to 1. Apply the parking brake, place the PTO control in
pass. Do not exceed the legal speed limit set in the ‘OFF’ position, the lift control lever in the
your area. down position, the remote control valve levers in
the neutral position and the transmission lever in
3. Use low beam lights when meeting a vehicle at neutral before starting the tractor.
night. Make sure the lights are adjusted to
prevent blinding the drive of an oncoming vehicle 2. Do not start the engine or operate controls while
standing beside the tractor. Always sit in the
4. Reduce speed before turning or applying the tractor seat when starting the engine or operating
brakes. Ensure that both brake pedals are locked
the controls.
together when traveling at road speeds or when
on public roads. Brake both wheels simulta-
neously when making an emergency stop.

00-16
SECTION 00 -- GENERAL -- CHAPTER 1
3. Do not bypass the neutral start switches. Consult a hazard both to the operator and to bystanders.
your authorized dealer if your neutral start Do not overload or operate with attached
controls malfunction. Use jump cables only in the equipment which is unsafe, not designed for the
recommended manner. Improper use can result particular task or is poorly maintained.
in a tractor runaway.
19. The tractor is designed to provide the minimum
4. Avoid accidental contact with the gear shift levers noise level at the operator’s ears and meets or
while the engine is running. Unexpected tractor exceeds applicable standards in this respect.
movement can result from such contact. However, noise (sound pressure level) in the
workplace can exceed 86 dB(A) when working
5. Do not get off the tractor while it is in motion.
between buildings or in confined spaces.
6. Shut off the engine and PTO and apply the Therefore, it is recommended that operators
parking brake before getting off the tractor. wear suitable ear protectors during vehicle
operation.
7. Do not park the tractor on a steep incline.
8. Do not run the tractor engine in an enclosed OPERATING THE PTO
building without adequate ventilation. Exhaust 1. When operating PTO driven equipment, shut off
fumes are toxic and can cause death. the engine and wait until the PTO stops before
9. Always wear a protective mask when working getting off the tractor and disconnecting the
with toxic spray chemicals. Follow the directions equipment.
on the chemical container. 2. Do not wear loose clothing when operating the
10. If the power steering or engine ceases operating, power take-off or especially when near rotating
stop the tractor immediately as the tractor will be equipment.
more difficult to control. 3. When operating stationary PTO driven equip-
11. Stop the engine and relieve pressure before ment, always apply the tractor parking brake and
connecting or disconnecting hydraulic, steering block the rear wheels front and back.
or fuel lines. 4. To avoid injury, do not clean, adjust, unclog or
12. Tighten all connections before starting the service PTO driven equipment when the tractor
engine or pressurizing lines. engine is running.
13. Pull only from the swinging drawbar or the lower 5. Make sure the PTO guard is in position at all
link drawbar in the lowered position . Use only a times and always replace the PTO cap when the
drawbar pin that locks in place. Pulling from the PTO is not in use.
tractor rear axle or any point above the axle may
cause the tractor to overturn. SERVICING THE TRACTOR
14. If the front end of the tractor tends to rise when 1. The cooling system operates under pressure
heavy implements are attached to the three- which is controlled by the radiator cap. It is
point hitch, install front end or front wheel dangerous to remove the cap while the system is
weights. Do not operate the tractor with a light hot. Always turn the cap slowly to the first stop
front end. and allow the pressure to escape before
removing the cap entirely.
15. Always select Position Control when attaching
implements and when transporting equipment. 2. Do not smoke while refueling the tractor. Keep
Be sure hydraulic couplers are properly installed any type of open flame away. Wait for the engine
and will disconnect safety in case of accidental to cool before refueling.
detachment of the implement. 3. Keep the tractor and equipment, particularly
16. Do not leave equipment in the raised position brakes and steering, maintained in a reliable and
when the vehicle is stopped or unattended. satisfactory condition to ensure your safety and
comply with legal requirements.
17. Ensure any attached equipment or accessories
are correctly installed, are approved for use with 4. To prevent fire or explosion, keep open flames
the tractor, do not overload the tractor and are away from battery or cold weather starting aids.
operated and maintained in accordance with the To prevent sparks which could cause explosion,
instructions issued by the equipment or use jumper cables according to instructions.
accessory manufacturer. 5. Stop the engine before performing any service
18. Remember that your tractor, if abused or on the tractor.
incorrectly used, can be dangerous and become

00-17
SECTION 00 -- GENERAL -- CHAPTER 1
6. Escaping diesel/hydraulic fluid under pressure 5. Do not fill the fuel tank to capacity. Allow room for
can penetrate the skin causing serious injury. expansion.
• Do not use your hand to check for leaks. Use 6. Wipe up spilled fuel immediately.
a piece of cardboard or paper to search for
7. Always tighten the fuel tank cap securely.
leaks.
• Stop the engine and relieve pressure before 8. If the original fuel tank cap is lost, replace it with
connecting or disconnecting lines. an approved cap. A non-approved cap may not
be safe.
• Tighten all connections before starting the
engine. 9. Keep equipment clean and properly maintained.
• If fluid is injected into the skin obtain medical 10. Do not drive equipment near open fires.
attention immediately.
11. Never use fuel for cleaning purposes.
7. Do not modify or alter or permit anyone else to
modify or alter the tractor or any of its 12. Arrange fuel purchases so that summer grade
components or any tractor function without first fuels are not used in the winter.
consulting an authorized dealer.
ROPS
8. The fuel oil in the injection system is under high
The tractor may be equipped with a safety frame
pressure and can penetrate the skin. Unqualified
(ROPS) which must be maintained in a serviceable
persons should not remove or attempt to adjust
condition. Be careful when driving through doorways
a pump, injector, nozzle or any other part of the
or working in confined spaces with low headroom.
injection system. Failure to follow these
instructions can result in serious injury.
1. Do not modify, drill, weld or alter the ROPS in any
9. Continuous long term contact with used engine way.
oil my cause skin cancer. Avoid prolonged
contact with used engine oil. Wash skin promptly 2. Never attempt to straighten or weld the ROPS or
with soap and water. retaining brackets, which have suffered damage.
By doing so you may weaken the structure and
DIESEL FUEL endanger your safety.
1. Under no circumstances should gasoline, 3. Do not secure any parts on the ROPS or attach
alcohol or blended fuels be added to diesel fuel. it with other than the special high tensile bolts and
These combinations can create an increased fire nuts specified.
or explosive hazard. In a closed container such 4. Never attach chains or ropes to the safety frame
as a fuel tank these blends are more explosive or roll bar for pulling purposes.
than pure gasoline. Do not use these blends.
5. Never take unnecessary risks even though your
2. Never remove the fuel cap or refuel with the safety frame or roll bar affords you the maximum
engine running or hot. protection possible.
3. Do not smoke while refueling the tractor or when 6. Whenever possible, operate with the ROPS in its
standing near fuel. Keep any type of open flame fully upright and locked position.
away. Wait for the engine to cool before refueling.
4. Maintain control of the fuel filter pipe nozzle when
filling the tank.

00-18
SECTION 00 -- GENERAL -- CHAPTER 1

IDENTIFICATION DECALS
A vehicle identification plate is located under the For convenience, the numbers shown on the plates
tractor hood. In addition, if your tractor is equipped should be recorded and given to your authorized
with optional four wheel drive, a similar plate is New Holland dealer in the event the tractor requires
affixed to the rear surface of the front axle housing. service.

Vehicle Identification Plate Front Axle Identification Plate


20024998

SAFETY DECALS
(North America Only)

The following safety decals have been placed on Keep the decals legible. If they are not, obtain
your machine in the areas indicated. They are replacements from your authorized dealer. The decal
intended for your personal safety and for those replacement part numbers are listed with each decal.
working with you. Please take this manual and walk
around your machine to note the content and location
of these warning signs.

2 3
5
6
1 4

10 11 8 7

00-19
SECTION 00 -- GENERAL -- CHAPTER 1

Lift releases or drops completely


when front raise/lower lift control
is operated.
DO NOT stand on implement or
between implement and tractor
while operating front raise/lower
lift control or injury may result.

00-20
SECTION 00 -- GENERAL -- CHAPTER 1

00-21
SECTION 00 -- GENERAL -- CHAPTER 1

ECOLOGY AND THE ENVIRONMENT


Soil, air, and water are vital factors of agriculture and 2. Avoid skin contact with all fuels, oils, acids,
life in general. When legislation does not yet rule the solvents, etc. Most of them contain substances
treatment of some of the substances which are which may be harmful to your health.
required by advanced technology, common sense
3. Modern oils contain additives. Do not burn
should govern the use and disposal of products of a
contaminated fuels and or waste oils in ordinary
chemical and petrochemical nature.
heating systems.
The following are recommendations which may be of 4. Avoid spillage when draining off used engine
assistance: coolant mixtures, engine, gearbox and hydraulic
oils, brake fluids, etc. Do not mix drained brake
• Become acquainted with and ensure that you fluids or fuels with lubricants. Store them safely
understand the relative legislation applicable to or dispose of in a proper way to comply with local
your country. legislation and available resources.
• Where no legislation exists, obtain information 5. Modern coolant mixtures, i.e. antifreeze and
from suppliers of oils, filters, batteries, fuels, other additives, should be replaced every two
antifreeze, cleaning agents, etc., with regard to years. Do not allow seepage into the soil. Collect
effect on man and nature and how to safely store, and dispose of safely.
use and dispose of these substances. Agricultur-
al consultants will, in many cases, be able to help 6. Repair any leaks or defects in the engine cooling
you as well. or hydraulic system immediately.
7. Do not increase the specified operating pressure
in a pressurized circuit as this may lead to
component failure.
PRECAUTIONS
8. Protect hoses during welding as penetrating
1. Avoid filling tanks using cans or inappropriate
weld splatter may burn or weaken the hose,
pressurized fuel delivery systems which may
allowing the loss of oils, coolant, etc.
cause considerable spillage.

00-22
SECTION 00 -- GENERAL -- CHAPTER 1

INTERNATIONAL SYMBOLS
Various universal symbols used on the instruments, controls, switches, and fuse box, are shown below with a brief
description.

Thermostart Radio P.T.O. Position


starting aid Control
Keep alive Draft
Alternator memory N Transmission Control
KAM
charge in neutral

Accessory
Turn signals Creeper socket
Fuel level gears

Turn signals Implement


Automatic --one trailer Slow or socket
Fuel shut-off low setting

Turn signals %age


--two trailers slip
Engine speed Fast or high
(rev/min x 100) setting
Front wind- Hitch raise
screen Ground (rear)
Hours recorded wash/wipe speed
Hitch lower
Rear wind- (rear)
Engine oil screen Differential
pressure wash/wipe lock
Hitch height
Heater temp- limit (rear)
Engine coolant Rear axle
erature control oil tem-
temperature
perature Hitch height
limit (front)
Heater fan
Coolant Transmission
level oil pressure Hitch dis-
Air conditioner abled

Tractor lights FWD


engaged Hydraulic and
Air filter transmission
blocked filters
Headlamp FWD dis-
main beam Parking engaged Remote
brake valve extend

Headlamp Brake fluid Remote


dipped beam level Warning!
valve retract

Work lamps Trailer Hazard Remote


brake warning lights valve float

Stop Roof Variable Malfunction!


lamps beacon control See Operator’s
Manual
Warning!
Horn Corrosive Pressurised! Malfunction! (alter-
substance Open carefully native symbol)

00-23
SECTION 00 -- GENERAL -- CHAPTER 1

FRONT TIRE PRESSURE AND PERMISSIBLE LOADS (2WD)


The following charts list the carrying capacity of the AXLE at the indicated tire pressures.

Tire Size Ply Inflation Pressure - bar


Rating
1.65 1.8 2.0 2.2 2.5 2.76 3.0 3.1 3.3 3.6 3.7
Load Capacity per AXLE – kg
7.50 X 16 6 900 998 1044 1089 1198 1261 1334 - - - -
8 900 998 1044 1089 1198 1261 1334
7.50 X 18 6 971 1089 1144 1198 1298 1379 1461 1288 1425 1497 1524
7.50 X 20 6 1062 1162 1144 1261 1379 - - - - - -
10.00 X 16 8 1425 1144 1452 1760 1896 1996 - - - - -

Tire Size Ply Inflation Pressures - PSI


Rating
24 28 30 32 36 40 44 45 48 52 54
Load Capacity per AXLE – lbs.
7.50 X 16 6 1980 2200 2300 2400 2640 2780 2940 - - - -
8 1980 2200 2300 2400 2640 2780 2940 2840 3140 3300 3360
7.50 X 18 6 2140 2400 2520 2600 2860 3040 3220 - - - -
7.50 X 20 6 2340 2560 2670 2780 3040 - - - - - -
10.00 X 16 8 3140 2520 3200 3380 4180 4400 - - - - -

The above charts are for tractors operated at speeds damaged tires, always install tires of the same make,
up to 19 MPH (30 Km/h). For exact information model and size as the tires are removed. The
regarding inflation pressures and loads for your installation of other tire combinations will result in
particular tires, consult your authorized New Holland excessive tire wear, loss of useable power or severe
dealer. damage to drive line components. If in doubt, consult
your New Holland dealer. For front tires installed on
IMPORTANT: The tires installed on tractors with four wheel drive tractors, see “Rear Tire Pressures
optional four wheel (4WD) match the gearing of the and Permissible Loads” on the following pages.
transmission and axle. When replacing worn or

00-24
SECTION 00 -- GENERAL -- CHAPTER 1

REAR TIRE PRESSURES AND PERMISSIBLE LOADS (CROSS PLY TIRES - INCLUDING
FRONT TIRES ON 4WD TRACTORS)
The following chars give the carrying capacity by TIRE at the pressures indicated.

TIRE LOAD LIMITS AT VARIOUS COLD INFLATIONS PRESSURES


TIRE kPa 12 14 16 18 20 22 24 26 28 30 32
SIZE Psi 80 100 110 120 140 150 170 180 190 210 220
7.50 kg 450 500 530 580 615(4)
lbs. 990 1100 1170 1280 1360(4)
8.3-16 kg 290 325 345 375 400 425(4) 437 462 487 500 515 545 @ 230(6)
lbs. 640 715 760 825 880 935(4) 965 1020 1070 1100 1140 1200 @ 34(6)
8.3-22 kg 355 412 437 450 500 530 560 580 600 630 650
lbs. 785 910 695 990 1100 1170(4) 1230 1280 1320 1390 1430 1760 @ 36(6)
8.3-24 kg 400 437 462 500 530 560(4)
lbs. 880 965 1020 1100 1700 1230(4)
9.5-16 kg 375 412 437 475 500(4) 530 560 580 615 630(6)
lbs. 825 910 965 1050 1100(4) 1170 1230 1280 1360 1390(6)
9.5-22 kg 450 515 545 560 615 650 690 710 750 775 800
lbs. 990 1140 1200 1230 1360(4) 1430 1520 1570 1650 1710 1760(6)
9.5-24 kg 500 545 580 630 670(4) 710 750 775 825 850(6)
lbs. 1100 1200 1280 1390 1480(4) 1570 1650 1710 1820 1870(6)
9.5-32 kg 560 615 670 710 750(4) 800 850 875 925 950 1000 2830 @ 50(10)
lbs. 1230 1360 1480 1570 1650(4) 1760 1870 1930 2040 2090 2200 2470 @ 40(8)
9.5-36 kg 600 650 710 750 800(4)
lbs. 1320 1430 1570 1650 1760(4)
9.5-42 kg 650 710 750 825 875(4) 925 975 1030 1060 1090 1150 1320 @ 280(8)
1450 @ 330(10)
2910 @ 40(8)
lbs. 1430 1570 1650 1820 1930(4) 2040 2150 2270 2340 2400 2540 3200 @ 48(10)
11.2-24 kg 600 650 710 750(4) 800 850 900 950(6) 975 1030 1060 1150 @ 250(8)
lbs. 1320 1430 1570 1650(4) 1760 1870 1980 2090(6) 2150 2270 2340 2450 @ 36(8)
11.2-28 kg 630 690 750 800(4)
lbs. 1390 1520 1650 1760(4)
11.2-36 kg 710 800 850 925(4)
lbs. 1570 1760 1870 2040(4)
11.2-38 kg 750 800 875 950(4)
lbs. 1650 1760 1930 2090(4)
12.4-16 kg 545 600 650(4) 690 750 775 825(6) 875 900 950 975(8) 1250 @ 330(12)
lbs. 1200 1320 1430(4) 1520 1650 1710 1820(6) 1930 1980 2090 2150(8) 2760 @ 48(12)
12.4-24 kg 710 775 850(4) 900 975 1030 1090(6) 1120 1180 1215 1285(8)
lbs. 1570 1710 1870(4) 1980 2150 2270 2400(6) 2470 2600 2680 2830(8)
12.4-28 kg 775 850 900(4)
lbs. 1710 1870 1980(4)
12.4-36 kg 875 950 1030(4) 1090 1150 1215 1285(6) 1360 1400 1450 1550(8) 1750 @ 280(10)
lbs. 1930 2090 2270(4) 2400 2540 2680 2830(6) 3000 3080 3200 3420(8) 3860 @ 40(10)
12.4-38 kg 900 975 1060(4) 1120 1180 1250 1320(6) 4770 @ 56(14)
lbs. 1980 2150 2340(4) 2470 2600 2760 2910(6) 3470(8) 4360 @ 40(12)
12.4-42 kg 925 1030 1120(4) 1180 1250 1320 1400(6) 1450 1550 1600 1650(8) 1900 @ 280(10)
lbs. 2040 2270 2470(4) 2600 2760 2910 3080(6) 3200 3420 3520 3640(8) 4180 @40(10)
12.4-46 kg 975 1060 1150 1250 1320 1400 1500(6) 1550 1600 1700 1750(8) 2000 @ 280(10)
lbs. 1250 2340 2540 2760 2910 3080 3300(6) 3420 3520 3740 3860(8) 440 @40(10)
13.6-16 kg 650 710(4)
lbs. 1430 1570(4)
13.6-24 kg 1870 2040(4) 2200 2340 2540 2680(6) 2830 2910 3080(8)
lbs. 850 925(4) 1000 1060 1150 1215(6) 1285 1320 1400(8)
13.6-26 kg 1930 2090(4) 2270 2470 2600 2750(6) 2910 3000 3200(8)
lbs. 875 950(4) 1030 1120 1180 1250(6) 1320 1360 1450(8)
13.6-28 kg 1980 2200(4) 2340 2540 2680 2830(6) 3000 3080 3300(8) 3420 3520 3740 @ 36(10)
lbs. 900 1000(4) 1060 1150 1215 1285(6) 1360 1400 1500(8) 1550 1600 1700 @ 250(10)

00-25
SECTION 00 -- GENERAL -- CHAPTER 1

TIRE LOAD LIMITS AT VARIOUS COLD INFLATIONS PRESSURES - Continued


TIRE kPa 12 14 16 18 20 22 24 26 28 30 32
SIZE Psi 80 100 110 120 140 150 170 180 190 210 220
13.6-38 kg 2340 2540(4) 2760 2910 3080 3300(6)
lbs. 1060 1150(4) 1250 1320 1400 1500(6)
13.6-46 kg 2540 2830(4) 3000 3200 3420 3640(6) 3860 3960 4180(8)
lbs. 1150 1285(4) 1360 1450 1550 1650(6) 1750 1800 1900(8)
13.9-36 kg 2270 2470(4) 2680 2830 3000(6)
lbs. 1030 1120(4) 1215 1285 1350(6)
14.9-24 kg 2200 2400(4) 2600 2830 3000(6) 3200 3300 3520(8) 3640 3740 3960 4400 @ 38(12)
lbs. 1000 1090(4) 1180 1285 1350(6) 1450 1500 1600(8) 1650 1700 1800 2000 @ 260(12)
420/70-24 kg 2340 2540 2760(6) 2910 3080 3300(8) 3520 3640(10)
lbs. 1060 1150 1250(6) 1320 1400 1500(8) 1600 1650(10)
14.9-26 kg 2270 2540 2680 2910 3080(6) 3300 3420 3640 3740 3960 4080(10)
lbs. 1030 1150 1215 1320 1400(6) 1500 1550 1650 1700 1800 1850(10)
14.9-28 kg 2340 2600(4) 2830 3000 3200(6) 3420 3520 3740(8) 3860 4080 4180(10)
lbs. 1060 1180(4) 1285 1360 1450(6) 1550 1600 1700(8) 1750 1850 1900(10)
14.9-30 kg 2470 2680 2910 3080 3300(6) 3520 3640 3860(8) 3960 4180 4300(10)
lbs. 1120 1215 1320 1400 1500(6) 1600 1650 1750(8) 1800 1900 1950(10)
14.9-38 kg 2760 3000 3300 3520 3740(6)
lbs. 1250 1360 1500 1600 1700(6)
15.5-38 kg 2600 2830 3080 3300 3520(6) 3740 3860 4080(8)
lbs. 1180 1285 1400 1500 1600(6) 1700 1750 1850(8)
16.9-24 kg 2680 2910 3200 3420(6) 3640 3860 4080(8) 4300 4400(10)
lbs. 1215 1320 1450 1550(6) 1650 1750 1850(8) 1950 2000(10)
16.9-26 kg 2760 3080 3300 3520(6) 3740 3960 4180 4400 4540(10)
lbs. 1250 1400 1500 1600(6) 1700 1800 1900 2000 2050(10)
16.9-28 kg 2910 3200 3420 3640(6) 3860 4080 4300(8) 4540 4580(10)
lbs. 1320 1450 1550 1650(6) 1750 1850 1950(8) 2060 2120(10)
16.9-30 kg 3000 3300 3520 3740(6) 3960 4180 4400(8) 4680 4940(10)
lbs. 1360 1500 1600 1700(6) 1800 1900 2000(8) 2120 2240(10)
16.9-34 kg 3200 3420 3740 3960(6) 4300 4540 4580(8) 4940 5200(10)
lbs. 1450 1550 1700 1800(6) 1950 2060 2120(8) 2240 2360(10)
16.9-38 kg 3300 3640 3960 4180(6) 4540 4800 4940(8)
lbs. 1500 1650 1800 1900(6) 2060 2180 2240(8)
18.4-16.1 kg 2150 2340 2540(6) 2680 2910(8) 3080 3200 3300(10)
lbs. 975 1060 1150(6) 1215 1320(8) 1400 1450 1500(10)
18.4-24 kg 3200 3520 3860(6) 4080 4400(8) 4540 4800 5080(10) 5360 5520 5680(12)
lbs. 1450 1600 1750(6) 1850 2000(8) 2060 2180 2300(10) 2430 2500 2575(12)
18.4-26 kg 3300 3640 3960(6) 4180 4540(8) 4800 4940 5200(10)
lbs. 1500 1650 1800(6) 1900 2060(8) 2180 2240 2360(10)
18.4-28 kg 3420 3740 4080(6) 4400 4680(8) 4940 5200 5360(10) 5680 5840 6150(12)
lbs. 1550 1700 1850(6) 2000 2120(8) 2240 2360 2430(10) 2575 2650 2800(12)
18.4-30 kg 3520 3860 4180(6) 4540 4800(8) 5080 5360 5520(10)
lbs. 1600 1750 1900(6) 2060 2180(8) 2300 2430 2500(10)
18.4-34 kg 3740 4180 4400(6) 4800 5080(8) 5360 5680 6000 6150 6400 6600(12)
lbs. 1700 1900 2000(6) 2180 2300(8) 2430 2575 2725 2800 2900 3000(12)
18.4-38 kg 3960 4400 4880(6) 5080 5360(8) 5680 6000 6400(10) 6600 6800 7150(12) 7600(14)
lbs. 1800 2000 2120(6) 2300 2430(8) 2575 2725 2900(10) 3000 3075 3250(12) 3450(14)

To avoid the possibility of tire creep (movement if the The above tables are for guidance only. For exact
tire on the rim), tire pressures below (1.0 bar) 14 PSI information regarding inflation pressures and loads
should not be used with cross ply tires for operations for your particular tires, consult your authorized New
having a high torque requirement, e.g. sub-soiling, Holland dealer.
ploughing, etc. When mounted implements are used,
rear tire loads may be increased by up to 20% with
no increase in inflation pressures when operated at
speeds below 20 km/h (12 MPH).

00-26
SECTION 00 -- GENERAL -- CHAPTER 1

REAR TIRE PRESSURE AND PERMISSIBLE LOADS (RADIAL TIRES - INCLUDING FRONT
TIRES ON 4WD TRACTORS)
Radial tire performance is now denoted by a Load
Index and Speed Symbol replacing the Ply Rating
commonly found on cross ply tires. Figure 1 shows
typical markings to be found on the side wall of radial
ply tires.

Figure 1 - Typical Tire Data Marking


1. Oil ply rating mark
2. Maximum inflation pressure (in bar)
3. Maximum load at 40 km/h (25 MPH)
4. Load Index
5. Speed Symbol
358--110
NOTE: All tires installed on New Holland tractors
have a Speed symbol ‘A8’ and are suitable for 1
speeds up to 40km/h (25 MPH).

The maximum load that may be carried by the tire is


dependent upon the Load Index shown on the side
wall. In the following charts the loads given are for
individual tires operated at speeds up to 30 Km/h (19
MPH). The right-hand (shaded) column indicates the
maximum load at speeds up to 40 km/h (25 MPH).

00-27
SECTION 00 -- GENERAL -- CHAPTER 1

LOAD INDEX CHART

Load Index kg lbs. Load Index kg lbs. Load Index kg lbs.


80 450 990 110 1060 2340 140 2500 5520
81 462 1020 111 1090 2400 141 2575 5680
82 475 1050 112 1120 2470 142 2650 5840
83 487 1070 113 1150 2540 143 2725 6000
84 500 1100 114 1180 2600 144 2800 6150
85 515 1140 115 1215 2680 145 2900 6400
86 530 1170 116 1250 2760 146 3000 6600
87 545 1200 117 1285 2830 147 3075 6800
88 560 1230 118 1320 2910 148 3150 6950
89 580 1280 119 1360 3000 149 3250 7150
90 600 1320 120 1400 3080 150 3350 7400
91 615 1360 121 1450 3200 151 3450 7600
92 630 1390 122 1500 3300 152 3550 7850
93 650 1430 123 1550 3420 153 3650 8050
94 670 1480 124 1600 3520 154 3750 8250
95 690 1520 125 1650 3640 155 3875 8550
96 710 1570 126 1700 3740 156 4000 8800
97 730 1610 127 1750 3860 157 4125 9100
98 750 1650 128 1800 3960 158 4250 9350
99 775 1710 129 1850 4080 159 4375 9650
100 800 1760 130 1900 4180 160 4500 9900
101 825 1820 131 1950 4300 161 4625 10200
102 850 1870 132 2000 4400 162 4750 10500
103 875 1930 133 2060 4540 163 4875 10700
104 900 1980 134 2120 4680 164 5000 11000
105 925 2040 135 2180 4800 165 5150 11400
106 950 2090 136 2240 4940 166 5300 11700
107 975 2150 137 2300 5080 167 5450 1200
108 1000 2200 138 2360 5200 168 5600 12300
109 1030 2270 139 2430 5360 169 5800 12800

00-28
SECTION 00 -- GENERAL -- CHAPTER 1

Inflation Pressure - bar


Load
L d 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.6
Index
Load Capacity per TIRE - kg
107 680 725 770 815 860 910 955 1000 1050 975
109 720 765 815 860 910 960 1005 1055 1100 1030
114 830 885 940 990 1050 1100 1155 1210 1260 1180
116 885 940 995 1055 1115 1170 1225 1280 1340 1250
119 965 1020 1090 1145 1210 1270 1335 1390 1455 1360
121 1020 1080 1150 1220 1285 1355 1420 1485 1555 1450
122 1045 1120 1185 1265 1330 1400 1465 1535 1605 1500
123 1070 1145 1220 1295 1365 1430 1515 1585 1660 1550
124 1105 1180 1260 1335 1410 1490 1565 1640 1715 1600
126 1170 1250 1335 1415 1495 1580 1660 1740 1820 1700
127 1200 1285 1370 1450 1535 1620 1710 1780 1875 1750
128 1230 1320 1410 1495 1580 1670 1755 1840 1926 1800
134 1445 1550 1655 1760 1855 1965 2065 2165 2270 2120
135 1510 1615 1720 1825 1920 2030 2130 2230 2335 2180
136 1550 1660 1765 1875 1975 2080 2185 2290 2395 2240
137 1605 1710 1820 1925 2035 2140 2245 2350 2460 2300
139 1715 1825 1935 2050 2155 2270 2380 2495 2600 2430
141 1820 1935 2055 2170 2290 2410 2520 2640 2760 2575
142 1875 1990 2115 2230 2355 2480 2595 2710 2836 2650
144 1980 2110 2240 2360 2490 2615 2745 2975 3000 2800
146 2085 2225 2370 2510 2650 2790 2930 3070 3210 3000
153 2525 2700 2875 3045 3215 3390 3565 3755 3905 3650
155 2675 2865 3045 3225 3415 3595 3780 3960 4150 3875
157 2835 3035 3235 3430 3630 3825 4020 4260 4415 4125
159 3000 3210 3420 3635 3845 4060 4260 4475 4685 4375
166 3695 3945 4190 4435 4685 4935 5180 5425 5675 5300
Use this table for guidance only. For exact information regarding inflation pressures and loads for a particular
tire, consult an authorized New Holland dealer.

00-29
SECTION 00 -- GENERAL -- CHAPTER 1

REAR TIRE PRESSURE AND PERMISSIBLE LOADS (RADIAL TIRES - INCLUDING FRONT
TIRES ON 4WD TRACTORS) (CONTINUED)
Inflation Pressure - PSI
Load
L d 12 13 15 16 17 18 20 22 23 23
Index
Load Capacity per TIRE - lbs.
107 1500 1600 1695 1795 1895 2005 2105 2205 2315 2150
109 1585 1685 1795 1895 2005 2115 2215 2325 2430 2270
114 1830 1950 2070 2180 2315 2425 2545 2665 2780 2600
116 1950 2070 2195 2325 2460 2580 2700 2820 2955 2755
119 2125 2250 2405 2525 2665 2800 2945 3065 3205 3000
121 2250 2380 2535 2690 2830 2985 3130 3275 3430 3195
122 2305 2470 2610 2790 2930 3085 3230 3385 3540 3305
123 2360 2525 2690 2855 3010 3150 3340 3495 4135 3860
124 2435 2600 2775 2945 3110 3285 3450 3615 3780 3525
126 2580 2755 2945 3120 3295 3485 3660 3835 4010 3745
127 2645 2830 3020 3195 3385 3570 3770 3925 4135 3860
128 2710 2910 3110 3295 3485 3680 3870 4055 4245 3970
134 3185 3415 3650 3880 4090 4330 4550 4770 5005 4675
135 3330 3560 3790 4025 4230 4475 4695 4915 5145 4805
136 3415 3660 3890 4135 4355 4585 4815 5050 5280 4940
137 3538 3770 4010 4245 4485 4715 4950 5180 5425 5070
139 3780 4025 4265 4520 4750 5005 5245 5500 5730 5355
141 4010 4265 4530 4785 5050 5315 5555 5820 6085 5675
142 4133 4385 4660 4915 5190 5465 5720 5975 6250 5840
144 4365 4650 4940 5200 5490 5765 6050 6560 6615 6170
146 4595 4905 5225 5535 5840 6150 6460 6770 7075 6615
153 5565 5950 6340 6715 7085 7475 7860 8280 8610 8045
155 5895 6315 6715 7110 7530 7925 8335 8730 9150 8540
157 6250 6690 7130 7560 8000 8430 8860 9390 9735 9095
159 6615 7075 7535 8015 8475 8950 9390 9865 10330 9645
166 8145 8695 9235 9775 10330 10880 11420 11960 12510 11685

Use this table for guidance only. For exact information regarding inflation pressures and loads for a particular
tire, consult an authorized New Holland dealer.

GROUND SPEEDS
4 1
A decal similar to that shown in Figure 2 is affixed to
the right rear fender.
The decal illustrates the gear shift pattern and the
approximate ground speed in all forward and reverse
ratios at three alternative engine speeds. The
example shown is for a tractor having a rated engine
speed of 2100 rev/min.
Figure 2 - Ground Speed Decal
1. Gearshift lever positions
2. Tire size 2 3
3. Ground speeds
4. Engine speed range 2
The right-hand side of the decal represents the range
and main shift lever positions. To the left are columns
representing the gear ratios selected.

00-30
SECTION 10 -- ENGINE -- CHAPTER 1

SECTION 10 - ENGINE

Chapter 1 - Diesel Engines


CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Grease and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Crankshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cylinder Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Diesel Engine Strip-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Separating the Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Disassembly and Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Rocker Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Valve and Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Valve Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Rocker Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Engine Front Cover and Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

10-1
SECTION 10 -- ENGINE -- CHAPTER 1

Connecting Rods, Bearings, Pistons, and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53


Connecting Rod Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Rear Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Oil Filter Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77, 80
Balancer Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Camshaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84, 85
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84, 86
Engine Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Compression Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Compression Test Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Engine Break-in (Low Hp Application) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Engine Break-in (Other Than Low Hp Application) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

10-2
SECTION 10 -- ENGINE -- CHAPTER 1

ENGINE SPECIFICATIONS
Model Unit TB100 TB110 TB120
Turbocharged Engine Yes Yes Yes
Cylinders 4 4 6
Bore mm 111.8 111.8 111.8
in 4.4 4.4 4.4
Stroke mm 127.0 127.0 127.0
in 5.0 5.0 5.0
Displacement cu cm 4987 4987 7472
cu in 304 304 456
Compression Ratio 17:5--1 17:5--1 17:5--1
Cylinder Bore Compression bar 25.85 25.85 25.85
(at cranking speed of 200 rpm)
psi 375 375 375
Firing Order (clockwise) 1--3--4--2 1--3--4--2 153624
Idle Speed rev/min +/-- 50 750 750 750
Maximum No-Load Speed rev/min 2320 ± 50 2220 2320
Rated Engine Speed rev/min 2170 2070 2070

CYLINDER BLOCK

Cylinder Bore Taper maximum wear limit 0.127 mm 0.005 in.


maximum repair limit 0.025 mm 0.001 in.
Cylinder Bore Out-of-Round maximum wear limit 0.127 mm 0.005 in.
maximum repair limit 0.030 mm 0.001 in.
Cylinder Bore Diameter 111.778-111.841 mm 4.4007-4.4032 in.
Rear Oil Seal Diameter 140.77-140.87 mm 5.542-5.546 in.
Head-to-Block Surface Flatness any 152 mm (6 in.) area 0.080 mm 0.003 in.
Limit any 25.40 mm (1 in.) area 0.030 mm 0.001 in.
overall 0.127 mm 0.005 in.

CYLINDER HEAD

Valve Guide Bore Diameter 9.469-9.495 mm 0.3728-0.3738 in.

10-3
SECTION 10 -- ENGINE -- CHAPTER 1

EXHAUST VALVES

Face Angle relative to valve head 44°15′-44°30′


Stem Diameter Std 9.401-9.421 mm 0.3701-0.3709 in.
0.076 mm 0.003 in.
oversize 9.477-9.497 mm 0.3731-0.3739 in.
0.381 mm 0.015 in.
oversize 9.781-9.802 mm 0.3851-0.3859 in.
0.762 mm 0.030 in.
oversize 10.163-10.183 mm 0.4001-0.4009 in.
Head Diameter 42.88-43.13 mm 1.688-1.698 in.
Stem-to-Guide Clearance 0.048-0.094 mm 0.0019-0.0037 in.
Lash Clearance cold 0.43-0.53 mm 0.017-0.021 in.
Valve Head-to-Cylinder Head Face Depth 1.2-1.6 mm 0.047-0.063 in.

INTAKE VALVES

Face Angle relative to valve head 29°15′-29°30′


Stem Diameter Std 9.426-9.446 mm 0.3711-0.3719 in.
0.076 mm 0.003 in.
oversize 9.502-9.522 mm 0.3741-0.3749 in.
0.381 mm 0.015 in.
oversize 9.807-9.827 mm 0.3861-0.3869 in.
0.762 mm 0.030 in.
oversize 10.188-10.208 mm 0.4011-0.4019 in.
Head Diameter 47.37-47.63 mm 1.865-1.875 in.
Stem-to-Guide Clearance 0.023-0.069 mm 0.0009-0.0027 in.
Lash Clearance cold 0.36-0.46 mm 0.014-0.018 in.
Valve Head-to-Cylinder Head Face Depth 0.86-1.32 mm 0.034-0.052 in.

VALVE SPRINGS

Free Length 60.7 mm 2.4 in.


Length loaded at 28-31 kg (62-68 lbs.) 48.3 mm 1.9 in.
Length loaded at 61-69 kg (135-152 lbs.) 35.7 mm 1.4 in.

VALVE TIMING

Intake Opening before top dead center 12°


Intake Closing after bottom dead center 38°
Exhaust Opening before bottom dead center 48°
Exhaust Closing after top dead center 12°

10-4
SECTION 10 -- ENGINE -- CHAPTER 1

VALVE INSERTS

Insert Oversize 0.25 mm 0.010 in.


0.50 mm 0.020 in.
0.76 mm 0.030 in.
Exhaust valve Insert 44.17-44.20 mm 1.739-1.740 in.
Cylinder Bore Diameter in Head 44.42-44.45 mm 1.749-1.750 in.
44.68-44.70 mm 1.759-1.760 in.
Intake Valve Insert 50.01-50.04 mm 1.969-1.970 in.
Cylinder Bore Diameter in Head 50.27-50.29 mm 1.979-1.980 in.
50.52-50.55 mm 1.989-1.990 in.

VALVE SEATS

Exhaust Valve 45°00′-45°30′


Intake Valve 30°00′-30°30′
Interference Valve Face Angle-to-Valve Seat Angle 0°30′-1°15′
Valve Seat Concentricity with Valve Guide Total Indicator Reading 0.051 mm 0.002 in.
Bore
Seat Width Exhaust Valve 1.8-2.3 mm 0.071-0.091 in.
Intake Valve 1.9-2.5 mm 0.075-0.098 in.

CAMSHAFT IDLER GEAR (47 Teeth)

End-Play 0.076-0.35 mm 0.003-0.014 in.


Bushing Inside Diameter 50.81-50.83 mm 2.000-2.001 in.
Adapter Outside Diameter 50.76-50.77 mm 1.998-1.999 in.
Backlash with Crankshaft Gear 0.15-0.46 mm 0.005-0.018 in.
Backlash with Camshaft Gear 0.025-0.38 mm 0.001-0.015 in.
Backlash with Fuel Injection Pump 0.10-0.15 mm 0.004-0.006 in.

CAMSHAFT GEAR (52 Teeth)

Timing Gear Backlash 0.025-0.38 mm 0.001-0.015 in.

ROCKER ARM SHAFT

Shaft Diameter 25.40-25.43 mm 1.000-1.001 in.


Shaft Support Internal Diameter 25.45-25.50 mm 1.002-1.004 in.

10-5
SECTION 10 -- ENGINE -- CHAPTER 1

ROCKER ARM

Inside Diameter 25.48-25.50 mm 1.003-1.004 in.

TAPPETS

Clearance-to-Bore 0.015-0.053 mm 0.0006-0.0021 in.


Tappet Diameter 25.11-25.13 mm 0.988-0.989 in.
Tappet Bore Diameter 25.15-25.17 mm 0.990-0.991 in.

CAMSHAFT

Bearing Journal Diameter 60.693-60.719 mm 2.389-2.390 in.


Bearing Clearance 0.025-0.076 mm 0.001-0.003 in.
End-Play 0.051-0.018 mm 0.002-0.007 in.

CONNECTING RODS

Small-End Bushing
g Internal Diameter Naturally Aspirated 38.113-38.120 mm 1.500-1.501 in.
Turbocharged 41.288-41.295 mm 1.625-1.626 in.
Bushing-to-Piston Pin Clearance 0.013-0.025 mm 0.0005-0.001 in.
Side Float 0.13-0.33 mm 0.005-0.013 in.
Twist Limit maximum 0.30 mm 0.012 in.
Bend Limit maximum 0.10 mm 0.004 in.

PISTON PIN

Outside Diameter Naturally Aspirated 38.095-38.100 mm 1.499-1.500 in.


Turbocharged 41.270-41.275 mm 1.624-1.625 in.

PISTONS

Skirt-to-Cylinder Clearance Naturally Aspirated 0.14-0.17 mm (new engine) 0.0055-0.0067 in.


0.14-0.28 mm (run engine) 0.0055-0.011 in.
Turbocharged 0.17-0.19 mm (new engine) 0.0067-0.0075 in.
0.17-0.28 mm (run engine) 0.0067-0.011 in.
Taper out-of-round 0.063-0.127 mm 0.0025-0.005 in.
Grading Diameters at right angles to piston pin 111.64-111.74 mm 4.395-4.399 in.
in increments of 0.0127 mm 0.0005 in.
Piston Pin Clearance at 21°C (70°F) 0.003-0.014 mm 0.00012-0.00055 in.
Piston Crown-to-Block Naturally Aspirated 0.28-0.58 mm 0.011-0.023 in.
Face Turbocharged 0.0-0.3 mm 0.0-0.012 in.

10-6
SECTION 10 -- ENGINE -- CHAPTER 1

PISTON RINGS (87802355 THRU 87802360)

Compression
p Rings
g Number 2 off
Location 1st and 2nd from piston top
Naturallyy Aspirated
p Top Ring Chrome Plated Internal Chamfer
2nd Ring Napier Ductile Iron Taper Face with Step
Turbocharged
g Top Ring Keystone Tapered Internal Chamfer
2nd Ring Napier Ductile Iron Taper Face with Step
Oil Control Rings
g Number 1 off
Location directly above piston pin Chrome Plated Symmetrical
Gap
p Clearances Top Ring 0.29-0.53 mm .012-.021 in.
2nd Ring 0.49-0.63 mm .020-.029 in.
0.4200.76 mm .017-.030 in. 0.015-0.033 in.

PISTON RINGS

p
Compression g
Rings Number 2 off
Location 1st and 2nd from piston top
Naturallyy Aspirated
p Top Ring Parallel Sides Inner Chamfer
Engine 2nd Ring Straight Face Inner Step
Turbocharged
g Top Ring Keystone Tapered Internal Chamfer
Engine 2nd Ring Straight Face Inner Step
Oil Control Rings
g Number 1 off
Location directly above piston pin Slotted with Expander
Side Face Clearance-to- Top Ring 0.112-0.155 mm 0.0044-0.0061 in.
Ring Groove 2nd Ring 0.099-0.142 mm 0.0039-0.0056 in.
Oil Ring 0.061-0.104 mm 0.0024-0.0041 in.
Gap
p Width Top Ring 0.38-0.84 mm 0.015-0.033 in.
2nd Ring 0.66-1.12 mm 0.026-0.044 in.
Oil Ring 0.38-0.84 mm 0.015-0.033 in.

10-7
SECTION 10 -- ENGINE -- CHAPTER 1

CRANKSHAFT

Main Journal Diameter 85.631-85.644 mm 3.3713-3.3718 in.


Main Journal Length except thrust, rear or inter- 36.96-37.21 mm 1.455-1.465 in.
mediate
Main Journal Wear (maximum) 0.127 mm 0.005 in.
Main and Crankpin Fillet Radius 3.048-3.556 mm 0.12-0.14 in.
Thrust Bearing Journal Length 37.06-37.11 mm 1,459-1.461 in.
Intermediate Bearing Journal Length 36.96-37.21 mm 1.455-1.465 in.
Rear Bearing Journal Length 37.97-38.48 mm 1.495-1.515 in.
Crankpin Journal Length 42.62-42.72 mm 1.678-1.682 in.
Crankpin Diameter 69.840-69.850 mm 2.749-2.750 in.
End-Play 0.10-0.20 mm 0.004-0.008 in.
Crankpin Out-of-Round Total Indicator Reading 0.005 mm 0.0002 in.
Taper Surface parallel to center of Main 0.005 mm 0.0002 in.
Journal
Crankshaft Rear Oil Seal Journal Diameter 122.12-122.28 mm 4.808-4.814 in.
Crankshaft Pulley Journal Diameter 44.45-44.48 mm 1.750-1.751 in.
Crankshaft Timing Gear Journal Diameter 46.23-46.25 mm 1.820-1.821 in.
Crankshaft Flange Run-Out (maximum) 0.038 mm 0.0015 in.
Cankshaft Drive Gear Teeth 26

MAIN BEARING

Liner Length without thrust liner 27.94-28.19 mm 1.10-1.11 in.


Liner Length with thrust liner 39.91-39.96 mm 1.453-1.455 in.
Bearing Clearance assembled, vertical 0.055-0.117 mm 0.0021-0.0046 in.

CRANKPIN BEARINGS

Liner Length 35.56-35.81 mm 1.40-1.41 in.


Bearing Clearance assembled, vertical 0.035-0.094 mm 0.0014-0.0037 in.

NOTE: Reduce the main and crankpin journal diameters the same amount as the undersize bearings used,
when regrinding a crankshaft. The rear end of the crankshaft should be located on the 60° chamfer of the pilot
bearing- bore.

10-8
SECTION 10 -- ENGINE -- CHAPTER 1

CRANKSHAFT REGRINDING

Undersize Bearings Available Main Journal Diameters


0.051 mm 0.002 in. 85.580-85.593 mm 3.3693-3.3698 in.
0.254 mm 0.010 in. 85.390-85.402 mm 3.3618-3.3623 in.
0.508 mm 0.020 in. 85.136-85.148 mm 3.3518-3.3523 in.
0.762 mm 0.030 in. 84.882-84.894 mm 3.3418-3.3423 in.
1.016 mm 0.040 in. 84.628-84.640 mm 3.3318-3.3323 in.
Undersize Bearings Available Crankpin Journal Diameters
0.051 mm 0.002 in. 69.789-69.799 mm 2.7476-2.7480 in.
0.254 mm 0.010 in. 69.956-69.606 mm 2.7400-2.7404 in.
0.508 mm 0.020 in. 69.342-69.352 mm 2.7300-2.7304 in.
0.762 mm 0.030 in. 69.088-69.098 mm 2.7200-2.7204 in.
1.016 mm 0.040 in. 68.834-68.844 mm 2.7100-2.7104 in.

CRANKSHAFT BALANCER

Gear Backlash at 90° Intervals 0.05-0.25 mm 0.002-0.010 in.


Shaft-to-Bushing Clearance 0.012-0.038 mm 0.0005-0.0015 in.
Shaft Diameter 25.133-25.400 mm 0.9895-1.000 in.
Backlash Between Balancer Drive Gear and Crankshaft Gear 0.05-0.20 mm 0.002-0.008 in.
End Float of Assembled Gears 0.20-0.51 mm 0.008-0.20 in.

FLYWHEEL

Ring Gear Run-Out 0.63 mm 0.025 in.


Flywheel Run-Out 0.27 mm 0.011 in.
Skimmed Face Maximum Depth 3 mm 0.118 in.

OIL PUMP

Rotor Clearance 0.025-0.15 mm 0.001-0.006 in.


Rotor-to-Pump Housing Clearance 0.15-0.28 mm 0.006-0.011 in.
Rotor End-Play 0.025-0.089 mm 0.001-0.0035 in.
Oil Pressure minimum at idle speed 1.24 bar 18 psi
minimum at rated speed 2.76 bar 40 psi
Pump Gear-to-Camshaft Gear Backlash 0.40-0.56 mm 0.016-0.022 in.

10-9
SECTION 10 -- ENGINE -- CHAPTER 1

OIL FILTER SUPPORT

Relief Valve Operating Pressure 4.0 bar 59 psi


Flow rate 68-75 liters/min 18-20 gal/min
Relief Valve Spring
p g Free Length 52.8 mm 2.08 in.
Compressed Length with 15.6 kgs (34.3 lbs.) 37.0 mm 1.46 in.

ENGINE OIL CAPACITIES (With Oil Filter)

Model Liters Imp Gals U S Gals


U.S.
4 Cyl/6Cyl 11 4/19
11.4/19 2 5/4 2
2.5/4.2 3 0/5 0
3.0/5.0

MAIN FUEL TANK CAPACITY

Model Liters U S Gals


U.S.
4 Cyl/6Cyl 135 35 6
35.6

10-10
SECTION 10 -- ENGINE -- CHAPTER 1

LUBRICANTS
Transmission/rear axle hydraulics, four wheel drive
differential casing and front hubs: 134 D Hydraulic Oil

Grease fittings: Lithium base EP high temperature


grease

Engine oil should meet A.P.I. (American Petroleum


Institute) quality ‘CF4’ - as per the original factory fill.
At minimum, the oil must at least meet A.P.I. quality
level ‘CD’.
Choose the correct viscosity grade from the chart on
the right.

Engine Oil Viscosity Chart

NOTE: In areas where prolonged periods of extreme


temperatures are encountered, local lubricant
practices are acceptable; such as the use of SAE5W
in extreme low temperatures or SAE50 in extreme
high temperatures.

358--209

Temperature Oil Viscosity and Type API Classification Engine Oil and Filter
Change Period (hours)
--1°C Low Ash, SAE 5W SF/CD/CF--4c 150
(Below 10°F) or Low Ash SAE 5W/20 150
or SAE 10W--30 150
--12°C to 4°C Low Ash, SAE 10W SF/CD/CF--4 150
(10°F to 40°F) Series 3 or SAE 10W--30 300
0°C to32°C Low Ash, SAE 30W SF/CD/CF--4 300
(32°F to 90°F) Series 3 or SAE 10W--40 300
Above 24°C
24 C Low Ash, SAE 30W SF/CD/CF--4
SF/CD/CF 4 300
(75°F) Series 3 or SAE 15W--40

NOTE: When using diesel fuel with a sulphur content below 1.0%, Series 3 diesel engine oil with an A.P.I.
classification of CD may be used instead of CF--4 oil, but the oil and filter interval must be reduced to 150 hours.

When using diesel fuel with a sulphur content between 1% and 1.3% use only oils listed above but reduce the
oil and filter change period to every 50 hours.

10-11
SECTION 10 -- ENGINE -- CHAPTER 1

NOTE: Refer to the Torque Value table as a guide when reassembling components and assemblies. For
calculating torque values not listed, or when installing hardware different from that specified, use the Standard
Torque chart titled “Minimum Hardware Tightening Torque” provided in this section.

TORQUE VALUES

Description N⋅ m Ft.-Lb.
Main Bearing Bolts 197 145
Connecting Rod Bolts 149 110
Cylinder Head Bolts (engine cold) Final Torque 217 160
Intake Manifold-to-Cylinder Head 35 26 (312 in.-lb.)
Exhaust Manifold-to-Cylinder Head 38 28 (336 in.-lb.)
Exhaust Pipe-to-Flange 31 23 (276 in.-lb.)
Flywheel-to-Crankshaft 197 145
Oil Pan Drain Plug 41 30
Valve Rocker Cover Bolts 24 18 (216 in.-lb.)
Crankshaft Pulley-to-Crankshaft 284 210
Valve Rocker Arm Self Locking Screw 24 18 (216 in.-lb.)
Injector Attachment Bolts 23 17 (204 in.-lb.)
Cover Bolts 31 23 (276 in.-lb.)
Oil Pump-to-Block 23 17 (204 in.-lb.)
Water Pump-to-Cylinder Block 35 26 (312 in.-lb.)
Water pump Cover-to-Pump 27 20 (239 in.-lb.)
Oil Pan-to-Cylinder Block (cast) 38 28 (336 in.-lb.)
Injector Line Banjo Bolts 24 18 (216 in.-lb.)
Leak-Off Tube Banjo Fitting Bolts 11 8 (96 in.-lb.)
Injection Pump-to-Front Cover 24 18 (216 in.-lb.)
Camshaft Idler Drive Gear-to-Block 237 175
Front Cover-to-Cylinder Block 24 18 (216 in.-lb.)
Thermostat Housing Bolts 24 18 (216 in.-lb.)
Camshaft Gear Bolt 69 51
Camshaft Rear Gear Plate Bolts 47 35
Oil Filter Adapter Bolts 42 31
Oil Filter Mounting Bolt Insert 34 25 (300 in.-lb.)
Starting Motor-to-Rear Adapter Plate 31 23 (276 in.-lb.)
Injection Pump-to-Gear Nut (4-cylinder) 79 58
Oil Pressure Switch Assembly 31 23 (276 in.-lb.)
Turbocharger-to-Exhaust Manifold Nut 44 33
Fan Blade-to-Support Body 27 20 (239 in.-lb.)
Crankshaft Rear Oil Seal Retainer Initial Torque 12 9 (108 in.-lb.)
Crankshaft Rear Oil Seal Retainer Final Torque 23 17 (204 in.-lb.)
Belt Tension Pulley 54 40
Temperature Senders 20 15 (180 in.-lb.)
Tensioner-to-Water Pump Bolt 54 40
Idler Pulley Bolt 54 40
Pump Connector-to-Block 24 18 (216 in.-lb.)
Dynamic Balancer-to-Cylinder Bore 117 86
Cylinder Block Plugs (1/4 in-27 NPT) 11 8 (96 in.-lb.)
Cylinder Block Plugs (1/4 in-18 NPT) 30 22 (266 in.-lb.)
Cylinder Block Plugs (3/4 in-18 NPT) 38 28 (336 in.-lb.)
Cylinder Block Plugs (3/4 in-14 NPT) 27 20 (240 in.-lb.)

10-12
SECTION 10 -- ENGINE -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES


IN FOOT POUNDS (NEWTON-METERS) FOR NORMAL ASSEMBLY APPLICATIONS

INCH HARDWARE AND LOCKNUTS


SAE GRADE 2 SAE GRADE 5 SAE GRADE 8 LOCKNUTS

NOMINAL UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED GR.B GR.C NOMINAL
SIZE or W/ZnCr or W/ZnCr or W/ZnCr w/GR5 w/GR8 SIZE
PLATED PLATED PLATED BOLT BOLT
SILVER GOLD SILVER GOLD SILVER GOLD

1/4 55* (6.2) 72* (8.1) 86* (9.7) 112* (13) 121* (14) 157* (18) 61* (6.9) 86* (9.8) 1/4
5/16 115* (13) 149* (17) 178* (20) 229* (26) 250* (28) 324* (37) 125* (14) 176* (20) 5/16
3/8 17 (23) 22 (30) 26 (35) 34 (46) 37 (50) 48 (65) 19 (26) 26 (35) 3/8
7/16 27 (37) 35 (47) 42 (57) 54 (73) 59 (80) 77 (104) 30 (41) 42 (57) 7/16
1/2 42 (57) 54 (73) 64 (87) 83 (113) 91 (123) 117 (159) 45 (61) 64 (88) 1/2
9/16 60 (81) 77 (104) 92 (125) 120 (163) 130 (176) 169 (229) 65 (88) 92 (125) 9/16
5/8 83 (112) 107 (145) 128 (174) 165 (224) 180 (244) 233 (316) 90 (122) 127 (172) 5/8
3/4 146 (198) 189 (256) 226 (306) 293 (397) 319 (432) 413 (560) 160 (217) 226 (306) 3/4
7/8 142 (193) 183 (248) 365 (495) 473 (641) 515 (698) 667 (904) 258 (350) 364 (494) 7/8
1 213 (289) 275 (373) 547 (742) 708 (960) 773 (1048) 1000 (1356) 386 (523) 545 (739) 1

NOTE: Torque values shown with * are inch pounds.


IDENTIFICATION
CAP SCREWS AND CARRIAGE BOLTS

SAE GRADE 2 SAE GRADE 5 SAE GRADE 8

REGULAR NUTS SAE GRADE 5 SAE GRADE 8


HEX NUTS HEX NUTS

LOCKNUTS

GRADE IDENTIFICATION GRADE IDENTIFICATION


GRADE A NO NOTCHES GRADE A NO MARKS
GRADE B ONE CIRCUMFERENTIAL NOTCH GRADE B THREE MARKS

GRADE C TWO CIRCUMFERENTIAL NOTCHES GRADE C SIX MARKS


MARKS NEED NOT BE LOCATED
AT CORNERS

GRADE A NO MARK
GRADE B LETTER B
GRADE C LETTER C
GRADE IDENTIFICATION

10-13
SECTION 10 -- ENGINE -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES


IN FOOT POUNDS (NEWTON-METERS) FOR NORMAL ASSEMBLY APPLICATIONS

METRIC HARDWARE AND LOCKNUTS


CLASS 5.8 CLASS 8.8 CLASS 10.9 LOCKNUT
NOMINAL CL.8
SIZE UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED W/CL8.8
W/ZnCr W/ZnCr W/ZnCr BOLT

M4 15* (1.7) 19* (2.2) 23* (2.6) 30* (3.4) 33* (3.7) 42* (4.8) 16* (1.8)
M6 51* (5.8) 67* (7.6) 79* (8.9) 102* (12) 115* (13) 150* (17) 56* (6.3)
M8 124* (14) 159* (18) 195* (22) 248* (28) 274* (31) 354* (40) 133* (15)
M10 21 (28) 27 (36) 32 (43) 41 (56) 45 (61) 58 (79) 22 (30)
M12 36 (49) 46 (63) 55 (75) 72 (97) 79 (107) 102 (138) 39 (53)
M16 89 (121) 117 (158) 137 (186) 177 (240) 196 (266) 254 (344) 97 (131)
M20 175 (237) 226 (307) 277 (375) 358 (485) 383 (519) 495 (671) 195 (265)
M24 303 (411) 392 (531) 478 (648) 619 (839) 662 (897) 855 (1160) 338 (458)

NOTE: Torque values shown with * are inch pounds.


IDENTIFICATION
HEX CAP SCREW AND CARRIAGE BOLTS
CLASSES 5.6 AND UP

MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS

HEX NUTS AND LOCKNUTS


CLASSES 05 AND UP

MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS CLOCK MARKING

10-14
SECTION 10 -- ENGINE -- CHAPTER 1

SPECIAL TOOLS

Description Old Part Number Global Part Number


Kit, Fuel Injection Pump Timing FNH08126 380000081
Tool, Engine Separating 290740 380000216
Kit, Valve Stem Guide Reamer FNH02136 380000319
Installer, Water Pump Seal FNH04672 380000321
Installer, Engine Seal FT6212 380000332
Adapter, Timing Degree Wheel 380000409
Wheel, Timing Degree 380000410
Protector, Shaft (set of 6) FNH09212 380000564
Handle, Driver Camshaft FNH01442
Tool, Connecting Rod Bushing FNH00053
Tool, Crank Gear Alignment FNH00881
Driver, Camshaft FNH01255
Installer, Crankshaft Rear Main Seal FNH01301
Adapter, Nozzle Reverse Flush FNH08124
Socket, Nozzle Nut Torque FNH08126
Puller, Grip-O-Matic FNH09198
Adapter, Step Plate (set of 11) FNH09210
Driver, Set FNH09514
Puller, Crabnkshaft/Water Pump Pulley FNH09539
Tool, Splitting MS2700C
Support, Engine MS2700C--8
Replacer, Front Crank Seal T87T-6019-A

GREASE and SEALANTS

PART NUMBER TYPE NAME

Ambra GR9 NH 1 710 A Grease --General Purpose


Ambra GR75MD NH 1 720 A Grease--Molybdenum Disulphide
82995768 ESE--M4G194--B Sealer--Anaerobic Low strength
82995776 ESE--M4G195--A Sealer--Silicone
82995774 SP--M4G9112--A Sealer--Polyester Urethane
82995773 SP--M4G9112--C Sealer--Polyester Urethane
82995772 ESE--M4G217--A Sealer--Anaerobic
82995771 SP--M2G9121--B Sealer--RTV Silicone rubber
82995782 Gasket Removal -- Spray

10-15
SECTION 10 -- ENGINE -- CHAPTER 1

FAULT FINDING
IMPORTANT: Investigate and correct the causes of malfunctions during the repair cycle. This will prevent repeat
failures.

NOTE: Quantify all complaints of excessive oil consumption before initiating repairs. Maximum (North American)
engine oil consumption should be no more than three tenths of one percent (0.3%) of the fuel consumed by
volume, or no more than 1 quart of oil for every 83 gallons (US) of fuel usage. Record fuel and engine oil usage
for a minimum of 50 engine hours before calculating the rate of oil consumption. Oil consumption less than that
specified is not considered excessive.

The following table lists problems, probable causes, and recommended remedial action.

PROBLEM PROBABLE CAUSES REMEDY


Engine does not develop 1. Clogged air cleaner 1. Clean or replace element
full power
2. Fuel line obstructed 2. Remove obstruction

3. Faulty injectors 3. Clean and reset or replace

4. Incorrect valve lash adjustment 4. Check and reset

5. Burnt, worn or sticking valves 5. Replace valves or oversize,


and/or machine the valve guide
bores

6. Blown head gasket 6. Check head flatness and


replace gasket

7. Incorrect fuel delivery 7. Check injectors and fuel pump

8. Low cylinder compression 8. Replace piston rings or


re-bore/re-sleeve as necessary
Excessive exhaust 1. Oil leak on compressor or 1. Overhaul turbocharger
smoke turbine side of turbocharger,
(where installed)

2. Exhaust leak on exhaust 2. Install new gasket


manifold side of turbocharger,
(where installed)

3. Air cleaner dirty or restricted 3. Clean

4. Excessive fuel delivery 4. Check timing. Overhaul


injection pump and injectors.
Water temperature gauge 1. Faulty temperature sender 1. Replace sender switch
fails to reach normal oper-
ating temperature 2. Incorrect or faulty thermostat 2. Replace thermostat

3. Faulty water temperature 3. Replace temperature gauge


gauge

10-16
SECTION 10 -- ENGINE -- CHAPTER 1

PROBLEM PROBABLE CAUSES REMEDY


Engine knocks 1. Diluted or thin oil 1. Check crankshaft bearings for
damage, change as required.
Drain and refill with specified
oil and replace filter. Investi-
gate cause of dilution
2. Insufficient oil supply 2. Check oil level and top up as
necessary. Overhaul or replace
pump as necessary. Check
that oil filter is not clogged
3. Low oil pressure 3. Overhaul pump or relief valve
as necessary
4. Excessive crankshaft end--play 4. Install new thrust bearing liner
5. Flywheel or ring gear run-out 5. Skim flywheel or install new
excessive ring gear
6. Excessive connecting rod or 6. Install new bearing inserts and/
main bearing clearance or regrind crankshaft
7. Bent or twisted connecting 7. Replace connecting rods
rods
8. Crankshaft journals out-of- 8. Regrind crankshaft and install
round undersize bearing inserts
9. Excessive piston-to-cylinder 9. Re-bore/re-sleeve block and fit
bore clearance new pistons
10. Excessive piston ring 10. Install new pistons and rings
clearance
11. Broken rings 11. Install new rings, check bore
and pistons for damage
12. Excessive piston pin clearance 12. Install new piston or pin
13. Piston pin retainer loose or 13. Install new retainer, and check
missing bore/pistons for damage
14. Excessive camshaft play 14. Install new thrust plate
15. Imperfections on timing gear 15. Replace timing gear
teeth
16. Excessive timing gear 16. Replace timing gear
backlash

10-17
SECTION 10 -- ENGINE -- CHAPTER 1

PROBLEM PROBABLE CAUSES REMEDY


Engine overheats 1. Hose connection leaking or 1. Tighten hose connection or
collapsed replace damaged hose.
2. Radiator cap defective or not 2. Replace radiator cap
sealing
3. Radiator leakage 3. Repair/replace radiator
4. Improper fan belt adjustment 4. Readjust fan belt
5. Radiator fins restricted 5. Clean with compressed air
6. Faulty thermostat 6. Replace thermostat
7. Internal engine leakage 7. Check for source of leakage,
replace gasket or defective
parts
8. Water pump faulty 8. Overhaul water pump
9. Exhaust gas leakage into 9. Replace cylinder head gasket.
cooling system Check head for damage or
distortion
10. Coolant aeration 10. Tighten all connections and
check coolant level.
Ensure cylinder head gasket
has not blown
11. Cylinder head gasket 11. Replace cylinder head gasket
improperly installed
12. Hot spot due to rust and scale 12. Reverse flush entire cooling
or clogged water jackets system
13. Obstruction to radiator air flow 13. Remove the obstruction
14. Extended engine idling 14. Do not allow engine to idle for
long periods
15. Oil cooler tube blocked 15. Clean
16. Radiator core tubes blocked 16. Check free flow

10-18
SECTION 10 -- ENGINE -- CHAPTER 1

PROBLEM PROBABLE CAUSES REMEDY


Low oil pressure 1. Engine oil level low 1. Top off as necessary

2 Wrong grade of oil 2. Drain and refill with correct


grade of oil

3 Blocked oil pump sump screen 3. Clean pump screen

4 Oil pressure relief valve faulty 4. Install new relief valve

5 Oil pump worn 5. Replace Oil Pump

6 Excessive oil pump rotor and 6. Overhaul pump


shaft assembly clearance

7 Excessive main or connecting 7. Install new bearing inserts and/


rod bearing clearance or regrind crankshaft
Excessive oil 1. Engine oil level too high 1. Reduce oil level
consumption
2. External oil leaks 2. Replace gaskets and seals,
where necessary. Check
mating surfaces for damage or
distortion

3. Worn valves, valve guides or 3. Replace defective parts


bores

4. Cylinder head gasket leaking 4. Replace gasket. Check head


for damage or distortion

5. Oil loss past the pistons and 5. Replace rings and/or re-bore,
rings or re-sleeve block as
necessary

6. Oil cooler leak 6. Repair/replace oil cooler


assembly

7. Overfilling engine crankcase 7. Reduce oil level

8. Plugged crankcase breather 8. Remove obstruction

9. Failed turbocharger 9. Replace seal


compressor seal

10-19
SECTION 10 -- ENGINE -- CHAPTER 1

PROBLEM PROBABLE CAUSES REMEDY


Engine tends to keep 1. Air cleaner dirty or restricted 1. Clean or replace element
firing after fuel is shut
2. Oil leak on compressor side of 2. Overhaul turbocharger
off
turbocharger (where installed)
Engine power poor or 1. Intake manifold leaking at joint 1. Replace gasket
runs roughly face.
2. Replate manifold
2. Intake manifold cracked

10-20
SECTION 10 -- ENGINE -- CHAPTER 1

DESCRIPTION AND OPERATION A helical gear mounted on the rear of the camshaft,
This chapter describes the overhaul and repair of the drives the engine oil lubrication pump located
TB series direct injection diesel engine. These forward of the flywheel.
engines are available in 4-cylinder or 6-cylinder
Naturally Aspirated or Turbocharged form. The CRANKSHAFT ASSEMBLY
engines are of similar design, and service Five main bearings on the 4-cylinder engine, and
procedures are common throughout the range. A seven main bearings on the 6-cylinder, support the
design difference within the 4-cylinder engine crankshaft in the cylinder block.
includes the installation of a dynamic balancer
assembly. Manufacturing of the crankshaft involves two types of
materials, depending on the model:
All engines feature cross-flow cylinder heads, with
the intake and exhaust manifolds on opposite sides • Nodular iron with rough cast crank webs
of the cylinder head. The fuel and air combustion or
process takes place in the specially designed bowl in
the crown of the pistons. • Steel with machine finished crank webs

A thrust bearing incorporated in the center main


CYLINDER HEAD ASSEMBLY bearing of the crankshaft, controls end-thrust.
The cylinder head incorporates valves and springs,
with the valve rocker arm shaft assembly bolted to A heat-shrunk gear on the crankshaft transmits drive
the cylinder block through the cylinder head. Cylinder from the crankshaft, through meshed gears, to the
head retaining bolts are evenly spaced with a dynamic balancer assembly bolted to the bottom of
six-point pattern around each cylinder. This ensures the cylinder block. The dynamic balancer ensures
an even clamping load across the cylinder head smooth engine performance throughout the life cycle
area. of 4-cylinder engines. The crankshaft gear also
provides timing to the balancer assembly.
Bolted to the head on the right-hand side of the
engine is the intake manifold, and on the left-hand The external damper and the internal balancer attach
side, is the exhaust manifold. Installed on the outside to the crankshaft pulley. The 6-cylinder engine only
of the rocker cover are the diesel injectors. Located requires the external damper for smooth running
behind the radiator in front of the cylinder block, is the performance.
water outlet connections and thermostat.
CONNECTING RODS
The valve guides function as an integral part of the
cylinder head. The valve ports contain special Each engine contains a matched set of heavy beam
replaceable cast alloy valve seats, pressed into each constructed connecting rods, designed with a wedge
shaped end to reduce reciprocating weight at the end
port during manufacture. Repair includes valves with
oversized stems, and oversized valve seats where of the pistons. The connecting rods attach to the
available. crankshaft with insert-type copper lead or aluminum
tin alloy bearings.
Installed with the exhaust valves are positive valve
rotators. Both intake and exhaust valves contain The connecting rods, held in place by an end cap and
(umbrella) type oil seals. Adjustment of a self-locking two bolts, contain replaceable bronze bushings on
the wedge shaped end, allowing attachment of the
screw mounted in each rocker arm maintains valve
lash. free-floating piston pin.

CAMSHAFT ASSEMBLY PISTONS


The camshaft operates within replaceable bearings, Pistons constructed of aluminum silicon alloy with an
three for the 4-cylinder, and five for the 6-cylinder. iron insert for the top ring provide increased weight
and strength. The combustion chambers recess into
The camshaft idler and timing gears mesh with and
drive, the camshaft drive gear. the piston crowns. Each piston contains two
compression rings and an oil ring, which reduce
A thrust plate bolted to the block, between the friction and increase positive sealing. The rings
camshaft gear and the front camshaft journal, install above the piston pin.
controls the camshaft end-thrust.

10-21
SECTION 10 -- ENGINE -- CHAPTER 1

MANIFOLDS
The cross-flow type aluminum intake and cast iron
exhaust manifold, are on opposite sides of the
cylinder head. This design ensures a balance of heat
distribution within the cylinder head. The configura-
tion of the manifolds minimizes heat transfer to the
intake manifold.

Tubing connects the intake manifold to the air


cleaner. A trapped hole at the rear of the manifold
allows for the installation of ‘thermostart’, or other
cold starting aids.

NOTE: Tightly plug the intake manifold on tractors


that do not have cold start equipment installed, to
prevent ingestion of contaminants. Entry of grit or
other foreign materials will cause considerable
damage to the cylinder bores. In addition, dirt and grit
may enter through the air cleaner connections if not
properly secured.

CYLINDER BLOCK ASSEMBLY


The cylinder block, manufactured from alloy cast
iron, incorporates deep cylinder skirts and water
jackets for cooling the cylinders. The block contains
cylinder bores machined during the manufacturing
process.

The cylinders are vertical, in line, and numbered from


1 to 4 or 6 from the front of the engine to the rear.
Boring of the cylinders will allow the installation of
sleeves and oversized pistons (where available).

The oil pan, which functions as the reservoir for the


engine oil lubrication system, mounts to the bottom
of the cylinder block.

An aluminum cover attaches to the front engine


adapter-plate to protect the timing gear.

TIMING GEARS
During manufacturing the crankshaft timing gear is
heated and press fit onto the front of the crankshaft
with a high degree of accuracy. This enables precise
timing during the life of the engine. The crankshaft
gear drives the camshaft idler gear attached to the
front of the cylinder block. The idler gear then drives
the camshaft and the fuel injection pump via meshing
helical gears. A keyed camshaft gear, bolted to the
front of the camshaft, maintains position. It is
possible to check timing by observing punch marks
on all the gears.

10-22
SECTION 10 -- ENGINE -- CHAPTER 1

LUBRICATION SYSTEM main bearing. The gear has small oil passages
Installed on the rear of the engine block, behind the machined on both sides allowing excess oil to
flywheel left side, is a rotor type pump, which escape.
provides engine lubrication, Figure 1. The camshaft
The pressure lubricated camshaft drive gear
drives the oil pump, which draws oil from the engine
bushing, and oil splashed from the cam follower
oil pan through a tube and screen assembly.
chamber, lubricates the timing gears.
The oil filter body mounted on the left side of the
A drilled passage from the cylinder block crankshaft
engine block incorporates an integral spring-loaded
thrust bearing web to the balancer housing lubricates
relief valve to prevent over pressurization of the
the dynamic balancer on 4-cylinder engines. Oil
system.
flows through the balancer housing to the drilled
The spin-on type oil filter mounted to the support balancer gear shafts, and onto the bushings in the
housing allows easy access at service intervals. Oil balancer gears.
flows from the filter to the main oil gallery, which runs
A drilled passage on the cylinder block directs an
the length of the cylinder block and intersects the
intermittent flow of oil to the valve rocker arm shaft
camshaft follower chamber.
assembly. This is located vertically above the No. 1
The main gallery also supplies oil to the crankshaft camshaft bearing and aligns with a hole in the
main bearings and connecting rods. The underside cylinder head. The rotation of the camshaft allows a
of the pistons and pins are lubricated by oil pressure controlled intermediate flow of lubrication.
jets mounted adjacent to each main journal housing.
The oil filter support housing supplies oil to the
The camshaft drive gear bushing is pressure turbocharger (where installed).
lubricated through a drilled passage from the front

Engine Oil Flow

1
Engine Lubrication System with Turbocharger Installed

10-23
SECTION 10 -- ENGINE -- CHAPTER 1
Engine Components -- Right Side

1. Air Cleaner
2. Fuel/Water Sediment Separator
3. Fuel Injection Pump with Wax Plug
4. Fuel/Water Separator
5. Engine Oil Dip Stick
6. Electric Lift Pump and Fuel Filter Assembly
7. Starting Motor and Solenoid
8. Engine Intake Manifold and Thermostart Unit
9. Radiator Recovery Tank

2
Engine Components -- Left Side

1. Vertical Exhaust Muffler


2. Alternator
3. Exhaust Manifold
4. Oil Filter Assembly with Relief Valve
5. Mounting point for Auxiliary Pump and Breather
6. Fuse Box
7. Oil Pressure Sender

3
Engine Components -- Front

1. Center Support Bracket


2. Coolant Temperature Sender
3. Water Pump, Pulley and Fan
4. Fuel Injection Pump and Engine Timing Cover
5. Radiator Hose
6. Thermostatic Switch
7. Thermostat Housing

10-24
SECTION 10 -- ENGINE -- CHAPTER 1

DIESEL ENGINE STRIP-DOWN


Certain operations can be performed with the engine
still in the tractor, or unattached at the connection to
the front axle support, or separated from the
transmission housing as follows:

Overhaul and repair procedures with the


engine still in the tractor:
• Cylinder head and associated inlet and exhaust
components
• Fuel injection pump and related parts
• Water pump, thermostat, and associated compo-
nents
• Oil pump relief valve
• Oil pan and gasket
• Turbocharger

Overhaul and repair procedures with the


engine separated from the front axle:
• Front timing cover/timing gear removal
• Crankshaft and balancer, bearing shells, piston
removal, and oil pump suction tubing
• Front pulley and damper assembly

Overhaul and repair procedures with the


engine separated from the transmission
housing, and the oil pan removed:
• Crankshaft rear oil seal and carrier removal
• Oil pump and drive gear removal

10-25
SECTION 10 -- ENGINE -- CHAPTER 1

WARNING
Separating the tractor at any location is a
dangerous operation. Always use the appropri-
ate tools, lifting cranes, hoists, slings and
support stands. Securely support the tractor
where necessary when removing attaching
hardware for the front axle, transmission and
engine. Failure to adhere to safe maintenance
practices may lead to serious personal injury or
death, or cause irreparable damage to the tractor.

SEPARATING THE TRACTOR


The following procedures describe two methods of 1
disconnecting the engine from the tractor. The
method required depends on the component, the
location of the component, and the extent of the
maintenance action.

Engine-to-Front Axle
1. Raise the engine hood assembly (1).
2. Disconnect the battery negative (ground) cable.

5
3. Disconnect power steering hoses (1) from the
steering cylinder (2). Cap and plug openings to 2
prevent contamination. Drain excess hydraulic
fluid into a suitable container.

6
4. On four-wheel drive models:
• Disconnect the front differential lock hydraulic
tube. Cap and plug openings to prevent
contamination.
• Disconnect and remove the axle-shaft guard
bolts (1) and axle-shaft guard.
• Remove the driveshaft from the tractor.

10-26
SECTION 10 -- ENGINE -- CHAPTER 1
5. Open the drain cock (1) at the lower left side of
the radiator, and allow coolant to drain into a
suitable container.

NOTE: Loosening the radiator cap will facilitate fast-


er draining.
6. Remove radiator hoses from engine block. 1

7. Disconnect oil cooler hoses. Drain excess


hydraulic oil into a suitable container. Cap and
plug openings to prevent contamination.
8. Remove horn assembly connectors.
50025593

8
9. Remove fan guards (where installed).
10. Remove the center brace connected at the top of
the radiator below the air cleaner intake tube, and
at the front of the engine block (1).
11. Position Splitting Tool No. MS2700C with engine
Support Tool No. MS2700--C--8 in position. If the
splitting tool is unavailable, use an overhead 1
crane with suitable straps. Position straps at the
front and rear of the front support for maintaining
balance.

WARNING 20031379
Separating the tractor at any location is a
dangerous operation. Always use the appropri- 9
ate tools, lifting cranes, hoists, slings and
support stands. Securely support the tractor
where necessary when removing attaching
hardware for the front axle, transmission and
engine. Failure to adhere to safe maintenance
practices may lead to serious personal injury or
death, or cause irreparable damage to the tractor.

12. Support the engine at the front of the


transmission, and insert wedges, between the
axle and the front support.
13. Remove the hardware securing the engine to the
front support.
14. Wheel the front support and axle away from the
engine.

10-27
SECTION 10 -- ENGINE -- CHAPTER 1
Engine-to-Front Transmission
WARNING
Separating the tractor at any location is a
dangerous operation. Always use the appropri-
ate tools, lifting cranes, hoists, slings and
support stands. Securely support the tractor
where necessary when removing attaching
hardware for the front axle, transmission and
engine. Failure to adhere to safe maintenance
practices may lead to serious personal injury or
death, or cause irreparable damage to the tractor.

1. Disconnect the battery negative (ground) cable.


1
2. Raise the hood assembly (1).

10
3. Remove the radiator recovery tank hose (1),
recovery tank (2) and bracket (3).
1
4. Remove fuel lines to the lift pump and filter
assembly. Cap all openings to prevent the
2
ingestion of contaminants.

20031385

11
5. Remove electrical connector (1) at the lift pump
and filter assembly (2).

20031385

12

10-28
SECTION 10 -- ENGINE -- CHAPTER 1
6. Remove the mounting bolts and the lift pump and
filter assembly (1) to facilitate removal of the
starting motor.

20031385

13
7. Remove the battery ground wire (1) attached to
the engine block near the starting motor (2).

1
2

40031376

14
8. Remove the protective cover (1), and then
disconnect the starting motor solenoid wires (2).

40031370

15

10-29
SECTION 10 -- ENGINE -- CHAPTER 1
9. Remove the retaining bolts (1) and starting motor
(2).

1 2

20031390

16
10. Remove the throttle control-to-injection pump
linkage.
11. Remove fuel tank-to-injection pump fuel line (1). 1
Cap and plug openings to prevent contamina-
tion.
12. Remove leak-off tube from fuel injectors to fuel
tank.

40031375

17
13. Remove air cleaner restriction warning switch (1)
from the intake tube (2). Secure wires and 1
connectors out of the way.

2
20031388

18

10-30
SECTION 10 -- ENGINE -- CHAPTER 1
14. Remove the Thermostart connector (1) from the
intake manifold (2).

40031370

19
15. Remove the rearward hose of the rocker cover
breather (1).
1

20031382

20
16. Remove the steering motor tubes (1) from the
steering motor (2). Cap and plug all openings to
prevent contamination.

2
40031372

21

10-31
SECTION 10 -- ENGINE -- CHAPTER 1
17. Remove the rear center support bracket (1) at the
engine block. 1

20031383

22
18. Disconnect the front-main harness-to-rear main
harness connectors (1).
19. On four-wheel drive models, remove the axle
shaft cover.
20. Remove the axle shaft.
21. Support the engine using a suitable hoist and 1
Special Tool No. 380000216.

WARNING
Due to the complexity of each engine configura-
tion, perform a thorough inspection to ensure
20031388
that all necessary components, brackets, wires
and tubes are removed before separating the 23
tractor. This will prevent damage to the
equipment or personal injury.

22. Remove the low-pressure, lubrication hydraulic


lines (1). Cap and plug all openings to prevent
contamination.
23. Remove the left and right-hand buckle-up bolts
(2) between the engine and transmission (only
two shown).
24. Place the engine on a suitable stand for repair.
2

20031390 1

24

10-32
SECTION 10 -- ENGINE -- CHAPTER 1
Re-assembling an engine separated at the front 5. Purge coolant system of air by running the
axle or front transmission engine until reaching normal engine operating
Re-assembly of a separated engine at the front axle temperature. Refer to Section 10, Chapter 2
or front transmission follows the separation “Engine Cooling System”.
procedures in reverse with the following require-
6. Purge the hydraulic system of air. Refer to
ments:
Section 35 “Hydraulic System”.

WARNING 7. Check fuel control linkage for binding.


Before operating the engine after reassembling, 8. Check for obstructions around the fan belt and
verify that no wires or other components contact pulleys.
moving parts. 9. Check the air cleaner connections for tightness.
An improperly installed air cleaner will seriously
1. Check all hardware for correct installation and impede engine performance.
tightness. Refer to the Torque Values Table at the 10. Secure the front--main wire harness across the
front of this chapter, and refer to the standard top of the cylinder head. Ensure the harness
Minimum Hardware Tightening Torque Chart. does not contact any moving part or hot exhaust
2. Check all wires and connections for correct area.
routing and tightness. 11. Operate the engine and verify that all systems
3. Replenish all fluid levels. function correctly, and check fluid connections
for leakage. Top-up all fluids.
4. Purge fuel system of air. Refer to Section 10,
Chapter 4 “Fuel System”.

10-33
SECTION 10 -- ENGINE -- CHAPTER 1

DISASSEMBLY AND OVERHAUL


1
NOTE: When performing maintenance on the
engine, cap and plug all openings to prevent
contamination of fluids, or the ingestion of dirt and
other debris into the engine.

NOTE: Replace gaskets, seals and O-rings when


reassembling the engine or engine components.

1. Raise the engine hood assembly (1).

25
2. Disconnect the grille mounted headlamp har-
ness (1). 2

20031383

26

WARNING
Support the hood assembly before removing the
gas strut or hood retaining bolts. Without
support the hood assembly will fall and cause
damage to equipment or personal injury.

3. Support the hood assembly. Remove the hood


1 2
assembly gas strut retaining bolts (1), and
remove gas strut (2).
4. Remove the hood assembly retaining bolts (2),
Figure 26, and remove hood assembly.
40031378
5. Remove air cleaner restriction warning switch.
27

10-34
SECTION 10 -- ENGINE -- CHAPTER 1
6. Loosen air cleaner tube clamps and remove
intake tubes and connections.
7. Remove air cleaner retaining bolts (1). Remove
the air cleaner (2), and bracket (3).
1
2
3

40031376

28
8. Remove retaining bolts and ‘C’ clamp (1).

20031380

29
9. Remove retaining bolts and ‘C’ clamp (1).
Remove muffler assembly.
1
10. Remove engine fan belt guards.
11. Remove the front-main wire harness and ties,
which cross the cylinder head.

20031382

30

10-35
SECTION 10 -- ENGINE -- CHAPTER 1
12. Remove turbocharger protective cover (1).
2
13. Remove turbocharger assembly (2) (where
installed). Refer to Section 10, Chapter 5
“Turbocharger”.

1
20031382

31
14. Open the drain cock at the bottom left side of the
radiator, and allow coolant to drain into a suitable 1
container.
NOTE: Loosening the radiator cap (1) will facilitate
faster draining, Figure 32.

20031385

32
NOTE: Removal of the radiator will facilitate removal
of the water pump. However, it is not a requirement.

15. Remove the oil cooler (1) following the


procedures in Section 35 Hydraulics. 2
16. Remove the radiator (2) following the procedures
in Section 10, Chapter 2 “Engine Cooling
System”.
17. Remove the radiator recovery tank and bracket.
1
40031377

33

10-36
SECTION 10 -- ENGINE -- CHAPTER 1
NOTE: Figure 34 displays an incomplete engine to
facilitate the identification of components. 3 1

18. Loosen the alternator adjusting bolt (1), and


remove the fan belt.
19. Disconnect alternator wires.
20. Remove alternator (2).
21. Remove the water pump (3). Refer to Section 10,
Chapter 2 “Cooling System”. 2

20031386

34
22. Disconnect rocker cover breather and tubes (1).
23. Remove the rocker cover and discard gasket. 1

20031382

35
24. Close the main fuel tank shut-off valve.
25. Disconnect the fuel lines to the fuel filters,
Thermostart plug, lift pump, and fuel/water
separator.
26. Disconnect the fuel injector high-pressure and
leak-off tubes.
27. Clean the area around the fuel injectors to
prevent contamination, then remove injectors
(1).

36

10-37
SECTION 10 -- ENGINE -- CHAPTER 1
28. Remove the Thermostart connector (1) from the
intake manifold (2). 1
29. Disconnect lift pump and filter assembly
electrical connectors.
30. Remove the lift pump and filter assembly.
31. Remove the intake manifold and discard gasket
(1).
2

40025682

37
32. Remove the intake manifold and discard gasket
(1). 1
33. Remove the exhaust manifold and discard 2
gasket (2).
34. Rotate the push rods with the valve closed and
check for bent rods.

38

10-38
SECTION 10 -- ENGINE -- CHAPTER 1

CYLINDER HEAD

ROCKER SHAFT

Removal and Disassembly


NOTE: When removing the rocker shaft assembly,
leave the bolts in the shaft supports.

NOTE: Remove the rocker shaft retaining bolts


evenly and alternately. Remove the rocker shaft as
a complete assembly.
1. Remove the cylinder head bolts which retain the
rocker shaft and pass through the rocker shaft
supports.
2. Remove the push rods one at a time, and place
in a number rack to facilitate reinstallation.
3. Remove the retaining bolts (1), shaft supports
(5), rocker arms (2), springs (4) and spacers (3)
from the shaft (6).

39
Rocker Shaft Assembly
1. Bolts
2. Rocker Arm
3. Spacer
4. Spring
5. Rocker Arm Shaft Support
6. Groove at Front of Shaft

10-39
SECTION 10 -- ENGINE -- CHAPTER 1

VALVE AND SPRING ASSEMBLY

Removal and Disassembly


1. Remove cylinder head retaining bolts.
2. Remove retainer locks (2), valve springs (3) and
rotators with a valve spring compressor (1).
Place parts in a numbered rack to facilitate
reinstallation.

40

41
Valve Assemblies
Intake Valve Exhaust Valve
1. Valve Spring Lock 6. Valve
2. Spring Rotator 7. Spring
3. Seal 8. Seal
4. Spring 9. Spring Rotator
5. Valve 10. Spring Rotator
11. Valve Spring Lock

10-40
SECTION 10 -- ENGINE -- CHAPTER 1
Inspection and Repair
NOTE: Replace all valve stem seals when evidence
of smoke at start up or oil in the exhaust exists.
1. Leaking and/or discolored cylinder head core
plugs require changing. Remove all old sealant
from the cylinder head before installing new
plugs. Apply sealant G (see Specifications
Table), to the new plug mating faces, and drive
the new plugs into location, Figure 42.
Core plugs required:
4 CYL - four off in the top; one off in the rear of the
cylinder head; three off in the intake face.
6 CYL - six off in the top; one off in the rear of the
cylinder head; five off in the intake face.

42
Core Plug Installation

2. Scrape all gasket surfaces clean. Wash cylinder


head and valve guide bores in a suitable solvent.

NOTE: Before cleaning, remove injector washers.

3. Inspect cylinder head for nicks and burrs on


mating face. Remove with a suitable abrasive
and clean faces after repair.
4. Check cylinder head for flatness in all directions
using a straight edge (1) and feeler gauge (2).
Disparity should not exceed 0.03 mm (0.001 in.)
in any 25.4 mm (1 in.) area, or 0.127 mm (0.005
in.) overall, Figure 43.
43
5. Perform the following check for a resurfaced
cylinder head: Place the cylinder head (without
the gasket) on the cylinder block, and install bolts
hand tight. Ensue all bolt faces seat.
6. Install rocker shaft supports with long bolts.
Using a feeler gauge, check clearance between
underside of bolt heads and cylinder head or
rocker shaft support.
7. A bolt that bottoms out allows the insertion of a
0.25 mm (0.10 in.) feeler gauge under the bolt
head. To correct, increase the cylinder block
thread using a 9/16--13 UNC--2A thread tap.
Install the bolts in the holes originally checked in.

44

10-41
SECTION 10 -- ENGINE -- CHAPTER 1

VALVE INSERTS
Cylinder Head Counter Bore

Insert Oversize Exhaust Valve Insert Intake Valve Insert


0.25 mm (0.010 in.) 44.17-44.20 mm (1.739-1.740 in.) 50.01-50.04 mm (1.969-1.970 in.)
0.50 mm (0.020 in.) 44.42-44.45 mm (1.749-1.750 in.) 50.27-50.29 mm (1.979-1.980 in.)
0.76 mm (0.030 in.) 44.68-44.70 mm (1.759-1.760 in.) 50.52-50.55 mm (1.989-1.990 in.)

NOTE: To maintain compression, coordinate


refacing the valve seat with refacing of the valve.

1. Examine the valve seat inserts and reface if


pitted. Replace loose or damaged inserts.
2. To install a new valve insert, the cylinder head
must be counter bored, as described in the above
chart. Chill new inserts in Dry Ice before
installing.

Valve Seat Specifications, Figure 45.

• Valve Seat Angle:


Intake 30.0°--30.30°
45
Exhaust 45.0°--45.30° Valve Seat Dimensions
1. Valve Seat Angle
• Valve Seat Width: 2. Valve Seat Width
Intake 1.9--2.5 mm (0.075--0.098 in.) 3. Valve Head Face to Cylinder Head Depth
Exhaust 1.8--2.3 mm (0.071--0.091 in.)

• Valve Head Face to Cylinder Head Face Depth:


Intake 0.86--1.32 mm (0.034--0.052 in.)
Exhaust 1.2--1.6 mm (0.047--0.063 in.)

NOTE: On occasion, oversized valve inserts with a


diameter of 0.25 mm (0.010 in.) and 0.5 mm (0.020
in.), are installed during manufacture. Cylinder
Heads with oversize inserts are stamped SO10/OS,
SO2O/OS, on the exhaust manifold side in line with
the valve seat concerned.

3. Check the width of the valve seat inserts, and


reface by grinding to dimensions as needed.

10-42
SECTION 10 -- ENGINE -- CHAPTER 1
4. Use a Dial Indicator (1) to measure the
concentricity of the valve seats. In addition,
measure valve seat to valve guide bore. Total
indicator reading should not exceed 0.051 mm
(0.002 in.), Figure 46.

46
Valve Seat Concentricity
1. Dial Indicator
2. Measuring Probe

5. Use a seat cutter to correct any seat eccentricity,


or clean up of pits and grooves. Ensure after
rework that seat width is within specified limits,
Figure 45.
6. Rotate a new or refaced valve in the seat using
engineering blue. Ensure all the blue is
transferred to the valve head protrusion. If any
blue remains below or around the seat, raise or
lower the seat accordingly, Figure 47 in the
following manner:
• Exhaust Valve - Raise by using 60 degree
grinding wheel on surface of seat bottom,
lower by using 30 degree grinding wheel on
surface of seat top. 47
Raising and Lowering of Valve Seats
1. Lowering the Valve Seat
2. Raising the Valve Seat

• Intake Valve - Raise by using 45 degree


grinding wheel on surface of seat bottom,
lower by using 15 degree grinding wheel on
surface of seat top.

48
Critical Valve Points
1. Valve Land Edge
2. Valve Head
3. Valve Face Angle
4. Valve Face
5. Valve Stem
6. Valve Tip

10-43
SECTION 10 -- ENGINE -- CHAPTER 1

VALVE GUIDES
1. Use a telescopic gauge (1) and a micrometer, to
measure the valve guide bore (2) clearance.
Check for a maximum clearance of 0.023-0.069
mm (0.0009-0.0027 in.) on the intake valve stem;
and 0.048-0.094 mm (0.0019-0.0037 in.) on the
exhaust valve stem, Figure 49.
NOTE: Production cylinder heads may have one or
more machined, oversize valve guide bores, or
valves installed 0.38 mm (0.015 in.). Such cylinder
heads have 15 or VO15OS stamped on the cylinder
head, exhaust manifold side, adjacent to the valve
concerned.
49
Measuring the Valve Guide Bore
2. Ream out the valve stem guide as per the
1. Telescopic Gauge
following reamer and pilot combinations: When
2. Valve Guide Bore
going from a standard valve stem to an oversize,
always use reamers in sequence.
0.076 mm (0.003 in.) oversize reamer and
standard diameter pilot.
0.38 mm (0.015 in.) oversize reamer, and 0.076
mm (0.003 in.) oversize pilot.
0.76 mm (0.030 in.) oversize reamer, and 0.38
mm (0.015 in.) oversize pilot.

10-44
SECTION 10 -- ENGINE -- CHAPTER 1

VALVE SPRINGS
1. Check the square of the valve spring (1) on a flat
surface. The distance from the top of the springs
edge to a flat vertical edge positioned next to it,
should not exceed 1.52 mm (0.060 in.) as shown
in Figure 50.
2. Check both the free length, and the loaded length
of the valve springs as follows:
Free length 60.7 mm (2.39 in.)
Installed length 47-49.6 mm (1.86-1.95 in.)
Loaded length 48.26 mm (1.9 in.) using a weight
of 28-31 kg (61-68 lbs.)
Loaded length 35.69 mm (1.4 in.) using a weight 50
of 61-69 kg (135-153 lbs.) Valve Spring Squareness
1. Measuring Spring Squareness

3. Ensure the valve spring retainer locks (2) are in


good condition, and replace if worn or damaged.

51

10-45
SECTION 10 -- ENGINE -- CHAPTER 1

ROCKER SHAFT
Inspection
1. Check the internal and external diameters of the
rocker shaft for signs of wear or damage.
Thoroughly clean reused rocker shaft in solvent,
making sure all oil passages are clear before
reassembling.
2. Inspect rocker arm adjusting screws (1),
adjusting screw ball-ends, and push rods (2) for
wear, distortion, nicks and any other visible
damage, Figure 52. Replace defective parts as
needed.
3. Inspect the inside diameter of the rocker arm for
damage or wear. If any of these characteristics
are not to specification replace with new parts.
52
NOTE: Do not attempt to straighten bent push rods,
Rocker Shaft Assembly
replace with new.
1. Rocker Arm Adjusting Screw
2. Push Rod

Assembly and Installation


1. Position the shaft identification groove (6)
forward and upward to ensure oil grooves and
holes face downward.
2. Assemble rocker shaft assembly with the rocker
shaft support (5), springs (4), spacers (3), rocker
arms (2) and retaining bolts (1), as illustrated in
Figure 53. Tighten bolts to a torque of 217 N⋅m
(160 ft.-lb.)

53
Rocker Shaft Assembly
1. Bolts
2. Rocker Arm
3. Spacer
4. Spring
5. Rocker Arm Shaft Support
6. Groove at Front of Shaft

10-46
SECTION 10 -- ENGINE -- CHAPTER 1

CYLINDER HEAD
Assembly
1. Insert valves into original guide bores. Lap with
a suitable paste. Remove all traces of paste after
lapping.
2. Lubricate all components with clean engine oil
when reassembling. Use a spring compressor to
reassemble the valves, valve springs, retainers,
rotators, and keepers. Install new seals.
3. Insert each push rod into its original position,
ensuring to seat each ball end in its cam follower.
Installation 4 Cylinder
Installation of the cylinder head assembly and
components follows the removal procedures in
reverse with the following requirements:

1. Install new cylinder head, intake and exhaust


manifold gaskets.
6 Cylinder
NOTE: Ensure correct installation of exhaust
manifold gasket to suit profile of exhaust ports.

2. Tighten the cylinder head bolts in sequence


progressively in three stages, Figure 54.
Stage l 156 N⋅m (115 ft.-lb.)
54
Stage 2 190 N⋅m (140 ft.-lb.) Cylinder Head Bolt Tightening Sequence
Stage 3 217 N⋅m (160 ft.-lb.)
NOTE: Lubricate bolts before assembling. Torque
bolts to specification with the engine cold.
3. Adjust valve lash setting with each piston in turn
at Top Dead Center with rockers free to move,
Figure 55.
Intake Valve Lash 0.36-0.46 mm
(0.014-0.018 in.) 1
Exhaust Valve Lash 0.43-0.53 mm
(0.017-0.021 in.)
NOTE: Set valve lash only when the engine is cold.
4

3 2

55
Setting Valve Lash
1. Adjuster Screw
2. Rocker Arm
3. Valve Stem
4. Feeler Gauge

10-47
SECTION 10 -- ENGINE -- CHAPTER 1
4. Install the fuel injectors (1), with new washers (3),
and cork washers (4), Torque mounting bolts (2)
to 23 N⋅m (17 ft.-lb.).
5. Install the injector fuel and leak off pipes with new
washers. Tighten banjo bolts to a torque of 11
N⋅m (8 ft.-lb.).
NOTE: Hold the leak off plastic tubing securely when
tightening to prevent pipes from pivoting.

6. Install exhaust manifold bolts and tighten to a


torque of 38 N⋅m (28 ft.-lb.).
7. Install intake manifold bolts and tighten to a
torque of 35 N⋅m (26 ft.-lb.). 56
Injector Removal
1. Fuel Injector
2. Mounting Bolts
3. Copper Washer
4. Cork Washer

ENGINE FRONT COVER AND TIMING


GEAR
Removal
1. Separate the Tractor. Refer to Section 10,
Chapter 1 “Separating the Tractor”.
2. Remove the radiator. Refer to Section 10,
Chapter 2 “Engine Cooling System”.
3. Remove the tensioner and fan belt.
4. Remove the crankshaft pulley bolt and washer.
5. Use Puller (3) Tool No. FNH09539 and Shaft
Protector (1) Tool No. 380000564 to remove 57
crankshaft pulley (4), spacer and O-ring. Crankshaft Pulley Removal
1. Shaft Protector
6. Drain the engine oil and remove the oil pan. 2. Bolt
3. Puller
4. Crankshaft Pulley

7. Remove the retaining bolts and the front cover


with gasket.

58
Timing Gear Cover Removal
1. Timing Cover Gasket
2. Timing Cover
3. Fuel Pump Timing Gear Cover
4. Tachometer Drive Elbow (where installed)

10-48
SECTION 10 -- ENGINE -- CHAPTER 1
IMPORTANT: Do not remove the crankshaft timing
gear (2). The gear is heat shrunk on the crankshaft
and aligned to the crankshaft No. 1 pin to within 0.10
mm (0.004 in.). A damaged gear will require a new
crankshaft.

59
Timing Gears
1. Camshaft Gear
2. Crankshaft Gear
3. Camshaft Idler Gear
4. Fuel Injection Pump Drive Gear

8. Use a dial indicator or feeler gauge (1) to


measure the backlash between each set of
gears, before removing the timing gears.
9. Rotate the gears and check the backlash at four
equal points on the gears. Replace if the
backlash exceeds the following specifications,
Figure 60:
Backlash to 0.15-0.46 mm
crankshaft gear (0.005-0.013 in.)
Backlash to 0.025-0.38 mm
camshaft gear (0.001-0.015 in.)
Backlash to 0.010-0.15 mm
fuel injection pump gear (0.004-0.006 in.) 60
Timing Gear Backlash
1. Feeler Gauge

TIMING GEAR
Removal
1. Use a lever (1) to pry the camshaft gear (3) away
from thrust plate (4). Using a dial indicator or
feeler gauge (2), to check the clearance for
0.076-0.35 mm (0.002-0.014 in.). Install a new
camshaft thrust plate if not within specifications.
2. Remove the camshaft idler gear and adapter
from the block.
3. Remove the camshaft gear.
4. Remove retaining nut and washer from the fuel
injection pump gear, and use a puller to remove 61
the gear from the shaft. Camshaft End Play Measurement
5. If necessary, remove the six retaining bolts and 1. Lever
pry the rear cover from the engine block. 2. Feeler Gauge
3. Camshaft Gear
4. Thrust Plate

10-49
SECTION 10 -- ENGINE -- CHAPTER 1
Inspection
1. Wash all gears in a suitable solvent.
2. Inspect gear teeth for wear, burrs or scratches.
Remove minor defects with a fine abrasive.
Thoroughly clean gears after repairing.
3. Inspect bushings for obvious damage.
4. Check camshaft idler gear adapter for obstruc-
tion.
5. Inspect camshaft key and key-way for damage.
6. Replace defective parts before reassembling.

Timing Gear Initial Installation


1. If previously removed, install the rear cover with
a new seal and six retaining bolts.
2. Tighten retaining bolts to a torque of 24 N⋅m (18
ft.-lb.).
3. Position piston No. one at Top Dead Center using
the flywheel timing marks.
4. Install camshaft gear with spacer and key.
Tighten to a torque of 69 N⋅m (51 ft.-lb.).
5. Install the camshaft idler gear using alignment
marks (1) with the crankshaft and camshaft
gears. Tighten to a torque of 237 N⋅m (175 ft.-lb.).

62

10-50
SECTION 10 -- ENGINE -- CHAPTER 1
Depending on configuration, proceed as follows:

DPS Non-Emissionized Engine


6. Position piston No. one at Top Dead Center.
7. Install the fuel injection pump with new seal,
aligning mark on pump flange, to timing mark on
front cover at 0°.
8. Tighten the injection pump retaining bolts to a
torque of 24 N⋅m (18 ft-lb.).
9. Install the pump gear over the pump shaft.
10. Align timing marks to the camshaft idler gear and
torque pump shaft retaining nut to 79 N⋅m (58
ft-lb.) Recheck the backlash between the fuel
injection pump and camshaft idler gear.

63
DPS Pump Gear to Camshaft Drive Gear
1. Pump Drive Gear
2. Camshaft Idler
3. Timing Mark

10-51
SECTION 10 -- ENGINE -- CHAPTER 1
DP203 Series Fuel Injection Pump
1. Set engine at 28° Bottom Top Dead Center
compression stroke using flywheel timing marks.

APB10008

64
2. Install the pre-timed fuel injection pump with a
new seal, in the locked position (2) to the engine
block and front cover.
3. Tighten the retaining bolts to a torque of 24 N⋅m
(18 ft.-lb.).
4. Install pump gear on pump shaft.
5. Install the nut and washer loose enough to allow
the gear to rotate freely on the pump shaft.
6. Initially tighten the pump gear nut to a torque of
9 N⋅m (6.7 ft.-lb.) while holding gear in a
clockwise position, to remove backlash.
7. Unlock the pump by releasing the locking bolt. 65
8. Install spacer between the pump body and
locking bolt head (1).
9. Tighten the pump gear retaining nut to a final
torque of 81 N⋅m (60 ft.-lb.).

10-52
SECTION 10 -- ENGINE -- CHAPTER 1
Final Installation of Timing Gear
Replace the oil seal every time after removing the
front cover as follows:

1. Drive out the old oil seal in the front cover with a
punch (2).
2. Position a new gasket on the front cover (1).
3. Install front cover by aligning dowel pins.

66
4. Tighten the retaining bolts in sequence as shown
in Figure 67 and torque as follows:
• Torque 5/16 in 18 UNC bolts to 18--24 N⋅m
(13--18 lb.-ft.)
• Torque 3/8 in 16 UNC bolts to 34--41 N⋅m
(25--30 lb.-ft.).

67
5. Install a new O-ring (1) over the crankshaft into
the front cover.

68

10-53
SECTION 10 -- ENGINE -- CHAPTER 1
6. Lubricate seal retainer (1) and push onto Tool No.
NH10--103 (2). Use the tool to press the seal into
the front cover over the new seal.
7. Clean surfaces and apply a 3 mm (0.19 in) bead
of flexible gasket sealant to the fuel injection
pump gear cover.
8. Tighten the retaining bolts to a torque of 37 N⋅m
(28 lb.--ft.).
9. Lubricate the crankshaft.
10. Install the crankshaft key into key-way. 2

69
11. Slide the pulley spacer (1) over the key.
12. Push the crankshaft pulley onto the crankshaft.
Ensure to seat the pulley completely.
13. Tighten the crankshaft pulley retaining nut to a
torque of 284 N⋅m (210 lb.--ft.).
14. Install the oil pan. Refer to Section 10, Chapter
1 “Oil Pan”.
15. Connect the engine to the front axle. Refer to
Section 10, Chapter 1 “Separating The Tractor”.
16. Install the radiator. Refer to Section 10, Chapter
2 “Engine Cooling System”.
70

10-54
SECTION 10 -- ENGINE -- CHAPTER 1

OIL PAN
Removal
2
WARNING
Due to the weight of the oil pan it is
recommended that a hydraulic jack is used to
support and lower the oil pan to the ground.

1. Drain engine oil through oil pan plug (2) and


remove oil level indicator.
NOTE: On models with four-wheel drive, remove the
axle shaft guard (1), Figure 71, and axle shaft to
facilitate removal of the oil pan.
71
2. Remove oil pan bolts, including those through
transmission, front support, and oil pan, to
ground.

Inspection and Repair


1. Clean gasket material from sump face and clean
sump in a suitable solvent. Inspect sump for
cracks, damaged threads, or damaged sump face.
Installation
Installation is the removal procedures in reverse with
the following requirements:
1. Ensure block face is clean and free of gasket
material. Install a new gasket to the front cover
and oil pan. Apply sealer to the front plate, and
rear oil seal return joints.
2. Position the oil pan (2) and install a bolt at each
corner, finger tight, to hold in position. Install
remaining bolts and torque to 38 N⋅m (28 lb.-ft.).
3. Install oil pan plug (1) and tighten to a torque of
41 N⋅m (30 lb.-ft.)
4. Replenish oil and check pan for leakage. 72

CONNECTING RODS, BEARINGS,


PISTONS, AND RINGS
Removal
NOTE: The connecting rods and pistons are
removable with the engine installed, once the cylinder
head and oil pan sump are removed. Step 1 is critical
when reusing old pistons, to prevent ring land damage.

1. With the cylinder head removed, clean off any


ridge from the top of the cylinder bores using a
ridge remover.
2. With the piston at the bottom of the stroke remove
the end cap bolts, cap (2), and liner (1). Push the
piston assembly out through the top of the block, 73
and remove the liner from the connecting rod, Connecting Rod end Cap Removal
Figure 73. 1. Bearing Liner
2. End Cap

10-55
SECTION 10 -- ENGINE -- CHAPTER 1
3. Turn the crankshaft and repeat the process for
the remaining pistons. 1
NOTE: Match bearing caps and liners to each
respective connecting rod.

4. Remove snap rings (1) with an expander tool (2),


from each side of the piston, Figure 74 and
remove piston pin (3), Figure 75.

74
Piston Ring Removal

5. Ensure each piston and rod remain matched for


reassembling into the cylinder block, Figure 75.

75
Piston Assembly Disassembled
1. Piston
2. Pin Retainers
3. Piston Pin
4. Connecting Rod
5. Bearing Liners
6. Bearing Cap
7. Retaining Bolts
8. Piston Rings

10-56
SECTION 10 -- ENGINE -- CHAPTER 1
Inspection and Repair
Refer to Figure 76.

1. Clean the piston and connecting rod assemblies


in a suitable solvent. Inspect for damage to ring
lands, skirts, or pin bosses.
2. Check connecting rod components for damage,
and place in an alignment fixture (where
available) to check for distortion. Ensure that any
distortion found is within specification as follows:
A). Maximum twist - 0.30 mm (0.012 in.)
B). Maximum bend - 0.10 mm (0.004 in.)
3. Check piston pin bushing for damage or wear in
the following manner:
Measure the outside diameter of the piston
pin(1), and inside diameter (2) of the connecting
rod bushing to:
• Piston Pin Outside Diameter
Naturally Aspirated -- 38.095 - 38.100 mm
(1.4998 - 1.5000 in.)
Turbocharged -- 41.270 - 41.275 mm (1.6248
- 1.6250 in.)
• Connecting Rod Bushing Internal Diameter
(small end)
Naturally Aspirated -- 38.113 - 38.120 mm
(1.5005 - 1.5008 in.)
Turbocharged -- 41.288 - 41.295 mm (1.6255
- 1.6258 in.)

76

10-57
SECTION 10 -- ENGINE -- CHAPTER 1

CONNECTING ROD BUSHINGS


Repair
1. Use Tool No. FNH00053 to remove and replace
defective connecting rod bushings. Refer to
Figure 77.
NOTE: Align the split in the smaller bushing at a right
angle to the center line of the connecting rod.

NOTE: Change connecting rods as a matched set.

T1B10029

77

Connecting Rod Bush Installation


Removal Installation
1. Washer 8. Connecting Rod Facing up
2. Collar 9. Remover Insert 1
3. Installation Insert 1 10. Remover Insert 2
4. Bush 11. Remover Insert 3
5. Installation Insert 2 12. Connecting Rod Location
6. Pins 13. Washer
7. Fixture 14. Location Plate

10-58
SECTION 10 -- ENGINE -- CHAPTER 1
2. When special tooling is not available for the
removal or installation of the connecting rod
bushing, install a standard bushing in the
following manner:
• Manufacture a press bar from suitable bar
stock with the end face angled enough to suit
the connecting rod bushing side face. Place
the connecting rod securely in a bench press.
Position the tool (1) on the bushing (2), and
gently drive the bushing from its position.
Manufacture a guide to assist in aligning the
bar stock during this operation.
NOTE: When installing a new bushing on the smaller
end of the connecting rod, position the slot in the 78
bushing at a right angle to the center line of the Connecting Rod Bushing Fitment
connecting rod. 1. Press Tool
2. Bushing
• Press fit a new bushing using suitable bar 3. Machined Side
stock with an end face machined flat. Use a 4. Bushing Slot Alignment
guide as described and gently drive new
bushing into the connecting rod.
• Grind the side faces of the new bushing to
match the side faces of the connecting rod
after installation. Remove all sharp edges
and loose metal shavings from the connect-
ing rod before reassembling on the engine.
3. After installing a new bushing, drill a 4.6 mm
(0.181 in.) hole through the top of the connecting
rod and drill through the existing oil hole,
Figure 79.
4. Use an expanding reamer to obtain correct
bushing to piston pin clearance of 0.013-0.025
mm (0.005-0.0010 in.). Remove burrs and metal
shavings before installing on engine.

79
Drilling of Connecting Rod
1. Connecting Rod
2. Drill

10-59
SECTION 10 -- ENGINE -- CHAPTER 1

CYLINDER BLOCK
Overhaul
Cylinder block plugs and senders on 4-6 cylinder
engines must be replaced if leaking or rusty. Before
installing new plugs, remove all old sealant off the
block. Install new plugs with a suitable sealant.

NOTE: Assemble new parts, with mating faces and


threads coated in sealant, as listed below (refer to
Engine Specifications section):

Front and left hand side of the engine block.


Plug (1) Drive into block.
1
Plug (2) Apply sealant 82995768 and torque to
8--14 N⋅m (6--10 ft.-lb.).

Fitting (3) Apply sealant 82995768 and torque to


24--34 N⋅m (18--25 ft.-lb.).

Plug (4) Apply sealant 82995768 and torque to


68--95 N⋅m (50--70 ft.-lb.).

Fitting (5) Apply sealant 82995768 and torque to


24--34 N⋅m (18--25 ft.-lb.).

Plug (6) Apply sealant 82995768 and torque to


27--47 N⋅m (20--35 ft.-lb.).
5 6
2

4 3

APB10052

80

10-60
SECTION 10 -- ENGINE -- CHAPTER 1
Rear and right hand side of the engine block.
Plug (1) Apply sealant 82995772 and drive into
block.
5 1
Oil Jets (2) replace with new if damaged, apply
engine oil only on re-assembly ‘‘Do not use sealant”.

Plug (3) Apply sealant 82995768 and torque to


24--34 N⋅m (18--25 ft.-lb.).

Plug (4) Apply sealant 82995768 and torque to 8--14


N⋅m (6--10 ft.-lb.).
2
Plug (5) Torque to 54--81 N⋅m (40--60 ft.-lb.).

1 3

APB10053

81

10-61
SECTION 10 -- ENGINE -- CHAPTER 1

CYLINDER BORE

Inspection
1. Check the cylinder bore for scuffing or grooves
around the ring travel area. Check for
irregularities by running a finger over the surface
of the bore.
2. Use a telescopic gauge to check for roundness,
wear, or taper by using a telescopic gauge,
Figure 82.

TA6010040
82
Refer to Figure 83.
C
• Measure diameter of bore crosswise at point
A and again at point B. In addition, measure A
diameter crosswise at point C and again at
point D. Variances between the measure-
ments indicate out-of-round.
• Measure diameters of bore lengthwise from
point A to point B and again from C to point
D. Variances between the measurements B
indicate taper.
D
TA6010041
83
Cylinder Bore-to-Piston Clearance
Refer to Figure 84. 1

1. Measure the diameter of the cylinder bore 82.6


mm (3.25 in) from the top of the engine block (1)
and label Point A.
2. Measure the diameter of the piston 97.28 mm
(3.83 in) from the top of the piston, and 90° from
the piston pin (2) and label Point B.
3. Subtract Point B from Point A and compare with 2
the specifications to follow:
• Naturally Aspirated Engine – 0.14--0.17 mm
(0.0055--0.0067 in) 84
• Turbocharged Engine – 0.17--0.19 mm
(0.0067--0.0075 in)
The maximum cylinder bore-to-piston clearance on
a settled (run) engine is 0.28 mm (0.011 in).

10-62
SECTION 10 -- ENGINE -- CHAPTER 1
Specifications Bore or hone cylinder bores not within specifications,
Cylinder Bore Taper: to fit the next oversize piston. Determine finished
bore size by measuring the piston diameter at right
• Repair Limit – 0.025 mm (0.001 in) angles to the piston pin, and adding the appropriate
• Wear Limit – 0.127 (0.005 in) piston-to-bore clearance.

Cylinder Bore Out-of-Round: Oversize pistons


• Repair Limit – 0.03 mm (0.001)
0.10 mm (0.004 in.)
• Wear Limit – 0.127 mm (0.005 in)
0.51 mm (0.020 in.)
Cylinder Bore Diameter: 2.0 mm (0.040 in.)
• 111.778 -- 111.841 mm (4.4007 -- 4.4032 in.) Bores to take 0.10 mm (0.004 in.) oversize pistons
need only be honed using a rigid hone with a grit size
Repair of 150-220. Clean thoroughly after boring and
When clearance exceeds specifications, recheck honing.
with a new piston. If clearance still exceeds
Sleeving of the cylinder bores becomes expedient
specifications, measure remaining cylinder bores
when oil consumption is high due to porosity, when
and pistons to establish the largest clearance. Based
replacing sleeves installed in service, and when the
on this resultant, re-bore to the next oversized piston,
cylinder bore is damaged beyond re-boring limits.
or sleeve the block and install new pistons.

For clearance less than specification, hone the bore NOTE: Use only standard pistons when recondition-
until obtaining the desired clearance. ing engines equipped with sleeves.

10-63
SECTION 10 -- ENGINE -- CHAPTER 1

SLEEVES
Boring and Honing
1. Measure the outside diameter (1), Figures 85
and 86, of the sleeve in several places, and
average the dimension. Counter bore the
cylinder block using the average dimension to
obtain a press fit between bore and sleeve.
Interference of sleeve to the cylinder bore is
0.025-0.076 mm (0.001-0.003 in.).
2. Counter bore the cylinder block to a depth of
204.7 mm (8.06 in.) from the block face. Surface
finish of the bore must not exceed 80 microns.
Leave a step at the bottom of the bore a minimum 85
of 9.7-10.2 mm (0.380-0.400 in.) to allow for run Cylinder Block Sleeving
out of chamfers.
3. Bore the sleeve through to a diameter of
113.13-113.18 mm (4.454-4.456 in.).
4. Clean the cylinder bores and thoroughly dry.
5. Grease the sleeve and press the sleeve home to
the lip in the bore. The top of the sleeve should
protrude through the top of the block 0.127-1.0
mm (0.005-0.040 in.).
6. Bore the sleeve to 111.72-111.76 mm
(4.398-4.400 in.).
7. Skim the block face and top of sleeves to achieve
the specified flatness of 0.08 mm (0.003 in.), in 0.127
any 152 mm (6 in.) area, and 0.03 mm (0.001 in.), 45°
1.0
in any 25.4 mm (1 in.) area. Maintain a chamfer
of 45° x 0.5 mm (0.020 in.) in the internal
diameter at the top of the sleeve, to prevent 1.5
piston damage on re-assembly.
8. Break the sharp edge at the bottom of the sleeve 210.8
before honing.
1
9. Hone the cylinder bore to: 215 204.7
Grade A 111.777-111.798 mm
(4.4007-4.4015 in.)
9.6
Grade B 111.798-111.818 mm 10.16
(4.4015-4.4023 in.)
NOTE: Surface finish must average 20 to 30
Microns, with a cross hatch of 35° -55°. 113.13--113.18

10. Maximum taper is 0.025 mm (0.001 in.) to bottom


of the bore, and maximum oval is 0.038 mm
(0.0015). APB10057
86

10-64
SECTION 10 -- ENGINE -- CHAPTER 1
Assembly
IMPORTANT: When installing the pistons, align the
letter or grade mark on the piston with the pip mark
on the connecting rod, and facing the front of the
engine.

NOTE: When replacing pistons, use the same type


piston as the one removed, with the same
identification letters and numbers, as embossed on
the underside of the old piston.

1. With the piston at Top Dead Center, use a dial


indicator (1) to record the piston-to-block height,
Figure 87. Compare measurement with the
87
following specifications:
Piston to Cylinder Block Height
Naturally Aspirated 0.28-0.58 mm
(0.011-0.023 in.)
Turbocharged 0-0.3 mm
(00.00-0.012 in.)

2. Check the cylinder bore-to-piston clearance


using the procedure previously described in this
chapter.
NOTE: Always install new pistons when the cylinder
bore-to-piston clearance exceeds specification.
3. Lubricate all of the components with engine oil.
4. Assemble the piston (1), and connecting rod (2)
with the letter or grade mark on the piston aligned
to the pip on the rod and facing the front of the
FRONT
engine.

1
2

88
Piston Connecting-Rod Alignment
1. Piston
2. Piston Rod

10-65
SECTION 10 -- ENGINE -- CHAPTER 1
5. Check the piston ring gap (2) width, using a feeler
gauge (1), in a vertical position at the top, middle,
and bottom of the bore to:
Top compression ring 0.38-0.84 mm
(0.015-0.033 in.)
2nd compression ring 0.66-1.12 mm
(0.026-0.044 in.)
Oil control ring 0.38-0.84 mm
(0.015-0.033 in.)

89
Piston Ring Gap
1. Feeler Gauge
2. Ring

6. Ensure to use the correct expander (1) to remove


or install piston rings (2).

90
Piston Ring Installation
1. Piston Ring Expander
2. Piston Ring

7. Use a feeler gauge (2) to check the gap between


a new piston ring (1) and groove.
Compare to the following specification:
Top compression ring 0.112-0.155 mm
(0.0044-0.0061 in.)
2nd compression ring 0.099-0.142 mm
(0.0039-0.0056 in.)
Oil control ring 0.061-0.104 mm
(0.0024-0.0041 in.)

91
Piston Ring Side Clearance
1. Piston Ring
2. Feeler Gauge
3. Piston

10-66
SECTION 10 -- ENGINE -- CHAPTER 1
8. Install the piston rings as shown in Figure 92:
NOTE: Before installing new pistons and rings into a
used cylinder bore, remove the high polish
(de-glaze) from the cylinder walls with a suitable
honing tool, preferably a Flex-Hone, as previously
described. Hone and install new rings and pistons
when oil consumption is excessive and the engine
has run a minimum of 300-400 hours. If the original
cross hatch pattern is evident in the cylinder bore
area, do not hone. If honing is required, hone with a
150 grit stone in a 35 to 55 degree cross hatch
pattern. Do not hone more than enough to rough up
the polish on the cylinder bores. After honing ensure
all parts are clean, and lightly oil the bores.

9. Install top and second compression rings with the


word top towards the top of the piston. Stagger
the ring gaps a minimum of 40° from each other
on the diameter, and with no gap on the thrust
side of the piston.

92
Piston Ring Assembly
Naturally Aspirated Turbocharged
1. 1st Compression Ring 1. 1st Compression Ring
2. 2nd Compression Ring 2. 2nd Compression Ring
3. Oil Control Ring 3. Oil Control Ring

10-67
SECTION 10 -- ENGINE -- CHAPTER 1
Piston Assembly into Block
1. Select the correct bearing liners (refer to the
following crankshaft section) and install in the rod
and cap. Ensure the liner tang locates in the slots
of the rod and cap.
2. Turn the crankshaft to position No 1, crank pin at
the bottom of the stroke, and lubricate all parts
with new engine oil. Using a ring compressor (2),
and a soft drive (1), slide pistons into bores,
ensuring grade letter on pistons is toward the
front of the engine, Figure 93.

93
Piston and Connecting Rod Installation
1. Soft Drive
2. Ring Compressor

3. Ensure the connecting rod bearing liner seats on


the crank pin with the bearing cap installed to the
connecting rod as a matched assembly. Install
new bolts lubricated with oil, and torque to 149
N⋅m (110 ft.-lb.).
4. Use a feeler gauge (1) to check connecting
rod-to-crankshaft for side clearance of 0.13-0.33
mm (0.005-0.013 in.) as shown in Figure 94.

94
Connecting Rod Bearing Side Clearance
1. Feeler Gauges

BALANCER, MAIN BEARINGS, FLYWHEEL,


AND CRANKSHAFT
NOTE: Installation of replaceable bearing liners in
production ensures correct crankshaft journal-to-
bearing clearance. It is possible to overhaul the main
bearings with the engine in the tractor, however, the
crankshaft can only be serviced after removal from
the tractor.

To remove the flywheel, split the engine from the front


transmission, or remove engine from the tractor.
Refer to Section 10, Chapter 1 “Separating the
Tractor”.

10-68
SECTION 10 -- ENGINE -- CHAPTER 1

BALANCER (4 Cylinder Engines)


Removal and Disassembly
1. Remove the oil pan to expose the balancer, and
using a dial indicator gauge (1), check backlash
between crankshaft gear and balancer drive
gear (2). Position the dial plunger to the face of
one of the drive gear teeth, and then rock the
gear to measure backlash. Take readings at 90_
intervals around the drive gear to 0.05-0.30 mm 2
(0.002-0.012 in.). Install new balancer gear if out
of specification. 1

95
Balancer Gear Backlash
1. Dial Indicator
2. Backlash Check at Gears

2. Extract the roll pins (1) securing the shafts (6) to


the housing (2) and disassemble driven gears
(4). Retain washers (3, 5) for reassembly.

96
Balancer Gears
1. Roll Pin 4. Driven Gears
2. Housing 5. Thrust Washers
3. Thrust Washers 6. Shafts

Inspection and Repair Assembly


1. Measure the outside diameter of the shafts and 1. Position balancer gears and thrust washers in
the inside diameter of the gear bushings, and the housing, with timing marks aligned, and
compare to clearance of 0.012-0.038 mm facing the roll pin side of the balancer. Install
(0.0005-0.0015 in.). Replace shaft and/or gear shafts from the opposite side and secure with roll
assembly if exceeded. pins.
2. Examine shafts and balancer gear teeth for wear 2. Using a feeler gauge measure end-float of
and damage, and replace as necessary. Ensure assembled gears to the specification of
lubrication holes in the shafts are free from 0.20-0.51 mm (0.008-0.020 in.).
obstruction upon re-assembly. 3. Position a dial indicator gauge to the tooth of one
For crankshaft balancer gear repair and assembly, gear, and hold the other firmly. Rocking the free
refer to the crankshaft section of this chapter. gear measure backlash at 90° intervals around
the gears to 0.05-0.25 mm (0.002-0.010 in.).

10-69
SECTION 10 -- ENGINE -- CHAPTER 1
Installation
1. Clean all the mating surfaces and install a new
seal (1) around the lubrication passage,
Figure 97.

97
Balancer Gear Assembly
1. O-ring

2. Rotate crankshaft until timing mark (1) on


crankshaft gear aligns with timing mark on
balancer drive gear, Figure 98. Position balancer
on dowels, install the bolts (2) and torque to
108-120 N⋅m (80-90 lb.-ft.).
3. Recheck the gear backlash between crankshaft
and balancer gear as previously described.
Reinstall the oil pan if removal is not required for
other maintenance. Refer to “Oil Pan” section of
this chapter. 1
2

98
Timing of Balancer to Crankshaft
1. Gear Alignment Marks
2. Attaching Bolts

10-70
SECTION 10 -- ENGINE -- CHAPTER 1

MAIN BEARING
Removal
1. Remove the oil pan and balancer, to gain access
to the crankshaft. When repairing the journal,
remove the main bearing cap, and install only
one set at a time. Leave the remainder securely
in place.
NOTE: If needed, fabricate a liner removal tool from
a 25.4 mm (1 in x 1/8 in.) split pin. Flatten and bend
the head to conform to angle as shown in Figure 99.
2. Install the bearing liner removal tool Figure 99, in
the crankshaft journal oil passage. Turn the
crankshaft counter clockwise until the tool forces
the bearing out of the cylinder block.

99
Bearing Liner Removal Tool

Inspection and Repair


Thoroughly clean bearing liners, journals, and caps
in a suitable solvent. Inspect for wear, scores, burrs,
and other damage. Replace as necessary.

Installation
1. Coat all parts in new engine oil before assembly.
Position the bearing cap with locking tang
towards the camshaft side of the engine and
install the bolts. Torque bolts evenly to 190-203
N⋅m (140-150 ft.-lb.).
2. Align bearing when installing a new thrust
bearing liner. See crankshaft procedures.

10-71
SECTION 10 -- ENGINE -- CHAPTER 1

FLYWHEEL
Removal
1. To gain access to the flywheel, separate the
engine at the front transmission. Refer to Section
10, Chapter 1 “Separating the Tractor”.
2. Before removing the flywheel (2), rotate wheel
with a dial indicator (1) attached and check that
total indicator reading measures 0.127 mm
(0.005 in.), Figure 100. Check crankshaft to
flywheel seating if not within specifications.

100
Flywheel Runout
1. Dial Indicator
2. Flywheel

Inspection and Repair


Inspect the flywheel ring gear for damage. If
necessary, replace damaged ring following steps
below:
1. Cut old ring gear free from the flywheel.
2. Clean the mating surfaces of the new ring gear
and flywheel.
3. Use temperature-indicating crayons to mark the
side face of the ring gear (1) in six equal places.
Mark with a 204°C (400°F) crayon at a point 13
mm (0.5 in.) below the root of the teeth, and mark
with a 212°C (450°F) crayon at a point just below
root of the teeth. 101
4. Use an oxyacetylene torch with a tip size of No.
2 maximum, and direct the flame against the
internal face of the gear.
5. Stop applying heat when the 204°C (400°F)
crayon mark melts, but before the 212°C (450°F)
crayon mark melts.
6. Quickly place the hot gear on the flywheel, with
flat face against the shoulder on the flywheel.
The gear-to-flywheel run out should be checked
using a dial indicator and should not exceed a
Total Indicator Reading of 0.63 mm (0.025 in.)

In the event of flywheel surface damage due to


excessive clutch wear, skim the surface a maximum
of 3 mm (0.118 in.)

Installation
1. Clean the crankshaft rear flange and mating
surfaces and install the flywheel. Torque the bolts
to 197 N⋅m (145 ft.-lb.).

10-72
SECTION 10 -- ENGINE -- CHAPTER 1

REAR COVER PLATE


Removal
To gain access to the engine oil pump, camshaft
gear, or end of camshaft, remove the oil pan as
previously described, then remove the rear cover,
Figure 102 in the following manner: 2 1
1. Split tractor. Refer to Section 10, Chapter 1
“Separating the Tractor”.
2. With rear of engine exposed, loosen and remove
the twelve retaining bolts (1). Gently pry oft the
cover plate (2).
3. Clean off all sealer, remove crankshaft oil seal, 102
and check for damage or distortion around the Rear Cover Plate Removal
sealing faces. 1. Retaining Bolts
2. Cover Plate

Installation
1. Install a new gasket and apply sealer to faces.
With the plate in the recess, install the retaining
bolts loosely. Do not tighten.
2. Apply a liberal coating of new engine oil on a new
oil seal, and position the rear seal (1) over the
end of the crankshaft. Attach special Tool No.
FNH 01301 (2) on the end of the crankshaft using
the three mounting bolts. Tighten evenly and
squarely until the seal is fully seated, Figure 103.

As an alternative the rear crankshaft oil seal can be


installed using the following installation tool.
103
3. Apply a liberal coating of clean engine oil to the Rear Crankshaft Oil Seal Installation
rear seal retainer, seal, and journal. A new seal 1. Rear Oil Seal
should be mounted on the crankshaft, then bolt 2. Tool No. FNH 01301
tool 380000332 t o crankshaft end and install the
new seal squarely.
4. Secure centre stock of tool to crankshaft flange
with two screws. Assemble cylinder end plate to
centre stock and secure with nut and washer.
Tighten the nut until outer diameter of tool abuts 1
retainer. Tool must not be over tightened as
stress and distortion could be imposed on the
retainer.
5. Remove the tool after assembly and check the
crankshaft seal run out as shown in Figure 106.
NOTE: The first seal replacement should be pushed
into retainer with plain end of tool and subsequent
seals with stepped end of tool which will reposition
TA6010055
seal 1.52mm (0.060 in) further in.
104

10-73
SECTION 10 -- ENGINE -- CHAPTER 1

6. Torque the twelve bolts in sequence as illustrated


in Figure 105 to 16-23 N⋅m (144-204 in.-lb.).
7. Ensure edges of the retainer and seal assembly
are even with edges of the block (3) within 0.08
mm (0.003 in.), Figure 105. If not to specification,
loosen and realign retainer in the recess and
repeat the installation procedure.

105
Rear Cover Plate
1. Sealer Application
2. Retaining Bolts
3. Plate Alignment

8. With new crankshaft seal (1) installed, place a


dial indicator (2) on the end of the crankshaft, and
ensure seal run out is within 0.51 mm (0.020 in.)
Total Indicator Reading, Figure 106.

106
Measuring Crankshaft Seal Runout
1. Crankshaft Seal
2. Dial Indicator

10-74
SECTION 10 -- ENGINE -- CHAPTER 1

OIL PUMP
Removal
1. Separate the engine from the front transmission.
Refer to Section 10, Chapter 1 “Separating the
Tractor”.
2. Remove the flywheel, back plate, oil pan and oil
pump tube.
3. Before removing the oil pump, check backlash
(1) of pump gear-to-camshaft gear. Compare
measurement to 0.40-0.56 mm (0.016-0.022 in.)
and replace gears if measurement exceeds
specifications.
107
4. Remove the camshaft gear to expose oil pump. Engine Oil Pump
5. Remove mounting bolts and detach the oil pump 1. Gear Backlash Measurement
from the block, Figure 107. 2. Pump to Block Mounting Bolts

Disassembly
Loosen and remove three pump face-plate to body
mounting bolts for the 4 cylinder engine, and four
bolts for the 6 cylinder engine. Disassemble the
pump and discard the O-rings, Figure 108.

108
Oil Pump Disassembly
1. Retaining Bolt
2. Retaining Bolt 6 Cylinder
3. O-ring Intake Port
4. O-ring Outlet Port

Inspection and Repair


1. Clean all parts in a suitable solvent. Inspect
inside of pump plate and body for excessive wear
and damage. Proceed with the following checks
when finding no discrepancies.
2. Invert pump plate/rotor assembly and place
outer rotor (2) over inner rotor (1). Place a
straight edge (3) across the top of both and insert
a feeler gauge (4) between straight edge and
inner rotor. Check specification to 0.025-0.089
mm (0.001-0.0035 in.), Figure 109.

109
Measuring Oil Pump Rotor
1. Inner Rotor
2. Outer Rotor
3. Straight Edge
4. Feeler Gauge

10-75
SECTION 10 -- ENGINE -- CHAPTER 1
3. Place outer rotor (1) in pump body (2). Use a
feeler gauge (3) to check for clearance between
the rotor and body. Replace pump if clearance
exceeds a maximum of 0.55 mm (0.022 in.),
Figure 110.
IMPORTANT: Reduced pressure from a worn pump
will result in reduced engine life.

Assemble
1. Clean parts in a suitable solvent, and coat in new
engine oil. Place outer rotor in pump body and
ensure free rotation. Insert inner rotor and pump
plate assembly into the body and ensure that 110
shaft is fully seated into bushing. Measuring Outer Rotor to Pump Body
2. Assemble the front plate to the body using 3 or 4 1. Outer Rotor
bolts, and torque to 23-28 N⋅m (204-252 in.-lb.). 2. Pump Body
3. Feeler Gauge
NOTE: After tightening, check drive gear rotates
freely by hand for five revolutions. If not, disassemble
and repeat installation procedures.
Installation
3. Install a new O-ring to the output tube. Lubricate
and insert the pump into the block. Torque bolts
to 23-28 N⋅m (204-252 in.-lb.), Figure 111.

111
Assembly of Oil Pump
1. Output Tube O-ring
2. Retaining Bolts
3. Oil Pump

10-76
SECTION 10 -- ENGINE -- CHAPTER 1
4. Install a new O-ring on suction port. Lubricate
and insert pump intake tube/screen assembly (2)
into oil pump (1) through bottom of engine. Install
new gasket (4) and tighten retaining bolts (3) to
a torque of 27-34 N⋅m (240-300 in.-lb.),
Figure 112.
NOTE: It is not necessary to remove plug (5),
Figure 112. Installation of the plug occurred during
manufacturing to facilitate machining, and remains in
position throughout engine life.

112
Oil Pump Intake Tube
1. Oil Pump
2. Pump Intake Tube
3. Retaining Bolts
4. Gasket
5. Plug

OIL FILTER SUPPORT ASSEMBLY

Procedure for turbocharged 4-cylinder engine

Removal and Disassembly


1. Unscrew and discard the old oil filter (1). Remove
the oil connections. Cap and plug all openings to
prevent contamination.
2. Remove the retaining bolts (2) and filter support
assembly from the block. Discard O-rings (3),
Figure 113.
113
Oil Filter Assembly 4 Cylinder
1. Oil Filter
2. Filter Housing Support Bolts
3. O-rings

3. Remove the plug (1), spring (2), pressure relief


valve (3), and O-ring (4) Figure 114.

Inspection and Repair


1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Check the pressure relief valve spring free-
length and compare to 52.8 mm (2.08 in.). Check
the compressed length using a weight of 15.6 kgs
(34.3 lbs.) and compare to 37 mm (1.46 in.).
Replace spring if not within specification.
114
Oil Filter Relief Valve
1. Relief Valve Plug
2. Spring
3. Valve
4. O-ring

10-77
SECTION 10 -- ENGINE -- CHAPTER 1
3. Inspect all parts for damage or wear and replace
as necessary. An improperly functioning filter
assembly will cause premature engine wear due
to contaminated oil bypassing the filter and
returning to the fuel system.

Installation
1. Lubricate the pressure relief valve and spring,
then insert into the filter housing. Check that
parts move freely.
2. Install a new O-ring on the plug and install on filter
assembly. Tighten the plug to a torque of 55 N⋅m
(41 ft.-lb.).
3. Install filter support assembly with new O-rings
and tighten retaining bolts to a torque of 42 N⋅m
(31 ft.-lb.).
4. Screw on a new filter element hand tight
5. Install fuel pipes and tighten connections.
6. Check filter assembly and connections for
leakage.
Procedure for Naturally Aspirated 6-cylinder
Engine

Removal
1. Unscrew and discard the old oil filter (1). Remove
the oil connections. Cap and plug all openings to
prevent contamination.
2. Remove the retaining bolts (2) and filter support
assembly from the block. Discard O-rings (3),
Figure 115.

115
Oil Filter Assembly 4 Cylinder
1. Oil Filter
2. Filter Housing Retaining Bolts
3. O-rings

10-78
SECTION 10 -- ENGINE -- CHAPTER 1
3. Remove and retain the blank-off plate (1),
Figure 116, at the oil return-to-engine block port.

Inspection and Repair


1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Inspect all parts for damage or wear and replace
as necessary. An improperly functioning filter
assembly will cause premature engine wear due
to contaminated oil bypassing the filter and
returning to the fuel system.

Installation
116
1. Install a new O-ring (4) on the plug (1) Figure 116
Oil Filter Relief Valve
and install on filter assembly.
1. Relief Valve Plug
2. Install filter support assembly with new O-rings 2. Spring
and blank-off plate. Tighten retaining bolts to a 3. Valve
torque of 42 N⋅m (31 ft.-lb.). 4. O-ring
3. Screw on a new filter element hand tight
4. Install fuel pipes and tighten connections.
5. Check filter assembly and connections for leakage.

CRANKSHAFT
Removal
1. Remove the engine from the tractor and place on
engine stand.
2. Remove the following components following the
procedures described in Section 10, Chapter 1:
Flywheel
Crankshaft Pulley
Rear Cover
Front Cover
Oil Pan
Oil Pump
Balancer Assembly
Connecting Rod Caps
3. Rotate the engine on the stand to put engine
bottom face up.
4. Support the crankshaft with hoist.
5. Remove main bearing caps and liners.
6. Remove the crankshaft from the cylinder block.
Inspection and Repair
NOTE: Undersized crankshaft main or crank pin
journals of 0.25 mm (0.010 in.) may be installed in
current engine models. A stamp of 010 MUS and/or
010PUS on one of the crankshaft counterbalance
weights identifies this condition.
1. Clean crankshaft in a suitable solvent. Allow
shaft to dry.
2. Inspect crankshaft timing gear teeth for wear or
damage and replace if necessary.

10-79
SECTION 10 -- ENGINE -- CHAPTER 1
3. Measure diameter of each crankshaft journal in
four places (A, B, C, D) Figure 117. The following
determinations can be made:
Measurement A compared with B indicates
vertical taper
Measurement C compared with D indicates
horizontal taper
Measurement A & B compared with C & D
indicates journal out-of-round

117
Measuring Crankshaft Journal

4. If the journal exceeds limits (refer to Engine


Specifications section), refinish journal to the
next undersize bearing.
5. Examine the rear oil seal journal for score marks.
Correct minor imperfections with fine emery
cloth. Severe damage will require replacing the
crankshaft.

BALANCER GEAR
Removal
NOTE: Replaceable gears are not available in all
markets. Consult your dealer for the latest
information. Install a new crankshaft if new gears are
not available.

Inspect the balancer gear for wear or damage to the


teeth and replace if necessary.

1. Use a suitable tool to split the gear and remove


from crankshaft. Remove residue and/or burrs
from gear journal.

Installation
1. Support the crankshaft in a vertical position nose
down.
2. Heat a new ring gear until reaching a
temperature of 193.3-215.6°C (380-420°F) as
evident in the gear turning blue.
3. Install heated ring gear over crankshaft journals
to mating surface.
4. Align gear tooth to the crankshaft timing mark
within 0.76 mm (0.030 in). Push gear on
completely.

10-80
SECTION 10 -- ENGINE -- CHAPTER 1
5. Completely seat gear to the shoulder. Check that
run-out has a Total Indicator Reading of 0.25 mm
(0.010 in.) with a dial indicator, Figure 118.

118
Crankshaft Balancer Gear
1. Balancer Gear
2. Gear Location
3. Dial Indicator

TIMING GEAR
Removal
NOTE: Replaceable gears are not available in all
markets, consult your Dealer for the latest
information. Install a new crankshaft if new gears are
not available.

Inspect the timing gear for wear or damage to the


gear teeth. If damaged or worn replace with a new
gear in the following manner:

1. Heat the gear sufficiently until obtaining free


movement and removal of the gear from the
crankshaft.
Installation
1
1. Place a new gear into Alignment Tool (3) No.
FNH00881 and align the gear by the indexing pin
(1). Set the crankshaft locating-pin (2) to 4 or 6
cylinder position before heating, Figure 119.

3
2

119
Crankshaft Gear Installation
1. Gear Indexing Pin
2. 4/6 Cylinder Position Crankshaft Locating Pin
3. Alignment Tool No. FNH00881

10-81
SECTION 10 -- ENGINE -- CHAPTER 1
2. Heat the new gear and the tool to 193°-216°C
(380°-420°F). Once heated place the alignment
tool onto the crankshaft key-way and push fully
home.
IMPORTANT: The gear/tool assembly must remain
in position until cooled to ambient temperature.
Moving the gear while hot may dislodge or disrupt
engine timing.

CRANKSHAFT
Assembly
1. Check the crankshaft bearing clearance using a 1
plastigauge (1) as follows:
2. Position a piece of correct size plastigauge 2
across the full width of the bearing cap (2),
approximately 6.35 mm (0.25 in.) off center,
Figure 120.
3. Install cap and tighten bolts to 149 N⋅m (110
ft.-lb.).
4. Remove the cap and use the scale to check the
width of the flattened plastigauge, Figure 120. 120
Checking Bearing Clearance

5. Widest point of gauge establishes the minimum


clearance.
6. Narrowest point of gauge establishes maximum
clearance. The taper equals the difference
between the two readings.
NOTE: Normally main bearing journals wear evenly
and will not be out-of-round, but if a liner which is to
specification is installed in an out-of round journal,
ensure liner suits maximum diameter of journal.

7. When combinations of liners do not produce


specified clearance, refinish crankshaft and
install undersize bearings. See “Engine Specifi-
cations” for bearings available.
IMPORTANT: Engines contain assembled liners of
different materials, however, always use the same
materials on the same journal.

8. Position the bearing liners and caps in the block


and coat with oil. For a refinished crankshaft,
install correct undersize bearing liners.
9. Ensure the bearing surfaces are clean, and that
bearing liner tangs align with slots in the block
and cap.

10-82
SECTION 10 -- ENGINE -- CHAPTER 1
10. Align the timing mark on the crankshaft gear with
that of the camshaft idler gear, and install the
crankshaft. Install a thrust bearing cap (1) with
flange type bearing liner (2) first, and install
remaining bearing caps to original locations,
Figure 121.

121
Thrust Bearing Installation
1. Thrust Bearing Cap
2. Liner

11. Tighten all bearing caps (except thrust bearing


cap, leave finger tight) to a torque of 197 N⋅m
(145 ft.-lb.).
12. Pry the crankshaft forward against thrust surface
of bearing. Hold crankshaft forward and pry
bearing cap rearwards taking care not to pry
against flange of bearing liner. This will align thrust
surfaces of both halves of bearing. Keep forward
pressure on crankshaft and tighten bearing cap
bolts to a torque of 197 N⋅m (145 ft.-lb.).

6010069
122
13. Check crankshaft end-play with a dial indicator (1)
gauge. Pry crankshaft towards front of engine and
set dial indicator to zero. Pry crankshaft towards
rear of engine and note reading on dial. Install a
new crankshaft bearing liner if end-play exceeds
0.10-0.20 mm (0.004-0.008 in.), Figure 123.

123
14. If the end-play is less than specification, check Measuring Crankshaft End Play
thrust bearing for burrs, scratches, or dirt. 1. Dial Indicator
Realign thrust bearing.
15. Install rear crankshaft oil seal as previously
described in rear plate removal.
NOTE: To ensure proper seating, assemble the seal
with the rear plate. Do not pre-install seal into
retainer.

10-83
SECTION 10 -- ENGINE -- CHAPTER 1

CAMSHAFT
Removal
NOTE: Maintenance on the camshaft bearings and
tappets requires the removal of the engine from the 1
tractor.

1. Remove the engine front cover and cylinder head


using procedures described in Section 10,
Chapter 1.
2. Check camshaft end-play (see timing gear
procedures) and remove gear. Install a new
thrust plate before reassembling.
3. After removal of the flywheel and rear cover,
remove the camshaft oil pump drive gear. APB10094
4. If camshaft bearings need replacing, then invert 124
engine on the stand and remove the oil pan.
5. Remove camshaft (1) from the rear of the engine,
Figure 124.
NOTE: Camshafts on 4-cylinder engines consist of
three sets of bearing shells, and 6-cylinder engine
camshafts contain five sets.

6. Lift out the tappets (1), Figure 125 and place in


a numbered rack for reassembling.

125
Camshaft Tappet Assembly
1. Tappets

Inspection and Repair


1. Inspect the camshaft journals and lobes for
damage, pitting, or heat discoloration. If any of
these conditions exist, install a new camshaft.
2. Inspect the oil pump drive gear on camshaft for
broken or worn teeth, and mating gear on oil
pump. If any wear or damage exists, replace
gears.
3. Check each tappet for wear or damage, and
tappet bore diameter for 25.15-25.17 mm
(0.990-0.991 in.), Figure 126. Replace tappet if
not within specifications.
4. Measure the diameter and out-of-round condi- 396--E--23 TI
tion of bearing journals to 60.693-60.719 mm 126
(2.389-2.390 in.). Replace camshaft if not within
specifications.

10-84
SECTION 10 -- ENGINE -- CHAPTER 1

CAMSHAFT BEARINGS
1. Inspect the camshaft bearings for wear or
damage. Measure the clearance between the
internal diameter of bearing and outside
diameter of respective journal to 0.025-0.076
mm (0.001-0.003 in.).
2. If required, remove and replace bearings using
Drive Set Tool No. FNH01255, Figure 127.
3. To remove, position tool (3) against bearing (1)
and drive bearing from bore.
4. To install new bearing: Align oil holes (2) of new
bearing with holes in block and drive bearing into
bore using tools described in step 2. 127
Camshaft Bearing Removal and Installation
5. Perform an alignment check with the crankshaft 1. Camshaft Bearing
removed. Insert a 4.6 mm (0.018 in.) rod down 2. Oil Hole
the oil passage from the crankshaft main
3. Tool No. FNH01255
bearing. Correctly position liner by passing end
of rod through oil hole in liner.
NOTE: A positive alignment check must be made
with crankshaft removed, to facilitate a 4.6 mm
(0.018 in.) rod inserted down the oil passage from the
crankshaft main bearing. Correctly position liner by
passing end of rod through oil hole in liner.

Installation
1. Apply petroleum jelly to each tappet foot, and
coat tappet body with oil. Install tappets into
original bores.
2. Oil camshaft journals and apply petroleum jelly to
the cam lobes. Install camshaft on engine.
3. Install new spacer and key-way on end of
camshaft.
4. Install camshaft gear, and align the camshaft
gear timing mark. Recheck end-play.
5. Tighten bolt to a torque of 55-77 Nm (43--58
ft.-lb.).
6. Recheck end-play.
7. Apply a sealant 82995782 to sealing flange of
front cover plate when reassembling.

10-85
SECTION 10 -- ENGINE -- CHAPTER 1

INTAKE AND EXHAUST MANIFOLDS

Description and Operation


The intake and exhaust manifolds mount on opposite
sides of the cylinder head. This configuration
maintains balanced heat distribution within the
cylinder head, and ensures minimum heat transfer to
the intake manifold.
A one-piece, cross flow, cast aluminum, plenum
chamber type intake manifold, attached to the right
side of the engine block, Figure 128, directs air from
the air cleaner into the cylinder head via tubing. A
threaded hole at the rear of the intake manifold
allows for the installation of a thermostart for cold
starting operations.

IMPORTANT: On tractors without the thermostart


installed, a plug prevents the ingestion of dirt and
other debris into the cylinder bores. Ensure the
tightness of the plug at all times.

IMPORTANT: Air cleaner tube connections must be


128
tight at all times to prevent dirt and other debris from
entering the cylinder bores.
A one-piece, cast iron exhaust manifold attached to
the left side of the engine block, Figure 129,
channels spent exhaust fumes into the muffler via
tubing. When installed, the turbocharger mounts to
the exhaust manifold.

129

10-86
SECTION 10 -- ENGINE -- CHAPTER 1

INTAKE MANIFOLD

Removal
1. Disconnect the battery negative (ground) cable.
2. Raise engine hood assembly.
3. Disconnect fuel system water separator pipes.
Cap and plug openings to prevent contamina-
tion.
4. Remove injector fuel pipes. Cap and plug all
openings to prevent contamination.
5. Remove wires at the thermostart (where
installed).
6. Remove fuel pipe at the thermostart (where
installed).
7. Remove vacuum pipe at bottom of intake
manifold (where installed).
8. Remove intake tube and clamps.
9. Remove radiator recovery tank, bracket and
tube.
10. Remove air cleaner assembly, brace and
bracket.
11. Remove the lift pump and filter assembly.
12. Remove the retaining bolts and remove intake
manifold from the tractor. Discard sealing
gaskets and retaining bolt O-rings.

Inspection
1. Clean the components in a suitable solvent.
Allow parts to dry. Use light grit sandpaper to
remove all traces of old gasket on mating face.
2. Inspect manifold for cracks or obstructions,
3. Inspect joint mating face for imperfections, which
may allow air leakage.
4. Replace manifold if damaged.

10-87
SECTION 10 -- ENGINE -- CHAPTER 1
Installation
Installation of the intake manifold follows the removal 1
procedures in reverse with the following require- 2
ments:

1. Replace sealing gasket (1), Figure 130 and


retaining bolt O-rings.
2. Tighten intake manifold retaining bolts to a
torque of 35 N⋅m (310 in.-lb.).
3. Replenish fuel and purge air from fuel system.

130
EXHAUST MANIFOLD -- OVERHAUL

Removal
1. Disconnect the battery negative (ground) cable.
2. Raise the engine hood assembly.
3. Remove the vertical exhaust muffler.
4. Remove the turbocharger.
5. Remove the retaining bolts and remove the
exhaust manifold from the tractor. Discard
sealing gasket.

Inspection
1. Clean all components in a suitable solvent. Use
a wire brush to remove carbon deposits. Use light
grit sandpaper to remove all traces of old gasket
on mating face.
2. Inspect manifold for cracks or obstructions,
3. Inspect joint mating face for imperfections, which
may allow air leakage.
4. Replace manifold if damaged.

Installation
Installation of the exhaust manifold follows the
removal procedures in reverse with the following
requirements:

1. Replace sealing gasket (2), Figure 130.


2. Tighten exhaust manifold retaining bolts to a
torque of 38 N⋅m (336 in.-lb.).

10-88
SECTION 10 -- ENGINE -- CHAPTER 1

ENGINE TESTING indicates that the rings are performing satisfactorily


and that leakage from the valves is occurring.
COMPRESSION TEST PROCEDURE
If compression has increased over the original
1. Ensure battery performance meets specifica-
reading, there is leakage past the rings.
tions.
2. Warm up the engine by operating for a minimum During a compression test, if the pressure fails to
of 30 minutes, at 1200 rev/min. climb steadily and remains the same during the first
two successive strokes, but climbs higher on the
3. Stop the engine and remove the fuel injector and succeeding strokes, or fails to climb during the entire
seat washer from no. 1 cylinder. test, suspect a sticking valve.
4. Clean the injector bore, and crank the engine to
blow out any loose carbon particles. ENGINE BREAK-IN
5. Install an engine compression test gauge into the (LOW HP APPLICATION)
injector bore, using a new seat washer and the NOTE: Cylinder walls and piston rings are designed
injector mounting bolts. with optimum hardness for long engine life. A light
6. Connect the gauge and hose to the adapter. load during the break-in period, however, may cause
a cylinder wall condition that allows oil to creep due
7. Crank the engine. Measure at 200 rev/min. with
to failure of the rings to seat. Therefore, perform the
throttle closed and fuel shut-off solenoid following procedures if anticipating a “light load”
de-energized. Minimum compression must be at break-in period.
least 290 psi with no more than 50 psi variation
between cylinders.
1. Fill engine with recommended break-in engine
8. Observe the gauge reading and repeat the oil.
compression test for each cylinder.
2. Break in engine by operating vehicle on a PTO
COMPRESSION TEST READINGS dynamometer for 5 hours using the following
schedule:
1. All cylinder compressions should be uniformly
within 50 psi of each other. NOTE: To run the engine at 1200 rpm with 20% load,
means that when performing this test with a tractor
2. A reading of more than the 1.7 bar (25 psi) below rated at 80 hp; start by placing a load equivalent to 16
the other cylinders indicates leakage at the hp (20% of 80 hp) on the dynamometer, and run it at
cylinder head gasket, piston rings or valves. 1200 rpm for 30 minutes. Similar sequences run at
3. A reading of more than 1.7 bar (25 psi) above the 40%, 60%, 80% etc., loads. To test 25 minutes at
other cylinders indicates excessive carbon 1600 rpm with full throttle means to run the engine at
deposits on the piston and cylinder head. full throttle, and then apply sufficient load on the
dynamometer to bring the engine speed down to
4. Even compression in two adjacent cylinders 1600 rpm.
indicates a cylinder head gasket leak. Check this
gasket before condemning the rings or valves. 1) 30 minutes at 1200 rpm with 20% load
COMPRESSION TEST CONCLUSION 2) 30 minutes at 1400 rpm with 40% load
To determine whether the rings or the valves are at
3) 30 minutes at 1600 rpm with 60% load
fault, squirt the equivalent of a tablespoon of heavy
oil into the combustion chamber. Crank the engine to 4) 30 minutes at 1800 rpm with 80% load
distribute the oil and repeat the compression test.
5) 30 minutes at 2000 rpm with 90% load
The oil will temporarily seal any leakage past the
rings. Obtaining approximately the same reading 6) 30 minutes at 2070 rpm with 100% load and
full throttle

10-89
SECTION 10 -- ENGINE -- CHAPTER 1
7) 05 minutes at 1200 rpm with no load ENGINE BREAK-IN
(OTHER THAN LOW HP APPLICATION)
8) 25 minutes at 1600 rpm with 100% load and
full throttle 1. Fill engine with recommended break-in engine
oil.
9) 05 minutes at 1400 rpm with no load
2. Break-in engine by operating vehicle on a PTO
10) 25 minutes at 2000 rpm with 100% load and dynamometer for 2 hours and 40 min using the
full throttle following schedule::
TIME LOAD
11) 05 minutes at 1400 rpm with no load
15 min 0
12) 25 minutes at 1800 rpm with 100% load and 30 min 10%
full throttle 30 min 25%
30 min 50%
13) 05 minutes at 1600 rpm with no load 30 min 75%
10 min 100%
14) 25 minutes at 2000 rpm with 100% load and 05 min 0
full throttle 10 min 100%
NOTE: For units not conveniently run on a 3. Check for leaks. Recheck valve lash and reset to
dynamometer such as Skid Steer, Loaders and minimum lash.
Backhoes: operate units as follows:
4. Operate the vehicle under normal working
1) 05 minutes at 1200 rpm with no load conditions, until recording a total of 50 hours on
the rebuilt engine. Then drain and discard engine
2) 25 minutes at 1200 rpm with 100% load and oil and filter.
full throttle
5. Install new oil filter. Replenish and check oil level
3) 05 minutes at 1200 rpm with no load dipstick. Do not overfill the engine by using the
“FULL” mark on the dipstick. Most engines will
4) 25 minutes at 1200 rpm with 100% load and not burn oil when the level is at the low operating
full throttle range, but will burn oil if continually filled to the
5) 05 minutes at 1400 rpm with no load maximum level.

6) 25 minutes at 1800 rpm with 100% load and


full throttle

7) 05 minutes at 1600 rpm with no load

8) 25 minutes at 2000 rpm with 100% load and


full throttle

3. Check for leaks. Recheck valve lash and reset to


minimum lash.
4. Operate the vehicle in normal working conditions
until recording 50 hours on the rebuilt engine.
Drain and discard engine oil and filter.
5. Install new oil filter, replenish with recommended
oil and recheck level at dipstick. Do not overfill
the engine by using the “FULL” mark on the
dipstick. Most engines will not burn oil with the
level at the low operating range, but will burn oil
if continually filled to he maximum level.

10-90
SECTION 10 -- ENGINE -- CHAPTER 2

SECTION 10 - ENGINE

Chapter 2 - Engine Cooling System

CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cooling System Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Temperature Warning Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

10-1
SECTION 10 -- ENGINE -- CHAPTER 2

SPECIFICATIONS
THERMOSTAT
Opening Temperature 79--83°C 174--181°F
Fully Open 93--96°C 199--205°F

RADIATOR CAP
Opening Pressure 0.9 bar 13 lbs in2

WATER PUMP
Type Centrifugal
Drive Multi ‘V’

IMPORTANT: Coolant Mixture -- Water 50%, Antifreeze 50%. If the recommended antifreeze is not available,
use a heavy-duty antifreeze with a 5% solution of corrosion Inhibitor. It is critical to add this inhibitor to the cooling
system. It is available from Dealers Part No FW 15.

COOLING SYSTEM CAPACITIES


Model Litres U.S. Gals
4 Cylinder 13.7 3.6
6 Cylinder 14.0 3.7

COOLING SYSTEM TORQUES


Description Nm Lb.-Ft.
Thermostat Housing Bolts 24 18
Temperature Sender 20 15
Idler Pulley 54 40
Water Pump-to Cylinder Block 48 35
Cylinder Blade to Support Body 23 17
Water Pump Cover 27 20
Fan Blade-to-Support Body 27 20

SEALANTS

Part Number Name

82995768 Sealer--Anaerobic Low strength

82995776 Sealer--Silicone

82995774 Sealer--Polyester Urethane

82995773 Sealer--Anaerobic

10-2
SECTION 10 -- ENGINE -- CHAPTER 2

FAULT FINDING
IMPORTANT: When effecting a repair the cause of The following table lists problems and their possible
the problem must be investigated and corrected to causes with recommended remedial action.
avoid repeat failures.

PROBLEM PROBABLE CAUSES REMEDY

Engine overheats 1. Hose connection leaking or 1. Tighten hose connection,


collapsed replace hose if damaged

2. Radiator core tubes blocked 2. Check free flow

3. Radiator cap defective or not 3. Replace radiator cap


sealing

4. Radiator leakage 4. Repair/replace radiator

5. Radiator fins restricted 5. Clean with compressed air

6. Faulty thermostat 6. Replace thermostat

7. Internal engine leakage 7. Check for source of leakage,


replace gasket or defective
parts

8. Water pump faulty 8. Overhaul water pump

9. Exhaust gas leakage into 9. Replace cylinder head gasket.


cooling system Check head for damage or
distortion

10. Coolant aeration 10. Tighten all connections and


check coolant level. Check
cylinder head gasket.

11. Cylinder head gasket 11. Replace cylinder head gasket


improperly installed

12. Hot spot due to rust and scale 12. Reverse flush entire cooling
or clogged water jackets system

13. Obstruction to radiator air flow 13. Remove the obstruction

14. Extended engine idling 14. Do not allow engine to idle for
long periods

15. Oil cooler tube blocked 15. Clean

Water temperature gauge fails to 1. Faulty temperature sender 1. Replace sender switch
reach normal operating tempera-
ture 2. Incorrect or faulty thermostat 2. Replace thermostat

3. Faulty water temperature 3. Replace temperature gauge


gauge

10-3
SECTION 10 -- ENGINE -- CHAPTER 2

DESCRIPTION AND OPERATION


The cooling system ensures correct engine
temperature and performance during vehicle opera-
tion by providing a continuous flow of cooled water
around the cylinder block. It is a recirculating by-pass
type system consisting of full-length water jackets for
each cylinder.

A single ‘V’ type belt from the crankshaft pulley drives


the water pump, which mounts to the front of the
engine. The pump draws coolant from the bottom
tank of the radiator and directs the coolant to the
cylinder block. The coolant then flows through cored
passages to cool the cylinder walls.
Passages in the cylinder head gasket allow coolant
to flow from the cylinder block to the cylinder head.
In addition, cored passages guide coolant to the fuel
injector nozzles.

Coolant passes a thermostat before reentering the


water pump. The thermostat detects temperature
changes and adjusts the flow of coolant accordingly.
To provide a faster warm-up, a by-pass allows the
coolant to re-circulate from the cylinder head to the
block with the thermostat closed. When the engine
reaches normal operating temperature, the thermo-
stat opens and allows cooled water to circulate
through the radiator and back into the block.
1
IMPORTANT: A faulty thermostat will cause the Recirculating Coolant Bypass
engine to operate at temperatures too hot or cold, A. Thermostat Closed Bypass in Operation
which will result in impaired engine performance or B. Thermostat Open Bypass Closed
damage.

Coolant within the radiator passes through exposed


cores, as an engine driven fan forces air across the
cores to cool the water.

10-4
SECTION 10 -- ENGINE -- CHAPTER 2

COOLING SYSTEM OVERHAUL

Draining the Coolant


NOTE: Discharge the coolant into a suitable
container and dispose of in accordance with local
regulations

1. Remove the drain plug (1) on the left-hand side


of the engine block at the rear of the oil filter (2),
Figure 2.

2
Engine Block Drain Plug (left hand side)

2. Open the drain cock (1), Figure 3 at the bottom


of the radiator tank, left side. Discharge the
coolant into a suitable container and dispose of
in accordance with local regulations.

50025593

10-5
SECTION 10 -- ENGINE -- CHAPTER 2

RADIATOR

Removal
1. Raise the engine hood assembly.
2. Disconnect the battery negative (ground) cable.
3. Remove engine coolant drain plug (1), located
behind the oil filter on the left side of the engine.
Drain coolant into a suitable container.

4
4. Unscrew oil cooler retaining eyebolts (1) and
position the oil cooler (2) away from the radiator 4
(3). If necessary, remove the oil cooler 3
completely by disconnecting the hydraulic oil
hoses (4) and draining the oil into a suitable
container. Cap and plug all openings to prevent
5
contamination. 6
5. Remove the horn electrical connectors (5) and
attaching hardware and remove the horn (6)
assembly.

2 1

40031377

5
6. Remove the center bracket between the top of
the radiator and the engine block.
2
7. Remove radiator shell side--guards (1).
8. Remove the radiator shell.
9. Remove radiator cap.
10. Open drain cock on the bottom left side of the
radiator, and drain coolant into a suitable 1
container.
11. Remove radiator hoses (2). Cap and plug all
openings to prevent contamination. 3
40036175
12. Remove the radiator attaching bolts (3) and lift
radiator off the tractor. 6

10-6
SECTION 10 -- ENGINE -- CHAPTER 2
Disassemble
1. Disassemble the radiator overflow tank (1),
1
radiator and tubes (2) and fan with shroud (3),
Figure 7.

Inspection and Repair


1. Clean all components and allow parts to dry.
2. Inspect radiator fins for damage or obstruction.
3. Inspect all tubing, O-rings and seals for
deterioration and leakage.
4. Inspect all brackets and supports for cracks and
corrosion.
2

Assembly
Assembly of the radiator and associated compo-
nents follows the disassembly procedures with the
following requirements:

1. Replace all O-rings and seals before assembly.


2. Check all connections, clamps, and fittings for
tightness.

Installation
Installation of the radiator follows the removal
procedures in reverse with the following require-
ments:

1. Replenish the coolant using the recommended


grade and quantity.
2. Replenish engine oil using the recommended
grade and quantity. 3
3. Operate the engine and check for leakage in the
radiator and tubes. Recheck fluid levels.

10-7
SECTION 10 -- ENGINE -- CHAPTER 2

THERMOSTAT
Removal
1. Drain the cooling system below the level of the
thermostat housing.
2. Remove the thermostat housing (1) retaining
bolts and slide the connection with the hose
attached to one side.
3. Remove the thermostat (2) and gasket (3).

8
Inspection and Repair
Refer to Figure 9.

1. Place the thermostat (1) in a container of water


and heat the water. If the thermostat valve does
not open at 79-83°C (174-181°F) or near the 2
specified temperature, or fails to close, install a
new thermostat. Use a thermometer (2) to check
the water temperature. 1

Installation
Installation of the thermostat follows the removal
procedure in reverse with the following require-
ments: 9

1. Coat a new coolant outlet connection gasket with


sealer and position on the cylinder head, or
manifold, before installing the thermostat.
2. Coat the edge of the thermostat with grease, and
install with the heat element located in the
cylinder head.
3. Tighten the thermostat housing retaining bolts to
a torque of 24 N⋅m (216 in.-lb.).
4. Replenish the coolant level with the correct grade
and quantity of antifreeze. Refer to specifications
table.

TEMPERATURE WARNING SENDER


The engine temperature warning sender, is located
on the thermostat housing.

Installation
1. Apply sealant to the threaded portion of the
sender body.
2. Install the temperature warning sender into the
thermostat housing.
3. Tighten the sender to a torque of 16--24 N⋅m
(144--216 in.-lb.)

10-8
SECTION 10 -- ENGINE -- CHAPTER 2

WATER PUMP
Removal
1. Drain the cooling system - refer to Section 10,
Chapter 2 “Engine Cooling System Overhaul”.
2. Remove the radiator - refer to Section 10,
Chapter 2 “Radiator”.
3. Remove the fan drive belt.
4. Remove the water hose.
5. Remove the four bolts that pass through the
water pump into the block. Slide the pump away
from the rear connector (1). Discard the O-rings
(2).
6. Remove the pump as a complete assembly. 10
Discard the gaskets (3).

Disassembly
1. Remove the attaching bolts and remove the fan
from the pump pulley.
2. Hold the pump pulley in a fixed position and place
an open ended spanner on the nut to the rear of
the clutch assembly spacer. Loosen the nut in a
clockwise direction.
3. Remove the pulley from the shaft with Puller Tool
No. FNH09198 (1), and a sleeve (2) slightly
smaller than the shaft.

11
4. Using a pair of heavy snap ring pliers, remove the
snap ring (1) from the rear of the pump body.
Carefully ease out the backplate (2). Remove
and discard the O-ring (3), Figure 12.

12

10-9
SECTION 10 -- ENGINE -- CHAPTER 2
5. Place the pump body (3) impeller side down.
Support the pump in a manner to allow the
impeller diameter to drop clear of the pump.
Press out the pump body using the correct tool
(2), Figure 13.
6. Apply pressure to the outer bearing and shaft
simultaneously, and press out from the pump
body.

13
7. With the impeller/shaft assembly (3) removed
from the pump, place the impeller (2) on supports
(4) and press out the shaft (3) assembly from the
impeller, Figure 14.
8. The seal assembly (5) attached to the bearing
shaft (3) is not removable or serviceable. During
the manufacturing process the seal is pressed
onto the shaft and is destroyed on removal, this
is to meet pre load conditions and maintain an
effective water seal.

Inspection and Repair


1. Inspect the bearing shaft and seal assembly for
signs of wear or leaks and if evident, replace with 14
new parts.
2. Inspect the impeller for worn or damaged vanes.
Replace if not to an acceptable standard.
3. Clean and check the pump body for signs of
cracks, erosion or leaks.
Assembly
1. To install the bearing (2) into the pump body (3),
place the body rear face down onto a flat surface.
Install the bearing with the longer stepped end of
the shaft (1) in the body and using a sleeve (4)
that contacts the bearing outer race only, press
(5) the bearing into the body. Once installed in the
body the bearing case end face must be flush
with the pump front face to within 0.000--0.006 in
0.00--0.076 mm). Reference “6”, Figure 15.

15

10-10
SECTION 10 -- ENGINE -- CHAPTER 2
2. With the water pump (5) placed front face down
and the shaft (1) supported, place the seal
assembly (4) on the end of the shaft, with its
smallest diameter uppermost. To insert the seal
assembly place Tool No. 380000321 (3) over the
seal and press (2), until the lip on the seal body
seats on the pump body, Figure 16.

16
3. With the seal installed correctly the seal working
height should be maintained at 0.470--0.490 in
(11.9--12.4 mm), Reference “A”, Figure 17.

17
4. With the water pump rear face up (2) and the
shaft (4) supported, place the impeller (3) over
the shaft and press (1) the impeller into the water
pump body. Installed correctly the face of the
impeller fins to the operating face of the water
pump should be 0.010--0.035 in (0.25--0.88 mm),
Reference “A” Figure 18.
5. Check the dimension from the rear face of the
impeller to the rear face of the pump. The
dimension should be maintained at 0.46--0.485
in (11.6--12.2 mm), Reference “B”, Figure 18.

18

10-11
SECTION 10 -- ENGINE -- CHAPTER 2
6. With the pump rear face down and the shaft
supported, press the pulley onto the shaft
ensuring that the pulley front face to the ear face
of the pump dimension is, 5.091--5.101 in
(127--129 mm), Reference “A” Figure 19.
7. Install a new O-ring and place the water pump
backplate in position. Install the snap ring into
groove. Make sure the water pump pulley/impel-
ler assembly rotates freely by hand prior to
re-assembly. If not disassemble and recheck the
relevant dimensions.

19
Installation

Installation of the water pump follows the removal


procedures in reverse. Observe the following
requirements.

1. Clean the block face and install a new gasket (3)


between the connector and block face, Fig-
ure 20, then torque the two bolts to 15--21 ft.-lbs.
(20--28 N⋅m) 2.0--2.9 kgfm.
2. Install two new O-rings (2) over the connector
outlet port (1) as required, Figure 20.
3. Place the water pump (4) over the connector. 20
Install and torque the four pump bolts to 45--50
lbs ft (61--68 N⋅m) 6.2--6.9 kgfm.
4. Ensure the fan belt tensioner pulley rotates freely
and the swinging arm of the tensioner returns to
rest freely. Gently lever the arm up to enable the
fan belt to be seated in the grooves on the
pulleys. The water pump belt (1) deflection must
be 9.5 mm (.37 in.) with moderate finger pressure
applied to the longest run of the belt. The 1
alternator belt (2) deflection must be 13--19 mm
(0.5--0.7 in.) with moderate finger pressure
applied to the longest run of the belt. Refit the fan
blade assembly.
5. After installation of the radiator, refill the cooling 2
40036178
system and run the engine. Check for leaks.
Refer to the Specifications tables at the front of 21
this chapter for coolant quantity.

10-12
SECTION 10 -- ENGINE -- CHAPTER 3

SECTION 10 - ENGINE

Chapter 3 - Air Cleaning System

CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air Cleaner Assembly Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

10-1
SECTION 10 -- ENGINE -- CHAPTER 3

SPECIFICATIONS

TORQUE VALUES

Description N⋅ m In.-lb.
Air Cleaner Tube Clamps 2.0 18 in.-lb.
Air Cleaner Retaining Bolts 23 204 in.-lb.

FAULT FINDING

Problem Possible Cause Remedy


Air Cleaner Warning Light illuminates Air Cleaner Filter Elements Clean or replace elements
clogged
Air Cleaner Warning Light illuminates after Vacuum Switch faulty Replace switch
filter service

10-2
SECTION 10 -- ENGINE -- CHAPTER 3

DESCRIPTION AND OPERATION


1
The air cleaning system consists of a dry--type air
cleaner located under the hood assembly (1), above
the intake manifold. The air cleaning system
removes impurities from the air, while allowing a
sufficient volume of air to enter the engine to ensure
complete combustion of the fuel.

Air enters the cleaner in a circular direction, and


centrifugal force causes the heavier particles to
propel to the outside of the container, then collect at
the container bottom. A rubber valve provides a
provision for removal of the collected particles. The 20031385
Lighter particles in the air collect on the outer
(primary) filter element and stay suspended until 1
cleaned during servicing.
Located within the outer element is the inner
(secondary) element. The inner element protects the
engine from fine dust particles that pass by the outer
filter element, and provides filtration if the outer
element fails.
1
The air cleaner restriction warning switch (1), located
in the air intake tube (2), detects increases in vacuum
caused by an obstructed cleaner. When activated, 2
the switch illuminates a warning light on the
instrument panel to notify the operator that the air
cleaner requires servicing.
40031368
IMPORTANT: When observing an air cleaner
restriction warning light, stop the engine as soon as 2
possible and investigate the cause. Improper airflow
to the engine will cause poor engine performance,
and the ingestion of dirt and other particles into the
engine will cause catastrophic engine failure.

10-3
SECTION 10 -- ENGINE -- CHAPTER 3

AIR CLEANER ASSEMBLY FILTERS


1
Removal
1. Raise the engine hood assembly. 2
2. Unlock the air cleaner assembly end cap
securing clips (1) and remove end cap (2).

40031376

3
3. Grasp and pull the outer filter element (1) out of
the cleaner.
1

4
4. Grasp and pull the inner filter element (1) out of
the cleaner.
1

10-4
SECTION 10 -- ENGINE -- CHAPTER 3
Inspection and Repair
1. Clean and examine the outer canister. Repair
any damaged seams.
2. Check the condition and fit of the rubber dust
collector.
3. If dust is present inside the outer element, it must
be replaced. If satisfactory, clean the element.

WARNING
Wear a face shield and eye protection when
using compressed air to clean a filter element.

4. Use compressed air with a maximum pressure of


2.1 bar (30 psi) to clean the filter element. Insert
the air nozzle inside the element and blow the
debris from the inside, through the element and
out. Blow debris off the outside of the element by
holding the nozzle a minimum of 150 mm (6 in)
from the element, Figure 6.
IMPORTANT: Never use oil, petrol or solvent to
clean a filter element. Only use water warm enough 6
to touch.
Cleaning Element with Compressed Air

5. Seal the small hole at the end of the filter element


with tape and place the element open end up in
a deep container. Add a non-suds producing
detergent such as automatic dishwashing soap
to the inside of the element. Add warm water until
level rises to the top open end of the element.
Allow the element to soak for a minimum of 15
minutes, Figure 7.
IMPORTANT: Do not allow the filter element to soak
in water and detergent longer than 24 hours or
damage to element will occur.

7
Washing the Element

6. After soaking, gently agitate the element as


shown in Figure 8, but do not allow dirty cleaning
solution to enter, into the inside portion of the
element.
7. Rinse the element in clean cold water. Use a
hose to trickle water from the outside to the inside
of the element, until water comes through clear.
Do not use water under pressure.
8. Remove the tape and shake excess water from
the element. Allow the element to dry naturally,
which will take approximately 24 -- 48 hours.

8
Agitating the Element

10-5
SECTION 10 -- ENGINE -- CHAPTER 3
IMPORTANT: Do not attempt to dry the filter element Installation
with compressed air. The element must be Installation of the air cleaner assembly follows the
thoroughly dry before installation to prevent rupture removal procedures in reverse with the following
during operation. requirements:

9. Install a new filter element and save the cleaned 1. When installing the filter elements, ensure the
element for the next service interval. This step is rubber sealing rings are completely seated and
critical in preventing the installation of a filter secure.
element that is not completely dry.
2. Tighten the air cleaner assembly retaining bolts
10. When the element completely dries, inspect the to a torque of 23 Nm (204 in.-lb.).
paper pleats by passing a light through the
3. Tighten the air cleaner tube clamps to a torque of
element, and observing for an even unob-
2.0 Nm (18 in.-lb.).
structed pattern of light.
11. Clean the inner filter element using compressed
air only. Follow the procedure described for the

INNER ELEMENT
The inner element should not be disturbed unless
damaged, or contaminated by dirt through failure of
the outer element. To clean the inner element, follow
the procedure for cleaning the outer element, using
compressed air only.

10-6
SECTION 10 -- ENGINE -- CHAPTER 4

SECTION 10 - ENGINE

Chapter 4 - Fuel System

CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel Injection Pump – Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Maximum No-load Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DP203 Series Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DP203 Series Fuel Injection Pump Shaft Lock Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fuel Injector Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Electric Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

10-1
SECTION 10 -- ENGINE -- CHAPTER 4

SPECIFICATIONS
FUEL SYSTEM SPECIFICATIONS

Fuel Tank Capacity

Model Liters Gallons


TB100, TB110, TB120 135 36

Components

Description TB100, TB110, TB120


Fuel Injection Pump Lucas DP203 series
Engine Timing BTDC Engine Position 28°
Pump Timing Locking Bolt Position 29°
Fuel Injector Type Lucas
Adjustment variable
Pressure Setting 290--300 bar (4206--4351 psi)
Fuel Injector Change Interval 1200 hours

10-2
SECTION 10 -- ENGINE -- CHAPTER 4

TORQUE VALUES
Description Nm LB.-FT. (LB.-IN.)
Throttle Cable Locknut 50 37
Throttle Lever Stop Bolts 10 7 (84 lb--in)
Fuel/water Separator Retaining Bolts 30 22 (264 lb--in)
Fuel Pump Gear Retaining Nut 77 57
Fuel Pump--to--Front Plate Retaining Bolts 24 18 (216 lb--in)
Fuel Injector Retaining Bolts 22 16 (216 lb--in)
Fuel Injector Nozzle Retaining Nut 48 35
Fuel Pipe Gland Nuts 32 24 (288 lb--in)
Fuel Tank Sender Retaining Screws 3 2 (24 lb--in)
Fuel Filter Element Retaining Bolt 10 7 (84 lb--in)
Fuel Filter Retaining Bolts 30 22 (264 lb--in)
Leak off Pipe--to--Elbow 24 16 (216 lb--in)
Leak off Pipe--to--Injector Line 24 16 (216 lb--in)
Exhaust Muffler Retaining Clamp 35 26
Thermostart Plug 37 27
Thermostart Tube Union 10 7 (84 lb--in)

10-3
SECTION 10 -- ENGINE -- CHAPTER 4

FAULT FINDING

DIESEL ENGINES
The following tables list problems, probable causes, and recommended remedial action.

PROBLEM PROBABLE CAUSES REMEDY

Fuel not reaching injection pump 1. Restricted fuel filters 1. Check and flush the fuel
filters clean.
2. Air in system 2. Bleed the fuel filters.
3. Fuel leakage 3. Check the fuel lines and
connectors for damage.

Fuel reaching nozzles but engine 1. Low cranking speed 1. Check the cranking speed
will not start
2. Incorrect throttle 2. Check the throttle control
adjustment rod travel
3. Incorrect pump timing 3. Check the pump timing
4. Fuel leakage 4. Check the fuel lines and
connectors for leakage
5. Faulty injectors 5. See injector
troubleshooting
6. Low compression 6. Check the engine
compression

Engine hard to start 1. Low cranking speed 1. Check the cranking speed
2. Incorrect pump timing 2. Check the pump timing
3. Restricted fuel filters 3. Replace filters
4. Contaminated fuel 4. Check for water in the fuel
5. Low compression 5. Check the engine
compression
6. Air in system 6. Check for air leaks on the
suction side of the system

Engine starts and stops 1. Fuel starvation 1. Check and flush clean
restricted fuel lines or fuel
filters
2. Contaminated fuel 2. Check for water in the fuel
3. Restricted air intake 3. Check for restrictions in the
air intake
4. Engine overheating 4. Check cooling system
5. Air in system 5. Check for air leaks on the
suction side of the system

10-4
SECTION 10 -- ENGINE -- CHAPTER 4

PROBLEM PROBABLE CAUSES REMEDY

Erratic engine operation (surge, 1. Fuel leakage 1. Check the injector lines and
misfiring, poor governor connectors for leakage
regulation)
2. Fuel starvation 2. Check and flush clean
restricted fuel lines or
filters
3. Incorrect pump timing 3. Check the pump timing
4. Contaminated fuel 4. Check for water in the fuel
5. Air in system 5. Bleed the fuel system
6. Faulty or sticking injector 6. See injector
nozzles troubleshooting
7. Incorrect engine timing 7. Check for faulty engine
valves

Engine emits black smoke 1. Restricted air intake 1. Check for restricted air
intake
2. Engine overheating 2. Check cooling system
3. Incorrect timing 3. Check the pump timing
4. Faulty injectors 4. See injector
troubleshooting
5. Low compression 5. Check the engine
compression
6. Incorrect engine timing 6. Check the engine valves

Engine does not develop full 1. Incorrect throttle 1. Check for insufficient
power or speed adjustment throttle control movement
2. Incorrect maximum no-load 2. Check maximum no-load
speed speed adjustment
3. Fuel starvation 3. Check and flush clean
restricted fuel lines and
filters
4. Air in system 4. Check for air leaks on the
suction side of the system
5. Incorrect timing 5. Check pump timing
6. Low compression 6. Check engine compression
7. Incorrect engine timing 7. Check for improper valve
adjustment or faulty valves

10-5
SECTION 10 -- ENGINE -- CHAPTER 4

PROBLEM PROBABLE CAUSES REMEDY

Low pressure at pump outlet 1. Low or no fuel in tank 1. Refill tank


2. Blocked filter in lift pump 2. Clean filter
3. Actuating Shaft Worn 3. Replace Shaft
4. Pump Worn 4. Replace Pump

Air in the fuel from pump outlet 1. Blocked fuel tank breather 1. Clear blockage
2. Loose fuel connections 2. Check and tighten
3. Fuel Pump Diaphragm 3. Replace Pump
Perforated
4. Fuel pump body seam 4. Replace Pump
Leaking
5. Pump Worn 5. Replace Pump

Engine emits black smoke 1. Faulty injectors 1. Overhaul or replace injectors


Nozzle does not “buzz” while 1. Dirty or sticking needle valve 1. Clean or replace needle valve
injecting and nozzle holder
2. Valve seat leakage 2. Clean or replace valve and
nozzle assembly
3. Damaged nozzle retaining nut 3. Replace retaining nut
Nozzle leak back 1. Worn needle valve 1. Replace needle valve and
nozzle holder
2. Dirty nozzle and/or holder 2. Clean or replace nozzle and
holder
3. Loose nozzle retaining nut 3. Tighten nut
Nozzle opening pressure 1. Adjusting nut loose 1. Tighten nut
incorrect
2. Damaged nozzle or seized 2. Replace needle valve and
needle valve nozzle holder
3. Blocked nozzle holes 3. Clean nozzle
4. Incorrect shims fitted 4. Adjust shim pack
Nozzle seat leakage 1. Dirty nozzle and/or nozzle 1. Clean or replace nozzle and
holder nozzle holder
2. Sticking needle valve 2. Clean or replace needle valve
and nozzle holder
Incorrect spray pattern 1. Dirty nozzle and/or nozzle 1. Clean or replace nozzle and
holder nozzle holder
2. Restricted nozzle holes 2. Clean or replace nozzle and
nozzle holder
3. Damaged needle valve or 3. Replace needle valve and
nozzle nozzle holder

10-6
SECTION 10 -- ENGINE -- CHAPTER 4

PROBLEM PROBABLE CAUSES REMEDY

Engine emits black smoke 1. Faulty injectors 1. Overhaul or replace


injectors
Nozzle does not “buzz” while 1. Dirty or sticking needle 1. Clean or replace needle
injecting valve valve and nozzle holder
2. Valve seat leakage 2. Clean or replace valve and
nozzle assembly
3. Damaged nozzle retaining 3. Replace retaining nut
nut
Nozzle leak back 1. Worn needle valve 1. Replace needle valve and
nozzle holder
2. Dirty nozzle and/or holder 2. Clean or replace nozzle
and holder
3. Loose nozzle retaining nut 3. Tighten nut
Nozzle opening pressure 1. Adjusting nut loose 1. Tighten nut
incorrect
2. Damaged nozzle or seized 2. Replace needle valve and
needle valve nozzle holder
3. Blocked nozzle holes 3. Clean nozzle
4. Incorrect shims fitted 4. Adjust shim pack
Nozzle seat leakage 1. Dirty nozzle and/or nozzle 1. Clean or replace nozzle
holder and nozzle holder
2. Sticking needle valve 2. Clean or replace needle
valve and nozzle holder
Incorrect spray pattern 1. Dirty nozzle and/or nozzle 1. Clean or replace nozzle
holder and nozzle holder
2. Restricted nozzle holes 2. Clean or replace nozzle
and nozzle holder
3. Damaged needle valve or 3. Replace needle valve and
nozzle nozzle holder

Low pressure at pump outlet 1. Low or no fuel in tank 1. Refill tank


2. Blocked filter in lift pump 2. Clean filter
3. Actuating Shaft Worn 3. Replace Shaft
4. Pump Worn 4. Replace Pump

Air in the fuel from pump outlet 1. Blocked fuel tank breather 1. Clear blockage
2. Loose fuel connections 2. Check and tighten
3. Fuel Pump Diaphragm 3. Replace Pump
Perforated
4. Fuel pump body seam 4. Replace Pump
Leaking
5. Pump Worn 5. Replace Pump

10-7
SECTION 10 -- ENGINE -- CHAPTER 4

FUEL SYSTEM -- DESCRIPTION AND


OPERATION 1
The primary components of the fuel system include
the fuel tank, electric lift pump, filter/water
separators, fuel gauge, fuel injection pump, fuel
injectors, hand and foot throttle (1) linkage.

Routine maintenance on the main filter assembly


and the filter/water separators reduces malfunctions
to the fuel system caused by contaminated fuel, and
will enhance the performance of the engine, as well
as reduce fuel consumption.
40036177
The fuel flows from the fuel tank to the fuel/water
separator, then to the fuel/water sediment separator 1
and on to the main fuel filter and lift pump. The
electric lift pump primes the fuel up to the injection
pump. The fuel injection pump delivers the fuel at
high pressure to each injector, while using extra fuel
from the transfer pump for cooling and lubrication.
The transfer pump, an integral part of the injection
pump, provides fuel flow from the lift pump. The fuel
used for cooling and lubrication circulates back to the
fuel tank via a fitting on the injection pump governor
control housing and leak-off line. Excess fuel leaking
past the needle valves of the injectors returns to the
fuel tank through the leak-off line.

The emissionized engine includes a Thermostart


element, thermostatic switch and a wax plug to
reduce smoke and emissions when cold starting the
engine.

10-8
SECTION 10 -- ENGINE -- CHAPTER 4
IMPORTANT: To prevent the ingestion of dirt and
other contaminants into the fuel system, thoroughly
clean the surrounding areas of the component during
maintenance, especially before loosening fuel
system connections.

The diesel fuel system of the emissionized engine on


the TB tractor consists of the following components:

• Fuel Tank
• Fuel Tank Sender
• Fuel Quantity Gauge
• Fuel/water Separator
• Fuel/water Separator Warning Switch
• Fuel/water Separator Warning Light
• Fuel/Water Sediment Separator
• Main Fuel Filter Assembly
• Electric Lift Pump
• Fuel Shut-off Relay
• Fuel Shut-off Solenoid
• Fuel Injection Pump
• Cold Advance Wax Plug
• Cold Advance Thermostatic Switch
• Thermostart
• Fuel Control Hand Throttle
• Fuel Control Foot Throttle
• Fuel Injectors
• Fuel Hoses and Tubes
Fuel Tank
The fuel tank (1), constructed of steel, mounts on the
left and right-hand sides of the vehicle under the
platform. The tank functions as the reservoir and
contains breathers for venting and a locking filler cap
(2).

1 2
40036179

10-9
SECTION 10 -- ENGINE -- CHAPTER 4
Fuel Tank Sender
The integral fuel probe contains an electrical sender
(1), which transmits a signal to the fuel quantity
gauge on the instrument panel. The fuel tank sender
mounts on the forward, right-hand side of the tank,
and is accessible through the battery compartment.
Refer to Section 55 Electrical Systems.
1

20031389

Fuel Quantity gauge


A needle type fuel gauge (1), incorporated within the
instrument panel indicates the level of fuel in the fuel 1
tank. The needle enters the red colored area of the
gauge when the fuel level reduces to less than 1/4 of
the tank capacity. The gauge receives input from the
electrical sender connected to the fuel probe on the
fuel tank, and receives power from the ignition
key-switch. Refer to Section 55 Electrical Systems.

10-10
SECTION 10 -- ENGINE -- CHAPTER 4
Fuel/Water Separator with Warning Switch
A fuel/water separator mounts on the lower
right-hand side of the engine, below the fuel injection
pump. Water in the fuel from the fuel tank collects in 3
the bowl assembly (1). The warning switch (2)
attached to the side of the bowl will illuminate the
fuel/water warning light on the instrument panel with
water accumulation in the bowl. If the warning light
illuminates with no water in the bowl, such as after
draining, suspect a faulty switch. A bleed screw (3) 1
allows the purging of air from the separator when 2
necessary. The drain plug (4) provides a provision for
draining water from the bowl during maintenance. 40036174
4

To clean the fuel/water separator: 5

1. Close the fuel tank shut-off valve.


2. Open the bleed screw (3).
3. Position a suitable container under the drain plug
(4) and open the plug. Allow any moisture in the
bowl assembly to drain into the container. Close
the drain plug when finished.
4. Remove the warning switch (2) from the bowl.
5. Remove the bowl and flush with clean fuel.
Reinstall the bowl and tighten when finished.
6. Reinstall the warning switch.
7. Close the bleed screw.
8. Open the fuel tank shut-off valve.

CAUTION
To prevent damage to the lift pump and starter
motor, do not operate the ignition key-switch in
the ON position longer than 60 seconds.

9. Check all connections for tightness. then turn the


ignition key-switch to the ON position for 10
seconds to allow the electric lift pump time to
charge the fuel delivery lines. Turn the
key-switch OFF.
10. Slowly open the bleed screw (3) and discharge
air from the separator until air bubbles no longer
emit from the bleed screw. Repeat the bleeding
procedure if necessary.
11. When finished bleeding air from fuel/water
separator, close and tighten the bleed screw.
Start the engine to circulate fuel throughout the
system, and check for leaks.

10-11
SECTION 10 -- ENGINE -- CHAPTER 4
Fuel/Water Sediment Separator
The fuel/water sediment separator mounts to the
cylinder head on the forward right-hand side of the 4
engine. The assembly consists of a cast head, glass
collecting bowl, bleed screw, and drain plug.

Fuel enters the separator, and flows into the glass


bowl (2) through the cast head. Once in the bowl the
fuel flows around the edges of an internal separator
cone. Larger, heavier particles of dirt and water
separate from the fuel and sink to the bottom of the
collecting bowl. The drain plug (3) provides a
provision for draining water and sediment during
SMG092
maintenance. A retaining bolt (4) secures the glass
bowl to the cast head. The bleed screw (1) allows 6
purging of air from the separator when necessary.

To clean the fuel/water sediment separator:

1. Close the fuel tank shut-off valve.


2. Open the bleed screw (1).
3. Position a suitable container under the drain plug
(3) and open the plug. Allow any moisture in the
bowl assembly to drain into the container. Close
the drain plug when finished.
4. Remove the retaining bolt (4) and separate the
glass bowl (2) and inner parts from the cast head.
Flush the bowl with clean fuel. Reinstall the glass
bowl and inner parts in reverse order of removal.
Tighten the retaining bolt when finished.
5. Close the bleed screw.
6. Open the fuel tank shut-off valve.

CAUTION
To prevent damage to the lift pump and starter
motor, do not operate the ignition key-switch in
the ON position longer than 60 seconds.

7. Check all connections for tightness, then turn the


ignition key-switch to the ON position for 10
seconds to allow the electric lift pump time to
charge the fuel delivery lines. Turn the
key-switch OFF.
8. Slowly open the bleed screw (1) and discharge
air from the separator until air bubbles no longer
emit from the bleed screw. Repeat the bleeding
procedure if necessary.
9. When finished bleeding air from fuel/water
sediment separator, close and tighten the bleed
screw. Start the engine to circulate fuel
throughout the system, and check for leaks.

10-12
SECTION 10 -- ENGINE -- CHAPTER 4
Main Fuel Filter with Lift Pump Assembly
The main fuel filter (1) mounts to the right-hand side 2
of the engine forward of the starter motor. An electric
fuel delivery pump (2) mounts on top of the filter
housing. Inside the filter bowl, fuel passes through a 4
5-micron filter element, which removes contami-
nants from the fuel before it reaches the injection
pump. A drain plug (3) provides a provision for
draining water from the filter bowl during mainte- 1
nance. The bleed screw (4) on top of the filter housing
allows the purging of air from the filter when
necessary.
3
To clean the main fuel filter:
7
1. Close the fuel tank shut-off valve.
2. Open the bleed screw (4).
3. Position a suitable container under the drain plug
(3) and open the plug. Allow any moisture in the
bowl assembly to drain into the container. Close
the drain plug when finished.
4. Remove and replace the filter element. Install the
bowl and hand-tighten.
5. Close the bleed screw.
6. Open the fuel tank shut-off valve.

CAUTION
To prevent damage to the lift pump and starter
motor, do not operate the ignition key-switch in
the ON position longer than 60 seconds.

7. Check all connections for tightness. then turn the


ignition key-switch to the ON position for 10
seconds to allow the electric lift pump time to
charge the fuel delivery lines. Turn the
key-switch OFF.
8. Slowly open the bleed screw (4) and discharge
air from the filter assembly until air bubbles no
longer emit from the bleed screw. Repeat the
bleeding procedure if necessary.
9. When finished bleeding air from the filter
assembly, close and tighten the bleed screw.
Start the engine to circulate fuel throughout the
system, and check for leaks.

10-13
SECTION 10 -- ENGINE -- CHAPTER 4
When removing the electrical lift pump from the top
of the main filter housing, ensure to replace the
O-rings (1) before reassembling. The lift pump is
self-bleeding.

8
Fuel Shut-off Solenoid
The fuel shut-off solenoid, which receives power 1
from the ignition key-switch and the fuel shut-off
relay, provides an electrical means of stopping fuel
flow. With the ignition key-switch in the OFF position,
a spring-loaded plunger in the solenoid prevents the
fuel from entering the injection pump through the
main feed port. In the ON position, the key-switch
energizes the magnetized plunger, drawing the
plunger up into the body of the solenoid, which allows
fuel back into the injection pump.

9
Injection Pump Fuel Shut Off
1. Fuel Shut Off Solenoid

Fuel Tank Shut-off Valve


The fuel tank shut-off valve (2) provides a means of
stopping fuel flow to the fuel system. It is located on
the supply port on the lower right-hand side of the
tank.
2
To clean the fuel tank shut-off valve: 1

1. Position a suitable container under the shut-off


valve. Open the valve and allow the fuel to drain
completely.
2. Unscrew and remove the shut-off valve and filter
screen (1).

CAUTION 10

Never use gasoline or solvents to clean the filter


screen, or damage to the screen may occur.

3. Flush the inside of the filter screen with diesel fuel


until clear, dirt-free fuel runs out of the outside of
the screen.
4. Allow the filter screen to air dry before
reinstalling.

10-14
SECTION 10 -- ENGINE -- CHAPTER 4
Thermostart Plug
The Thermostart system aids the engine in cold 1
starting conditions. The system consists of a plug (1)
installed in the intake manifold (2), Figure 11, fuel
lines, and an electric circuit within the starting
system. The Thermostart plug receives gravity fed
fuel.

40025682

11
Moving the key-start ignition switch to Position four
energizes the heater coil (2) and the igniter coil (1)
within the Thermostart plug. The heater coil opens an
internal check valve (3), in the plug, allowing fuel to
reach the igniter coil. The igniter coil in the manifold
ignites the fuel, which heats passing air in the engine
intake before entering the combustion chamber.
Releasing the key-start ignition switch de-energizes
the heater coil, causing the check valve to close,
cutting off the fuel supply to the igniter coil, Figure 12.

IMPORTANT: Operating the Thermostart plug


longer than 30 seconds will cause damage to the
plug.
12
Thermostart Assembly
1. Ignitor Coil
2. Heater Coil
3. Ball Check Valve

10-15
SECTION 10 -- ENGINE -- CHAPTER 4
Thermostatic Switch and Wax Plug
The thermostatic switch (1), Figure 13, located on
the thermostat housing at the front of the engine,
increases the cold advance performance of the
emissionized engine.

40025673

13
During engine start-up, the cylinders remain slightly
cool until the engine warms up to normal operating
temperature. During which time, the engine timing
advances slightly to reduce white smoke and
emissions. The cold advance thermostatic switch
detects when the engine reaches the desired
temperature and completes a circuit to a wax plug (1)
on the fuel injection pump, Figure 14. The wax plug
brings the engine back to normal advance.
1

40025681

14
DP203 Series Fuel Injection Pump
The emissionized engine fuel system incorporates
the DP203 series fuel injection pump (1) as shown in
Figure 15. The sealed DP203 series pump requires
only minimal service. The fuel shut-off solenoid (1) is
replaceable.

IMPORTANT: A faulty DP203 series fuel injection


pump requires specialized equipment, and service
by an authorized specialist. Unauthorized repair of
this type of pump on an emissionized engine will
invalidate any existing warranty and may cause the
tractor to break local emission standards and
regulations.
15

10-16
SECTION 10 -- ENGINE -- CHAPTER 4

INJECTORS
The fuel injectors (1) mounted in the cylinder head
supply fuel in the form of a spray pattern into the
cylinder bores. The controlled amounts of fuel
ensure optimum engine performance throughout the
operating range.

16
FUEL INJECTION PUMP – ADJUSTMENTS

Priming (Pressurizing) the Fuel System


IMPORTANT: Do not crank the starting motor
continuously for more than 60 seconds, as doing so
may cause starting motor failure.

NOTE: Prime the fuel system after disconnecting or


replacing fuel system components to expel air in the
system.
Emissionized Engine
1. Ensure the fuel tank contains a sufficient amount
of fuel.
2. Check all connections for tightness.
3. With the throttle in the ‘no-load’ speed position,
operate the key-start ignition switch to activate
the electric fuel pump (1). The fuel system will be
primed approximately 1 minute after start-up. A
good indication of a primed fuel system will be a
difference in the audible sound of the system
compared to initial start-up.
NOTE: Prime the fuel system after disconnecting or
replacing fuel system components to expel air in the 17
system

10-17
SECTION 10 -- ENGINE -- CHAPTER 4

FUEL INJECTION PUMP IDLE SPEED


ADJUSTMENT
NOTE: The fuel control pedal and hand throttle
linkages connect behind the steering motor cover on
the right-hand side, and share common linkage to the
fuel injection pump. Therefore, after performing the
fuel injection pump idle speed adjustment, operate
both the foot pedal and the hand throttle to verify
correct operation.

1. Run the engine until reaching the recommended


engine operating temperature.
2. Remove the cotter and clevis pins to the fuel
control linkage where the short and long rods
attach near the fuel injection pump.
3. Loosen the locknut and adjust the idle speed stop
screw (1), Figure 18, until obtaining an idle speed
of 700--800 rpm. Tighten the locknut.
4. Reconnect the throttle linkage with cotter and
clevis pins.
5. Recheck idle speed and readjust as required.
6. Ensure that no excessive free-play exists within
the throttle linkage due to worn components. To
determine if free-play exists, move the throttle 1
controls through the foot pedal, and then the
hand throttle. The input to the fuel injection pump
should be immediate as evident in the engine
rpm lowering or increasing. 18

10-18
SECTION 10 -- ENGINE -- CHAPTER 4

FUEL INJECTION PUMP MAXIMUM


NO-LOAD SPEED ADJUSTMENT
NOTE: The maximum NO-LOAD speed is estab-
lished and set at factory. Ensure only an authorized
New Holland dealer performs adjustment.

NOTE: The fuel control pedal and hand throttle


linkages connect behind the steering motor cover on
the right-hand side, and share common linkage to the
fuel injection pump. Therefore, after performing the
fuel injection pump idle speed adjustment, operate
both the foot pedal and the hand throttle to verify
correct operation.
1. Run the engine until reaching the recommended
engine operating temperature.
2. Remove the cotter and clevis pins to the fuel
control linkage where the short and long rods
attach near the fuel injection pump (1), Figure 19.
3. Loosen the maximum no-load speed stop screw
(1), Figure 19.
4. Set the throttle linkage to the maximum no-load
speed of 2320 ± 50 rpm. Adjust screw as needed
to obtain specification.
5. Tighten the locknut to a torque of 7--9 Nm (60--84
in.-lb.) and secure with locking sleeve and
sealing wire.
1
6. Reconnect the throttle linkage with cotter and
clevis pins.
7. Recheck maximum no-load speed and readjust
as required.
19
8. Ensure that no excessive free-play exists within
the throttle linkage due to worn components. To
determine if free-play exists, move the throttle
controls through the foot pedal, and then the
hand throttle. The input to the fuel injection pump
should be immediate as evident in the engine
rpm lowering or increasing.

10-19
SECTION 10 -- ENGINE -- CHAPTER 4

SOLENOID SHUT-OFF VALVE

Removal
Refer to Figure 20.

It is possible to remove the fuel injection pump


solenoid shut-off valve and replace as necessary.

1. Disconnect the battery negative (ground) cable


if not already done.
2. Remove the electrical connectors from the
solenoid shut-off valve terminals.
3. Unscrew the solenoid and remove from the fuel 20
injection pump complete with the O-ring, piston Solenoid Shut-Off Valve Components
and spring. Discard the O-ring. 1. Solenoid Valve
4. Plug the fuel injection pump opening to prevent 2. Rubber O-ring
contamination. 3. Piston
4. Spring
Installation
Installation of the fuel injection pump solenoid
shut-off valve follows the removal procedures in
reverse with the following requirements:

NOTE: Replace the fuel injection pump solenoid


shut-off valve as a complete, matched assembly.

1. Install a new O-ring on the solenoid valve.


2. Tighten the solenoid shut-off valve into the fuel
injection pump to a torque of 28 Nm (248 ft-lb.).

10-20
SECTION 10 -- ENGINE -- CHAPTER 4

SPECIAL TOOLS
(FUEL INJECTION PUMP TIMING)
To time the engine and lock time the pump, use Fuel
Injection Timing Kit Tool No. 380000081 which
includes:
• Degree Wheel Tool No. 380000410 (1),
Figure 21.
1

21
• Pump to Degree Wheel Adapter 380000409 (1),
Figure 22.

• Fuel Injection Pump Drive Gear Puller, Fig-


ure 23.

22

23
Fuel Injection Pump Drive Gear Puller

1. Bolt 5/16 -- UNF x 2 in (51mm), With integral washer (3 3. Holes 0.375 in (9.5mm) dia on 2.2 in (56.87mm) dia
Bolts required) equally spaced material of 0.394 in (10mm) Plate
2. Bolt 3/4 x 16 -- UNC x 2 in (51mm) HRLC P&O Steel.

10-21
SECTION 10 -- ENGINE -- CHAPTER 4
All items shown are part of kit 380000081. However,
you do not need the splined shaft (1), and DPS timing
gauge (2), to lock time the DP203 Series pumps.

20012272

24

10-22
SECTION 10 -- ENGINE -- CHAPTER 4

DP203 SERIES FUEL INJECTION PUMP


(EMISSIONIZED ENGINE)
Removal

NOTE: The direction of engine rotation, clockwise


and counterclockwise, is as viewed from the flywheel
end of the engine.
The fuel injection pump, Figure 25, must be removed
for timing. This process involves setting the engine to
a specified basic timing position, locking the fuel
injection pump drive shaft into position, and
removing the pump.

1. Disconnect the battery negative (ground) cable.


2. Clean all dirt from the injection pump and
surrounding areas.
3. Shut off the fuel supply.

25
4. Disconnect the throttle control linkage (1), the
fuel shut-off solenoid wire, (2); and the wax plug 1
2
wire, (3), Figure 26.
5. Disconnect all fuel lines from the pump and cap
all openings to prevent contamination.
6. Remove the fan shields, if equipped, located to
the front of the fuel injection pump.
7. Remove the fan belt.
8. Remove the fixed pulley.

20012252 3
26
9. Remove the engine timing cover (1), Figure 27.

20012261

27

10-23
SECTION 10 -- ENGINE -- CHAPTER 4
10. Loosen the cap screw retaining the engine
flywheel inspection cover, and swing the cover
(1), out of the way. The timing marks (2), are
located on the flywheel. There is an arrow
marked above the inspection opening (3),
3
1
Figure 28.

APB10008
2

28
11. Install a socket on the crankshaft pulley retaining
screw (1), Figure 29, and rotate the engine
counterclockwise until the No. 1 piston is 1
approximately 29 degrees Before Top Dead
Center (BTDC) on the compression stroke.

20012255

29
12. If the flywheel indicates that the No. 1 piston is 29
degrees BTDC, and the pump mounting bolts (1),
Figure 30, are accessible through the pump
drive gear (2), the engine is on the compression
stroke. Otherwise, rotate the engine 360
degrees. The pump mounting bolts should now
be accessible through the pump drive gear.
2

19983010

30

10-24
SECTION 10 -- ENGINE -- CHAPTER 4
13. With the No. 1 piston approximately 29 degrees
BTDC on the compression stroke, continue to
rotate the engine counterclockwise until the PUMP TIMING DEGREE CHART
flywheel is exactly at the basic timing as shown
on the “Pump Timing Degree Chart,” Figure 31. Cylinder Basic Pump Lock
Timing Degree

4 N/A 28 Degrees BTDC 29 Degrees

4 T/C 28 Degrees BTDC 29 Degrees

6 Cyl 28 Degrees BTDC 29 Degrees

31
14. To ensure accuracy, look straight in at the
stationary marker above the timing opening (1),
Figure 32, and align it with the basic timing mark
on the flywheel.
1
15. If the basic timing mark is passed by, back the
flywheel up several degrees to clear backlash out
of the drive gear train. Again attempt to set the
timing exactly at the basic timing mark. Accuracy
in this step is critical.

APB10008

32
16. Remove the pump timing gear retaining nut (1),
Figure 33, and washer (2), but do not break the
gear free from the shaft .

19983010

33

10-25
SECTION 10 -- ENGINE -- CHAPTER 4
17. Lock the fuel injection pump by loosening the
locking bolt, moving the locking tab to the locked
position, and torquing the locking screw to 13
N⋅m (120 in.-lb.). Figure 34 shows the locking
tab. Callout (1) shows the unlocked position;
callout (2) is the locked position. 1

34
18. Install the puller (1), Figure 35, and break the fuel
injection pump drive gear away from the tapered
pump shaft.
1
NOTE: The gear will remain inside the front cover.

20012257

35
19. Remove the puller, then remove the pump
retaining screws (1), by accessing them through 1
the slots in the pump drive gear (2), Figure 36.
20. Remove the pump and cap all openings to
prevent contamination.

19983009

36

10-26
SECTION 10 -- ENGINE -- CHAPTER 4

DP203 SERIES FUEL INJECTION PUMP


SHAFT LOCK TIMING
With the engine static timing set and the pump locked
before removal, the fuel injection pump should be
properly lock timed. The procedure that follows will:
• Verify the pump lock timing on a pump removed
from the engine.
• Verify pump timing on a pump that has been
returned from an authorized Delphi distributor, or
received from parts.
• Lock time a pump that has been removed without
being lock timed.

To lock time the fuel injection pump or verify lock


timing:
1. Install the woodruff key, part number 72769 (1),
Figure 37, onto the pump drive shaft. The pump
is driven by the fit of the tapered drive gear to the
tapered drive shaft on the pump. The key shown
is for lock timing the pump only. Do not attempt 1
to install the pump with the key installed.

37
2. Install the pump to degree wheel adapter
380000409 (1), over the shaft in alignment with
the key. Also install the washer (part number
4
83918488), (2); and nut (part number 83918492)
1
(3). Hold the adapter 380000409 and tighten the
nut to 13 Nm (10 ft.-lb.). If necessary, use the 2
washer and nut that retained the pump drive gear
to the pump on the engine. 3
3. Install the collar (4) from kit 380000081, over the
pump.

19983002

38

10-27
SECTION 10 -- ENGINE -- CHAPTER 4
4. Set the degree wheel tool 380000410 (1), Figure
39, at the pump lock degrees shown in 3
Figure 31, before the tool is installed on the 2
pump.
5. Install the marker (2) firmly to the degree wheel 1
tool (1) with the thumb screw (3).

39
6. Install the degree wheel, over the master spline
on the degree wheel adapter, Figure 40. Do not
rotate the pump drive shaft. Keep locked at this
point.

1
19983005

40

10-28
SECTION 10 -- ENGINE -- CHAPTER 4
7. Align the slotted marker arm on the degree wheel
(1), Figure 41, the scribe mark on the pump, 2.

19983006

41
8. If the slot on the degree wheel does not align with
the scribe mark on the pump, unlock the pump by
loosening the shaft locking bolt (1), Figure 42,
and rotate the degree wheel until the slotted
marker on the degree wheel aligns with the
scribe mark on the pump.
9. Lock the pump by moving the locking tab to the
locked position and torquing the locking screw to
13 Nm (10 ft.-lb.).
10. Remove the degree wheel, nut, washer, gear,
key, and guide from the pump.
19983007
1
IMPORTANT: Remove the key from the pump.
42
NOTE: If the pump was at a distributor for any
internal repair or calibration other than just lock
timing, the original reference scribe mark should
have been ground off and a new one made. The
accuracy of the above procedure is based on the
scribe mark on the pump housing being correct.

10-29
SECTION 10 -- ENGINE -- CHAPTER 4

INSTALLATION
The following procedure is for installing a fuel
injection pump if the engine flywheel timing marks
are accessible and the pump was removed using the
standard removal procedure.

1. Clean the fuel injection pump drive shaft taper of


all residual oil and dirt as well as the taper in the
fuel injection pump drive gear. Use a non-residu-
al solvent. This is to prevent possible drive gear
slip when in operation.
2. Ensure the engine is at the proper basic timing
according to the “Pump Timing Degree Chart”,
Figure 31.
3. Install the pump on the engine using new o-rings,
on each bolt before inserting the bolts through
the mounting holes. Failure to use new o-rings on
the mounting bolts may allow engine lubricant to
leak out. Torque the hardware to 20 -- 24 Nm (15
-- 18 ft.-lb.).
4. Install the washer and start the nut on the fuel
injection pump drive shaft. Initially tighten the
pump drive gear retaining nut to 20 Nm (15
ft.-lb.).
5. Loosen the pump lock screw, move the tab to the
unlocked position (1), Figure 43, and torque the
screw to 13 Nm (10 ft.-lb.).

43
6. Tighten the pump drive gear retaining nut (1), to
a final torque of 75 -- 81 Nm (55 -- 60 ft.-lb.),
Figure 44.
7. Connect all fuel lines to the fuel injection pump.
Torque the high pressure gland nuts at the
injection pump to 33 Nm (24 ft.-lbs.).

19983010

44

10-30
SECTION 10 -- ENGINE -- CHAPTER 4
8. Connect the throttle control linkage (1), fuel
shut-off solenoid wire, (2); and wax plug wire, (3), 1
2
Figure 45.
9. Install the engine timing cover and torque the
hardware to 22 Nm (16 ft.-lb.).

20012252 3
45
10. Slip the fan belt back on. Make sure it is routed
properly over the pulleys and fits correctly in the
pulley grooves.
11. Install the fan shields, if equipped, and any other
parts removed to gain access during the
procedure.
12. Swing the flywheel timing inspection cover back
into place and tighten the screw.
13. Connect the battery negative (ground) cable.
14. Before starting the engine, turn the key on to
allow the electric fuel pump to run. The lift pump
should lug down when it pressurizes the system.
If the pump does not fill the system with fuel
within 1 -- 2 minutes, shut the key off. On some
units, it may be difficult to prime the system if the
fuel level is low or the fuel was bled out of the
electric lift pump suction line. Fill the fuel tank
first. If the unit still does not prime, some other
method may be required to initially get the fuel to
the lift pump.

10-31
SECTION 10 -- ENGINE -- CHAPTER 4

FUEL INJECTORS
The fuel injectors apply fully atomized fuel to each
cylinder, creating a condition which fuel burns
efficiently and with a minimum of smoke.

Each fuel injector consists of a nozzle assembly,


needle valve, injector body, and regulating spring.

The fuel injection pump delivers fuel to the injector


inlet port. Fuel flows through a drilling in the injector
body to the needle valve seat. The pressurized fuel
from the injection pump lifts the needle valve off the
seat against the spring force. The fuel atomizes
when forced through the five holes in the nozzle tip.
A loss of fuel pressure from the fuel injection pump
allows the spring force to reseat the needle valve.

To lubricate the fuel injectors, a small amount of fuel


passes between the needle valve and nozzle body.
The excess fuel rises to the top of the injector and
returns to the fuel tank via the injector leak-off line.

OVERHAUL
2
Removal
1. Raise the engine hood assembly.
3
2. Disconnect the battery.
3. Clean the area around the fuel injectors to
prevent contamination.
4. Remove the fuel pipes (1) at the injectors from
the injection pump. Cap and plug all openings to 1
prevent contamination, Figure 46.
5. Remove the banjo bolts (2) and discard the two
copper washers with each bolt. Remove the 46
leak-off piping (3), Figure 46.
6. Remove the two retaining bolts (3) from each
injector and remove injectors from the cylinder
head. Discard the cork dust washer (1) and
cooper-sealing washer (2), Figure 47.
NOTE: The cooper sealing washer may need 1
extraction from the cylinder bore.
3
7. Cover the cylinder head injector openings to
prevent contamination.

47

10-32
SECTION 10 -- ENGINE -- CHAPTER 4

FUEL INJECTOR TESTING


WARNING
The spray from a fuel injector test set will pierce
skin with fatal results. Always point the spray
from an injector away from self and by-standers.

WARNING
Fuel spray is flammable. Ensure no open flames
exist in the testing area, and do not generate
excessive vapor.

NOTE: During the Nozzle Opening Pressure and


Spray Pattern tests, collect the spray in a container
partially filled with rags to absorb the spray (1),
Figure 48.

1. Fill the tester with calibrating type fuel oil and


leave the filler cap slightly loose to prevent the 1
forming of a vacuum during testing.

TA6010115

48
2. Prime the tester until emitting fuel oil from the
testing line. 2
3. Connect the injector to be tested (1), Figure 49. 1
4. Screw in the right-hand knob on the tester to
prevent a blocked injector nozzle from damaging
the gauge.
5. Pump the tester to check nozzle. If nozzle opens
begin testing. If nozzle is blocked or jammed,
disassemble the injector.

Nozzle Opening Pressure Setting


Slowly pump the injector tester and observe the APB10004
pressure at which the needle valve lifts, and fuel 49
emits from the nozzle tip. The opening pressure must
be 290 bar (4206 psi) for emissionized engines.
Adjust the nozzle opening pressure setting by
rotating the adjuster on top of the injector (2)
clockwise or counterclockwise, Figure 49.

Spray Pattern Test


Pump the tester rapidly and observe the spray
pattern from the holes in the nozzle. Ensure an
atomized spray, free from distortion and irregular
streaks of fuel, emits from the nozzle. The tester will
not provide a suitable test for atomization under
working conditions; however, it is a reliable indication
of how well the nozzle works.

10-33
SECTION 10 -- ENGINE -- CHAPTER 4
Nozzle Seat Leakage Test
Wipe the nozzle tip dry and apply pressure of 230 bar 1
(3336 psi). The nozzle tip and bottom face must
remain essentially dry with no accumulation or drips
of fuel. Replace the nozzle assembly when leakage
occurs. A slight dampness will not necessitate
replacing the nozzle assembly. Use blotter paper to
check fuel accumulation on the nozzle tip (1),
Figure 50.

Nozzle Back Leakage Test


Apply 230 bar (3336 psi) of pressure to the injector,
then release the tester handle. Measure the time
taken for pressure to fall from 148 bar to 99 bar 50
(2147-1435 psi). If the time taken is less than 6
seconds, replace the nozzle. If the time taken s
greater than 45 seconds, suspect carbon on the
valve or blocked back leak drillings.

NOTE: Reinstall the injectors on the engine after all


tests end successfully.
Disassembly
1. Place the injector in a suitable holding fixture with
the nozzle upward. Do not clamp the injector
body in a vise or damage will result. Use a ratchet
(1) and Socket Tool No. FNH08126 to loosen the 1
nozzle retaining nut.
2
NOTE: Socket in Figure 51 is shown cut-away to
display injector tip.

51

10-34
SECTION 10 -- ENGINE -- CHAPTER 4
2. Remove the nozzle retaining nut, nozzle body
(1), needle valve (2) and the adapter plate.
1

52
3. Remove the injector body (1), from the holding
fixture. Invert and remove the regulating spring
seat (2), spring (3) and adjustment shims.
NOTE: Place injector components in clean fuel until 1
installing to prevent corrosion.

2
3

53

10-35
SECTION 10 -- ENGINE -- CHAPTER 4

INSPECTION AND REPAIR


1. Clean the injector body by soaking in a carbon
solvent and brushing with a brass wire brush.
Inspect the body for damaged threads and
pressure face, making sure the holes in the
injector nozzle are thoroughly clean with no signs
of corrosion or pitting.
2. Clean the spring and spring seat using a brass
wire brush and check for scoring, pitting or
corrosion.

3. Clean the dowel adaptor plate using a brass wire


brush. Inspect the plate for loose or bent dowels,
damaged pressure face or corrosion.
4. Clean the needle valve and body by soaking in a
carbon solvent and brushing with a brass wire
brush. Using a suitable Nozzle Cleaning Kit,
clean the nozzle as follows:
NOTE: Discard the needle valve if damaged or
evidence of overheating exists (valve will be blue in
color). Replace needle valve and needle body
assembly as a matched set.

54
5. Clean the nozzle spray holes with a cleaning wire
protruding 1.5 mm (0.06 in.) from a pin vise (1).
Insert the wire into each hole, pushing and
rotating gently to clear holes, Figure 55.

55

10-36
SECTION 10 -- ENGINE -- CHAPTER 4
6. Clean the needle valve seat using a valve seat
scraper (1) by rotating and pushing the tool onto 1
the valve seating.
7. Clean the fuel port using a fuel port scraper.
Insert the scraper into the port, press hard
against the side of the cavity and rotate to clear
all carbon deposits from this area.

56
8. Use a Reverse Flush Nozzle Adaptor, Tool No.
FNH08124 (1), on the injector tester and reverse
flush the nozzle to remove the carbon loosened
during cleaning. 1
9. After flushing the nozzle, polish the valve seat by
placing a very small amount of tallow on the end
of a polishing stick and rotate in the nozzle.

57
10. Clean the top of the needle valve using a needle
valve scraper (1).
11. Clean the nozzle retaining nut threads with a
brass wire brush. Remove carbon deposits and
inspect threads for damage.

1
APB10013

58

10-37
SECTION 10 -- ENGINE -- CHAPTER 4
Assembly
1. Rinse all injector parts in clean fuel oil and 4
assemble injectors wet. 3
2. Pass the regulating spring (1) and spring seat (2)
into the injector body (3). Place the injector body
into a suitable holding fixture. 5
3. Assemble the needle valve (4) into the nozzle
body and position the dowel adapter plate onto
the nozzle body. Insert this assembly into the
retaining nut (5).
2 1

59
4. Assemble the dowel adapter plate (1) and nozzle
retaining nut assembly onto the injector body.
Tighten the retaining nut to a torque of 48 Nm (35
ft.-lb.).
5. Perform fuel injector testing procedures.

60
Installation
Installation of the fuel injectors follows the removal
procedures in reverse with the following require-
ments:

1. Install the injectors into the cylinder head with


new cork dust washers and cooper sealing
washers.
2. Install the injector retaining bolts and tighten to a
torque of 22 Nm (195 in.-lb.).
3. Connect the leak-off pipes using new washers
and tighten the banjo bolts to a torque of 12 N⋅m
(106 in.-lb.).
4. Connect fuel lines from injection pump to fuel
injectors and tighten pipe nuts at both ends to a
torque of 32 Nm (283 in.-lb.).
5. Replenish fuel system as needed and purge
system of air.

10-38
SECTION 10 -- ENGINE -- CHAPTER 4

ELECTRIC LIFT PUMP

Removal
NOTE: Tractors with fuel systems incorporating the
DP203 series fuel injection pump include the electric
lift pump.

1. Disconnect the battery negative (ground) cable.


2. Disconnect the wiring from the lift pump (1),
Figure 61.
3. Unscrew the filter head assembly connection
and remove lift pump.

61
Installation
Installation of the electric lift pump assembly follows
the removal procedures in reverse with the following
requirement:

1. Replace the O-rings (1), at the lift pump-to-filter


assembly connection point, Figure 62.

62

10-39
SECTION 10 -- ENGINE -- CHAPTER 4

10-40
SECTION 10 -- ENGINE -- CHAPTER 5

SECTION 10 - ENGINE

Chapter 5 - Turbocharger

CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

10-1
SECTION 10 -- ENGINE -- CHAPTER 5

TURBOCHARGER SPECIFICATIONS

Description
Bearing Journal Radial Clearance 0.056-0.127 mm 0.002-0.005 in
Thrust Bearing Axial Clearance 0.025-0.084 mm 0.0010-0.0033 in

SPECIFICATIONS

Turbocharger Torque Values


Turbine Housing/Locking Plate Bolts 20-25 Nm 177-221 in.-lb.
Turbocharger-to-Manifold Bolts 41-47 Nm 30-35 ft.-lb.
Oil Intake Pipe Banjo Bolt 54-81 Nm 40-60 ft.-lb.
Oil Intake-to-Oil Filter Connector 18-20 Nm 159-177 in.-lb.
Oil Intake Pipe Connector-to-Oil Filter 54-81 Nm 40-60 ft.-lb.
Oil Return Pipe-to-Turbocharger Bolts 20-25 Nm 177-221 in.-lb.
Oil return Pipe –to-Block Connector 54-81 Nm 40-60 ft.-lb.
Oil Return Pipe Connector-to-Block 27 Nm 239 in.-lb.
Intake /Exhaust Hose Clamps 2-3 Nm 18-27 in.-lb.

10-2
SECTION 10 -- ENGINE -- CHAPTER 5

TURBOCHARGER FAULT FINDING fact would not be evident after removing the
A turbocharger will not compensate for incorrect turbocharger from the engine.
engine operating temperatures; deficiencies of the
engine air intake, fuel, or exhaust systems; or for Furthermore, failure to take appropriate steps to
damaged engine components such as valves, ensure correct installation, such as repairing or
pistons, rings, liners, etc. Replacing a good replacing defective clamps or ducting, could cause
turbocharger with another will not correct engine the replacement unit to fail in a similar manner.
deficiencies.
The following chart contains information pertaining to
Consequently, systematic troubleshooting of a probable failure modes of turbocharged engines,
suspected turbocharger failure is essential for two probable causes for such failures, and the
very important reasons. First, it must be determined maintenance action required remedying each
what, if anything, is wrong with the turbocharger so probable cause. It is not represented that this
that it can be repaired. Second, it must be information is all-inclusive.
determined what action will prevent a reoccurrence
of the failure. In general, perform the troubleshooting procedures
with the least effort, and in the least amount of time,
In many cases, the evidence required to determine first. Perform no removal or disassembly procedures
the cause of a malfunction is destroyed in the until visual inspections and sensory tests (sight and
process of removing the turbocharger from the feel) with the turbocharger installed have been
engine. If a turbocharger failed as a result of faulty performed. The probable causes and remedy are
installation (such as loose duct connections that generally arranged in the order of ease of
permitted ingestion of dirt by the compressor), this accomplishment.

10-3
SECTION 10 -- ENGINE -- CHAPTER 5

FAULT FINDING
PROBLEMS PROBABLE CAUSES
1. Engine lacks power or emits black Dirty air cleaner
smoke
Loose compressor-to-intake manifold connections
Leak at engine intake at turbocharger mounting flange
Turbo rotating assembly binding
Air cleaner-to-turbocharger duct restricted
Compressor-to-intake manifold duct restricted
Engine exhaust system restricted
Engine malfunction (rings, pistons, valves and associated
parts).
2. Engine exhaust emits blue smoke Dirty air cleaner
Loose compressor-to-intake manifold connections
Leak at engine intake manifold
Plugged engine oil filter
Restricted duct between air cleaner and turbocharger
compressor
Seal leak at compressor end of turbocharger
Engine malfunction (rings, pistons, valves and associated
parts)
3. Excessive engine oil consumption Wrong type or viscosity of engine lubricating oil
Seal leaks at compressor end of turbocharger (indicated by
oil in housing or on wheel)
Oil in engine exhaust manifold (caused by malfunction of
rings, pistons, valves and associated parts).
4. Noisy turbocharger Dirty air cleaner
Foreign material or object in compressor-to-intake manifold
duct
Foreign object in engine exhaust system
Carbon buildup in turbine housing
Turbocharger rotating assembly binding or dragging
5. Turbocharger rotating assembly Damaged compressor wheel
binding or dragging
Damaged turbine wheel
Compressor or turbine wheel rubbing on housing due to
worn bearings, shaft journals or bearing bores
Excessive dirt buildup in compressor (housing or wheel)
Excessive carbon buildup behind turbine wheel (overhaul
turbine)

10-4
SECTION 10 -- ENGINE -- CHAPTER 5

PROBLEM PROBABLE CAUSES


6. Seal leaks at compressor end of Dirty air cleaner
turbocharger
Restricted duct between air cleaner and turbocharger
Loose compressor-to-intake manifold dust connections
Leak at engine intake manifold
Restricted turbocharger oil drain line
Plugged engine crankcase breather
Worn or damaged compressor wheel (worn bearings, bores
or journals)
Excessive piston blow-by or high internal crankcase
pressure

7. Seal leaks at turbine end of Excessive pre-oiling


turbocharger
Plugged engine crankcase breather
Restricted turbocharger oil drain line
Worn turbocharger bearings, bearing, bores, or journals.
8. Worn turbocharger bearings, bores Inadequate pre-oiling following turbocharger installation or
or journals engine lube servicing
Contaminated or improper grade of engine oil used in
engine
Insufficient oil supplied to turbocharger due to “oil lag”
Restricted turbocharger oil feed line
Plugged engine oil filter
Insufficient lube oil supplied to turbocharger due to engine
oil pump malfunction

10-5
SECTION 10 -- ENGINE -- CHAPTER 5

TURBOCHARGER

Description and Operation


The turbocharger (1) consists of gas turbine and air
compressor wheels mounted on opposite ends of a
common shaft. The wheels are enclosed by a
housing, and the shaft by a center housing.

The exhaust turbine is a centripetal (from outside to


center), radial inflow designed mechanism consist-
ing of a cast turbine wheel, wheel shroud, and a
specially designed housing that encloses the wheel 1
40036176
and directs the flow of gas through the turbine.
1
The intake compressor is a centrifugal, radial outflow
mechanism consisting of a cast compressor wheel,
a backplate assembly, and a specially designed
housing that encloses the wheel and directs the flow
of air through the compressor.

The center housing supports the compressor and


turbine wheel shaft, within a pair of identical
bearings. Passages drilled in the center housing
direct oil, supplied by the engine from the inlet port,
to the oil grooves machined in the bearing bores. The
oil grooves align with holes in the bearings.

Piston rings, installed at each end of the shaft


between the bearing and adjacent wheel, prevent
lubricating oil from entering the turbine and
compressor area.
During operation of the turbocharged engine,
exhaust gas from the exhaust manifold flows into the A
turbine (C). The exhaust gas pressure and heat
energy extracted causes the turbine wheel to rotate,
which causes the compressor wheel to rotate.

The turbine housing directs cooled and expanded D B


exhaust gas leaving the turbine wheel to the engine
exhaust system (D), where it expels to the
atmosphere.

Rotation of the compressor wheel draws ambient air


(B) from the air cleaner into the compressor housing, APB10501 C
where the air compresses and flows to the engine
intake manifold (A). 2
A. To intake manifold
B. From air cleaner
C. From exhaust manifold
D. To exhaust muffler

10-6
SECTION 10 -- ENGINE -- CHAPTER 5
The increased volume and density of the air
delivered to the engine cylinders permit a corre- 4
sponding increase in the volume of fuel that can be
introduced into the cylinders, while maintaining the
air/fuel ratio required for proper combustion. Since
engine power output is a function of the volume of
fuel burned, the increase in the volume of fuel 5
introduced as a result of turbocharger operation
results in an increase in engine power output. 3 2

3
1. From air cleaner
2. Compressed air flow
3. Engine cylinder
4. Exhaust gas flow
5. Turbine

10-7
SECTION 10 -- ENGINE -- CHAPTER 5

OVERHAUL
1
Removal
Refer to Figure 4. 2

1. Disconnect the battery negative (ground) cable 3


2. Raise the hood assembly.
3. Remove the vertical exhaust muffler (1).
4. Remove the exhaust muffler-to-turbocharger
clamp (2), bracket and tube.
20031380
5. Disconnect the intake manifold-to-turbocharger
clamp and tube (3). 4
6. Disconnect and remove the oil pipes (4). Cap and
plug all openings to prevent contamination,
Figure 5.
7. Remove the retaining bolts and remove the
turbocharger (1) from the exhaust manifold (3).
Discard the sealing gasket (2), Figure 5. 1

3
4

Disassembly
1. Clean the turbocharger in a suitable solvent
before disassembly. Allow part to dry.
2. To facilitate re-assembly, mark the compressor
housing, turbine housing and center housing (1),
Figure 6.

10-8
SECTION 10 -- ENGINE -- CHAPTER 5
3. Remove compressor housing ‘C’ clip from center
housing intake side (1).
NOTE: Exercise care when removing the compres-
sor housing to avoid damaging the compressor
wheel blades. If needed, tap the turbine housing with
a soft faced hammer.

7
4. Loosen and remove bolts from the turbine
housing exhaust side, and lockplates (1).

8
Cleaning
Before cleaning, inspect all parts for burning,
rubbing, or impact damage that may not be evident
after cleaning. Clean all parts in a non caustic
solution, using a soft bristle brush, a plastic blade
scraper, and dry compressed air to remove residue.

DO NOT -- Use abrasive cleaning methods which


might damage or destroy machined surfaces.

DO NOT -- Immerse the center housing/ rotating


assembly in solvent.

DO NOT -- Blow under compressor wheel with


compressed air.

DO NOT -- Permit wheel/shaft assembly to spin when


blowing off solvent and residue.

10-9
SECTION 10 -- ENGINE -- CHAPTER 5
Inspection
1. Inspect the compressor housing as follows:
• Check for wheel rubbing damage in the
contour area. Remove minor imperfections
with 80 grit silicon carbide abrasive cloth.

• Inspect snap ring grooves for wear, damage


or corrosion.

• Check for dents, burrs or distortion between


the compressor housing and the center
housing/rotating assembly, which may pre-
vent proper sealing.

Replace compressor housing if defective.

2. Inspect the turbine housing as follows:


• Check for wheel rubbing damage in the
contour area. Remove minor imperfections
with 60 grit silicon carbide abrasive cloth.

• Inspect snap ring grooves for wear, damage


or corrosion.

• Check for dents, burrs or distortion between


the turbine housing and the center housing/
rotating assembly, which may prevent proper
sealing.

NOTE: Disassembly of the compressor/rotating


assembly will negate the precise balancing per-
formed at the factory, and necessitate replacing the
assembly.

10-10
SECTION 10 -- ENGINE -- CHAPTER 5
Center Shaft Radial Check
Check the bearing journal radial clearance when
discovering compressor or turbine wheel rubbing, or
1
when noticing a high pitched sound during operation,
as follows:

1. Remove turbocharger from the tractor


2. Attach a dial indicator (1) with a suitable probe to
the center housing. The indicator plunger must
extend through the oil outlet port and contact the
shaft of the turbine wheel assembly.
3. Manually apply an equal amount of pressure
simultaneously to the compressor and turbine
wheels to move the shaft away as far as possible 9
from the dial indicator probe.
4. Set the dial indicator to zero.
5. Manually apply an equal amount of pressure
simultaneously to the compressor and turbine
wheels to move the shaft toward the dial indicator
probe as much as possible. Record the reading
on the indicator.
NOTE: To achieve the most accurate measurement
possible, roll the wheels slightly in both directions
while applying pressure.

6. Manually apply an equal amount of pressure


simultaneously to the compressor and turbine
wheels, to move the shaft away from the plunger
again. Note that the indicator pointer returns
exactly to zero.
7. Repeat Steps 2 through 6 several times to
ensure recording the correct measurement of
maximum radial clearance, as indicated by shaft
movement.
8. Replace the center housing/rotating assembly if
maximum clearance not within 0.056-0.127 mm
(0.002-0.005 in.).

10-11
SECTION 10 -- ENGINE -- CHAPTER 5
Thrust Bearing Axial Clearance Check
Check the thrust bearing axial clearance as follows:

1. Remove the turbocharger from the tractor.


2. Place a dial indicator (1) with the probe on the
compressor end of the shaft assembly.
3. Manually move the compressor/turbine wheel
assembly as far from the plunger as possible.
4. Set the dial indicator to zero.
5. Manually move the compressor/turbine wheel
assembly toward the plunger as much as
possible. Record the shaft movement as shown
on the indicator dial. 10

6. Manually move the compressor/turbine wheel


assembly as far away from the plunger as
possible. Note that the indicator plunger returns
to zero.
7. Repeat steps 2 through 5 several times to ensure
recording the correct measurement of maximum
axial clearance, as indicated by shaft movement.
8. Replace the center housing/rotating assembly if
maximum clearance not within 0.025-0.084 mm
(0.0010-0.0033 in.).

Assembly
NOTE: When replacing parts during overhaul,
transfer scribe marks made during disassembly from
the old part to the new part.

1. Replace the following components when over-


hauling the turbocharger:
• Compressor Housing Snap Ring

• Compressor Housing O-ring

• Turbine Housing Retainer Plates

• Turbine Housing Retaining Bolts

2. Replace the following components only if faulty:


• Center Housing/Rotating Assembly

• Compressor Housing

• Turbine Housing
3. Transfer alignment scribe marks on old snap
rings, made during disassembly, to new snap
rings. Coat rings in clean engine oil.
4. Install new snap ring on the compressor end of
the center housing/rotating assembly, with the
beveled side facing the turbine end.

10-12
SECTION 10 -- ENGINE -- CHAPTER 5
5. Install O-ring (1) on center housing flange
(compressor end). Place compressor housing
into position. Do not damage compressor
blades.
6. Rotate the compressor housing to line up with
scribe marks made during disassembly.
7. Install the snap ring (lug first) into the compressor
housing groove. Face the beveled side toward
the turbine end and align with scribe marks made
during disassembly. Ensure snap ring fits
completely into groove.

11
8. Position the turbine housing discharge side
down, on a flat level surface. Place the turbine
wheel end of the shaft into the housing. Do not
damage the turbine blades. Align with scribe
marks.

12

9. Position the locking plates. Coat the retaining


bolts (1) in a suitable anti-seize compound and
install. Tighten the bolts to a torque of 20-25 Nm
(177-221 in.-lb.).

13

10-13
SECTION 10 -- ENGINE -- CHAPTER 5
Installation
Installation of the turbocharger follows the removal
procedures in reverse with the following require-
ments:

1. Fill the turbocharger center housing with clean oil


and rotate the main shaft to lubricate the
bearings.
2. Install a new sealing gasket and position
turbocharger on exhaust manifold. Tighten
retaining bolts to a torque of 41-47 Nm (30-35
ft.-lb.).
3. Install washers and connect the oil feed tube
banjo bolt. Tighten banjo bolt to a torque of 30-40 14
Nm (22-30 ft.-lb.).
4. Install the oil feed tube connector-to oil filter
head. Tighten connector to a torque of 54-81 Nm
(40-60 ft.-lb.).
5. Connect oil feed tube pipe to the oil filter head
connector and tighten to a torque of 18-20 Nm
(159-177 in.-lb.).
6. Place a suitable container below the oil outlet
port.
7. Disconnect the electrical solenoid at the fuel
injection pump.
8. Crank the engine until oil flows from the outlet
port. After obtaining oil flow, stop the engine and
reconnect the electrical solenoid at the fuel
injection pump.
9. Install new gasket. Connect the oil outlet pipe to
the turbocharger connector and tighten to a
torque of 20-25 Nm (177-221 in.-lb.).
10. Tighten return pipe-to-block fitting to a torque of
27 Nm (239 in.-lb.).
11. Connect oil return pipe to the block fitting and
tighten to a torque of 54-81 Nm (40-60 ft.-lb.).
12. Connect the air inlet and outlet tubes. Tighten
clamps to a torque of 2-3 Nm (18-27 in.-lb.).
13. Check engine oil level and replenish as needed.
14. Idle engine and check all tubes, pipes and seals
for leakage.
15. Operate the engine at rated speed and listen to
turbocharger for signs of metal contact. If
noticed, stop engine immediately and recheck
turbocharger.
NOTE: The turbocharger rotating assembly will
coast freely to a stop upon engine shut-down, as long
as the engine ran at normal operating temperature.
If after stopping the engine, the rotating assembly
jerks to a stop, immediately investigate and correct.

10-14
SECTION 10 -- ENGINE -- CHAPTER 5
Testing 8. Internal inspection of the center housing can be
1. With engine stopped, check duct clamping accomplished by removing the oil drain line and
devices for tightness. looking through the oil drain opening. When a
sludged or coked condition exists, a heavy
2. With engine running at idle speed, lightly spray sludge buildup will be seen on the shaft between
duct connections with starting fluid. Leaks at the bearing journals and in the center housing
connections will be indicated by an increase in from the oil drain opening back of the turbine end.
engine speed due to the starting fluid being
drawn into the compressor and pumped into the 9. Thorough cleaning of the air induction system is
engine combustion chambers. essential following compressor wheel damage
due to foreign object impact. In many cases,
3. With engine running at idle speed, check duct metal pieces from the wheel become imbedded
connections for leaks by applying lightweight oil in the air cleaner element. If the element is not
or soap suds to areas of possible leakage and changed in such cases, these metal pieces can
look for bubbles. Exhaust gas leakage between be drawn into the replacement turbocharger and
the cylinder head, exhaust manifold and the cause it to fail in the same manner as the original
turbocharger inlet will create a noise level unit.
change.
10. With the air inlet and exhaust gas ducting
4. With engine running at idle speed, check for removed from the turbocharger, examine both
unusual noise and vibration. If either condition is the compressor and turbine wheels for blade
noted, shut down the engine immediately to damage. Examine the outer blade tip edges for
protect the turbocharger and engine from further evidence of rubbing on adjacent housing
damage. With the engine stopped, check the surfaces.
turbocharger shaft steel assembly for damage.
NOTE: A light is required for examining the turbine
5. With engine running, a change in the noise level wheel blade tips, which are positioned inside the
to a higher pitch can indicate air leakage between turbine housing. View surfaces requiring inspection
the air cleaner and the engine, or a gas leak from the outlet end of the turbine housing.
between the engine block and the turbocharger
inlet. Rotate the rotating assembly by hand and feel for
6. Exhaust gas leakage may be indicated by heat smooth turning, dragging or binding. Push the
discoloration in the area of the leak. rotating assembly sideways while rotating to feel for
wheel rub. If indication of rubbing exists, perform the
7. With the engine running, noise level cycling from bearing clearance inspection procedures. If the
one level to another can indicate a plugged air rotating assembly rotates freely and no evidence of
cleaner, a restriction in the air cleaner- binding or rubbing exists, assume that the
to-compressor duct, or a heavy buildup of dirt in turbocharger is serviceable.
the compressor housing or on the compressor
wheel.

10-15
SECTION 10 -- ENGINE -- CHAPTER 5

10-16
SECTION 18 -- CLUTCH -- CHAPTER 1

SECTION 18 - CLUTCH

Chapter 1 - Clutches

CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

18-1
SECTION 18 -- CLUTCH -- CHAPTER 1

SPECIFICATIONS

Components

Disc Assembly 14in (355.6 mm) Single Disc Dry Plate


Type
Material Cerametalic
Pressure Plate Assembly Belleville (diaphragm) Spring
Type (Self Adjusting -- No Maintenance)
Release Bearing Mechanically Operated with 8 x 2 (16 x 4) Transmissions
Type
Clutch Pedal Free Play
Adjustment -- (Mechanically .75 -- 1.0 in (19 -- 25.4 mm)
Operated Clutch Only)
Transmission Input Shaft Ambra lithium and molybdenum disulphide grease GR75MD
Lubricant

TORQUE VALUES

Components lb.ft. Nm

Clutch Cover to Flywheel Bolts 26 35


Clutch Pedal Operating Rod Turnbuckle 25 34
Locknut
P.T.O. Drive Plate Bolts 95 129
Cross shaft Release Bearing fork 35 47
Retaining Bolt

18-2
SECTION 18 -- CLUTCH -- CHAPTER 1

SPECIAL TOOLS

Description Old Part Number Global Part Number

Tool, Centering FNH02142

Puller, Attachment FNH09190

Puller, Grip-O-Matic FNH09198

Plate, Step (set of 11) FNH09210

Plate, Step (set of 6) FNH09211

Attachment, Bearing Cup Puller FNH09507

Driver, Set FNH09514

Puller, Bearing Cup FNH09564

Hammer, Slide FNH09507

FAULT FINDING

PROBLEM PROBABLE CAUSES REMEDY

No drive when gear selected Rear axle or transmission 1. Engage differential lock. If
and clutch pedal released defective tractor drives, fault indicated
from output of differential unit.
If still no drive, possible
transmission or rear axle fault.
2. Engage FWD. If tractor drives,
transmission O.K.

Clutch incorrectly adjusted 1. Adjust clutch


(mechanical)

Clutch bearing not releasing 1. Adjust linkage


2. Adjust pedal

Friction disc completely worn 1. Replace friction disc

Pressure plate faulty 1. Repair pressure plate

18-3
SECTION 18 -- CLUTCH -- CHAPTER 1

PROBLEM PROBABLE CAUSES REMEDY

Engine speed increases without Clutch friction disc slipping 1. Check clutch adjustment
a corresponding rise in road
speed, clutch pedal released. Worn friction disc 2. Replace friction disc

Pressure plate defective 3. Replace pressure plate

Difficulty engaging gears Clutch Dragging (not fully 1. Check clutch adjustment
disengaging)

Worn friction disc 2. Replace friction disc

Pressure plate defective 3. Replace pressure plate

Impossible to engage gears, Clutch not disengaging 1. Check clutch adjustment


engine stalls when tractor
halted, clutch pedal depressed Linkage faulty 2. Check linkage

3. Clutch disc seized onto


flywheel, pressure plate or
input shaft splines

Pressure plate defective 4. Replace pressure plate

Noise from transmission bell Release bearing worn 1. Replace release bearing
housing, noise changes when
pedal is depressed and
released Clutch pilot bearing worn 2. Replace pilot bearing

Clutch fails to engage smoothly Defective clutch friction disc 1. Replace friction disc

Defective pressure plate 2. Replace pressure plate

Worn clutch pilot bearing 3. Replace pilot bearing

Defective flywheel 4. Inspect flywheel as detailed in


the Engine Section

18-4
SECTION 18 -- CLUTCH -- CHAPTER 1

DESCRIPTION AND OPERATION

DESCRIPTION
A larger high capacity clutch is equipped on TB series
tractors. The 356 mm (14 in) clutch delivers long
service life, including work requiring frequent
engagement and disengagement. The following lists
major characteristics:

• Better absorption of torsion vibrations and


increased torque reserve capacity.
• An extended clutch service life expectancy of
5000 hours during normal operation.
• NO MAINTENANCE is required to the clutch 10024888
assembly during the service life, due to a simple
diaphragm design. 1
The single plate dry friction, clutch disc Figure 1,
incorporates friction linings, on each side and a
splined-hub, which is located on the forward end of
the transmission input shaft. The disc is installed
between the flywheel, a pressure plate, and the
cover assembly that is attached to the flywheel.

18-5
SECTION 18 -- CLUTCH -- CHAPTER 1

OPERATION levers. This draws the pressure plate away from the
With the clutch engaged, the spring loaded pressure clutch disc, releasing the disc from contact with the
plates force the clutch disc into contact with the flywheel. Thus, the frictional drive disconnects from
engine flywheel. the transmission, allowing gear changing to occur.

Frictional contact between the disc linings, the After releasing the clutch pedal, a spring returns the
pressure plate, and the surfaces of the flywheel, pedal to the free position. In addition, the release
transmits drive from the flywheel to the shaft of the bearing moves away from the release levers of the
transmission via the clutch disc. pressure plate assembly.

A rod connects the clutch pedal to a lever, and The main springs of the pressure plate assembly
release shaft assembly. then reassert pressure on the pressure plate, moving
it towards the clutch disc, and into contact with
Depression of the clutch pedal moves the release the flywheel. This reestablishes drive to the
shaft and fork, in turn moving the release bearing transmission.
forward, which depresses the pressure plate release

18-6
SECTION 18 -- CLUTCH -- CHAPTER 1

CLUTCH OVERHAUL
REMOVAL
1. Separate the tractor between the engine and
transmission, refer to Section 10, ‘SEPARATING
THE TRACTOR’.
2. Remove the bolts securing the clutch pressure
plate and cover assembly to the flywheel and
remove the pressure plate assembly together
with the clutch disc.
NOTE: Loosen the bolts evenly and diagonally
across the clutch to prevent distortion of the cover
assembly.

2
3. Remove the clutch release fork retaining bolt, (3)
Figure 3, and remove the clutch release shaft (4)
from the casing. Remove the clutch release fork
(2) from the transmission. Slide the clutch
release bearing (1) and hub from the clutch
release hub support.

3
REMOVAL
1. Remove the clutch pedal return spring (1).
2. Remove the pedal shaft snap ring and remove
the shaft (3). Pull the pedal (2) from the tractor. 3
1

18-7
SECTION 18 -- CLUTCH -- CHAPTER 1

INSPECTION AND REPAIR


NOTE: The diaphragm type clutch has no
serviceable components. A new assembly will be
required if there is discovery of any faults during
inspection.

Friction Disc
Inspect the clutch disc to ensure the linings are not
loose, cracked, worn or contaminated with oil. Check
for secure rivets. If signs of overheating from clutch
slipping or excessive wear are evident, replace the
disc.

IMPORTANT: Investigate the source of any oil or


grease on the facings and repair before installing a
new disc.

Pressure Plate
Inspect the diaphragm fingers for equal height on the
pressure plate assembly. Check the face of the
pressure plate for cracks, scoring or distortion.
Check for discoloration due to excessive heat. Check
for smooth operation. Discard the plate if discovering
any of the above discrepancies.

Release Bearing
Check that bearing hub moves freely over the
transmission hub carrier. Ensure the bearing rotates
smoothly, and check the face of the bearing for
damage or wear. Examine the clutch release fork for
cracks, bends, and end alignment. Replace any
damaged parts.

Clutch Pedal
Inspect the clutch pedal for cracks, and excessive
free-play between the bushings and pedal shaft.
Replace any damaged parts.

Clutch Release Cross-Shaft


Inspect the clutch release cross-shaft and transmis-
sion housing bushings. The shaft should rotate
smoothly without any free-play. Replace any
damaged parts.

18-8
SECTION 18 -- CLUTCH -- CHAPTER 1

INSTALLATION
IMPORTANT: When installing a new pressure plate 4. Remove the locator tool from the clutch disc.
or cover assembly, remove the protective film off the
friction face with white spirit. 5. Lubricate the hub bore with high melting point
grease.
1. Lightly lubricate the hub splines of the
transmission-input shaft with a suitable grease. 6. Tighten the release shaft fork pinch bolt to a
torque of 47 Nm (35 ft.-lbs.).
2. Position the clutch disc on the flywheel with the
marked face and damper springs towards the 7. Reconnect the engine to the front transmission
flywheel. Use Tool Kit No. FNH02142 to assembly. Refer to Section 10 “Separating the
centralize the disc. Tractor.”

3. Locate the clutch assembly on the flywheel and 8. To ensure total release of the clutch when the
install the spacers (where applicable) between pedal is fully depressed, check pedal travel.
the flywheel and the clutch cover. Install the bolts Adjust as necessary.
and washers and tighten to the specified torque,

ADJUSTMENTS
Pedal Travel
Free travel is the amount of pedal movement from
the fully released position to the point when first
encountering resistance (1). If not within 19--25 mm
(.75--1.0 in), adjust pedal free travel as follows:
1

50025061

1. Loosen the lock nut (1); and turn to lengthen or


shorten the operating rod.
• Turn the lock nut counterclockwise to
lengthen the rod.
• Turn the lock nut counterclockwise to
shorten the rod.

50025060

18-9
SECTION 18 -- CLUTCH -- CHAPTER 1

TORQUE 27--37 LB-FT

TORQUE SEE APPROPRIATE 82886182

[BEFORE ASSEMBLY LUBRICATE


LD HUB AND LUGS]

(MUST BE ASSEMBLED WITH


BOLT HEAD TOWARDS FRONT
OF VEHICLE)

[BEFORE ASSEMBLY
LUBRICATE DISC SPLINES]

[BEFORE ASSEMBLY LUBRICATE


SHAFT O.D. & TRANSCASE
BUSHING I.D. (BOTH ENDS)]

[APPLY APPROPRIATE GREASE


(BOTH ENDS). TORQUE 69-- 103
LB-IN]

10024891

18-10
SECTION 18 -- CLUTCH -- CHAPTER 2

SECTION 18 - CLUTCH

Chapter 2 - Servicing Clutch Associated Parts

CONTENTS

Section Description Page


Clutch Pilot Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18-1
SECTION 18 -- CLUTCH -- CHAPTER 2

CLUTCH PILOT BEARING


DESCRIPTION
Installed within the flywheel, at the rear end of the
engine crankshaft, and located in the PTO drive
plate, is a pre-lubricated ball bearing assembly,
which supports the front end of the transmission-in-
put shaft.
NOTE: When overhauling or installing the bearing,
pack the area to the front of the bearing within the
flywheel with a suitable high melting point grease.

OVERHAUL
Removal
1. Remove the clutch. See Chapter 1.
2. Use the Slide Hammer (2), Tool No. FNH 09567,
and Bearing Cup Puller (1), Tool No. FNH 09564,
to remove the PTO drive plate bearing (3), Figure
1.

1
Installation
1. Lightly tap the bearing into the rear end of the
crankshaft or PTO drive plate, with the shield
side facing outwards. Use a suitable Step Plate
(1), Tool No. FNH09210 or FNH09211, to install
the bearing (3), Figure 2 into the flywheel (2).
Reinstall the pilot bearing retainer and flywheel,
and tighten the retaining bolts to the correct
torque.
2. Install the clutch. See Chapter 1.

18-2
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

SECTION 21 - TRANSMISSION SYSTEMS

Chapter 1 - 8 x 2 Transmission

CONTENTS

Section Description Page


Specifications, Tightening Torques and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8 x 2 Non-synchromesh Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ground Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Introduction to Transmission Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gear Shift Levers and Covers -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Neutral Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission Front End -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Complete Transmission Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

21-1
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

SPECIFICATIONS

8 X 2 NON-SYNCHROMESH TRANSMISSION
Item
Output Shaft End-Float 0.076 mm (0.003 in.)
Shims Available 0.127 mm (0.005 in.)
0.305 mm (0.012 in.)
Output Shaft End-Float 0.038 - 0.086 mm
(0.0015 - 0.0034 in.)
Oil Capacity 56 liters (14.8 gal)

NOTE: On models with front wheel drive, increase


the rear axle oil quantity by 1.2 liters (1.3 quarts).
TORQUE VALUES
Description Nm Ft.-Lb.
Clutch Release Bearing Hub Support Bolts 67 49
Clutch Release Fork Bolt 47 35
Front Support Plate Bolts 44 32
Gear Shift Cover Assembly Bolts 56 41
Gear Shift Fork Retaining Screws 31 23
Oil Baffle/Shift Lever Stop Plates 22 16
Output Shaft Retainer Bolts 44 32
Rear Support Plate Retaining Bolts 44 32
Reverse Idler Shaft Retaining Bolt 23 17
Start Inhibitor Switch 40 30

21-2
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

SPECIAL TOOLS
DESCRIPTION Old Part Number Global Part Number
Adapter, part of Kit FNH02003 FNH00705
Compressor, PTO 8x2 Dual Power FNH01312
Puller, Planetary Shaft part of Kit FNH02879 FNH04721
Gauge, 0--600 psi part of Kit FNH02990A FNH06653
Puller, Attachment FNH09190
Puller, Grip-O-Matic FNH09196
Puller, Grip-O-Matic FNH09198
Plate, Step (set of 11) FNH09210
Protector, Shaft (set of 6) FNH09212
Puller (includes legs and pads) FNH09506
Attachment, Bearing Cup Puller FNH09507
Puller, Grip-O-Matic FNH09516
Legs, Puller 16-1/2 in (pr) FNH09521
Attachment, Bearing Puller FNH09526
Puller, Bearing Cup FNH09564
Hammer, Slide FNH09567

GROUND SPEED TABLE 1


Table 2 lists ground speeds in km/h (mph) for tractors Rear Tire size Conversion Factor
with 16.9--34 sized rear tires installed. Ignore speeds
listed under ‘POWER’, or by a ‘C’ in Table 2, for 13.6 - 36 0.960
tractors without Dual Power or Creeper options. For 13.6 - 38 0.993
tires outside of this size range, multiply each ground 15.5 - 38 0.993
speed by the conversion factor listed in Table 1.
16.9 - 30 0.933
16.9 - 34 0.954
16.9 - 38 1.067
18.4 - 26 0.899
18.4 - 30 0.966
18.4 - 34 1.033
18.4 - 38 1.101
20.8 - 38 1.148
23.1 - 26 0.785

21-3
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

TABLE 2
Ground Speeds in Miles Per Hour (16.9 -- 34 Rear Tires)

Main Range Dual Miles Per Hour Trans


Shift Lever Power Engine Speed (rev/min) Gear
Le er
Lever Ratio
1500 1900 2100 2200
1 C Power 0.16 0.20 0.23 0.24 67.08
1 C Direct 0.21 0.27 0.30 0.31 52.18
2 C Power 0.20 0.26 0.29 0.30 53.75
2 C Direct 0.26 0.33 0.37 0.38 41.81
3 C Power 0.36 0.46 0.50 0.53 30.63
3 C Direct 0.46 0.59 0.65 0.68 23.82
4 C Power 0.48 0.61 0.68 0.71 22.50
4 C Direct 0.63 0.80 0.88 0.92 17.50
1 L Power 0.93 1.18 1.31 1.37 11.74
1 L Direct 1.20 1.52 1.69 1.76 9.13
2 L Power 1.17 1.49 1.64 1.72 9.41
2 L Direct 1.51 1.91 2.11 2.21 7.32
3 L Power 2.05 2.60 2.88 3.01 5.36
3 L Direct 2.64 3.34 3.70 3.87 4.17
4 L Power 2.80 3.54 3.91 4.10 3.94
4 L Direct 3.59 4.55 5.03 5.27 3.06
1 H Power 3.35 4.25 4.69 4.92 3.29
1 H Direct 4.30 5.45 6.03 6.31 2.56
2 H Power 4.18 5.29 5.85 6.13 2.63
2 H Direct 5.38 6.81 7.53 7.89 2.05
3 H Power 7.34 9.29 10.27 10.76 1.50
3 H Direct 9.44 11.95 13.20 13.84 1.17
4 H Power 9.99 12.65 13.98 14.65 1.10
4 H Direct 12.84 16.26 17.98 18.83 0.86
R C Power 0.31 0.39 0.33 0.45 46.67
R C Direct 0.36 0.46 0.42 0.53 36.30
R L Power 1.35 1.71 1.89 1.98 8.17
R L Direct 1.73 2.19 2.42 2.54 6.35
R H Power 4.81 6.10 6.74 7.06 2.29
R H Direct 6.19 7.84 8.62 9.08 1.78

21-4
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Ground Speeds in Kilometers Per Hour (16.9 -- 34 Rear Tires)

Main Range Dual Kilometers Per Hour Trans


Shift Lever Power Engine Speed (rev/min) Gear
Le er
Lever Ratio
1500 1900 2100 2200
1 C Power 0.27 0.34 0.37 0.39 67.08
1 C Direct 0.34 0.47 0.48 0.50 52.18
2 C Power 0.33 0.41 0.46 0.48 53.75
2 C Direct 0.42 0.54 0.59 0.62 41.81
3 C Power 0.58 0.73 0.81 0.85 30.63
3 C Direct 0.74 0.94 1.04 1.09 23.82
4 C Power 0.78 0.99 1.10 1.15 22.50
4 C Direct 1.01 1.28 1.42 1.48 17.50
1 L Power 1.51 1.91 2.11 2.21 11.74
1 L Direct 1.94 2.45 2.72 2.84 9.13
2 L Power 1.88 2.38 2.64 2.76 9.41
2 L Direct 2.42 3.07 3.39 3.55 7.32
3 L Power 3.31 4.19 4.63 4.85 5.36
3 L Direct 4.25 5.38 5.95 6.23 4.17
4 L Power 4.50 5.70 6.30 6.60 3.94
4 L Direct 5.78 7.32 8.10 8.84 3.06
1 H Power 5.39 6.83 7.55 7.91 3.29
1 H Direct 6.93 8.77 9.70 10.16 2.56
2 H Power 6.73 8.52 9.42 9.87 2.63
2 H Direct 8.65 10.96 12.11 12.69 2.05
3 H Power 11.81 14.96 16.63 17.32 1.50
3 H Direct 15.18 19.23 21.25 22.27 1.17
4 H Power 16.07 20.36 22.50 23.57 1.10
4 H Direct 20.67 26.18 28.93 30.31 0.86
R C Power 0.38 0.48 0.53 0.56 46.67
R C Direct 0.49 0.62 0.68 0.72 36.30
R L Power 2.17 2.75 3.04 3.18 8.17
R L Direct 2.79 3.53 3.90 4.09 6.35
R H Power 7.75 9.81 10.85 11.36 2.29
R H Direct 9.96 12.62 13.95 14.61 1.78

21-5
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

TRANSMISSION - DESCRIPTION AND


OPERATION 1--5 2--6 4--8 C
A non-synchromesh transmission with a constant
mesh design, provides eight forward, and two L
reverse speeds through two manually operated
levers. The main gear lever selects any one of four
forward, or one reverse speed, and a second shorter N
lever selects an overall high or low ratio.

A neutral start switch Incorporated in the transmis- 3--7 R1--R2 H


sion, prevents the starter motor from operating when
the secondary (range) lever is not in the neutral
OM286 MT
position.

The gears are all in constant mesh and gear 1


connections are made by sliding couplings. The Gear Shift Lever Positions
transmission main shaft is located in the top drive line (With Optional Creeper Gears)
L = Low Range
and the main countershaft and output shaft are N = Neutral
located in the bottom drive line. The transmission is C = Creeper gears
available with Independent single or two speed PTO, H = High Range
not shiftable. Refer to the “POWER TAKE-OFF” -- R = Reverse
Section 31 for further details of the PTO drive line.

The transmission features straight cut type gears on


all gears. Roller bearings are used throughout the
transmission, except on the output shaft assembly
where taper roller bearings are used. Shims between
the output shaft end cover and bearing retainer
provide the method of controlling output shaft end
float.

The low-pressure hydraulic system provides a


proportionate amount of oil for pressure lubrication of
the front transmission. The oil cooler located at the
front of the tractor cools the hydraulic oil, then directs
the oil to the front transmission through external
tubing.

The main countershaft and output shaft are hollow,


and consist of cross drilling, which allows passage of
the hydraulic oil from the cooler, to lubricate and cool
the transmission gears.

Returning hydraulic oil from the front transmission


flows to the rear axle, and then back to the hydraulic
system. Therefore, a common oil reservoir between
the front transmission, rear axle, and hydraulic
system exists.

A Dual Power option which consists of a planetary


gear set installed directly between the clutch and
input shaft of the standard transmission is available.
The planetary gear set provides either a direct drive
or an underdrive in each gear ratio of the standard
transmission. Refer to 8 ¢ 2 Dual Power Section 21.

21-6
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

21-7
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

INTRODUCTION TO TRANSMISSION GEAR SHIFT LEVERS AND COVER -


OVERHAUL OVERHAUL
To assist in overhauling the transmission, note the Removal
following on component accessibility:
1. Remove floor panel.
Components Accessible With Transmission 2. Place the gear shift levers in the neutral position.
Installed:
3. Disconnect the Battery negative (ground) cable.
• Gear Shift Levers
4. Disconnect the neutral start switch connector
• Gear Shift Cover Assembly from the wire harness.
• Neutral Start Switch 5. Remove the gearshift cover retaining bolts and
partially lift the cover from the transmission
Components Accessible With Engine Removed casing. With the cover raised, disconnect the
Only: neutral start switch wires from the switch and
All items above, plus the following: remove the shift cover assembly from the
transmission.
• Clutch Assembly Disassembly
• Clutch Release Shaft Fork and Bearing 1. Remove the oil baffle plate retaining bolts from
Assembly the underside of the shift cover and remove the
plate and washers.
• Main Input Shaft
2. Unscrew and remove the gear shift lever knobs.
• Front Upper and Lower Shaft Front Bearings
3. Use a hacksaw to partially cut the lever retaining
• Front End Oil Seal snap rings. If possible place the gear shift lever
into the jaws of a vice as close to the snap ring as
Components Accessible With Transmission possible. Then using a chisel, finally break off the
Removed: rings. During this operation ensure the retaining
rings are not dangerously ejected from the
All items above, plus the following:
grooves on the levers. Slowly release the vice
• Rear Cover Assembly and remove the springs, ball retainers and
levers.
• PTO Drive Shaft
NOTE: It is not necessary to remove the lever
• Selector Rails, Forks, Detent Components and locating pins in the cover assembly as the levers are
Interlocks slotted.

• Output Shaft Assembly


Inspection
• Range Cluster Gear
1. Wash the shift cover and shift lever assemblies
• Front Upper Shaft Components in a suitable solvent and dry with a clean, lint free
cloth or compressed air.
• Front Lower Shaft Components
2. Inspect the shift cover for cracks or other
• Reverse Idler Components damage. Replace the cover when necessary.
3. Inspect the shift lever ball seats and ends for
wear, and the lever locating pins in the cover. If
needed, press new pins into the cover.
4. Inspect the lever retaining springs for cracks or
distortion, and inspect the retaining snap ring
grooves on the levers.
5. Inspect the neutral start switch wiring harness for
damage. Replace the harness if necessary.

21-8
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Top Cover Assembly

1. Plug 11. Locknut


2. Washer 12. Lever Fork Dual
3. Shift Cover Bolt 13. Locknut
4. Start Inhibitor Switch Wiring Harness 14. Lever Arm
5. Cover 15. Drive Support
6. Knob Speed 16. Arm
7. Knob Dual 17. Fork
8. Pivot Gear Dual 18. Locknut
9. Lever Assembly 19. Stop
10. Sleeve

ASSEMBLY INSTALLATION
1. Lubricate the ball seats with a suitable grease Installation of the gear shift levers and cover follows
and pass the shift levers through the shift cover. the removal procedures in reverse with the following
requirements.
2. Assembly the ball retainers and springs.
Compress the springs and install new retaining 1. Install a new shift cover gasket to the cover
snap rings. assembly, hold in place with a suitable grease.
3. Assemble the two oil baffle washers to the • Ensure the neutral start actuator housing aligns
underside of the shift cover, the oil baffle plate with the locating pin in the shift cover.
and the retaining bolts.
• Tighten the cover retaining bolts to a torque of 56
Nm (41 lbf. ft.).

21-9
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

NEUTRAL START SWITCH


Removal
1. Remove the shift cover as described in Section 21
“GEAR SHIFT LEVERS AND COVER --
OVERHAUL”.
2. Unscrew the neutral start switch from the
housing.

Inspection
1. Inspect the neutral start switch for wear or
damage. Replace as necessary.

Assembly and Installation


Assembly and installation of the neutral start switch
follows the removal procedures in reverse, with the
following requirements:

1. Test the switch operation by connecting a test


bulb in series with the switch terminals and a
battery. Move the switch actuator housing along
the high/low shift rail and away from the center
line of the actuating dowel. The test bulb should
only light when the actuator housing is centered
over the actuating dowel.
40036182
NOTE: Do not move the actuator housing more than
6 mm (0.25 in) from the actuating dowel center line 4
or the dowel may come out of the shift rail.

TRANSMISSION FRONT END - OVERHAUL


Removal
1. Separate the engine from the transmission, see
Section 10 “SEPARATING THE TRACTOR”.
2. Remove the gear shift levers and cover as
described in Section 21 “GEAR SHIFT LEVERS
AND COVER -- OVERHAUL”.

Disassembly
1. Remove the clutch release fork retaining bolt (3),
and remove the clutch release shaft (4) from the
casing. Remove the clutch release fork (2) from
5
the transmission. Slide the clutch release
bearing and hub (1) from the clutch release hub
support, Figure 5.

21-10
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
2. Transmissions With Dual Power: Disassemble
the Dual Power unit as described in 8 ¢ 2 Dual
Power Section. Remove the Dual Power housing
retaining bolts and lift the housing from the
transmission casing. Take care not to lose the
anti-spin washer located between the transmis-
sion main shaft front gear and front bearing, if the
bearing comes away with the dual power
housing.

6
Transmissions Less Dual Power: Disconnect the
low pressure lubrication lines from the clutch
release bearing hub support and the front
support plate. Remove the hub support (1),
Figure 6. Remove the snap ring (1) retaining the
main drive input shaft (2) to the transmission
main shaft, Figure 7 and remove the input shaft.

7
3. Remove the front support plate retaining bolts
(2), Figure 8 and remove the plate (1) from the
housing. If necessary, drive the plate from the
housing using a suitable drift inserted into the
main transmission compartment.

8
Inspection and Repair
1. Inspect the clutch release components for wear,
see “CLUTCHES” - Section 18.
2. Transmission Without Dual Power: Inspect the
main shaft front oil seal located in the clutch
release bearing hub support, and if necessary,
use Slide Hammer, Tool No. FNH09567, to
remove the seal. Use a Step Plate, Tool No.
FNH09210 and sleeve of suitable diameter to
install a new seal, with the sealing lip facing
rearwards. Lubricate the sealing lip with a
suitable grease before installing.

21-11
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
3. Inspect the main drive input shaft and retaining
snap ring and replace if worn or damaged.
4. Inspect the main countershaft front bearing and
replace if worn or damaged. Use Puller Tool No.
FNH09196 (2) and Shaft Protector Tool No.
FNH09212 or 380000564 (3) to remove bearing
(1) from the shaft, Figure 9.
Use a sleeve of 32 mm (1.25 in) internal diameter
and 41 mm (1.62 in) external diameter to install
a new bearing onto the countershaft.

9
Assembly
1. Install the front support plate to the transmission
case using a new gasket. If necessary, lift the
main shaft and main countershaft to align the
countershaft front bearing. Install the retaining
bolts and tighten to 44 Nm (32 ft.-lb.).
Transmissions With Dual Power: Re-assemble
the Dual Power components as detailed in the 8
¢ 2 Dual Power Section.
NOTE: If the front bearing (3) came off with the Dual
Power Housing during the removal procedure,
ensure that the anti-spin washer (2) is properly
reinstalled and secured in place between the
transmission main shaft front gear (1) and bearing
Figure 10. If the bearing has remained on the main
shaft during disassembly, coat the outer edge of the
bearing with a suitable adhesive, such as New
Holland Stud and Bearing Lock, Part No. 82995772
before reassembling, to prevent the bearing from
rotating in the Dual Power Housing.
10
Transmissions Without Dual Power: Install the
main drive input shaft into the forward end of the
transmission main shaft and secure with the
snap ring. Place studs in two of the five bolt holes
to ensure correct alignment of the clutch release
hub on assembly. This will prevent damage to the
release hub oil seal. Position a new gasket on the
front support plate and slide the clutch release
hub support over the studs. Drive the support into
position with the drain hole downwards. Remove
the studs, install the retaining bolts, and tighten
to 67 Nm (49 ft.-lb.).
2. Install the clutch release bearing and hub
assembly onto the hub support.
3. Insert the release fork fingers into the slots in the
hub and install the release shaft through the
casing and release fork. Install the fork retaining
bolt and tighten to 47 Nm (35 ft.-lb.).

21-12
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

COMPLETE TRANSMISSION OVERHAUL


Disassembly
1. Remove the clutch operating mechanism, clutch
release hub support, Dual Power transmission
(when installed), front support plate and main
drive input shaft assembly as previously
described in this Chapter.
2. Remove the shift levers and cover assembly as
previously outlined in this Chapter, together with
the neutral start switch from the high/low shift rail.
3. Remove the snap ring (4), the thrust washer (3)
and the hydraulic pump idler gear (2), located on
the output shaft retainer, Figure 11. 11

4. Remove the rear support plate retaining bolts (1),


Figure 11 and using a soft faced mallet drive the
forward end of the PTO drive shaft rearwards.
This will separate the rear support plate (1) from
the transmission casing. If necessary, lever the
rear support plate from the casing and remove
the plate with the PTO drive shaft (4), Figure 12.
5. Remove the snap ring (2) retaining the PTO drive
shaft rear bearing (5) and drive the shaft and
bearing out of the support plate.
6. Remove the bolts securing the output shaft
retainer to the rear support plate and remove the
retainer (3) Figure 12 and shims from the rear
support plate. 12

7. Partially remove the secondary countershaft


assembly (1) until the front bearing is out of the
location. Lift the secondary countershaft to allow
the output shaft assembly (2) to be removed from
the rear compartment, Figure 13, followed by
removal of the secondary countershaft.

13

21-13
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
8. Remove the high/low sliding coupling (1) from
the rear of the main countershaft, Figure 14.

14
Gear Shift Mechanism
1. Remove the four detent plungers (1) and springs
(2). The detent balls (3) located below the springs
should be collected with shift rail removal,
Figure 15.

15
2. Unscrew the neutral start switch (5) from the
housing. Loosen the locknut and remove the bolt
locking the high/low range fork (6) to the shaft.
Remove the range lever connector (4) from the
shaft and slide the rail out from the rear of the
gearbox, Figure 16. Place a clean cloth beneath
the neutral start switch actuator housing. Take
care to ensure the ball, spring and actuating
dowel are collected from the housing and rail. Lift
the high/low shift fork from the rear compartment.
3. Unscrew the locknut and retaining screw from
the 1st-5th/3rd-7th shift fork (3) at the front of the
shift rail, Figure 16. Drive the rail forward from the
transmission casing, pushing the sealing plug
out with the end of the rail. Remove the shift 16
connector and fork.
4. Unscrew the locknut and retaining screws from
the 4th-8th shift fork (8) and connector (1) and
push the shift rail rearwards from the transmis-
sion case, Figure 16. Remove the fork and the
connector.
5. Unscrew the locknut and retaining screw from
the Reverse/2nd-6th shift arm (2) and connector
and slide the top rail out rearwards, Figure 16.
Lift the shift arm and the connector from the
transmission case.

21-14
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
6. Remove the locknut and screw (1) retaining the
Reverse/2nd-6th shift fork to the lower shift rail
(4), Figure 17 and push out the rail rearwards.
Remove the shift fork from the transmission
casing.
7. Remove the interlock plungers from the cross
bore in the transmission case. If necessary,
remove the bore plug situated on the left-hand
side of the case to facilitate removal of the
plungers.

Reverse Idler Assembly


1. Bend down the locktab and remove the bolt (3)
retaining the reverse idler shaft to the transmis- 17
sion case, Figure 17.
2. Drive the shaft out forwards and lift out the
reverse idler gear (2).

Mainshaft Assembly
1. Position a Step Plate, Tool No. FNH09210, in the
bore at the rear of the main shaft.
2. Drive the shaft forwards, using a suitable drift,
from the transmission case and remove the
4th-8th coupling gear.
Main Countershaft Assembly
1. If not previously removed, use Puller Tool No.
FNH09196 and Step Plate Tool No. FNH09210,
to remove the main countershaft, front bearing.
Remove the snap ring (4) located behind the
bearing, and remove thrust washer (2),
Figure 18.
2. Slide the main countershaft (3) rearwards, and
remove the gears (1), couplings, and thrust
washer. Store components in the order of
removal to aid in reassembling.
NOTE: The inner and outer sections of the sliding
couplings are matched during manufacture and
should not be separated. 18

21-15
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

INSPECTION AND REPAIR


Rear End Components
1. Inspect the PTO drive shaft and bearing
assembly. If the bearing is worn or damaged, use
Puller, Tool No. FNH09516, Pulling Attachment,
Tool No. FNH09190 and Shaft Protector, Tool No.
FNH09212 to remove. Use a convenient length
of sleeve 37 mm (1.44 in.) internal diameter and
44 mm (1.75 in.) external diameter to install a
new bearing.
2. Inspect the output shaft retainer and rear bearing
cup for wear or damage. If necessary, remove
the cup from the retainer using a suitable punch.
Use Step Plate, Tool No. FNH09210 and a
suitable punch to install the new bearing cup.
3. Inspect the output shaft assembly for wear or
damage. If necessary, use Puller, Tool No.
FNH09198 (1), Puller Adaptor, Tool No.
FNH09190 (2) and Shaft Protector, Tool No.
FNH09212 (4), to remove the front pilot bearing
cone and roller assembly (3), Figure 19.

19
4. Use Puller, Tool No. FNH09516 (1) and Shaft
Protector, Tool No. FNH09212 (4), to remove the
gear (2), rear bearing (3), and thrust washer in
one operation, Figure 20.
5. Inspect the output gear bushing for wear, and
replace the gear and bushing assembly if
necessary.

20

21-16
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
6. Install the steel thrust washer by aligning the flats
of the washer with the flats of the shaft. Position
the rear bearing on the output shaft. Use Puller
Tool No. FNH09516 (1), Pulling Attachment Tool
No. FNH09526 (3), and Shaft Protector Tool No.
FNH09212 (5), to assemble. Use a suitable
sleeve with a 40 mm (1.6 in.) internal diameter,
and 50 mm (2 in.) external diameter (2), to pull
the bearing (4) into position, Figure 21.
7. Inspect the secondary countershaft assembly for
wear or damage. If necessary, use Puller, Tool
No. FNH09516, Pulling Attachment, Tool No.
FNH09526 and Step Plate, Tool No. FNH09210,
to remove the rear bearing (3), Figure 20. 21
8. If necessary, remove the secondary countershaft
front bearing (2), using 2 steel rods (4) 4.6 mm
(.18 in.) diameter and 51 mm (2 in.) long. Insert
rods through the two holes in the driving gear.
Use Puller Tool No. FNH09516 (1), Pulling 5
Attachment Tool No. FNH09190 (3), and Step
Plate Tool No. FNH09210 (5), to push the bearing
from the countershaft, Figure 22. 4
9. Use Puller, Tool No. FNH09516, Pulling
Attachment, Tool No. FNH09190 and Step Plate,
Tool No. FNH09210, to install both front and rear
bearings.

22
Main Shaft Components
1. Inspect the main shaft assembly, the front and
rear bearings and PTO drive shaft oil seal located
inside the forward end of the shaft.
2. If necessary, use Puller Tool No. FNH09516 (1),
Pulling Attachment Tool No. FNH09190 (2), and
Step Plate Tool No. FNH09210 (4) to remove the
main shaft front and rear bearing (3). When
removing the front bearing, in addition to the
special tools listed above, use 2 steel rods 4.6
mm (.18 in.) diameter and 51 mm (2 in.) long,
inserted through the two holes in the driving gear
Figure 23.
3. Use Puller, Tool No. FNH09516, Pulling 23
Attachment, Tool No. FNH09526 and Step Plate,
Tool No. FNH09210 to install a new rear bearing.
A new front bearing should be installed using the
above tools together with a sleeve 64 mm (2.5
in.) internal diameter and 76 mm (3.0 in.) external
diameter of convenient length.

21-17
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
NOTE: Whenever removing or installing the main
shaft, front bearing ensure the anti-spin washer is in
good condition before assembling.

4. Inspect the PTO drive shaft oil seal located within


the main shaft and remove if worn or damaged.
After lightly greasing the sealing lip, install a new
seal with the sealing lip facing rearwards. Use a
Step Plate, Tool No. FNH09210 and sleeve of
convenient size to drive the seal into location.
Main Countershaft Components
1. Inspect the main countershaft assembly and if
necessary, use Puller, Tool No. FNH09506 (1),
Puller Legs, Tool No. FNH09521 (6), Ratchet,
Tool No. FNH09162 (2), Pulling Attachment, Tool
No. FNH09526 (3) and Shaft Protector, Tool No.
FNH09212 (5), to pull the rear bearing (4) from
the countershaft, Figure 24.
2

24
2. Inspect the output shaft pilot bearing cup located
in the end of the main countershaft (1) for
excessive wear, damage or corrosion. If
necessary, remove the bearing cup using a
suitable punch (2) inserted through the two holes
in the gear (3), Figure 25.
3. Use a suitable Step Plate, Tool No. FNH09210
and Puller, Tool No. FNH09516, to install a new
output shaft pilot bearing cup into the rear of the
main countershaft.

25
4. Use Puller, Tool No. FNH09516 (1), Pulling
Attachment, Tool No. FNH09526 (3), Step Plate,
Tool No. FNH09210 (5) and a sleeve 51 mm
(2.00 in.) internal diameter and 82 mm (3.21 in.)
external diameter of convenient length (4), to
install a new rear bearing (2) onto the main
countershaft, Figure 26.

26

21-18
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
5. Inspect all gears which mount on the main
countershaft for damage and wear. With the
gears on the countershaft, check the bushings
for free play. Inspect the reverse idler gear and
bushing assembly and replace if necessary.
6. Inspect the main countershaft rear bearing cup
(1) situated in the transmission case and if
damaged or worn, use Slide Hammer, Tool No.
FNH09567 (2), to remove, Figure 27. Install a
new cup using a suitable drift.
7. Inspect the countershaft front bearing for wear
and damage. If necessary, install a new bearing.
8. Inspect all components with internal splines, 27
external splines, or gear teeth, and if worn,
broken or damaged, replace on reassembly.
9. Inspect the lubrication drillings for obstruction.

21-19
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
Gear Shift Mechanism c. Phosphor-bronze thrust washer.
1. Inspect the gear shift forks, rails, arms and d. Reverse gear (dog-teeth rearward).
connectors for wear or distortion. Inspect the
detent on the shift rails and replace if worn. e. Phosphor-bronze thrust washer.

f. 1st-5th gear (dog-teeth forward).


Transmission Case
1. Wash out the transmission case with a suitable g. 3rd-7th/1st-5th sliding coupling and
solvent to remove all particles of metal and dirt. connector.
Dry with a clean, lint free cloth or compressed air.
h. 3rd-7th gear (dog-teeth rearward).
2. Inspect the case for cracks or other damage.
Replace if necessary. i. Thrust washer

Assembly j. Snap ring.


NOTE: Refer to Figure 31 during transmission k. Front bearing.
reassembly unless otherwise stated.
2. Support the main countershaft during reas-
sembly and ensure the rear bearing seats
Main Countershaft Assembly squarely in the bearing outer track.
1. Pass the main countershaft through the rear
compartment and assemble the gears in the 3. Position the high/low sliding coupling on the rear
following sequence: of the main countershaft.

a. 2nd-6th gear (dog-teeth forward). Main Shaft Assembly


NOTE: The connectors mentioned in step 1(b) have 1. Check for correct positioning of the snap ring
a chamfer on one side of the inside diameter. This retaining the main shaft rear bearing in the
chamfer must face the rear of the transmission to transmission casing.
allow the connector to seat correctly on the main 2. Install the 4th-8th coupling gear on the rear of the
countershaft splines. The sliding coupling and main shaft with the shift fork groove to the front.
connector are matched during manufacture and
should be installed with the etched marks aligned. 3. Position the main shaft assembly in the
transmission casing.
b. Reverse/2nd-6th sliding coupling and con-
4. Drive the main shaft assembly rearwards to seat
nector.
the rear bearing in the location within the casing.

21-20
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
Reverse Idler Assembly
1. Position the reverse idler gear (1) between the
supporting lugs, Figure 28, with the extended
hub of the gear towards the front of the
transmission.
2. Install the reverse idler shaft from the rear
compartment with the retaining bolt hole
forwards. Install the retaining bolt (2) and locktab,
and tighten the bolt to 23 Nm (17 ft.-lb.) and bend
up the locktab.

28
Gear Shift Mechanism
Refer to Figure 29.

1. Install the Reverse/2nd-6th shift fork (4) onto the


appropriate sliding coupling on the main
countershaft and install the lower shift rail (5)
from the rear compartment with the fork retaining
hole to the rear of the shift rail, Figure 29. Install
the fork retaining screw and lock nut then tighten
the screw to 31 Nm (23 ft.-lb. ). Secure with the
lock nut.
2. Insert the two interlock plungers into the bore
from the left-hand side of the transmission case
and install the plug. Position each plunger 29
between the three shift rail bores.
3. Position the 4th-8th shift fork (10) on the sliding
coupling. Install the shift rail (1) from the rear, with
the oil relief groove rearwards and pass through
the bore in the shift fork. Install the retaining
screw and locknut and tighten to 31 Nm (23
ft.-lb.).
NOTE: When installing the remaining top shift rails,
ensure the rails already installed are in the neutral
position so the interlock plungers do not prevent the
rail from entering the front support bore.

4. Position the lower end of the Reverse/2nd-6th


shift arm (6) into the locating hole in the
Reverse/2nd-6th shift fork (4). Pass the
Reverse/2nd-6th top shift rail (9) in from the rear
with the oil relief groove rearwards. With the shift
rail correctly located in the shift arm, install the
retaining screw and locknut then tighten to 31 Nm
(23 ft.-lb.).

21-21
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
5. Position the 1st-5th/3rd-7th shift fork (3) in the
sliding coupling located at the front of the main
countershaft. Install the 1st-5th/3rd-7th shift rail
(2) from the front of the transmission. Insert the
rail in the shift fork and secure with the retaining
screw. Install the shift connector to the rear of the
rail and secure with the retaining screw. Tighten
the retaining screws and lock nuts to 31 Nm (23
ft.-lb.). Install the sealing plug at the front of the
rail.
6. Position the high/low shift fork (7) in the groove
of the high/low sliding coupling located on the
output shaft. Install the high/low shift rail (8) in the
shift fork. Secure the shift fork with the retaining
screw and tighten the screw and lock nut to 31
Nm (23 ft.-lb.).
NOTE: The shorter plunger is located in the vertical
bore above the high/low shift rail.
7. Install the four shift rail detent balls, springs and
plungers. Ensure the balls and plungers slide
freely in the bores.
Rear End Components
1. Ensure the snap ring located immediately in front
of the secondary countershaft front bearing is in
position in the transmission casing bore.
2. Hold the secondary countershaft assembly in
position at the top of the rear compartment, while
installing the output shaft assembly. Align the
secondary countershaft and drive forward until
the front bearing seats against the locating snap
ring in the transmission case.
3. Position the rear support plate without the output
shaft retainer assembly, on the transmission rear
face. Drive the plate into position on the dowels,
then install the retaining bolts Tighten bolts to a
torque of 44 Nm (32 ft.-lbs.).
4. Install the PTO drive shaft and rear bearing
through the rear of the transmission. Use a
soft-faced mallet to drive the shaft and bearing
into position. Secure the rear bearing with a snap
ring.
5. Install shims between the rear support plate and
output shaft, bearing retainer, to obtain the
specified end-play in the output shaft, taper roller
bearings. Use the following procedure:
1. Install shims to obtain a thickness of 1.6 mm
(0.06 in.), and install the output shaft bearing
retainer assembly on the rear support plate.
2. Install the four retaining bolts and tighten to
a torque of 44 Nm (32 ft.-lbs.).

21-22
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
3. Position the plunger of a dial indicator gauge
(3) against the end face of the output shaft
(2), Figure 30. Lever the shaft in and out and
note the end-play reading. If no end-play is
registered, add additional shims to produce
a gauge reading.
4. Remove the indicator gauge and the four
retainer bolts. Withdraw the retainer (1) and
shims.
5. Remove shims to obtain an end float
between 0.038 mm (0.0015 in.) and 0.086
mm (0.0034 in.)

30
NOTE: Shims are available in thicknesses of 0.076
mm, 0.127 mm and 0.305 mm (0.003 in., 0.005 in.
and 0.012 in.).

6. After obtaining the correct end-play, install


the bearing retainer (with the oil slot to the
top), shims, and bolts. Tighten bolts to a
torque of 43 Nm (32 ft.-lbs.). Recheck end
play.
7. Install the hydraulic pump idler gear, thrust
washer, and snap ring.
Assemble the front-end components following the
procedures outlined in “Transmission Front End -
Overhaul”.

Assemble the shift levers, cover, and neutral start


switch following the procedures outlined in “Gear
Shift Levers and Cover - Overhaul”.

Installation
1. Connect the transmission to the engine and rear
axle, see Section 10 “SEPARATING THE
TRACTOR”.
2. Refill the transmission/rear axle with the correct
grade and quantity of oil.

21-23
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
Key to Figure 31
Transmission Components

A -- Input Shaft Assembly D -- Main Countershaft


1. Clutch Release Bearing Hub Support 1. Main Countershaft Front Bearing
2. ‘O’ Ring Seal 2. Snap Ring
3. Input Shaft Seal 3. Washer
4. Input Shaft Retaining Clip 4. 3rd -- 7th Gear
5. Seal 5. Coupling Matched With Connector, item 6
6. Input Shaft 6. Connector Matched With Coupling, item 5
7. Seal 7. 1st -- 5th Gear
8. Washer
9. Reverse Gear
10. Washer
11. Coupling Matched With Connector, Item 12
12. Connector Matched With Coupling, Item 11
13. 2nd -- 6th Gear
B -- Top Shaft (Mainshaft)
14. Bearing Outer Cup
1. Input Cluster Gear Front Bearing 15. Taper Bearing
2. Anti--Spin Washer -- With Dual Power Only 16. Countershaft
3. Input Cluster Gear 17. Bearing Outer Cup
4. Input Cluster Gear Rear Bearing
5. Casing Snap Ring
6. 4th --8th Connector Gear
E -- Output Shaft Assembly
1. Taper Bearing
2. Lube Oil Transfer Tube
3. High/Low range Coupling
4. Output Shaft
C -- Secondary Countershaft (Range 5. Low Range Gear
Cluster) 6. Thrust Washer
7. Taper Bearing
1. Casing Snap Ring
2. Secondary Countershaft Front Bearing
3. Secondary Countershaft Gear Cluster
4. Secondary Countershaft Rear Bearing F -- End Cover Assembly
1. Snap Ring
2. Snap Ring
3. PTO Shaft Bearing
4. Snap Ring
5. PTO Shaft
6. Bearing Outer Cup
7. End Cover
8. Shims
9. Output Shaft Retainer

21-24
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

31

21-25
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

21-26
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

SECTION 21 - TRANSMISSION SYSTEMS

Chapter 2 - 16 x 4 Dual Command (Dual Power) Transmission

CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dual Command Transmission -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Under-Drive Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Planetary Gear Set -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Planetary Gear Set Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

21-1
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

SPECIFICATIONS

Planetary Gear Set Free Play 0.10-0.51 mm


(0.004-0.020 in)
Planetary Gear Set Free Play 0.33 mm (0.013 in.)
Shims Available 0.81 mm (0.032 in.)
Planetary Cover to Housing 1.17-1.52 mm
Shimming Gap (0.046-0.060 in.)
Planetary Gear Set Free Play Average Planetary cover Shim Thickness to
Shimming Chart to Housing Gap be added

0.025-0.33 mm (0.001-0.013 in.) 1.14 mm (0.045 in.)


0.36-0.66 mm (0.014-0.026 in.) 0.81 mm (0.032 in.)
0.69-0.81 mm (0.027-0.032 in.) 0.66 mm (0.026 in.)
0.84-1.14 mm (0.033-0.045 in.) 0.33 mm (0.013 in.)
1.17-1.52 mm (0.046-0.060 in.) None
Dual Command System at 2100 rev/min
Pressure (Low Pressure 15.2-18 bar (220-261 psi)
Hydraulic Circuit Test)
Tarnsmission Lubrication at 1000 rev/min
Pressure Test 5.3-8.5 bar (73-123 psi)

TORQUE VALUES
Description N⋅ m Ft.-Lb.
Control Valve Solenoid Nut 5.4 4
Control Valve Spool Plug 38 28
Control Valve Body Retaining Bolts 44 32
Planetary Housing Retaining Bolts 105 77
Planetary Cover Retaining Bolts 47 35
Lubrication Tube Connector 18 13
Pressure Line Control Tube Connector 13 9

21-2
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

FAULT FINDING
The following table lists problems and possible causes, with recommended remedial action.

PROBLEM PROBABLE CAUSE REMEDY

Dual Command system 1. Direct drive clutch snap ring 1. Replace snap ring
pressure below specification displaced
in normal drive only
2. Damaged or leaking control 2. Replace gasket
valve body gasket

3. Leaking sealing rings on direct 3. Replace sealing rings and/or


drive clutch housing hub or Dual Command housing
worn Dual Command housing

4. Leaking inner or outer seals on 4. Replace seals


direct drive clutch piston

5. Broken or cracked direct drive 5. Replace piston or housing


clutch piston or housing

Dual Command system 1. Damaged or leaking control 1. Replace gasket


pressure below specification valve body gasket
in power drive only
2. Leaking inner or outer seals on 2. Replace seals
under drive clutch piston
3. Broken or cracked underdrive 3. Replace piston
clutch piston

Dual Command system 1. Fault in low pressure hydraulic 1. Refer to Hydraulic Systems,
pressure below specification circuit Pressure Testing, Section 35.
in both normal drive and
power drive

Dual Command system 1. Fault in low pressure hydraulic 1. Refer to Hydraulic Systems,
pressure above specification circuit Pressure Testing, Section 35.
in both normal drive and
power drive

No power to rear wheels when 1. Low Dual Command system 1. Refer to first problem
normal drive engaged (power pressure in direct drive clutch
drive operative) circuit

2. Scorred, burred or binding 2. Replace piston


direct drive clutch piston
3. Control valve spool jammed in 3. Check control valve spool
underdrive position

4. Worn or defective direct drive 4. Replace clutch plates


clutch plates

5. Direct drive clutch pressure 5. Install snap ring correctly or


plate snap ring out of groove or replace
broken

21-3
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

PROBLEM PROBABLE CAUSE REMEDY

No power to rear wheels when 1. Scorred, burred or binding 1. Replace piston


power drive engaged (normal underdrive clutch piston
drive operative)

2. Control valve spool jammed in 2. Check control valve spool


direct drive position

3. Worn or defective underdrive 3. Replace clutch plates


clutch plates

No power to rear wheels when 1. Low Dual Command system 1. Check system pressure
Dual Command is engaged in pressure
normal drive or power drive

2. Defective planetary gear set 2. Check components and


ring gear, planetary carrier, sun replace as necessary
gear, shaft or main shaft splines

3. Main transmission or rear axle 3. Check and overhaul as


problem necessary

4. Clutch problem 4. Overhaul clutch

Engine stalls or lugs when 1. Scorred, burred or binding 1. Replace piston


shifting from power drive to underdrive clutch piston
normal drive

2. Broken or defective underdrive 2. Replace springs


clutch piston return springs

3. Warped or defective underdrive 3. Replace clutch plates


clutch plates

Engine stalls or lugs when 1. Scorred, burred or binding 1. Replace piston


shifting from normal drive to direct drive clutch piston
power drive

2. Broken or defective direct drive 2. Replace springs


clutch piston return springs

3. Warped or defective direct 3. Replace clutch plates


drive clutch plates

Lubrication pressure below 1. Weak or broken cooler/lubrica- 1. Overhaul cooler/lubrication


specification tion valve spring, or valve stuck valve
open

2. Blocked or restricted oil cooler 2. Replace oil cooler

Lubrication pressure above 1. Incorrect cooler/lubrication 1. Overhaul cooler/lubrication


specification valve spring or valve stuck valve
closed

21-4
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

DUAL COMMAND TRANSMISSION -


DESCRIPTION AND OPERATION
The Dual Command transmission consists of a
planetary gear set installed directly between the
clutch and the input shaft of the transmission.
The planetary gear set incorporates two hydraulic
operated clutches, which lock an element (s) of the
planetary gear system together, to produce either
direct drive or power under-drive. Power under-drive
lowers the speed and increases torque.
Normal Direct Drive
With reference to Figure 1.

Locking any two members of a planetary gear


system together results in a direct drive with no
change in speed or direction of rotation.

Compressing the direct drive clutch plates locks the


sun gear (3) to the planetary carrier (2) which is the
output member of the system. Applying power to the
ring gear (1) results in normal direct drive.

1
Power Underdrive
With reference to Figure 2.

Compressing the underdrive clutch plate, locks the


sun gear (4) to the planetary housing. Applying
power to the ring gear (1) forces the pinions (2) to
rotate and ‘walk’ around the sun gear, taking the
planetary carrier (3) with them. The planetary carrier
turns in the same direction as the ring gear at a lower
speed with a resultant increase in torque. This
condition produces a power underdrive.

2
A two position control valve (1) operates the Dual
Command feature, Figure 3. Located on the side of
the planetary gear set housing, the valve directs oil
from the steering section of the tandem hydraulic
system pumps, to engage either the direct drive or
the underdrive clutch assembly. The low pressure
regulating valve and the lubrication circuit relief valve
housed within the PTO valve assembly, regulates the
oil pressure.
Ground speeds in normal direct drive remain 1
unchanged from the previous 8-speed transmission.

21-5
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2
Oil Flow to the Direct Drive Clutch
With the Dual Command control switch (1) Figure 4, 1
located on the main shift lever, is in the normal (direct
drive) position, electric current flows to the control
valve solenoid, and energizes the solenoid coil.

The energized solenoid coil closes the pilot valve,


preventing hydraulic oil at Port ‘A’ from acting on the
top of the control valve spool.

Refer to Figure 5.

The hydraulic oil flows through the center of the


50025054
control valve and applies pressure to the bottom of
the spool, forcing the spool upward. Hydraulic oil 4
from Port ‘A’ is then directed between the lands of the
spool, to the gallery drilled in the planetary housing,
which connects with the gap between the second
and third sealing rings on the direct drive clutch hub.

A drilled passage in the direct drive clutch hub allows


the hydraulic oil to act behind the direct drive clutch
piston. The pressure acts on the piston, which
compresses the piston spring, locking the direct drive
clutch plates together, engaging the direct drive
clutch.

Hydraulic oil from the rear of the under-drive clutch


piston returns to sump via the control valve and
planetary housing.

21-6
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

R5--4--03 TI
5
Oil Flow to Direct Drive Clutch
Reservoir and
Pressure Oil Lubrication Oil Exhaust Oil

1. Pilot Valve 8. Hub Support Plate 14. Pinion


2. Control Valve Spool 9. Direct Drive Clutch Plates 15. Planetary Carrier
3. Sealing Rings 10. Direct Drive Clutch Piston 16. Planetary Housing
4. Transmission Input Shaft Return Spring 17. Underdrive Clutch Plate
5. Direct Drive Clutch Piston 11. Sun Gear 18. Underdrive Clutch Piston
6. Transmission Countershaft 12. Centre Shaft Return Springs
7. Direct Drive Clutch Housing 13. Ring Gear and Input Shaft 19. Underdrive Clutch Piston

21-7
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

R5--4--04 TI
6
Oil Flow to Underdrive Clutch
Reservoir and
Pressure Oil Lubrication Oil Exhaust Oil

1. Pilot Valve 8. Hub Support Plate 14. Pinion


2. Control Valve Spool 9. Direct Drive Clutch Plates 15. Planetary Carrier
3. Sealing Rings 10. Direct Drive Clutch Piston 16. Planetary Housing
4. Transmission Input Shaft Return Spring 17. Underdrive Clutch Plate
5. Direct Drive Clutch Piston 11. Sun Gear 18. Underdrive Clutch Piston
6. Transmission Countershaft 12. Centre Shaft Return Springs
7. Direct Drive Clutch Housing 13. Ring Gear and Input Shaft 19. Underdrive Clutch Piston

21-8
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2
Engaging the direct drive clutch locks the planetary The planetary carrier rotates at a slower speed than
carrier to the sun gear, which is splined to the direct the ring gear, thereby producing an under-drive with
drive clutch housing. When any two members of the a decrease in speed and increase in torque.
planetary assembly lock together, a direct drive
results with no change in speed or direction of
rotation. Therefore, as the planetary carrier and the Lubrication OIl Flow
sun gear lock together, power input at the ring gear The low-pressure hydraulic system supplies lubricat-
passes directly to the planetary carrier, which is ing oil via tubing through the oil cooler, to port ‘B’ of
splined via a connecting shaft to the input shaft of the the control valve, Figure 6.
transmission.
The oil passes through a drilled passage in the
planetary housing between the first and second
UNDER--DRIVE CLUTCH
sealing rings on the direct drive clutch hub and
through a drilled passage in line with the direct drive
Oil Flow clutch plates. The oil flows around the clutch plates
Refer to Figure 6. and through the planetary assembly. As the
members of the planetary assembly rotate, oil is
Placing the Dual Control switch on the gear lever to thrown off to lubricate the bearings and other
the ‘POWER’ position breaks the current flow to the components in the housing. Oil in the bottom of the
control valve, which de-energizes the solenoid. housing is directed through a tube connecting the
housing with the main countershaft bearing in the
The de-energized solenoid coil opens the pilot valve. hub support plate.
Hydraulic oil enters at port ‘A’ and acts on both ends
of the control valve spool. The larger surface area of Excess oil in the housing flows directly into the
the upper spool in comparison with the lower end transmission case to lubricate the transmission
causes oil pressure to force the spool downward. gears and bearings. Oil entering the hub support
Hydraulic oil passes through a drilling in the plate flows into the center passage of the
planetary housing to the under-drive clutch piston. countershaft and lubricates the bearings and gears
through cross drillings in the shaft. As the
Oil pressure acting on the piston compresses the components on the countershaft and output shaft
piston spring and locks the plates together to engage revolve, oil is carried to the input shaft and range
the under-drive clutch. cluster gear to lubricate the upper gears and
bearings in the transmission case. Excess oil in the
Hydraulic oil from the direct drive clutch piston countershaft flows directly into the transmission
returns to sump through the control valve and casing through a slot in the front support plate.
planetary housing.
Oil collected in the transmission case is allowed to
Engaging the under-drive clutch locks the direct drive flow into the rear axle center housing, with which it
clutch housing to the planetary housing. The sun forms a common oil reservoir, through passages in
gear also locks to the planetary housing. With power the transmission output shaft retainer.
applied, the pinions rotate around an axis, and ride
along the locked sun gear on the spline of the inner
hub of the direct drive clutch, causing the planetary
carrier to rotate in the same direction.

21-9
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

PLANETARY GEAR SET -- OVERHAUL


Removal
1. Drain the oil from the transmission and rear axle
center housings.
2. Disconnect the wiring harness from the wire
assembly at the plug connector located above
the transmission bell-housing. It is not necessary
to take the wire assembly out of the transmission
plug.
3. Pull the large rubber plug free from the
transmission bell-housing and disconnect the MTG21203
lubrication and pressure control lines from the
control valve body. 7

4. Unplug the wire assembly (2) from the Dual


Command solenoid Figure 7.
5. Remove the bolts securing the valve body (4) to
the planetary housing and remove the valve
body.
6. Remove the gasket from the valve body.
7. Remove the pressure line connector (5) and
lubrication line connector (1) from the valve body
and remove the O-ring seals from the
connectors.
8. Separate the engine from the transmission as
described in Section 10 “SEPARATING THE
TRACTOR”.
9. Disconnect the rod between the clutch pedal and
the clutch release cross-shaft lever by removing
the clevis pin at the lever end.
10. Remove the clutch release fork retaining pin (5),
Figure 8, support the fork (4) and remove the
clutch release cross-shaft (6).
11. Remove the fork and clutch release bearing
assembly (3).
12. Remove the bolts (1) from the planetary cover
(2).
13. Remove the cover from the planetary housing.
14. Remove the gasket from the cover.

21-10
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2
15. Remove the ring gear and shaft assembly, 16. Remove the planetary carrier, shaft, sun gear and
Figure 9, from the housing. direct drive clutch assembly as a complete unit.

9
Planetary Gear Set Components -- Exploded View

1. Cover 8. Underdrive Clutch Assembly


2. Thrust Washer 9. Planetary Carrier
3. Sun Gear 10. Pilot Bearing
4. Direct Drive Clutch 11. Ring Gear and Shaft Assembly
5. Shaft 12. Shim
6. Thrust Washer 13. Ring Gear Bearing
7. Planetary Housing

17. If necessary, use Slide Hammer (3) Tool No.


FNH09567 and Shaft Puller (4) Tool No.
FNH04721 to remove the reduction gear set and
direct drive clutch (1) from the ring gear bearing
when removing the ring gear. Place the Shaft
Puller over the shaft (2).

10
18. If necessary, remove the pilot bearing from the
shaft using Puller, Tool No. FNH09198, Pulling
Attachment, Tool No. FNH09190 and Step Plate,
Tool No. FNH09210.
19. Remove the shaft and separate the planetary
carrier from the direct drive clutch assembly.
20. Remove the sun gear from the inner splines of
the direct drive clutch assembly.
21. Remove the bolts (2) securing the planetary
housing (1) to the transmission case, Figure 11.

11

21-11
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2
22. Remove the planetary housing from the case.
NOTE: Take care not to lose the anti-spin washer
located between the transmission main shaft front
gear and front bearing, if the bearing comes away
with the Dual Command housing.

23. Remove and discard the gasket on the rear hub


of the planetary housing.
24. Remove the O-ring between the planetary
housing and the transmission front plate.

12
Direct Drive Clutch Assembly -- Exploded View
1. Steel Plates 7. Piston Return Spring
2. Pressure Plate 8. Sealing Rings
3. Snap Ring 9. Direct Drive Clutch Housing
4. Friction Plates 10. Piston Seals
5. Snap Ring 11. Piston
6. Spring Retainer

DISASSEMBLY
Direct Drive Clutch
1. Remove the sealing rings (8), Figure 12, from the
rear hub of the direct drive clutch housing (9).
2. Depress the piston return spring and remove the
snap ring (3) from the inner hub using Clutch
Compressor, Tool No. FNH01312 (4) and either
Puller, Tool No. FNH09516 or a press ram (1),
Figure 13.
3. Release the pressure and ensure the spring
retainer (2) does not enter the snap ring groove.
4. Remove the spring retainer and spring. 13

21-12
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2
5. Remove the clutch pressure plate snap ring (2),
as shown in Figure 14.
NOTE: When removing the clutch plates, note the
order of removal to facilitate installation.

6. Remove the pressure plate, the friction and steel


plates from the clutch housing (1).

WARNING
To prevent the piston from causing injury during
removal, place the direct drive clutch housing
face down on a bench. When using an air nozzle
to aid in removal, the piston rapidly expels.
14
7. Place an air hose nozzle in the hole between the
middle and rear sealing ring grooves in the clutch
housing hub and blow out the piston.
8. Remove the piston inner and outer seals.

15
Underdrive Clutch
1. Remove the large snap ring (1) from the inner
surface of the planetary housing (2), Figure 16.

WARNING
To prevent injury when removing the large snap
ring from the internal surface of the planetary
housing, manufacture four restraining clamps as
shown in Figure 14, and equally space around
the planetary housing rim. Use the planetary
housing bolts to retain the clamps, Figure 15.

16

21-13
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2
2. After removing the snap ring, gradually release
the restraining clamps.
NOTE: When removing the clutch plates, note the
order of removal to facilitate installation.

3. Remove the spring retainer (4), pressure plate


(2) and friction plate (5), Figure 17.
4. Remove the piston return springs (1), locating
dowel pins (11) and rear plate (6), Figure 17.

WARNING
To prevent the piston from causing injury during
removal, place the direct drive clutch housing
face down on a bench. When using an air nozzle 17
to aid in removal, the piston rapidly expels. Underdrive Clutch Assembly -- Exploded View
1. Piston Return Springs
2. Pressure Plate
5. Place an air hose nozzle in the pressure supply 3. Snap Ring
port of the control valve housing and carefully 4. Spring Retainer
blow out the underdrive piston (10), Figure 17. 5. Friction Plate
6. Remove the inner and outer seals from the piston 6. Rear Plate
(7), Figure 17. 7. Piston Seals
8. Control Valve Body
9. Planetary Housing
10. Piston
11. Dowel Pins

Control Valve Assembly


Refer to Figure 18.

1. Remove the plug (2) located in the control valve


body (3) at the opposite end of the solenoid (1).
2. Remove the solenoid and pilot valve assembly.
3. Remove the control valve spool (4).

18
Inspection and Repair
1. Clean all parts in a suitable solvent and dry
thoroughly with a dry, lint-free cloth or
compressed air.
2. Examine the lubrication inlet tube, the pressure
inlet tube, and the lubrication oil tube for damage
or distortion. Discard any defective tubes.
3. Examine the control valve solenoid cable for
damage or loose connections.

21-14
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2
4. Inspect the clutch release hub (2) and bearing (4)
for excessive wear or damage. If necessary,
remove the bearing from the hub with Pulling
Attachment, Tool No. FNH09190 (3), Step Plate,
Tool No. FNH09210 (5) and either a press or
Puller, Tool No. FNH09198 (1), see Figure 19.
Press a new bearing onto the hub ensuring the
thrust face of the bearing faces away from the
shoulder on the hub.
5. Pack the recess in the bearing hub bore with a
high melting point grease.
6. Inspect the clutch release fork for cracks or
excessive wear and replace as necessary.
19
7. Inspect the cross-shaft and lever for distortion or
excessive wear and install a new assembly, if
damage is evident. Inspect the shaft bushings for
excessive wear and replace if found to be
defective. Drive bushings into the housing until
flush with the outside edges of the cross-shaft
locating bores.
8. Inspect the planetary cover for damage or
distortion. Check the face of the cover and the
mating surface for nicks or burrs and remove any
imperfections with an abrasive stone.
9. Inspect the planetary carrier and gears,
planetary shaft, pilot bearing and thrust washer
for damage or wear. Install new parts as
necessary.
10. Inspect the sun gear for excessive wear or
damaged teeth.
11. Inspect the sealing rings from the rear hub of the
direct drive clutch assembly for damage,
distortion or cracks.
When installing new seals, insert the seals in a 60
mm (2.38 in.) internal diameter test bore for a
period of 10 minutes before assembling. This
procedure ensures the seals obtain the correct
amount of pre-tension to avoid damage on
assembly. Install the new seals using suitable
grease to hold the seals in position, and ensure
the seals do not protrude above the lands of the
direct drive housing.
12. Inspect the bore in the hub of the planetary
housing where the direct drive sealing rings
locate. Replace the planetary housing if
excessive wear or damage is detected.

21-15
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2
13. Inspect the direct drive clutch housing both
externally for cracks or damage and internally for
wear and piston scuffing. Inspect the housing
external splines for cracked, broken or missing
teeth.
14. Inspect the direct drive clutch piston, friction
plates, steel plates, pressure plate and snap ring
and install new piston seals.
15. Inspect the direct drive clutch piston return
spring, spring retainer and snap ring for damage.
16. Inspect the thrust washer for damage or
distortion.
17. Inspect the planetary housing for cracks or
damage. Inspect the underdrive clutch piston,
locating dowel pins, springs, rear plate, friction
plate, pressure plate, spring retainer and snap
ring and install new piston seals. Discard and
replace any cracked, damaged or badly worn
parts.
18. Inspect the transmission input shaft front bearing
(4) in the hub of the planetary housing (3). If
necessary, use Puller, Tool No. FNH09506 (2)
and Slide Hammer, Tool No. FNH09567 (1) to
remove the bearing, Figure 20. Press in a new
bearing.
19. Inspect the ring gear and shaft assembly for 20
damage or wear. Inspect the shaft splines for
damage. If necessary, install a new ring gear and
shaft assembly.
IMPORTANT: The shim located behind the ring gear
bearing governs the planetary gear set end-play. If
any of the major components of the planetary gear
set are changed, refer to ‘Planetary Gear Set
Shimming Procedure’ in this Chapter, to determine
the correct size shim to be installed.
20. Inspect the ring gear bearing (2) for wear or
damage. If necessary, remove the bearing with 6
Puller, Tool No. FNH09506 (6), Puller Legs, Tool
No. FNH09521 (5), Pulling Attachment, Tool No.
FNH09526 (4) and Step Plate, Tool No.
FNH09210/4 (1), as shown in Figure 21. Take
care not to damage the shim located behind the
bearing. Ensure to place the shim against the
step on the ring gear shaft (3) and then press the
new bearing onto the shaft, using a convenient
length sleeve of 82.6 mm (3.25 in.) internal
diameter and 95.3 mm (3.75 in.) external
diameter.

21

21-16
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2
21. Inspect the valve spool bore in the valve body for 3. Install the planetary carrier and thrust washer
damage or wear. onto the sun gear and ensure the splines of the
planetary carrier engage all of the direct drive
22. Inspect the valve spool lands for scratches, wear
clutch friction plates.
or other damage. Remove minor burrs or
scratches with a fine abrasive material. Clean 4. Hold the components tightly together and install
and dry prior to reassembly. the planetary shaft from the rear. Tap the shaft,
if necessary, to ensure full engagement.
23. Inspect the solenoid for cracks or damage. if any
doubt exists as to the serviceability of this 5. Press the pilot bearing onto the shaft using a
component, replace with a new solenoid sleeve of 41.2 mm (1.62 in.) internal diameter
assembly. and 47.8 mm (1.88 in.) external diameter.
6. Position the planetary housing (with underdrive
Assembly clutch installed) on a bench.
Assembly of the direct drive clutch, the underdrive
NOTE: Support the planetary housing on blocks so
clutch and control valve follows the disassembly
that the rear of the planetary shaft does not contact
procedure in reverse, with the following require-
the workbench when installing the direct drive clutch
ments:
and planetary gear set.
1. Apply a proprietary thread sealant on the pilot
7. Place the thrust washer in the housing with the
valve assembly threads and tighten the nut to a
tab up and towards the rear of the transmission.
torque of 5.4 Nm (4 ft.-lb.).
8. Install the direct drive clutch and planetary gear
2. Ensure the gap of the underdrive clutch retaining
set assembly in the housing. Ensure the
snap ring is placed in line with the lubrication port
assembly is fully seated in the housing.
of the Dual Command housing.
9. Install the ring gear and shaft assembly (without
PLANETARY GEAR SET SHIMMING the ring gear bearing or shim) in the housing.
PROCEDURE Place the Ring Gauge, Tool No. FNH01303, on
IMPORTANT: Perform the planetary gear set the step of the ring gear shaft.
shimming procedure after installing a new cover, 10. Position the cover on the planetary housing
bearing, ring gear, planetary carrier, sun gear, direct without the gasket.
drive clutch or planetary housing.
IMPORTANT: Ensure proper seating of all compo-
A shim located between the bearing and the step on nents in the housing.
the ring gear shaft, effects free play between the
components of the planetary housing. 11. Measure the distance between the face of the
cover and the face of the housing at three
Free play must be between 0.10-0.51 mm conveniently spaced intervals. Average the three
(0.004-0.020 in.). For available shims, see Specifica- measurements.
tions. If the average measurement falls between 1.17-1.52
mm (0.046-0.060 in.) the free play is within the
Determine the shim required to give the specified required limits and no shims are necessary.
free play as follows:
With an average measurement less than specifica-
1. Install the sun gear in the inner splines of the tion, determine the shim thickness required by
direct drive clutch assembly. referring to the relevant chart in Specifications
Section.
2. Place the thrust washer in the planetary carrier
and align the splines.

21-17
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2
12. Remove the cover and the ring gear and shaft
assembly from the planetary housing. Remove
the ring gauge and place the appropriate shim(s)
on the step of the ring gear shaft. Press the
bearing onto the ring gear using a convenient
length sleeve of 82.6 mm (3.25 in.) internal
diameter and 95.3 mm (3.75 in.) external
diameter.
13. Remove the components from the planetary
housing and retain in order for final installation.

Installation
IMPORTANT: When installing a new cover, bearing,
ring gear, planetary carrier, sun gear, direct drive
clutch or planetary housing, refer to ‘Planetary Gear
Set Shimming Procedure’ in this Chapter, before
installing the planetary components in the transmis-
sion case.

Installation of the planetary gear set and control


valve follows the removal procedures in reverse, with
the following requirements:

1. The cover easily seats in the housing with


correctly installed components. Do not force the
cover. Difficulty installing the cover indicates
improper assembly.
2. Install new O-ring seals on the lubrication oil
transfer tube.
3. Coat all tube joints with a proprietary sealing
compound.
4. Install new O-ring seals on the control valve
pressure line and lubrication line connections.
5. Ensure the grommet fits firmly in place over the
solenoid wire.

21-18
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

SECTION 21 - TRANSMISSION SYSTEMS

Chapter 3 - Reduction Gearbox Assembly

CONTENTS

Section Description Page


Specifications, Tightening Torques, and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Reduction Gearbox -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Reduction Gearbox Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

21-1
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

SPECIFICATIONS, TIGHTENING TORQUES, AND SPECIAL TOOLS

SPECIFICATIONS

Reduction Ratio 10:1

Output Shaft End Float with 0.0015-0.0034 in


Reduction Gearbox (0.038-0.086 mm)

Output Shaft Torque Pre-Load with Pull required to turn the output shaft with string
Reduction Gearbox wound around output shaft splines
9.5-16 lb. (1.0-1.8 N)

Output Shaft Pre-Load Shims 0.004 in. (0.10 mm)


Available for Reduction Gearbox 0.006 in. (0.15 mm)
0.020 in. (0.50 mm)

TIGHTENING TORQUES

Components ft.-lb. Nm

Rear Support Plate Retaining Bolts 32 44

Output shaft Retainer Socket Head Screws 23 31

21-2
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

REDUCTION GEARBOX The selector fork and gearshift rail allows movement
of the coupling. In the neutral position, no
engagement between the coupling and any
Description and Operation component of the reduction gear set exists.
The reduction gearbox, available as an option on the Therefore, the coupling and output shaft are not
8 x 2 transmission, provides an extra reduction ratio driven.
below the standard low range. An epicyclic gear set
mounted on the transmission output shaft provides Sliding the gear shift rail rearwards to the detent
this reduction. position, adjacent to neutral, selects the movement
of the rail, through the selector fork. This causes the
When installed on the 8 x 2 non-synchromesh coupling to engage the reduction gear set carrier.
transmission, the gearbox provides an additional Power transmits from the secondary countershaft,
creep range of four forward, and one reverse speed, via the carrier and coupling to the output shaft. The
which increases the total number of ratios available carrier consists of the same number of gear teeth on
to twelve forward and three reverse. On 16 x 4 the outside diameter as the output shaft gear utilized
transmissions with dual command installed, an on standard transmission. The ground speeds
additional eight forward and two reverse speeds are obtained in the low range are identical to those of a
provided, increasing the total ratios available to standard transmission.
twenty-four forward and six reverse.
Sliding the gear shift rail and fork further rearward to
The epicyclic gear set provides a reduction ratio the final detent position selects the coupling, moved
below the low range of 10:1, and consists of: by the selector fork inside the carrier assembly,
engages the intermediate ring gear. Power transmits
• An outer ring gear positioned in relation to the from the secondary countershaft to the coupling via
transmission housing. the planetary gear set.
• Planetary gears mounted on the carrier, with the The planetary gear set design allows drive of the
rear gear teeth engaging the outer ring gear. carrier, causing the planetary gears to rotate with the
rear teeth engaged in the stationary ring gear. The
• A carrier with teeth formed on the outside
forward teeth of the planetary gears engage and
diameter to act as the output shaft gear.
drive the intermediate ring gear at reduced speed.
• An intermediate ring gear, which engages the The coupling engages the intermediate ring gear,
front teeth of the planetary gears. and drives the output shaft at a reduced speed to
obtain the required creep range.
• A coupling, which drives the output shaft and
engages the carrier or intermediate ring gear.

21-3
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

1
Reduction Gearbox
1. Roller Bearing 11. Support Plate
2. Thrust Washer 12. Intermediate Ring Gear
3. Needle Roller Bearing 13. Planetary Gear
4. Spacer 14. Carrier
5. Taper Roller Bearing 15. Coupling
6. Output Shaft Retainer 16. Output Shaft
7. Roller 17. Needle Roller Bearing
8. Socket Head Screw 18. Thrust Washer
9. Shim(s) 19. Selector Fork
10. Outer Ring Gear 20. Gear Shift Rail

21-4
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

REDUCTION GEARBOX OVERHAUL


Removal
1. Drain the oil from the transmission.
2. Separate the rear axle from the transmission,
see “SEPARATING THE TRACTOR” Section
10.
3. Remove the gear shift cover.
4. Remove the snap ring, thrust washer and
hydraulic pump idler gear, located on the output
shaft retainer.
5. Remove the rear support plate retaining bolts (2)
and lever the support plate (1) away from the 2
transmission, Figure 2.
6. Remove the rear support plate (2) and the PTO
shaft (1) as an assembly, Figure 3.

3
7. Extract the secondary countershaft assembly
(1) enough to free the bearing from it’s location.
Lift up on the secondary countershaft and
remove the output shaft and reduction gear set
assembly (2).
8. Remove the secondary countershaft.
9. Remove the high/low/creep coupling from the
rear of the transmission, or the output shaft, as
required.

21-5
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3
Disassembly
1. Remove the output shaft retainer (1) from the
rear support plate (2), Figure 5.
2. Remove the outer ring gear (3) from the rear
support plate.

5
3. Remove the output shaft (2) from the reduction
gear set assembly (1). If necessary, use a soft 3 1
faced hammer to drive the output shaft forwards
out of the assembly, Figure 6. Ensure the
intermediate ring gear (3) remains inside the
reduction gear set.
NOTE: Removal of the output shaft will push the
bearing off the rear of the output shaft.

6
4. Remove the thrust washer (3) and needle roller
bearing from the output shaft (or intermediate
ring gear (4) should these components remain
inside the gear set assembly).
5. Lay the epicyclic gear set on the bench with the
intermediate ring gear upward. Remove the
intermediate ring gear (4), Figure 7.
6. Remove the thrust washer, needle roller bearing,
spacer and second needle roller bearing from the
carrier.
7. Remove the planetary gears (2) from the carrier
(1). Take care to retain the bearing rollers, Figure
7. 7

21-6
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3
Inspection and Repair
1. Inspect the output shaft retainer and rear bearing
cup for wear or damage. If necessary, use Pulling
Attachment, Tool No. FNH09507 and Slide
Hammer, Tool No. FNH09567 to remove the cup
from the retainer. Use a suitable Step Plate, Tool
No. FNH09210 to install a new bearing cup.
2. Inspect the rear support plate for wear or damage
and replace if necessary.
3. Inspect the output shaft and pilot bearing.
Replace worn or damaged components.
4. Inspect the secondary countershaft and PTO
drive shaft bearings located in the rear support
plate. Replace any unserviceable bearing with a
suitable Step Plate, Tool No. FNH09210.
5. Inspect all needle roller bearings and thrust
washers. Replace any unserviceable items.
6. Inspect the planetary gear set carrier, ring gears
and planetary gears and replace any worn or
damaged components on reassembly. However,
if several components are worn, the complete
reduction gear set must be replaced.
7. Inspect the coupling and gear shift mechanism.
Replace any unserviceable components.
Assembly
Assembly follows the disassembly procedures in
reverse with the following requirements.

1. Use high quality grease to position the thirteen 5


mm diameter rollers (3) and eleven 9 mm
diameter rollers (1) around the planetary gears
(2), Figure 8.

21-7
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3
2. Install the planetary gears (3) and rollers (4) in
the carrier (1). Rest inside the outer ring gear (2),
which acts as an assembly gauge. During
installation, turn each gear until the master tooth
(marked with a punched dot) points towards the
center of the carrier.

9
Planetary Gear to Carrier Relationship
NOTE: If gear identification marks for the master
tooth do not exist, use a rod between the gears to
establish which pair of teeth on the rear gear, align
with a pair on the front gear, then proceed as follows:

10
Refer to Figure 11 (viewed from the front).

1. Identify the right-hand tooth of any aligned pair


on the 12 teeth gear as the master tooth.

11
1. 16 Teeth Gear
2. 12 Teeth Gear
3. Master Tooth on 12 Teeth Gear
4. Rod Used to Establish Alignment of Gear Teeth

21-8
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3
2. Install the smaller diameter thrust washer (2),
chamfered side up, on the carrier hub before
installing the intermediate ring gear (1) into the
carrier to fully engage with the planetary gears,
Figure 12.
3. Place the gear coupling, groove to the front, on
the output shaft.

12
4. Position the larger diameter washer (1) on the
output shaft (2) with the chamfered side facing
the coupling (3) Figure 13.
5. Lubricate the needle roller bearings with high
quality grease and install the narrow needle roller
bearing in the intermediate ring gear. Install the
two wide needle roller bearings, with the spacer
between them, in the carrier.
6. Hold the previously assembled output shaft
vertically and install the carrier assembly on the
output shaft.

13
NOTE: With the carrier installed, the output shaft will
protrude above the carrier rear thrust face.

7. Push the output shaft rear bearing against the


output shaft shoulder (1).
8. Use feeler gauges (2) to check the clearances
between the bearing (3) and the carrier. The gap
should be 0.3-0.8 mm (0.012-0.032 in.), Figure
14.

14

21-9
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3
Installation
1. Install the assembled carrier and output shaft unit
in the transmission. Ensure the coupling
engages the selector fork.
2. Remove the outer ring gear from the reduction
gear set assembly.
3. Install the rear cover plate on the transmission.
4. Install the support plate retaining bolts and
tighten to a torque of 47 Nm (35 ft.-lb.).
5. Install the outer ring gear into the rear cover.
6. Replace the shims, and bolt the output shaft
retainer to the support plate to support the ring
gear. Tighten the socket head screws to a torque
of 31 Nm (23 ft.-lb.).
7. Using a pull scale and string wound around the
output shaft, check the output shaft torque
pre-load. With the transmission in neutral, the
pull scale should read between 1.0-1.8 N (9.5-16
lb.). Add or subtract shims from between the
output shaft retainer to obtain the correct
pre-load
Alternatively, if a pull scale is not available, add or
subtract shims to obtain an output shaft end float
of between 0.038-0.086 mm (0.0015-0.0034 in.).
8. Install the hydraulic pump, idler gear, and thrust
washer, and retain with the snap ring.
9. Replace the gear shift cover.
10. Reconnect the transmission and rear axle as-
sembly.
11. Fill the transmission with the correct grade and
quantity of oil.

21-10
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1

SECTION 23 - FRONT AXLE TRANSFER BOX

Chapter 1 - Front Axle Transfer Box

CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clearances and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Shim Thickness Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

23-1
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1

SPECIFICATIONS
CLEARANCES AND TOLERANCES
Item
Clutch Spring Free Length 48.0 mm 1.89 in
Output Shaft Bearings Rolling Resistance 1.5-3.5 kgs 3.3-7.7 lb
Idler Gear Bearing Rolling Resistance 0.4-1.0 kgs 0.90-2.2 lb
Output Shaft End-Float 0.025-0.075 mm 0.001-0.003 in

SHIM THICKNESS AVAILABLE


Item
Output
p Shaft Bearings
g 0.1 mm 0.004 in
and
d Idler
Idl Gear
G Bearing
B i 0.25 mm 0.010 in
0.3 mm 0.012 in
0.5 mm 0.020 in
Shaft End-Float 1.00-2.25 mm 0.04-0.089 in
(in increments of 0.05 mm) (in increments of 0.002 in.)

OIL CAPACITY
Lubricated by Rear Axle Oil
Transfer Box Increases Rear Axle Oil Level by 1.3 liters 1.4 qt

SPECIAL TOOLS
Tool Old Part Number Globel Part Number
Gauge, Idler Gear Shim FTC307979
Puller, Attachment FNH09190
Protector, Shaft (set of 6) 380000564
Puller, Grip-O-Matic FNH09516

TORQUE VALUES
Component
Rear Bearing End-Plate Retaining Bolts 40 Nm 30 ft.-lbs.
Front Bearing End-Plate Retaining Bolts 40 Nm 30 ft.-lbs.
Idler Gear Retaining Bolt 80 Nm 59 ft.-lbs.
Transfer Box Retaining Bolts 80 Nm 59 ft.-lbs.
Drive Shaft-to Drive Flange Attaching Bolts 57 Nm 42 ft.-lbs.

23-2
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1

DESCRIPTION AND OPERATION transfer box, to a third gear on the lower shaft. The
The transfer box assembly connects main transmis- number of teeth on the lower output gear determines
sion output to the front drive axle, through a the gear ratio of the transfer box assembly, Figure 1.
universally jointed drive shaft. The transfer box For compatibility with different rear tire sizes, the
mounts under the rear axle, center housing, and the transfer box ratio varies at 0.97:1 (42/43), 1.1 (43/43)
drive shaft passes along the central axis of the tractor. or 1.23:1 (44/43). A stamped plate located at the top
All transfer box assemblies consist of identical left side of the transfer box identifies the ratio. The
construction with the exception of the internal gear number of teeth (42, 43, or 44) on the lower, driven
ratio. Different ratios are required for the various gear effects transfer box ratio. Changing the original
types of front and rear tire sizes. A stamped ratio on gear to one with more or less teeth will result in a
the forward face of the housing below the output change of transfer box ratio.
shaft, identifies which transfer box is installed. Two taper roller bearings support the lower shaft, which
The transfer box assembly features a simple dog has a sliding dog type clutch meshed on the center
type clutch to engage the front axle. Hydraulic portion. The drive gear carries a mating dog type clutch
pressure from the power-take off and dual power that is free to rotate on the shaft when not engaged with
circuits activates the dog clutch. the sliding component. The clutch engages by four
radically positioned springs and releases by hydraulic
A helical gear mounted on the pinion shaft of the rear pressure controlled from the four-wheel drive select
axle, transmits drive through a mating helical idler switch.
gear, carried in two taper roller bearings in the

1
Transfer Box Assembly -- Cutaway View

1. Sliding Clutch 5. Electrical Feed Connection 9. Double Check Valve


2. Coil Springs (4 off) 6. Hydraulic Oil Connection 10. Oil Transfer Tube
3. Output Shaft 7. Sealing Rings 11. Driven Gear
4. Solenoid Valve 8. External Oil Tube 12. Idler Gear

23-3
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1
An electro-solenoid operated valve directs hydraulic gear to rotate on the shaft, and disconnects drive to
pressure from the power take-off and dual power the front axle.
circuits via tubing that connects to the rear of the
transfer box. When electric current activates the A broken electrical circuit deactivates the solenoid,
solenoid, hydraulic pressure flows through the which causes hydraulic pressure to collapse within
transfer tube to the center bore of the lower shaft. the feed lines and chamber ‘A’. The radically
positioned springs then force the sliding clutch
Hydraulic pressure enters a double check valve element towards the driven gear. As the sliding clutch
positioned in the center bore, and lifts an inner check moves, discharging oil slides the whole check valve
ball off the seat, allowing hydraulic pressure to pass rearwards, and the inner ball seats, preventing oil
through the check valve, and reach chamber ‘A’, from passing through the valve center. The moving
Figure 2. valve exposes a large exhaust path through drilled
passages in the shaft and the gear, to the rear axle
Chamber ‘A’, sealed by two rings, expands and reservoir. This permits rapid engagement of the
moves the sliding clutch element against the clutch. A small amount of oil also exhausts from the
radically positioned springs, and out of engagement solenoid to allow the check valve to move.
with the teeth on the driven gear. This action frees the

2
Clutch Operation -- Schematic View (Inset showing clutch engagement)
1. Driven Gear 5. Spring Keeper Plate
2. Oil Transfer Tube (inlet) 6. Sliding Clutch
3. Check Valve (ball unseated) 7. Oil Exhaust Route
4. Return Springs (4 off) 8. Check Valve (ball seated, valve moved rearwards)

23-4
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1

OVERHAUL
Removal
1. Park the tractor on a hard level surface. Set the
parking brake and chock the wheels.
2. Remove the drive shaft guard.
3. Disconnect the drive shaft from the axle input
flange coupling. Slide the rear coupling from the
transfer box assembly output shaft and remove
the drive shaft.
4. Remove the rear axle/transmission drain plug
from the transfer box casing and allow the oil to
drain into a suitable container, Figure 3. 3
Transfer Box Installed Beneath Rear Axle
1. Retaining Bolts (13 off)
2. Drain Plug
3. Solenoid Valve Cover
4. Feed Wire Protection Tube
5. Hydraulic Feed Pipe

5. Remove the solenoid cover plate on the


right-hand side of the transfer box assembly, and
disconnect the wire and protective tube, Figure
4.
6. Disconnect the hydraulic oil tubing from the
casing.
7. Support the transfer box with a suitable jack.
Remove the retaining bolts and lower the transfer
box assembly from the tractor.

4
Solenoid Cover Removed and Electrical
Connections
1. Coil Feed
2. Solenoid Assy
3. Earth Connection
4. Supply Wire
5. Electrical Protection Tube
6. Hydraulic Feed Pipe

23-5
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1
Disassembly
1. Remove the external oil tube linking the solenoid
port to the transfer box end plate. Remove the
solenoid coil-retaining nut and slide the coil from
the core. Unscrew the core and valve assembly
from the recess, Figure 5.

5
Solenoid Valve/Core Removed from Casing
1. Valve/Core
2. Earth Wire
3. Coil Retaining Nut
4. Coil and Feed Wire

2. Unscrew the socket head bolt securing the idler


gear and bearing assembly, Figure 6. If
necessary, apply heat to the thread-locking
compound on the nut to aid in removal.

6
Idle Gear Shaft Retainer
1. Shaft
2. Socket Head Bolt
3. Idler Gear
4. Shouldered Anchor Nut

3. Drive out the central shaft or arbor. Mark the front


of the idler gear to aid reinstallation. Remove the
gear and bearing assemblies, keeping the
bearings, spacers and shims together to
facilitate reinstallation, Figure 7.

7
Removing Idler Gear
1. Idler Gear
2. Shaft
3. Bearing Assembly

23-6
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1
4. Remove the output shaft end plate retaining bolts
and remove plate. Collect and identify the shims
positioned between the plate and the bearing
outer track, Figure 8.

8
Removing Output Shaft End Plate/
Seal Carrier and Shims
1. Shims
2. Output Shaft
3. End Plate/Seal Carrier
4. O-ring Seal

5. Remove the rear end plate retaining bolts and


remove plate, Figure 9. Remove the oil transfer
tube from the shaft.
6. Gently drive the shaft forward and backward to
remove the bearing outer tracks.

9
Removing Output Shaft Rear End Plate
1. End Plate
2. Bearing Assembly
3. Oil Transfer Tube
4. O-ring Seal

23-7
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1
7. Lever the clutch spring keeper against the
springs, Figure 10. To release the load, remove
the snap ring.
8. Remove the four clutch springs.

10
Levering Clutch Spring Keeper Plate
Against Clutch Springs
1. Levers (Pry Bars)
2. Snap Ring
3. Keeper Plate
4. Clutch Spring (4 off)
5. Suitable Sockets

9. Position two suitable lengths of steel rod or


tubing between the driven gear and the front of
the casing, for passing the shaft through the
driven gear. Remove the bearing, Figure 11.
10. Ease the shaft forward as far as the clutch will
permit and lift out the driven gear and thrust
washer.

11
Removing Output Shaft Rear Bearing
1. Adaptor
2. Bearing
3. Driven Gear
4. Output Shaft
5. Support Rods

23-8
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1
11. Remove the output shaft front bearing using
Puller Tool No. FNH09516, Attachment Tool No.
FNH09190, and Shaft Protector Tool No.
380000564, Figure 12.
12. Remove the clutch snap ring, by passing it along
the shaft, over the short spline area.

12
Removing Output Shaft Front Bearing
1. Shaft Protector 380000564
2. Puller Tool
3. Bearing
4. Attachment
5. Output Shaft

13. Ease the shaft rearward and draw the clutch


forward, to expose the clutch rear-sealing ring,
Figure 13. Remove ring.

13
Clutch Sealing Rings on Output Shaft
1. Rear Sealing Ring
2. Clutch Body
3. Front Sealing Ring
4. Output Shaft

23-9
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1
14. Ease the shaft rearwards from the transfer box,
through the clutch and out the rear-bearing bore,
Figure 14. Lift out the clutch and spring keeper.

14
Output Shaft Moved Rearward from
Transfer Box Case
1. Clutch Body
2. Spring Keeper
3. Output Shaft

15. Remove the check valve from the center bore of


the shaft, Figure 15.
NOTE: Applying air pressure to the cross drilling
between the clutch sealing rings will aid in removal of
the check valve.

15
Check Valve Removed from Inner Bore of
Output Shaft
1. Output Shaft
2. Check Valve
3. Central Bore

23-10
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1

16
Transfer Box Assembly -- Exploded View
1. Bolt 17. Shim
2. Shim 18. Front End Plate
3. Spacer 19. Felt/Lip Seal
4. Idler Gear 20. O-ring
5. Rear End Plate 21. Bearing
6. Oil Transfer Tube 22. Spring (4 off)
7. O-ring 23. Solenoid Cover
8. Bearing 24. Solenoid/Valve
9. Thrust Washer 25. Casing
10. Check Valve 26. Oil Tube
11. Driven Gear 27. Retainer
12. Output Shaft 28. Shim
13. Sealing Rings 29. Bearing
14. Sliding Clutch 30. Shim
15. Spring Keeper 31. Bearing
16. Snap Ring 32. Shaft

23-11
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1
Inspection and Repair
1. Remove the O-ring seals from the shaft end
plates, Figure 17, and the remaining sealing ring
on the center of the shaft.

17
Output Shaft End Plates
1. O-ring Seal -- Front Plate
2. O-ring Seal -- Rear Plate

2. Remove the felt seal from the output shaft, front


end plate and discard, Figure 18. Do not install a
new seal at this stage.
3. Clean all components with a suitable solvent.
Allow parts to dry.
4. Remove the transfer box hydraulic feed pipe
from the tractor and clean the filter/screen inside
the adapter.

18
Output Shaft Front End Plate
1. End Plate
2. Felt/Lip Seal

5. Inspect the valve core O-ring and back-up seals.


Replace as necessary, Figure 19.

19
Solenoid Valve Core
1. O-rings
2. Back-up Rings
3. O-rings
4. Valve Core

23-12
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1
6. Inspect the idler gear bearings for wear or
damage. If necessary, replace bearings as a
matched set. Slide the inner tracks from the gear,
Figure 20.
7. Inspect the idler gear and lower gear teeth for
wear or damage, and if discovered, inspect the
drive gear on the rear axle pinion.

20
Idler Gear Bearing Inner Tracks
1. Idler Gear
2. Separating Shoulder
3. Inner Track (2 off)

8. Inspect the clutch ”dog teeth” on both the sliding


clutch component and the driven gear for wear or
damage. If discovered, replace as a matched set,
Figure 21.
9. Inspect the clutch springs for deformity and
cracks. Check that spring free-length measures
48.0 mm (1.89 in.).
10. Inspect the spline of the clutch and shaft for wear
or damage.
11. Inspect the lower shaft bearing assemblies for
wear or damage.
12. Inspect the output shaft to drive shaft spline for
wear or damage. 21
Clutch Dog Teeth
1. Clutch Dog Teeth
2. Driven Gear Dog Teeth

Assembly
1. Install new O-ring seals on the two end plates
and a new clutch sealing ring on the shaft at the
small diameter. Do not install the larger sealing
ring until positioning the shaft inside the casing.
2. Coat the check valve with grease, and install the
valve in the shaft with the spring facing forward
and the ball to the rear, Figure 22. The grease will
hold the valve in place during assembly.

22
Check Valve Installation in Output Shaft
1. Output Shaft
2. Check Valve
3. Identification Section

23-13
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1
3. Thoroughly lubricate the inside of the clutch.
Position the clutch in the casing with the spring
keeper plate.
4. Pass the shaft through the rear bore, the clutch,
and the keeper plate. Install the larger
diameter-sealing ring, and then lubricate both
the large and small sealing rings, Figure 23.
5. Completely install the clutch on the shaft in the
closed position.
6. Move the shaft completely forward, and install
the driven gear and thrust washer on the shaft.

23
Output Shaft Entered in Casing
1. Rear Sealing Ring
2. Clutch Body
3. Front Sealing Ring
4. Output Shaft

7. Support the output shaft and press the rear


bearing on using a suitable spacer, Figure 24.
8. Install the snap ring on the output shaft adjacent
to the keeper plate.
9. Drive the front bearing on the output shaft using
a suitable sleeve on the inner track.

24
Pressing Rear Bearing onto Output Shaft
1. Adaptor
2. Bearing
3. Driven Gear
4. Output Shaft

23-14
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1
10. Install the four clutch springs. Compress the
keeper plate and springs to facilitate installing the
snap ring. Completely seat the snap ring in the
groove, Figure 25.

25
Levering Clutch Spring Keeper Against Clutch Springs
1. Levers (Pry Bars)
2. Snap Ring
3. Keeper Plate
4. Clutch Springs (4 off)
5. Sockets

11. Ensure the check valve is in position inside the


shaft. Install the bearing outer track and the
bearing end-plate with the oil transfer tube,
Figure 26. Tighten the bolts to a torque of 40 Nm
(30 ft.-lbs.).
12. Install the front bearing outer track and front
bearing retainer, without the felt seal and shims.

26
Installing Output Shaft Rear End Plate
1. End Plate
2. Bearing Assembly
3. Oil transfer Tube
4. O-ring Seal

13. Temporarily tighten the bolts.


14. Determine the degree of end float with a dial
indicator mounted against the clutch assembly,
by moving the shaft forward and backward,
Figure 27.
15. Select shims to equal the end float result, then
add another 0.1 mm (0.004 in.) shim to the total.

27
Assessing Output Shaft End Float

23-15
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1
16. Remove the front bearing retainer, install the
shim pack and plate then hand-tighten the
retaining bolts, Figure 28.

28
Installing Output Shaft End Plate and Shims
1. Shims
2. Output Shaft
3. End Plate Without Lip Seal
4. O-ring Seal

17. Use a string wrapped around the output shaft and


a spring balance, to measure the rolling
resistance of the shaft within the bearings.
Progressively tighten the end-plate bolts until
reaching a torque of 40 Nm (30 ft.-lbs.) and
record the resistance, Figure 29.
NOTE: During the rolling resistance measurement,
keep the string from over wrapping on the shaft, and
read the spring balance only when the shaft is
rotating, and not at the very beginning of rotation.

18. Add shims to increase the rolling resistance or


subtract shims to decrease, until obtaining the
specified figure of 1.5-3.5 kgs (3.3-7.7 lb) with the 29
bolts tightened to 40 Nm (30 ft.-lbs.). Measuring Rolling Resistance of Output
19. Remove the front bearing plate to install a new Shaft Bearings
felt seal. Squarely seat the seal and install the 1. String
bearing plate without damaging the seal. Tighten 2. Spring Balance
the bolts to the torque specified in step 18.
20. Assemble the solenoid valve and transfer tube
following the disassembly procedures in reverse.
21. Calculate the taper roller bearing pre-load,
before reassembling the idler gear, by measuring
the rolling resistance, using Shim Gauge Tool
No. FTC307979 as follows:
• Slide the bearing outer tracks into the idler
gear and assemble the inner bearings with
the spacer and a 0.3 mm (0.012 in.) shim
between them.

23-16
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1
• Mount this assembly on the special tool and
tighten the tool bolt to a torque of 68 Nm (50
ft.-lbs.), Figure 30.

30
Idler Gear and Bearing Assembly Mounted
on Special Tool
1. Idler Gear
2. Special Tool
3. Spacer
4. Shim

• Lock the tool stock in a vise. Wrap string


around the gear and use a spring balance to
measure the rolling resistance of the
bearings, Figure 31.
NOTE: During the rolling resistance measurement,
keep the string from over wrapping on the gear, and
read the spring balance only when the shaft is
rotating, and not at the very beginning of rotation.

31
Measuring Rolling Resistance of Idler Gear Bearings
1. Special Tool
2. String
3. Spring Balance

23-17
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1
• Increase the shim value placed between the
bearings to reduce rolling resistance, or
decrease the shim value to increase the
resistance. Adjust shims until obtaining the
specified rolling resistance of 0.4-1.0 kgs
(0.90-2.2 lb).
• Measure the distance across the bearing
inner races as shown in Figure 32, using a
deep throat micrometer and record as
measurement ‘A’

32
Measuring Distance Across Idler Gear
Bearing Inner Races
1. Bearing Inner Races
2. Micrometer
3. Shim and Spacer
4. Special Tool

• Measure the distance across the casing idler


gear mounting lugs with an internal vernier
caliper, Figure 33, and record as measure-
ment ‘B’.
• Subtract measurement ‘A’ from measure-
ment ‘B’ and make a shim pack equal to this
result. Divide the resultant value by two and
place this value of shims on each side of the
bearing assemblies.
NOTE: It is not necessary for the shims to be of equal
value on each side of the bearings, as long as the
sum of the shims equals the required amount.

33
Measuring Width of Idler Gear Mounting Lugs in
Transfer Box Casing

Example:

Measurement ‘A’ = 3.75 mm


Measurement ‘B’ = 3.95 mm

Then B - A = C

3.95 mm - 3.75 mm = 0.2 mm


(0.16 in. - 0.15 in. = 0.01 in.)

Divide total by two:

0.2 mm ÷ 2 = .1 mm
(0.01 in. ÷ 2 = 0.005 in.)

Place .1 mm (0.005 in.) thick shim on each side


of bearing assemblies.

23-18
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1
22. Remove the idler gear from the special tool.
Lightly lubricate and assemble the gear,
bearings and shims to the transfer box casing as
shown in Figure 34. Apply thread-locking
compound and tighten retaining bolt to a torque
of 80 Nm (59 ft.-lbs.).

34
Idler Gear Installed in Transfer Box Casing --
Sectioned View
1. Idler Gear
2. Shim
3. Center Shaft
4. Shim
5. Spacer
6. Casing
7. Shim

Installation
Installation of the transfer box assembly follows the
removal procedures in reverse with the following
requirements:

NOTE: Use the specified gasket between the


transfer box and rear axle housing. Any variation in
thickness or material could result in gear noise, rapid
wear, or other discrepancies.

1. Tighten the transfer box assembly retaining bolts


to a torque of 80 Nm (59 ft.-lbs.). Apply suitable
thread-locking compound to the drive shaft-to-
axle drive flange coupling bolts and tighten to a
torque of 57 Nm (42 ft.-lbs.).
2. Fill the rear axle with recommended type and
quantity of oil.

23-19
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1

23-20
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1

SECTION 25 - FRONT AXLE--FOUR WHEEL DRIVE

Chapter 1 - Four Wheel Drive

CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clearances and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Shim Thickness Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Track Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hub and Planetary Reduction Gear Assembly - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Axle Shafts - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Steering Swivel Pin Bearings - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Steering Cylinder and Track Rods – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Front Axle – Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Differential Crown Wheel and Pinion Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . 33
Drive Shaft - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

25-1
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1

SPECIFICATIONS
CLEARANCES AND TOLERANCES
Front Axle Ratio Overall 1:17.5
Crown Wheel/Pinion 1:2.9
Planetary Hubs 1:6
Maximum Front Axle Loading
g TB120HC 3250 kg (7165 lbs.)
TB100 2860 kg (6305 lbs.)
TB110, 120 3062 kg (6750 lbs.)

Item Specification
Front Wheel Toe-In 0-6.0 mm 0-0.24 in
Front Wheel Toe-Out 0-13 mm 0-0.5 in
Hub bushings 20 mm 0.79 in
24 mm 0.95 in
Axle Hub Bearings Rolling Resistance Non-adjustable Non-adjustable
Differential Bearing Rolling Resistance 2-6 kgs 4.4-13.2 lb
Pinion Bearings Turning Torque 14.3-20.4 kgs-cm 12-18 lb-in
Swivel Bearing Turning Torque 8-11 N⋅m 6-8 ft.-lbs.
Swivel Pin Bearing Pre-Load 0.20-0.40 mm 0.008-0.016 in
Crown Wheel to Pinion Gear Backlash 0.15-0.25 mm 0.006-0.010 in
Limited Slip
p Differential Clutch Pack Clearance 0.1-0.2 mm 0.004-0.008 in
New Plate Size 1.6 mm 0.063 in
Maximum Wear 0.15 mm 0.006 in
Thrust Plates under Side Gears New Plate Size 2.8 mm 0.11 in
Maximum Wear 0.1 mm 0.004 in
Axle Shaft End Float Non-adjustable Non-adjustable
Steering Angle 30° -- 50° adjustable

SHIM THICKNESS AVAILABLE


Item
Axle End-Float Thrust Washers 1.5 mm 0.060 in
2.0 mm 0.079 in
2.5 mm 0.098 in
Swivel Bearing
g Shims 0.6 mm 0.024 in
0.8 mm 0.031 in
1.0 mm 0.039 in
1.2 mm 0.047 in
1.4 mm 0.055 in
1.6 mm 0.063 in
1.8 mm 0.071 in
2.0 mm 0.079 in
Differential Clutch Pack Shims 2.8 mm 0.110 in
2.9 mm 0.114 in
3.0 mm 0.118 in
3.1 mm 0.122 in
3.2 mm 0.126 in
3.3 mm 0.130 in
Differential Bearing Resistance Shims 0.6-1.8 mm 0.024-0.071
(in increments of 0.1 mm) (in increments of 0.004 in.)

25-2
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1

OIL CAPACITY
Axle Differential 6 liters 6.3 qt
Front Hub – Four Wheel Drive – Each 1.0 liters 1.1 qt

SPECIAL TOOLS
Tool Old Part Number Global Part Number
Installer, Pinion Oil Seal FTC307971
Installer, Shaft Bushing FTC307974
Installer, Center Housing Axle Bushing FTC307975
Wrench, Pinion Bearing Nut FTC307978
Gauge, Pinion Setting FNH09190
Attachment, Bearing Cup Puller FNH09507
Puller, Grip-O-Matic FNH09516
Puller, Pilot Bearing FNH09527
Hammer, Slide FNH09567

TORQUE VALUES
Component
Ring Gear and Carrier Assembly Retaining Bolts 95 Nm 70 ft.-lbs.
Planetary Carrier Assembly Cover Shouldered Studs 70 Nm 52 ft.-lbs.
Planetary Carrier Assembly 8 mm Socket Screws 80 Nm 59 ft.-lbs.
Upper and Lower Swivel Pin Retaining Bolts 120 Nm 89 ft.-lbs.
Track Control Rod End-to-Steering Arm Retaining Bolts 120 Nm 89 ft.-lbs.
Differential Assembly Bearing Adjuster Locking Plate Bolts 13 Nm 10 ft.-lbs.
Differential Assembly Support Casing Retaining Bolts 169 Nm 125 ft.-lbs.
Drive Shaft-to Drive Flange Attaching Bolts 57 Nm 42 ft.-lbs.
Steering Cylinder Ball Joints 300 Nm 221 ft.-lbs.
Steering Cylinder End-Plate Retaining Bolts 120 Nm 89 ft.-lbs.
Crown Wheel Retaining Bolts 230 Nm 170 ft.-lbs.
Front and Rear Support Piller Bolts 370 Nm 273 ft.-lbs.
Track Rod Clamp Bolt 25 Nm 18 ft.-lbs.
Disc to Hub Nuts 244--298 Nm 180--220 ft.-lbs.
Disc to Rim Nuts 310--340 Nm 228--251 ft.-lbs.

25-3
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1

DESCRIPTION AND OPERATION


An identification plate attached to the right-hand rear
side of the axle casing carries the axle type, a
stamped serial number, total gear ratio, reference
number, oil capacity/type, and grease type. Use this
information when servicing parts.

The axle width measures 1910 mm (75.2 in) at the


wheel mounting flange. Wheel tack adjustment is
achieved using separate wheel rim and disc
assemblies.

The pivoting center of the axle allows articulation


when traveling rough ground. The input shaft, or
drive pinion, passes through the hollow center of the
rear articulation bushing. This arrangement keeps
the drive shaft, connecting the front axle with the
transfer case assembly, in a straight plain, through all
degrees of articulation.

The drive shaft runs in a mid-point mounted,


single-row ball bearing, for additional support.

Axle shafts consist of double, universal joint


assemblies, which allow constant running, and a
splined output for drive shaft connection.

Three epicyclic planet gears, in the hub and


planetary gear assembly, accomplish final reduction.
The hub and planetary gear assemblies attach to the
axle center casing by swivels, which use both cone
and cup type bearings.

The axle features a differential assembly in a


removable casing, attached to the axle center
casing. The differential assembly is equipped with a
standard self-applied, limited slip system.

25-4
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1

1
Front Axle -- Cutaway View
1. Drive Shaft Input Coupling 9. Front Articulation Trunnion Mounting
2. Steering Cylinder Rod 10. Crown Wheel
3. Track Rod End Assembly 11. Planetary Reduction Gear
4. Hub and Planetary Reduction Gear Assembly 12. Center Casing Breather
5. Axle Shaft Double Universal Joint Assembly 13. Removable Differential Assembly Carrier
6. Swivel Casing 14. Steering Cylinder
7. Swivel Pin Assembly 15. Rear Articulation Trunnion Mounting
8. Axle Center Casing

25-5
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
The multi-plate clutch on each side of the differential which connect the steering cylinder rod to each hub
side gears provides limited slip action. As traction is assembly. The steering cylinder attaches to the
lost on one front wheel, the torque reaction on the differential assembly carrier and is removable.
differential exerts an axial outward force through the
The hub and planetary reduction gear assembly, axle
side gears to pressurize the clutch plates. The outer
shafts, steering swivels, steering cylinder, and track
plates lock to the differential casing and the inner
control rods do not require removal of the axle from
plates to the side gears. As the force increases,
the tractor to service and overhaul.
relative movement between the friction surfaces
becomes difficult and locks the side gears to the
casing, effectively locking the differential. As soon as Front Wheel Track Adjustment – Four Wheel
the slip tendency is overcome, the torque reaction Drive
collapses and the system automatically unlocks. Front wheel drive tractors have fixed axle assem-
blies. However, the track width is adjustable by
A double acting piston controls the steering cylinder
changing the wheel rim relative to the center disc, the
rod as it extends through each side of the steering
rim and/or disc relative to the axle hub, or by
cylinder, outward to the ball mounted track rods,
interchanging both front wheels.

25-6
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
The sectioned drawings shown in the chart illustrate
the wheel rim and disc positions relative to he hub at
various track widths. (The track width is the distance
between the center of each tire at ground level). The
track widths shown are nominal and may vary by up
to10 mm (0.4 in.).

358--266

2
Front Axle Adjustment (FWD)

25-7
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1

TRACK WIDTH (TB120 MUDDER)


Tread Width Adjustment of Front and Rear
Wheels
Front and rear treads are adjustable to 72 in., 76 in.,
80 in. and 84 in. These adjustment are obtained by
mounting the rims and disc in the combinations
shown in the corresponding chart.

The standard tires provided for this tractor


are13.6--38/12.4--46 on both front and rear.

WARNING
With a front wheel on a four wheel drive tractor
supported on a stand, never attempt to rotate the
wheel or start the engine. This may cause the rear
wheels to move resulting in the tractor falling from
the stand. Wheels should always be supported
with tires just clear of the ground.

NOTE: When interchanging left and right-hand


wheel assemblies, ensure the ’V’ of the tire tread
remains pointing in the direction of forward travel.

WARNING
Never operate the tractor with a loose wheel rim
or disc. Always tighten nuts to the specified
torque and at the recommended intervals.
Ensure that all steering components are
maintained in a reliable and satisfactory
condition to ensure safe operation and comply
with legal requirements.

When installing or adjusting a wheel, tighten the bolts


to the following torques and re-check after driving the
tractor for 200 m (200 yds.), after 1 hour and 8 hours
of operation and thereafter, at the 50-hour service
intervals:

Front wheels torques


Disc to hub nuts 244 -- 298 Nm (180 -- 220 ft.-lbs.)
Disc to rim nuts 310 -- 340 Nm (228 -- 251 ft.-lbs.)

Rear wheels torques


Disc to hub nuts 407 -- 475 Nm (300 -- 350 ft.-lbs.)
Disc to rim nuts 310 -- 340 Nm (228 -- 251 ft.-lbs.)

IMPORTANT: If your tractor is equipped with the


optional front fenders, ensure there is adequate
clearance under all operating conditions. Also, at the
smaller track setting an interference condition may
3
occur between the tire and tractor when the wheels
are turned to the full articulation. To avoid this Axle Adjustment -- TB 120 Mudder
condition it is necessary to adjust the steering stops.

25-8
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1

HUB AND PLANETARY REDUCTION GEAR


ASSEMBLY - OVERHAUL
Removal
1. Position the tractor on a hard level surface, apply
parking brake and chock the rear wheels.
2. Disconnect the battery negative (ground) cable.
3. Jack up the front axle and securely support the
front of the tractor.
4. Remove the front wheel(s).
5. Turn the wheel hub to position filler/drain plug at
the lowest point and drain the oil.
6. Remove the two 8 mm socket screws (2) and the
two shouldered wheel studs (1), Figure 4 that
secure the planetary carrier to the hub assembly.
7. Tap the planetary carrier with a soft mallet. Pry
the carrier from the hub using the slots provided.

4
Planetary Carrier Retainers

8. Remove the planetary carrier, Figure 5, being


careful of the thrust pad located on the center of
the carrier.

5
Removing Planetary Carrier from
Hub Assembly

25-9
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
9. Remove the sun gear retaining snap ring and
remove gear, spacer and thrust washer from axle
shaft, Figure 6.

6
Removing Sun Gear Components
1. Thrust Washer
2. Spacer
3. Sun Gear
4. Snap Ring

10. Remove the ring gear and carrier retaining bolts,


Figure 7.

7
Ring Gear and Carrier Retaining Bolts
1. Axle Shaft
2. Ring Gear and Carrier
3. Retaining Bolts

11. Install four of the retaining bolts into the threaded


jacking holes in the ring gear. Tighten the bolts
evenly to draw off the ring gear and carrier.
Figure 7 and Figure 8.

8
Using Jack Bolts to Remove Ring Gear
and Carrier Assembly
1. Jack Bolts

25-10
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
12. Remove hub assembly, and if necessary tap the
hub using a soft mallet on the rear face, Figure 9.

9
Removing Hub Assembly

13. Carefully pry off inner bearing from the swivel


casing, Figure 10.
14. Remove the oil seal from the inner side of the
hub.

10
Levering Off Hub Inner Bearing

25-11
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
Disassembly
NOTE: When disassembling planetary carrier
assembly, keep all parts for each shaft together to
facilitate reassembling.

Inspect for oil leakage between the shaft cover and


carrier. If no leakage is found, it is not necessary to
remove the cover.

1. Remove the planetary carrier outer cover


screws. Remove cover.
2. Drive out the pins that secure each shaft to the
planetary carrier, Figure 11.
3. Push shafts outward and collect thrust washers,
planetary gears, and bearing rollers.

11
Removing Shaft Roll Pins
1. Shaft
2. Housing
3. Planet Gear
4. Roll Pin

25-12
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1

12
Planetary Carrier -- Exploded View 709--S2
1. Thrust Washer 9. Cover Plate
2. Planet Gear 10. Retaining Screw
3. Needle Roller Bearings 11. Shaft O ring Seal
4. Thrust Pad 12. Shaft
5. Locating Dowel 13. Roll Pin
6. Shouldered Wheel Stud 14. Carrier Housing
7. Carrier to Hub Screw 15. Thrust Washer
8. Drain/Filler Plug

Inspection and Repair


1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Inspect the hub main bearings. Inspect the outer
tracks in the hub housing and replace if
necessary, by using a drift punch to remove and
pressing the new outer tracks in until fully seated.
3. Inspect the planetary gear bearings, rollers and
shafts, and replace as complete sets if found to
be worn or damaged. A worn roller will
undoubtedly signify wear to the bearing path
inside the planetary gear and to the shafts.
4. Remove the retaining rings and separate the ring 13
gear and carrier. Inspect the ring gear teeth and Ring Gear and Carrier
retaining rings for wear or damage, Figure 13. 1. Retaining Ring
2. Retaining Ring
3. Carrier
4. Ring Gear

25-13
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
5. Inspect the ring gear carrier-to-swivel fixed
bushings.
NOTE: Two bushing sizes exist on each hub. Seven
bushings have a diameter of 20 mm (0.79 in.) and
one bushing has a diameter of 24 mm (0.95 in.). The
larger bushing serves as a master locator, and
ensures the correct installation of the carrier, Figure
14.

6. Inspect the eight, hub bushings for damage


caused by fretting, particularly if noticed that the
bolts were below torque during disassembly.
7. Inspect the sun gear, planetary gear, thrust
washers, spacers, and the thrust pad for wear 14
and damage. Replace any defective compo- Ring Gear and Carrier Retention -- Section View
nents. 1. Axle Shaft
2. Swivel Casing
3. Hub
4. Carrier
5. Locating Bushing (7 x 20 mm + 1 x 8 mm)
6. Carrier Retaining Bolt

8. Replace the planetary gear shaft O-ring seals.


9. Inspect the swivel assembly oil seal journal for
damage, Figure 15. To replace, cut off the journal
and thoroughly clean the swivel assembly
surfaces. Press on a new journal using a
continuing bead of suitable fixture agent to the
mating surface. This is critical in preventing oil
leakage.

15
Hub Oil Seal Wear Journal
1. Swivel Casing
2. Wear Journal

10. If necessary, fabricate a special tool as shown in


Figure 16 to facilitate pressing the journal against
the mating surface.
11. Inspect the planetary shaft cover, carrier, and
hub mating surfaces for minor nicks or burrs. Use
an abrasive stone to remove.
A. 90 mm (3.543 in.)
B. 140 mm (5.512 in.)
C. 155.2 mm (6.110 in.)
D. 175 mm (7.0 in.)
E. 18.5 mm (0.728 in.)
Material: Mild Steel

16
Oil Seal Journal Installation Tool

25-14
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
Assembly
Assembly of the planetary carrier follows the
disassembly procedures in reverse, with the
following requirements:

1. Ensure thirty bearing rollers are in each planetary


gear.
2. Use new roll pins to secure the shafts to the
housing.
3. Apply sealant to the chamfered heads of the
three cover attaching bolts.

Installation
1. Install the hub inner bearing onto the swivel
assembly. Install a new oil seal into the hub, and
ensure proper seating.
2. Lubricate the oil seal journal area with suitable
grease.
3. Assemble the hub to the swivel assembly.
4. Support the hub and slide in the outer bearing.
Maintain the hub in position while installing the
ring gear and carrier.

25-15
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
NOTE: The hub bearings, hub housing, and the
swivel stub, are machined to fine limits, eliminating
the need for bearing pre-load or rolling resistance
adjustments.

5. Assemble the ring gear and carrier with the


retaining rings.
6. Bolt the ring gear and carrier to the swivel
assembly, Ensure the correct position of the
larger bushing, Figure 17.
7. Tighten the bolts evenly to a torque of 95 Nm (70
ft.-lbs.).
17
Tightening Ring Gear and Carrier Assembly
Retaining Bolts
1. Axle Shaft
2. Ring Gear and Carrier
3. Retaining Bolts

8. Install the thrust washer, spacer, sun gear and a


new snap ring, Figure 18.
9. Coat the mating surfaces of the planetary carrier
and the hub with a suitable sealant.

18
Installing Sun Gear Components
1. Thrust Washer
2. Spacer
3. Sun Gear
4. Snap Ring

10. Install the thrust pad in the center of the carrier


assembly and position the carrier on hub. Install
the two 8 mm socket screws and tighten to a
torque of 80 Nm (59 ft.-lbs.).
11. Install the two shouldered wheel studs and
tighten to a torque of 70 Nm (52 ft.-lbs.), Figure
19.
12. Install the drain plug and replenish hub with oil.
See Specifications.

19
Installing Planetary Carrier Retainers
1. Socket Screws
2. Shouldered Studs

25-16
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1

AXLE SHAFTS - OVERHAUL


Removal
1. Remove the planetary carrier assembly, sun
gear, spacer and thrust washer as previously
described in Section 25, Chapter 1 “Hub and
Planetary Reduction Gear Assembly--Overhaul.”
2. Position a suitable sling around the hub and
swivel casing, Figure 20.
3. Disconnect the track rod end from the steering
control arm.

20
Hub and Swivel Assembly Supported by Sling

4. Remove the upper and lower swivel pin retaining


bolts, Figure 21, and pry the swivel pin out using
the lever slot. Collect and note the position of the
shims from top to bottom to facilitate assembly.

21
Upper Swivel Pin and Retaining Bolts
1. Swivel Pin
2. Retaining Bolts
3. Lever Slot
4. Greaser

5. Carefully ease the hub and swivel assembly from


the axle casing Figure 22. Ensure not to pull the
axle shaft from the axle casing. Support the outer
end of the axle shaft as it passes through the seal
when the hub and swivel casing is moved away
from the axle casing.

22
Removing Swivel Casing and Hub Assembly

25-17
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
6. Carefully pull the axle shaft from the axle casing,
while guiding it through the outer oil seal, Figure
23.

23
Removing Axle Shaft from Axle Casing

Inspection and Repair


1. Clean all components with a suitable solvent.
Allow parts to dry.
2. Inspect the universal joints for wear to the plated
metal in the inner and outer yokes, and inspect
the axle shaft spline for fretting and wear.
3. Inspect the bearing and seal journal areas for
wear or damage.
4. Disassemble the universal joints and inspect for
wear or damage. If damage is present, consider
replacing the complete axle shaft.
5. Remove the axle shaft oil seals from the axle
casing, Figure 24. 24
Removing Axle Shaft Oil Seal from Axle Casing
1. Slide Hammer
2. Oil Seal

6. Remove the swivel casing assembly oil seal


Figure 25.

25
Removing Oil Seal from Swivel Casing
1. Swivel Casing
2. Oil Seal
3. Slide Hammer

25-18
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
7. Inspect the axle shaft bushings in the swivel
casing and in the axle casing. Replace worn or
damaged bearings using Attachment Tool No.
FNH09507 and Hammer Tool No. FNH09567,
Figure 26.
NOTE: An internally positioned spring ring prevents
the moving of the axle shaft bushing in the swivel
casing. Do not damage this ring during removal.

26
Removing Axle Shaft Bushing from Axle Casing
1. Bushing
2. Tool
3. Tool

8. Remove worn or damaged bushing in the swivel


casing using Installer Tool No. FTC307974,
Figure 27.

27
Installing Axle Shaft Bushing in Swivel Casing
1. Bushing Installer Special Tool
2. Driver Handle

9. Remove and replace worn or damaged bushing


in the axle casing using Installer Tool No.
FTC307975. Fully seat bushings.
10. Install new oil seals in the swivel and axle
casings. Position seals squarely.

28
Installing Oil Seal in Swivel Casing
1. Driver Handle
2. Oil Seal Installer Special Tool

25-19
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
Installation
NOTE: When reassembling the axle shafts, ensure
each bearing cup is correctly installed, with no
interference of bearing rollers, and positively seat
snap rings into grooves.

1. Lubricate the bushing and oil seal in the axle


casing and swivel casing using suitable grease.
2. Pass the axle shaft through the axle casing
bushing and install in the differential side gear.
Ensure not to damage the oil seal.
3. Pass the swivel casing over the axle shaft and
onto the axle casing. Ensure not to damage the
oil seal.
4. Install the swivel pins and shims in exactly the
same location where removed.
5. Tighten the swivel pin retaining bolts to a torque
of 120 Nm (89 ft.-lbs.).
6. Install the sun gear thrust washer spacer and sun
gear.
7. Installation of the planetary gear carrier to the
hub assembly follows the removal procedures in
reverse.
8. Fill the hub assembly with oil. See specifications.
Check the differential oil, and grease the swivel
bearings.

25-20
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1

STEERING SWIVEL PIN BEARINGS -


OVERHAUL
Removal
1. Position the unit on a hard level surface and raise
the front wheel. Securely support the unit in this
position and remove the front wheel.
2. Remove the planetary gear carrier assembly,
sun gear, spacer, and thrust washer, as
described in Section 25, Chapter 1, “Hub and
Planetary Reduction Gear Assembly--Overhaul.”
3. Disconnect the steering track control rod end
from the steering arm.
4. Support the hub and planetary carrier assembly
using a crane and sling, Figure 29.

29
Hub and Swivel Assembly Supported by Sling

5. Remove the upper and lower swivel pin retaining


bolts, Figure 30, and pry the swivel pin out using
the lever slot. Collect and note the position of the
shims from top to bottom to facilitate assembly.

30
Upper Swivel Pin and Retaining Bolts
1. Swivel Pin
2. Retaining Bolts
3. Lever Slot
4. Greaser

31
Removing Upper Swivel Pin
1. Swivel Pin
2. Shim

25-21
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
6. Carefully ease the hub and swivel assembly from
the axle casing, Figure 32. Ensure not to pull the
axle shaft from the axle casing. Support the outer
end of the axle shaft as it passes through the seal
when the hub and swivel casing is moved away
from the axle casing.

32
Removing Swivel Casing and Hub Assembly

Disassembly
1. Remove the upper and lower swivel pin grease
seals, Figure 33.

33
Removing Swivel Pin Grease Seal

2. Remove the swivel pin bearing outer cup using


Attachment Tool No. FNH09507 and Hammer
Tool No. FNH09567, Figure 34.
NOTE: It may be necessary to heat the axle casing
or apply a bead of weld to the inner surface of the
bearing, to cause the bearing to contract for ease of
removal.

34
Removing Swivel Pin Bearing Outer Cup
1. Slide Hammer
2. Outer Cup

25-22
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
3. Drive off the cone half of the swivel bearing for
each pin using a suitable drift, Figure 35.

Inspection
1. Clean all components with a suitable solvent,
including the axle casing ends. Allow parts to dry.
2. Inspect the oil seal in the swivel casing and
replace if worn or damaged.
3. Inspect the greasers for blockage

35
Removing Swivel Pin Bearing Cone

Assembly
1. Install new outer bearing cups on the axle casing
ends using a suitable driver, Figure 36.
NOTE: It may be necessary to heat the axle casing
and chill the bearing to aid installation.
1

36
Installing Swivel Pin Bearing Outer Cup
1. Suitable Driver Tool
2. Bearing Cup

2. Install new oil seals adjacent to each bearing


cup, Figure 37.

37
Installing Swivel Pin Grease Seal

25-23
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
3. Press and seat new cones halves onto the swivel
pins, Figure 38.

38
Pressing Swivel Pin Bearing Cone Onto Pin
1. Spacer Block
2. Bearing Cone
3. Swivel Pin

Installation
1. Reposition the hub and swivel casing on the axle
shaft and install on the axle casing. Ensure not to
damage the seal by the axle shaft passing
through the swivel casing. Ensure not to damage
the upper and lower swivel pin seals.
NOTE: The swivel pin bearings are pre-loaded by
0.20–0.40 mm (0.008-0.016 in.). Adjust the pre-load
after installing a new bearing, or a new swivel casing.
Set the pre-load at the upper limit for new bearings
and at the lower limit for resetting old bearings.

2. Install the lower swivel pin assembly with a 1.0


mm (0.040 in.) shim positioned under the head of
the pin, Figure 39.
3. Install the upper swivel pin assembly without
shims.
4. Tighten the upper and lower swivel pins to a
torque of 120 Nm (89 ft.-lbs.).
39
Lower Swivel Pin and Shim Installation
1. Swivel Pin
2. Shim (1 mm)

25-24
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
5. Record swivel pin bearing clearance by
mounting a dial gauge with the stylus on the top
of the upper swivel pin, and the body clamped to
the axle casing, Figure 40.
6. Set the gauge to zero and move the swivel casing
upwards. Record the amount of free-play
generated by the 1.0 mm (0.040 in.) shim.
7. Add the specified pre-load to the recorded
measurement and subtract the total from 1.00
mm (0.040 in.) shim already in position. The end
total is the resultant thickness of shim needed to
obtain the specified pre-load. Divide this
resultant shim size by two, for two shim packs of
equal size for the lower and upper swivel pins. 40
Dial Gauge Mounted to Record Swivel Pin
Bearing Clearance

Example:
Recorded movement ‘A’ = 0.20 mm (0.008 in.)
Specified pre-load ‘B’ = 0.40 mm (0.016 in.)
Shim in place ‘C’ = 1.0 mm (0.040 in.)

Calculation C - (A + B)

= 1.0 mm – [0.20 mm + 0.40 mm]


= 1.0 mm - 0.60 mm
= 0.40 mm

Or

= 0.040 in. – [0.008 in. + 0.016 in]


= 0.040 in. - 0.024 in.
= 0.016 in.

Then,

0.40 mm ÷ 2 = 0.20 mm (shim value per swivel pin.)

Or

0.016 in. ÷ 2 = 0.008 in. (shim value per swivel pin.)

8. Remove the swivel pins and the original 1.00 mm


(0.40 in.) shims and install the calculated shim
value to each swivel pin.
9. Grease the swivel pins with suitable grease.
10. Install the planetary gear carrier thrust washer,
spacer, and sun gear. Fill the hub with oil.
11. Connect the track control rod end to the steering
arm and tighten bolt to a torque of 180 Nm (133
ft.-lbs.).

25-25
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1

STEERING CYLINDER AND TRACK RODS


– OVERHAUL
Removal
NOTE: Remove the steering cylinder if the
differential support casing requires removal. It is not
necessary to remove the steering cylinder for
steering cylinder seal leakage.

1. Position the tractor on a hard level surface.


2. Loosen the cylinder end plate, and the cylinder to
differential casing retaining bolts, by two turns,
Figure 41.
3. Turn the steering wheel to the left and unseat the
end cap and cylinder from the differential casing.
NOTE: There will be a slight loss of oil from the end
cap.

4. Apply parking brake and chock rear wheels.


Raise the left wheel and block the axle securely.
Remove left wheel.

41
Steering Cylinder End Plate/Retaining Bolts
1. Retaining Bolts
2. End Plate
3. Cylinder Rod
4. Hydraulic Hose

5. Disconnect the left and right-hand track control


rod ends from the steering arms, Figure 42.

42
Steering Track Rod End
1. Track rod
2. Steering Arm

25-26
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
6. Unscrew the track control rods from the steering
cylinder ball joints and unscrew the ball joints
from the steering cylinder, Figure 43.
NOTE: A high torque value on the connections will
require support and proper tooling to loosen.

43
Disconnecting Track Rod and Ball Joint from
Cylinder Rod
1. Ball Joint
2. Track Rod
3. Track Rod Clamp
4. Cylinder Rod

7. Disconnect the hydraulic hoses and remove


fitting from right side of cylinder.
8. Remove the four mounting bolts and steering
cylinder from the differential carrier, Figure 44.
Cap all open hose connections to prevent
contamination.

44
Removing Steering Cylinder from
Differential Carrier Mounting
1. Hydraulic Hose

Disassembly
1. Remove the piston and rod assembly (2) from the
steering cylinder barrel (1), Figure 45.
2. Slide the cylinder end plate off from the left side
of the barrel.
3. Remove the wear rings, piston seals, O-rings,
end plate seal and wiper seals from the cylinder,
Figure 44.

45
Removing Cylinder Rod and Piston Assembly
from Cylinder Barrel
1. End-plate
2. Cylinder Piston

25-27
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1

46
Steering Cylinder Exploded View
1. Wear Ring 7. Wiper Seal
2. Wiper Seal 8. End Plate O-Ring Seal
3. Oil Seal 9. Wear Ring
4. Cylinder Barrel 10. Piston Seal
5. End Plate 11. Piston Seal Expander (O-Ring)
6. Oil Seal 12. Cylinder Rod and Piston

Inspection
1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Inspect the piston and rod assembly for damage.
Remove minor nicks and abrasions using an
abrasive stone.
3. Inspect the inside of the cylinder barrel for
damage.
NOTE: Replace the complete steering cylinder
assembly after discovering damage to the piston and
rod assembly, or the cylinder barrel.
4. Inspect the track control rod ends, and the
cylinder rod ball joint for looseness. Replace the
ball joint if worn or damaged.

25-28
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
Assembly
1. Install new seals in the cylinder end plate and
right-hand side cylinder end.
2. Install new seals and wear rings on the piston,
and a new O-ring on the end plate.
3. Lubricate all seals and the piston assembly with
clean hydraulic oil and reinstall into the cylinder
barrel.
NOTE: Allow the center seal with the O-ring on the
piston and rod assembly, to contract naturally before
installing into cylinder barrel.

Installation
1. Installation of the steering cylinder follows the
removal procedures in reverse with the following
requirements:
2. Tighten the steering cylinder ball joints to a
torque of 470 Nm (345 ft.-lbs.), and torque the
cylinder end plate retaining bolts to 120 Nm (89
ft.-lbs.).
3. Position hydraulic connections and hoses to
prevent interference with other components,
through all degrees of front axle steering.
4. Replenish the hydraulic oil and check level.
5. Adjust and set the front wheel toe-in 0--6 mm
(0.025 in). Ensure to take measurement at the
inside of each wheel rim, at hub height, and at the
front and rear of the wheel, as shown in Figure
47.

47
Toe-in Adjustment
1. Rear Measurement
2. Hub Height
3. Front Measurement

25-29
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1

FRONT AXLE – REMOVAL AND


INSTALLATION
Removal
NOTE: If the unit is equipped with a front weight kit
or ballast, or a front mounted implement, consider
removing these components before proceeding.

1. Position the tractor on a hard level surface. Apply


the parking brake and chock the rear wheels.
2. Remove the drive shaft guard retaining bolts and
remove guard.
3. Remove the drive shaft to axle drive flange
retaining bolts, Figure 48.
4. Slide the shaft from the transfer box output shaft
and remove.
5. Raise the front of the tractor until both wheels 48
clear the ground and securely block the tractor Drive Shaft to Axle Coupling
below the junction of the engine to front 1. Axle Drive Flange
transmission. 2. Drive Shaft to Drive Flange Retaining Bolts
3. Drive Shaft
6. Remove the front wheels.
7. Disconnect the hydraulic hose connections from
the steering cylinder.
NOTE: Consider delaying the disconnection of
hoses until partially lowering the axle from the front
support, to improve access.

8. Position suitable jacks or lifting equipment to


support the weight of the axle. Before removing
the front and rear support pillars, ensure the
stability of the axle.

25-30
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
9. Loosen the front and rear support retaining bolts,
Figures 49 and 50, evenly, and gradually lower
the jacks or lifting equipment. Check that the axle
is stable and secure.

49
Front Support Pillar Retaining Bolts
1. Retaining Bolts

10. Remove the front and rear support retaining


bolts, and lower the axle to the ground.
Disconnect the steering hoses if not discon-
nected previously, as the axle is lowered.

50
Rear Support Pillar Retaining Bolts
1. Support Pillar
2. Retaining Bolts
3. Flange Coupling

Inspection and Repair


1. Clean all components with a suitable solvent.
Allow parts to dry.
2. Inspect the bushings on the front and rear
trunnions of the axle and differential casings for
wear or damage, Figure 51.

51
Front and Rear Support Pillar Bushings
1. Rear Support Bushing
2. O-ring Seal
3. Rear Trunnion Bushing
4. Front Support Bushing
5. Front Trunnion Bushing

25-31
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
3. Remove the O-ring seal from the bushing inside
the rear support, Figure 52. Clean all mating
surfaces of the bushing and rear support.
4. Install the front, and rear supports onto the
trunnions, and assess the degree of wear by
rocking the supports from side to side. Replace
bearings in pairs if wear or damage is excessive.
NOTE: Fore and aft movement of the axle before
removal signifies worn bushing thrust faces.

5. Removal of the bushings in the supports requires


the removal of the locating bolt and greaser
assembly. Use a press to remove the rear
support bushing. Cutting may be required to 52
remove the front support bushing. Install new Rear Support Pillar Bushing and O-Ring Seal
bushings with the grease holes aligned with the 1. O-ring Seal
drilling in the support and replace the locating 2. Bushing
bolt and greaser assembly. 3. Bushing Locator and Greaser
4. Support Pillar
6. Remove the axle drive flange as described in this
5. Locators
chapter.
7. Remove the trunnion bushings, cutting length-
wise to ease removal. Install new bushings in
trunnions.
8. Reinstall the axle drive flange as described in this
chapter.

Installation
Installation of the axle follows the removal
procedures in reverse with the following require-
ments.

1. Apply thread locking compound to the axle input


coupling flange-to-drive shaft retaining bolts and
tighten to a torque of 57 Nm (42 ft.-lbs.).
2. Tighten the support pillar bolts to a torque of 370
Nm (273 ft.-lbs.).
3. Replenish the hydraulic oil and recheck level.
4. Cycle the steering from lock to lock to purge air
from the circuit. Recheck reservoir level.
5. Check and adjust front wheel toe-in as described
in this chapter.

25-32
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1

DIFFERENTIAL CROWN WHEEL AND


PINION ASSEMBLY – OVERHAUL
Removal
1. Remove the axle assembly as described in this
chapter.
2. Remove the swivel casings, and axle shafts, as
described in this chapter.
3. Remove the steering cylinder assembly as
described in this chapter.
4. Drain the oil from the differential housing.
5. Position the axle housing so that the differential
support casing is upwards. Remove the
differential support to axle retaining bolts, Figure
53. Remove the support.

53
Differential Support Casing Retaining Bolts

Disassembly
1. Remove the drive flange retaining snap ring and
remove the flange from the pinion shaft, Figure
54.

54
Removing Drive Flange
1. Input Shaft
2. Drive Flange
3. Snap Ring

25-33
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
2. Remove the O-ring seal from the inner face of the
drive flange and the spacer positioned in front of
the pinion/bearing retaining nut, Figure 55.
3. Position a piece of hard wood in mesh with the
crown wheel and pinion to effectively lock the two
gears to facilitate removal of the pinion and
bearing retaining nut.
4. Remove the retaining nut and washer using
Wrench Tool No. FTC307978.

55
Drive Flange O-Ring Seal
1. Spacer/Washer
2. O-ring Seal
3. Drive Flange
4. Snap Ring

5. Remove the differential unit bearing adjuster ring


lock nut locking plates, Figure 56.

56
Differential Unit Bearing Adjuster Locking Plates
1. Locking Plates

6. Mark the bearing adjuster ring nuts relative to the


respective bores and the position of each within
the bores. This will aid when assembling new
components that effect bearing pre-load. Mark
each end cap to the casing to prevent
interchanging during assembly, Figure 57.

57
Marking Bearing Caps Relative to Casing

25-34
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
7. Remove the bearing cap retaining nuts. Remove
caps and adjuster nuts. Lift out the differential.
crown wheel assembly from the support casing.
Collect the bearing outer tracks and identify them
to the respective sides, Figure 58.

58
Removing Differential and Crown Wheel Assembly

8. Remove the crown wheel retaining bolts, Figure


59, and separate the crown wheel from the
differential housing.

59
Crown Wheel Retaining Bolts
1. Retaining Bolt
2. Crown Wheel
3. Differential

9. Turn the housing over and allow the differential


gear shift-locking pin to fall out. Slide the shaft
from the differential housing, Figure 60.

60
Differential Gear Shaft Locking Pin
1. Shaft
2. Pin

25-35
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
10. Manipulate the two differential gears to the
opening in the housing and remove the gears
and the thrust washers, Figure 61.

61
Removing Differential Gears
1. Thrust Washer
2. Gear
3. Side Gear

11. Remove the side gears and the limited slip,


differential lock clutch components. Keep the
clutch plates in order, and place them on the
side-gear mounts for subsequent inspection and
assembly, Figure 62.

62
Removing Differential Side Gear and Clutch Pack
1. Side Gear
2. Clutch Pack

12. Push out the drive pinion from the differential


support casing, and collect the collapsible
spacer and outer bearing inner race, Figure 63.

63
Drive Pinion Removed from Differential Support Casing
1. Pinion and Bearing
2. Support Casing
3. Washer
4. Retaining Nut
5. Outer Bearing Inner Race
6. Collapsible Spacer

25-36
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
Inspection and Repair
1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Remove all traces of sealant from the differential
support casing mounting face, and mating
surfaces of the axle casing.
3. Remove all traces of locking compound from the
crown wheel retaining bolts, and locating dowels.
4. Inspect the crown wheel and pinion teeth for
wear or damage. Replace both gears as a
matched set if necessary.
5. Inspect the differential side bearings. If neces-
sary, pull off the inner race using Puller Tool No.
FNH09516, and Attachment Tool No.
FNH09190, Figure 64.

64
Removing Differential Side Bearing
1. Puller
2. Shaft Protector
3. Pulling Attachment
4. Bearing Inner Race

6. Inspect the pinion bearings for wear or damage.


If necessary, remove the inner bearing, inner
race using Puller Tool No. FNH09516, and
Attachment Tool No. FNH09190, Figure 65.
Drive out the outer tracks from the differential
support casing.
NOTE: Retain the shim positioned between the
pinion inner bearing and the head of the pinion.

7. Inspect the differential gears, thrust washers and


shaft for wear or damage, and replace as
necessary.
8. Inspect the side gears and the spline within each
gear for wear or damage, and replace as 65
necessary. Removing Pinion Inner Bearing Race
1. Puller
2. Shaft Protector
3. Pinion
4. Pulling Attachment
5. Bearing Inner Race

25-37
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
9. Inspect the bushings in the differential housing
for wear. If necessary pull bushings out using
Puller Tool No. FNH09527, Figure 66. Press in
new bushings.

66
Removing Differential Housing Bushing
1. Puller
2. Bushing

10. Inspect the limited slip, differential clutch packs,


Figure 67. The plates should be perfectly flat.
Inspect the internal spline area and the outer lugs
on the interfacing plates, and the internal wearing
plates for maximum wear of 0.15 mm (0.006 in.).
New plates measure 1.6 mm (0.063 in.) thick.
Inspect the thrust plate under the head of each
side-gear for maximum wear of 0.1 mm (0.004
in.). New thrust plates measure 2.8 mm (0.11 in.)
thick.

67
Side Gears and Clutch Packs
1. Side Gears
2. Interfacing Drive Plate
3. Internally Splined Driven Friction Plate
4. Inner Thrust Plate

11. Inspect the condition of the axle casing, the


differential support casing, and the differential
gear housing.
12. Remove the input drive flange oil seal from the
differential support casing, Figures 68 and 69.

68
Input Drive Flange Oil Seal
1. Oil Seal

25-38
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
Assembly assembly, or pinion bearings, or when changing
1. Recalculate the thickness of the shim placed the differential support casing. If all these
behind the head of the drive pinion on the pinion components are reusable, then use the original
shaft, when replacing the crown wheel and pinion calculated shim value.

69
Differential, Crown Wheel and Pinion Assembly -- Exploded View
1. Bushing 17. Pinion
2. Adjusting Ring 18. Crown Wheel
3. Shaft Lock Pin 19. Adjuster Ring
4. Differential Gear 20. Locking Plate
5. Thrust Washer 21. Bearing
6. Oil Seal 22. Bushing
7. Coupling Flange 23. Thrust Washer
8. Snap Ring 24. Differential Gear
9. O-ring 25. Differential Housing
10. Spacer 26. Shaft
11. Nut 27. Clutch Pack
12. Keyed Washer 28. Side Gears
13. Bearing 29. Clutch Pack
14. Collapsible Spacer 30. Bearing
15. Bearing 31. Locking Plate
16. Shim

25-39
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
2. Calculate the shim thickness as follows:
• Install the pinion bearings in the differential
support casing as shown in Figure 70. Lightly
clamp the bearings using Pinion Setting
Gauge, Tool No. FNH04775. Install tool disc
with the cut-away side upward. Tighten the
clamp enough to lightly hand turn the bearing
cones. Do not over-tighten.
• Install the differential support casing, side
bearing caps (not the bearing tracks) and
tighten the retaining nuts to a torque of 169
Nm (125 ft.-lbs.)

70
Pinion Bearings Clamped in Casing
1. Part of Setting Gauge Tool
2. Pinion Bearing Assemblies

• Measure the side bearing bore using an


internal micrometer or vernier caliper and
record measurement as dimension ‘A’,
Figure 71.

71
Measuring Diameter of Differential Housing
Bearing Bores

25-40
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
• Place the circular bar from Tool No.
FNH04775 across the two bearing bores in
the support casing, Figure 72 and use a
depth gauge to measure and record as
dimension ‘B’.
• Use the recorded measurements and the
formula below to determine the required
thickness of shim needed:
C = B – 25.0 mm (0.98 in.) [Diameter of bar] + 1/2 A

The difference between calculation ‘C’ and the


dimension etched on the head of the pinion results in
the actual shim thickness.
72
Example:
Measuring Dimension ‘B’
C = 104.1 mm – 25 mm +1/2 (90 mm) = 124.1 mm 1. Depth Gauge
Etched on the pinion is 121.0 mm 2. Bar Gauge
3. Pinion Shaft Bearings
124.1 mm – 121.0 mm = 3.1 mm (shim thickness) 4. Pinion Setting Gauge
5. Differential Support Casing
Select the calculated shim thickness from the
range available, (See Specifications). Install on
the pinion shaft with the chamfer adjacent to the
pinion gear.
3. Press the inner bearing onto the pinion shaft until
completely seated, Figure 73.
IMPORTANT: Use a new collapsible spacer on the
pinion shaft. DO NOT use the old part.

4. Assemble the pinion bearing and spacer


assembly into the differential support casing and
install the outer bearing and retaining nut.
Eliminate bearing free-play by tightening the nut,
using Wrench, Tool No. FTC 307978.

73
Pressing Inner Bearing onto Pinion
1. Press
2. Protector
3. Pinion
4. Shim
5. Inner Bearing Race

25-41
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
5. Wrap string evenly around the exposed pinion
input spline, and use a pull scale to measure the
force required to rotate the pinion shaft within the
bearings, Figure 74. Read the scale during
rotation, not when the rotation starts.
6. Progressively tighten the retaining nut until
obtaining a force of 14.3-20.4 kgs-cm (12-18
lb-in.) It may be necessary to temporarily reinstall
the differential and crown wheel, to preset
rotation of the pinion during tightening of the
bearing retaining nut.

74
Checking Pinion Shaft Bearing Rolling Resistance
1. Spring Balance
2. String
3. Differential Housing
4. Pinion Shaft

7. After obtaining the specified scale reading, lock


the retaining nut to the shaft by placing the
retaining nut locking sleeve in the machined slot
of the pinion shaft.
8. Assemble the differential side-gears and limited
slip, clutch components. Position the gears in the
housing with the inner thrust plate adjacent to the
side-gear. The inner thrust plate wear face must
be adjacent to the interfacing drive plate with
external lugs, followed by a driven friction plate
with an internal spline. Each side-gear should be
equipped with one inner thrust plate, five
interfacing drive plates (external lugs), and four
driven friction plates (internal spline), Figure 75. 75
Side Gears and Clutch Packs
1. Side Gears
2. Interfacing Drive Plate
3. Internally Splined Driven Friction Plate
4. Inner Thrust Plate

25-42
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
9. Position the differential gears and the thrust
washers in the housing and assemble the shaft.
Slide the shaft into position, aligning the locking
bore with the matching bore in the housing.
Install the shaft-locking pin, Figure 76.
10. Install the crown wheel with the locating dowel in
place. Coat the threads of the retaining bolts with
a suitable locking compound and tighten to a
torque of 230 Nm (170 ft.-lbs.).

76
Installing Differential Gear Shaft Locking Pin

11. Press and completely seat the two side bearings


onto the housing.
12. Place the assembled differential housing into the
support casing. Position the bearing outer tracks,
support casing bearing caps and bearing
adjuster rings, Figure 77. Ensure the correct
positioning of the centering bushings, the crown
wheel, and pinion. The crown wheel must be to
the left of the pinion when viewed from the input
side.
13. Tighten the bearing cap retaining nuts just
enough to support the caps, while adjusting the
adjuster rings to remove all free-play. First
tighten the crown wheel, side-locking ring to 77
move the crown wheel against the pinion, and Installing Differential Housing Side Bearing
then tighten the other adjuster until it becomes Outer Track Adjuster Ring and Cap
difficult to move. Do not force the adjuster. 1. Crown Wheel
2. Centering Bushing
3. Adjuster Ring
4. Bearing
5. Bearing Outer Track
6. Cap

25-43
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
NOTE: Serious damage to the gear set will occur if
the bearing cap retaining nuts are over tightened,
forcing the crown wheel against the pinion.

14. Measure the backlash between the crown wheel


and pinion with a dial indicator. Place the stylus
90_ to the crown wheel teeth, Figure 78.
15. Use the adjuster rings to obtain a desired
backlash of 0.15-0.25 mm (0.006-0.010 in.).
Adjust the rings in equal amounts, moving the
crown wheel to and from the pinion. During this
procedure, gently tap each bearing cap with a
soft mallet, to ensure bearings remain correctly
seated. Repeat procedure in two equally spaced 78
positions around the crown wheel. Measuring Crown Wheel to Pinion Back Lash
16. Adjust the pre-load on the differential side 1. Dial Indicator
bearings using the following method: 2. Crown Wheel
3. Adjuster Ring
• Determine the resistance of the pinion 4. Pry Bars
bearings as described in steps five and six if
not previously done, and record as measure-
ment ‘D’.
• With the crown wheel in mesh with the pinion,
and the correct backlash set, use a string and
pull scale to measure the resistance required
to rotate the pinion and crown wheel/differen-
tial assembly, and record as measurement
‘E’.
• Subtract the original pinion bearing resist-
ance measurement ‘D’ from the new
measurement ‘E’ taken from the pinion and
crown wheel/differential assembly, resist-
ance and record as measurement ‘F’.
Example:
9.1 kgs (20 lb) = ‘D’
12.25 kgs (27 lb) = ‘E’
12.25 kgs – 9.1 kgs = 3.15 kgs (7 lb) = ‘F’

• Tighten each differential side bearing


adjuster in equal amounts (to preserve the
backlash adjustment), until obtaining resist-
ance within the lower band of 2-6 kgs
(4.4-13.2 lb).
17. Tighten the differential assembly bearing adjust-
er locking plate bolts to a torque of 13 Nm (10
ft.-lbs.).
18. Recheck the backlash and install adjuster ring
locking tabs. Tighten the adjuster rings to align
the locking tab with the slot.

25-44
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
19. Recheck the bearing resistance.
20. Install a new drive flange oil seal in the pinion
shaft bore using Installer FTC307971, Figure 79.
Install the spacer O-ring seal and input flange on
the pinion shaft. Lubricate the sealing surface on
the flange with axle oil. Install a new snap ring to
secure the input flange on the shaft.

79
Installing Drive Flange Oil Seal
1. Installer Tool
2. Oil Seal
3. Pinion Shaft Bore
4. Driver Handle

Installation
1. Apply suitable sealant to the differential support
casing and axle casing mating surfaces.
NOTE: Thoroughly clean the differential support
casing and axle casing mating surfaces before
applying sealant.

2. Assemble the differential support casing to the


axle housing and evenly tighten the retaining
bolts to a torque of 169 Nm (125 ft.-lbs.).
3. Assemble the swivel hub and drive shafts to the
axle as described in this chapter.
4. Install the axle on the tractor as described in this
chapter.
5. Fill the axle differential and the wheel hubs with
the correct grade and quantity of oil.

25-45
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1

DRIVE SHAFT - OVERHAUL


Removal
1. Position the tractor on a hard level surface. Apply
the parking brake and chock the wheels.
2. Remove the drive shaft guard.
3. Before disassembling, inspect the universal and
sliding joints for wear. Additionally, inspect the
tubular sections of the drive shaft for buckling or
damage.
4. Remove the drive shaft coupling-to-front axle
drive flange retaining bolts and disconnect the
coupling, Figure 80. 80
5. Slide the shaft off the transfer box, output shaft. Drive Shaft Front Universal Joint
On TB 120 models, remove the central 1. Coupling
support-bearing carrier retaining bolts and then 2. Yoke
slide the shaft off the transfer box output shaft. 3. Spider
4. Greaser

Inspection
1. Thoroughly clean the area around the universal
joints and inspect for wear or damage. The
discovery of worn yokes on both universals may
require replacement of the drive shaft.
2. Thoroughly clean the sliding joint and inspect the
spline for wear and fretting.

Installation
Installation of the drive shaft and guard assembly
follows the removal procedures in reverse, with the
following requirements.

1. Apply a suitable thread-locking compound to the


axle input coupling flange-to-drive shaft retaining
bolts.
2. On TB 120 models, tighten the central support
bearing sleeve set screws.

25-46
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

SECTION 27 - MECHANICAL REAR WHEEL DRIVE

Chapter 1 - Rear Axle

CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rear Axle Shaft Bearing Pre-load Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Differential Bearing Pre-load Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clearances and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Maximum Rear Axle Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Final Reduction Gear Assembly (Planetary Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear Axle Shaft Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Planetary Gear Assembly and Axle Housing – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Differential and Differential Lock Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Differential Lock Control Linkage – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Drive Pinion Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Rear Axle Assembly Final Reduction Drop Trumpet (Drop Box) -- Component Overhaul 28
Manual Adjust Rear Wheels (Where Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

27-1
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

SPECIFICATIONS
REAR AXLE SHAFT BEARING PRE-LOAD SPACERS
Axle shaft rolling torque using a torque wrench at 11.6 - 28.2 N⋅m (8.03 - 20.8 lb-ft)

RESULTANT SPACER TO BE INSTALLED


FIGURE
1.24-1.32 mm (0.049-0.052 in) 1.14 mm (0.045 in)
1.35-1.42 mm (0.053-0.056 in) 1.24 mm (0.049 in)
1.45-1.52 mm (0.057-0.060 in) 1.35 mm (0.053 in)
1.55-1.63 mm (0.061-0.064 in) 1.45 mm (0.057 in)
1.65-1.73 mm (0.065-0.068 in) 1.55 mm (0.061 in)
1.75-1.83 mm (0.069-0.072 in) 1.65 mm (0.065 in)
1.85-1.93 mm (0.073-0.076 in) 1.75 mm (0.069 in)
1.96-2.03 mm (0.077-0.080 in) 1.85 mm (0.073 in)
2.06-2.13 mm (0.081-0.084 in) 1.96 mm (0.077 in)
2.16-2.24 mm (0.085-0.088 in) 2.06 mm (0.081 in)
2.26-2.34 mm (0.089-0.092 in) 2.16 mm (0.085 in)

DIFFERENTIAL BEARING PRE-LOAD SPACERS


Differential bearing rolling torque using a Spring Pull Gauge at 7 - 30 kgf (15 - 67 lbs)

MEASURED SHIM TO BE INSTALLED


GAP
0.61-0.74 mm (0.024-0.029 in) 0.97-1.02 mm (0.038-0.040 in)
0.76-0.87 mm (0.030-0.034 in) 1.12-1.17 mm (0.044-0.046 in)
0.91-1.04 mm (0.036-0.041 in) 1.27-1.32 mm (0.050-0.052 in)
1.07-1.19 mm (0.042-0.047 in) 1.42-1.47 mm (0.056-0.058 in)
1.22-1.35 mm (0.048-0.053 in) 1.58-1.63 mm (0.062-0.064 in)
1.37-1.50 mm (0.054-0.059 in) 1.73-1.78 mm (0.068-0.070 in)
1.52-1.63 mm (0.060-0.064 in) 1.88-1.93 mm (0.074-0.076 in)
1.65-1.78 mm (0.065-0.070 in) 2.03-2.08 mm (0.080-0.082 in)

CLEARANCES AND TOLERANCES


Item
Rear Axle Shaft Rolling Torque 11.6 28.2 Nm
11.6-28.2 8.56 20.8 ft.-lbs.
8.56-20.8 ft. lbs.
End-Float 0.025-0.076 mm 0.001-0.003 in
Drive Pinion Bearing Pre-Load (Pull Scale) 5.9-10.5 kg 13-23.2 lb
Differential Bearing Rolling Torque (Pull Scale) 7.0-30 kg 15-66 lb

27-2
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

TORQUE VALUES
Hardware Nm Ft.-Lbs.
Rear Disc to Hub Nuts (Manual Adjust Wheels) 407-475 Nm 300-350 ft.-lbs.
Rear Disc to Rim Nuts (Manual Adjust Wheels) 310-340 Nm 228-251 ft.-lbs.
Buckle-Up Bolts 240-298 Nm 177-220 ft.-lbs.
Differential Case Retaining Bolts 92-125 Nm 68-92 ft.-lbs.
Drive Pinion Bearing Retainer Bolts 136-170 Nm 100-125 ft.-lbs.
Planetary Gear Retaining Bolt 339-542 Nm 250-400 ft.-lbs.
Axle Shaft Housing Retaining Bolts 176-258 Nm 130-190 ft.-lbs.
Axle Shaft Retaining Bolts 339-542 Nm 250-400 ft.-lbs.
Differential Ring Gear Retaining Nuts 115 Nm 85 ft.-lbs.
Differential Lock Fork Pivot Shaft Retaining Bolts 57-76 Nm 42-56 ft.-lbs.
Differential Lock Hanger Retaining Bolts 57-76 Nm 42-56 ft.-lbs.
Inner Brake Housing Retaining Bolts 88-121 Nm 65-89 ft.-lbs.
Ring Gear Thrust Block 37-50 Nm 27-37 ft.-lbs.
Power Adjust Wheels 712 Nm 525 ft.-lbs.

OIL CAPACITY
Quantity
Liters 56.0
Gallons 14.8

TB120HC capacity for each final reduction -- 4.5L (1.2 gal).

27-3
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

SPECIAL TOOLS
Tool Old Part Number Global Part Number
Wrench, Drop Trumpet Nut FNH00002
Bridge, Pre-load part of Kit FNH02141 FNH01503
Block, Pre-load part of Kit FNH02141 FNH01504 380000226
Spacer, Pre-load part of Kit FNH02141 FNH01505
Gauge, Differential Bearing Pre-Load FNH02141
Remover, Rear Axle Collar FNH02184
Puller, Attachment FNH09190
Puller, Grip-O-Matic FNH09198
Plate, Step (set of 11) FNH09210
Plate, Step (set of 6) FNH09211
Protector, Shaft (set of 6) FNH09212
Puller, (includes legs and pads) FNH09506
Attachment, Bearing Cup Puller FNH09507
Driver, Set FNH09514
Puller, Grip-O-Matic FNH09516
Legs, Puller 16-1/2″ (pr) FNH09521
Attachment, Bearing Puller FNH09526
Hammer, Slide FNH09567
Ring, Slave CT9056

MAXIMUM REAR AXLE LOADING


Model Kg Lb
TB110, 120, 120HC 5443 12,000
TB100 4990 11,000

NOTE: Total rear axle weight measured with rear wheels on the scale inclusive of liquid and cast iron ballast and
with mounted equipment in the raised position.

27-4
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

FAULT FINDING

PROBLEM POSSIBLE CAUSE REMEDY

1. Rear Axle Noisy 1. Lack of oil 1. Top up as required

2. Incorrect oil specification 2. Drain and refill with oil of


correct specification

3. Worn axle bearings 3. Disassemble and inspect


bearings

2. No Drive 1. Axle Shaft Housing 1. Operate the tractor. If the


components defective tractor drives, suspect the
(NOTE: Refer to fault finding axle shaft housing
chart in Section 18 “Clutches”) components and overhaul
2. Differential Unit components 2. Operate the tractor. If the
defective tractor does not drive,
suspect the differential unit
components and overhaul

3. Differential Lock not 1. External linkage damaged or 1. Replace/repair as required


engaging (mechanically broken
engaged)

2. Internal linkage, cross shaft 2. Remove the HPL top cover


rod, fork or pivot shaft and inspect
damaged/broken

3. Damaged or broken teeth on 3. Remove differential and


differential lock adaptor or inspect differential lock
coupling assembly

4. Differential Lock not 1. Spring broken between 1. Remove differential and


disengaging (mechanically adaptor and coupling replace spring
engaged)
2. Teeth of adaptor or coupling 2. Remove differential and
damaged/burred replace damaged parts

27-5
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

DESCRIPTION AND OPERATION • Independent Power Take-Off Components


Engine and gearbox drive transmits to the rear • Transmission Handbrake
wheels via the rear axle assembly, which attaches to
the rear of the front transmission. Housed within the The drive coupling transmits drive from the
rear axle assembly are the following components: transmission output shaft to the spiral bevel pinion.
The pinion meshes with the differential ring gear, and
is located between two preloaded, opposing, tapered
• Main Drive Pinion and Differential Ring Gear
bearings in front of the rear axle housing.
• Differential Assembly
• Differential Lock Assembly Taper roller bearings mounted in the axle shaft
• Rear Wheel Brake Assembly housings, support the ring gear, riveted to the
differential case assembly.
• Final Reduction Gears
• Axle Half Shafts

1
Rear Axle Assembly
1. Outer Brake Housing 13. Planet Gears
2. Axle Housing Outer Bearing 14. Axle Housing Inner Bearing
3. Axle Shaft 15. Sun Gear
4. Axle Shaft Oil Seal 16. Differential Lock Fork
5. Planet Gear Carrier
17. Drive Pinion
6. Axle Housing
18. Drive Pinion Locknut
7. Brake Torque Pin
19. Rear Axle Center Casing
8. Differential Assembly
9. I.P.T.O Drive and Driven Gears 20. Pinion Bearing Retainer
10. I.P.T.O Rear Shaft 21. Differential Ring Gear
11. Differential Lock Assembly 22. Thrust Block
12. Rear Wheel Brake Assembly 23. Inner Brake Housing

27-6
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
NOTE: Replace the rivets with bolts and nuts when
removing the ring gear from the differential case 1 2
assembly.

A thrust block on the heavy-duty axle prevents the


ring gear from flexing due to pre-loading from the
drive pinion.

The casting of the block ensures an adequate


quantity of lubricating oil flows to the drive pinion
bearings.

The axle shaft housings operate with higher oil levels 3


than the center housing. The left-hand axle housing
(1) and the right-hand axle housing (2) both have 2
restrictions (3) to maintain the increased levels, Left and Right Hand Axle Housings
Figures 2 and 3. 1. Right Hand Axle Housing
2. Oil Restrictor
The differential case assembly forms two halves
3. Left Hand Axle Housing
which bolt together to enclose the differential spider
and side gears.
The drive from the pinion transmits via the ring gear
and differential case assembly to the arms of the
spider. Pinion gears mounted on the spider are in
constant mesh with the side gears.

The brake assemblies mount on the spline end of the


intermediate shafts, which spline into the side gears.

The outer end of each intermediate gear forms the


sun gear of an epicyclic final reduction gear set,
mounted within the axle housings.

A reduction gear set transmits drive to the wheels


from the intermediate shaft to the axle shaft.
3
The planetary gear carrier mounts to the inner spline Left Hand Oil Restrictor
of the outer axle shaft. Tapered roller bearings
1. Rear Axle Center Housing
installed in each axle housing support the axle
2. Plastic Plug
shafts.

Hydraulic system oil lubricates the rear axle


components. The partially immersed differential ring
gear assembly splash feeds oil to the bearings and
bushings.

Differential Lock Assembly


The differential lock assembly installed on the
left-hand side of the crown wheel, overcomes tractor
wheel slippage, by connecting one of the side gears
to the differential case assembly. This action locks
the differential assembly together, which provides
direct drive to both wheels.

27-7
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
The differential lock assembly consists of a sliding
coupling (3) connected to the spline of the side gear,
an adapter (2) positioned between the coupling and
left-hand differential case (1), and a spring (4)
positioned between the coupling and adapter. In
addition, there is a fork and lever assembly (not
shown), Figure 4.

The spring ensures engagement of the coupling to


the adapter only when required, and the disengage-
ment of the adapter dog-teeth with the differential
case.

The fork and lever assembly connects to a foot pedal


through spring controlled linkage. Depressing the foot 4
pedal causes the fork to force the coupling dog-teeth
to mesh with the adapter, locking the side gear to the
differential case. There is no requirement to depress
the foot pedal after the differential lock engages.
The mechanically operated differential lock automat-
ically disengages when spring pressure overcomes
the side forces acting on the coupling teeth, which
occurs when there is equal torque to both wheels.

FINAL REDUCTION GEAR ASSEMBLY


(PLANETARY GEAR)
The rear axle housing incorporates an epicyclic
reduction gear assembly to increase the torque
transmitted to the rear wheels. The outer end of the
intermediate shaft acts as a planetary sun gear for
three planet gears installed within a carrier. The
carrier mounts to the spline of the rear axle shaft.
The planet gears mesh with a ring gear mounted in
the axle housing. The revolving intermediate shaft
forces the planet gears to revolve around the inside
of the ring gear, causing the planet gear carrier to
rotate at a reduced speed and transmit increased
torque to the rear axle and wheels.

OPERATIONS OR REPAIRS PERFORMED


WITH THE LEFT-HAND HALF AXLE
REMOVED:
• Differential Fork Overhaul
• Sun Gear Assembly Overhaul
• Half Shaft Assembly Overhaul
• Left-hand Brake Plate Overhaul
OPERATIONS OR REPAIRS PERFORMED
WITH THE RIGHT-HAND HALF AXLE
REMOVED
• Differential Lock Assembly Overhaul
• Sun Gear Assembly Overhaul
• Half Shaft Assembly Overhaul
• Crown Wheel and Pinion Assembly Overhaul
• Right-hand Brake Plate Overhaul

27-8
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

REAR AXLE SHAFT ASSEMBLY – OVERHAUL


Removal 4. Safely raise and support the rear of the tractor.
1. Chock the front wheels to prevent movement. 5. Remove the fenders and roll over protection
Release the hand brake. devices, then remove the rear wheels. Reinstall
2. Drain the oil from the rear axle center casing. nuts onto studs to prevent damage to the stud
threads during overhaul.
3. Disconnect hydraulic lift rods, automatic pick-up
hitch tie rods, hand-brake cables and foot-brake 6. Support the rear of the platform and remove the
linkage. left or right fuel tank, depending on axle removed.

MTG27009

5
Rear Axle Half Shaft Assembly

1. Planetary Reduction Gears and Carrier 6. Sun Gear and Shaft


2. Carrier Retaining Bolt and Lock Tab 7. Axle Shaft
3. Inner Brake Housing 8. Axle Shaft Housing
4. Brake Discs and Actuator 9. Axle Shaft Bearing
5. Outer Brake Housing 10. Shim

7. Support the axle shaft housing on a suitable


trolley jack. Remove the retaining bolts and then
separate the axle housing from the tractor,
Figure 6.

MTG27005

27-9
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
Disassembly
1. Remove the large O-ring located in the inner end
of the axle housing.
NOTE: If removing the right-hand housing, remove
the differential assembly to prevent damage during
axle overhaul, Figure 7.

2. Remove the inner brake retaining bolts.


3. Remove the inner brake housing, brake linkage,
friction disks, and actuating disc assembly, using
the procedures outlined in Section 33 “Brakes”.
MTG27006
4. Lift the intermediate shaft and sun gear out of the
axle, and remove the outer brake housing. 7
5. Remove the axle shaft locking bolt and tab.
NOTE: It may be necessary to heat the locking tab to
melt the sealant applied during production.

27-10
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

WARNING
Do not remove or replace the planetary gear
assembly without the specified tools, or without
positioning the specified tools correctly, as this
may result in personal injury.

6. Remove the planet gear and carrier assembly (2)


from the axle housing using Puller (1) Tool No.
FNH09507, Figure 8. Collect the shim and
washer from underneath the carrier assembly.

8
7. Separate the seal retainer in the outer end of the
axle housing.
8. Remove the axle shaft and inner bearings from
the housing. Use a special fabricated tool for
pressed fit bearings as shown in Figures 9
and 10.
9. Repeat steps for opposite axle housing.

17.0 in
15.5 in

4.0 in

7.75 in
8.5 in
5/ in
8

1.0 in -- 12 UNF

11.0 in

3/ in
4

9
Axle Shaft Removal Tool

27-11
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
Inspection and Repair
1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Inspect all components for damage or excessive
wear, and replace parts as necessary.

10

3. If the axle shaft outer cone and roller assembly


(3) requires removal, use Puller (4) Tool No.
FNH09506, Legs (1) Tool No. FNH09521,
Attachment (2) Tool No. FNH09526, and Shaft
Protector Tool No. FNH09212, Figure 11.
4. Install the shaft seal following the cone and roller
bearing assembly using a suitable sleeve and
press.

11
5. If necessary, use a Slide Hammer Tool No.
FNH09567 (1) to remove the bearing cup (3)
from the outer end of the axle housing (2),
Figure 12. To replace the cup, use a suitable step
plate and a mallet. Ensure to seat cup completely
in the housing.

12
Assembly
Re-assembly of the rear axle shaft assembly follows
the disassembly procedures in reverse with the
following requirements:

1. Assemble the inner brake housing, brake


linkage, friction disks, and actuating disc
assembly, using the procedures outlined in
Section 33 “Brakes”.

27-12
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
Installation
Installation of the axle shaft assembly follows the
removal procedures in reverse with the following
requirements:

1. Apply a suitable wheel bearing grease to the


shaft seal, and the cone and roller assembly
2. Perform the following adjustments before
installing the axle shaft housing completely,
using the procedures described in this chapter.
1. Adjust the axle Shaft Bearing Pre-Load
2. If replacing any of the following components,
perform a Differential Bearing Pre-Load:
• Planetary Ring Gear
• Outer Brake Housing
• Inner Brake Housing
• Rear Axle Center Casing
• Right-Hand Axle Housing
3. Tighten all hardware to the correct torque values
as listed in Section 27 “Specifications”.
4. Refill the rear axle center casing with the correct
type and quantity of oil. Refer to Section 27
“Specifications”.
5. If necessary, adjust the mechanical linkage to the
foot brake and handbrake (where installed).

PLANETARY GEAR ASSEMBLY AND AXLE


HOUSING – OVERHAUL
Removal
1. Remove the axle housing. Refer to Section 27
“Rear Axle Shaft Assembly – Overhaul”.
2. Remove the planetary gear assembly. Refer to
Section 27 “Rear Axle Shaft Assembly –
Overhaul”.
Disassembly
1. Remove the retaining ring securing the planet
gear shafts (1), Figure 13.
2. Place the carrier assembly on a press. Remove
the cone and roller assembly (5), and the planet
gear shafts (3), using a Step Plate (1) Tool No.
FNH09211, and three sockets (2), Attachment
(4) Tool No. FNH09526, Taper Base (6) Tool No.
370 and Slave Ring (7) Tool No. CT9056,
Figure 13.

13

27-13
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
3. Remove the gears (3), thrust washers (2 & 5) and
spacers from the carrier (7). Retain the rollers (4)
located between the planet gear shafts (8) and
the gears for reassembling, Figure 14.
4. Use Slide Hammer Tool No. FNH09567 and
Puller Tool No. FNH09507 to remove the bearing
cup installed in the axle housing.

14
Planet Gear Carrier Assembly
1. Retaining Ring
2. Thrust Washer
3. Planet Gear
4. Rollers
5. Thrust Washers
6. Cone and Roller Assembly
(S Model Only)
7. Carrier
8. Planet Gear Shaft

Inspection and Repair


1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Inspect all components for damage and
excessive wear. Replace all defective parts.
3. If the planetary ring gear (1) requires replace-
ment, perform the following procedure, Fig-
ure 15:
A. Insert Special Tool (2) SW6 behind the ring
gear (1) and adjust the moveable plates to
desired location. Tighten the locknuts (4),
Figure 15. If needed, manufacture a special
plate for use with tool SW6 as shown in
Figure 16.

15

27-14
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
B. Position the axle housing under a hydraulic
press with the ball end of the housing
downward. Insert a bar between the Special
Tool No. SW6 and the press ram. Press the
ring gear out.
C. Install a new ring gear with the bell end of the
axle housing up. Press the ring gear in, until
completely seated and no gap exist between
bottom of the gear and the housing shoulder.

10.0 in

3.0 in 3.0 in

0.5 in
0.5 in 60° 60° 45°

4.0 in 2.5 in

4 x 0.5 in B.S.W. R 5.0 in.

16
Ring Gear Removal Adaptor Plate

27-15
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
Assembly
Assembly of the planetary gear assembly follows the
disassembly procedures in reverse with the following
requirements:

1. Install an equal number of rollers either side of


the spacer within the gear bores.
2. Use grease to hold rollers in position while
installing the shafts (1), through the planet gears
(2). Position the shafts with the flat portion of the
shaft heads away from the center of the carrier,
for proper installation of the retaining ring (3),
Figure 17.
17
Installation
Install the planetary gear and axle housing
assemblies using the procedures described in
Section 27 “Rear Axle Shaft Assembly – Overhaul”
with the following requirement:

1. Tighten all hardware to the correct torque values


as specified in Section 27 “Specifications”.

DIFFERENTIAL AND DIFFERENTIAL LOCK


ASSEMBLY – OVERHAUL
Removal
1. Chock the front wheels to prevent movement.
Release the hand brake.
2. Drain the oil from the rear axle center casing.
3. Disconnect hydraulic lift rods, automatic pick-up
hitch tie rods, hand-brake cables and foot-brake
linkage.
4. Safely raise and support the tractor to
accommodate removal of the right-hand wheel
and axle shaft housing assembly.
5. Remove the fender and roll over protection
devices, then remove the right-hand rear wheel.
Reinstall nuts onto studs to prevent damage to
the stud threads during overhaul.
6. Support the right-hand axle shaft housing on a
suitable trolley jack. Remove the retaining bolts
and then separate the axle housing from the
tractor.
7. Remove the differential assembly.

27-16
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

Disassembly
1. Remove the differential lock ring (9) from the end
of the side gear. Remove the stop washer (10),
coupling (8), spring (11) and adapter (12),
Figure 18.
2. Identify the two halves of the differential case to
facilitate assembling.

18
Differential Assembly
1. Cone and Roller Assembly 9. Retaining Ring
2. Ring Gear and Housing Assembly 10. Washer
3. Side Gear 11. Spring
4. Pinion Gear Assembly 12. Adaptor
5. Side Gear 13. Retaining Bolt
6. Differential Case 14. Thrust Washer
7. Cone and Roller Assembly 15. Thrust Washer
8. Coupling

27-17
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
3. Remove the cone and roller assembly (3) from
the smaller half of case, using Puller (1) Tool No.
FNH09516, Attachment (2) Tool No. FNH09526 1
and Step Plate (4) Tool No. FNH09210 and 4
FNH09211, Figure 19.
4. Remove the differential case retaining bolts (13),
Figure 18.
5. Separate the differential case (6), Figure 18.
6. Remove the thrust washer (14), first side gear 3
(5), spider and pinion assembly (4), second side 2
gear (3) and thrust washer (15), Figure 18.
10024897
7. Remove the cone and roller assembly (1) on the
ring gear half (2), using Puller Tool No. 19
FNH09516, Attachment Tool No. FNH09526 and
Step Plate Tool No. FNH09210, Figure 18.
8. Separate the pinion gears from the spider
assembly.
Inspection and Repair
1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Inspect all parts for damage and excessive wear.
Replace any defective component.
3. If replacing a differential ring gear, drill out the
rivets and replace with bolts and nuts. Tighten
the bolts to a torque of 115 Nm (85 ft.-lbs.).
NOTE: When replacing the ring gear, install a new
matching drive pinion assembly. Refer to section 27
“Drive Pinion Assembly - Overhaul”.

27-18
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

Assembly
Re-assembly of the differential and differential lock
follows the disassembly procedure in reverse with
the following requirements:

1. Coat all bearings with suitable grease before


installing.
2. To correctly install retaining ring (part number
81803542) after installing the pilot bearing on the
pinion shaft, place the ring into the groove, and
use pliers to form the ring in the groove.
3. Tighten the differential case retaining bolts to
torque of 92-125 Nm (68-92 ft.-lbs.).

Installation
Installation of the differential and differential lock
follows the removal procedures in reverse with the
following requirements:

1. Check the differential bearing pre-load. Refer to


Section 27 “Adjustments”.

DIFFERENTIAL LOCK CONTROL LINKAGE


– OVERHAUL
Removal
1. Remove the retaining bolts and the hanger (3)
5
and pedal assembly (5) from the center housing,
4
Figure 20.
2. Remove the control rod (1) and sleeve assembly. 3
3. Remove the control rod oil seal if previously
leaking or damaged.
4. If the operating fork requires replacement,
remove the left-hand axle housing, see Section 2
27 “Rear Axle Shaft Assembly – Overhaul”.
5. Remove the retaining ring and washer. Slide the 1
pivot shaft out of the fork.

20
Differential Lock Linkage

1. Control Rod
2. Bush -- 2 off
3. Hanger
4. Hanger Pivot Pin
5. Foot Pedal

27-19
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
Inspection and Repair
1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Inspect all components for excessive wear and
damage. Replace all defective parts.
3. If the hanger and pedal assembly bushings
require replacement, perform the following
procedure:
A. Remove the pin from the hanger and pedal
assembly.
B. Separate the pedal and the hanger.
C. Use Driver Set Tool No. FNH09514 to
remove and install new bushings.
D. Position hanger with pedal and install pin.

Installation
Installation of the differential lock control linkage
follows the removal procedures in reverse with the
following requirements:

1. Tighten the differential lock fork pivot shaft


retaining bolts to a torque of 57--76 Nm (42--56
ft.-lbs.).
2. Tighten the hanger retaining bolts to a torque of
57--76 Nm (42--56 ft.-lbs.).
3. If removed, ensure to follow all installation
procedures when reinstalling the rear axle
housing assemblies as described in Section 27
“Rear Axle Shaft Assembly – Overhaul”.
4. Refill the rear axle center casing with the correct
grade and quantity of oil.

27-20
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

DRIVE PINION ASSEMBLY – OVERHAUL


Removal
1. Release the handbrake.
2. Separate the tractor between the Front Trans-
mission and the Rear Axle.
3. Remove the PTO clutch assembly, see Section
31 “Power Take-Off”.
4. Remove the transmission handbrake assembly
(where installed). Refer to Section 33 “Braking
System”.
NOTE: If installed, remove the transmission
handbrake shield for the pinion drive gear, before
removing the pinion assembly.

5. Remove the differential and differential lock


assembly. Refer to Section 27 “Differential and
Differential Lock Assembly – Overhaul”.
6. Remove the drive pinion retaining bolts,
washers, and drive pinion assembly (1) from the
housing (3). Two threaded holes are provided in
the pinion bearing retainer (2) for jacking bolts
(4), to facilitate removal, Figure 21.

21

27-21
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
Disassembly Inspection and Repair
With reference to Figure 22: 1. Clean all components in a suitable solvent. Allow
parts to dry.
NOTE: There is either a staked nut or double nut with
a locking tab washer arrangement securing the 2. Inspect all components for excessive wear and
pinion shaft to the bearing retainer. damage. Replace all defective parts.
3. If necessary, remove the bearing cups from the
1. Bend down the lock washer tabs (8), then retainer using Slide Hammer Tool No.
remove locknut (7), lock washer (8), adjusting nut FNH09567 and Puller Tool No. FNH09507. To
(6), spacer (5), hand brake gear (9) where install new bearing cups, use a press and Step
installed, and shims (10). Plate Tool No. FNH09210.
2. Use a soft mallet to knock the front end of the 4. To install the rear bearing on the pinion shaft, use
pinion shaft assembly (2) from the bearing Puller Tool No. FNH09516 and Attachment Tool
retainer (3) and remove the cone and roller No. FNH09190 and a suitable sleeve.
assembly (11).
3. Remove the retaining ring (1) from the pinion
gear (2) and pull the pinion bearing (12) from the
shaft.

12
11 1
10
9

2
8

7 4
6 5 50032156

22
Drive Pinion Assembly

1. Retaining Ring 7. Locknut


2. Pinion Shaft 8. Lock Washer
3. Bearing Retainer 9. Handbrake Gear
4. Cone and Roller Assembly 10. Shims
5. Spacer 11. Cone and Roller Assembly
6. Adjusting Nut 12. Pinion Bearing

27-22
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

Assembly
NOTE: Installation of a new pinion shaft requires the
installation of a new matching differential gear. Refer
to Section 27 “Differential and Differential Lock
Assembly – Overhaul”.

Re-assembly of the drive pinion follows the


disassembly procedures in reverse with the following
requirements:

1. Check the pinion bearing pre-load. Refer to


Section 27 “Adjustments”.

Installation
Installation of the drive pinion assembly follows the
removal procedures in reverse with the following
requirement:

1. Tighten the bearing retainer support bolts to a


torque of 136-170 Nm (100-125 ft.-lbs.).

27-23
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

ADJUSTMENTS
Rear Axle Shaft Bearing Pre-Load
1. Install the axle shaft into the axle shaft housing.
2. Install the inner bearing cone and roller assembly
onto the shaft. Using a suitable sized tube, tap
the bearing onto the shaft. DO NOT completely
seat the bearing into the bearing cone.
3. Install a 2.16 mm (0.085 in) spacer (1), Figure 23,
onto the axle shaft and install the planetary gear
carrier into the housing.
4. Install the carrier retaining bolt and tighten to a
torque of 339-542 Nm (250-400 ft.-lbs.).

23
5. Set a dial indicator (3) as shown in Figure 24.
Zero the gauge and measure the end-float by
lifting the axle casing (1).
6. Subtract the measured end-float from the size of
the spacer installed and record.

24

27-24
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
Table 1:

RESULTANT SPACER TO BE
FIGURE INSTALLED
1.24--1.32 mm 1.14 mm
(0.049--0.052 in) (0.045 in)
1.35--1.42 mm 1.24 mm
(0.053--0.056 in) (0.049 in)
1.45--1.52 mm 1.35 mm
(0.057--0.060 in) (0.053 in)

1.55--1.63 mm 1.45 mm
(0.061--0.064 in) (0.057 in)
1.65--1.73 mm 1.55 mm
(0.065--0.068 in) (0.061 in)
1.75--1.83 mm 1.65 mm
(0.069--0.072 in) (0.065 in)
1.85--1.93 mm 1.75 mm
(0.073--0.076 in) (0.069 in)
1.96--2.03 mm 1.85 mm
(0.077--0.080 in) (0.073 in)
2.06--2.13 mm 1.96 mm
(0.081--0.084 in) (0.077 in)
2.16--2.24 mm 2.06 mm
(0.085--0.088 in) (0.081 in)
2.26--2.34 mm 2.16 mm
(0.089--0.092 in) (0.085 in)

7. Determine the correct size of spacer required by


comparing the recorded measurement with
Table 1.

Example:

Spacer Installed 2.16 mm


Reading Obtained 0.66 mm
Resultant Figure 1.50 mm

Spacer Installed 0.085 in


Reading Obtained 0.026 in
Resultant Figure 0.059 in

Therefore, the required spacer is 1.35 mm (0.053 in).

8. Remove the axle shaft retaining bolt and remove


the planet gear carrier assembly, lock washer
and large 2.16 mm (0.085 in) spacer.
9. Install the new selected spacer, washer and
planet gear carrier assembly. Tighten the
retaining bolt to a torque 339-542 mm (250-400
ft.-lbs.).

27-25
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
10. After shimming is complete, measure the axle
shaft rolling torque. Fabricate a plate (1) to slide
over the wheel studs (3) as shown in Figure 25,
with a bolt head or nut welded in the center. Using
a suitable torque wrench (2), check the rolling
torque to 11.6-28.2 Nm (8.6-20.8 ft.-lbs.). If
necessary, add shims to reduce the rolling torque
or subtract the shims to increase.
11. Repeat steps for opposite rear axle shaft.

25
Differential Bearing Pre-Load
Adjust the bearing pre-load by adding or subtracting
shims between the differential bearing cup, and the
inner brake housing. Make this adjustment to the
bearing in the right-hand axle shaft housing.

1. Install the inner brake disc without the


intermediate shaft, brake discs, and brake
actuator assembly into the axle shaft housing.
2. Remove the differential bearing cup and shim
from the inner brake housing.
3. Place the Gauge Block Tool No. 1504 from Kit
Tool No. 2141 into the vacant bearing location.
26
4. Install the Bridge Tool No. 1503 from Kit Tool No.
2141 across the inner brake housing flange.
Install the Spacer Tool No. 1505 from Kit Tool No.
2141 between the flange and the special tool.
5. Use a feeler gauge to measure the gap between
the underside of the Bridge and the top side of the
Gauge Block, Figure 26.

27-26
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

Table 2:

GAP SHIM TO BE
MEASURED INSTALLED

0.61--0.74 mm 0.97--1.02 mm
(0.024--0.029 in) (0.038--0.040 in)

0.76--0.87 mm 1.12--1.17 mm
(0.030--0.035 in) (0.044--0.046 in)

0.91--1.04 mm 1.27--1.32 mm
(0.036--0.041 in) (0.050--0.052 in)

1.07--1.19 mm 1.42--1.47 mm
(0.042--0.047 in) (0.056--0.058 in)

1.22--1.35 mm 1.58--1.63 mm
(0.048--0.053 in) (0.062--0.064 in)

1.37--1.50 mm 1.73--1.78 mm
(0.054--0.059 in) (0.068--0.070 in)

1.50--1.63 mm 1.88--1.93 mm
(0.060--0.065) (0.074--0.076 in)

1.65--1.78 mm 2.03--2.08 mm
(0.066--0.071) (0.080--0.082 in)

6. From Table 2 determine the initial size of shim to


be used.
7. Remove the Bridge and Gauge Block. Install the
selected shim and bearing.
8. After correctly shimming the bearing, check the
rolling torque of the differential assembly using
the following procedure:
A. Remove the left-hand axle shaft housing if
not already removed.
B. Remove the pinion and bearing retainer
assembly.

27-27
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
C. Remove the differential lock spring, and slide
the differential lock coupling into the engage
position (1), Figure 27.
D. With the differential assembly installed, and the
right-hand inner brake housing flange bolted to
the axle center casing, install the intermediate
shaft into the differential assembly.
E. Wrap a length of string around the
intermediate shaft (2) and attach a Pull Scale
(3). Measure the rolling torque after the shaft
is moving. Do not measure when the shaft
initially begins to turn. Check for a rolling
torque of 7.0-30 kg (15-66 lb) on the Pull
Scale, Figure 27. 27
F. If necessary, add shims to increase the
rolling torque or subtract shims to decrease,
until obtaining the specified torque.
G. Assemble the rear axle shaft assemblies.
Refer to Section 27 130 “Rear Axle Shaft
Assembly – Overhaul”.
Drive Pinion Bearing Pre-Load
The following procedure must be observed when
installing the new washers and locknuts.

1. Install the thrust washer and one locknut on the


pinion shaft.
2. Tighten the locknut to obtain a rolling torque
preload of 12 -- 16 in. lbs. or 16 -- 21 lbs. of pull
on a pull scale.
3. Install the tab washer and second locknut finger
tight.
4. Rotate the shaft several times, then tighten the
second locknut to 80 ft. lbs. while holding the first 28
locknut to prevent it from turning.
5. Recheck drive pinion bearing pre-load and
readjust locknuts if necessary. 1
6. Bend one tab of the tab washer over a flat on the 4
first locknut and the other tab over the second
locknut.

2
3

29
1. Tab Washer 960E--4636
2. Thrust Washer C5NN--4667--B
3. Locknuts (2), 960E--4634
4. Pinion Shaft

27-28
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

REAR AXLE ASSEMBLY FINAL 10. Remove the output shaft inner bearing (33) and
REDUCTION DROP TRUMPET (DROP BOX) spacer (34).
-- COMPONENT OVERHAUL NOTE: Do not let the output shaft gear drop while
removing the shaft from the drop box.
Removal
1. Park the tractor on a hard, level surface. Set the 11. Pull the output shaft (41), outward while grasping
parking brake and chock the front wheels. the output shaft gear (3).

2. Jack the right or left-hand rear axle assembly as 12. Remove the output shaft seal (38).
necessary. 13. Remove the retaining bolts (40) with washers
3. Remove the cover retaining bolt (44) with washer (39) to facilitate removing the bearing retainer
(43) and remove cover. (42). (37). Remove the retainer, bearing (36) and
spacer (35).
4. Remove wheel assembly.
14. Remove the pinion cover retaining bolts (17) and
5. Remove the oil level plug (1C) and washer (1B) washers (16). Remove pinion cover (15).
to facilitate oil drainage.
15. Remove the outer snap ring (14), spacer (13),
6. Remove oil plug (47) and drain drop box oil into inner snap ring (12) and bearing (11).
a suitable container.
16. Remove the pinion shaft assembly (10).
7. Remove the retaining bolts (49) with washers
(48) to the output shaft gear cover (46). Remove 17. Remove the pinion shaft inner bearing (9); snap
cover and gasket (45). ring (8) and seal (7).

8. Remove retaining bolts (29) with washers (30) to 18. Remove the idler shaft retaining bolt (28) with
facilitate removing the output shaft inner cover washer (27), retainer (26) and discard O-ring
(31). Remove cover. (25).

9. Use Wrench Tool No. FNH00002 to remove the 19. Remove the snap ring (22) and pull out the idler
output shaft retaining nut (32). shaft assembly (24), while removing outer
bearing (23), idler gear (21), inner spacer (20),
NOTE: For instructions on manufacturing the special bearing (19) and spacer (18) from inside the drop
Wrench Tool No. FNH00002, see Figure 32. box.

27-29
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

30

27-30
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
Installation
Installation of the final reduction drop box compo- 7. Tighten the idler gear retaining bolt (22) to a
nents follows the removal procedures in reverse with torque of 24 Nm (18 ft.-lbs.).
the following requirements:
8. Tighten the output shaft inner cover bolt (10) to
a torque of 24 Nm (18 ft.-lbs.).
1. Replace output shaft gear cover gasket (5)
before installing cover (2). 9. Tighten the output gear cover retaining bolts (1)
to a torque of 24 Nm (18 ft.-lbs.).
2. Apply a bead of liquid gasket FP--119 to all cover
mating surfaces except the output shaft gear 10. Tighten the pinion drive cover retaining bolt (21)
cover, which contains a solid gasket. to a torque of 24 Nm (18 ft.-lbs.).
3. Replace the O-ring (25), Figure 30, on the idler The oil in the center housing of the rear axle remains
shaft assembly. separate from the final reduction drop trumpet (drop
box) axle.
4. Ensure the pinion inner seal (15), seats correctly
into the drop box to prevent oil leakage from the IMPORTANT: Use oil specification ESN--M2C86--B
rear axle to the drop box. The seal must sit 132 or ESN--M2C159--B when servicing the rear axle
mm (5.1 in) from the mating surface where the final reduction drop trumpet assemblies.
pinion cover rests, inward. See reference (A),
Figure 31.
11. Unscrew the oil level plug (1C), Figure 29. Add oil
5. Tighten the output shaft bearing and seal retainer to the drop box until the level reaches the height
bolts (25) to a torque of 51 Nm (38 ft.-lbs.). of the oil level plug. The drop box assembly
requires 4.5 liters (9.5 pints) of oil. Drain
6. Tighten the output shaft retaining nut (6), using
excessive oil by removing the oil drain plug (47),
Wrench Tool No. FNH00002, to a torque of
Figure 30 and allowing the oil to pour into a
583--733 Nm (430--540 ft.-lbs.).
suitable container.
12. Recheck the oil level and install the oil level plug.

27-31
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

18
16
15 17

20

19

21

22
12 23

24 25
11

10 13 14

9
8

7
27
6

5 26
1

2
4
3

20032151

31

27-32
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

ITEM DESCRIPTION ITEM DESCRIPTION


1 Output Gear Cover M8 x 1.25 x 30 Retaining Bolts 15 Pinion Inner Seal
2 Output Shaft Gear Cover 16 Pinion Inner Bearing and Snap Ring
3 Output Shaft Gear 17 Pinion Shaft Assembly
4 Output Gear Cover Oil Drain Plug 18 Pinion Outer Bearing and Snap Ring
5 Output Shaft Gear Cover Gasket 19 Pinion Shaft Assembly Cover
6 Output Shaft M70 Retaining Nut 20 Pinion Outer Spacer and Snap Ring
7 Output Shaft Assembly Inner Cover 21 Pinion Shaft Cover M8 x 1.25 x 30 Retaining Bolts
8 Output Shaft Assembly 22 Idler Gear M8 x 1.5 x 20 Retaining Bolt
9 Output Shaft Bearing and Spacer 23 Idler Gear O--ring and Retainer
10 Output Shaft Inner Cover M8 x 25 Retaining Bolts 24 Output Shaft Outer Spacer and Bearing
11 Idler Gear Inner Spacers x2 and Bearing 25 Output Shaft Bearing Retainer M10 x 1.5 x 30 Bolts
12 Idler Shaft 26 Output Shaft Bearing Retainer and Outer Seal
13 Idler Gear 27 Output Shaft to Wheel Rim Bolts
14 Idler Gear Outer Retaining Ring and Bearing A 132 mm (5.1 in)

27-33
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
If necessary, fabricate Wrench Tool No. FNH00002.

32

27-34
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

MANUAL ADJUST REAR WHEELS


(WHERE INSTALLED)
WARNING Not
Possible
Your tractor is produced with lights which meet
lighting regulations when operating or traveling
on the public highway. If the wheel track setting
is adjusted beyond the initial factory position,
you may be required to comply with legal
requirements. Additionally, before traveling on 1422 mm
the highway, ensure that the overall tractor width (56 in.)
does not exceed the maximum permitted in your
country.

Rear wheel track adjustment is effected by changing


the wheel rim relative to the center disc, the rim 1524 mm
and/or the disc relative to the axle hub or by (60 in.)
interchanging the rear wheels.

WARNING
Tractor wheels are very heavy. Handle with care
and ensure, when stored, that they cannot topple 1626 mm
and cause injury. (64 in.)

IMPORTANT: When interchanging left and right-


hand wheel assemblies, ensure the ‘V’ of the tire
tread remains pointing in the direction of forward
travel. 1727 mm
(68 in.)
NOTE: With certain options and/or tire sizes, the
smaller track setting may not be attainable due to
minimal clearance between tires and fenders or
equipment.
1829 mm
WARNING (72 in.)
Never operate the tractor with a loose wheel rim
or disc. Always tighten nuts to the specified
torque and at the recommended intervals.

The sectioned drawings shown in Figure 33 illustrate 1930 mm


the wheel rim and disc positions relative to the hub at (76 in.)
various track width settings. Track widths (the
distance between the centers of the tires at ground
level) are nominal and may vary by as much as 13
mm (0.5 in.).
2032 mm
When refitting or adjusting a wheel, tighten the bolts (80 in.)
to the following torques then recheck after driving the
tractor for 200 m (200 yds.), after 1 hour and 8 hours
of operation and thereafter at the 50-hour service
intervals: 33

Disc to hub nuts 407--475 Nám (300--350 ft.-lbs.)


Disc to rim nuts 310--340 Nám (228--251 ft.-lbs.)

27-35
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

TRACK WIDTH (TB120 MUDDER)


Tread Width Adjustment of Front and Rear
Wheels
Front and rear treads are adjustable to 72″, 76″, 80″
and 84″. These adjustment are obtained by mounting
the rims and disc in the combinations shown in the
corresponding chart.

The standard tires provided for this tractor


are13.6--38/12.4--46 on both front and rear.

WARNING
With a front wheel on a four wheel drive tractor
supported on a stand, never attempt to rotate the
wheel or start the engine. This may cause the rear
wheels to move resulting in the tractor falling from
the stand. Wheels should always be supported
with tires just clear of the ground.

NOTE: When interchanging left and right-hand


wheel assemblies, ensure the ’V’ of the tire tread
remains pointing in the direction of forward travel.

WARNING
Never operate the tractor with a loose wheel rim
or disc. Always tighten nuts to the specified
torque and at the recommended intervals.
Ensure that all steering components are
maintained in a reliable and satisfactory
condition to ensure safe operation and comply
with legal requirements.

When installing or adjusting a wheel, tighten the bolts


to the following torques and re-check after driving the
tractor for 200 m (200 yds.), after 1 hour and 8 hours
of operation and thereafter, at the 50-hour service
intervals:

Front wheels torques


Disc to hub nuts 244 -- 298 Nm (180 -- 220 ft.-lbs.)
Disc to rim nuts 310 -- 340 Nm (228 -- 251 ft.-lbs.)

Rear wheels torques


Disc to hub nuts 407 -- 475 Nm (300 -- 350 ft.-lbs.)
Disc to rim nuts 310 -- 340 Nm (228 -- 251 ft.-lbs.)

IMPORTANT: If your tractor is equipped with the


optional front fenders, ensure there is adequate
clearance under all operating conditions. Also, at the
smaller track setting an interference condition may
34
occur between the tire and tractor when the wheels
are turned to the full articulation. To avoid this Axle Adjustment -- TB 120 Mudder
condition it is necessary to adjust the steering stops.

27-36
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

SECTION 31 - POWER TAKE-OFF

Chapter 1 - Power Take-Off System

CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clearances and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Shim Thickness Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PTO Clutch -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PTO Shafts and Gears -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Single Speed Shafts and Gears -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Two-speed Shafts and Gears -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

31-1
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

SPECIFICATIONS
CLEARANCES AND TOLERANCES
Description
Pressure Regulating Valve 11.7--13.8 bar (170--200 psi) at 2100 engine rev/min
9--11 bar (130--160 psi) at 800 engine rev/min
Relief Valve 2.9--3.5 bar (42--50 psi) at 800 engine rev/min
Output Shaft End--Play 0.076--0.127 mm 0.003--0.005 in
Upper Shaft End--Play 0.025--0.737 mm 0.001--0.029 in
Output Shaft Turning Torque 0--7 Nm 0--62 lb--in
Hydraulic Oil Operating Temperature 57--63_ C 134--146_ F

SHIM THICKNESS AVAILABLE


Location
Pressure Regulating Valve 1.20 mm 0.050 in
Relief Valve 1.20 mm 0.050 in
Drive Gear End--Play 0.025 mm 0.001 in
0.076 mm 0.003 in
0.127 mm 0.005 in
0.305 mm 0.012 in
0.508 mm 0.020 in
Output Shaft Bearing 0.051 mm 0.002 in
0.076 mm 0.003 in
0.254 mm 0.010 in
Upper Shaft -- (two shims required) 0.254 mm 0.010 in

TORQUE VALUES
Description
Brake Band Adjuster Screw Initial Torque 1--1.2 Nm 9--11 lb--in
Brake Band Adjuster Screw Final Torque back off adjuster screw 2-1/2 turns
Pressure Regulating Valve Locator Pin (Front) 27--35 Nm 20--25 lb--ft
Pressure Regulating Valve Locator Pin (Rear) -- 21--27 Nm 16--20 lb--ft
Back Off 1/4Turn then Final Torque
Output Shaft Bearing Retainer Bolts 190--230 Nm 140--170 lb--ft
Upper Shaft Rear Bearing Retainer Bolts 65--85 Nm 48--63 lb--ft
Clutch Support Bolts 19--23 Nm 14--17 lb--ft
Shift Fork Bolts 27--34 Nm 20--25 lb--ft
Sump Cover Retaining Bolts 37--50 mm 27--37 lb--ft

31-2
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

SPECIAL TOOLS
Tool Old Part Number Global Part Number
Gauge, Pressure 400 lb FNH00074
Adapter, PTO Clutch Control Valve Test FNH01221A
Compressor, Spring FNH01312
Adapter, Banjo and Bolt FNH04646
Puller, Attachment FNH09190
Puller, Grip--O--Matic FNH09198
Plate, Step (set of 11) FNH09210
Attachment, Bearing Cup Puller FNH09507
Driver, Set FNH09514
Puller, Grip--O--Matic FNH09516
Attachment, Bearing Puller FNH09526
Hammer, Slide FNH09567

31-3
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

1
PTO Schematic (Single Speed Shown)

1. PTO Output Shaft Cap 7. PTO Input Shaft


2. PTO Output Shaft 8. Hydraulic Pump Drive Gear
3. Driven Gear 9. PTO Clutch Assembly
4. Oil Supply Pipe 10. Brake Band
5. PTO Valve Assembly 11. PTO Rear Shaft
6. Hydraulic Pump Idler Gear 12. Drive Gear

DESCRIPTION AND OPERATION The speed of the output shaft is independent of the
The power take-off (PTO) enables the transfer of transmission or tractor ground speed, but directly
engine power directly to mounted or trailed related to the speed of the engine.
equipment through an output shaft at the rear of the
During engagement of the PTO, a hydraulically
tractor.
operated piston clamps the friction and steel drive
The output shaft speed is restricted to 540-rev/min plates together, thereby transmitting drive from the
for equipment designed for use with the 6-spline flywheel to the PTO output shaft. A valve assembly
shaft, and 1000-rev/min for equipment designed for located in the left-hand side of the rear axle housing
the alternate 21-spline shaft. controls hydraulic oil to the clutch piston. The control
valve spool features a hydraulic feathering capability,
The PTO input shaft passes through the transmis- which allows for the smooth engagement of the PTO
sion upper shafts, and attaches to both the engine clutch. A brake band applied by a small hydraulic
flywheel and the PTO clutch hub with spline ends. actuator holds the clutch housing stationary upon
disengagement.

31-4
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
The PTO output shaft will rotate by hand to facilitate
attachment of equipment.
The TB series tractor incorporates one of three types
of PTO systems as follows:
• Single Speed PTO -- Operates the standard
6-spline output shaft, which rotates at 540
rev/min. at 1900 engine rpm.
• Two-Speed PTO (Non shiftable) – Operates
either the 6-spline shaft at 540 rev/min, or the
21-spline shaft at 1000 rev/min. at 2060
engine rpm.
• Two-speed PTO (Shiftable) – Operates the
6-spline output shaft at 540 rev/min at two
separate engine speeds, and the 21-spline
output shaft at 1000 rev/min. at 2060 engine
rpm.

SHG31006

2
Non Shiftable Two Speed PTO Shaft Installation

1. Drive Gear Assembly 8. Sleeve


2. Drive Gear Bearing Shims 9. Thrust Washers
3. Bearing Retainer 10. Sump Cover Plate
4. 540 rev/min Driven Gear 11. Needle Thrust Bearing
5. 1000 rev/min Driven Gear 12. Output Shaft Front Bearing
6. Output Shaft Snap Ring 13. Upper Shaft
7. Output Shaft 14. Snap Ring

31-5
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
Whether or not the tractor is in motion, it is possible
to engage, operate and disengage the PTO system.
The clutch for single speed PTO systems operates
mechanically or electrically.

3
Mechanical Operation
IMPORTANT: Never operate the tractor with the PTO
output shaft removed. The shaft supports the driven
gears and acts as a bearing. Operation without the
shaft installed may cause severe damage.
A selector lever located on the left-hand side of the
driver’s seat provides for mechanical operation of the
PTO clutch, and control valve. Operating the selector
lever moves linkage to the control valve spool to the
‘engage’ or ‘disengage’ position.
Oil Flow – Clutch Disengage
Refer to Figure 4.
With the engine operating, the rear steering pump
supplies hydraulic oil to the inlet port of the PTO
control valve.
The pressure regulating valve housed within the PTO
assembly maintains the oil pressure at 800 rev/min to
9-11 bar (130-160 psi). When engine speed increases
to 2100 rev/min, the oil pressure increases to 11.7-13.8
bar (170-200 psi). In addition, the oil pressure
regulating valve directs lubricating oil to the PTO clutch
and dual power circuits. A relief valve in the lubricating
circuit restricts oil pressure to a maximum of 3.5 bar (50
psi). Refer to Section 35 “Hydraulics” for a detailed
description of the lubricating oil circuit.
Under normal operation, the pressure regulating
valve remains in the closed position.
Moving the selector lever full rearward (disengage
position) mechanically pulls the control valve spool to
the left. The center land area of the spool opens an
orifice, which allows low-pressure circuit oil to flow
past the spool and enter the brake cylinder through
a drilled passage. Oil pressure acting on the brake
piston tightens the brake band, which prevents the
PTO output shaft from turning. A spring ball and
detent lock the spool to the full left side.
When the engine stops running, the pressure
regulating valve closes, and a groove in the land of
the control valve spool allows oil from the brake
piston to return. This action releases the brake.

31-6
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

4
Low Pressure Circuit Oil Lubrication Oil Return to Reservoir Oil

PTO Oil Flow -- Clutch Disengaged (Mechanically Operated PTO Control Valve)

1. Clutch Housing 10. Detent Ball and Spring


2. Sealing Rings 11. Brake Piston
3. Clutch Support 12. Brake Piston Return Spring
4. Orifice 13. Clutch Piston Return Spring
5. Cooler/Lubrication circuit Relief Valve 14. Clutch Hub
6. Pressure Regulating Valve 15. Clutch Plates
7. Transfer Port to Oil Cooler 16. Brake Band
8. Orifice 17. Clutch Piston
9. Control Valve Spool

31-7
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
Oil Flow – Clutch Engaged the spool. Oil pressure builds and acts on the spool,
With reference to Figure 5. forcing the spool to the left and compressing the
spring between the two halves of the spool. As the
The control valve spool consists of two parts spool moves left, oil from the supply orifice is now
connected by a link and spring, which enables blocked. This restriction of oil flow ensures a
feathering of clutch engagement. feathering of clutch engagement in relation to the
movement of the selector lever.
Initial movement of the selector lever to the forward
(engage position) mechanically moves the control With the selector lever full forward (engage position),
valve spool to the right. The center landed area of the a spring ball and detent holds the spool in place at the
spool blocks an orifice that receives oil supplied by full right position. Pressurized oil acting on the clutch
the pump to the brake piston, and opens a return port piston compresses the clutch return spring, and
for the brake and clutch piston oil to exhaust. forces the clutch plates together for clutch
engagement. Due to the locked condition of the
Continued movement of the selector lever forward spool, feathering is no longer possible and clutch
mechanically moves the spool further to the right until engagement receives maximum pressure. The
uncovering the supply oil orifice, allowing oil pressure regulating valve continues to maintain oil
pressure to cross the spool and reach the clutch pressure during clutch engagement.
piston. Oil pressure acting on the clutch piston,
forces the piston against the clutch return spring, In preventing a subsequent shock load to the system,
causing system pressure to increase. the small supply oil orifice restricts the rate of oil flow
to the clutch when rapid movement of the selector
Through a small drilling in the center land area of the lever occurs.
spool, supply oil pressure reaches the right side of

31-8
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

5
Low Pressure Circuit Oil Lubrication Oil Return to Reservoir Oil

PTO Oil Flow -- Clutch Engaged (Mechanically Operated PTO Control Valve)

1. Clutch Housing 10. Detent Ball and Spring


2. Sealing Rings 11. Brake Piston
3. Clutch Support 12. Brake Piston Return Spring
4. Orifice 13. Clutch Piston Return Spring
5. Cooler/Lubrication circuit Relief Valve 14. Clutch Hub
6. Pressure Regulating Valve 15. Clutch Plates
7. Transfer Port to Oil Cooler 16. Brake Band
8. Orifice 17. Clutch Piston
9. Control Valve Spool

31-9
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

PTO CLUTCH – OVERHAUL


Removal 2
1. Remove the hydraulic top cover to expose The
PTO clutch assembly (1) and control valve (2),
Figure 6.

6
2. Remove the PTO rear shaft bearing retainer (1),
and remove the shaft, bearing and drive gear (2),
Figure 7.

7
3. Release the clip securing the intake tube to the
control valve. Remove the tube.
4. Remove the plastic transfer tube from the oil
cooler feed port.
5. Remove the oil cooler tube banjo bolt (1), and the
rear locating pin and locknut (2), and the front
locating pin (3), Figure 8.
6. Slide the clutch and valve assembly rearwards,
and disengage linkage to the control valve spool.

31-10
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
7. Remove the clutch housing (1) and control valve
assembly (2), Figure 9.

9
PTO Clutch and Valve Assembly
1. PTO Clutch Housing
2. Valve Assembly

Disassembly
1. Remove the clutch housing hub (2) and thrust
washer (3) from clutch housing (1), Figure 10.

10
PTO Hub and Clutch Assembly
1. Clutch
2. Hub
3. Thrust Washer

2. Slide clutch from clutch support. Remove snap


ring (4) and disassemble clutch pack from
housing (1). The clutch pack includes the
feathering spring (2), five internal spline friction
plates (3), a pressure plate (5) and five external
spline steel plates (6), Figure 11.
IMPORTANT: Note the order of removal for the
clutch plates.

11
Clutch Housing and Drive Plates
1. Clutch Housing
2. Feathering Spring
3. Internally Splined Friction Plates (5 off)
4. Snap Ring
5. Pressure Plate
6. Externally Splined Steel Plates (5 off)

31-11
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
3. Use Spring Compressor Tool No. FNH01312 and
Puller Tool No. FNH09516, to remove piston (1)
2
and return spring (2), Figure 12.
NOTE: Apply compressed air to the port between the
front and center sealing ring grooves in the clutch
housing hub to expel the piston from the housing if
needed.

4. Remove the O-ring and seal from the piston.

12
Clutch and Valve Assembly
1. Piston
2. Return Spring

5. Disassemble clutch brake band assembly (1),


Figure 13.
1
6. Separate clutch support (2) from valve body (3),
Figure 13.

13
PTO Control Valve and Brake Band
1. Brake Band
2. Clutch Support
3. Valve Body

31-12
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
7. With reference to Figure 14, disassemble clutch
control valve and brake components.

14
PTO Clutch Control Valve and Brake Components

1. Split Pin 8. Guide


2. Spring 9. Plug (chamfer facing spring)
3. Control Valve Spool 10. Snap Ring
4. Control Valve Body 11. Cooler/Lubrication Circuit Relief Valve
5. Brake/Piston 12. Pressure Regulating Valve
6. Return Spring 13. Detent Ball and Spring
7. Snap Ring

31-13
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
Inspection and Repair
1. Clean all components with a suitable solvent.
Allow parts to dry.
2. Inspect the cast iron sealing rings (1) on the
clutch housing, Figure 15. Replace if worn or
damaged.
3. Inspect the clutch housing externally for cracks
or damage, and internally for wear and piston
scuffing.
4. Inspect the clutch piston for scoring or burrs and
install a new O-ring and seal.
5. Inspect the clutch hub spline and gear for wear
and damage.

15
Assembly
Assembly of the power take-off clutch follows the
disassembly procedures in reverse with the following
requirement:

1. Use new O-rings and seals.


2. Install the pressure regulating valve with the “V”
groove land positioned away from the valve
spring.

31-14
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
3. If the brake band requires replacement, soak the
band in rear axle oil for at least 3 minutes before
installation.
4. Adjust the brake band as follows:
• Loosen the locknut (1), Figure 16.
• Screw in adjuster (2) to tighten the band until
reaching a torque of 1-1.2 Nm (9-11 in.-lb.),
Figure 16.
• Loosen adjuster screw by 2-1/2 turns and
tighten locknut.
• To check brake band concentricity after
adjustment, hold the PTO clutch and brake
as shown in Figure 16, with the control valve 16
housing at the 3 o’clock position. The control
valve housing should fall to the 6 o’clock
position under it’s own weight.
• Lightly bend band to shape if required and
repeat adjustment procedure.

Installation
Installation of the power take-off clutch follows the
removal procedures in reverse with the following
requirements:

1. Use the following procedure when tightening the


locating pins and locknuts:
• Install the front pin first and tighten to a torque
of 27-35 Nm (239-310 in.-lb.).
• Install the rear pin and tighten to a torque of
1 Nm (9 in.-lb.). Loosen rear pin by 1/4 turn
and tighten to a torque of 21-27 Nm (186-239
in.-lb.).
• Ensure clutch is free to rotate.

31-15
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

PTO SHAFTS AND GEARS – OVERHAUL


SINGLE SPEED SHAFTS AND GEARS -
OVERHAUL
Removal
1. Drain oil from rear axle/transmission.
2. Remove the split pins and clevis pins. Remove
the hydraulic lift rocker.
3. Unscrew and remove the output shaft cap.
4. Remove retaining bolts and then remove the
upper shaft with the bearing and retainer as an
assembly.
5. Remove the output shaft gear retaining nut
split-pin, retaining nut, and washer.
6. Remove the output shaft retaining bolts, output
shaft, bearing retainer, and shims.
Disassembly
4 1
1. Separate the bearing retainer from the upper
shaft and bearing assembly.
2. Use Puller (1) Tool No. FNH09198 and
Attachment (2) Tool No. FNH09190 to remove
the bearing (4) from the upper shaft (3),
Figure 17.

3
2
10024900

17

31-16
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

4
3

2
10024901

18
3. Remove the drive gear attached to the spline
shaft.
4. Remove the output shaft (1) from the bearing
retainer (2), Figure 18.
5. Remove the bearing cone and roller assembly 1
from the output shaft driven gear (3) & (4), and 4
remove from center housing, Figure 18.
6. Use Puller (1) Tool No. FNH09516 and
Attachment (2) Tool No. FNH09526 to remove
outer bearing cone and roller assembly (4) from
2
3
the output shaft (3), Figure 19.
10024902

Inspection and Repair 19


1. Clean all components with a suitable solvent.
Allow parts to dry.
2. Inspect gears for wear, cracks, and chipped teeth.
3. Inspect bearing assemblies for wear or discolor-
ation due to overheating.
4. Inspect the oil seal and bearing cup in the output
shaft bearing retainer. If necessary, remove the
cup and oil seal using Hammer Tool No.
FNH09567 and Puller Tool No. FNH09507.
Install new oil seal in the retainer before replacing
the bearing cup.
5. Inspect the upper shaft rear bushing in the center
housing for wear and replace if necessary. Use
Bushing Kit Tool No. FNH09514 to extract and
reinstall a new bushing. Liberally coat the new
bushing with oil before installing on the shaft.
6. Inspect the output shaft bearing cup in the center
housing for scouring or excessive wear. If
necessary, replace cup using Puller Tool No.
FNH09507 and Hammer Tool No. FNH09567
with Step Plate Tool No. FNH09210.

31-17
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
Assembly
Assembly of the PTO single speed shaft and gears
follows the disassembly procedures in reverse.

Installation
Installation of the PTO single speed shaft and gears
follows the removal procedures in reverse with the
following requirements:
1. Install the output shaft bearing retainer (3)
without the shims and tighten the four retaining
bolts (2) finger tight. Rotate the shaft (4) by hand 4
to correctly seat the bearings, Figure 20.
Retighten the bolts finger tight.
1
2. Measure the gap between the bearing retainer
(3) and the center housing with a feeler gauge
(1), Figure 20, at various points to ensure the
housing is parallel with the center housing. 2
3. To ensure correct end-play, select a combination
of shims equal in thickness to the measured gap
plus 0.127 mm (0.005 in). Remove the output 3
10024903
shaft bearing retainer and reinstall with shims.
Tighten the retainer bolts to a torque of 190-230 20
Nm (140-170 ft.-lbs.) and check that shaft turns
by hand. Use a dial indicator gauge to check
output shaft end-play to 0.076-0.127 mm
(0.003-0.005 in). After obtaining the correct
end-play, apply a suitable sealing compound to
the four retaining bolts and torque to 190-230 Nm
(140-170 ft.-lbs.).
4. Check output shaft turning torque for a
measurement of 0-7 Nm (0-62 in.-lb.)

31-18
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

TWO-SPEED SHAFTS AND GEARS –


OVERHAUL
Removal
1. Remove the rear axle center housing drain plug
(3), Figure 21, and drain oil into a suitable
container.
2. Remove the output shaft cap and retaining ring.
3. Remove the output shaft.
4. Remove the retaining bolts and output shaft
bearing retainer. 3
10024904

21
5. Remove the upper shaft rear bearing retainer
bolts and retainer (1), Figure 22. 1

10024905

22
6. Remove the PTO drive gear assembly (1),
Figure 23.

23

31-19
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
NOTE: Retain shims located between the drive gear
assembly and the ring on the upper shaft. The front
bearing cup remains in the housing.

7. Remove the sump cover bolts, cover and gasket.

CAUTION
The PTO driven gears will drop to the bottom of
the housing when removing the output shaft
sleeve, bearing, seal and thrust washer.

24

25
Two Speed PTO Upper Shaft Components

1. Bearing Retainer 6. Snap Ring


2. Shims (drive gear end float) 7. Snap Ring
3. Drive Gear Assembly 8. Bearing
4. Shims (rear shaft end float) 9. Bearing
5. Upper Shaft

31-20
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
8. Hold the PTO output shaft driven gears in
position, remove the output shaft sleeve,
bearing, seal, and thrust washer.
9. Remove the two driven gears through the bottom
of the center housing and retain four thrust
washers and the needle thrust bearing.

26
Two Speed Non Shiftable PTO Output Shaft and Driven Gears

1. Output Shaft Retaining Ring 9. Thrust Washer (thin)


2. Output Shaft Cap 10. Thrust Washer (thick)
3. Output Shaft Bearing Retainer 11. Output Shaft Front Bearing
4. Gasket 12. Needle Thrust Bearing
5. Output Shaft Sleeve Oil Seal 13. 1000 rev/min Driven Gear
6. Output Shaft Sleeve 14. Output Shaft Rear Bearing
7. Thrust Washers 15. Snap Ring
8. 540 rev/min Drive Gear 16. PTO Output Shaft

31-21
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
Disassembly
1. Remove the output shaft sleeve oil seal located 1
in the output shaft bearing retainer and the O-ring
seal from the sleeve.
2. Remove the output shaft rear bearing retaining
ring (1), and remove the bearing (2) from the
sleeve (3), Figure 27.
3. Use Puller Tool No. FNH09507 and Hammer
FNH09567 to remove the output shaft front
needle bearing from the housing. 3

10024906
2
27
4. Remove the drive gear bearings (4) from the
drive gear assembly (3) using Puller (1) Tool No. 1
FNH09198, Attachment (2) Tool No. FNH09190
and Step Plate (5) Tool No. FNH09210,
Figure 28. 5
5. Remove the drive gear front bearing cup from the
housing and the rear bearing cup from the
bearing retainer using Puller Tool No. FNH09507 2
and Hammer Tool No. FNH09567. Identify the
shims and spacer, located between the rear
bearing cup and bearing retainer.
3
4
10024907

28
Inspection and Repair
1. Clean all components with a suitable solvent.
Allow parts to dry.
2. Inspect the upper shaft spline for cracks,
excessive wear and distortion.
3. Inspect gears for chipped teeth and wear.
4. Inspect the bearings for wear and discoloration
due to overheating.
5. Inspect the output shaft, sleeve, seal, rear
bearing retainer, thrust needle bearing and thrust
washers for obvious damage or excessive wear.
6. Replace all unserviceable parts.

31-22
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
Assembly NOTE: Do not install the upper shaft at this time.
Assembly follows the disassembly procedures in
reverse with the following requirements: b). Remove the rear bearing retainer from the
housing and remove the cup from the
1. Use sleeves of a suitable diameter, or step plates retainer. Install approximately 2.0 mm (0.080
to install the bearings in the housing. in) of shim thickness behind the rear bearing
cup to create a gap between the retainer and
2. Replace the seal in the output shaft rear bearing center housing.
retainer and the O-ring seal located in the output
shaft sleeve. c). Install the bearing retainer without the O-ring
3. Install the output shaft rear bearing on the sleeve seal with the word ‘TOP’ upwards, and
with retaining ring. tighten the bolts sufficiently enough to seat
bearings.
4. Press on the drive gear assembly bearings onto
the drive gear assembly. d). Measure the gap with a feeler gauge
between the housing and the bearing
retainer at several places, to determine the
Installation
average gap.
Installation of two-speed PTO shafts and gears
follows the removal procedures in reverse with the e). Calculate shim thickness required:
following requirements:
Example:
1. Install a thrust washer between the two driven
gears and the rear driven gear (1000-rev/min) Shim Thickness
and the sleeve.
Installed 2.03 mm (0.080 in.)
2. Install the needle thrust bearing and washers Average Gap 0.36 mm (0.014 in.)
between the front driven gear (540-rev/min) and
(subtract) 1.67 mm (0.066 in.)
the housing.
End-Float 0.10 mm (0.004 in.)
3. Install the rear bearing retainer with the word
(subtract) 1.57 mm (0.062 in.)
‘TOP’ upwards.
4. Perform the following adjustment If replacement Shim Thickness
of the upper shaft, drive gear assembly, drive Required 1.57 mm (0.062 in.)
gear assembly bearings, drive gear rear bearing
retainer or rear axle center housing has f). Install the required shim pack into the
occurred: retainer behind bearing cup. Install a new
O-ring seal.
NOTE: If reassembling all original components, then
install original shims. g). Install the upper shaft with front and rear
retaining rings, but without shims. Reinstall
a). Install the drive gear and bearing assembly the rear bearing retainer with the word ‘TOP’
into the center housing and ensure correct upwards, and tighten the bolts to a torque of
seating of the front bearing. 68 Nm (50 ft.-lbs.).

31-23
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
5. Shim the upper PTO shaft as follows:
a). Push the shaft rearwards until the rear ring
on the shaft contacts the drive gears.

b). Use a feeler gauge (1) to measure the


end-play between the shoulder ring (3) on
the front of the shaft (2) and the rear of the
PTO clutch housing (4), Figure 29.

c). If necessary, add shims to obtain an upper


shaft end-play measurement of 0.025-0.737
mm (0.001-0.029 in). Adding shims requires
the removal of the rear bearing retainer, drive
gear assembly and upper shaft.
29
d). Install the correct amount of shims on the
PTO shaft and reassemble. Recheck upper
shaft end-play, Figure 29.
6. The drive gear assembly should rotate freely by
hand with no radial or axial movement of the
gear. If there is radial or axial movement, recheck
the shimming procedure. If the gear does not
easily rotate, remove the PTO upper shaft and
reinstall the drive gear and bearing retainer, or
check for proper installation of the clutch and
clutch brake. If the gear will not rotate, recheck
the shimming procedure.
7. Install the driven gears using the following
procedure:
a). Insert the 1000-rev/min driven gear through
the opening in the bottom of the housing and
hold rearwards. Support the gear and insert
the 540-rev/min driven gear to engage with
the spigot on the front of the 1000-rev/min
gear.

b). Push both gears forward as an assembly, to


engage the 540-rev/min spigot with the
recess in the front bearing housing. Support
the gears.

c). Install the rear bearing and sleeve.

8. Loosen the PTO valve locating pins to enable the


upper shaft spline to engage with the clutch.
9. Adjust the PTO clutch locating pins and locknut.
10. If experiencing difficulty installing the two-speed
6-spline output shaft, use a screwdriver fitted in
one of the slots to turn the shaft sleeve, and align
the spline in the sleeve with those of the shaft.
11. Check that the turning torque of the PTO shaft
reads 0-7 Nm (0-62 in.-lb.).

31-24
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

SECTION 33 - BRAKING SYSTEM

Chapter 1 - Braking System

CONTENTS

Section Description Page


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disc Brake Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

33-1
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

DESCRIPTION AND OPERATION


The standard braking system consists of two
mechanically operated brake assemblies installed in
the left and right rear axle housings. Brake pedals
transmit input to the brake assemblies via
mechanical linkage. A T-handle and ratchet
assembly locks the pedals for parking and
emergency stopping.

4
8

7
6
3

1 5

20024908

1
TB100, 110 -- Brake Assembly
1. Brake Disc (224 mm) 6. Ball
2. Intermediate Disc 7. Spring
3. Actuating Disc 8. Actuating Links
4. Inner Brake Housing 9. Brake Actuating Rod
5. Outer Brake Housing

Rear Brake Assemblies The left brake pedal connects to the left actuating rod
The brake assembly contains three brake discs for by way of a cross-shaft and lever. The right brake
TB100, 110 (1), and four brake discs for TB120, 120 pedal connects to the right actuating rod via an
high clearance, an internal spline, intermediate discs attachment on the shaft of the right pedal assembly.
(2), and a two-disc actuating assembly (3). In
addition, the brake assembly splits to an inner (4) and When the bake pedals are depressed, rotation of the
outer (5) housing, Figure 1. actuating assembly discs relative to one another
cause the steel balls to ride up the disc ramps, forcing
The actuating assembly discs incorporate ramp the actuating discs apart.
pockets in which steel balls (6) ride during the braking
process. Springs (7) hold the actuating discs Upon moving apart, the actuating discs force the
together, and two links (8) connect the actuating rod brake discs against the brake housing, providing a
(9) to the actuating assembly, Figure 1. braking action on the intermediate shaft.

33-2
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
Foot Brake Assembly
The left and right foot brake pedal assemblies (2),
Figure 2 operate independently, to aid turning the
tractor in confined spaces, or together for normal
stopping. A sliding pin on the underside of the brake
pedal assemblies locks both pedals together.
1
During field operation, the brake pedal assemblies
may be unlocked. Due to the close proximity of the 2
pedals to one another, it is still possible to apply both
brakes together when required.

The left brake pedal incorporates teeth for 10024307


engagement with the parking brake ratchet mecha-
nism. 2

Two springs return the brake pedals to the unapplied


position (upward) when foot pressure is released.

WARNING
Always lock the brake pedal assemblies together
when traveling at transport speeds, or if
operating the tractor with a trailer installed.

Parking Brake
The parking brake consists of a T-handle (1), Figure
2, rod assembly, and a ratchet mechanism located on
the rear hood assembly.

During application of the parking brake, the ratchet


mechanism locks the foot brake pedals in the applied
position. This results after locking the left and right
pedal assemblies together with the sliding pin,
pulling the T-handle and rotating 1/4 turn, and
depressing the foot pedals until the teeth of the
ratchet mechanism engage the pedal assemblies.
Disengaging the T-handle unlocks the foot brake
pedals.

IMPORTANT: Never use the parking brake to stop a


moving tractor, except in an emergency. After such
an event, inspect all transmission and parking brake
components for damage. Ensure to release the
parking brake before moving the vehicle.

33-3
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

DISC BRAKE ASSEMBLY – OVERHAUL Disassembly


1. Remove the split pin and clevis pin and
Removal disconnect the brake control rod from the
Refer to Section 27 “Rear Axle Shaft Assembly – actuating links.
Overhaul”.
2. Remove the bolts retaining the links to the
1. Remove the rear axle housing on the side of the actuating discs.
tractor, which requires maintenance on the disc 3. Unclip and remove four actuating disc retaining
brake assembly as follows: springs, and separate the discs.
-- Chock the front wheels to prevent move- 4. Remove and retain the six steel balls for
ment. Release the hand brake. reassembling.
-- Remove the drain plug and drain oil from the
rear axle center casing into a suitable
Inspection and Repair
container.
1. Clean all components in a suitable solvent. Allow
-- Disconnect hydraulic lift rods, automatic
parts to dry.
pick-up hitch tie rods, hand--brake cables
and foot-brake linkage. 2. Inspect components for wear or damage and
-- Raise and support the rear of the tractor. replace parts as necessary.
-- Remove the fenders and roll over protection
devices, then remove the rear wheels. Assembly
Reinstall nuts onto studs to prevent damage Re-assembly of the disc brake assembly follows the
to the stud threads during overhaul. disassembly procedures in reverse.
-- Support the axle shaft housing on a suitable
trolley jack. Remove the retaining bolts and
then separate the axle housing from the Installation
tractor. Installation of the disc brake assembly follows the
2. Remove the inner brake retaining bolts. removal procedures in reverse.

33-4
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

BRAKE ADJUSTMENT
See Figures 3 and 4.

WARNING
Owners should be aware of local regulations
concerning the braking system. Regularly
maintain the brakes to ensure compliance with
the law and to ensure your safety. If in doubt,
contact your New Holland dealer.

Free play at the brake pedals should be 38 mm (1.5


in.). With the brake pedals locked together, the
tractor should stop in a straight line when the brakes
3
are applied.

Figure 3 - Brake Pedal Adjustment (From the


Right-Hand Side)
1. Locknut
2. Adjusting nut

Adjustment is made on the brake rods, under the


tractor, between the right-hand rear axle and the
hydraulic filter. Jack up the front and rear wheels.
Release the parking brake and make sure the pedals
are not locked together.

Figure 4 - Brake Adjustment Measurement


A. Brake adjustment measurement

Loosen the locknut on the right-hand brake rod and


turn the adjusting nut until the free play on the A
right-hand pedal is 38 mm (1.5 in.). Tighten the locknut.
10024307
1. Check the free play on the pedals by measuring
the distance from the inner part of the support to 4
the platform and record this measurement.
2. Press the pedal firmly with your hand to the point
where it actuates and measure again as
mentioned in Step 1 above.
3. Subtract the value in 2, above, from 1, above,
and the difference should be 38 mm (1.5 in.).

Repeat in the left pedal of the brake.

Repeat on the left-hand brake pull rod.

Lock the brake pedals together and road test to


ensure that brakes are balanced and will stop the
tractor in a straight line. Any further adjustment
necessary to balance the brakes should be carried
out on the right-hand brake.

Block the wheels to stop the tractor from moving and


release the parking brake. Check the parking brake
to see that it works properly after adjusting the
pedals.

33-5
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

33-6
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

SECTION 35 - HYDRAULIC SYSTEM

Chapter 1 - Hydraulic Circuits

CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clearances and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic Component -- General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

35-1
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

SPECIFICATIONS

CONTROL VALVE SIZES

Color mm In.
Orange 15.029-15.034 0.5917-0.5919
Green 15.034-15.039 0.5919-0.5921
Yellow 15.039-15.044 0.5921-0.5923
Blue 15.044-15.052 0.5923-.05926
White 15.052-15.057 0.5926-0.5928

CONTROL VALVE BUSHING SIZES

Color mm In.
Green/White 25.400-25.405 1.0000-1.0002
Orange 25.405-25.410 1.0002-1.0004
Green 25.410-25.415 1.0004-1.0006
Yellow 25.415-25.420 1.0006-1.0008
Blue 25.420-25.425 1.0008-1.0010
White 25.425-25.430 1.0010-1.0012
Blue/White 25.430-25.435 1.0012-1.0014

35-2
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
LIFT CYLINDER RETAINING BOLT SIZES

1 BOLT 76 mm 3.0 in
2 BOLT 64 mm 2.5 in
3 BOLT 57 mm 2.2 in
4 BOLT 76 mm 3.0 in

1
LIFT CYLINDER PISTON SIZES

A 105 mm 4.13 in
B 134 mm 5.28 in
C 3.0 mm 0.12 in
D 40 mm 1.58 in
E 155 mm 6.10 in

THREE-POINT LINKAGE
Maximum lift capacity at maximum hydraulic pressure (link horizontal)

At Link Ends 2880 kg 6350 lbs


24 in. to Rear of Link Ends 2227 kg 4910 lbs

35-3
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

SPECIAL TOOLS

Description Old Part Number Global Part Number


Gauge, Hydraulic Lift Control Valve Setting FNH00014
Tee, Hydraulic FNH00027
Sraight FNH00035
Hose, Hydra-Analyzer FNH00093
Wrench, Coupler Spanner FNH00095
Adapter, part of Kit FNH02003 FNH00705
Fitting, assy from FNH06946 and 0705 FNH00835
Gauge, Hydraulic Lift Control Valve Setting FNH01261
Installer, Hyd Pump Inlet Seat FNH01305
Remover, Hyd Pump Inlet Seat FNH01306
Installer, Needle Bearing FNH01326
Remover, Needle Bearing FNH01327
Fitting, assy from FNH00027 and 0035 FNH01393
Valve, Needle FNH01394
Gauge, Pressure 0-5,000 psi FNH02028
Remover/Installer, Control Valve Bushing FNH02191
Tester, Hydraulic 50 GPM to 5,000 psi FNH02755
Kit, Essential FNH02879
Locator, Lift Cross-shaft Bearing FNH06209
Adapter, Hydraulic Test FNH06211
Fitting, Straight FNH06946
Adapter, Control Valve Bushing Locator FNH10090
Gauge, 0--600 psi part of Kit FNH02990A FNH06653
Puller, Attachment FNH09190
Plate, Step (set of 11) FNH09210
Hammer, Slide FNH09567
Extension FNH08510-1A
Adapter, Guide FT08510-1C
Gauge, Setting FT8527
Adapter 4RT859

DESCRIPTION
Adaptor -- Steering Flow Test (3/4 in x 18UNS female--3/4 in JIC male)
Adaptor -- Steering Pressure Test (11/16 in --16UN to 7/16 in JIC male)
Adaptor -- Trailer Brake Pressure Test (M18 --1.5 male to 7/16 in JIC male)
Adaptor -- Main Pump Flow/Pressure Test (1--14UNS female to 1/4 in BSP female)
Adaptor -- Main Pump Flow/Pressure Test (1/4 in BSP male to 3/4 in JIC male)
Adaptor -- Main Pump PRessure Test (1/4 in BSP male to 7/16 in JIC male)
Adaptor -- Steering Pump Flow Test (13/16 in --16UN female to 3/4 in JIC male)

35-4
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

CLEARANCES AND TOLERANCES

Description
Hydraulic Oil Operating Temperature 57-63_ C 135-146_ F
Hydraulic Oil Maximum Operating Temperature 77_ C 170_ F
High Pressure Circuit Maximum Operating Pressure 183 bar 2650 psi
Detent Regulating Valve Opens 148-162 bar 2150-2350 psi
Steering Motor Relief Valve Opening Pressure 2WD 138-145 bar 2000-2100 psi
with Engine speed at 1200 rpm
Steering Motor Relief Valve Opening Pressure 4WD 166-172 bar 2400-2500 psi
with Engine speed at 1200 rpm
Steering Circuit Maximum Pressure 2WD 145 bar 2100 psi
Steering Circuit Maximum Pressure 4WD 172 bar 2500 psi
Oil Cooler Maximum Leak Detection Pressure 1.7 bar 25 psi
Lubrication Circuit Operating Pressure 5.0-8.5 bar 73-123 psi
with Engine speed at 2100 rpm
Low Pressure Circuit Operating Pressure 15.2-17.9 bar 220-260 psi
with Engine speed at 2100 rpm
Priority Valve (Hydraulic Top Cover) 5-5.9 bar 70-85 psi
Unload Valve (Priority Valve Pack) 4.1-21 bar 60-300 psi
Unload Valve Spring Length (Priority Valve Pack) 4.8 cm 1.9 in
Flow Control Valve Spring Length (Priority Valve Pack) 7.3 cm 2.9 in
Auxiliary Circuit Check Valve Spring Length (Combining 5.5 cm 2.2 in
Valve)
Lift Cylinder Piston Diameter 105 mm 4.13
Lift Cylinder Relief Valve 197-210 bar 2850-3050 psi
Lift Cylinder Safety Valve Opening Pressure 197-203 bar 2850-2950 psi
Hydraulic Lift Control Lever Pull Check 45-71 N 20-30 lb
Lubrication Circuit Relief Valve Operating Pressure 5.0-8.5 bar 73-123 psi
Auxiliary Pump Remote Circuit Relief Valve 186-190 bar 2700-2750 psi
Drop Poppet Valve Opening Pressure .7-.8 bar 10-12 psi
Main Pump Flow Rate (New Pump) 35 litrs/min 9.3 gal/min
minimum of 166 bar (2400 psi) at 2100 Engine rpm
Main Pump Flow Rate (Used Pump) 32 litrs/min 8.4 gal/min
minimum of 166 bar (2400 psi) at 2100 Engine rpm
Main Pump Relief Valve Operating Pressure 176-183 bar 2550-2650 psi
Steering Pump Flow Rate (New Pump) 35 litrs/min 9.3 gal/min
at 2100 Engine rpm
Steering Pump Flow Rate (Used Pump) 31 litrs/min 8.2 gal/min
at 2100 Engine rpm
Engine Mounted Fixed Displacement Auxiliary Pump 30 litrs/min 8 gal/min
(New Pump)
minimum of 166 bar (2400 psi) at 2100 Engine rpm
Engine Mounted Fixed Displacement Auxiliary Pump 23 litrs/min 6 gal/min
(Used Pump)
minimum of 166 bar (2400 psi) at 2100 Engine rpm
Oil Capacity Including Filter 56 liters 15 gal
Oil Capacity Including Filter and Remote Valve 59 liters 15.5 gal/max
With FWD Increase Oil Capacity by 1.2 liters (1.3 quarts)

35-5
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

TORQUE VALUES

Description Nm Ft.-lb./In.-lb.
Hydraulic Lift Pump Drive Gear Nut 50-56 Nm 37-41 ft.-lb.
Hydraulic Lift Pump Front End-Cover Mounting Bolts 50-62 Nm 37-46 ft.-lb.
Transmission Mounted Pump Retaining Bolts 57-76 Nm 42-56 ft.-lb.
Hydraulic Lift Pump Pressure Relief Valve 60-68 Nm 44-50 ft.-lb.
Engine Mounted Pump End-Cover Retaining Bolts 61-68 Nm 45-50 ft.-lb.
Engine Mounted Pump Drive Gear 40-45 Nm 30-33 ft.-lb.
Engine Mounted Pump Retaining Bolts 57-76 Nm 42-56 ft.-lb.
Engine Mounted Pump Inlet Tube Retaining Bolts 15-20 Nm 133-177 in.-lb.
Hydraulic Lift Cylinder-to Lift Cover Retaining Bolts 224-271 Nm 165-200 ft.-lb.
Hydraulic Lift Cylinder Safety Valve 102-122 Nm 75-90 ft.-lb.
Hydraulic Lift Cover Assembly-to-Rear Axle Casing 136-170 Nm 100-125 ft.-lb.
Hydraulic Lift Arm Retaining Nuts 27-41 Nm 240-360 in.-lb.
Hydraulic Lift Filler Plug 50 Nm 37 ft.-lb.
Control Valve Turnbuckle Locknut 14 Nm 124 in.-lb.
Control Valve Front and Rear Plate Retaining Bolts 43 Nm 32 ft.-lb.
Control Rod Turnbuckle Lock Nut 34 Nm 301 in.-lb.
Quadrant Assembly-to-Lift Cover Bolts 68 Nm 50 ft.-lb.
Selector Lever Adjuster Rod Locknut 12 Nm 106 in.-lb.
Lift Lever Adjuster Rod Locknut 12 Nm 106 in.-lb.
Draft Control Nut Set Screw 30 Nm 266 in.-lb.
Position Control Adjusting Screw Locknut 24 Nm 212 in.-lb.
Yoke Retaining Nut Set-Screw 27-34 Nm 240-300 in.-lb.
Priority Valve Pack-to-Lift Cover Retaining Bolts 57-76 Nm 42-56 ft.-lb.
Unload Valve Front Plug 23-48 Nm 204-420 in.-lb.
Flow Control Valve Rear Plug 27 Nm 240 in.-lb.
Detent Shaft Pivot Coupling 7 Nm 60 in.-lb.
Detent Housing Retaining Screws 7 Nm 60 in.-lb.
Priority Check Valve 7 Nm 60 in.-lb.
Remote Coupler Sleeve 81 Nm 60 ft.-lb.
Remote Valve-to-Mounting Bracket 27-35 Nm 240-312 in.-lb.
Remote Valve Centering Spring Retaining Bolt 9 Nm 80 in.-lb.
Remote Valve Housing-to Coupler Bolts 15-20 Nm 133-177 in.-lb.

35-6
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

FAULT FINDING
IMPORTANT: To avoid repeat failures, investigate
and correct the cause of the defect when making
repairs to the hydraulic system.

Problem Probable Cause Correction


Failure to lift implement Pressure relief valve opening too Check relief valve setting
soon
Flow control valve malfunction Check flow setting
Overhaul or replace valve if defective
Control valve malfunction Check for sticking valve or bent spool
Mechanical malfunction Check for seized cross-shaft, bent levers,
and all linkage for smooth operation and
proper lubrication. Replace defective
parts
Lift cylinder malfunction Check for seized piston, worn cylinder, in-
correct safety valve setting or leakage.
Overhaul or replace defective parts
Hydraulic Pump Perform pressure test of pump
Check filter for clogging
Overhaul or replace defective pump
Rear axle oil level incorrect Check and replenish as necessary
Priorityy valve p
pack Check valve pack for leakage
Overhaul or replace defective valve pack
Slow lift or failure to lift under Pressure relief valve opening too Check relief valve setting
load soon
Implement too heavy Lighten load
Blocked oil galleries Remove obstruction
Control valve malfunction Check for sticking valve or bent spool
Hydraulic pump Perform pump pressure test
Check filter for clogging
Overhaul or replace pump
Lift and No drop
p Draft Control malfunction Check main spring adjustment
Control valve stuck in lift position Overhaul or replace control valve
Lift drops
p with control lever in Unload valve sticks Overhaul or replace valve
l
lower or neutrall when
h engine
i Combining valve sticks Overhaul or replace valve
stopped
Control valve sticks Overhaul or replace valve
Implement
p lifts but drops
p with Lift cylinder
y malfunction Check piston seals
controll lever
l in
i neutrall or raise
i Check cylinder for wear or cracking
position
Overhaul or replace cylinder
Safety valve malfunction Check setting of valve

35-7
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

FAULT FINDING (continued)

Problem Probable Cause Correction


Remote valve slow operation Flow control valve incorrect Adjust flow control knob to desired setting
setting
System pressure low Check system components
Detent regulating valve incorrect Adjust detent regulating valve
setting
Remote valve malfunction Pressure check remote valve
Low oil level Replenish oil in rear axle center casing
Initial hesitation when resum- Check valve worn or spring Overhaul or replace check valve
i a remote cycle
ing l Check valve spring distorted Overhaul or replace check valve
Hydraulic
y system
y relief valve Centering spring damaged Replace faulty components
opens at end
d off remote cycle
l Detent regulating valve set too Adjust setting of valve
high
Remote valve spool returns to Detent regulating valve set too low Adjust setting of valve
neutral before cylinder reach-
es end of stroke Remote control valve spool worn Overhaul or replace remote valve

35-8
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

DESCRIPTION AND OPERATION


The hydraulic system provides oil flow at regulated
pressures for the operation and lubrication of various
circuits within the tractor, as well as providing
accurate and sensitive control of implements over a
wide range of operating conditions.

The standard hydraulic system consists of a top link


sensing and three-point linkage system, a single or
tandem (gear type) main pump, an engine mounted
auxiliary pump (optional with the tandem pump
installed), lift cylinder assembly, and optional remote
valve(s). The rear axle center casing functions as the
hydraulic system reservoir.

A lift control valve, and priority valve pack containing


several valves, function together to direct the
hydraulic oil as needed. A pressure regulator, and
various relief-valves and check valves protect the
circuits and components from overload conditions,
encountered during normal and arduous operation,
as well as prevent back-flow of oil.

The hydraulic system includes two major circuits:

• The High Pressure Circuit

• The Low Pressure, Steering and Lubrication


Circuit

35-9
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

High-Pressure Circuit The front pump within the (tandem gear) main pump
Refer to Figure 3. assembly circulates pressurized hydraulic oil to the
priority valve pack. A relief valve installed in the pump
Operating with a maximum pressure of 183 bar
protects the circuit from overload, with an operating
(2650 psi), the high-pressure circuit supplies oil for
pressure of 176-183 bar (2550-2650 psi).
control of the hydraulic lift assembly, remote control
valve(s), and auxiliary equipment (where installed). The oil supply from the auxiliary pump flows to the
priority valve pack via external tubing, while the
With two or more remote valves installed on the
supply from the main pump flows to the priority valve
tractor, it is necessary to supplement the (tandem
pack through internal galleries within the hydraulic
gear) type transmission mounted pump output, with
top cover.
an engine mounted (auxiliary) pump.

3
Hydraulic Circuit for Tractor with Fixed Displacement Tandem Gear Type Pump, Engine Mounted Single
Gear Type Pump, and Top Link Sensing Hydraulic Lift Assembly

1. Position Control Link 13. Exhaust Valve


2. Selector Link 14. Lift Cylinder Safety Valve
3. Draft Control Mainspring 15. Auxiliary Pump Intake Filter
4. Yoke 16. Engine Mounted Auxiliary Hydraulic Pump
5. Selector Rod and Roller Assembly (where installed)
6. Actuating Link 17. Check Valve
7. Pressure Relief Valve (High Pressure) 18. Combining (Sequencing) Valve
8. Steering Pump 19. Flow Control Valve
9. Hydraulic Lift Pump 20. Priority Valve Pack
10. Pump Intake Filter 21. Unload Valve
11. Lift Piston 22. Check Valve
12. Control Valve 23. Lift Arms

35-10
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
Low-Pressure, Steering and Lubrication Circuit The rear pump within the (tandem gear) main pump
The low-pressure hydraulic circuit performs two assembly circulates pressurized hydraulic oil
major functions. To supply pressurized hydraulic oil through tubing to the steering motor, hydraulic PTO
for the operation of the steering system, 4WD clutch, clutch control valve, and to the Dual Power clutch
hydraulic PTO clutch, PTO brake, and Dual Power control valve (where installed) within the transmis-
assembly (where installed). Secondly, to supply sion housing.
lubricating oil to the hydraulic PTO clutch, Dual
Power assembly (where installed) and the transmis- With a (single gear) main pump assembly, the engine
sion. Before entering the transmission, lubricating oil mounted pump supplies pressurized oil to the
passes through an oil cooler mounted in front of the steering system
radiator.
A pressure regulating valve in the hydraulic PTO
Designed with an open center, the low-pressure and clutch assembly controls oil flow to the lubricating
lubrication circuit provides a constant flow of and cooling circuit. In addition, excessive oil in the
hydraulic oil throughout the system for as long as the lubrication circuit discharges to sump through an
engine continues to run. adjacent relief valve. The relief valve protects the
circuit from overloading with a minimum operating
pressure of 5.3 bar (77 psi).

35-11
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

4
Low-Pressure, Steering, and Lubrication Circuit with (tandem gear) Transmission Mounted Pump
(Sheet 1 of 2)

35-12
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

5
Low-Pressure, Steering, and Lubrication Circuit with (tandem gear) Transmission Mounted Pump
(Sheet 2 of 2)

35-13
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
Refer to Figures 4 and 5.

A = High Pressure Oil 183 bar (2650 psi) 1. Transmission Mounted Tandem Gear Pump
B = Steering Pressure 2. Transmission 8 x 2
2WD -- 145 bar (2100 psi) 3. 4WD Clutch
4WD -- 172 bar (2500 psi)
4. Low-Pressure Regulating Valve. See Item C.
C = Low Pressure Oil 15.2 -- 17.9 bar (220 -- 260 psi) 5. Lubrication Relief Valve. See Item D.
D = Lubrication Oil 5.0 -- 8.5 bar (73 -- 123 psi) 6. PTO Control Valve -- Engaged

E = Suction / Return to Sump 7. PTO Clutch Assembly -- Engaged

35-14
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
High-Pressure Hydraulic Circuit Oil Flow With the control valve in the neutral position, the
Refer to Figure 6. following functions occurs:
Refer to Figure 7.
The rear axle center casing functions as a reservoir,
and supplies oil to the hydraulic circuits. Hydraulic oil • The trapped hydraulic oil within the lift cylinder
drawn by the pump assembly enters the pump inlet holds the cylinder in the desired position.
port, and passes through a micron filter assembly.
• Pressurized oil enters the combining valve,
The lift (main) pump discharges pressurized oil located in the priority valve pack on top of the
through the outlet port, where the oil circulates to the hydraulic lift cover. The combining valve either
hydraulic lift assembly control valve. The control returns the oil to the reservoir, or directs it to the
valve directs the hydraulic oil depending upon the remote valve(s), depending on demand.
position of the spool as described in the following:
Hydraulic circuits without remote valves installed, do
not require a combining valve.

6
Hydraulic Circuit for Tractor with Fixed Displacement Tandem Gear Type Pump
and Top Link Sensing Hydraulic Lift Assembly
1. Position Control Link 13. Exhaust Valve
2. Selector Link 14. Lift Cylinder Safety Valve
3. Draft Control Mainspring 15. Auxiliary Pump Intake Filter
4. Yoke 16. Engine Mounted Auxiliary Hydraulic Pump
5. Selector Rod and Roller Assembly
17. Check Valve
6. Actuating Link
18. Combining (Sequencing) Valve
7. Pressure Relief Valve
19. Flow Control Valve
8. Steering Pump
9. Transmission Mounted Hydraulic Pump 20. Priority Valve Pack
10. Pump Intake Filter 21. Unload Valve
11. Lift Piston 22. Check Valve
12. Control Valve 23. Lift Arms

35-15
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
With the control valve in the neutral position, the
following oil flow occurs:
Refer to Figure 7.
• Pump pressure enters the lift cover at Gallery E,
where the control valve prevents the oil from
entering Galleries C & D.

• Pressurized oil flows up Gallery E to the flow


control valve and unload valve.

• The unload valve opens to return at the left side


via Gallery C, and the control valve center.

• Oil pressure applied to the center face of the


spool in the unload valve holds the spool to the
left.

• With the unload valve held to the left, oil in Gallery


D, and in the spring-loaded end of the flow control
valve, returns to sump through Gallery G, by way
of a small internal drilling in the unload valve.

• Oil pressure in Gallery E now acts on the


right-hand face of the flow control valve via an
internal drilling, and moves the valve full left,
which allows the oil to flow from Gallery E to
Gallery F.

• With the remote valve(s) in neutral, the load


sensing, line pressure vents to sump through the
remote valve(s). Pressurized oil in Gallery F acts
on the right-hand side of the combining valve,
and moves the valve to the left, which ports oil
from Gallery F to return through Gallery G.

• The oil in the lift cylinder remains trapped in


Galleries A and B by the control valve land, and
the check valve.

35-16
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

7
Control Valve Oil Flow in Neutral
(Tractors with Fixed Displacement Hydraulic Pump)

Main Pump Auxiliary Exhaust Oil Trapped Oil


Pressure Oil Pump Oil

1. To Remote Valves 5. From Main Pump 10. To Reservoir


2. Combining Valve 6. Control Valve 11. Remote Valve Pilot Line
(Sequencing) Valve 7. Exhaust Valve (Load Sense Line)
3. Unload Valve 8. To Lift Cylinder 12. From Auxiliary Pump
4. Flow Control Valve 9. Check Valve
GALLERY A, To Lift Cylinder and Auxiliary Services GALLERY H, Auxiliary Pump Supply
Valve (where fitted)
GALLERY E, Main Pump Supply GALLERY G, Return to Sump

35-17
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
With the control valve in the lowering position,
the following functions occur:
• Pressurized oil enters the combining valve,
located in the priority valve pack on top of the
hydraulic lift cover. The combining valve either
returns the oil to the reservoir, or directs it to the
remote valve(s), depending on demand.

• Hydraulic oil within the lift cylinder returns to


sump through the control valve and exhaust
valve.

With the control valve in the lowering position,


the following oil flow occurs:
Refer to Figure 8.

• Pump pressure enters the lift cover at Gallery E,


where the control valve prevents the oil from
entering Galleries C and D.

• Pressurized oil flows up Gallery E to the flow


control valve and unload valve.

• The unload valve opens to sump on the left side


via Gallery C, and the control valve center.

• Oil pressure applied to the center face of the


spool forces the spool to the left.

• With the unload valve held to the left, oil in Gallery


D, and in the spring-loaded end of the flow control
valve, returns to sump through Gallery G, by way
of a small internal drilling.

• Oil pressure in Gallery E acts on the right-hand


face of the flow control valve via an internal
drilling, which moves the valve full left, allowing
the oil to flow from Gallery E to Gallery F.

• In both the neutral and lowering positions, a lack


of demand from the remote valve(s) will cause
the combining valve to discharge hydraulic oil
back to sump.

• As the control valve moves to the right from


neutral to the lowering position, lift cylinder oil
flows out of Galleries A and B, through the control
valve, and on to sump through the exhaust valve.

• Excess oil flow from the lift cylinder through the


exhaust valve forces the valve down against the
spring, which reduces the exhaust port aperture.

NOTE: The reduced exhaust port aperture conse-


quently controls the lowering of the lift arms
irrespective of the loading on the lift linkage.

35-18
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

R8--333

8
Control Valve Oil Flow in Lowering Position
(Tractors with Fixed Displacement Hydraulic Pump)

Main Pump Auxiliary Exhaust Oil Trapped Oil


Pressure Oil Pump Oil

1. To Remote Valves 5. From Main Pump 10. To Reservoir


2. Combining Valve 6. Control Valve 11. Remote Valve Pilot Line
(Sequencing) Valve 7. Exhaust Valve (Load Sense Line)
3. Unload Valve 8. To Lift Cylinder 12. From Auxiliary Pump
4. Flow Control Valve 9. Check Valve
GALLERY A, To Lift Cylinder and Auxiliary Services GALLERY H, Auxiliary Pump Supply
Valve (where fitted)
GALLERY E, Main Pump Supply GALLERY G, Return to Sump

35-19
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
With the control valve engaged in the ‘slow’
raising position, the following functions occur:
When raising the hydraulic lift, two conditions occur,
referenced as ‘slow’ and ‘fast’ raises. The number of
open ports in the control valve that direct pressurized
oil to the lift cylinder determines the speed of the lift.

Moving the lift control lever to the point where the


hydraulic lift starts to raise, engages ‘slow’ lift
and the following functions occur:
• Pressurized oil flows to the lift cylinder or
combining valve.

• The position of the control valve determines the


position of the flow control valve, giving priority to
lift cylinder demand, and diverting the surplus oil
to the combining valve.

• The combining valve either returns the surplus oil


to the reservoir, or directs it to the remote
valve(s), depending on demand.

With the control valve engaged in the ‘slow’


raising position, the following oil flow occurs:
Refer to Figure 9.

• The initial movement of the lift control lever shifts


the control valve from the neutral to the ‘slow’
raise position. This allows pressurized oil from
Gallery E to flow to Gallery C through a drilled
passage in the control valve, and the left-hand
end of the unload valve.

• The combination of spring pressure in the unload


valve, and oil pressure in Gallery C, shifts the
unload valve spool full right, connecting Galleries
E and D through a large cross drilling.

• The channel drilled in the unload valve restricts


the hydraulic oil flow to 7.6 litrs/min (2 gal/min),
which induces a smooth initial lift. The reduced
pressure acts on the left-hand face of the flow
control valve spool, and moves it to the right. The
initial oil flow from the flow control valve enters
Galleries A and B through a check valve.

• Further movement of the control valve to the left,


uncovers a series of ports connecting Gallery E
with Gallery D. Oil flow increases into Gallery D,
which speeds up the lift cylinder movement. The
flow control valve moves further to the right,
reducing oil flow from Gallery E to Gallery F.

35-20
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

9
Control Valve Oil Flow in Slow Raising Position
(Tractors with Fixed Displacement Hydraulic Pump)

Main Pump Reduced Pump Auxiliary


Pump Oil Exhaust Oil
Pressure Oil Pressure Oil

1. To Remote Valves 5. From Main Pump 10. To Reservoir


2. Combining Valve 6. Control Valve 11. Remote Valve Pilot Line
(Sequencing) Valve 7. Exhaust Valve (Load Sense Line)
3. Unload Valve 8. To Lift Cylinder 12. From Auxiliary Pump
4. Flow Control Valve 9. Check Valve
GALLERY A, To Lift Cylinder and Auxiliary Services GALLERY H, Auxiliary Pump Supply
Valve (where fitted)
GALLERY E, Main Pump Supply GALLERY G, Return to Sump

35-21
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
With the control valve engaged in the ‘fast’
raising position, the following functions occur:
• The flow control valve gives full priority to the lift
cylinder.

• At this point, operation of the remote valve(s)


would only be possible with an additional
auxiliary engine mounted pump installed.

With the control valve engaged in the ‘fast’


raising position, the following oil flow occurs:
Refer to Figure 10.

• The full rear movement of the lift control lever


shifts the control valve pass the ‘slow’ raise
position to the ‘fast’ raise position. All the ports in
the control valve bushing uncover, allowing
increased pump oil flow from Gallery E to Gallery
D.

• The combination of spring pressure in the unload


valve, and oil pressure in Gallery C, shifts the
unload valve spool full right, connecting Galleries
E and D through a large cross drilling.

• Oil flows from Gallery E to Gallery D with less


restriction and the pressure on both sides of the
flow control valve equalizes. The flow control
vale spring moves the spool to the full right
position, closing off Gallery E from Gallery F.

• All pressurized oil from the pump diverts to the lift


cylinder through Gallery A, giving the lift cylinder
priority over the remote valve(s).

• The size of the ports in the flow control valve


bushing limit the oil flow to the lift cylinder to a
maximum of 31 litrs/min (8 gals/min)

• The completely closed off Gallery F allows the


combining valve to move to the right, preventing
oil flow to sump through Gallery G, unless there
is an auxiliary engine mounted pump installed.

35-22
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

10
Control Valve Oil Flow in Fast Raising Position
(Tractors with Fixed Displacement Hydraulic Pump)

Main Pump Auxiliary Exhaust Oil


Pressure Oil Pump Oil

1. To Remote Valves 5. From Main Pump 10. To Reservoir


2. Combining Valve 6. Control Valve 11. Remote Valve Pilot Line
(Sequencing) Valve 7. Exhaust Valve (Load Sense Line)
3. Unload Valve 8. To Lift Cylinder 12. From Auxiliary Pump
4. Flow Control Valve 9. Check Valve
GALLERY A, To Lift Cylinder and Auxiliary Services GALLERY H, Auxiliary Pump Supply
Valve (where fitted)
GALLERY E, Main Pump Supply GALLERY G, Return to Sump

35-23
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
Fixed Displacement Engine Mounted
(Single Gear) Pump - Oil Flow
Refer to Figure 11.

The optional auxiliary engine mounted pump


supplements pressurized oil to the remote valve(s)
circuit.

• A pilot (load sensing) signal applied to the left end


of the combining valve moves the valve to the
right. This blocks the connections of Gallery F to
G and Gallery H to G progressively, depending
on the hydraulic requirements of the remote
valve(s).

• Pressurized oil from the auxiliary pump enters


the priority valve pack and forces open the
remote valve feed check-valve open to combine
with oil flow from the main pump in Gallery F.

• With the remote valve(s) circuit in neutral, the


load sensing line vents, and pump oil pressure in
Gallery F moves the combining valve to the left,
opening pump oil flow to return through Gallery
G.

• The relief valve within the combining valve vents


oil to return through Gallery G, if pressure
exceeds 186-190 bar (2700-2750 psi) in the load
sensing line, or if there is an overload in the
remote circuit. The change in pressure across
the combining valve moves the spool to the left,
allowing excess oil flow from both pumps in
Galleries F and H to be exhausted to return
through Gallery G.

35-24
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

11
Control Valve Oil Flow in Fast Raising Position
(Tractors with Fixed Displacement Engine Mounted Hydraulic Pump)

Main Pump Auxiliary Exhaust Oil


Pressure Oil Pump Oil

1. To Remote Valves 5. From Main Pump 10. To Reservoir


2. Combining Valve 6. Control Valve 11. Remote Valve Pilot Line
(Sequencing) Valve 7. Exhaust Valve (Load Sense Line)
3. Unload Valve 8. To Lift Cylinder 12. From Auxiliary Pump
4. Flow Control Valve 9. Check Valve
GALLERY A, To Lift Cylinder and Auxiliary Services GALLERY H, Auxiliary Pump Supply
Valve (where fitted)
GALLERY E, Main Pump Supply GALLERY G, Return to Sump

35-25
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
Low Pressure, Steering and Lubrication Circuit
Oil Flow
The rear pump (steering) within the transmission
mounted tandem pump assembly, provides pressur-
ized hydraulic oil to the low-pressure, steering and
lubrication circuit.

• A relief valve incorporated within the steering


motor, controls the maximum oil pressure
supplied to the steering circuit during steering
operation. The relief valve operates at 145 bar
(2100 psi) on 2 wheel drive tractors, and 172 bar
(2500 psi) on all other models.

• The flow of oil leaving the steering motor returns


to the steering pump body, then is redistributed
to the hydraulic PTO clutch control valve
assembly through the rear axle center casing,
and external tubing.

• Oil also flows to the dual power clutch control


valve (where installed) located in the front
transmission housing.

• After full actuation of the dual power clutch


(where installed) and hydraulic PTO clutch,
system pressure rises until the pressure
regulating valve, located within the hydraulic
PTO clutch control valve assembly, opens to
release oil into the lubrication circuit.

• The majority of hydraulic oil in the lubrication


circuit passes through external tubing to an oil
cooler mounted in front of the radiator.

• A proportion of hydraulic oil exhausts through the


hydraulic PTO clutch assembly to lubricate the
clutch plates.

• A relief valve adjacent to the pressure regulating


valve in the hydraulic PTO clutch control valve
assembly protects the lubrication circuit against
excessive pressures, by discharging surplus oil
directly to sump.

• Cooled oil from the oil cooler flows to the front


transmission, and through the dual power
housing (where installed) to the center passages
of the transmission countershaft and output
shafts. Radial drillings in the shafts facilitate
pressure lubrication of the bearings and gears.

• The lubrication oil exhausts to the common front


and rear transmission reservoirs.

35-26
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
Hydraulic System Control
Two distinct systems are incorporated:

• Draft Control

• Position Control

The control system selected depends on the type of


implement in use and the operating conditions.

A position control lever and a draft control lever


operating in a quadrant on the right-hand side of the
operator’s seat, provide control of the hydraulic lift
system.
12
Hydraulic Control Selector Lever
The Draft Control lever (1), Figure 12, operates in a
slotted bracket with formed notches to prevent
accidental movement of the lever. The lever clears
the notches for moving, when eased to the left.

A decal adjacent to the Draft Control lever clearly


identifies the Draft and Position Control settings.

With the Draft Control lever in the forward notch (3),


the hydraulic system operates Draft Control in
maximum sensitivity. This is the most sensitive
setting and variations in soil density cause the
hydraulic system to respond with relatively large
corrections. Moving the Draft Control lever progres-
sively away from the forward most notch, decreases
draft control sensitivity. The rearmost notch (2)
positions the system in Position Control, Figure 12.

IMPORTANT: Always set the draft control lever to the


rearmost notch, when not operating the Draft
Control, such as when attaching equipment,
transporting equipment, or with no equipment
attached.

Hydraulic Lift Control Lever


The hydraulic lift control lever (5), raises or lowers the
three-point linkage and implement to the required
height or working depth. Pushing the lift control lever
forward lowers the implement. Pulling the lift control
lever to the rear raises the implement.

An adjustable stop (4), Figure 12, provides a means


of returning the lift control lever to the selected setting
during use. The stop can be by-passed by easing the
lever to the right until clear.

35-27
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
Principles of Draft Control the top link against the tractor. The draft force will
The Draft Control system manages the working alter according to the depth of work and soil type.
depth of soil engaging implements to maintain an
even pull on the tractor, and to reduce wheel When draft forces increase beyond selection, the
slippage. compressive force on the top link (3) pushes the yoke
(2) further into the hydraulic lift cover, and the
When lowering a soil-engaging implement, e.g. a hydraulic system raises the implement until restoring
plow, into the ground, the draft forces (A) applied to the desired amount of draft. When draft forces
the implement tend to make the plow pivot at the decrease below selection, the compressive force on
point where it attaches to the lower links (B). Without the top link reduces, and the yoke moves out from the
the top link, the plow would tip up (C). Due to the top top cover, and the hydraulic system responds by
link resistance, the plow stays level in the ground. lowering the implement until restoring the desired
This demonstrates compressive force (1) acting on amount of draft.

13
The Principal of Draft Forces Applied Through the Hydraulic Linkage
1. Compression Force A. Draft Forces
2. Draft Control Yoke B. Lower Link Pivot Point
3. Top Link C. Tipping Force

35-28
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
Top Link Sensing and Three-Point Linkage
Draft forces applied to an implement, transmit
mechanically from a rocker (1) and control yoke (2),
to the Draft Control mechanism, via the top link (3) of
the three-point linkage. The hydraulic system
responds by raising or lowering the implement, to
restore and maintain uniform draft loading.

14
Draft Control – Lowering The lowering action stops, when the implement draft
The draft control lever (11) connects to the control compresses the draft control main spring (2) in a
arm (9) by a clevis link. As the control lever moves forward direction enough to cause the main spring
downward, the arm rises and aligns the control rod plunger to move the control link forward. This action
and roller assembly (5). The control rod and roller causes the control rod to pivot the actuating lever
assembly attaches to the far end of the lever arm. about the top attaching point. The actuating lever
The top pivot point of the control link (4) connects to overcomes the rearward pressure of the control
the draft control main spring plunger (1). valve spring and moves the control valve spool
forward into the neutral position.
Downward movement of the lift control lever (10)
moves the actuating lever (14) forward. The actuating
lever pivots about the control rod connector (8) and
allows the control valve spring (7) to move the control
valve spool rearward into the lowering position.

12 13 14 1
11

2
10

3
9

8 7 6 5 4

15
Draft Control -- Lowering into Work (Less Cab)

35-29
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
Draft Control – Raising main spring eases. The control valve spring moves
An increase in draft to the implement transmits the control valve spool rearward, back into the
through the yoke (1) to compress the draft control neutral position.
main spring (2), moving the draft control main spring
plunger (3) in a forward direction. The control rod and A further decrease in draft reduces the draft control
roller assembly (4) connected to the plunger by the main spring compression and the pressure on the
control link (5), pivots about the actuating lever (6). actuating lever. The control valve spring extends and
The actuating lever overcomes the pressure of the moves the control valve spool, rearward into the
control valve spring (7), and moves the control valve lowering position. As the implement runs deeper, the
spool forward, into the raise position. As the draft increases and the control valve spool returns to
implement lifts, the draft forces acting on the yoke the neutral position.
reduce, and the compression of the draft control

6 3

4 5

16

35-30
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
Draft Control – Transport Position During Position control, the control rod and roller
Pulling the draft control lever (9) to the top of the assembly (1) aligns with the lower end of the control
quadrant selects the transport position. The top of link (2). With the control rod and roller in this position,
the actuating lever (4) pivots rearwards about the any variations in draft loading applied to the yoke (3)
control rod connector, which allows the control valve through the top link and three-point linkage system
spring (5) to move the control valve spool forward, will not alter the control rod and roller. Consequently,
into the raise position. the actuating lever (4) and control valve (5) remain
unchanged unless movement of the draft control
To limit the height of the implement, the piston skirt lever (9) occurs.
contacts a stop pin attached to the actuating lever,
when reaching the full raised position. The control Moving of the lift control lever (6) pivots the control
valve spool moves rearward into the neutral position, rod and repositions the control valve spool, to raise
stopping further movement of the lift piston. The stop and lower the implement as required.
pin functions in both Draft and Position control.
As the lift arms move, the position control link (7)
rides the position control cam (8), moving the control
Principles of Position Control rod and actuating lever. With the lift arms in the
The system of Position control enables the working desired position, the actuating lever returns the
depth or height of an implement, relative to the control valve to neutral, which stops further
tractor, to be pre-set and maintained. movement of the lift arms. Therefore, a direct
relationship exists between the height of the lift arms
and the position of the draft control lever.

17
Position Control Linkage Operation
1. Control Rod and Roller Assembly 6. Position Control Lever
2. Selector Link 7. Position Control Link Roller
3. Yoke 8. Position Control Cam
4. Actuating Lever 9. Draft Control Lever
5. Control Valve/Spring Assembly

35-31
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

HYDRAULIC COMPONENT Flow Control Valve


The flow control valve, located in the priority valve
GENERAL DESCRIPTION pack, controls oil flow to the lift control valve, by
sensing pressure variations. The flow control valve
Fixed Displacement Transmission Mounted also diverts surplus oil to the combining valve.
(Tandem Gear) Type Pump
The fixed displacement, transmission mounted
(tandem gear) type pump, located on the right-hand Unload Valve
side of the rear axle center casing, consists of a front The unload valve, located in the priority valve pack,
(lift) pump and a rear (steering) pump. The pump responds to flow control valve movement, and
assembly directs pressurized oil through internal operates in two positions. In the raised position, the
galleries within the hydraulic top cover, to the valve allows oil to flow to the lift cylinder. In the neutral
high-pressure circuit, and through external tubing to or lowering position, the valve directs oil to the
the low-pressure, steering and lubrication circuit. reservoir (rear axle center casing).

The pump receives drive via an idler gear from the


Power Take-off (PTO) clutch hub. See Section 35, Combining Valve
Chapter 2 for more detail. The combining valve regulates the flow of oil to the
remote valve circuit, and combines the flow of oil from
the main and auxiliary pumps as required.
Fixed Displacement Engine Mounted
(Single Gear) Type Pump The combining valve performs the following
The fixed displacement, engine mounted (single functions:
gear) type pump, located on the left-hand side of the
• Directs main hydraulic and auxiliary pump oil flow
engine, functions differently depending on the type of
to remote circuits on demand, and returns oil flow
pump installed on the transmission. On tractors fitted
to sump when no demand exists.
with a (tandem gear) type main pump, the engine
mounted (auxiliary) pump supplies pressurized oil to • Directs oil flow to sump if pump output exceeds
the priority valve pack to supplement the remote remote circuit demand.
valve(s) circuit. On tractors fitted with a (single gear)
type main pump, the engine mounted (steering • Protects the remote circuits and auxiliary pump
pump) supplies pressurized oil to the steering circuit from excessive pressure.
system. A drive gear at the rear of the camshaft
drives the pump. See Section 35, Chapter 2 for more
detail. Hydraulic Lift Control Valve
The hydraulic lift control valve, mounted under the
top lift cover, controls the lift cylinder. The control
Hydraulic Top Cover valve ports pressurized oil to the lift cylinder for ‘slow’
The hydraulic top cover provides a base for mounting or ‘fast’ raising, or directs oil back to sump for the
the priority valve pack, brackets for the hydraulic lift ‘neutral’ and ‘lowering’ positions. The lift control
control lever, draft control lever, and quadrant. In valve receives mechanical input from the lift control
addition, the cover houses the top link sensing and lever through internal linkage.
draft control linkage system, hydraulic lift control
linkage, lifting cylinder and arms, internal galleries,
and covers the hydraulic reservoir (rear axle center Hydraulic Lift Cylinder
casing). The lift cylinder operates the lift arms to raise, lower
and transport an implement. The lift cylinder
assembly consists of a control valve, piston, exhaust
Priority Valve Pack valve, safety valve, drop poppet valve, and a
The priority valve pack, located on top of the restrictor valve.
hydraulic lift cover contains a set of valves, which
establishes pump oil priority, and controls the flow of
oil to the lift cylinder, auxiliary equipment and remote
valves.

35-32
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
Lift Cylinder Exhaust Valve Pressure Relief Valves
The spring-loaded exhaust valve, located in the lift The pressure relief valve, located in the main pump,
cylinder, restricts the flow of exhaust oil from the lift limits maximum pressure in the high-pressure
cylinder, thereby maintaining the rate of drop for hydraulic system, and prevents pump overload.
controlled lowering.
A pressure relief valve located in the combining valve
protects the remote circuits and auxiliary pump.
Lift Cylinder Safety Valve
The spring-loaded lift cylinder safety valve, located in A relief valve installed in the steering motor protects
the lift cylinder wall, protects the lift cylinder circuit the steering circuit from excessive pressure.
from overloading, such as, when transporting
implements over rough ground. The safety valve
requires no servicing. Hydraulic Oil Filters
A full flow micron filter assembly screws on the
transmission mounted main pump housing.
Priority Valves
A smaller micron filter screws onto the auxiliary
Installed in the lines between each individual remote
engine mounted pump.
valve, priority valves enable the remote valve with
the highest operating pressure complete control of oil
flow from the pump.
Pressure Regulating Valve
The pressure regulating valve housed within the
Power Take-Off (PTO) assembly maintains low-pres-
Check Valves
sure circuit oil at 15.2-17.9 bar (220-260 psi). The
The priority valve pack contains two check valves:
valve controls oil pressure acting on the hydraulic
A check valve, installed in the auxiliary pump, supply PTO clutch piston during clutch engagement, and the
port, prevents back feed from the main pump to the clutch brake, and supplies the lubrication and cooling
auxiliary pump. circuit with oil. When the engine stops running, the
pressure regulating valve closes.
A second check valve, installed in the base of the
priority valve pack, prevents oil flow from the lift
cylinder to the flow control valve, during lift cylinder
lowering, neutral, or shock loading conditions.

Other check valves, installed in the lines between two


or more remote valves, prevent oil back flow between
the valves.

A double-spool remote valve contains a check valve


within the valve housing.

35-33
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

35-34
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

SECTION 35 - HYDRAULIC SYSTEM

Chapter 2 - Hydraulic Pumps

CONTENTS

Section Description Page


Fixed Displacement Transmission Mounted (Tandem Gear) Type Pump . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fixed Displacement Engine Mounted (Single Gear) Type Pump . . . . . . . . . . . . . . . . . . . . . . 11
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

35-1
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

FIXED DISPLACEMENT TRANSMISSION MOUNTED (TANDEM GEAR) TYPE PUMP

DESCRIPTION AND OPERATION hub via an idler gear (7). The lift pump supplies oil to
The fixed displacement (tandem gear) type pump the high-pressure circuit, to operate the hydraulic lift
mounts on the right-hand side of the rear axle center and remote control valve(s).
casing. The pump housing contains two separate
The rear pump (3), with narrower gears, referred to
gear type pumps:
as the steering pump, provides oil to the
The front pump (5), referred to as the hydraulic lift low-pressure, steering, and lubrication circuits.
pump, receives drive from the hydraulic PTO clutch

1
Cross Section of Transmission Mounted Fixed Displacement Gear Type Pump
1. Outlet Port to Hydraulic Lift 6. Hydraulic Lift Pump Outlet Port
2. Steering Pump Drive Gear 7. Pump Assembly Drive Gear (idler gear)
3. Steering Pump Driven Gear 8. Hydraulic Lift Pump Drive Gear
4. Outlet Port to PTO 9. Drive Link
5. Hydraulic Lift Pump Driven Gear 10. Pump Inlet Port (Both Pumps)

35-2
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2
Both pumps share a common full flow, intake filter
mounted on the pump.

The hydraulic PTO clutch hub transmits drive to the


hydraulic lift pump via an idler gear, and a drive link
(1) transmits drive from the lift pump to the steering
pump, Figure 2.

The gears in both pumps continuously revolve at the


same speed as long as the engine runs. Aluminum
bearing blocks incorporating steel bushings provide
support for the gears.

35-3
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2
Oil Flow
The fixed displacement (tandem gear) type pump
assembly receives oil from the rear axle center
casing reservoir through an intake tube attached to
the pump inlet port.
When the engine runs, the hydraulic PTO idler gear
drives the pump and draws oil through the inlet port
and intake filter into the spaces between the gear
teeth in each pumping unit (B). As the gears rotate
(1), trapped oil between the gear teeth and pump
body flows to the pump outlet ports and discharges
into the hydraulic circuits (A).

A relief valve operating at 176-183 bar (2550-2650


psi) protects the lift pump from excessive pressure.
The valve allows excess oil to return directly to sump
whenever an overload condition occurs. There is no
requirement to remove the pump from the tractor to
replace the relief valve. However, it is not an
adjustable valve, and will require removal if not within
specifications.

Low-pressure oil expelled from the pump mounting


face flows through the wall of the rear axle center
casing, and through tubing to the hydraulic PTO 3
clutch control valve assembly. From the hydraulic
PTO control valve, oil flows to the oil cooler, before
providing pressure lubrication to the transmission
and dual power clutches (where installed).

A relief valve within the steering motor provides


protection for the steering system.

OVERHAUL

Removal
1. Drain oil from the rear axle center casing.
2. Disconnect brake pedal return springs.
3. Remove the right-hand platform.
4. Disconnect the brake actuating rods from the
levers. Refer to Section 33 “Braking Systems”.
5. Disconnect the Dual Power pressure feed tube
(16x4 transmissions) from the hydraulic pump.
6. Remove the brake pedal linkage. Refer to
Section 33 “Braking Systems”.
7. Disconnect all hydraulic connections at the
pump. Cap and plug all exposed openings to
prevent contamination.
8. Remove the pump retaining bolts and remove
the pump.

35-4
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2
Disassembly
NOTE: When disassembling the pump, lay compo-
nents out in the order of removal to facilitate
re-assembly.

Refer to Figure 4.

1. Remove the pressure relief valve with O-rings


and back-up ring from the pump. The relief valve
is not adjustable and therefore requires
replacement if not operating within specifica-
tions.
2. Remove the transfer tube and O-ring.
3. Unfold tabs and remove the input drive gear nut
(3) and locking washer (4) at the front (lift) pump.
Then remove the input drive gear (2) and key (5)
from the drive link (1). 6
NOTE: Use a soft mallet to loosen the drive gear from
the tapered drive shaft if necessary.

4. Remove the six end-cover retaining bolts and


washers (6), Figure 4.
5
3 4

4
5. Ease the cover (1) forward to clear the locating
dowels (3) and then tilt the cover to clear transfer
tube (2). Lift cover off pump, Figure 5.

35-5
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2
6. At the front pump, remove the drive shaft and
driven gear (16) as an assembly, and collect the
bearing blocks (3), (14). Identify components to
facilitate assembly, Figure 6.
7. Observe the positioning of the seals (12), (13), to
facilitate re-assembly, Figure 6.

CAUTION
An internal snap ring secures the drive shaft to
the driven gear assembly. Damage to the snap
ring or drive shaft is likely to occur if
disassembly is attempted.

6
Hydraulic Lift Pump (Front Pump) -- Exploded View

1. Pump Housing 9. Locking Washer


2. Steering Pump 10. Drive Gear
3. Bearing Block 11. Oil Seal
4. Driven Gear 12. Nylon Back--Up Ring
5. Transfer Tube 13. Seal
6. End Cover 14. Bearing Block
7. Bolts (4 Long, 2 Short) 15. Woodruff Key
8. Nut 16. Drive Shaft and Gear Assembly

35-6
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2
8. Remove the rear (steering) pump assembly (1),
Figure 7, from the pump housing.
9. Remove the gears and bearing blocks.
10. Remove the sandwich plate (7), Figure 7.
11. Identify the positioning of all components
including the nylon back-up rings and seals to
facilitate re-assembly.

7
Steering Pump (Rear Pump) -- Exploded View

1. Pump Body 9. Nylon Back--Up Ring


2. Seal 10. Pump Housing
3. Nylon Backing Strip 11. Seal
4. Bearing Block 12. Nylon Backing Strip
5. Driven Gear 13. Bearing Block
6. Seal 14. Transfer Tube and Snap Ring
7. Sandwich Plate 15. Drive Gear
8. Seal

35-7
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2
Inspection and Repair
1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Inspect bushings and bearing blocks for wear or
damage. Check for blocked lubrication scrolls in
the bushings. Replace the gears and bearing
blocks as a matched set if required. DO NOT
service separately.
3. Inspect pump gears for wear or damage,
particularly the bearing journals, gear teeth and
side facings.
4. To ensure maximum pump efficiency, the width of
each pair of pump gears must be within 0.005
mm (0.0002 in) of one another, and the journals
within 0.013 mm (0.0005 in).
5. Remove light scoring marks on the gear facing
areas using a sheet of ‘O’ grade wet or dry
abrasive paper and lubrication on a true flat
surface. Polish the area repaired using light
pressure in a rotating motion. Polished journals
will achieve free movement in the body.
6. Inspect the gear track, embedded during the
manufacturing process for the gear teeth, on the
suction side of the pump. The track depth must
not exceed 0.10 mm (0.004 in), or continue
beyond the suction half of the gear aperture.
Replace the pump when gear tracks do not fall
within specification.
7. Burrs found at the edge of the gear track should
be removed with ‘O’ grade emery paper.
8. Inspect the pump cover for damage or cracks,
particularly adjacent to the inlet and outlet ports,
filter connection and pump face. Check internal
passages for blockage.
9. Any component found unserviceable should
necessitate replacing the pump assembly. If in an
emergency, worn components are replaced
individually, note the following points:
• The installation of new bearings will re-center
the gears and prevent the tips of the gear
teeth from bottoming, if continuing to use a
pump body where the track is out of
specifications. Thereby resulting in pump
inefficiency.
• Under working conditions, hydraulic pres-
sure within the pump loads the gears towards
the inlet side of the pump body. Continued
use of worn bearing and gear journals
causes the gears to shift, thus deepening the
gear track in the pump body.

35-8
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2
Assembly
Assembly of the fixed displacement transmission
mounted (tandem gear) type pump follows the
removal procedures in reverse with the following
requirements:

1. When replacing the pump dowels, install new


dowels with 2.54 mm (0.10 in) protruding from
the pump housing.
2. Replace all O-rings and seals.
3. Install washers (1) and (5) and O-ring seals (2)
and (4) on the transfer tube (3), Figure 8.
4. Coat all seals and O-rings with petroleum jelly.
5. Lubricate all parts with clean hydraulic oil.
6. Assemble original gears with original bearings
exactly as removed. This step is critical in
maintaining pump efficiency.

8
7. The bearing block (4) in the steering pump body
(2), contains a radius edge (4). Install the radius
edge’ at the bottom of the steering pump body
bore (3), Figure 9.
NOTE: Only one of the two bearing blocks installed
in the steering pump contains a corner radius edge.
Installation of the sharp edged radius block in this
position will prevent correct assembly and cause
damage to the pump.

8. Pack the cavity behind the lips of the front-end


cover input drive shaft seal with high melting
point grease.
9
Bearing Block Installation
1. Relieved Edge
2. Steering Pump Body
3. Radiused Edge
4. Radiused Edge

35-9
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2
9. The end-cover bolts have different lengths.
Ensure to install the correct bolts in the locations
exactly as removed, Figure 10, and tighten to a
torque of 50-62 Nm (37-46 ft.-lb.).
10. Install the pressure relief valve and tighten to a
torque of 60-68 Nm (44-50 ft.-lb.).
11. Install the input drive gear nut and tighten to a
torque of 50-56 Nm (37-41 ft.-lb.). Bend the
washer locking-tab against the pump drive, gear
nut.
12. Keep all ports and lines capped and plugged until
installation of hydraulic connections to prevent
entry of foreign objects and contaminants. 10
End Cover Bolt Location
A. Bolt M10 x 100 mm with Ground Shank
B. Bolt M10 x 100 mm with Dull Black Shank
C. Bolt M10 x 115 mm with Ground Shank
D. Bolt M10 x 115 mm with Dull Black Shank

Installation
The installation of the transmission mounted fixed
displacement (tandem gear) type pump follows the
removal procedures in reverse with the following
requirements.

1. To prevent internal and external leakage, and


improve pump efficiency, perform the following
when installing new O-rings and seals:
• Lubricate with clean hydraulic fluid

• Do not allow connections to pinch, or O-rings


to roll and twist when installing.

• Ensure proper positioning.

• Completely seat into grooves.

2. Before installing, fill pump suction port with clean


hydraulic oil and hand rotate the gears.
3. Tighten the pump-to-transmission retaining bolts
to a torque of 57-76 Nm (42-56 ft.-lb.).
4. Tighten all hydraulic connections and fittings.
5. Replenish the rear axle center casing oil. Refer
to Section 27 “Mechanical Rear Wheel Drive”.
6. Perform a pressure test of the pump. Refer to
Section 35, Chapter 5 “Adjustments and
Testing”.
7. Operate the brake pedals after assembling, and
check for binding and proper operation. Refer to
Section 33 “Braking System”.

35-10
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

FIXED DISPLACEMENT ENGINE MOUNTED (SINGLE GEAR) TYPE PUMP


DESCRIPTION AND OPERATION
The fixed displacement, engine mounted (single gear)
type pump, located on the left-hand side of the engine,
functions differently depending on the type of pump
installed on the transmission. On tractors fitted with a
(tandem gear) type main pump, the engine mounted
(auxiliary) pump supplies pressurized oil to the priority
valve pack to supplement the remote valve(s) circuit.
On tractors fitted with a (single gear) type main pump,
the engine mounted (steering pump) supplies
pressurized oil to the steering system. A drive gear at
the rear of the camshaft drives the pump.
The pump contains one set of spur type gears
supported by aluminum bearings and steel bushings.
The gears constantly rotate as the engine runs.

A replaceable micron filter screwed onto a threaded


adapter in the pump cover cleans the oil before
entering the pump.

Oil Flow
On entering the pump (B), hydraulic oil fills the spaces
between the teeth of the revolving gears (1). As the
gears continue to rotate, oil trapped between the gear
teeth and pump body flows to the pump outlet port (A)
and discharges into the auxiliary or steering circuit,
Figure 11.

The fixed displacement engine mounted pump


contains a screw-on type filter bowl. After passing
through the filter element and up the center of the 11
membrane, the oil moves rearward, exiting near
upper section.

35-11
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

OVERHAUL

Removal
1. Thoroughly clean the pump area before removal.
2. Disconnect the hydraulic connections from the
pump. Cap and plug all openings to prevent
contamination.
3. Disconnect the engine crankcase breather
assembly tube and clamp (where installed) from
the pump housing
4. Remove the pump retaining bolts, lock washers,
and then lift the pump from the engine.

12 13
7 11
10
8 9
6
1
2 4
3 5

14
15

20026042

12

35-12
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2
Disassembly
Refer to Figure 12.

1. Mark the external gear housing (7), pump body


(12) and cover (not shown) to facilitate relocating
parts upon installation exactly as removed,
Figure 12.
2. Unscrew and remove the micron filter assembly
from the pump base (13).
3. Remove the retaining ring (1) and large dished
plug (2) from the external gear housing (7).
4. Release the lock washer (4) and remove the
locknut (3), key (5) and external gear (6). Tap the
end of the drive gear shaft to release the drive
gear from the tapered shaft if necessary.
NOTE: Ensure not to damage the threads on the end
of the pump drive shaft, and do not allow the shaft key
to damage the shaft seal.

5. Remove the pump cover retaining bolts (14).


NOTE: If necessary, remove the hydraulic fittings
installed in the pump body to facilitate removal of the
pump cover retaining bolts.

6. Use a soft mallet to separate the external drive


gear housing (7), pump body (12), and pump
base (13).
7. Remove the driven gear (10), drive shaft (15),
bearing block (9), bearing block (11) and seals.
Identify orientation of the components to
facilitate re--assembling.
8. Remove the retaining clip (2) from the end of the
idler gear shaft and remove it from the housing
(3), Figure 13. 2
9. Remove the plug from the end of the idler gear
shaft by giving the housing a sharp tap on a
wooden block.
NOTE: Compressed air administered to the bleed
hole located on the pump--to--engine mounting face
will facilitate removal of the plug.
3
10. Remove the idler gear shaft, idler gear and two 1
washers. 20026043

13

35-13
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2
Inspection and Repair
1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Inspect bearing block and bushing for wear and
damage. Check for blocked lubrication scrolls in
the bushings. If necessary, replace block
together with gears and do not service
separately.
3. Inspect pump gears for wear or damage. In
particular, inspect the bearing journals, gear
teeth and side facings.
20026044

14

35-14
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2
4. To ensure maximum pump efficiency, the width of
each pair of pump gears must be within 0.005 A A
mm (0.0002 in) of one another (B), and the
journals within 0.013 mm (0.0005 in) (A),
Figure 15.
5. Remove light scoring marks on the bearing face
area using a sheet of ‘O’ grade emery paper
lubricated with paraffin on a true flat surface. B
Polish the area repaired using light pressure in a
rotating motion. Polished journals will achieve
free movement in the body.
6. Inspect the pump body for a light track cut by the 20026045
gear teeth on the suction side of the pump body.
Using an internal micrometer measure the body 15
at the bearing location, and at the track position
to determine depth. The track should not exceed
0.10 mm (0.004 in) depth, or continue beyond the
suction half of the gear aperture. Replace the
pump when gear tracks do not fall within
specification
7. Burrs found at the edge of the gear track should
be removed with ‘O’ grade emery paper.
8. Inspect the pump cover for damage or cracks,
particularly adjacent to the inlet and outlet ports,
filter connection and pump face. Check internal
passages for blockage.
9. Inspect the external gear and housing for wear,
damage, cracks, and the idler gear for free
rotation on the shaft.
10. Any component found unserviceable should
necessitate replacing the pump assembly. If in an
emergency, worn components are replaced
individually, note the following points:
11. The installation of new bearings will re-center the
gears and prevent the tips of the gear teeth from
bottoming, if continuing to use a pump body
where the track is out of specifications. Thereby
resulting in pump inefficiency.
12. Under working conditions, hydraulic pressure
within the pump loads the gears towards the inlet
side of the pump body. Continued use of worn
bearing and gear journals causes the gears to
shift, thus deepening the gear track in the pump
body.

35-15
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2
Assembly Installation
Assembly of the fixed displacement engine mounted Installation of the fixed displacement engine
(single gear) pump follows the disassembly mounted (single gear) type pump follows the removal
procedures in reverse with the following require- procedures in reverse with the following require-
ments: ments:

1. Replace all seals and O-rings. 1. Before installing, fill pump suction port with clean
hydraulic oil and hand rotate the gears.
2. Coat all seals with petroleum jelly, and ensure
correct positioning. 2. Insert a new O-ring on the pump.
3. Lubricate all parts with recommended hydraulic 3. Tighten the pump-to-engine retaining bolts to a
oil. torque of 57-76 Nm (42-56 ft.-lb.)
4. Assemble original gears with original bearings 4. Tighten the inlet tube retaining bolts to a torque
exactly as removed. This step is critical to of 15-20 Nm (133-177 in.-lb.).
maintain pump efficiency.
5. Tighten the outlet tube retaining screws to a
5. Install the bearing block with the recess against torque of 7-10 Nm (62-89 in.-lb.)
the gear faces, and the relieved radius edge
6. Install the engine crankcase breather assembly
toward the pump outlet.
tube, and clamp (where installed) on the pump
6. Assemble the bearings with the ‘Y’-shaped housing.
recesses adjacent to the gear faces and the
7. Check the pump pressure output. Refer to
relieved radii facing the outlet side of the body.
Section 35, Chapter 5 “Adjustments and
7. Pack the cavity behind the lips of the front-end Testing”.
cover input drive shaft seal with high melting
point grease.
8. Install the idler gear shaft plug with the slotted
face towards the shaft.
9. Install the pump end-cover retaining bolts and
tighten to a torque of 61-68 Nm (45-50 ft.-lb.).
10. Install the external drive gear with locking tab,
washer and nut. Tighten nut to a torque of 40-45
Nm (30-33 ft.-lb.). Ensure to bend the washer
locking-tab against the external drive gear nut.
11. Keep all ports and lines capped and plugged until
installation, to prevent entry of foreign objects
and contaminants.

35-16
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

SECTION 35 - HYDRAULIC SYSTEM

Chapter 3 - Remote Control Circuit

CONTENTS

Section Description Page


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Remote Valve Circuit Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remote Control Valve -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Remote Control Valve Coupler -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

35-1
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

DESCRIPTION AND OPERATION


A remote valve circuit Installed on the tractor consists
of a remote control valve(s), remote valve supply 1
line, load sensing line, auxiliary pump supply line (if
necessary), a remote valve return line, and a priority
valve pack (1), Figure 1.

The hydraulic lift cylinder receives priority over the


remote valve(s) for oil supply, with surplus oil directed
through the combining valve in the priority valve pack
to the remote valve(s).

A circuit with two or more remote valves requires a 20031393


check valve installed at the ‘T’ fitting in the pilot (load
sensing) line for each valve. 1

The rate of flow through the remote valve, controlled


by a restrictor, varies the speed of operation for
attached implements.

The remote valve couplers remain spring-loaded to


the closed position when disconnected from auxiliary
equipment.

35-2
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Figure 2 shows the principle components of the
double spool, remote valve assembly, which will
assist in identifying the parts detailed in the oil flow
description that follows.

A single-spool remote valve contains the same


individual components as a double spool less the
second spool.

REMOTE VALVE CIRCUIT OIL FLOW

Neutral Position
Refer to Figure 3.

• A centering spring holds the control valve spool


in neutral with the center land blocking pump
supply Gallery B.

• The control valve spool also isolates Galleries G


and H from pump supply Gallery B, and oil return
Galleries E and F. This traps the hydraulic oil in
both ends of the lift cylinder.

• Galleries C and D connect with the return oil


Galleries E and F, allowing pressure in the load
sensing lines to return to sump.

• The combining valve moves to the left,


compressing the spring, and diverts oil flow from
the pumps, back to the reservoir through the
priority valve pack.

35-3
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

24

25

26
28 27

2
Double Spool Remote Control Valve

1. Valve Body 15. Detent Regulating Valve Spring


2. Spool 16. Spacer
3. Flow Restrictor 17. Detent Regulating Valve
4. Load Check Valve 18. Detent Housing
5. Flow Restrictor End Plug 19. Shuttle Check Valve
6. Flow Restrictor Control Shaft 20. Flow Control Spring
7. Flow Restrictor Control Knob 21. Flow Control Spool
8. Detent Plunger 22. Priority Check Valve Ball (double spool only)
9. Spool Centering Spring 23. Priority Check Valve Retainer
10. Locknut 24. Spiral Retaining Clip
11. Detent Piston Spring 25. Seals
12. Detent Piston 26. Detent Cap Retaining Ring
13. Detent Valve Spring Adjuster 27. End Cap
14. Detent Balls 28. Seals

35-4
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

3
Single Remote Control Valve Operation--Neutral

Pump Pressure Oil Exhaust Oil Trapped Oil

1. Flow Control Restrictor 9. Centering Spring 17. Return to Sump*


2. Load Check Valve 10. External Cylinder 18. Auxiliary Pump Supply*
3. Check Valve Spring 11. Valve Body 19. Hydraulic Priority Valve Assembly*
4. Flow Control Knob 12. Control Valve Spool 20. Supply to Remote Valve
5. Detent Regulating Valve 13. Shuttle Check Valve 21. Combining (Sequencing) Valve*
6. Detent Spool 14. Load Sense Line (Pilot Line) 22. Main Pump Supply via Combining
7. Detent Plunger and Spring 15. Flow Control Spring Valve*
8. Detent Balls 16. Flow Control Spool
* Tractors with Fixed Displacement Hydraulic Pump Only

35-5
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Raise Position
Refer to Figure 4.

• With the remote control valve lever in the raise


position, the control valve spool moves forward
and the spring-loaded detent balls engage the
rear grooves in the detent plunger.

• Pump supply Gallery B connects to Galleries G


and D while Galleries H and C connect to return
through Gallery E.

• When initially moving the remote control valve


lever, the pressure in Gallery D equalizes with the
cylinder pressure, or the hydraulic back-pres-
sure, whichever is greater.

• The pressurized oil in Gallery D flows to the


shuttle check valve and through an internal
drilling to the detent regulating valve, flow control
valve spool, and the pilot line (load sensing).

• The pilot line (load sensing) pressure from


Gallery D acts on the end of the combining valve
spool, moving the spool to the right. The return
Gallery in the priority valve pack closes and the
main hydraulic and auxiliary pump pressure oil
flows to the remote control valve inlet port A.

• Pump pressurized oil flows from Gallery A to


Gallery B through the flow control valve spool,
flow control restrictor, and the load check valve.

• The flow control restrictor setting (manually


pre-set with the flow control knob) determines the
volume of oil entering Gallery B and flowing to
Gallery G.

• Exhaust oil from the cylinder Gallery H returns to


the reservoir through Gallery E.

• When the cylinder fully extends, pump supply


pressure increases until the detent regulating
valve opens. Pump pressurized oil moves the
detent spool against the detent spring and
releases the clamping effort on the detent balls at
the end of the control valve spool. The centering
spring now moves the spool back to the neutral
position.

35-6
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

4
Single Remote Control Valve Operation--Raising

Pump Pressure Oil Exhaust Oil

1. Flow Control Restrictor 9. Centering Spring 17. Return to Sump


2. Load Check Valve 10. External Cylinder 18. Auxiliary Pump Supply
3. Check Valve Spring 11. Valve Body 19. Hydraulic Priority Valve
4. Flow Control Knob 12. Control Valve Spool Assembly
5. Detent Regulating Valve 13. Shuttle Check Valve 20. Supply to Remote Valve
6. Detent Spool 14. Load Sense Line (Pilot Line) 21. Combining (Sequencing) Valve
7. Detent Plunger and Spring 15. Flow Control Spring 22. Main Pump Supply via
8. Detent Balls 16. Flow Control Spool Combining Valve

35-7
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Lowering Position
Refer to Figure 5.

• Moving the remote control valve lever to the


lowering position forces the control valve spool
rearwards, allowing the spring loaded detent
balls to engage the front groove in the detent
plunger.

• Gallery B connects to Galleries H and C, and


Gallery G connects to Galleries D and F. This
action reverses the connection to-and-from the
cylinder. Pressurized oil retracts the remote
cylinder in the same manner as described in the
raising sequence.

• The shuttle check valve enables the pilot line to


sense pressure in Gallery C, and directs the flow
of oil to operate the detent regulating valve and
flow control valve spool.

• The flow control restrictor rotates, reducing the


slotted area in which oil flows into Gallery B and
to the control valve and, restricting oil flow to
Gallery B. The degree of restriction, causes
supply pressure to increase compared to pilot
line pressure.

• Pressure from the pump supply line, acts on the


right hand end of the combining valve, and the
spool moves against the spring, diverting surplus
oil to sump.

35-8
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

5
Single Remote Control Valve Operation--Lowering with Slow Flow Control Setting

Pump Pressure Oil Reduced Oil Flow Exhaust Oil

1. Flow Control Restrictor 9. Centering Spring 17. Return to Sump


2. Load Check Valve 10. External Cylinder 18. Auxiliary Pump Supply
3. Check Valve Spring 11. Valve Body 19. Hydraulic Priority Valve
4. Flow Control Knob 12. Control Valve Spool Assembly
5. Detent Regulating Valve 13. Shuttle Check Valve 20. Supply to Remote Valve
6. Detent Spool 14. Load Sense Line (Pilot Line) 21. Combining (Sequencing) Valve
7. Detent Plunger and Spring 15. Flow Control Spring 22. Main Pump Supply via
8. Detent Balls 16. Flow Control Spool Combining Valve

35-9
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Cylinder Overload
Refer to Figure 6.

Under normal operating conditions, a detent


regulating-valve protects the remote circuit from
excessive pressure, by returning the control valve
spool to neutral when high pressure arises, or the
cylinder reaches the end of the stroke. If the operator
overrides the detent, protection of the circuit occurs
through the following:

• Excessive cylinder pressure in the pilot line from


Gallery H opens the integral combining valve
relief valve, reducing the pressure acting on the
left-hand end of the valve.

• The combining valve spool moves left and directs


oil flow from the pumps to return, limiting
maximum remote pressure to 192 bar (2750 psi).

35-10
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

6
Single Remote Control Valve Operation--External Cylinder Overload

Pump Pressure Oil Reduced Oil Flow Exhaust Oil

1. Flow Control Restrictor 9. Centering Spring 17. Return to Sump


2. Load Check Valve 10. External Cylinder 18. Auxiliary Pump Supply
3. Check Valve Spring 11. Valve Body 19. Hydraulic Priority Valve
4. Flow Control Knob 12. Control Valve Spool Assembly
5. Detent Regulating Valve 13. Shuttle Check Valve 20. Supply to Remote Valve
6. Detent Spool 14. Load Sense Line (Pilot Line) 21. Combining (Sequencing) Valve
7. Detent Plunger and Spring 15. Flow Control Spring 22. Main Pump Supply via
8. Detent Balls 16. Flow Control Spool Combining Valve

35-11
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Double Remote Valve Oil Flow
Refer to Figure 7.

• Operation of two or more remote valves


simultaneously, is possible irrespective of
cylinder load.

• When two spools operate a light load and heavy


load circuit simultaneously, the oil flowing from
the control valve attempts to flow to the light load
circuit The flow control spool maintains pre-set
flow to the light load circuit.

• The shuttle ball in the load sense line pushes


firmly toward the low pressure circuit, isolating
the line from the remote valve operating under
the lighter load condition.

• Hydraulic oil from pump supply Gallery B flows to


the left side of the flow control valve spool
through the shuttle check valve. Oil flows through
radial holes in the spool at Gallery A to Gallery B.

• When pressure differs greatly between two


operating remote circuits, an excessive amount
of oil flows from the pump supply Gallery B
through the flow control valve, via the restrictor,
to the remote circuit operating at the lower
pressure. This additional flow results in in-
creased pressure generated on the right-hand
end of the flow control spool.

• The flow control spool moves to the left and


compresses the spring, progressively covering
the radial holes in the spool. This restricts oil from
Gallery A to the load check valve, and eliminates
excessive oil flow to the light load circuit, while
maintaining supply line pressure from the heavy
load circuit.

35-12
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

7
Double Remote Control Valve Operation
Pump Controlled Reduced Exhaust Oil
Pressure Oil Oil Flow Oil Flow

1. Flow Control Restrictor 9. Centering Spring 17. Return to Sump


2. Load Check Valve 10. External Cylinder 18. Auxiliary Pump Supply
3. Check Valve Spring 11. Valve Body 19. Hydraulic Priority Valve
4. Flow Control Knob 12. Control Valve Spool Assembly
5. Detent Regulating Valve 13. Shuttle Check Valve 20. Supply to Remote Valve
6. Detent Spool 14. Load Sense Line (Pilot Line) 21. Combining (Sequencing) Valve
7. Detent Plunger and Spring 15. Flow Control Spring 22. Main Pump Supply via
8. Detent Balls 16. Flow Control Spool Combining Valve

35-13
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Oil Flow in Float
Refer to Figure 8.

• The float position allows operation of single


acting cylinders when lowering under light load
conditions.

• With the remote control lever full forward to the


‘float’ position, the control valve spool moves
rearward past the lowering position to allow
engagement of the detent balls with the float
detent plunger groove.

• The control valve spool requires manual


movement to neutral by the operator, as the
shuttle check valve generates no pressure to
release the detent mechanism.

• Galleries E, F, G and H connect to return,


allowing the cylinder to ‘float’ and assume any
position.

• Galleries C and D also connect to Galleries E and


F, allowing only low back pressure on either side
of the shuttle check valve. There is no pressure
in the pilot line, and the pump output returns to
the reservoir through the combining valve.

35-14
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

8
Single Remote Control Valve Operation--Float

Pump Pressure Oil Exhaust Oil Trapped Oil

1. Flow Control Restrictor 9. Centering Spring 17. Return to Sump


2. Load Check Valve 10. External Cylinder 18. Auxiliary Pump Supply
3. Check Valve Spring 11. Valve Body 19. Hydraulic Priority Valve
4. Flow Control Knob 12. Control Valve Spool Assembly
5. Detent Regulating Valve 13. Shuttle Check Valve 20. Supply to Remote Valve
6. Detent Spool 14. Load Sense Line (Pilot Line) 21. Combining (Sequencing) Valve
7. Detent Plunger and Spring 15. Flow Control Spring 22. Main Pump Supply via
8. Detent Balls 16. Flow Control Spool Combining Valve

35-15
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Remote Valve Coupler Oil Flow
Refer to Figure 9.

• The couplers remain spring-loaded to the closed


position when disconnected from auxiliary
equipment.

• With equipment connected and the remote valve


pressurized, oil forces the hose connection
check valve off the seat, while the spring-loaded
probe remains in contact with the face of the
check valve.

• Pressurized oil forces the locking sleeve within


the coupler rearward, applying the locking balls
against the end of the probe, preventing the
probe from moving rearward.

• The probe locks in the forward position, which


holds the connector check valve fully open, even
under low-pressure conditions.

35-16
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

9
Remote Valve Coupler Operation

A Coupler Disconnected (Not Pressurized) 1. Coupler Assembly


B Coupler Connected (Pressurized) 2. Auxiliary Equipment Hose Connector
3. Hose Connector Check Valve
4. Probe
5. Locking Sleeve
6. Locking Balls

35-17
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Remote Valve Control Levers
Two levers operate the remote control valves at the 1
rear of the tractor. Located at the right-hand side of
the operator’s seat, the outer lever (1) controls the
outer valve, and the inner lever (2) controls the inner
valve within the remote housing, Figure 10.

The remote control valve levers operate in four 2


positions:

• Pull lever back from the neutral position to extend


the cylinder.
20031387
• Push the lever forward past neutral to retract the
cylinder. 10
• Push the lever full forward past the retract
position to select the float position.

• Align lever with the symbol on the decal for


neutral.

Symbols on a decal affixed adjacent to the control


levers, identify the extend, neutral, retract and float
positions

In the float position, the cylinder extends and retracts


freely, allowing implements to follow the ground
contour. In addition,

A detent-regulating valve locks the remote control


lever in either the extended or retracted position, and
allows the control lever to spring to the neutral
position when the cylinder reaches the end of the
stroke. Manual positioning of the control lever to
neutral is possible. In the ‘float’ position, the lever will
not return to neutral automatically.

35-18
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Remote Valves
Each remote control valve incorporates a flow control
valve and a pair of couplers. The couplers lock and
are self-sealing, but will allow the remote cylinder
hoses to pull free, if the implement becomes
disconnected.

An ‘extended cylinder’ symbol molded into the rubber


dust cap identifies the upper (lift) coupler (2),
Figure 11.

A ‘retracted cylinder’ symbol identifies the lower


(drop) coupler (3), Figure 11.

11

Remote Cylinders NOTE: When topping off the rear axle oil level to the
full mark on the dipstick to accommodate remote
WARNING cylinder implements, a maximum of 59 liters (15.5
Before connecting or disconnecting hydraulic gal) should not be exceeded. Alternatively, installa-
hoses or the remote cylinders, lower the tion of remote control cylinders with a total oil
implement, stop the engine and relieve the capacity of up to 18 liters requires no additional oil
pressure in the circuit by moving the remote provided the tractor operates on level ground.
control levers full forward to the ‘float’ position
and back to neutral. Never work under, or allow To connect a remote cylinder, insert the feed or return
anyone near raised equipment, as it will drop hose through the slit in the appropriate dust cap.
when relieving system pressure. Check hose for correct seating with the coupler, and
for sufficient slack in the hose to allow the
tractor/equipment to turn in either direction.
WARNING
Never work under implements raised by a After connecting a remote cylinder to a remote valve,
hydraulic device, as a sudden loss of pressure, run the engine and toggle the control levers to the
inadvertent control selection, or a ruptured hose ‘float’ position and back to neutral to equalize
may cause the implement to drop, even with the pressure between the valve, hose and coupler.
engine shut down.
Pushing the hose into the coupler and quickly pulling
the hose back will pop it free from the coupler.
IMPORTANT: Before connecting remote cylinder
hoses, stop the engine. Thoroughly, clean the The flow control valve meters the flow of oil to the
connections to prevent oil contamination. Remote remote cylinder and thus controls the rate of
cylinders operate with oil drawn from the tractor response of the cylinder. Turning the flow control
hydraulic system. Therefore, always check and knob counterclockwise increases the rate of flow,
replenish the hydraulic system oil after connecting, and turning the knob clockwise decreases the rate of
and after cycling remote cylinder equipment. flow (4), Figure 11.
Operating the tractor with a low oil level, or with
broken down, or contaminated oil could result in Detent adjusting screws (1) on the remote valves
failure of the rear axle, transmission or hydraulic allow adjusting of the detent mechanism within the
systems. valve, thereby effecting the neutral position,
Figure 11.

35-19
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Double-Acting Cylinders
Refer to Figure 12. 4 1
Installation of a double-acting cylinder requires a
feed hose (1) connection from the remote upper
coupler (4) to the piston-end of the cylinder, and a
return hose (2) from the lower coupler (3) to the
rod-end of the cylinder.

Positioning the control lever rearwards to the ‘raise’


position extends a double-acting cylinder.

Positioning the control lever forward to the ‘lower’ 3 2


position retracts a double-acting cylinder.
12
Further movement of the control levers forward
selects ‘float’ which allows the cylinder to extend or
retract freely. This feature assists with equipment
such as scraper blades and loaders.
Single-Actuating Cylinders
Refer to Figure 13.
1
Connect the hose (1) from a single-actuating cylinder
to the upper coupler (2) on the remote control valve.

Positioning the control lever rearward to the ‘raise’


position extends a single-acting cylinder.

Manually return the lever to the neutral position to


stop the cylinder before full extension or allow the
valve to return to neutral automatically when the
cylinder reaches the end of the stroke. 2
Positioning the control lever to the full forward ‘float’ 13
position retracts a single-acting cylinder.

IMPORTANT: Select the ‘float’ position to lower a


single-acting cylinder. The ‘lower’ position operates
the double-acting cylinders.
Continuous Flow Hydraulic Equipment
Connect continuous flow type equipment, e.g. 4 1
hydraulic motors, with the feed hose (2) connected to
the lower coupler (3), and the return hose (1)
connected to the upper coupler (4), of the same
valve.
2
With the remote control lever moved toward the
forward ‘float ‘ position, the motor slows to a halt and
becomes stationary. The motor begins operating
again with the control lever moved out of the ‘float’
position.
3

14

35-20
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Observe the following safety precautions: hydraulic oil temperature must not exceed 77_ C
(170_ F).
1. Do not open any by-pass valves in the equipment 5. If high temperature persists under normal
or motor. Use the control valve to control the rate operating conditions, install an oil cooler in the
of flow or speed of the motor. motor return circuit.
2. Do not hold the remote control valve lever to
operate equipment. If the detent will not hold the Operating Several Remote Valves
lever, adjust the detent screw and check the Simultaneously or Remote Valves with
equipment for proper adjustment. Hydraulic Lift Simultaneously
NOTE: Holding the remote control valve lever after When operating two or more remote valves
the cylinder reaches the end of the stroke, causes the simultaneously, or remote valve(s) with the hydraulic
relief valve to open. Extended periods of oil flow lift simultaneously, adjust the remote valve(s) to a
through the relief valve results in a rising of oil partial flow rate. This prevents a full flow circuit from
temperature. receiving excessive oil from circuits with less
pressure.
3. To assure optimum hydraulic cooling and
prevent overheating, operate continuous flow
equipment at the highest flow setting and lowest Bleeding Air from Remote Cylinders
engine speed that produces the required It is necessary to bleed trapped air from a new
equipment performance and speed. cylinder, or from a cylinder that remained ‘out of
service’ for a period of time, or after disconnecting
4. Use a temperature gauge if possible, installed in and reconnecting hoses. After connecting hoses to
the remote circuit when operating hydraulic the remote control valve couplers, position the
motors for continuous operation. If over-heating cylinder requiring bleeding with the hoses upward.
occurs, stop the hydraulic motor and allow Extend and retract the cylinder at least seven times
cooling. Position the flow control setting to using the control lever.
maximum with engine speed at a minimum,
appropriate to equipment performance. The Check the rear axle oil level before and after remote
recommended operating temperature of 57-63_ cylinder operation.
C (134-146_ F) should be obtained. The

35-21
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

REMOTE CONTROL VALVE - OVERHAUL

Removal
1. Disconnect the control linkage (2), and hydraulic
connections (1, 3 and 4).

15
Disassembly
1. Separate the control valve (1) from the coupler
assembly (2).

16
2. Remove the end cap (3) and O-ring (4).
3. Remove the flow control spool (1) and spring (2)
from rear of housing.

17

35-22
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
4. Remove the flow control knob (2). Push the
restrictor end-plug (3) as far as possible into
housing and remove retaining clip (1).
NOTE: The plug only pushes into the housing by
approximately 1 mm (0.040 in), which is sufficient to
allow removal of the retaining clip.

18
5. Remove the flow control restrictor and compo-
nents as shown in Figure 19. Discard O-rings
and seals.

19
Flow Control Restrictor

1. Spiral Circlip 7. Load Check Valve


2. Knob 8. Flow Restrictor
3. O-ring 9. Restrictor End Plug
4. Back--up Ring 10. O-ring
5. Shaft 11. Back-up Ring
6. Spring

35-23
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
6. Remove fixing screws (4) and pull detent
assembly (1) from the end of the flow control
spool (3) and discard O-ring (2).

20
7. Using a suitable press, push in end-cap (2)
sufficiently into detent housing (12) to accommo-
date removal of snap ring (3). Press and release
the end-cap to allow spring within the detent
housing to eject end-cap.

21
Detent Mechanism

1. Lock Nut 10. Detent Balls


2. End Cap 11. Washer
3. Snap Ring 12. Detent Housing
4. Spring 13. Valve
5. Detent Spool 14. O-ring
6. Back-up Ring 15. Back-up Ring
7. O-ring 16. Rod
8. O-ring 17. Spring
9. Back-up Ring 18. Adjusting Screw

35-24
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
8. Disassemble detent assembly and detent
regulating valve components as shown in
Figure 22.
NOTE: Ensure to collect all nine detent balls (10),
Figure 22.

22
Detent Mechanism

1. Lock Nut 10. Detent Balls


2. End Cap 11. Washer
3. Snap Ring 12. Detent Housing
4. Spring 13. Valve
5. Detent Spool 14. O-ring
6. Back-up Ring 15. Back-up Ring
7. O-ring 16. Rod
8. O-ring 17. Spring
9. Back-up Ring 18. Adjusting Screw

35-25
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
9. Compress the centering spring (5) and remove
detent plunger (3) from shaft (2), Figure 23.
10. To prevent damage to the housing from the
exposed end of the main spool (7), remove the
spool from the opposite end of the housing.
Retain washer (4). Remove retainer (1) and (6).

23
Centering Spring Assembly

1. Retainer 5. Spring
2. Shaft 6. Retainer
3. Detent Plunger 7. Main Spool
4. Washer

11. Remove the retaining clip and shuttle check


valve (1). Remove and discard O-rings and
back-up rings (2, 3 and 5). Use a suitable tool (4)
to assist removing the valve, Figure 24.

24

35-26
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
12. Remove the priority check valve (2), ball (1) and
discard O-rings (3), Figure 25.

25
Inspection
1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Inspect all components for obvious damage,
excessive wear or distorted spools and valves.
Replace defective components.

35-27
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

NOTE: The main spool, flow control spool and restrictor match the valve body and are not available separately.

24

25

26
28 27

26
Double Spool Remote Control Valve

1. Valve Body 15. Detent Regulating Valve Spring


2. Spool 16. Spacer
3. Flow Restrictor 17. Detent Regulating Valve
4. Load Check Valve 18. Detent Housing
5. Flow Restrictor End Plug 19. Shuttle Check Valve
6. Flow Restrictor Control Shaft 20. Flow Control Spring
7. Flow Restrictor Control Knob 21. Flow Control Spool
8. Detent Plunger 22. Priority Check Valve Ball (double spool only)
9. Spool Centering Spring 23. Priority Check Valve Retainer
10. Locknut 24. Spiral Retaining Clip
11. Detent Piston Spring 25. Seals
12. Detent Piston 26. Detent Cap Retaining Ring
13. Detent Valve Spring Adjuster 27. End Cap
14. Detent Balls 28. Seals

35-28
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Assembly
Assembly of the remote valve(s) follows the
disassembly procedures in reverse, with the
following requirements:

1. Replace all O-rings and back-up rings.


2. Reassemble using Figure 26 for guidance of
component location.
3. Install housing O-rings as follows:
• Position O-ring (1) into the detent valve
channel in the housing.

27
• Install the spool (2) from the opposite end of
the housing with O-ring (1) as shown in
Figure 28.
4. Apply thread Lock to the threads of the detent
shaft.
5. Assemble centering spring, and screw shaft onto
main spool. Tighten to a maximum torque of 7
N⋅m (60 in.-lb.).
6. Reconnect the control valve to the coupler
assembly with the O-ring seal between the
coupler and valve. Tighten to a torque of 15-20
N⋅m (133-177 in.-lb.).
28

Installation 3. Replenish hydraulic oil and check level in the rear


Installation of the remote valve(s) follows the axle casing.
removal procedures in reverse with the following
4. Operate the remote valve(s) and check valve and
requirements:
connections for leakage.
1. Install the remote control valve on the tractor and 5. Purge air from hydraulic oil following the
tighten retaining bolts to a torque of 27-*35 Nm procedures in “Bleed Air From Remote Cylinder”
(240-312 in.-lb.). in this Chapter.
2. Reconnect the hydraulic connections and control
linkage.

35-29
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

REMOTE CONTROL VALVE COUPLER -


OVERHAUL
It is not necessary to remove the remote control valve
assembly from the tractor to overhaul the couplers.

Disassembly
1. Using a suitable spanner wrench, or Tool No.
FNH00095, or a prefabricated tool as shown in
Figure 29, unscrew coupling as follows:
• Fabricate the tool using a 30 mm socket (1)
welded inside of a sleeve (2), with three 6 mm
screws 120_ around the circumference of the
29
sleeve.
Tool for Removing Coupler
• Place the three locking screws into the round 1. 30 mm Socket (welded inside item 2
holes on the outer diameter of the coupler. 2. Sleeve
Use a standard wrench to unscrew the
3. Hardened Locking Screw (3 off) made from 6 mm
coupler. Bolts

35-30
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
2. Disassemble the coupling as shown in Fig-
ure 30.

30
Remote Valve Coupler

1. O-ring 12. Retaining Ring


2. Adaptor 13. Coupler Housing
3. Sleeve Assembly 14. Locking Body
4. Front Sealing Ring 15. Back-up Ring
5. O-ring 16. O-ring
6. Probe Assembly 17. Spring
7. Spring 18. Locking Sleeve
8. Washer 19. Retaining Ring
9. O-ring 20. Back-up Ring
10. Back-up Ring 21. O-ring
11. Locking Balls

35-31
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
3. Remove and discard O-rings (3) and slipper
seals (2) from inside the coupler housing (1),
Figure 31.

31
Inspection
1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Inspect all components for wear or damage.
Replace parts as necessary.
Assembly
Assemble the coupler using the disassembly
procedures in reverse with the following require-
ments:

1. Lubricate new O-ring seals with clean hydraulic


fluid and insert into the coupler housing grooves.
2. Shape the slipper seals (1) as in Figure 32 and
insert inside of O-ring seals.
3. Lightly oil the coupler and install into housing.
NOTE: The coupler engages and slightly expands
the slipper seal upon insertion.
32
4. Tighten the sleeve to a torque of 81 Nm (60
ft.-lb.).
5. Perform a pressure test of remote valve(s). Refer
to Chapter 5 “Adjustments and Testing”.

35-32
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

SECTION 35 - HYDRAULIC SYSTEM

Chapter 4 - Component Overhaul

CONTENTS

Section Description Page


Oil Cooler -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Pressure Regulating Valve -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Lift Cover -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

35-1
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

OIL COOLER – OVERHAUL PRESSURE REGULATING VALVE -


OVERHAUL
Removal
1. Raise the front hood panel. Removal
2. Unscrew the retaining bolt and remove horn. 1. Refer to Section 31 “Power Take-Off” for removal
of the PTO and control valve assembly.
3. Remove the clamps and disconnect the
hydraulic oil connections to the oil cooler
assembly. Cap and plug all exposed connections Inspection
to prevent contamination. 1. Clean all components in a suitable solvent. Allow
parts to dry.
4. Remove retaining ‘eye’ bolts and brackets.
Remove oil cooler. 2. Inspect the spool and locating bores for wear,
burrs, or scratches. Remove minor burrs or
scratches using a fine abrasive.
Inspection
1. Wash the external areas of the oil cooler 3. Inspect the valve spring for damage.
assembly to remove dirt and foreign matter. 4. Inspect oil passages for blockage.
Thoroughly clean the fin area.
5. Check that the spool moves freely within the
2. Inspect the fins for damage. Straighten any bent bore.
fins.
6. Replace all O-rings and seals.
3. Inspect hoses and connections for damage and
replace parts as necessary.
Installation
Refer to Section 31 “Power Take-Off” for assembly of
Installation the hydraulic PTO assembly.
Installation of the oil cooler assembly follows the
removal procedures in reverse with the following 1. Perform pressure test of the low-pressure and
requirements: lubrication circuits. Refer to Section 35 “Adjust-
ments and Testing”.
1. Check the hydraulic oil level and replenish as
necessary.
2. Operate the tractor and check the oil cooler
assembly for leaks.

35-2
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

35-3
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

35-4
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4
Refer to Figures 4 and 5.

A = High Pressure Oil 183 bar (2650 psi) 1. Transmission Mounted Tandem Gear Pump
B = Steering Pressure 2. Transmission 8 x 2
2WD -- 145 bar (2100 psi) 3. 4WD Clutch
4WD -- 172 bar (2500 psi)
4. Pressure Regulating Valve. See Item C.
C = Low Pressure Oil 15.2 -- 17.9 bar (220 -- 260 psi) 5. Lubrication Relief Valve. See Item D.
D = Lubrication Oil 5.0 -- 8.5 bar (73 -- 123 psi) 6. PTO Control Valve -- Engaged

E = Suction / Return to Sump 7. PTO Clutch Assembly -- Engaged

35-5
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

HYDRAULIC LIFT COVER - OVERHAUL

Removal
1. Place lift arms in the lowest position.
2. Remove the cotter pin and clevis pin from both lift
arms. Remove left and right-hand lift rods.
3. Remove the top link and disconnect the lift
linkage.
4. Remove the clips and clevis pin securing the
draft control main spring yoke to the rocker and
swing the rocker away from the yoke.
5. Disconnect the control levers from the remote
valve(s) by removing cotter pins.
6. Disconnect and remove the remote valve(s),
support bracket and tubing.
7. Remove the oil cooler feed tube in front of the
hydraulic lift cover.
1
8. Disconnect the remote feed (2), pilot line (3) and
auxiliary feed (4) tubing from the priority valve 4
pack (1). Plug and cap all exposed ports and
connections.
9. Remove the retaining bolt and support bracket
for the rear transmission dipstick.
2
10. Remove seat retaining bolts and seat assembly.
3
NOTE: If overhauling or removing the lift cylinder
loosen the lift cylinder retaining bolts before 20026046
removing the lift cover. Do not remove the lift cylinder
bolts completely. 3

11. Clean the lift cover before removing to prevent


contamination.
12. Remove the retaining bolts, and lift the cover
clear of the rear axle center casing. Support the
cover with the internal linkage facing upward. DO
NOT let the assembly rest on any of the controls.

35-6
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4
Disassembly
4
NOTE: Except for the removal of the selector arm,
which requires removal of the lift cylinder control rod,
removal of the internal linkage to the hydraulic lift 1
cover will not require removal of the lift cylinder, cross
shaft or lift arms.

1. Remove the cotter pin, clevis pin (1) and the


turnbuckle (4) of the control valve (3). Separate
from the actuating lever (2), Figure 4. 3
2. Remove the lift cylinder control rod to facilitate
removal of the selector arm. 20026047
2

4
3. Remove split pin, washers, and selector arm (4)
from the control rod and roller assembly, link (2), 6
Figure 5. 5
4. Remove the retaining clip and actuating lever (5), 1
Figure 5, from the position control lever shaft.
5. Slide the actuating lever (5) and control rod and
roller assembly (3) off the support pins. Remove
the retaining clip and separate the lever from the
control rod, Figure 5.
6. Disconnect the selector arm tension spring.
20026048 4 3 2

35-7
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

1
10
8

2
7

5 3
4
20026049

6
7. Remove the retaining clip and position control NOTE: To facilitate removal of the selector link and
link (10) from the intermediate link (3), Figure 6. intermediate link assemblies, turn the draft control
plunger.
8. Remove the retaining clip and selector link (2)
from the draft control linkage, Figure 6.
11. Remove the retaining nut and eccentric shaft (1),
9. Remove the draft control plunger centralizing Figure 6.
bolt and selector link tension spring bracket.
12. Remove the position control link (10) with spacer,
10. Remove clips and intermediate link (3) from the Figure 6.
selector link (2), Figure 6.

35-8
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4
Refer to Figure 7.
8
WARNING 1
Beware of internal spring pressure when 7
removing the hydraulic lift control lever,
retaining nut and washer.

13. Remove the lift position control lever retaining


nut (6) and washer (4). 2
14. Remove the control lever (8) and friction disc (3).
15. Remove quadrant retaining bolts (2) and rotate 6
the quadrant assembly (7) to disengage the draft
control lever (1).
16. Remove the lift position control lever shaft, spring 3
and washers from the top cover.
17. Knock out the two pins retaining the selector 4
lever handle to the selector arm shaft and
remove the handle. 5
20026050
18. Remove the lift arms by bending the lock tabs
back, and removing the retaining bolts. 7

19. Remove dust seals from cross-shaft bores.


20. Support the ram arm and drive the cross-shaft
out with a soft hammer. Remove the ram arm and
bushings from the shaft.
21. Remove the remaining two bushings on the
opposite side of the cover.
22. If required, remove the draft control mainspring
by unscrewing the yoke, loosening the set-screw
and removing the large hexagonal nut.
23. Remove the lift cover breather cap.

Inspection and Repair


1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Inspect all linkage for excessive wear, corrosion,
distortion, burrs or other visible damage.
Remove minor burrs with a fine abrasive.
Replace any defective components
3. Check all linkage for freedom of movement and
smooth operation.
4. Inspect springs for breaks and deformity.

35-9
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4
Assembly 14. Align the spline on the ram arm, and lift arms with
Assembly of the lift cover and components follows the corresponding spline on the cross-shaft.
the disassembly procedures in reverse with the
15. Install washers, locking tabs and bolts to both
following requirements:
ends of the cross-shaft. Tighten one bolt to a
torque of 27-41 Nm (240-360 in.-lb.) and secure
1. Replace all O-rings, gaskets and seals. lock tab. Tighten the opposite bolt until lift arms
2. Replace the draft control plunger yoke dust seal. fall slowly under own weight. Secure the lock tab.
3. Tighten the yoke retaining nut set-screw to a NOTE: Do not over tighten lift arm retaining bolts, as
torque of 27-34 Nm (240-300 in.-lb.). damage to the cross shaft seals will occur.
4. Lubricate the connecting rod, selector linkage,
16. After assembling, check for a pull of 45-71 N
hydraulic lift cross-shaft bushings, draft control
(20-30 lb) at the lift control lever handle, through
spring and plunger.
an arc of 100-125 mm (4-5 in) around the
5. Push the inner end of the lift control lever shaft quadrant periphery as measured from the
outward to compress the internal spring, for bottom stop. If necessary, adjust the lift position
engagement of the control lever on the flats at the control lever retaining-nut.
outer end of the shaft.
17. Check adjustments of the draft control main
6. Tighten the quadrant assembly-to-lift cover spring and hydraulic control linkage setting.
retaining bolts to a torque of 68 Nm (50 ft.-lb.). Refer to Section 35 Chapter 5 “Adjustments and
Testing”.
7. Tighten the lift control lever to a torque of 12 Nm
(106 in.-lb.). 18. before installing the hydraulic top cover, apply a
thin bead of a suitable gasket sealer to both sides
8. Centralize the control rod roller on the selector
of the cover gasket. The bead must continue
link.
around the entire face of the gasket to a
9. Tighten the control rod turnbuckle to a torque of thickness of 1 mm (1/32 in).
34 Nm (301 in.-lb.).
19. Install lift cover assembly retaining bolts and
10. Tighten the selector lever adjustable rod to a tighten to a torque of 136-170 Nm (100-125
torque of 12 Nm (106 in.-lb.). ft.-lb.).
11. Tighten the Position Control adjusting screw NOTE: Ensure to install various external brackets to
locknut to a torque of 24 Nm (212 in.-lb.). top cover retaining bolts exactly as removed, before
applying torque
12. Tighten the draft control nut set screw to a torque
of 30 Nm (266 in.-lb.).
20. Manually raise lift arms (engine not running) and
13. Tighten the control valve turnbuckle locknut to a check that arms fall slowly under weight.
torque of 14 Nm (124 in.-lb.). Recheck torque applied to lift arm retaining bolts
when arms fail to perform as specified.

35-10
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

PRIORITY VALVE PACK – OVERHAUL


Removal
1. Lower the hydraulic lift arms completely. 5
1
2. Disconnect the remote feed (2), pilot line (3) and
auxiliary feed (4) tubing from the priority valve 4
pack (1). Plug and cap all exposed ports and
connections.
3. Remove the retaining bolts (5) and remove
priority valve pack, Figure 8.
2
3
20026046
Disassembly
8
WARNING
Be aware of internal spring pressures when
disassembling valves.

NOTE: Identify the various components, component


locations, and order of removal to facilitate
re-assembling the valves.

NOTE: Remove and discard O-rings in the


counter-bore of the oil passages.

Lift Circuit Check Valve


1. Remove plug.
2. Remove the O-ring (6) cage (5), spacer (4),
spring (3), ball (2), O-ring and seat (1) from the
housing (7).

35-11
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4
Flow Control Valve
Refer to Figure 10. 13 14
5 12
1. Remove the plug (1) from the priority valve pack
(14). Discard the O-ring. 4
1
2. Remove the spring (4).
3. Remove the spool (5). 11
Unload Valve 3
8
1. Remove the plug (3) from the priority valve pack
(14). Discard O-ring.
7 2 9 10
2. Remove the spring (7).
6
3. Remove the spool (8).
Combining Valve 10
1. Remove the auxiliary pump fitting (where
installed) or the plug (6) (less pump fitting).
Discard the O-ring.
2. Remove the spring (9).
3. Remove the spool (10).
NOTE: The internal relief valve (2), Figure 10,
installed within the combining valve, protects the
auxiliary pump circuit from excessive pressure. It
requires no adjustment.
Auxiliary Pump Circuit Check Valve
1. Remove stop, ball (12) and spring (13).
NOTE: The auxiliary pump circuit check-valve and
the combining valve function together.
Priority Valve Pack Restrictor
1. Unscrew and remove restrictor (11). Discard the
O-ring.
Inspection
1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Inspect the valve bores, plugs and caps for
damage or burrs. Remove minor burrs or
scratches with a fine abrasive. Any heavy scoring
of the bores necessitates replacement of the
priority valve pack.
3. Inspect the valve springs for wear, damage or
deformity.
4. Inspect oil passages and ports for obstructions.
5. Check that spools move freely within the valves.
6. Replace all O rings and seals.
7. Inspect all linkage for excessive wear, corrosion,
distortion, burrs or other visible damage.
Remove minor burrs with a fine abrasive.
Replace any defective components.
8. Check all linkage for freedom of movement and
smooth operation.

35-12
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4
Assembly
IMPORTANT: Install spools into valves using gentle
pressure and rotation. Excessive force will damage
the valves
1. Coat all O-rings with petroleum jelly. Check that
O-rings seat properly (where installed).
2. Lubricate all parts with clean hydraulic oil.

Lift Circuit Check Valve


1. Install the O-ring and seat (1), ball (2), spring (3),
spacer (4), cage (5), and O-ring (6) into the
housing (7).
2. Install plug.

11
Flow Control Valve
1. Slide the spool into the flow control valve with the
‘four land’ section headfirst.
2. Insert the spring in the valve front.
3. Screw in the rear plug by one thread.
4. Install the front hexagon cap completely and
tighten.
5. Install the rear plug completely and tighten to a
torque of 27 Nm (240 in.-lb.).

Unload Valve
1. Insert the unload valve spool with the small end
headfirst.
2. Insert the spring into the valve front.
3. Install the front plug and tighten to a torque of
23-48 Nm (204-420 in.-lb.).

Combining Valve
1. Insert the combining valve spool with the relief
valve headfirst.
2. Insert the spring into the valve front.
3. Install the end cap and tighten to a torque of 27
Nm (240 in.-lb.).

Check Valve (auxiliary pump circuit)


1. Insert the ball, then the spring, and wire stop into
the rear of the check valve.
2. Install the plug and tighten.

35-13
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

DISASSEMBLY
1. Unscrew ASC control linkage connector (3), pull
knob (2) from lift cover and remove selector valve
stem (1), Figure 12.

12
ASC Valve Selector Linkage (where fitted)

1. Selector Valve Stem


2. Knob
3. Control Linkage Connector

2. Disconnect and remove control valve turnbuckle,


Figure 13.

13
Control Valve Turnbuckle

1. Clevis Pin
2. Turnbuckle Assembly
3. Control Valve
4. Lever
(part of Control Rod, Roller and Lever Assembly)

35-14
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

14
Hydraulic Lift Cover Internal Linkage

1. Selector Link 5. Lift Cylinder


2. Selector Arm 6. Position Control Link
3. Control Valve Turnbuckle 7. Control Rod and Roller
4. Control Valve

3. Remove four bolts securing cylinder to lift cover.


4. Move lift arms to raised position and carefully
remove cylinder from locating dowels.
5. Remove priority/unload valve return tube (1),
Figure 15.
6. Referencing Figure 14 to Figure 19 disassemble
the hydraulic lift assembly.

15

35-15
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

16
Eccentric Shaft and Selector Link Components
1. Sleeve 6. Snap Ring 10. Spacer
2. Nut 7. Cam Roller 11. Cam
3. Link 8. Spacer 12. Eccentric Shaft
4. Snap Rings 9. Snap Ring 13. Washer
5. Link

17
Draft Control Main Spring and Plunger
1. Snap Ring 6. Retainer Nut 10. Bracket
2. Plunger 7. Seal 11. Spring
3. Washer 8. Yoke 12. Selector Link
4. Spring 9. Set Screw 13. Washer
5. Washer

35-16
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

18
Lift Arm Assembly -- Exploded View
1. Lift Arm 3. Bolt 5. Thrust Washer
2. Locking Washer 4. Washer

19
Cross Shaft Assembly -- Exploded View

1. Bush 4. Cross Shaft 7. Bush


2. Bush 5. Piston Rod and Arm Assembly 8. Seal
3. Seal 6. Bush

35-17
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

20
Hydraulic Lift Cylinder -- Exploded View
1. Piston 6. Plug 11. Diffuser
2. O-rings (7 off) 7. O-ring 12. O-ring
3. Ring Dowels 8. Safety Valve 13. Exhaust Valve
4. Ball 9. Seal 14. ASC Valve Spool
5. Spring 10. Control Valve Bush 15. Control Valve

7. Disassemble lift cylinder with reference to


Figure 20.
8. Using a soft metal rod inserted through safety
valve bore eject lift cylinder piston.
9. Discard all O-rings and seals.
NOTE: The lift cylinder safety valve is not
serviceable.

10. Disassemble the control valve with reference to


Figure 21.
11. Where necessary, remove remaining plugs from
lift cover. Under normal circumstances the
removal of these plugs is not necessary. 21
Lift Cylinder Control Valve
1. Spool
2. Spring
3. Bolt
4. Plate
5. Sleeve

35-18
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

INSPECTION AND REPAIR


1. Wash all parts in suitable cleaning agent such as
paraffin (kerosene).
2. Check oil passages for obstructions.
3. Examine valves and bore for wear, burrs or
scratches. Remove minor damage to valve with
fine abrasive.
4. If the control valve bushing requires replacement
remove the bushing using Tool No. FNH02191.
The control valve bushing is color coded and the
original size as fitted by the factory is indicated by
a color ‘spot’ on the cylinder casting adjacent to
the control valve bore. Always install a new bush
with the same color code markings.
When replacing the bushing, the bush should be
lubricated and drawn through the bore, Fig-
ure 22.

22
Installing Control Valve Bushing
A. Bush Protrusion
1. Tool No. FNH02191
2. Control Valve Bushing
3. Bushing Locator Tool No. FNH10090
4. Extension Tool No. FT.8510--1A
5. Guide and Stop Adaptor Tool No. T.8510 1K

When the bush contacts the inner face of the


guide, remove guide and continue to draw bush
through the bore until the face of bush protrudes
2.54--2.62 mm (0.1--0.103 in), beyond the rear
face of the lift cylinder (A), Figure 23.
5. Ensure valves are thoroughly washed before
re-assembly and move freely in bores. Heavy
scoring of the ASC valve bore necessitates
replacement of lift cylinder.
6. When installing a new lift cylinder, select largest
control valve and ASC valve spools, which when
lightly lubricated, will operate in bore without
binding when turned through 360° and operated
over full length of stroke. 23
NOTE: The control valve bushing and ASC valve
bores are color coded as a guide for matching the
valve to the bore. To obtain an optimum fit lap with
proprietary brand of metal polish. Ensure all traces of
polish are washed away and dry components before
re-assembly. For valve sizes refer to the Specifica-
tions Table.

35-19
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4
7. If arm (2), piston rod (3) or retaining pins (1) and
(4) are worn, separate rod and arm assembly.
Refer to Figure 24. The pins are an interference
fit into the arm, to remove pins use a suitable
lever between rod and end face of pin.

24
ASSEMBLY
Assembly follows the disassembly procedures in
reverse, with the following requirements:

1. Replace all O-rings and seals.


2. Install piston O-ring (1) and back-up seal (2) as
shown in Figure 25.

25
3. To aid installation of piston (3), Figure 25 into lift
cylinder and prevent damage to the piston seals,
manufacture a guide to the dimensions shown in
Figure 26.

26
Piston Installation Guide

A. 105 mm (4.126 inch)


B. 134 mm (5.25 inch)
C. 3 mm (0.12 inch)
D. 40 mm (1.62 inch)
E. 155 mm (6.0 inch)

35-20
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4
4. Install piston (1) into cylinder (3) using guide (2)
as shown in Figure 27. Use a piston ring
compressor if no guide is available and the piston
is difficult to install.

27
5. Ensure the lift cylinder retaining bolts are
installed in the correct locations and torqued to
224--271 Nm (165--200 ft. lb.), Figure 28.
6. Before installation of the cross shaft, coat the
shaft and lip seals with grease.
7. The following torque procedure must be
observed when tightening the lift arm retaining
bolts.
A. Install the lift arms and tighten the left hand arm
retaining bolt to a torque of 27--40 Nm (20--30 ft.
lb.). Lock the bolt in position with the tab washer.
Refer to Figure 18.
B. Raise both lift arms and tighten the right hand 28
arm retaining bolt sufficiently to allow the arms to Lift Cylinder Retaining Bolt Locations
lower under their own weight. Lock the bolt in (Viewed from Top of Hydraulic Lift Cover)
position with the tab washer. DO NOT over
1. 76 mm (3 in.) Bolt
tighten bolts as damage to the cross shaft seals
2. 64 mm (2.5 in.) Bolt
will occur.
3. 57 mm (2.25 in.) Bolt
4. 76 mm (3 in.) Bolt with Thin Bolt Head

35-21
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

29

Hydraulic Lift Cylinder -- Exploded View

1. Piston 9. Seal
2. O-rings 10. Control Valve Bush
3. Ring Dowels 11. Diffuser
4. Ball 12. O-ring
5. Spring 13. Exhaust Valve
6. Plug 14. ASC Valve Spool
7. O-ring 15. Control Valve
8. Safety Valve

35-22
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

SECTION 35 - HYDRAULIC SYSTEM

Chapter 5 - Adjustments and Testing

CONTENTS

Section Description Page


Hydraulic Power Lift (HPL) 3-Point Internal Control Linkage Adjustments . . . . . . . . . . . . . . . 2
Main Draft Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Draft Control Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Position Control Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remote Control Valve External Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Testing Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Low-Pressure and Lubrication Circuit Pressure Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Remote Valve Detent Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

35-1
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

HYDRAULIC POWER LIFT (HPL) 3-POINT


INTERNAL CONTROL LINKAGE
ADJUSTMENTS
NOTE: The following procedures describe lift/lower
control linkage and draft/position control linkage
adjustments with the hydraulic power lift (HPL) top 1
cover removed from the tractor.

Internal Control Linkage Inspection


IMPORTANT: Perform the following inspections
before adjusting the internal control linkage.

1. Place the HPL top cover assembly (1), on a 1


support with the internal linkage facing upwards,
or vertically in a vice with the main draft spring
end upward. Ensure the assembly is not resting
on the external control selector levers and the
HPL arms (must move freely).

UP

35-2
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
2. Move the draft/position selector lever (1) and the
lift/lower control lever (2) into random settings. 1 2

3
3. At each setting manually move the HPL arms
upward (lower position) and downward (raised LOWER
position) while checking the internal linkage [cam
rod and roller (1), over-travel spring (2), pivot
block (3), and control valve spool (4)] for binding
RAISE
or other defects. See Figure 5.

5
1. Cam Rod and Roller
2. Over-Travel Spring
3. Pivot Block
4. Control Valve Spool

35-3
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
4. Place the HPL arms (1) in the raised position
RAISE
(perpendicular with the top cover on the support).
Rotate the lift/lower control lever (2) counter-
clockwise to the fully raised position (lever at top
of quadrant). This moves the control valve (3)
spool inwards.
1

3 2

6
5. Rotate the draft/position selector lever back and
forth while observing the travel of the roller (1)
across the cam (2). 2
1

7
6. The roller must move square and parallel (1) with
the cam and not at an angle (2) across the cam. 2
1

35-4
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
7. If necessary, place shims on the roller linkage (1)
to center the roller (2) horizontally on the cam (3).
(This may require 4 -- 6 shims). Do not over-shim 3
2
or eliminate all sideways movement.
8. Replace any worn components, and then
proceed with the HPL internal control linkage
adjustments.
IMPORTANT: To ensure the proper operation of the
HPL, perform the following adjustment procedures 1
(Main Draft Spring, Draft Control Linkage, Position
Control Linkage) in sequence.

9
Main Draft Spring Adjustment
RAISE
NOTE: Perform the main draft spring adjustment 4
5
before making any other adjustment to the HPL.

9. Move the HPL arms (1) to the fully raised position


(perpendicular to the top cover on the support).
1
10. Rotate the lift/lower control lever (2) and the
draft/position selector lever (3) until the rod and
3
roller (4) do not touch the cam (5). Ensure there
is no tension on the control valve spool and 6
spring (6). Check that the linkage is free to move. 2

10
• Move the draft/position selector lever in the
full position setting (top of quadrant where 3
the decal displays the word POSITION). 5
• Move the lift/lower control lever in the full
lowered setting (bottom of the quadrant).
4 2
11. Unscrew the yoke (1) from the plunger (2)
completely and the top cover (3) to remove any
previous pre-load.
12. Loosen the retainer nut set-screw (4) and turn the
retainer nut (5) counter-clockwise to create 6
free-play in the main draft spring (6). Then, turn 1
the retainer nut clockwise until free-play is
eliminated (evident by feeling spring resistance).
11

35-5
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
13. Screw the yoke (1) onto the plunger (should feel
spring resistance). Turn the yoke the least
amount necessary to position the hole in the yoke
horizontally.
14. Verify the elimination of free-play with a
screwdriver (2) by prying on the main draft spring
through the access hole (3).
15. Tighten the retainer nut set-screw (4) to a torque
of 27 -- 34 Nm (20 -- 25 ft. lb.).

12
Draft Control Linkage Adjustment
IMPORTANT: The following dealer made tools are
required for the proper adjustment of the draft control
linkage:

HPL Control Valve Depth Gauge (FNH00014)


Dimension A -- 20 mm (0.08 in)
Dimension B -- 11.7 mm (0.46 in)
Dimension C -- 12 mm (0.5 in)
Thickness D -- 3 mm (0.12 in) gauge steel D

Control Linkage Rod and Roller Setting Gauge 13


(FT8527 or FNH04654)
Tool not available for order. 72 mm 41 mm

See figure for dimensions.


25 mm 6 mm 10 mm

NOTE: Ensure the correct adjustment of the main A


draft spring before adjusting the draft control internal
linkage.

NOTE: The following procedures require the HPL top A = 0.76 mm (0.03 in) B

cover removed from the tractor and installed on a B = 49.5 mm (1.95 in)
support or in a vice.

SHG35450 6 mm

14

35-6
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

LOWER
2

3
A

15
16. Move the HPL arms (1, detail A) to the fully
lowered position (parallel with the top cover on
the support).
17. At the control lever side, check that the eccentric
pin (2, detail A) rotated so lobe (3, detail B) on
inside of assembly points into the top of the
assembly. If necessary, loosen the nuts (1 and 2,
detail B) and adjust the pin to obtain this position.

35-7
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
NOTE: To ensure the HPL lift cylinder piston reaches
the fully lowered position, remove the cylinder safety 4 5
3
valve. Replace the safety valve after obtaining the
fully lowered position. 2 1
18. Move the lift/lower control lever (1) forward with
the back edge even with the notch (2) on the
outside edge of the quadrant (3).
19. Move the draft/position selector lever (4) forward
into the seventh detent (5).

16
20. Check for over-compression of the rod and roller
over-travel spring (1), which is evident when a
gap exists between the rod and roller pivot block 1
and the washer.
2
If the rod and roller spring is over-compressed,
adjust the HPL control valve spool turnbuckle (2).

17
21. Loosen the draft/position selector lever quadrant
mounting bolts (1). Ensure the draft/position
selector lever remains in the seventh detent.
While observing the control valve spool,
gradually reposition the quadrant until the spool
2
moves approximately 2 mm (0.079 in) farther into
the control valve body (2), then hand-tighten the
quadrant mounting bolts.

18

35-8
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
22. Move the HPL arms (1) between the raised
LOWER
position (perpendicular with the top cover) and 1
the lowered position (parallel with the top cover)
while observing for movement of the HPL control
valve spool (2), [entering valve body when
RAISE
raising and exiting valve body when lowering].
If the spool does not move, torque the quadrant
mounting bolts (previously hand-tightened) to a
torque of 20 -- 29 Nm (15 -- 21 ft. lb.). 2
If the spool moves, gradually continue the
process of resetting the draft/position selector
lever quadrant until no further movement of the
spool exists.
19

23. Place the HPL arms (1) in the lowered position


(parallel with the top cover). LOWER

20

35-9
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
24. Check that the rod and roller sits 49.5 mm (1.95
in) deep into the top cover with the Control
Linkage Rod and Roller Setting Gauge (1),
(FT8527 or FNH04654).
Place the edge of the handle flush with the
machined surface of the top cover, then measure
down to the diagonal leg of the gauge (dimension
B).

21
If the rod and roller is not within specification,
repeat the Draft Control Linkage Adjustment
from the beginning.
IMPORTANT: Do not allow the drop poppet valve
and spring to fall from the lift cylinder housing.

HPL TOP
COVER
SURFACE

Draft A = 49.5 mm (1.95 in)


Position B = 0.76 mm (0.03 in)
20040362

22
IMPORTANT: Do not allow the drop poppet valve
and spring to fall from the lift cylinder housing.

25. Remove the control valve faceplate on the


opposite end of the control valve spool.
26. Place the HPL Control Valve Depth Gauge (1)
(FNH00014) into the end of the control valve
bushing (2).

23

35-10
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
27. Check that the control valve spool (1) just
touches the depth gauge (measured 11.7 mm
[0.46 in] from the edge of the bushing (2) --
dimension A). If necessary, adjust the spool by
loosening and tightening the control valve spool
3
turnbuckle (3), accordingly.
Apply threaded sealant (PN 82995773) to the
turnbuckle threads and tighten lock nut to a
torque of 163 Nm (120 ft. lb.).

24
Position Control Linkage Adjustment
IMPORTANT: The following dealer made tools are
required for the proper adjustment of the position
control linkage:

HPL Control Valve Depth Gauge (FNH00014)


Dimension A -- 20 mm (0.08 in)
Dimension B -- 11.7 mm (0.46 in)
Dimension C -- 12 mm (0.5 in)
Thickness D -- 3 mm (0.12 in) gauge steel D

25
Control Linkage Rod and Roller Setting Gauge 72 mm 41 mm
(FT8527 or FNH04654)
Tool not available for order.
25 mm 6 mm 10 mm
See FigureNO TAG for dimensions. A

NOTE: Ensure the correct adjustment of the main


draft spring and the draft control linkage before
adjusting the position control internal linkage. A = 0.76 mm (0.03 in) B
B = 49.5 mm (1.95 in)
NOTE: The following procedures require the HPL top
cover removed from the tractor and installed on a
support or in a vice. SHG35450 6 mm

26

35-11
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
NOTE: The following procedures require the HPL top
cover removed from the tractor and installed on a LOWER
support or in a vice.

28. Move the HPL arms (1) to the fully lowered


position (parallel with the top cover on the 1
support).

27
29. Move the lift/lower control lever (1) forward with
the back edge even with the notch (2) on the 4 5
3
outside edge of the quadrant (3).
30. Move the draft/position selector lever (4) 2 1
rearward into the first detent (5).

28
31. Place the edge of the handle flush with the
machined surface of the top cover (1).

29

35-12
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
32. Dimension A: the gauge diagonal leg top notch.
Check that the rod and roller sits 0.73 mm (0.03
in) out of the top cover with the Control Linkage
Rod and Roller Setting Gauge (FT8527 or
FNH04654).
If the rod and roller is not within specification,
repeat the Draft Control Linkage Adjustment
from the beginning, then the position control HPL TOP
COVER
linkage adjustment again. SURFACE

20040362

30
33. If not previously done, remove the retaining bolts
and the control valve faceplate on the opposite
end of the control valve spool.
IMPORTANT: Do not allow the drop poppet valve
and spring to fall from the lift cylinder housing.

34. Place the HPL Control Valve Depth Gauge (1),


(FNH00014) into the end of the control valve
bushing (2).
2

31
35. Check that the control valve spool (1) just
touches the depth gauge (measured 11.7 mm A
[0.46 in] from the edge of the bushing (2) --
dimension A).

32

35-13
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
If necessary, adjust the spool by loosening the
lock nut (1) and rotating the eccentric pin. 1
After obtaining the correct measurement, tighten
the eccentric pin lock nut to a torque of 20 -- 27
Nm (15 -- 20 ft. lb.).

33
IMPORTANT: Ensure the drop poppet valve and
spring, has not fallen from the lift cylinder housing.

36. Install the control valve faceplate.


37. Install the HPL on the tractor.

REMOTE CONTROL VALVE EXTERNAL PRESSURE TESTING HYDRAULIC PUMPS


LINKAGE ADJUSTMENT The following test procedures confirm the efficiency
NOTE: It is not a requirement to remove the hydraulic and output of the fixed displacement transmission
lift cover for adjustment of the remote valve external mounted (tandem gear) and auxiliary engine
linkage. mounted pumps. The pressure and flow values listed
throughout this chapter, represent the minimum
values acceptable before overhaul becomes neces-
1. Place the remote control valves in the neutral
sary. The values include adjustments for system
position. The distance from the center of the rod
back-pressure.
end hole to the valve body for neutral must be
38.1 mm (1.5 in). If the hydraulic lift, remote valve(s), PTO, steering or
2. Remove the trunnion lock nut at the inner end of other hydraulic component operates incorrectly after
the actuating rod. verifying pump efficiency, refer to the appropriate
section which describes the fault finding, and
3. Remove the split pin and washer. Separate the overhaul of the components.
trunnion from the actuator.
4. Turn the trunnion to adjust the actuating rod-end
until the control valve handle assumes a vertical
position within 2_. Check after reconnecting
trunnion, and with the valve spool still in the
neutral position.
5. Install the washer and split pin. Tighten the
trunnion locknut.

35-14
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
Main Hydraulic Pump Flow and Pressure Test
1. Remove plug (1) from the pump outlet port,
Figure 34.
2. Install adapter into the pump outlet port.
Adapter
• Adapter Part No. 81862770
• O-ring Part No. 83999938
• O-ring Part No. 83416161
• O-ring Part No. 83416165

3. Attach Test Hose Tool No. FNH00093 and Flow


Meter Tool No. FNH02755 to the pump outlet port 34
and the adapter.
4. Connect a Test Hose Tool No. FNH00093 from
the flow meter return to a remote valve raise port.
5. Move remote valve control lever to the ‘float’
position.
6. Open the load valve on the flow meter
completely.
7. Start engine and set speed to 2100 rev/min.
8. Gradually close the load valve until obtaining a
pressure reading of 137 bar (2000 psi) on the
flow meter gauge.
9. Run the tractor until the hydraulic oil reaches a
normal operating temperature of 57-63_C
(135-146_F). Do not allow oil to exceed a
maximum temperature of 77_C (170 _F).
10. Continue to close the load valve on the flow
meter until the relief valve begins to crack and
pressure no longer increases, as observed on
the flow meter gauge. The pressure must be
176-183 bar (2550-2650) psi, and remain
constant within 10% of the specified pressure
until the relief fully opens, and pressure reduces
to zero. Do not allow oil to exceed the maximum
pressure as damage to the pump may occur.
Remove and replace the pump relief valve if not
within specifications and recheck system.
11. If the relief valve operates correctly, open the
load valve on the flow meter until obtaining a
pressure of 166 bar (2400 psi), at 2100 engine
rpm and record the pump flow.
12. The minimum flow rate must be 35 liters/min (9.3
gal/min), for a new pump or 32 liters/min (8.4
gal/min) for a used pump. Overhaul the pump if
not within specifications and recheck.

35-15
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
Alternate Main Hydraulic Pump Pressure Test
If necessary, connect Pressure Gauge (0-6000 psi)
Tool No. FNH02028 in place of the flow meter to
check the maximum pump pressure.

Alternatively, in the absence of an auxiliary engine


mounted pump, connect the pressure gauge directly
into a remote valve. Operation of the remote valve
will accurately display pump pressure.

35
Checking Main Hydraulic Pump Pressure

1. Adaptor 4 FT. 858/2


2. Adaptor 4 FT. 858
3. Adaptor FNH00705
4. Pressure Gauge FNH02028
5. Test Hose Part No. 83936707

Steering Pump Flow Test


1. Disconnect the steering pump feed (1) and return
(2) tubes, Figure 36.

36

35-16
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
2. Connect Flow Meter FNH02755. Refer to
Figure 37.
NOTE: The flow meter must be capable of
withstanding back-pressure of 21 bar (300 psi).

NOTE: If using hoses of a different size with the flow


meter, use an adapter with a female thread size of
13/16″ – 16 ORFS for installation into the pump inlet
and outlet ports

3. Open flow meter load valve completely.


IMPORTANT: Damage to the steering pump will
occur if the flow meter load valve remains closed.
37
Installation of Flowmeter for
4. Start engine and set engine speed to 2100
Steering Pump Flow Test
rev/min.
5. Gradually close the load valve until obtaining a 1. Flowmeter Load Valve
pressure of 138 bar (2000 psi) on the flow meter 2. Return Hose from Flowmeter
pressure gauge. DO NOT increase the pump 3. Adaptors 4FT.859
pressure beyond this value. 4. Inlet Hose to Flowmeter

6. Observe the pump flow. Overhaul the steering


pump for values less then 31 liters/min (8.2
gal/min) for a used pump, or 35 liters/min (9.3
gal/min) for a new pump.

Low-Pressure and Lubrication Circuit Pressure


Tests
It is important that the flow of oil returning from the
steering motor to the tandem pump for redistribution
to the low pressure and lubrication circuits, is
regulated to the correct specification by the pressure
regulating valve and lubrication circuit relief valve in
the PTO assembly. It is, therefore, recommended
that when pressure testing the pump the following
low-pressure and lubrication circuit tests be
performed.

Low Pressure Circuit Test


1. Connect 0 -- 41 bar (0 -- 600 psi) Pressure Gauge
Tool No. FNH06653 at the pump low-pressure
circuit fitting.
2. Start the tractor and set engine speed to 2100.
rev/min
3. Observe pressure reading on gauge and
compare to 15.2 -- 17.9 bar (220 -- 260 psi).

35-17
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
Lubrication and Cooling Circuit Test
1. Operate the tractor and set engine speed to 1000
rev/min. Stop the engine but do not readjust the
throttle.
Refer to Figure 38.
1 2
2. Connect 0-41 bar (0-600 psi) Pressure Gauge
Tool No. FNH06653 (1), to the oil cooler inlet
hose (2). Use Test Hose No. FNH00093 (3), Test
Fitting Tool No. FNH0835 (4) (assembled from
FNH06946 and FNH00705), and a suitable 7/16
in adapter to connect the test hose to the inlet
hose.
3. With an assistant, start the engine and observe 3
the pressure gauge reading. Do not run the
engine longer than necessary to observe the 4
pressure gauge reading.
4. The pressure observed (depending on engine 38
speed) should be at the minimum operating Lubrication Circuit Relief Valve Check
pressure of the lubricating circuit relief valve,
1. Oil Cooler Inlet Hose
which is 5.0 -- 8.5 bar (73 -- 123 psi)
2. Hose Clamp
3. Suitable 7/16 in JIC Adaptor to Connect Test Hose
Auxiliary Engine Mounted Pump Flow Test to Inlet Hose
1. Remove the pressure relief valve from the 4. Test Hose 83936707
auxiliary engine mounted pump 5. Pressure Gauge FNH06653

2. Install Plug Part No. 83900652 and Seal Part No.


81800812 in place of relief valve. This will return
oil from the lift pump to sump.

35-18
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
3. Connect Flow Meter FNH02752755 and inlet
hose (1) to the right-hand inner remote control 2 1
valve (2) lift coupler, and the return hose (3) to the
outer lift coupler.
4. Set the remote valve flow control knob to
minimum flow.
5. Completely open the flow meter load valve (4). 3
6. Start the engine and set engine speed to 2100
rev/min.
7. Move the remote valve control lever to the ‘float’ 4
position, which controls oil flow from the flow
meter to the remote valve.
39
8. Move the remote valve control lever to the extend
position, which controls oil flow from the remote
valve to the flow meter.
9. Check that the flow meter registers oil flow in both
directions. Set remote control valve flow knobs to
maximum flow.
10. Adjust the load valve on the flow meter until
obtaining a pressure reading of 137 bar (2000
psi) on the gauge, and record the flow.
11. Oil flow readings of less than 23 liters/min (6
gal/min) necessitate overhauling the pump.
12. Gradually close, the load valve on the flow meter
until the reading on the pressure gauge no longer
increases. This value must be in the range of 176
-- 200 bar (2550 -- 2900 psi), which falls within the
operating range of the relief valve in the
combining valve. Overhaul the priority valve
pack if not within specifications.
13. Shut down the engine and remove plug from
pump. Reinstall the pump relief valve.
14. Check hydraulic oil for proper servicing.

35-19
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
Remote Valve Detent Pressure Test allow the hydraulic oil to reach an operating
Perform a pressure test of the remote valve after temperature of 57 -- 63 _C (135 -- 146 _F).
servicing.
9. Continue to close the flow meter load valve, while
observing a steady rise in pressure, until the
1. Install the inlet hose of a suitable flow meter into detent regulating valve opens, at which point the
the lift coupler of the valve to be tested. needle on the flow meter gauge fluctuates, and
2. Set the flow control knob to maximum flow. the remote control lever returns to neutral.
3. Install the flow meter return hose into the lift 10. The gauge reading immediately preceding
coupler of another valve on the tractor. needle fluctuation must be within 148 -- 162 bar
(2150 -- 2350 psi) which is the pressure when the
4. Open load valve on flow meter completely. detent regulating valve must open.
5. Ensure all connections are tight. Start tractor and 11. For readings not within specifications, adjust the
set engine speed to 1700 rev/min. ‘return to neutral’ pressure as follows:
6. Position the remote control lever of the valve with A. Loosen the detent regulating valve locknut.
the flow meter RETURN hose connected to the
full forward “float” position. B. Turn the adjusting screw to change pressure.
One-half turn of the adjusting screw changes the
7. Position the remote control lever of the valve
pressure approximately 31 bar (450 psi).
tested rearwards, to the ‘extend’ position.
8. Gradually close the flow meter load valve until
obtaining a pressure of 137 bar (2000 psi), and

35-20
SECTION 41 -- STEERING SYSTEM -- CHAPTER 1

SECTION 41 - STEERING SYSTEM

Chapter 1 - Hydrostatic Steering System

CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

41-1
SECTION 41 -- STEERING SYSTEM -- CHAPTER 1

SPECIFICATIONS

CLEARANCES AND TOLERANCES

Description
Front Wheel Toe-in 0-6.0 mm 0-0.24 in
Front Wheel Toe-out 0-13 mm 0-0.5 in
Steering Motor Relief Valve Opening Pressure (2WD) 138-145 bar 2000-2100 psi
Steering Motor Relief Valve Opening Pressure (4WD) 166-172 bar 2400-2500 psi
Steering Circuit Maximum Pressure (2WD) 145 bar 2100 psi
Steering Circuit Maximum Pressure (4WD) 172 bar 2500 psi
Transmission Mounted Steering Pump Flow Rate 35 litrs/min 9.3 gal/min
(New Pump)
at 2100 Engine rpm
Transmission Mounted Steering Pump Flow Rate 31 litrs/min 8.2 gal/min
(Used Pump)
at 2100 Engine rpm

41-2
SECTION 41 -- STEERING SYSTEM -- CHAPTER 1

TORQUE VALUES

Description N⋅m Ft.-Lb. (in.-lb.)


Steering Motor Upper Cover Bolts 27 20 (239 in.-lb.)
Steering Motor End-Cover Bolts 23 17 (204 in.-lb.)
Steering Motor-to-Mounting Bracket Bolts 24 18 (212 in.-lb.)
Steering Motor Hose Connections 13 -- 20 10 -- 15 (180 in.-lb.)
Steering Motor Relief Valve Plug 24 18 (212 in.-lb.)
Steering Cylinder Ball Joint Clamp 43 32
Steering Hose-to-Rigid Tubing Gland Connections 34 25 (301 in.-lb.)
Steering Cylinder End-Plate Bolts 120 89
Steering Cylinder-to-Anchor Adjusting Clamp 110 81
Steering Cylinder-to-Track Rod Adjusting Clamp 14 10 (124 in.-lb.)
Steering Cylinder Ball Joint Nuts 300 221
Steering Cylinder Gland and Tube-to-Cylinder 271 200

UNBALANCED STEERING CYLINDER BIAS VALVE

Description Part Number


Valve 82983361 12 bar 174 psi
Elbow 82983407 90_
Tube Assembly 82983405 Steel

41-3
SECTION 41 -- STEERING SYSTEM -- CHAPTER 1

SPECIAL TOOLS

Tool Description Old Part Number Global Part Number


Kit, Hydraualic Test 292870 380000240
Instealler, Seal part of Kit 380040100 CNH294056 380000281
Fitting, Steering part of Kit 380040092 291318 380000613
Adapter, Steering part of Kit 380040092 293874 380000618
Fitting, Straight FNH00119
Fitting, part of Kit FNH02003 FNH00724
Tee, part of Kit FNH02003 FNH00838
Gauge, Pressure 0--5,000 psi FNH02028
Hose, part of Kit FTC61682 FNH07099
Puller, Attachment FNH09190
Puller, Grip-O-Matic FNH09198

41-4
SECTION 41 -- STEERING SYSTEM -- CHAPTER 1

FAULT FINDING
IMPORTANT: To avoid repeat failures, investigate and correct the cause of the defect when making repairs to
the steering system.

STEERING SYSTEM

Problem Probable Cause Remedy


No steering available, or excessive effort Oil level incorrect Replenish oil with the correct
q
required to steer grade and quantity
Air in system Tighten loose connections.
Bleed air from system
Relief valve malfunctioning Test relief valve and overhaul
or replace if necessary
Steering pump malfunctioning Test pump and overhaul if
required
Steering cylinder leaking Tighten connections or
overhaul cylinder
Steering column shaft Repair or replace
damaged
Control valve spool sticking or Repair or replace
worn
Metering unit malfunctioning Repair or replace
Steering wanders Linkage or ball joint excessive Check for correct torque,
play Repair or replace defective
components
Steering cylinder leaking Tighten connections or
overhaul cylinder
Metering unit malfunctioning Repair or replace
Control valve spool sticking or Repair or replace
worn
Control valve return springs Replace springs
worn
Tire pressures not equal Service both tires to correct
pressure
Toe-in out of adjustment Adjust toe-in
Torsion bar worn (2WD) Repair or replace
Valve shimming incorrect Check for correct amount of
shims and modify accordingly
Front wheels surge when steering Steering cylinder leaking Tighten connections or
overhaul cylinder
Control valve spool sticking or Repair or replace
worn
Control valve return springs Replace springs
worn
Metering unit malfunctioning Repair or replace
High steering system noise Wrong filter installed on steer- Verify steering pump filter
ing pump, causing cavitation contains correct part number,
and vibration in piping to and that it is correctly installed
steering motor (Refer to ASIST 3572)
Oil level incorrect Replenish oil with the correct
grade and quantity
Air in system Tighten loose connections.
Bleed air from system
Oil contains water Replace oil

41-5
SECTION 41 -- STEERING SYSTEM -- CHAPTER 1

DESCRIPTION AND OPERATION The steering motor contains a metering unit to regu-
The steering system controls the direction of the front late the volume of oil to the steering cylinder, propor-
wheel assemblies with pressurized hydraulic oil. tional to the angular movement of the steering wheel.
There is no mechanical linkage connecting the steer- This controls the rate of turn. A check valve functions
ing column to the wheels, thereby making the steer- in combination with the metering unit to allow manual
ing system hydrostatic. operation of the steering system in the absence of
pressurized oil from the pump. The pressure relief
Steering system components include: valve, an integral part of the steering motor, protects
the system from over-pressurization.
• Transmission Mounted Steering Pump
The steering cylinder on 2WD tractors is a double
• Pressure Relief Valve acting, unbalanced type, which connects to the front
• Steering Wheel and Column axle beam on one end, and either the right-hand side
• Steering Motor of the tie bar, or left-hand wheel spindle, depending
on configuration. The combination of an unbalanced
• Steering Cylinder
steering cylinder (piston end area greater than rod-
• Hoses and Piping end area) with a reactionary steering valve, creates
a biased system. This disparity causes the front
The steering system receives pressurized oil from a wheels to drift left, whether the tractor is moving or
transmission mounted steering pump, driven by the stationary.
PTO idler gear. In addition, the rear axle serves as a
common hydraulic oil reservoir for the steering sys- A bias valve introduced into production in 2001, was
tem, as well as other systems. added in-line of the unbalanced steering cylinder
rod-end, to counteract the force of the larger piston
The steering wheel, when turned, rotates a spline area at the cylinder end. This action creates a bal-
shaft within the steering motor. The steering motor anced cylinder under a majority of operating condi-
reacts by directing hydraulic oil under pressure from tions.
the transmission-mounted pump to the double-act-
ing unbalanced steering cylinder (2WD), or the The steering cylinder on 4WD tractors is a double-
double-acting, balanced steering cylinder (4WD), to acting balanced type. The cylinder housing mounts
drive the front wheels. The steering column adjusts to the backside of the front axle, in the center, with the
to vary the angle of tilt. cylinder ball joints connecting to the left and right
front wheel swivel assemblies.

41-6
SECTION 41 -- STEERING SYSTEM -- CHAPTER 1

OIL FLOW through another passage within the spool and sleeve
The steering pump within the transmission mounted until reaching the steering cylinder.
tandem pump assembly; draws oil from the rear axle
Passages in the spool and sleeve allow oil from the
center casing, pressurizes the oil, and then directs
opposite side of the steering cylinder to flow back to
the oil to the steering circuit.
return by way of the steering motor housing
When holding the steering wheel still, springs in the
Manual steering provides a means of controlling the
steering motor maintain the spool and sleeve in the
tractor when a loss of oil pressure occurs. When turn-
neutral position, stopping the flow of oil to the steer-
ing the steering wheel for a right-hand turn, the me-
ing cylinder. Trapped oil within the cylinder transfers
tering unit forces oil into the power steering cylinder.
between the left and right sides of the cylinder as the
On the suction side of the metering unit, return oil
wheels react to the ground, providing feedback to the
flows from the steering cylinder through the check
operator.
valve to feed the metering unit. The same action oc-
Turning the steering wheel causes movement of the curs for left-hand turns.
control valve spool within the sleeve to form a series
Returning oil flow from the steering motor reenters
of passages. When turned right, oil flows through the
the steering pump body. The pump redistributes the
sleeve along a groove in the spool and into the steer-
oil through the rear axle center casing to the cooling
ing motor housing to the metering unit. The drive
and lubrication circuit.
shaft rotates the metering unit, directing the oil

41-7
SECTION 41 -- STEERING SYSTEM -- CHAPTER 1

1
Low-Pressure, Steering, and Lubrication Circuit with (tandem gear) Transmission Mounted Pump
(Sheet 1 of 2)

41-8
SECTION 41 -- STEERING SYSTEM -- CHAPTER 1

2
Low-Pressure, Steering, and Lubrication Circuit with (tandem gear) Transmission Mounted Pump
(Sheet 2 of 2)

41-9
SECTION 41 -- STEERING SYSTEM -- CHAPTER 1

41-10
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2

SECTION 41 - STEERING SYSTEM

Chapter 2 - Component Overhaul

CONTENTS

Section Description Page


Steering Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Steering Column Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Steering Cylinder – Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Steering Cylinder – Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Flow Control Valve -- Power Steering Pump (Where Installed) . . . . . . . . . . . . . . . . . . . . . . 25
Transmission Mounted Tandem Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Steering System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

41-1
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2

STEERING MOTOR

Removal
1. Disconnect battery negative (ground) cable.
2. Raise the engine hood.
3. Remove steering column consoles.
4. Before removing, identify and mark the position
of each steering hose and motor connection (1),
Figure 1, to facilitate re-assembly.
IMPORTANT: Failure to identify the correct position
of the hydraulic connectors on the steering motor
may lead to improper installation. The steering sys-
tem rapidly over heats with hydraulic connector part
number 390584S2 installed in the pressure ‘IN’ port
vice steering cylinder port.

5. Remove the four steering hoses from steering


motor. Cap and plug openings to prevent con-
tamination. 1

6. Remove the roll pin from the drive collar to sepa-


rate the steering shaft.
7. Remove bolts at base of steering column. Slide
steering motor from the upper section of the
steering column.
8. Remove the steering motor.

41-2
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2

2
1. Drive Pin 14. Check Valve Retainer
2. Control Valve Sleeve 15. Check Valve Ball
3. Centering Springs 16. Pressure Relief Valve Assembly
4. End Plate Retaining Bolts / Washers 17. Seal
5. End-Plate 18. Steering Motor Housing
6. O-Ring 19. Back-up Ring
7. Metering Unit Stator 20. Suction Valve Balls
8. O-Ring 21. Suction Valves
9. Rotor Plug 22. O-Ring
10. Metering Unit Rotor 23. Spring Retainer and Bearing Assembly
11. Distributor Plate 24. Thrust Washer
12. O-Ring 25. Control Valve Spool
13. Drive Link

41-3
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Disassembly
1. Secure the steering motor in a holding fixture with
the end-plate upward.
2. Remove the seven end-plate retaining bolts.
Note the position of the pin bolt (1) to facilitate re-
installation, Figure 3.
NOTE: The position of the pin bolt must remain the
same on re-assembly.

3
Refer to Figure 4.

3. Remove the end-plate (1).


4. Remove the O-ring (2) and discard.
5. Remove the rotor plug (4) from the metering unit
(3).

4
Refer to Figure 5.

6. Remove the metering unit (3).


7. Remove the O-ring (1) and discard.

41-4
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
8. Mark the alignment of the metering unit stator (1)
and the metering unit rotor (2), Figure 6.
9. Disassemble metering unit.

6
Refer to Figure 7.

10. Remove the drive link (1) from the steering motor
housing (2).
11. Remove the distributor plate (2).
12. Remove the O-ring and discard. See Figure 5.

7
Refer to Figure 8.

13. Remove the two suction valves (1) and balls (2).
14. Unscrew the check valve retainer (3).

41-5
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
15. Remove the check valve retainer (1) and ball (2),
Figure 9. 1
2

60--41--005 TI
9
16. Remove the pressure relief valve assembly (1),
Figure 10.
1

60--41--006 TI

10
17. Push out the control valve and outer sleeve (2)
from the steering motor body (1), Figure 11.
NOTE: When removing the control valve and outer
sleeve, position the drive-pin horizontally to prevent
the pin from slipping into the internal gallery.

11

41-6
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
18. Remove the thrust washer, spring retainer, and
bearing assembly (1) from the control valve, Fig- 1
ure 12.

60--41--009 TI

12
19. Note the arrangement of the centering-springs
(1) before removing, Figure 13. 2

60--41--010 TI

13
Refer to Figure 14.

20. Use a suitable guide (2) to push out centering


springs (1) from control valve, Figure 15.
21. Remove the drive-pin (2), Figure 14.
22. Remove the control valve spool from the outer
sleeve.
23. Discard O-rings.

20030989

14

41-7
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Inspection
1. Clean all components in a suitable oil-based sol-
vent. Allow parts to dry.
2. Inspect sleeves for scratches, burrs and nicks.
Remove minor imperfections with a fine abra-
sive. Replace components if defective.
Assembly
NOTE: Replace all O-rings and seals when re-
assembling.

Refer to Figure 15.

1. Insert the control valve spool (4) into outer sleeve


(2) and align slots (3).
2. Install the drive-pin (1).

15
3. Insert centering spring (2) into control valve (1)
slot as shown in Figure 16.

16
4. Install the thrust washer, spring retainer and
bearing assembly (1), Figure 17. 1
NOTE: Position the inner bearing race with chamfer
side facing the control valve spool.

60--41--009 TI

17

41-8
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
5. Apply a light coating of clean hydraulic oil to the
outer sleeve.
6. Insert the outer sleeve (2) into the steering motor
housing (1), Figure 18.

18
7. Coat O-ring and back-up rings with clean hydrau-
lic fluid and position on Seal Installer Tool No.
CNH294056 (1), Figure 19.

60--41--013 TI

19
8. Position Seal Installer Tool (1) into the sleeve (2)
and push down using a twisting action, Fig- 1
ure 20.
9. Completely seat the seal. 2
10. Remove seal installer tool.
11. Install control valve and spool.
NOTE: Position the control valve with the drive-pin
horizontal, to facilitate installation into the steering
motor housing.

60--41--014 TI

20

41-9
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
12. Install the pressure relief valve (1) with, spring,
retainer, and valve head, Figure 21.
1

60--41--006 TI

21
Refer to Figure 22.

13. Install the check valve, ball (2) and retainer (1) 3
into steering motor housing.
NOTE: Screw the check valve retainer down into the 4 1
motor body just below the surface.

14. Install the suction valves (3) and balls (4) into 2
steering motor housing.

60--41--005 TI
22
15. Position a new O-ring (3) and install distributor
plate (1) onto steering motor housing (2), Fig-
ure 23.

23

41-10
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Refer to Figure 24.

16. Before installing the drive link, align the control


valve drive pin (2), perpendicular (3) with the
front face of the motor housing (1).
17. Install the drive link (4) into the steering motor
housing. Ensure the drive link engages the drive-
pin correctly.

24
18. Assemble the metering unit stator and rotor (3),
using the guide mark (1) from ‘Disassembly Step
10. Ensure to align bolt holes (4) and the pin bolt
hole (2), Figure 25.

20030990

25
Refer to Figure 26.

19. Install new O-rings (1) if not previously done.


20. Install the assembled metering unit (3) to the dis-
tributor plate (2).

26

41-11
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Refer to Figure 27.

21. Install the rotor plug (4) into the metering unit (3).
22. Install a new O-ring (2).
23. Position the end-plate (1).

27
Refer to Figure 28.

24. Install the seven retaining bolts into the end-


plate. Ensure to install the pin bolt in the original
location of removal (1).
25. Tighten the retaining bolts to an initial torque of
11 Nm (97 in.-lb.).
26. Tighten the retaining bolts to a final torque of 29
N⋅ (257 in.-lb.).

28
27. Install the four hose connectors (1), Figure 29,
into the steering motor housing. Tighten connec- 1
tors to a torque of 83 Nm (61 ft.-lb.).
NOTE: Install the hydraulic connectors on the steer- 1
ing motor exactly as removed. The steering system
rapidly over heats with hydraulic connector part num-
ber 390584S2 installed in the pressure ‘IN’ port vice
steering cylinder port.

Installation
1. Install the steering motor into the steering column
and install bolts. 60--41--007 TI
29
2. Tighten the retaining bolts to a torque of 31 Nm
(274 in.-lb.).
3. Install roll pin into drive collar of steering shaft.
4. Attach the hoses to the connectors on the steer-
ing motor. Tighten gland nuts to a torque of 13 --
20 Nm (10--15 ft.-lb.).
5. Install the steering column consoles.
6. Connect the battery negative (ground) cable.
7. Replenish oil and purge air from hydraulic sys-
tem. Refer to Section 35 “Hydraulic Systems”.
8. Check steering system for proper operation.

41-12
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2

STEERING COLUMN REMOVAL AND


INSTALLATION

Removal
1. Remove the steering wheel, if required.
2. Remove the lower steering column cover com-
plete with multi-function switches.
3. Remove the upper steering column cover.
4. Remove the instrument console side panels.
5. Remove the four securing bolts securing the col-
umn to the frame.
6. Lift the column clear of the steering shaft and
clear of the instrument console.
7. Remove the pin from the spacer at the bottom of
the column and remove the steering shaft and
spacer.

Inspection
1. Inspect the steering shaft universal joint and
lower rubber coupling. Replace if any free play is
evident.
2. Inspect the column assembly for worn bushings
and replace assembly if found.

41-13
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Installation
1. Place spacer and steering shaft onto the steering
motor and install pin.
2. Carefully place the steering column through the
instrument console and over the steering shaft,
ensuring flat sides are aligned.
3. Replace the securing bolts at the top of the col-
umn. Tighten to 23 Nm (17 ft.-lb.).
4. Install the upper and lower column covers and
shuttle switch if fitted.
5. Install the instrument console panels.
6. Install the steering wheel.

41-14
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2

STEERING CYLINDER – TWO WHEEL DRIVE

R-8-493

30

Steering Cylinder Assembly


1. Clamp 9. Ball Joint
2. Ball Joint 10. Clamp
3. Wiper Seal 11. Wiper Seal
4. Gland Seal 12. Piston
5. Bearing Bush 13. Piston Seal Pack
6. Bearing Bush 14. Gland-to-Cylinder Seals
7. Gland Seal 15. Gland and Tube Assembly
8. Piston Rod

Removal
1. Park the tractor on a hard level surface with the
front wheels straight ahead.
NOTE: Observe the position and location of the
steering hoses and connectors to facilitate re-as-
sembly.

2. Disconnect the cylinder hoses. Cap and plug


openings to prevent contamination.
3. Remove the retaining nuts (3) and separate ball
joints (1) from the right-hand tie rod (2), and the
axle, Figure 35.
31

41-15
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Disassembly
1. Drain the cylinder of oil.
2. Remove the steering hose connector at the pis-
ton end. Remove the bias valve (2) and the 90_
elbow (1) at the cylinder rod-end (3), Figure 36,
(where installed).
3. Cap and plug openings to prevent contamination.

32
4. Loosen the bolt (1) and remove ball joint assem-
blies (2), Figure 37.
IMPORTANT: When using a holding fixture such as
a vice, do not clamp directly around the cylinder bar-
rel, as damage to the cylinder will occur.

33

41-16
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
5. Using a suitable spanner wrench (2) as shown in
Figure 38, unscrew the extension tube (1) and
gland assembly.
6. Remove the gland and piston rod assembly from
the cylinder.
7. Remove and discard O-rings and seals.

Inspection
1. Wash all components in a suitable solvent. Allow
parts to dry.

34
2. Inspect all parts for obvious damage and wear.
Replace defective components.
3. Inspect ball joints for looseness.

Assembly
1. Install new O-ring (3), piston seal (4) and wear
ring (1) onto piston (2), Figure 39.

35

41-17
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2

36
Steering Cylinder Assembly
1. Piston and Rod Assembly 9. Seal Kit items*
2. Cylinder 10. Nut
3. Extension Tube 11. Track rod end
4. Track Rod End 12. Clamp Bolt (where installed)
5. Dust Washer * Seal Kit Consists of:--
6. Clamp Bolt (where installed) Rod Seals and Bushing
7. Clamp Piston Seals
8. Nut Gland Seals

41-18
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
2. Install new rod seals (3) in gland (1). Ensure the
sealing lip faces towards oil pressure. Install new
back-up rings (5), O-rings (4) and rod wipers (2),
Figure 41.

37
3. Lubricate seals and slide gland assembly (2)
onto piston/rod (1), Figure 42.

38
4. Insert the piston/rod (1) and gland assembly (3)
into the cylinder barrel (2), Figure 43.
5. Screw gland into barrel and seat completely.

39

41-19
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
6. Install the steering hose connector at the steering
cylinder piston end. Install the 90_ elbow (1) and
the bias valve (2) at the cylinder rod-end (3), Fig-
ure 44 (where installed).

40
Installation
Installation of the steering cylinder follows the remov-
al procedures in reverse with the following require-
ments:

1. Screw anchor and ball joint into extension tube


completely, then unscrew ball joint a fraction of a
turn to correctly position connectors as shown in
Figure 45.
2. Tighten the ball joint clamps to a torque of 43 Nm
(32 ft.-lb.).
3. Compress the cylinder rod until piston bottoms in
the cylinder.
41
Refer to Figure 46.

4. Install cylinder anchor-end ball joint (1) to the


track rod.
5. Tighten the ball joint nut to a torque of 120 Nm (89
ft.-lb.).
6. Position the wheels to the full right-hand turn
position as shown in Figure 46.
7. Starting with the steering cylinder rod fully re-
tracted, extend the cylinder rod out by 4.0-10.0
mm (.16-0.4 in).

42

41-20
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
8. Adjust cylinder rod-end ball joint, until aligned
with lug on track rod, and then install ball joint nut.
9. Tighten ball joint nut to a torque of 173 Nm (130
ft.-lb.).
10. Position wheels straight ahead and adjust track
rod until obtaining a toe-out of 0-13 mm (0-0.5 in),
measured on the wheel rim at hub height. Use A
minus B as shown in Figure 47. Also see Section
44 “Front Axle”.
11. Ensure the spindle stops contact axle-housing
stops on full left and right turns.
12. Connect steering hoses.
43
13. Replenish hydraulic oil level.
14. Check cylinder and hoses for leakage, and purge
air from the hydraulic system by running the en-
gine, and operating the steering system.

STEERING CYLINDER – FOUR WHEEL


DRIVE

Removal
1. Position the tractor on a level surface with the
wheels straight ahead.
2. Loosen the retaining bolts (1) two turns, which
secure the cylinder end-plate (2), and cylinder (3)
to differential casing, Figure 48.
3. Turn the steering wheel to the left and unseat the
end cap and cylinder from the differential casing. R-10-530

44
Steering Cylinder End Plate/Retaining Bolts
1. Retaining Bolts
2. End Plate
3. Cylinder Rod
4. Hydraulic Hose

NOTE: There will be a slight loss of oil from the end


cap.

4. Remove the track rod and retaining bolt (1) from


the left and right-hand steering arm (2), Fig-
ure 49.

R-10-571

45
Steering Track Rod End
1. Track Rod
2. Steering Arm

41-21
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Refer to Figure 50.

5. Remove the clamp bolt (3), from the left and right-
hand track-rod (2).
6. Unscrew the track-rod, from the left and right-
hand ball joint (1).
7. Unscrew the left and right-hand ball joint from the
steering cylinder (4).

R-10-570

46
Disconnecting Track Rod and Ball Joint from
Cylinder Rod
1. Ball Joint
2. Track Rod
3. Track Rod Clamp
4. Cylinder Rod

8. Disconnect the hydraulic hoses. Cap and plug


openings to prevent contamination.
9. Remove fitting from right side of cylinder.
10. Remove steering cylinder retaining bolts and re-
move the steering cylinder from the differential
carrier, Figure 51.

R-10-531

47
Removing Steering Cylinder from Differential
Carrier Mounting
1. Hydraulic Hose

Disassembly
1. Remove the cylinder rod (4) with end-plate (3),
and piston assembly (2) from the cylinder barrel
(1), Figure 52.
2. Slide the end-plate off from the left side of the
cylinder.

R-10-580

48
Removing Cylinder Rod and Piston Assembly
from Cylinder Barrel
1. Barrel 3. End Plate
2. Piston (part of rod) 4. Rod

41-22
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Refer to Figure 53.

3. Remove the wear rings.


4. Remove the piston seal.
5. Remove the O-rings.
6. Remove the wiper seals.

R-10-581

49
Steering Cylinder Exploded View
1. Wear Ring 7. Wiper Seal
2. Wiper Seal 8. End Plate O-ring Seal
3. Oil Seal 9. Wear Ring
4. Cylinder Barrel 10. Piston Seal
5. End Plate 11. Piston Seal Expander (O-ring)
6. Oil Seal 12. Cylinder Rod and Piston

Inspection
1. Clean all components in suitable oil based sol-
vent. Allow parts to dry.
2. Inspect the rod, and piston assembly, for wear,
corrosion or distortion. Remove minor nicks and
abrasions using an abrasive stone.
3. Inspect the inside of the cylinder barrel for chaf-
fing.
When finding the rod and piston assembly, or the cyl-
inder barrel defective beyond service, replace the
complete steering cylinder.

4. Inspect both track rods, and both cylinder ball


joints for wear or looseness. Replace parts if
found defective.

41-23
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Assembly
Refer to Figure 53.

1. Install new wiper and oil seals in the cylinder end


plate.
2. Install new wiper and oil seals in the cylinder bar-
rel.
3. Install a new wear ring on the piston.
4. Install a new wear ring, piston seal and O-ring on
cylinder rod.
5. Lubricate all seals and the piston assembly with
clean hydraulic oil.
6. Install piston assembly into the cylinder barrel.
NOTE: Allow the center seal with the O-ring on the
piston and rod assembly to contract naturally before
installing into cylinder barrel.

Installation
Installation of the steering cylinder follows the remov-
al procedures in reverse with the following require-
ments:

1. Tighten the steering cylinder ball joints to a


torque of 300 Nm (221 ft.-lb.).
2. Tighten the cylinder end-plate retaining bolts to
a torque of 120 Nm (89 ft.-lb.).
3. Position hydraulic connections and hoses to pre-
vent interference with other components,
through all degrees of front axle steering.
4. Check the level of the hydraulic oil and replenish
as necessary with the correct grade and quantity.
5. Cycle the steering system and check for leaks,
correct operation.
6. Check for contact of the wheel swivels to the
steering stops at full left and full right movement.
If adjustment of stops is required, follow the pro-
cedures for “Steering Stops-adjustment” de-
scribed in this chapter.

41-24
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Steering Stops - Adjustment
Refer to Figure 54.

Each front wheel swivel contains two steering stops


(2), which contact machined areas (3) on the front
axle. Adjustment of the stops is as follows:

1. Loosen the locknut (1) of the steering stop requir-


ing adjustment.
2. Turn the stop bolt counter-clockwise to reduce
the steering angle of the wheels, or clockwise to
increase the steering angle.
OM16
3. After adjustment, check that the minimum clear-
ance between the tires, and any part of the tractor 50
on full left or full right movement, is 20 mm (0.75 Steering Stop
in). 1. Locknut
2. Stop Bolt
4. With wheels full left, check that the left-hand rear
3. Boss
steering stop makes contact with the front axle,
at the same time the right-hand front steering
stop makes contact with the front axle.
5. Tighten the stop bolt locknut to a torque of 150
Nm (110 ft.-lb.).
6. If necessary, check front wheel toe-in using the
procedures described in Section 25 “Front Axle”.

41-25
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
TRANSMISSION MOUNTED TANDEM PUMP
2
Removal
1. Remove the right-hand rear wheel assembly.
2. Remove the rear axle drain plug and drain the hy-
draulic oil.
3. Disconnect the brake actuating rods from the lev-
ers. Refer to Section 33 “Braking Systems”.
4. Remove the brake pedal assemblies. Refer to
Section 33 “Braking Systems”. 1

51
Fixed Displacement Gear Type Pump Installation
1. Return from Steering Motor
2. To Steering Motor

5. Disconnect all hydraulic connections at the


pump. Cap and plug all exposed openings to pre-
vent contamination.
6. Remove the pump retaining bolts and lift pump
off transmission housing.

Disassembly
1. Unfold tabs and remove the input drive gear nut 6
(5) and locking washer (4) at the front (lift) pump.
Then remove the input drive gear (2) and key (3) 3
from the drive shaft (1), Figure 52. 5
4
NOTE: Use a soft mallet to loosen the drive gear from
the tapered drive shaft if necessary.
2. Remove the six end-cover retaining bolts (6) and 52
washers.

41-26
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
3. Ease the end-cover (1) forward to clear the locat-
ing dowels (3), then tilt the cover to clear transfer
tube (2), Figure 53. Lift cover off pump.

CAUTION
Do not attempt to disassemble the internal snap
ring, which secures the drive shaft to the driven
gear assembly. Damage to the snap ring or drive
shaft is likely to occur.

53
Refer to Figure 54.

4. At the front pump, remove the drive shaft and


driven gear as an assembly, and collect the bear-
ing blocks. Identify components to facilitate as-
sembly.
5. Observe the positioning of the seals to facilitate
re-assembly.

54
Hydraulic Lift Pump (Front Pump) -- Exploded View
1. Pump Housing 9. Locking Washer
2. Steering Pump 10. Drive Gear
3. Bearing Block 11. Oil Seal
4. Driven Gear 12. Nylon Back--Up Ring
5. Transfer Tube 13. Seal
6. End Cover 14. Bearing Block
7. Bolts (4 Long, 2 Short) 15. Woodruff Key
8. Nut 16. Drive Shaft and Gear Assembly

41-27
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Refer to Figure 55.

6. Remove the rear (steering) pump assembly from


the pump housing.
7. Remove the gears and bearing blocks.
8. Remove the connector shaft and sandwich plate.
9. Identify the positioning of all components includ-
ing the nylon back-up rings and seals to facilitate
re-assembly.

55
Steering Pump (Rear Pump) -- Exploded View
1. Pump Body 9. Nylon Back-Up Ring
2. Seal 10. Pump Housing
3. Nylon Backing Strip 11. Seal
4. Bearing Block 12. Nylon Backing Strip
5. Driven Gear 13. Bearing Block
6. Seal 14. Transfer Tube and Snap Ring
7. Sandwich Plate 15. Drive Gear
8. Seal

41-28
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Inspection and Repair
1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Inspect bushings and bearing blocks for wear or
damage. Check for blocked lubrication scrolls in
the bushings. Replace the gears and bearing
blocks as a matched set if required. DO NOT ser-
vice separately.
3. Inspect pump gears for wear or damage, particu-
larly the bearing journals, gear teeth and side fac-
ings.
4. To ensure maximum pump efficiency, the width of
each pair of pump gears must be within 0.005
mm (0.0002 in) of one another, and the journals
within 0.013 mm (0.0005 in).
5. Remove light scoring marks on the gear facing
areas using a sheet of ‘O’ grade wet or dry abra-
sive paper and lubrication on a true flat surface.
Polish the area repaired using light pressure in a
rotating motion. Polished journals will achieve
free movement in the body.
6. Inspect the gear track, embedded during the
manufacturing process for the gear teeth, on the
suction side of the pump. The track depth must
not exceed 0.10 mm (0.004 in), or continue be-
yond the suction half of the gear aperture. Re-
place the pump when gear tracks do not fall with-
in specification.
7. Burrs found at the edge of the gear track should
be removed with ‘O’ grade emery paper.
8. Inspect the pump cover for damage or cracks,
particularly adjacent to the inlet and outlet ports,
filter connection and pump face. Check internal
passages for blockage.
9. Any component found unserviceable should ne-
cessitate replacing the pump assembly. If in an
emergency, worn components are replaced indi-
vidually, note the following points:
• The installation of new bearings will re-center
the gears and prevent the tips of the gear
teeth from bottoming, if continuing to use a
pump body where the track is out of
specifications. Thereby resulting in pump
inefficiency.
• Under working conditions, hydraulic pres-
sure within the pump loads the gears towards
the inlet side of the pump body. Continued
use of worn bearing and gear journals
causes the gears to shift, thus deepening the
gear track in the pump body.

41-29
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Assembly
Assembly of the fixed displacement transmission
mounted (tandem gear) type pump follows the disas-
sembly procedures in reverse with the following re-
quirements:

1. When replacing the pump dowels, install new


dowels with 2.54 mm (0.10 in) protruding from
the pump housing.
2. Replace all O-rings and seals.
3. Install washers (1) and (5) and O-ring seals (2)
and (4) on the transfer tube (3), Figure 56.
4. Coat all seals and O-rings with petroleum jelly.
5. Lubricate all parts with clean hydraulic oil.
6. Assemble original gears with original bearings
exactly as removed. This step is critical in main-
taining pump efficiency.

56
7. The bearing block (4) in the steering pump (2)
contains an edge with a radius (1). Install the
bearing block with the radius edge to the bottom
of the steering pump bore (3), Figure 57.
NOTE: Only one of the two bearing blocks installed
in the steering pump contains a corner edge with a
radius. Incorrect installation of the sharp edged ra-
dius block (13), Figure 55, will damage the pump.

8. Pack the cavity behind the lips of the front-end


cover input drive shaft seal with high melting
point grease.

57
Bearing Block Installation

41-30
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
9. The end-cover bolts have different lengths. En-
sure to install the correct bolts in the locations ex-
actly as removed, Figure 58, and tighten to a
torque of 50-62 Nm (37-46 ft.-lb.).
10. If removed, install the pressure relief valve and
tighten to a torque of 60-68 Nm (44-50 ft.-lb.).
11. Install the input drive gear nut and tighten to a
torque of 50-56 Nm (37-41 ft.-lb.). Bend the
washer locking-tab against the pump drive, gear
nut.
12. Keep all ports and lines capped and plugged until
installation of hydraulic connections to prevent
entry of foreign objects and contaminants. 58
End Cover Bolt Location
A. Bolt M10 x 100 mm with Ground Shank
B. Bolt M10 x 100 mm with Dull Black Shank
C. Bolt M10 x 115 mm with Ground Shank
D. Bolt M10 x 115 mm with Dull Black Shank

Installation
The installation of the transmission mounted fixed
displacement (tandem gear) type pump follows the
removal procedures in reverse with the following re-
quirements.

1. To prevent internal and external leakage, and im-


prove pump efficiency, perform the following
when installing new O-rings and seals:
• Lubricate with clean hydraulic fluid.
• Do not allow connections to pinch, or O-rings
to roll and twist when installing.
• Ensure proper positioning.
• Completely seat into grooves.
2. Before installing, fill pump suction port with clean
hydraulic oil and hand rotate the gears.
3. Tighten the pump-to-transmission retaining bolts
to a torque of 57-76 Nm (42-56 ft.-lb.)
4. Tighten all hydraulic connections and fittings.
5. Replenish the rear axle center casing oil. Refer
to Section 27 “Mechanical Rear Wheel Drive”.
6. Perform a pressure test of the pump. Refer to
Section 35, “Adjustments and Testing”.
7. Operate the brake pedals after assembling, and
check for binding and proper operation. Refer to
Section 33 “Braking System”.

41-31
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Steering System Testing
1. Start the engine and set engine speed to 1000
rev/min.
2. Turn the steering wheel quickly from stop to stop.
The reaction of the front wheels should be imme-
diate.
3. About the time the front wheels contact the axle
stops, the steering motor relief valve opens, and
engine speed reduces to approximately 970 rev/
min.

Steering Motor Pressure Relief Valve Testing


1. Disconnect the left-hand turn feed hose at the
steering cylinder.
2. Install a 0-5000 Pressure Gauge Tool No. FNH
02028, with Adapter Tool No. FNH00119, and a
locally procured 7/16 JIC male X 9/16 JIC male
adapter, to the cylinder feed hose.
3. Using Hydraulic Test Kit No. 292870, install
Adapters 293874 and 291318 into the banjo fit-
ting of the steering cylinder.
4. Start engine and set engine speed to 1450 rev/
min.
5. Turn the steering wheel counterclockwise, using
22 N (5 lb) of pull and observe reading on gauge.
6. Observe cylinder feed line gauge and compare
reading to the pressure relief valve setting:
2WD 153-163 bar (2220-2370 psi)

4WD 180-191 bar (2620-2770 psi)

Adjust the steering motor pressure relief valve when


necessary, to obtain specified pressures.

7. Check oil level and replenish as necessary.


8. Operate the steering system through several
complete cycles to verify correct operation, and
to purge air from the system.
9. Check connections for evidence of leaking.

41-32
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Steering Motor Pressure Relief Valve
Adjustment
Refer to Figure 59.

1. Disconnect the steering motor from the steering


column bracket. Refer to the “Steering Motor”
overhaul section of this chapter.
2. Connect suitable test hoses to the pressure and
return tubes of the steering motor as shown in
Figure 59.
3. Using a ‘T’ fitting, connect a 0-5000 psi gauge to
the pressure line of the steering motor.
4. Using a ‘T’ fitting, connect a 0-500 psi gauge to
the return line of the steering motor.
5. Check all test connections for tightness.
6. Start the engine and idle 1450-1500 rev/min. run
the engine until the transmission oil reaches the
recommended operating temperature of 63°C
(146°F).
7. Turn the steering wheel clockwise or counter-
clockwise until contacting stop. Compare read-
ing on Gauge A to 163 bar (2370 psi) on 2WD, or
191 bar (2770 psi) on 4WD.
8. Compare the reading on gauge B to 17 bar (250
psi).
9. To establish differential pressure, subtract the
measurement of gauge B from the measurement
of gauge A and compare to 145 bar (2100 psi) on
2WD, and 190 bar (2500 psi) on 4 WD.
10. If the pressure readings do not fall within specifi-
cations, turn the pressure relief valve adjuster
(13) using an 8 mm hexagon key. Half of a turn
on the adjuster equates to approximately 13.8
bar (200 psi).
11. After obtaining desired pressure setting, remove
test equipment.
12. Check oil level and replenish as necessary.
13. Operate the steering system through several
complete cycles to verify correct operation, and
to purge air from the system.
14. Check connections for evidence of leaking.

41-33
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2

1
13
2
12
3

9 B 10
T
11

8 7 A 6

59
Steering Motor Relief Valve Adjustment
1. Plug 8. Size 8 ORS Swivel Running Tee
2. Steering Shaft 9. Size 10 ORS Swivel Running Tee
3. Relief Valve 10. Pressure Gauge 0--500lbf.in2
4. Fabricated Steering Motor Output Hose 11. Size 6 ORS Blanking Cap
5. Tractor Tubes to Steering Cylinder 12. Spring
6. Fabricated Hose for Pump Supply to Steering Motor 13. Adjuster
7. Pressure Gauge 0--5000lbf.in2

41-34
SECTION 44 -- FRONT AXLE--TWO WHEEL DRIVE -- CHAPTER 1

SECTION 44 - FRONT AXLE--TWO WHEEL DRIVE

Chapter 1 - Two Wheel Drive

CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clearances and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Front Axle Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Shim Thickness Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Track Width Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wheel Hub and Bearing - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wheel Spindle - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front Axle Center Beam - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

44-1
SECTION 44 -- FRONT AXLE--TWO WHEEL DRIVE -- CHAPTER 1

SPECIFICATIONS
TOLERANCES
Adjustment mm in
Front Axle – Two Wheel Drive – Toe In 0--6.0 mm 0--0.24 in
Front Axle – Two Wheel Drive – Toe Out 0--13 mm 0--0.5 in

SPECIAL TOOLS
Description Old Part Number Global Part Number
Plate, Step (set of 11) FNH09210
Protector, Shaft (set of 6) FNH09212
Puller, Attachment FNH09190
Puller, Grip-O-Matic FNH09198

TORQUE VALUES
Hardware Nm FT.-LB.
Front Axle Support –to--Engine Bolts 380 Nm 280 ft.-lb.
Wheel/Tire Assembly –to--Hub Mounting Bolts 133 Nm 98 ft.-lb.
Wheel Hub Retaining Nut (initial torque) 27--40 Nm 20--30 ft.-lb.
Wheel Hub Retaining Nut (final torque) 61--74 Nm 45--55 ft.-lb.
Front Axle Extension Bolts 210 Nm 155 ft.-lb.
Track Rod--end-to-Steering Arm Bolts 150 Nm 110 ft.-lb.
Track Rod Adjustment Lock Nut 75 Nm 55 ft.-lb.
Track Rod Locator Bolts 25 Nm 18 ft.-lb.
Spindle-to-Spindle Arm Nuts 165 Nm 122 ft.-lb.

TRACK WIDTH ADJUSTMENT (2WD)


(SEE FIGURE 1)
Location mm in
A C 1321 52
B D 1422 56
C E 1524 60
D F 1626 64
E G 1727 68
F H 1829 72
G J 1930 76
1

LUBRICANT
Grease, High Temperature 82923047 (AMBRA GR9)

MAXIMUM FRONT AXLE LOADING (2WD)


All Models 2268 kg 5,000 lbs

44-2
SECTION 44 -- FRONT AXLE--TWO WHEEL DRIVE -- CHAPTER 1

DESCRIPTION AND OPERATION


Refer to Figure 2.
1
The two-wheel drive, front axle assembly consists of 3
a hollow, center beam with telescopic extensions,
and spindle assemblies (1) at each end. The center
beam mounts to the front support assembly (2) by a
support pin which provides radial movement of the
axle along the centerline of the tractor.
2
Machined holes placed 50 mm (2 in) apart in the
center beam telescopic extensions, and the track
control rods align, allowing adjustment of the axle 40036184
track within 102 mm (4 in) steps, to vary the axle
length between 1321 and 1930 mm (52--76 in). 2

Wheel spindles mount to each telescopic extension


to support the wheel axle assemblies. The offset
centerline of the wheel spindle creates a trailing
effect of the front wheels, eliminating a need for a
castor angle. The keyed upper portion of the wheel
spindles accepts installation of a spindle arm.

Two taper roller bearings support the wheel hub on


the wheel spindle. A nut on the spindle retains the
outer cone and roller assembly, and establishes
bearing pre-load. A grease nipple located in the
wheel hub assembly allows for regular greasing of
the wheel bearing.

A cylinder (3) mounted to the center beam, and


connected to the left-hand side of the front axle,
provides hydrostatic steering. Movement of the
cylinder piston and rod assembly transmits to the
wheel axles through the track control rod, steering
arms, and wheel spindle assemblies.

44-3
SECTION 44 -- FRONT AXLE--TWO WHEEL DRIVE -- CHAPTER 1

ADJUSTMENTS
4 1
The correct toe-in setting is set in production. The
spindle steering arms (1) and wheel axle assemblies
(3) contain scribed marks (2) to identify the correct
position of the front wheels, with the steering in the
straight-ahead position, Figure 3.

10024883
3

3
Front Wheel Toe-in/Toe-off Adjustment
If the toe-in alignment marks on the spindle arms and
outer axle assemblies are not visible, or installation A
of replacement parts occurred, use the following
procedure to determine the toe-in setting:
B
1. On flat, level ground, slowly drive the tractor in a
straight line for at least 3 m (10 ft). Stop the tractor
and ensure the front wheels remain in the
straight-ahead position.
2. Mark the inboard rim of both front wheels toward
the front, at center of wheel hub.
24666
3. Measure the distance between the two marks
and note as Dimension ‘A’, Figure 4. 4

4. Maintain the straight-ahead position, and move


the tractor forward so the wheels rotate 180_ and
the marks of dimension ‘A’ face the rear.
5. Measure the distance between the two marks
and note as dimension ‘B’.
NOTE: If dimension A is larger then B, the toe-out is
A minus B. If dimension B is larger than A, the toe-in
is B minus A.
6. To ensure accurate results, repeat procedure three
times with three different marks equally spaced
around each wheel rim, and take the average
dimension for toe-in / toe-out. This method
minimizes inaccuracy due to wheel rim run-out.
7. Check front wheel toe-in at 0-6.0 mm (0-0.24 in.),
i.e. the measurement taken at the front of the rims
should be the same as the rear or be smaller by up
to 6 mm (0,24 in.). Proceed with steps 8 through 12
if not within specification. Check toe-out by
subtracting dimension B from dimension A.
Compare the result to a specification of 0-13mm
(0.5in.). Dimension A must be equal to or greater
than dimension B up to 13 mm (0.5 in).
8. Set the front wheels in the straight-ahead
position.

44-4
SECTION 44 -- FRONT AXLE--TWO WHEEL DRIVE -- CHAPTER 1
9. Loosen the track control rod lock nut (2).
10. Remove the left-hand track control rod-end bolt
and nut (1).
1
11. Proceed as follows:

Toe-In Adjustment without Alignment Marks


Turn the threaded portion (3) of the track control rod,
until obtaining the desired toe-in. Check after
reinstallation of track control rod-end bolt. After
obtaining correct toe-in adjustment, establish new 3
alignment marks on the spindle arms and outer axle 2
40036183
assemblies.
5
Track Rod -- Hydrostatic Steering
Toe-In Adjustment with Alignment Marks (left-hand side illustrated)
Turn the threaded portion (3) of the track control rod,
until the desired marks align on both spindle arms
and the outer axle assemblies. Check marks after
reinstalling the track control rod-end bolt.
12. Install the track control rod-end bolt and tighten
to a torque of 25 Nm (18 ft.-lbs.).
13. Tighten the track control rod lock nut.
14. Recheck toe in.

44-5
SECTION 44 -- FRONT AXLE--TWO WHEEL DRIVE -- CHAPTER 1

TRACK WIDTH ADJUSTMENT


1. Apply the hand brake and chock the wheels.
2. Jack up front axle and place on axle stand.
3. Disconnect track control rod at the right-hand
side steering arm.
4. Remove the left and right-hand axle extension
retaining bolts (1), and slide out from axle center
beam (2), Figure 6.
5. Set the left and right-hand axle extensions to the
required track width as indicated in Table 1.
Ensure to adjust both axle extensions equally.
6
NOTE: Table 1 lists approximate tract setting Table 1
distances from the dished side of the wheel nearest Track Setting Securing Bolt
the axle hub. Increase the track settings by Locations
approximately 102 mm (4 in) for wheels reversed on in. mm Refer to 5
the hub.
52 1321 A C
1. Install the axle extension retaining bolts and 56 1422 B D
tighten to a torque of 210 Nm (155 lb-ft). 60 1524 C E
2. Position both front wheels straight ahead and 64 1626 D F
loosen the track control rod right-hand end 68 1727 E G
adjustment locking nut, until the retaining bolt fits 72 1829 F H
through the steering arm.
76 1930 G J
3. Install the right-hand track control rod-to-steering
arm retaining bolt and tighten to a torque of 150
Nm (110 lb-ft).
4. Tighten the track control rod adjustment locking
nut to a torque of 75 Nm (55 lb-ft).
IMPORTANT: After 50 hours of operating the tractor,
recheck the tightness of front axle hardware.

44-6
SECTION 44 -- FRONT AXLE--TWO WHEEL DRIVE -- CHAPTER 1

Hub and Spindle Assembly


1. Spindle 6. Grease Retaining Cap
2. Grease Retainer 7. Castellated Nut
3. Inner Bearing 8. Washer
4. Outer Bearing 9. Hub
5. Split Pin

WHEEL HUB AND BEARING – OVERHAUL


Removal
Refer to Figure 7. 5. Unscrew the hub grease-retaining cap (6).
6. Remove the split pin (5) installed in the
1. With the tractor on firm level ground, apply the castellated nut. Remove nut (7) and washer (8).
handbrake and chock the rear wheels.
7. Remove the hub assembly (9), and the outer
2. Loosen the front wheel retaining nuts ¼ turn. bearing (4) from the front wheel spindle.
3. Use a suitable jack or hoist to raise the front 8. Remove the retainer (2) and inner bearing (3)
wheels off the ground. from the wheel spindle (1).
4. Remove the wheel retaining nuts and remove
wheel assembly.

44-7
SECTION 44 -- FRONT AXLE--TWO WHEEL DRIVE -- CHAPTER 1
Inspection and Repair 6. Install the outer bearing special washer. Ensure
1. Clean all components in suitable solvent. Allow the key fits correctly in the key--way of the
parts to dry. spindle.

2. Inspect hub inner and outer bearing assemblies, 7. Install the hub retaining nut.
and cups for damage, excessive wear or 8. Tighten the wheel hub retaining nut to an initial
corrosion. torque of 27--40 Nm (20--30 ft.-lb.).
3. Check for proper seating of the bearing cups 9. Rotate the hub clockwise 3 to 6 revolutions to
against the shoulder of the wheel hub. seat the bearing.
If necessary, replace bearings and cups as matched
10. Tighten the hub retaining torque to a final torque
sets.
of 61--74 Nm (45--55 ft.-lb.).
11. Insert a new split-pin into retaining nut. If
Installation necessary, back retaining-nut off by two
Refer to Figure 7. castellated areas, and retighten to the nearest
position that allows insertion of the split pin.
1. Pack the hub and bearings with suitable grease. 12. Install the wheel and tire assembly on the hub
2. Install the hub inner bearing. and install nuts. Tighten wheel hub nuts to a
torque of 133 Nm (98 ft.-lb.).
3. Install the hub inner bearing--retainer.
13. Remove the jack or hoist and the wheel chocks.
4. Install the wheel hub on the spindle.
5. Install the hub outer bearing.

44-8
SECTION 44 -- FRONT AXLE--TWO WHEEL DRIVE -- CHAPTER 1

WHEEL SPINDLE – OVERHAUL

Removal
1. With the tractor on firm level ground, apply the
handbrake and chock the rear wheels.
2. Loosen the front wheel retaining nuts 1/4 turn.
3. Use a suitable jack or hoist to raise the front 1
wheels off the ground.
4. Remove the wheel retaining nuts and remove
wheel assembly.
5. Disconnect the tract control rod from the steering
arm.
6. Use a suitable file (2) to clean the threads at the
top of the spindle (1), Figure 8.

2
8
NOTE: Deformed during production, the top threads
of the spindle act as a locking device for the steering 1 3
arm retaining nut. It is necessary to file the threads
before removal of the steering arm.

7. Remove steering arm nut (3), Figure 9.


8. Remove the steering arm (1) and dust seal (2),
Figure 9, from the spindle. If necessary, use
Puller Tool No. FNH09198, Attachment Tool No.
FNH09190, and Shaft Protector Tool No.
FNH09212 to aid in removal. 2

9
9. Remove the wheel spindle; thrust bearing (1),
and spacer (2), Figure 10.

10

44-9
SECTION 44 -- FRONT AXLE--TWO WHEEL DRIVE -- CHAPTER 1
Inspection
1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Inspect the spindle thrust bearing and bearing
surfaces for excessive wear, damage or
corrosion.
3. Inspect upper and lower spindle bushings in the
telescopic extension for excessive wear, dam-
age or corrosion.
4. Inspect track control rod ball joints for excessive
wear, damage or corrosion.
Installation
1. Position spacer (2) on wheel spindle with
chamfered edge of spacer facedown.
2. Pack the thrust bearing (1) with suitable grease,
and install on the spindle with the shroud facing
upwards, as indicated by the manufacturer
reference stamp on the bearing.
3. Install wheel spindle into telescopic extension.
Ensure the spindle rotates freely in the bushings.
4. Install dust seal on the spindle with the groove in
the outer edge of the seal nearest the bottom.
5. Install steering arm. Ensure the toe--in marks
align on both the steering arm and the spindle. 11

6. Install the spindle retaining nut and tighten to a


torque of 165 Nm (122 ft.-lb.).
7. Install the wheel and tire assembly on the hub
and install nuts. Tighten wheel hub nuts to a
torque of 133 Nm (98 ft.-lb.).
8. Remove the jack or hoist and the wheel chocks.

44-10
SECTION 44 -- FRONT AXLE--TWO WHEEL DRIVE -- CHAPTER 1

FRONT AXLE CENTER BEAM – OVERHAUL 11. Remove pins, thrust washer and center beam
assembly.
Removal
1. With the tractor on firm level ground, apply the Inspection
handbrake and chock the rear wheels. 1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Loosen the left and right front wheel retaining
nuts 1/4 turn. 2. Inspect front support bushings for excessive
wear, damage or corrosion. If necessary, replace
3. Use a suitable jack or hoist to raise the front bushings using Step Plate Tool No. FNH09210.
wheels off the ground. Support the front axle
center beam to remove weight off the front 3. Inspect the front support assembly for cracks,
support. damage or corrosion. Repair or replace defective
components as required.
4. Remove the wheel retaining nuts and remove
wheel assemblies.
Installation
5. Remove the steering cylinder. Refer to Secion 41 Installation of the front axle center beam follows the
“Steering System”. removal procedures in reverse with the following
6. Disconnect tract control rod-to-steering arm requirements:
retaining nuts.
1. To limit play in the front axle-to-front support
7. Remove the retaining bolts to the left and assembly, install washers (part number
right-hand telescopic extensions. Remove ex- 82983456, 82983457).
tensions.
2. When replacing with new, install front axle
8. Straighten the locking tab on the support pin. support (82983575).
9. Remove the axle support pin retaining bolts and 3. Tighten front axle support-to-engine retaining
anchors. bolts to 380 Nm (280 ft.-lb.).
10. Push out support pin sufficiently to gain access
to retaining bolt flange.

44-11
SECTION 44 -- FRONT AXLE--TWO WHEEL DRIVE -- CHAPTER 1

44-12
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

SECTION 55 - ELECTRICAL SYSTEMS

Chapter 1 - Electrical System and Components

CONTENTS

Section Description Page


Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Instrument Panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical Components -- Operation and Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

55-1
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

SPECIFICATIONS

STARTING SYSTEM
Description
Battery
y ((wet)) Ampere capacity 90 A
Ampere rating (cold cranking) 800 CCA
Voltage 12 V
Cells 6
Ground polarity Negative
Alternator Type 90 A
Ground polarity Negative
Nominal voltage 12 V
Maximum alternator rev/min 15,000 rev/min
Maximum out-put at max engine speed 90 A
Rotor field winding resistance 3.2 ohm
Stator winding resistance (per phase) 2.43 ohm
Brush length (new) 20 mm (.79 in.)
Minimum brush length 5 mm (0.20 in.)
Alternator Internal
Regulator Controlled voltage 13.6-14.4 V
Starting
g Motor Positive engagement - solenoid operated
Maximum no-load current draw at 12 V and 80 A
8000 rev/min
Minimum brush length 7 mm (0.28 in.)
Maximum commutator diameter 42.5 mm (1.67 in.)
Maximum armature shaft end-play 0.4 mm (0.016 in.)

55-2
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

LAMPS
Description Rating/Type
Instrument Panel Illumination Bulbs 12 V
Instrument Panel Warning Light Bulbs 12 V
Work Lamp Bulb 12 V 55 W - H3
Tail Lamp/Warning Flasher Bulbs 12 V P21/P21 W
Turn Signal Bulb (where installed) 12 V 21W/P21 W
Headlamp Bulbs 12 V 60/55 W - H4

TORQUE VALUES
Description N⋅M LB FT (LB. IN.)
Starting Motor Housing Bolts 114 mm (4.5 in.) 7 N⋅m 5 (60 lb. in.)
Starting Motor Housing Bolts 127 mm (5 in.) 11 N⋅m 8 (96 lb. in.)
Starting Motor-to-Fly Wheel Housing Bolts 30 N⋅m 22 (264 lb. in.)
Starting Motor Solenoid Terminal Nuts 7 N⋅m 5 (60 lb. in.)
Starting Motor Solenoid Retaining Nuts 5 N⋅m 4 (48 lb. in.)
Starting Motor–to-Engine Block Retaining Bolts 34 N⋅m 25 (300 lb. in.)
Starting Motor End-Housing Nuts 10 N⋅m 7 (84 lb. in.)
Starting Motor Drive-Lever Eccentric Pivot Pin 22 N⋅m 16 (192 lb. in.)
Starting Motor End-Housing Ground Cable 15 N⋅m 11 (132 lb. in.)
Starting Motor Ground Cable Securing Nut 7 N⋅m 5 (60 lb. in.)
Alternator Main Output Terminal 6 mm (0.24 in.) 4 N⋅m 3 (36 lb. in.)
Alternator Phase Terminal Nut 5 mm (0.20 in.) 4 N⋅m 3 (36 lb. in.)
Alternator Shaft Nut 38 N⋅m 28 (336 lb. in.)
Alternator Housing Bolts 5 N⋅m 4 (48 lb. in.)
Alternator Rear Cover Screws 3 N⋅m 2 (24 lb. in.)
Alternator Regulator Retaining Screws 5 N⋅m 4 (48 lb. in.)
Alternator Terminal Nuts 3 N⋅m 2 (24 lb. in.)
Alternator Rectifier Retaining Screws 3 N⋅m 2 (24 lb. in.)
Alternator Regulator/Brush-Box Screws 3 N⋅m 2 (24 lb. in.)
Governor Drive Gear Nut 136 N⋅m 100 lb. ft.
Governor Housing-to-Engine Front Cover Bolts 30 N⋅m 22 (264 lb. in.)
Coolant Temperature Sender Switch 34 N⋅m 25 (300 lb. in.)
Air Filter Restriction Warning Switch 8 N⋅m 6 (72 lb. in.)
Oil Pressure Sender 30 N⋅m 22 (264 lb. in.)
Battery Terminal Retaining Nuts 7 N⋅m 5 (60 lb. in.)
Key-Start Ignition Switch Retaining Nut 8 N⋅m 6 (72 lb. in.)
Fuel Tank Float Retaining Nut 3 N⋅m 2 (24 lb. in.)
Turn Signal Switch Retaining Nut 4 N⋅m 3 (36 lb. in.)
Work Lamp Retaining Nut 18 N⋅m 13 (156 lb. in.)

55-3
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

FAULT FINDING
IMPORTANT: To avoid repeat failures, investigate
and correct the cause of the defect when making
repairs to the electrical system.

LIGHTING AND INSTRUMENTATION SYSTEMS


Problem Probable Cause Remedy
Several or all lights
g do not illuminate Battery discharged Recharge battery
Battery cables/terminals loose or Clean cables/terminals, tighten
defective connections, or replace defective
component
Harness connections loose Check connections for tightness
Fuse burned out Check circuit and replace fuse
Wiring defective Check circuit wiring and repair
Light switch defective Repair or replace switch
Bulbs burned out Check voltage regulator
Individual lights
g do not illuminate Bulb faulty or burned out Replace bulb
Bulb contacts defective or cor- Clean contacts or repair
roded
Fuse burned out Check circuit and replace fuse
Wires loose or broken Repair or replace wiring
Ground connection poor Clean and tighten ground connec-
tion
Lights
g burn-out repeatedly
p y Wire corroded or loose Repair or replace wiring
Bulb or mounting bracket loose Tighten bulb or bracket
Voltage regulator faulty Replace voltage regulator if neces-
sary
Warningg lights
g and g
gauges
g Key-start ignition switch faulty Replace switch
inoperative Fuse burned out Check circuit and replace fuse
Key-start ignition switch connec- Tighten connectors on back of
tors loose switch
Wiring defective Check wires and repair
Gauge
g erratic or inoperative
p Wiring defective Check wires and repair
Connectors loose Tighten connectors on back of
instrument panel
Gauge defective Replace gauge
Sender defective Replace sender
Voltage stabilizer defective Replace voltage stabilizer

55-4
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

STARTING SYSTEM
Problem Probable Cause Remedy
Engine
g will not crank and starting
g motor Battery discharged Charge battery
relay or solenoid will not engage Key-start ignition switch defective Check circuit, replace switch
Starting system relay defective Check circuit, replace relay
Neutral start switch defective Check circuit, replace switch
Starting circuit open, or high Check circuit connections and repair
resistance
Engine will not crank with starting motor Engine seized Check engine crankshaft. If binding,
relay or solenoid engaged repair defective component or check
remaining engine components.
Battery discharged Charge battery
Starting motor connections loose or Tighten connections or replace
defective
Battery connections loose or defective Tighten connections or replace
Starting motor defective Overhaul or replace starting motor
Starting motor relay or solenoid Check circuit and replace relay or
contacts burnt solenoid
Engine will not crank with starting motor Starting motor drive assembly Overhaul or replace starting motor
turning
g defective
Solenoid or pinion engagement levers Replace defective component
defective
Flywheel ring-gear defective Replace defective component
Engine
g cranks slowlyy Battery discharged Charge battery
Starting circuit operates under Check system components and replace
excessive resistance defective part
Starting motor defective Overhaul or replace starting motor

CHARGING SYSTEM
Problem Probable Cause Remedy
Battery
y low in charge
g or discharge
g Drive belt loose or worn Adjust tension or replace belt
Battery electrolyte low Replenish electrolyte
Connections loose causing high Tighten loose connections
resistance
Temperature sensor defective Replace sensor
Voltage regulator defective Replace voltage regulator
Alternator defective Overhaul or replace alternator
Battery
y overheats Battery defective Service battery or replace
Temperature sensor defective Replace sensor
Voltage regulator defective Replace voltage regulator
Alternator defective Overhaul or replace alternator
No alternator output
p Drive belt loose, worn or broken Adjust tension or replace belt
Connections loose or broken Tighten or repair connection
Temperature sensor defective Replace sensor
Voltage regulator defective Replace voltage regulator
Alternator defective Overhaul or replace alternator
Intermittent or low alternator output
p Drive belt loose, worn or broken Adjust tension or replace belt
Connections loose or broken Tighten or repair connection
Temperature sensor defective Replace sensor
Voltage regulator defective Replace voltage regulator
Alternator defective Overhaul or replace alternator

55-5
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

ALTERNATOR
Problem Probable Cause Remedy
Warning light dims and/or battery Charging circuit connection faulty Repair or replace defective
low connection
Rotor slip-rings or brushes Replace slip-rings or brushes
defective
Warningg light
g extinguishes
g but Rectifier defective Repair or replace rectifier
brightens with increased speed Charging circuit connection faulty Repair or replace defective
connection
Warning
g light
g out with battery
y hot Voltage regulator defective Replace voltage regulator
Temperature sensor defective Replace temperature sensor
Warningg light
g out with battery
y Voltage regulator defective Replace voltage regulator
discharged Stator defective Replace stator
Rectifier or diodes defective Replace rectifier or diodes
Warningg light
g illuminates Drive belt loose or broken Adjust tension or replace belt
continuously Surge protection diode defective Replace surge protective diode
Isolation diodes defective Replace isolation diodes
Temperature sensor defective Replace temperature sensor
Rotor slip-rings or brushes Replace slip-rings or brushes
defective
Voltage regulator defective Replace voltage regulator
Stator defective Replace stator
Rectifier or diodes defective Replace rectifier or diodes
Warningg light
g extinguished
g Bulb burned out Replace bulb
continuously Alternator connection faulty Repair connection
Rotor slip-rings or brushes Replace slip-rings or brushes
defective
Voltage regulator defective Replace voltage regulator
Stator defective Replace stator
Warning
g light
g flashes intermittentlyy Alternator connection faulty Repair connections
Charging system defective Check circuit and repair
Warning light dims continuously Rotor slip-rings or brushes Replace slip-rings or brushes
defective
Voltage regulator defective Replace voltage regulator

55-6
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

ELECTRICAL SYSTEM
PRECAUTIONARY STATEMENTS IMPORTANT: Note the routing of the wiring, position
Observe the following precautions to avoid damage of the wiring clamps, and terminal connections
to equipment, personal injury, or death. before removing components to facilitate installation.

IMPORTANT: Do not allow wiring and clamps to


WARNING come in contact with sharp edges, exhaust system
Batteries contain sulfuric acid. Avoid contact components or moving parts.
with the skin, eyes and clothing. Wear protective
clothing and face shield when working on IMPORTANT: Check conductors for exposure, and
batteries. terminal connections for correct engagement.

WARNING IMPORTANT: Check circuit current draw before


applying power to a new wire harness.
Do not make or break electrical connections,
including the battery terminals, with the engine
running. DESCRIPTION AND OPERATION
The electrical system features a 12-volt battery,
90-amp alternator, key-start ignition, neutral start
WARNING and PTO safety switches. The wiring, lights, and
Do not short-circuit any charging components to instrumentation specifications of the tractor will vary
ground. by model.

The standard lighting configuration includes:


WARNING
Disconnect the battery negative (ground) cable • Dual Beam Halogen Headlamps
before installing or removing electrical compo- • Halogen Working Lamp
nents, performing maintenance on electrical • Red/Amber Tail Lamps
components, or when using a battery charger.

Supplemental lighting combinations available (not in


WARNING all markets), which satisfy local governmental
Observe correct polarity when installing batter- regulations, operational requirements, and operator
ies or using a single slave battery to jump-start preferences, include:
the engine. Follow the instructions in the
operator’s manual, as well as the battery • Utility Lamp
manufacturer’s recommendations.
• Turn Indicator Lamps
• Stop Lamps
WARNING • Implement Lamp
Always replace fuses with the correct type and • License Plate Lamps
correct rating.
• Position Lamps

IMPORTANT: Check terminals and connections for


continuity and tightness before operating electrical
components.

55-7
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
The electrical system incorporates various compo- WIRE HARNESSES
nents, which provide for the operation, regulation The wire harnesses form an electrical circuit, which
and protection of the electrical system. The standard directs power to the components of the electrical
electrical configuration will contain all, or several of system by location. The harnesses attach
the following components: with connectors, and route from the front of the
tractor to the rear, and up the fenders. Each harness
• Instrument Panel removes independently of one another to facilitate
• Four-Wheel Drive (FWD) Select Switch maintenance.
• Dual Power Select Switch
• Key-Start Ignition Switch
• Lights/Horn Switch
• Power Take Off (PTO) Speed Switch
• Neutral Start Switch
• Cold Advance Thermostatic Switch
• Thermostart Switch
• Fuel/Water Separator Warning Sensor
• Air Filter Restriction Sensor
• Brake Switch
• Turn Signal Switch
• Work Lamp Switch
• Warning Flasher Switch
• Warning Flasher Unit
• Engine Oil Pressure Sender
• Engine Coolant Temperature Sender
• Fuel Tank Senders
• Fuse Box
• Relays
• Battery Temperature Sensor
• Seat Presence Switch
• Dual Power Oil Pressure Switch
• Creeper Switch
• Hand Brake Switch
• Fuel Shut-off Solenoid
• Dual Power Solenoid
• FWD Solenoid
• 7-Pole Socket

55-8
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
Front Headlamp Harness - Description and
Location
The grille mounted headlamp harness (1) connects
to the rear-main harness at the firewall of the engine 1
compartment.

20031383

1
The harness clamps to the hood assembly and
connects to each headlamp (1).

10024968

2
The electrical system of the TB series tractor
consists of the following harnesses:

• Front Headlamp Harness

• Front Main Harness

• Rear Main Harness

• FWD & Dual Power Harness [where installed]

• Rear Lights Harness

Each harness contains the necessary connectors for


attaching electrical components over a wide range of
models. When a component is uninstalled for any
reason, secure the unattached harness connector
away from hot engine components, and moving
parts.

55-9
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
Front Main Harness • Hazard Switch
The front main harness connects to the rear main
harness with a 4-pin and a 9-pin connector. The • Lights Switch/Horn
harness routes along the top of the engine and
• Buzzer Connection
clamps to the rocker cover, then branches at the
forward end of the engine to the following • Flasher Unit
components:
• Handbrake Switch
• Horn
• Transmission Neutral Start Switch
• Air Filter Restriction Switch
The fuse box mounts on the left-hand side of the
• Engine Coolant Temperature Sensor engine firewall and connects to the rear main
harness. A cover made of plastic or rubber fits over
• Alternator the fuse box to prevent dirt and debris from entering
• Engine Oil Pressure Sender the box. The fuses protect individual circuits from
overload conditions. When replacing a fuse, always
• Starter Solenoid use one of the same amperage.

• Thermostart Element Four-wheel Drive (FWD) and Dual Power Harness

• Fuel Shut-off Solenoid The four-wheel drive and dual power harness
supplies power to the following components:
• Thermostatic Switch
• Dual Power HI Indicator lamp
• Fuel Lift Pump
• Dual Power LO Indicator Lamp
• Cold Advance Wax Plug
• FWD ON Lamp
• Fuel/Water Separator
• Dual Power Switch
In addition, the front main harness grounds to the
tractor frame. • FWD Switch

• FWD Connector Lever Switch


Rear Main Harness
The rear main harness connects to the front main
harness with a 4-pin and a 9-pin connector, and to the Rear Lights Harness
front headlamp harness at the engine firewall. Most The rear lights harness connects to the rear main
of the rear main harness routes inside the operator’s harness and routes along the transmission on the
console and behind the steering column panels. On left0hand side of the tractor. This harness provides
the end opposite the front main connectors, the rear power to the following components:
main harness connects to the rear lights harness,
and to the four-wheel drive and dual power harness • PTO Neutral Safety Switch
(where installed). The components listed below
• Seat Presence Switch
receive power from the rear main harness.
• 7-Pole Socket
• Fuse Box
• Working Lamp Switch
• Instrument Panel/Cluster
• Left-hand side Tail Light
• Fuel Tank Sender
• Right-hand side Tail Light
• Ignition Key-switch
• Ground
• Turn Signal Switch
Each tail lamp assembly includes a connector for
• Cigarette Lighter attaching to the rear lights harness.

55-10
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

COMPONENT LOCATION
• Horn Assembly (1), located in front of the
radiator, Figure 3.

40031377

3
• Air Filter Restriction Switch (1), located in the
air intake tube at the rear of the engine,
Figure 4.

40031368

4
• Engine Coolant Temperature Sender (1)
located in the thermostat housing, Figure 5.

20031379

55-11
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
• Alternator (1), located at the front, left-hand
side of the engine, Figure 6.

20031380

6
• Engine Oil Pressure Sender (1), located on
the left-hand side of the engine block,
Figure 7.

40025676

7
• Starter Solenoid (1), located on the top of the
starting motor (2) on the right-hand side of
the engine block, Figure 8.

40031376

55-12
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
• Thermostart Element (1), located on the air
intake manifold, Figure 9.

40031370

9
• Fuel Shut-off Solenoid (1), located on the fuel
injection pump (2), on the right-hand side of 1
the engine block, Figure 10.

40031375 2

10
• Cold Advance Thermostatic Switch (1),
located in the thermostat housing, Figure 11.

• Coolant Temperature Sensor (2), located in


the thermostat housing.

1 2

40025673

11

55-13
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
• Lift Pump and filter assembly (1) on the
right-hand side of the engine block, Fig- 1
ure 12.

40025679

12
• Fuel Injection Pump Wax Plug (1), located on
the right-hand side of the engine block,
Figure 13. The wax plug mounts to the
DP200 Series fuel injection pump.

40025681

13
• Fuel/Water Separator Warning Switch, lo-
cated on the fuel/water separator (1),
Figure 14.

20031381
1

14

55-14
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
• Relays (1), located at the rear of the engine
compartment in the fuse box, Figure 15. The
two 12V relays are rated at 30A.
• Fuse Box (2), located on the rear of the
engine compartment behind the instrument
console panel, Figure 15.
2

1
10024965 1
15
• Instrument Panel/Cluster (1) located on the
rear hood assembly, forward of the steering 1
wheel, Figure 16.

16
• Fuel Tank Sender (1), located on the main
fuel tank probe, Figure 17.

20031389

17

55-15
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
• Key-Start Ignition Switch (1), located on the
console, on the right side of the steering
wheel, Figure 18.
• Turn Signal Switch (2), located on the lower
console, on the left side below the steering
column; Figure 18.
• Cigarette Lighter (3).
• Hazards Switch (4). 1
2

3 4
10024306

18
• Dual Power Select Switch (1), located on the
gear shift lever, Figure 19. 1

50025054

19
• Four Wheel Drive Select Switch (1), located
on the right side of the operator’s seat 1
mounted on the fender wall, Figure 20.

40031373

20

55-16
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
• Lights Switch (1), located on the rear console
assembly, lower left-hand side, Figure 21.

MDA0429A

21
• 7-Pole Socket (1), located at the rear of the
tractor on the left-hand side.

40036180 1
22
• A cover (1) protects the 7-pole socket from
dirt and other debris.
1

40036181

23

55-17
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

A C

5
1

3
2

6 7 8 9 10 11 12 13 14 15

24
A. Fuel Gauge 7. Dual Power “ON”
B. Tachometer and Hourmeter 8. PTO “ON”
C. Engine Coolant Temperature Gauge 9. Dual Power “OFF”
1. Alternator Charge 10. Parking Lights “ON”
2. Air Filter Restriction 11. High Beam “ON”
3. Dual Power Transmission Oil Pressure 12. Thermostart
4. Water Detection in the Fuel System 13. Parking Brake “ON”
5. Engine Oil Pressure 14. Four-Wheel Drive “ON”
6. Left Turn 15. Right Turn

55-18
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

25
A. Temperature (Wire: Blue/Green) 5. Alternator Charge (Wire: Brown/Yellow Green)
B. Electric Current (Wire: Green [3]) 6. Four Wheel Drive “On” (Wire: Brown/Black)
C. Lighting (Wire: Black/Red -- White) 7. Thermostart (Wire: Black/Brown -- Red)
D. Lighting (Wire: Black/Red -- White) 8. Dual Power “Off” (Wire: Green/Black)
E. Tachometer (Wire: White) 9. Dual Power “On” (Wire: Black/White)
F. Fuel (Wire: Green/Black) 10. Right Turn (Wire: Brown/Purple)
1. Engine Oil Pressure (Wire: White/Green/Brown) 11. Parking Brake (Wire: Black/Green)
2. Water Detection in the Fuel System 12. Lights “On” Warning Light (Wire: Black/Blue -- White)
(Wire: White/White) 13. Parking Lights (Wire: Black/Red -- White)
3. Dual Power Transmission Oil Pressure 14. PTO “On” (Wire: Black/White)
(Wire: Yellow/Green) 15. Left Turn (Wire: Green -- Brown/Black)
4. Air Filter Restriction (Wire: Green/Black/Clay)

55-19
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

INSTRUMENT PANEL DESCRIPTION


The instrument panel, Figure 24, provides gauges Air Cleaner Warning Light (2)
and warning lights for monitoring system perfor-
mance, operational limits and malfunctions, which
may occur while operating the tractor. The A red colored light, which illuminates when an
instruments illuminate with the lights switch in the increase in vacuum occurs in the air admission
‘ON’ position. system during engine operation, as detected by the
switch in the air intake tube. This usually indicates a
Refer to Figure 24 for the following descriptions. dirty or obstructed air filter.

Fuel Gauge (A) Dual Power Oil Pressure Warning Light (3)

A Needle-type gauge indicating the level of fuel A red colored light, which illuminates when oil
remaining in the fuel tanks. The needle enters the red pressure in the Dual Power system falls below
colored area of the gauge when the combined fuel normal operating limits.
level reduces to less than 1/4 of the tank capacities.
The gauge receives input from electrical fuel senders
attached to the fuel probe of the tanks, and receives Fuel/Water Detection Warning Light (4)
power from the key-start ignition switch.
A red colored light, which Illuminates when the
Tachometer with Hour Meter (B)
fuel/water separator contains water, as detected by
A needle-type gauge indicating engine revolutions the switch on the fuel/water separator.
per minute on a scale of 100 rev/min. Two symbols
on the tachometer scale identify engine speeds at
which the PTO obtains 540 or 1000 rev/min for
Engine Oil Pressure Warning Light (5)
standard PTO operation. The hour meter records
operating time for guidance on determining service
intervals. A red colored light, which Illuminates when engine oil
pressure in the main gallery falls below 0.83 bar (12 psi)
during engine operation. During start up, it is normal for
Engine Coolant Temperature Gauge (C) the warning light to briefly illuminate, then extinguish.

A Needle-type gauge Indicating coolant temperature Left Turn Light (6)


with the engine in operation. The needle enters the
red colored area when the coolant temperature rises A green colored light, which illuminates upon
dangerously above the normal operating tempera- activation of the left turn signal.
ture of the engine. The coolant temperature gauge
retains a random position with the key-start ignition
switch off.
Dual Power ‘ON’ Light (7)

Alternator Change Warning Light (1)


A green colored light, which illuminates upon
activation of the Dual Power system.
A red colored light, which illuminates when the
alternator charging circuit is defective. At first start
up, it is normal for the light to briefly illuminate, then
extinguish as the engine speed increases above idle.

55-20
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

Power Take Off Light (8) Thermostart Warning Light (12)

An amber colored light, which illuminates upon A red colored light, which illuminates when a fault in
activation of the Power Take-off (PTO) system. the Thermostart system occurs.

Dual Power ‘OFF’ Light (9) Parking Brake Light (13)

An amber colored light, which illuminates upon A red colored light, which illuminates upon activation
de-activation of the Dual Power system. of the parking brake.

Parking Lights ‘ON’ Light (10) Four--Wheel Drive Light (14)

A green colored light, which illuminates upon A green colored light, which illuminates upon
activation of the parking lights. activation of the four-wheel drive (4WD) system.

Lights ‘ON’ Light (11) Right Turn Light (15)

A blue colored light, which illuminates upon A green colored light, which illuminates upon
activation of the main lights. activation of the right turn signal.

55-21
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

ELECTRICAL COMPONENTS – OPERATION AND OVERHAUL

OIL PRESSURE SENDER


Operation
The oil pressure sender switch (1), installed on the
left-hand side of the engine block closes by way of
spring pressure when oil pressure drops below 0.83
bar (12 psi). This completes the warning circuit to
ground, which illuminates the oil pressure warning 1 2
light on the instrument panel. When oil pressure rises
above the spring force at approximately 0.55 (8 psi),
the contacts within the switch open, breaking the
circuit, and the warning light extinguishes. When
starting the engine, it is normal for the low-pressure 40025676
warning light to illuminate, and then extinguish
approximately 30 seconds after engine oil pressure 26
rises.

Removal
1. Disconnect the battery negative (ground) cable.
2. Remove the sender (2).
3. Unscrew the switch from the engine block and
remove.

Diagnostic Testing
Use a Multi-meter for the following test:

1. Turn the engine off.


2. Move the key-start ignition switch to Position 2.
3. Check for continuity between the oil pressure
switch terminal and ground. This will indicate a
closed switch and a complete circuit. The
warning light on the instrument panel will
illuminate.
4. Start the engine and run until reaching the
recommended oil operating pressure.
5. Check that NO continuity exists between the oil
pressure switch terminal and ground. This will
indicate an open switch and a broken circuit. The
warning light will extinguish.
Replace the oil pressure sender switch if the
continuity test fails.

Installation
Installation of the oil pressure sender switch follows
the removal procedures in reverse with the following
requirement:

1. Tighten the switch to a torque of 30 Nm (22 lb. ft.).

55-22
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
Four Wheel Drive Select Switch
Pressing the green side of the rocker switch causes 1
the switch to close and complete a circuit to the 2
four-wheel drive (FWD) solenoid. The FWD solenoid
engages the front wheel drive. Pressing the black
side of the switch breaks the circuit, and disengages
the FWD.

40031373

27
Removal
1. Disconnect the battery negative (ground) cable.
2. Remove the switch cover to gain access to the
back of the switch.
3. Remove the connector off the back of the switch.
4. Remove the light bulb connector.

1 2

28

5. Press in the retaining tab (1) on both sides of the


switch. Remove switch.
IMPORTANT: Prying the switch will break the plastic
tabs. Press the tabs in to remove.
1
Diagnostic Testing
Use a Multi-meter for the following test:

1. Select four-wheel drive by pushing in the green


side of the switch.

40025958

29

55-23
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
2. Check for continuity between terminal A and
terminal B.

40025959

30
3. Check for continuity between terminal D and
terminal E. Terminals D and E power the light D
bulb.
4. Disengage four-wheel drive by pushing in the E
black side of the switch.
5. Check for continuity between terminal B and
terminal C. 1
Replace switch if continuity test fails at any point.

Installation
Installation of the four-wheel drive select switch
40025960
follows the removal procedures in reverse.
31

Bulb Replacement
1. Press in the bulb retaining tab and pull the
retainer (1) from the back of the switch. Replace
with a 1.2 W bulb and snap bulb retainer back into
switch.

55-24
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
Dual Power Select Switch
Pressing the orange side of the rocker switch causes
the switch to close and complete a circuit to the dual
power solenoid. Pressing the black side of the switch
breaks the circuit, putting the transmission back in
direct drive.

The orange side of the switch contains a picture of a


tortoise (1), and it illuminates when selected. The
black side of the switch contains a picture of a hare
(2). 1 2

32
Key--Start Ignition Switch
The five positions of the key-start ignition switch
include:

Moving the key from the vertical position 1 in a


clockwise direction approximately 1/16 turn into
Position 2 directs current to the accessories. Another
1/16 turn to Position 3 energizes the warning lights
and gauges on the instrument panel, and activates
the lift pump for priming the fuel system. Position 4
completes a circuit to the thermostart system for cold
starting. The final 1/16 turn to position 5 activates the
starting motor to start the engine. The secondary 20030983
gearshift lever must be in the neutral position, and
the power take-off lever must be disengaged before 33
the starting motor receives power. When attempting 1. OFF
to reactivate the starting motor after the engine failed 2. ACCESSORIES ON
to start, return the key-start ignition switch to position 3. WARNING LIGHTS AND INSTRUMENTS ON
1 (OFF) before attempting to start the engine. 4. THERMOSTART SYSTEM ACTIVATED
5. STARTING MOTOR ACTIVATED
IMPORTANT: Operating the starting motor longer
than 60 seconds may damage the motor beyond
service.

55-25
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
Diagnostic Testing
Use a Multi-meter for the following test: C
B
1. With the key-start ignition switch in Position 1
(key is vertical), check that NO continuity exists
between terminals.
2. Move the switch to Position 2.
3. Check that continuity exists between terminals A D
and terminal D.
4. Move the switch to Position 3.
A E
5. Check that continuity exists between terminals A 40025961
and terminal D, between terminals B and
terminal D, and between terminals A and 34
terminals B.
6. Move the switch to Position 4.
7. Check that continuity exists between terminals A
and terminal C.
8. Move the switch to Position 5.
9. Check that continuity exists between terminal C
and terminal E, and between terminals A and
terminal C, and between terminals A and
terminal E.
Replace switch if continuity test fails at any point.

Key-Start Ignition Switch Terminal Continuity Testing

Terminals A B C D E
Positions
1
2 X X
3 X X X
4 X X
5 X X X

Installation
Installation of the key-start ignition switch follows the
removal procedures in reverse with the following
requirements:

1. Tighten the key-start ignition switch retaining nut


to a torque of 8 Nm (72 lb. in.).
2. Check wires and connections for interference
with hand throttle linkage.

55-26
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
Lights Switch/Horn
The lights switch (1) rotates to various positions for
different lighting configurations. Contacts within the
switch close to complete circuits to the lamps 1
selected as follows:

1. LIGHTS OFF
2. TAIL LAMPS ON
3. HEADLAMPS LOW BEAM
4. HEADLAMPS HIGH BEAM

MDA0429A

35
The lights switch also contains the horn switch.
Operating the horn switch completes a circuit to the
horn assembly (1), Figure 36, attached at the front of
the radiator.

1
40031377

36
Power Take--Off (PTO) Safety Switch
The PTO safety switch (3) mounts to the rear of the
PTO lever bracket (2). Moving the PTO lever (1) to
the disengaged position {rearward} forces the
plunger on the switch inward, and completes a circuit
to the starting system relay. With the PTO lever in the
engage position (forward), the open circuit prevents
the engine from starting. Moving the PTO lever to the
engage position after the engine starts will not
interrupt engine operation.

20030995

37

55-27
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
Removal
1. Disconnect battery negative (ground) cable.
1
2. Remove the two screws (1), spacers (2) and bar
(3), which mount the PTO switch to the PTO lever 3
bracket.
3. Remove the switch assembly.

2
40025967

38
4. Pull back the rubber guard (1) from the back of
the switch (2).
1
5. Pull the connector (3) away from the switch.

40025968

39

55-28
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
Diagnostic Testing
Use a Multi-meter for the following test:
D
1. Press in the PTO switch plunger and hold (PTO
disengaged position). C
2. Check that continuity exists between terminal A
and terminal D (outward two terminals). B
3. Release the PTO switch plunger (PTO engage
position). A

40025969

40
4. Check that continuity exists between terminal B
and terminal C (inward two terminals).
NOTE: Continuity should not exist between terminal
A and terminal B, or between terminal C and terminal
D.

Replace switch if continuity test fails.

Installation
Installation of the PTO switch follows the removal
procedures in reverse with the following require-
ments: 20030995

1. Install the PTO switch (3) on the PTO lever 41


bracket (2) forward enough to hear the switch
click into position against the lever (1), Figure 41.
Ensure the switch centers flatly against the PTO
lever with the lever in the bracket detent.

55-29
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
Neutral Start Switch
The neutral start switch prevents engine start-up with
the secondary gearshift lever (1) out of the neutral
position. 1

50025054

42
Cold Advance Thermostatic Switch
The thermostatic switch (1) located on the
thermostat housing increases the cold advance
performance of the emissionized engine.

During start-up, engine cylinders remain slightly cool


until the engine warms to normal operating 1
temperature. During which time, the engine timing
advances slightly to reduce white smoke and
emissions. The cold-advance thermostatic switch
detects when the engine reaches the desired
operating temperature and completes a circuit to the
wax plug installed on the fuel injection pump. 40025673

43
The wax plug (1) brings the engine back to normal
timing.

40025681

44

55-30
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
Air Filter Restriction Switch
An obstructed air cleaner (1) increases the vacuum 1
within the air intake tube to the engine.

20031385

45
As vacuum increases, the air cleaner restriction
switch (1), completes a circuit, which illuminates a
warning light on the instrument panel.

40031368

46
Removal
1. Raise the hood assembly.
2. Disconnect the battery negative (ground) cable.
3. Remove the front-main harness connectors from
the terminals on the air cleaner restriction switch.
4. Place a wrench on the shaft of the switch (1),
which screws into the intake tube. Turn the switch
counterclockwise until free from intake tube.
NOTE: Do not grasp the switch body by hand and 1
attempt to remove by twisting. This will cause
damage to the switch. 40025972

47

55-31
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
Diagnostic Testing
Use a Multi-meter for the following test:

1. Start the engine.


2. Check for zero voltage at the air cleaner
restriction warning light (1), on the instrument
panel.
Replace the air filter restriction warning switch when
the warning bulb illuminates on the instrument panel
with no obstruction to the air cleaner.

Installation
Installation of the air filter restriction switch follows
the removal procedures in reverse with the following
requirement:

1. Tighten the air filter restriction warning switch to


a torque of 8 Nm (72 lb. in).
Fuel/Water Separator Warning Switch
The fuel/water separator warning switch (1)
completes a circuit to the fuel/water warning light on
the instrument panel if the separator contains water.

1
20031381

48
Work Lamp Switch
The work lamp (1) contains a switch at the bottom of
the lens for turning the lamp ON and OFF. The switch
only receives power when the lights switch is ON.

10024317

49

55-32
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
Removal
1. Disconnect the battery negative (ground) cable.
2. Remove work lamp lens-cover screws.
3. Remove lens-cover.
1
4. Remove bulb connector (1) from the switch.
5. Squeeze the side clips (2). Remove work lamp
switch.

Diagnostic Testing
Use a Multi-meter for the following test: 2
40025974

1. Move the lights switch to Position 2. 50


2. Press the work lamp switch to the ‘ON’ position.
3. Check for +12 V at the bulb connector (1).
4. Press the work lamp switch to the ‘OFF’ position.
5. Check for zero voltage at the bulb connector.
6. Move the lights switch to Position1 ‘OFF’.

Replace switch if voltage test fails.

Installation
Installation of the work lamp switch follows the
removal procedures in reverse with the following
requirement:

1. Operate the work lamp switch to ensure correct


installation.

55-33
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
Lamps
A tail lamp assembly mounts to each Roll Over 1
Protection (ROP) bar of the tractor. The lens cover
contains 4 screws (1) to access the bulbs for service. 2
The upper inside bulbs (2) function as the tail and turn
lamps. The inside lower (3) bulbs function as the stop
lamp. The outside upper and lower bulbs (4) function 4
as the flasher/hazard lights. The tail lamp assembly
harness runs down the ROPS bar approximately 40 3
cm (15.75 in.) and connects to the rear harness. The
double filament bulb (2) rated at P21/5W controls the
tail light and turn signal. The single filament bulb (3)
rated at P21W controls the tail light. Two single 50024305
filament bulbs (4) rated at P21W control the flashers.
51

The headlamp assemblies (1) mount to the inside of


the engine hood. The lamps produce either a high or
low beam. The lights switch turns the headlamps ON 1
and OFF, or selects either low or high beam.

52

55-34
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
Adjustment screws (1) in the inner hood provide for
altering the headlamp beam angles.

Halogen Bulbs
The headlamp assemblies and the working lamp
contain halogen type bulbs. Use a cloth to avoid
touching the bulbs during servicing, as oil from skin
will reduce the life cycle of the bulb.
1

10024968

53
Fuses and Relays
The electrical circuits receive protection from 2 3
overloads through eight fuses arranged in a fuse box 4
mounted at the rear of the engine compartment 1
forward of the instrument console panel. The fuse
box also contains two 12 V relays (9) rated at 30 A. 5

6 8
7

10024965 9

54

Upper Row – Right to Left


Fuse No. Rating Circuit
F1 10 A Headlamp Low Beam
F2 15 A Headlamp High & Warning Lamps
F3 15 A Safety Relay, Turn Signal
F4 10 A Tail/Stop Lamps, Instrument Cluster Pilot

Lower Row – Right to Left


Fuse No. Rating Circuit
F5 10 A Fuel System Relay, Horn
F6 10 A Turn Signal
F7 10 A Position Lights, Work Lamp
F8 10 A Instrument Gauges, Warning Lights

IMPORTANT: Do not replace a blown fuse with


another of a different rating, to avoid compromising
electrical system safety.

IMPORTANT: When replacing fuses, firmly and


evenly seat the new fuse into the fuse box.

55-35
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

DIAGRAMS -- DESCRIPTION

Symbol Drawing Location Description


(A) Gauges
A1 1070 Tachometer/Hour meter
A2 1120 Temperature Gauge
A3 1180 Fuel Gauge

(B) Sensors & Senders


B1 160 Battery Temperature Sensor
B2 1530 Fuel Tank Sender
B3 1580 Engine Coolant Temperature Sensor
B4 1600 Engine Oil Pressure Sensor
B5 1650 Air Filter Restriction Sensor
B6 1680 Horn
B7 1750 Water Trap Sensor

(F) Fuses
10A 430 Stop Fuse
15A 460 Turning Light Fuse
15A 2160 High Beam Fuse
10A 2160 Low Beam Fuse
10A 2310 Lamp RH Fuse
10A 2310 Lamp LH Fuse
10A 2310 Flasher Fuse
10A 2310 Horn Fuse

(H) Lamp & Lights


H1 1080 Water Trap Warning Light
H2 1080 Air Filter Restriction Warning Light
H3 1080 Engine Oil Pressure Warning Light
H4 1080 Alternator Charge Warning Light
H5 1370 Four-Wheel Drive On Warning Light
H6 1370 High Beam Warning Light
H7 1370 Left Turn Warning Light
H8 1370 Right Turn Warning Light
H9 1370 PTO On Warning Light
H10 1370 Thermostart Warning Light
H11 1370 Dual Power Off Warning Light
H12 1370 Dual Power On Warning Light
H13 1370 Dual Power Transmission Oil Pressure Warning Light

55-36
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

Symbol Drawing Location Description


H14 1370 Parking Lamp Warning Light
H15 1170 Cluster Light
H16 1170 Rear Lamp Warning Light
H17 2030 Head Lamp RH
H18 2030 Head Lamp LH
HTD 2800 Assy Rear Indicator Lamp RH
H19 2800 Right Turn & Flasher
H20 2800 Right Turn & Flasher Additional
H21 2800 Position Rear Lamp RH
H22 2800 Stop Lamp RH
HTI 2800 Assy Rear Indicator Lamp LH
H23 2800 Stop Lamp LH
H24 2800 Position Rear Lamp LH
H25 2800 Left Turn & Flasher Additional
H26 2800 Left Turn & Flasher
H27 2800 Work Lamp

(G) Charging
G1 00 Battery
G2 150 Alternator

(K) Relays
K1 260 Ignition Relay
K2 800 Fuel Engine Shut Down Relay
K3 3180 Dual Power Relay
K4 3270 Flasher Unit Relay
K5 3810 Buzzer

(M) Motors
M1 40 Starter Motor
M2 530 Wax Motor

(R) Resistors
R1 870 Cigar Lighter
R2 1620 Thermostart Oil

55-37
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

Symbol Drawing Location Description


(S) Switches
S1 380 Ignition Switch
S2 280 PTO Speed Switch
S3 210 Transmission Safety Switch
S4 1820 Dual Power Oil Pressure Switch
S5 2170 Lights & Horn Switch
S6 3350 FWD Switch
S7 3160 Creeper Switch
S8 3220 Normal Drive Switch
S9 3530 TurnRH&LH Switch
S10 3650 Brake Switch
S11 3910 Hazard Switch
S12 4250 Seat Switch
S13 4400 Hand Brake Switch
S14 560 Thermo Switch for Wax Motor

(X) Power Sockets


X1 2940 7 Pole Socket

(Y) Solenoid Values


Y1 540 Fuel Shut Off Solenoid
Y2 630 Electrical Fuel Pump
Y3 3070 Dual Power Solenoid
Y4 3180 FWD Solenoid

Wire Color Codes


B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple

ELECTRICAL SYSTEM DIAGRAMS


Diagram Page
1. Starting, Charge and Safety Circuits 55-43
2. Thermostart, Injection and Transfer Pumps 55-44
3. Instrument Cluster 55-45
4. Senders 55-46
5. Main Light Switch, Front Lights 55-47
6. Rear, Position and Warning Lights 55-48
7. FWD and Dual Power Switches 55-49
8. Lights, Safety Switches and Flasher Unit 55-50
9. Safety Start Circuit 55-51

55-38
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

LINEAR WIRING DIAGRAMS


Figures 55 and 56.

Linear wiring diagrams, such as the ones used in this


manual, break down large, complex electrical
diagrams into smaller sections, or pieces. This type
of diagram allows easier navigation through the
various circuits while troubleshooting a system
failure.

Linking all the linear wiring diagrams together will


form the entire electrical circuit.

For definition of symbols and wire color, refer to the


legends at the beginning of the diagram section.

Turn the diagrams sideways to read. The linear


wiring diagram pages contain a title (1), which
identifies the circuit illustrated. The title appears at
the bottom of the diagram.

A unique reference number (2) allows quick


identification of each component.

Each component and connector pin appears only


once throughout the linear wiring diagram. When the
component crosses over to several circuits, such as
a processor or multi--function switch, it appears on a
separate page or within the circuit the component
influences most.

Two wires run across the top of every linear wiring


diagram. The upper most wire (3) represents the
constant power wire. The lower wire (4) represents
the ignition power wire.

The lower wire (5) running along the bottom of the


diagram represents the ground wire.

55-39
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

6 2

55

55-40
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
A reference line (6) at the very bottom of the diagram
contains numerical numbers in increments of ten for
locating components from one diagram to another.

Example:

A wire (7) which has no ending has the number 1480


assigned.

Find the diagram with the reference number 1480 on


the reference line (8) and look in that area of the
diagram to find the continuation of the wire (9).

55-41
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

56

55-42
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

57

55-43
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

58

55-44
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

59

55-45
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

60

55-46
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

61

55-47
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

62

55-48
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

63

55-49
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

64

55-50
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

65

55-51
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1

55-52
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2

SECTION 55 - ELECTRICAL SYSTEMS

Chapter 2 - Alternator and Charging System

CONTENTS

Section Description Page


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Alternator -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Alternator -- Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

55-1
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2

DESCRIPTION AND OPERATION


The charging system consists of a storage battery,
alternator with an internal regulator, and circuit
wiring. The alternating current (AC) produced by the
alternator provides a higher maximum output than a
direct current (DC) producing generator, and
increases the charge rate at lower engine speeds. In
addition, the alternator operates safely at high
engine speeds and requires no commutator, unlike a
DC generator.
The alternator mounts to the front of the engine on
the left-hand side, and contains the following
components:

Refer to Figure 1.

• Rotor (1)
• Stator (2)
• Rectifier Pack (3)
• Regulator/Brush Box (4)

20030998

2
1. Negative (ground) Connection
2. Engine Speed Sensor Connection (W Terminal)
3. Warning Lamp (D + Terminal)
4. Output Connection (B + Terminal)
5. Protective Terminal Sleeves

55-2
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Rotor
The engine crankshaft drives the alternator by way of
a belt-driven pulley (1) attached to the rotor shaft.
The rotor shaft rotates within a heavy-duty, sealed
roller bushing.

An integral fan (2) adjacent to the pulley draws air


through the alternator for cooling.

The rotor field coil receives current via two carbon


brushes, which bear against slip rings on the rotor 1
shaft. Current flowing through cooper wire in the rotor
field produces a magnetic field. The configuration of
2
20025990
the armature, formed into pole shoes, ensures the
concentration of the magnetic field. 3

4
Fan Belt Tensioner

1. Tensioner Assembly 5. Alternator


2. Fan 6. Alternator Pulley
3. Water Pump Pulley 7. Crankshaft Pulley
4. Tensioner Assembly Alternator

Stator Alternating current generates in a series of pulsation. To


The moving magnetic field created by the rotor and smooth output, the rotor features six pairs of poles. For
brushes induces current into the windings of the stator. every evolution of the rotor, the output characteristic of
each stator winding completes six cycles.
The stator, fabricated from laminations of thin steel
pressings wrapped by wound wires, collects and The battery requires pure direct current (DC) for
concentrates the magnetic field. The stator windings charging, making alternating current (AC) unsuitable.
contain currents, which pass from one direction to Therefore, the stator windings connect to a rectifier
another with each complete revolution of the rotor. pack, which converts the AC current to DC current.
This activity creates an S-phase alternating current.

55-3
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Rectifier
The rectifier consists of six diodes (1) and a module 1 2
(2) containing field diodes. The diodes check current
flow in one direction only. Three diodes mount in a
positive plate, and three diodes in a negative plate
(3). Terminal links connect each of the three stator
output wires to a different diode on each plate.

As the rotor revolves, the diodes convert the AC


current from the stator to DC current, which
effectively charges the battery.

The three field diodes contained within the field diode 3 1


20030999
module connect to the stator output wires and supply
DC current to the rotor field winding. 5

Regulator and Brush Box


The internal regulator (1) maintains output voltage at
a safe working level. The regulated output voltage
level, preset during manufacturing, requires no
adjustment. A sealed assembly houses the regulator
components within the brush-box. The regulator,
regulator components, and brush-box require
service as a complete assembly, Figure 6.

20031417

55-4
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2

7
Alternator Charging Circuit

A. To Starter Motor 4. Regulator


B. To Starter Relay 5. Alternator Frame
C. Speed Sensor Terminal to: Diagnostic Plug, to Module 6. Stator Output Windings (55 Amp Alternator)
Instrument Cluster and Transmission/EDC Processor 7. Rectifier Pack
1. Starter Solenoid 8. Charge Indicator Lamp
2. Battery 9. Key Start Switch
3. Rotor Field Winding

Alternator Operation through the rotor field winding. This action results in
Refer to Figure 7. an ever-increasing magnetic influence of the rotor
along with an associated rise in generated output
Turning the key-start switch (9) to the ‘ON’ position current and voltage.
directs a small current flow from the battery (2),
through the rotor field winding (3). A circuit During the rise in generated output voltage (reflected
establishes through the charge indicator warning at the D+ terminal), the brilliance of the warning light
light (8), alternator IND (indicator) terminal D+, rotor reduces. When voltage at the D+ terminal equals that
field winding, alternator regulator (4) and ground. of the battery side of the warning light, the lamp
The charge indicator warning light illuminates and extinguishes.
the rotor partially magnetizes.
The rising voltage continues until reaching the
When the engine starts, the partially magnetized predetermined regulated voltage level.
rotor revolves within the stator windings and
generates 3-phase AC current. A constant portion of If the drive belt fails, voltage will not build up within the
the current converts to DC current by the three field alternator, and the charge indicator warning-light
diodes incorporated in the rectifier pack (7). The DC remains on to indicate failure.
current feeds back to supplement current flowing

55-5
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2

ALTERNATOR -- OVERHAUL
Removal 1
1. Disconnect battery negative (ground) cable.
2. Disconnect electrical cables from back of
alternator.
3. Remove mounting bolts (1).

20031423

8
4. Remove the alternator (1).

20031380

55-6
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2

10
55 Amp Alternator Components

1. Rectifier Assembly 6. Stator


2. Pulley Retaining Nut 7. Rotor
3. Pulley 8. Regulator and Brushbox Assembly
4. Cooling Fan 9. Rear End Housing
5. Front End Housing

Refer to Figure 10. 7. Gently tap rear face of the front-end bracket to
separate the front-end bracket and rotor
Disassembly assembly from rear-end bracket, stator and
1. Remove the four nuts securing the terminal block rectifier assembly.
to the alternator. 8. Remove nuts, washers and insulators from the
2. Remove the nut from the battery temperature terminals on the rear bracket.
sensor terminal block. 9. Remove the rectifier retaining screws.
3. Remove the three securing bolts and regulator/ 10. Remove stator and rectifier from the rear
brush box assembly. Separate the wire connec- bracket.
tion to the regulator.
11. Unsolder stator leads from the tags on the
4. Remove remaining through bolt nuts. rectifier.
5. Tap the threaded end of the housing bolts to 12. Remove retaining nut on rotor shaft.
release spline at the hexagon head end.
13. Remove the components off the rotor shaft. Note
6. Mark the alternator front-end bracket, stator, and the order of removal to facilitate re-assembly.
rear-end bracket to facilitate proper alignment
when re-assembling. 14. Press rotor shaft out of the front-end bracket
bearing.

55-7
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2

INSPECTION AND REPAIR


1. Clean all components.
2. Examine parts for wear, or excessive damage.
3. Inspect rotor poles and stator for signs of
chaffing. Chaffed areas indicate excessively
worn bearings, misaligned housings or bent rotor
shaft, which will require replacement.
4. Replace entire front-end bracket and bearing
assembly for an excessively worn or defective
front-end (Drive-bearing).
5. Inspect rear-end bracket roller bearing for
excessive wear or damage.

20031421

11
To replace rear-end roller bearing, use the following
procedure:
1) Support rear-end bracket (2), and drive out
roller bearing (1) with a suitable size mandrel
as shown in Figure 12.

20031422

12

55-8
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
2) Press the new bearing (2) into the housing
(1). Position the bearing 0.50-0.70 mm (.020
- .028 in) from the inner face of the bearing
boss (3). See Figure 13.

ASSEMBLY
Assembly of the alternator follows the disassembly
procedures in reverse with the following require-
ments:

1. To avoid misalignment of the end brackets, install


the stator assembly in the front-end bracket, then
install rear-end bracket to the stator laminations.

13

55-9
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2

INSTALLATION
Installation of the alternator follows the removal 1
procedures in reverse with the following require-
ments:

1. Ensure the battery negative (ground) cable


remains disconnected from the battery while
installing the alternator.

20031423

14
NOTE: The water pump belt deflection must be
9.5 mm (.37 in.).
1
2. Adjust the alternator drive belt tension using the 3
adjusting bolt (1, Figure 14) until obtaining 13-19
mm (0.50-0.75 in) deflection; with moderate
finger pressure applied to the longest run of the
belt.
2
ALTERNATOR -- TESTING
Initial testing of the alternator will not require removal 4
of any charging system components from the tractor,
and includes the following: 50035642

15
• Alternator Plug Connection Test
1. Alternator
• Battery Temperature Sensor Circuit Test 2. Alternator Belt
• Alternator Charging Current and Controlled 3. Water Pump Belt
Voltage Test 4. Tensionometer
• Alternator Charging Circuit Voltage Drop
Test
• Ground Voltage Drop Test
• Alternator Maximum Output Performance
Test

Test Equipment Required:


• Voltmeter (0-30 V moving coil)
• Voltmeter (0-1 V)
• Ammeter (0-110 A moving coil)
• 1.5 ohm, 110 A Variable Load Resister
• Jumper Lead 6.35 mm (0.25 in) (if needed)

NOTE: Follow the manufacturer’s instructions when


using test equipment to ensure accuracy.

55-10
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Alternator Plug Connection Test
Refer to Figure 16.

1. Disconnect battery negative (ground) cable.


2. Disconnect the alternator (1) output B+ Terminal
(2) and warning circuit D+ (3) Terminal.
3. Reconnect the battery negative (ground) cable.
4. Turn the key--start switch to the ‘ON’ position. DO
NOT start the engine.
5. Connect the Voltmeter (4) negative side to the
alternator frame.
6. Connect the Voltmeter positive side to the 16
alternator output B+ Terminal, and then to the
alternator warning circuit D+ Terminal. Check for
battery voltage.
No voltage indicates a continuity fault in the external
cable circuitry. Investigate the cause and repair.

7. Connect the warning light (brown/yellow) D+


Terminal to the alternator frame.
Check that the alternator charging warning light on
the instrument panel illuminates.

8. Remove test equipment.


9. Reconnect the alternator terminals.
If the charging warning light fails to illuminate after
reattaching the terminals, suspect a fault within the
regulator or rotor circuits. In addition, check the
cleanliness of the D+ Terminal. Investigate the cause
and repair.

10. Remove test equipment.

55-11
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Alternator Charging Current and Controlled
Voltage Tests
Refer to Figure 17.

1. Turn off all electrical components, including the


key-start switch.
2. Disconnect the battery negative (ground) cable.
3. Disconnect the alternator output B+ Terminal (4).
4. Connect the Ammeter (1) negative side to the
removed (brown) connector (3).
5. Connect the Ammeter (1) positive side to the
alternator output B+ Terminal.
17
6. Connect the Voltmeter (2) negative side to the
alternator frame.
7. Connect the Voltmeter (2) positive side to the
alternator output B+ Terminal.
8. Connect the battery.
9. Start the engine and increase engine speed to
2000 rev./min.
10. Observe the Ammeter and Voltmeter readings.
Check that the voltage registers higher than the
battery voltage, and that the voltage stabilizes at 13.6
-- 14.4 V when the Ammeter reading falls below 10
Amps.

If the voltage exceeds 14.4 V, suspect the alternator


regulator. If the voltage registers below 13.6 V,
suspect a faulty alternator component, or a high
resistance fault in the external connections of the
charging circuit.

11. Stop the engine.


12. Investigate the cause and repair.
13. Disconnect the test equipment.
14. Reconnect the alternator terminals.

55-12
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Charging Circuit Voltage--Drop Test
Refer to Figure 18.

1. Turn the key-start switch to the ‘OFF’ position.


2. Disconnect the battery negative (ground) cable.
3. Disconnect the alternator output B+ Terminal (1).
4. Connect the milli-Voltmeter (4) negative side to
the positive terminal of the battery.
5. Connect the milli-Voltmeter (4) positive side to
the (brown) B+ Terminal cable (5).
6. Connect the Ammeter (2) negative side to the
(brown) B+ Terminal cable. 18
7. Connect the Ammeter (2) positive side to the
alternator output B+ Terminal (1).
8. Reconnect the battery negative (ground) cable.
9. Connect a variable-load resister (3), with the
slider in the minimum current draw position
(maximum resistance), across the battery
terminals.
10. Start the engine and increase engine speed to
2000 rev./min.
11. Slowly increase the current loading of the resistor
(decreasing resistance) until the Ammeter
registers 55 A. Milli-Voltmeter reading must not
exceed 400 mV.
If milli-voltmeter registers above 400 mV, suspect a
high resistance fault in the external circuit.

If alternator output not within specifications, and


milli--voltmeter registers below 400 mV, suspect a
faulty component within the alternator. Refer to the
“Alternator Component Testing” section of this
chapter. Investigate the cause of the fault and repair.

12. Remove the test equipment.


13. Reconnect the alternator output B+ Terminal.

55-13
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Ground Voltage--Drop Test
Refer to Figure 19.

1. Turn the key-start switch to the ‘OFF’ position.


2. Disconnect the battery negative (ground) cable.
3. Disconnect the alternator output B+ Terminal (1).
4. Connect the milli-Voltmeter (4), negative side to
the alternator frame.
5. Connect the milli-Voltmeter (4), positive side to
the negative terminal of the battery.
6. Connect the Ammeter (2) negative side to the
(brown) B+ Terminal cable. 19
7. Connect the Ammeter (2) positive side to the
alternator output B+ Terminal (1).
8. Reconnect the battery negative (ground) cable.
9. Connect a variable-load resister (3), with the
slider in the minimum current draw position
(maximum resistance), across the battery
terminals.
10. Start the engine and increase engine speed to
2000 rev./min.
11. Slowly increase the current loading of the resistor
(decreasing resistance) until the Ammeter
registers 55 A. Milli-Voltmeter reading must not
exceed 200 mV.
If milli-voltmeter registers above 200 mV, suspect a
high resistance fault in the external circuit.

If alternator output not within specifications, and


milli-voltmeter registers below 200 mV, suspect a
faulty component within the alternator. Refer to the
“Alternator Component Testing” section of this
chapter. Investigate the cause of the fault and repair.

12. Remove the test equipment.


13. Reconnect the alternator output B+ Terminal.

55-14
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Alternator Maximum Output Performance Test
Refer to Figure 20.

1. Turn the key-start switch to the ‘OFF’ position.


2. Disconnect the battery negative (ground) cable.
3. Disconnect the alternator output B+ Terminal
cable (5).
4. Connect the Ammeter (2) negative side to the
(brown) B+ cable.
5. Connect the Ammeter (2) positive side to the
alternator output B+ Terminal (1).
6. Connect the Voltmeter (4) negative side to the 20
alternator frame.
7. Connect the Voltmeter (4) positive side to the
alternator output B+ Terminal (1).
8. Reconnect the battery negative (ground) cable.
9. Connect a variable-load resister (3), with the
slider in the minimum current draw position
(maximum resistance), across the battery
terminals.
10. Start the engine and increase engine speed to
2000 rev./min.
11. Slowly increase the current loading of the resistor
(3) (decreasing resistance) until the Ammeter
registers 55 A. Observe the reading on the
Voltmeter.
If Voltmeter registers below 13.6 V, suspect a faulty
alternator component. Investigate the cause and
repair.

12. Disconnect the test equipment.


13. Reconnect the alternator terminals.
Regulator and Rotor Field Circuit Test
Refer to Figure 21.

1. Disconnect the battery negative (ground) cable.


2. Disconnect all alternator terminal connections.
3. Connect a 12 V battery and a 2.2 W test lamp (2)
in series, between the warning circuit D+
Terminal (1) and the alternator frame (negative
side to frame). Check test lamp for illumination.
No illumination of the test lamp indicates a fault in the
rotor circuit. Check brushes, slip rings and continuity
of rotor field windings.
21
4. Remove test equipment.
5. Reconnect all alternator terminals.
6. Connect the battery negative (ground) cable.

55-15
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Rectifier Assembly -- Positive/Negative Diode
Test
Refer to Figure 22.

1. Connect a Multimeter (2) in series with a diode


connecting pin (1), and to the diode mounting
plate.
2. Note the resistance reading and then reverse the
Multimeter connections.
The Multimeter (2) must indicate an open circuit
(infinity ohms) during one-half of the test only.

3. Test the remaining diodes.


Replace the rectifier if any one of the diodes fail. 22

Rectifier Assembly -- Field Diode Test


Refer to Figure 23.

1. Connect the Multimeter (2), negative side to the


warning circuit D+ Terminal (1).
2. Connect the Multimeter (2), positive side to one
of the field diodes (3).
3. Note the resistance reading and then reverse the
test connections.
The Multimeter (2) must indicate an open circuit
(infinity ohms) during one-half of the test only.

4. Test the remaining diodes. 23


Replace the rectifier if any one diode fails.

Stator -- Winding Continuity Test


Refer to Figure 24.

1. Connect the Ohmmeter (2) test leads between


wires (A), (B), and (C). Check for a small
resistance of 0.1 ohm between each wire.
A higher resistance indicates a possible break within
the winding. A lower resistance will indicate a
possible short circuit within the winding. Replace
stator and housing if test fails.

24

55-16
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Stator-Winding Continuity Test
Refer to Figure 25.

1. Connect any two, of the three, stator output-wires


(2) in series with a 12 V battery (3) and a 36 W test
lamp (4).
2. Observe test lamp for illumination. If the test lamp
fails to illuminate, replace the stator assembly
(1).
3. Transfer one of the test lamp leads to a third
stator output-wire.
4. Observe test lamp for illumination.
If the test lamp fails to illuminate, replace the stator
assembly.

Rotor Slip-Ring Inspection


Perform the following slip ring inspection before
20031435
testing the rotor components.
25
1. Clean each slip ring.
2. Inspect slip rings for indications of burnt areas,
which will require refinishing. If required, use fine
glass paper to refinish until producing a highly
polished surface. Replace defective rings if
necessary.
3. Re-clean slip rings after refinishing.
Field-Winding Resistance Test
Refer to Figure 26.

1. Connect an Ohmmeter (3) between the two slip


rings (2) of the rotor (1).
2. Observe reading on Ohmmeter for 3.2 ohm.
Replace the rotor if test fails.

20031436

26

55-17
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Field-Winding Insulation Test
Refer to Figure 27.

1. Connect a 110 V insulation tester or 250 V


Meg-ohm meter (3) to a slip ring (2) and rotor
pole (1).
2. Follow the manufacture’s instructions for the test
equipment used. If the test produces unsatisfac-
tory results, replace the rotor assembly.

Alternator Frequency Output Test


Check the alternator square-wave signal at terminal
‘W’ with an Electronic Signal Simulator Test Set
FNH01031A. This test set measures frequency in
hertz.

1. Table 1 lists acceptable alternator frequency


output results.
20031437

27

Table 1

Engine RPM Alternator Output Tolerance


500 102.5 Hz 480-520 RPM
1500 307.5 Hz 1480-1520 RPM
2500 512.5 Hz 2400-2500 RPM

55-18
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEMS

Chapter 3 - Starting Motor and System

CONTENTS

Section Description Page


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Starting System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Starting System Circuit Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Starting Motor -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

55-1
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 3

DESCRIPTION AND OPERATION The solenoid contacts close even if the pinion and
The starting system consists of a starting motor and ring gear misalign. When misalignment occurs, the
solenoid, a relay, transmission neutral-start switch, engagement spring compresses and forces the
PTO safety switch, key-start ignition switch, and pinion into full contact, as the starting motor begins
heavy-duty circuit wiring. to turn.

The starting motor, a four-poled, brush type motor, Power to the solenoid and starting motor stops by
incorporates an integral solenoid and positive-en- releasing the key-start ignition switch. The solenoid
gagement drive assembly. return spring, acting through the pivoting linkage
mechanism, pulls the drive-pinion out-of-mesh, and
The integral solenoid contains two windings reopens the solenoid contacts.
connected in parallel. One winding grounds through
the motor and functions as a low-resistance ‘pull in’ A clutch device incorporated in the drive-pinion
coil. The other winding grounds through the solenoid assembly prevents the armature from rotating
body and functions as a high-resistance ‘hold-in’ coil. excessively, if the drive-pinion remains in mesh with
The solenoid contains a single set of contacts and a the flywheel ring-gear after the engine starts.
two-piece plunger.
STARTING SYSTEM TESTING
Operating the key-start switch in the closed position,
Use a high rated Battery Starter Tester, a Voltmeter
with the transmission in neutral, energizes the
(0-20 V), and an Ammeter (0-500 A) for the most
starting motor solenoid coil. The now magnetized coil
conclusive test result, as well as a rapid diagnosis of
pulls the plunger into the solenoid core. Plunger
the starting system. When using test equipment,
movement transmits via a pivoting mechanism to
follow the manufactures recommended procedures.
force the drive-pinion into mesh with the flywheel ring
If the test equipment recommended above is not
gear. Upon full engagement, the solenoid plunger
available, use standard equipment providing the
closes a set of contacts to allow a direct feed from the
same ratings to determine if the starting system
battery to all four field coils, thus providing full power
operates correctly.
to the starting motor.
Before testing:
One end of the ‘pull-in’ coil now connects to the
positive side of the battery through the key-start
ignition switch. The opposite end connects to 1) Check the battery for full charge.
positive through the solenoid contacts. This action 2) Check entire starting system wiring for
causes the by-passing of the ‘pull-in’ coil, allowing frayed, broken or loose wires and connec-
the ‘hold-in’ coil to keep the solenoid plunger tions.
engaged.

55-2
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 3
Starting Motor Circuit Current Draw
Refer to Figure 1.

1. Disconnect the battery (3) negative (ground)


cable.
2. Disconnect the battery positive cable from the
starting motor solenoid (4).
IMPORTANT: When testing the starting system, only
use an Ammeter, which has a maximum capacity of
1000 A or greater, or damage to the Ammeter will
occur.

3. Connect the positive side of an Ammeter (1) to


the positive terminal of the battery.
4. Connect the negative side of the Ammeter to the
starting motor solenoid input-terminal 20031438
5. Reconnect the battery negative (ground) cable to
1
the battery negative terminal.
6. Connect the positive side of a Voltmeter (2) to the
positive terminal of the battery.
7. Connect the negative side of the Voltmeter to the
negative terminal of the battery.

8. Disconnect the wire from the shut-off solenoid


(1), Figure 2, on the fuel injection pump.
9. Start the engine.
10. Observe the readings on the Voltmeter and
Ammeter. Check that voltage remains steady at
12 V and amperage remains 250-300 A.
Overhaul or replace the starting motor when: 1
• Current measures less than specification.
• Current measures greater than specifica-
tions, and all other starting system circuit
40025678
tests produce satisfactory results.
If drawn current remains within specification, but a 2
voltage drop occurs, test the starting system circuit
resistance. Refer to this chapter.

STARTING SYSTEM CIRCUIT RESISTANCE


TEST
Test for voltage drops within each individual
component as follows:

IMPORTANT: Disconnect the wire from the shut-off


solenoid on the fuel injection pump (1), Figure 2.

55-3
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 3
Battery Positive Cable
1. Connect the positive side of a Voltmeter to the
positive terminal of the battery.
2. Connect the negative side of the Voltmeter to the
starting motor solenoid, battery terminal (1),
1
Figure 3.
3. Crank engine and observe the Voltmeter.
If voltage registers above 0.2 V, check cable
connections for looseness. Tighten connections and
recheck. Replace cable if voltage remains exces-
sive.
40025992

Battery Negative (Ground) Cable 3


1. Connect the positive side of a Voltmeter to the
engine block.
2. Connect the negative side of the Voltmeter to the
negative terminal of the battery.
3. Start the engine.
4. Observe the Voltmeter.
If the Voltmeter registers above 0.2 volts, check
ground cable connections for tightness. If voltage
remains excessive, replace the negative (ground)
cable.

Starting Motor Ground Connections


1. Connect the positive side of a Voltmeter to the
starting motor frame.
2. Connect the negative side of the Voltmeter to the
engine block.
3. Start the engine.
4. Observe the Voltmeter.
If the Voltmeter registers above 0.2 volts, check
ground connections between starting motor flange
and rear engine support. Replace ground connec-
tions if voltage remains excessive.

STARTING MOTOR - OVERHAUL


Removal
1. Disconnect battery negative (ground) cable.
2. Remove the retaining nut (1) and protective 2
cover (2) off the solenoid assembly on the
starting motor, Figure 4.
3. Disconnect the positive lead at the solenoid 1
assembly.
4. Disconnect the coil feed-wire.
40025993

55-4
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 3
5. Remove the three starting motor retaining bolts.
6. Remove the starting motor.
1

Disassembly
1. Disconnect the field coil housing-to-solenoid
assembly braided wire (1), Figure 5.
2. Remove front housing-assembly screws.
3. Remove solenoid assembly.

40025992

5
NOTE: The plunger remains in the drive engage-
ment lever.

4. Remove the plunger from the drive engagement


lever by gripping plunger, lifting up front--end,
and releasing it from the lever.
5. Remove nuts and screws, which secure the
end--cap and brush plate to the housing.
6. Remove C-clip.
7. Remove armature shaft shims.
8. Remove the end housing.
NOTE: The brush gear will remain on the
commutator.

9. Remove washer from the armature at the


commutator end.
10. Compress the brush spring, bend back the spring
retaining tabs, and release the spring to remove
the brush from the holder. Remove all four
brushes.
11. Remove the carrier.
12. Remove the motor casing from the armature and
drive--end bracket.
13. Remove the drive engagement lever pivot pin
from the drive--end housing.
14. Drive the thrust collar squarely off the snap ring
and remove snap ring from grooved area.
Remove the drive assembly and inner--plate--re-
taining ring from the armature shaft.
15. Remove the armature and drive assembly.

55-5
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 3
Inspection and Repair
1. Check brushes for minimum length of 7 mm (.28
in.).
2. The commutator face must be clean and free of
burnt spots. Use fine glass paper to remove
spots. Clean when finished.
3. If necessary, skim the commutator without
exceeding a minimum diameter of 42.5 mm (1.7
in.). After skimming, polish commutator with fine
glass paper and clean.

Brush Removal and Installation


1. Unsolder field brush leads from the field coils.
2. Unsolder ground brush leads from the brush
holders.
3. Solder new brush leads using 300 W soldering
iron and resin core solder.
4. Ensure new brushes move freely in holder.
Smooth rough edges of the brushes.
Armature Insulation Test
Refer to Figure 6.

1. Connect an Ohmmeter (1) between the armature 1


shaft (2) and commutator segments (3).
2. Observe reading on Ohmmeter.
If the Ohmmeter registers a reading, the armature
insulation test fails. 2

20031440 3
6

55-6
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 3
Field Coil Insulation Test
Refer to Figure 7. 2

1. Connect an Ohmmeter (1) between the field


winding brushes (2), in turn, and a clean,
unpainted part of the housing (3).
2. Observe reading on Ohmmeter.

If the Ohmmeter registers a reading, the field coil


insulation test fails.

Field Winding Continuity Test


1. Connect an Ohmmeter between each field-wind- 1 3
ing brush, and the main-feed terminal.
20031441
2. Check for a reading of 1 ohm.
Replace the field coil and housing assembly when 7
the field winding continuity test fails.

Drive Pinion Assembly Inspection


1. Check that the pinion rotates clockwise only. If
the pinion sticks, rotates in both directions, or if
there is damage to the pinion teeth, replace the
drive assembly.

Assembly
Assembly of the starting motor follows the
disassembly procedures in reverse with the following
requirements:

1. Before installing the starting motor, check


armature end play. Refer to this chapter.
2. Perform the starting motor no-load test. Refer to
this chapter.

Armature End-play
1. Attach a dial indicator to the drive end-housing
flange. Locate the dial indicator pointer on the
end of the armature shaft.
2. Lever the armature full forward and zero the dial
indicator.
3. Lever the shaft full rearwards and record the
reading on the dial indicator.
4. A reading greater than 4 mm (0.015 in.) indicates
excessive wear in the armature and brush
end-plate assemblies. Replace defective com-
ponents and re-check end play.

55-7
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 3
Starting Motor No-Load Test
Refer to Figure 8. 6 9
NOTE: To obtain the best results while performing
the starting motor no-load test, use a fully charged
battery, a battery starter tester (with a high rated
discharge), and a (carbon pile) variable load resistor.

1. Secure the starting motor in a vice.


2. Connect the battery negative (ground) cable to
the starting motor mounting flange (4).
8
3. Connect a jumper lead (6) to the battery terminal
on the starting motor solenoid.
4. Connect the opposite end of the jumper lead to 7
the switch terminal on the starting motor
solenoid. 20031442
5. Connect the positive side of a Voltmeter (7) to the
8
positive terminal of the battery.
6. Connect the negative side of the Voltmeter to the
negative (ground) terminal of the battery (8).
7. Connect the positive side of an Ammeter (9) to
the positive terminal of the battery.
8. Connect the negative side of the Ammeter (1) to
the battery terminal on the starting motor
solenoid.
9. Hold a hand tachometer (5) on the end of the
armature shaft.
10. Adjust the carbon pile to 11.7 V to actuate the
starting motor.
11. When the armature rotates between 7600 and
8500 rev/min, compare the current to a
maximum of 160 A.
If not within specification, check for the following
discrepancies:

• Grounded field coils


• Chaffing armature
• Distorted armature shaft.

55-8
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 4

SECTION 55 - ELECTRICAL SYSTEMS

Chapter 4 - Battery, Servicing and Testing

CONTENTS

Section Description Page


Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inspection and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

55-1
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 4

DESCRIPTION AND OPERATION


The electrical system features a 12-Volt, negative
ground, maintenance free lead-calcium (Pb-Ca) type 1
battery with six-cell construction (1), Figure 1.

NOTE: A maintenance free battery will not lose water


from the electrolyte under normal charging condi-
tions. Conditions that will cause water loss include
prolonged charging above 14.4 volts, and from the
use of faulty charging system or boost/recovery
charging equipment.

The battery functions as a source of current for


starting the engine, lighting the tractor, and providing
instrumentation. The battery also aids in controlling
voltage in the electrical system, and furnishes
current when the electrical demands exceed the
alternator output.
40031369
Construction of the battery includes six cells with
positive and negative plates placed alternately next 1
to one another within each cell. A non-conducting,
porous envelope separates each positive plate from
the negative plate. The positive plates, welded to a
bus-bar form a positive terminal, and the negative
plates, welded to a similar bus-bar form a negative
terminal.

NOTE: Touching of the negative and positive plates


together will short-circuit the cell.

Composition of the positive plate includes a lead grid


with lead peroxide pasted into the grid openings, and
the negative plate contains a lead grid with spongy
lead pasted into the grid openings. The plates remain
submerged in a liquid electrolyte solution of diluted
sulfuric acid.

The battery mounts under the platform on the


right--hand side of the tractor.

Battery Temperature Compensation


Changes in battery temperature and loading directly
affect the charging system. A circular temperature-
sensing pad attaches to the bottom of the battery
tray. The battery sensor detects changes in battery
temperature, and relays the information to the
voltage regulator, which adjusts the charge rate
accordingly.

55-2
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 4
Removal
WARNING
Do not remove the battery without protective
clothing, especially for the eyes and hands.
Batteries contain sulfuric acid, which when in
contact with the body will cause serious
personal injury or death.

1. Lift the battery compartment latch and raise the 1


cover (1) to expose the battery.
40036167

2
2. Remove the tool tray (1).

40036168

3
3. Remove the protective mat (1)

40036169

55-3
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 4

CAUTION
DO not allow the positive and negative cables to
contact each other while disconnecting.
1 3
4. Disconnect the battery negative (ground) cable
(1) then disconnect the positive cable from the
battery terminals.
5. Use the appropriate socket, extension and
ratchet to hold the battery strap securing bolts,
and remove the nuts from the outside, bottom of
2
the battery compartment. Remove the strap (2).
40036170
WARNING
5
Take necessary precaution to avoid spilling the
sulfuric acid from the battery while removing
from the battery compartment. Wear protective
clothing, especially for the eyes and hands.
Sulfuric acid will cause serious bodily injury or
death.

6. Grasp the battery handles and carefully remove


the battery from the compartment. It may be
necessary to tilt the battery to clear the tool tray
brackets (3) when removing the battery. Avoid
spilling the sulfuric acid.

Installation
Installation of the battery follows the removal
procedures in reverse. Follow all safety precautions
when installing the battery. Observe the following
requirements:

1. Ensure the correct battery terminal polarity.


Check the terminal connections for tightness.
2. Apply petroleum jelly (Vaseline or equivalent) to
the battery terminals to protect against electro-
lytic corrosion.
3. Ensure there is no movement of the battery
under the mounting strap.

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 4

INSPECTION AND SERVICING Servicing the Battery


Battery ‘State of Charge’ WARNING
The specific gravity of the battery electrolyte indicates Batteries contain sulfuric acid, which generates
the ‘state of charge’. The specific gravity of a fully a highly explosive mixture of hydrogen and
charged battery at 25 _C (77 _F) is 1.280 minimum. oxygen gas during charging.

The approximate state of charge may also be


determined using an accurate digital Voltmeter (+/-- WARNING
0.01 V) as follows: Never use equipment that generates flames or
Less than 10.5 V Battery unserviceable* sparks when controlling the electrolyte level.

Less than 11.8 V Battery discharged


WARNING
Less than 12.3 V Battery 1/2 charged
Do not remove the battery cover plugs without
Greater than 12.6 V Battery fully charged protection for eyes and hands.
*See “Performance Test” for possible recovery of a
mildly sulfated battery. When servicing a battery, observe the following
steps.
Measure voltage of an unloaded battery only. Rest
the battery for a minimum of four hours before 1. Maintain the electrolyte to the recommended
unloading. For recently operated tractors, or a level, approximately 5 mm (0.25 in) above the
battery recently charged, turn on the headlamps for plates in a standard battery. Failure to maintain
2 minutes. a proper level of electrolyte may result in a high
concentration of acid and will damage the
When a battery discharges, sulfuric acid in the separators and impair the performance of the
electrolyte combines chemically with the plates, plates.
which lowers the specific gravity of the solution.
2. Use only distilled or de-mineralized water. Never
A battery hydrometer will determine the specific use tap water. Do not overfill
gravity of the electrolyte in a cell, while the amount of
3. Always keep the battery at least 75% charged to
unused sulfuric acid in the solution measures the
prevent the plates from becoming sulfated,
degree of change of that cell.
which causes loss of efficiency and possible
damage to plates at lower temperatures.
A battery operating in a lower temperature requires
a greater charge, and the lower the temperature, the 4. Avoid overcharging the battery. Excessive
more necessary it is that the battery be in a fully charging will create high internal heat that will
charged condition. For example, a battery with a expand and warp the plates, distort the battery
specific gravity of 1.225 at 27 _C (80 _F) will operate case, or displace the sealing compound.
the starter motor at warm ambient temperatures but Excessive charging will also cause plate grid
may not, at lower ambient temperatures due to low deterioration and produce water loss.
battery efficiency. Correct care and periodic
5. When fast charging the battery, ensure the
inspection will maintain long battery life.
battery temperature remains below 50 _C (122
Table 1 shows the effect of temperature on the _F).
efficiency of a typical battery: 6. Do not add sulfuric acid to a cell unless loss of
electrolyte occurred through spilling. Before
Table 1 replenishing, ensure the correct specific gravity
Temperature Efficiency of a Fully of the solution.
Charged Battery 7. When fully charging a battery, use only a slow
25 _C (77 _F) 100% charge rate. A high charge rate will rapidly boost
0 _C (32 _F) 65% the battery capacity, but must be followed by a
slow charge to bring the battery to full capacity.
--18 _C (0 _F) 40%
--29 _C (--20.2 _F) 25%

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 4
Dry-Charged Batteries 2. When using a fast or high rate of charge, follow
1. Remove the battery cell vent plugs. the manufacture’s instructions for the battery and
the charger. High rated charging raises the
2. Fill each cell with electrolyte to the recommended temperature of the electrolyte. Unless the charger
level with electrolyte of 1.280 specific gravity. consists of an automatic time or temperature
NOTE: The electrolyte must be diluted with sulfuric acid device, the electrolyte temperature may exceed
preferably at a temperature of 21-32 _ C (70-90_ F). 50 _C (122 _F), which will result in violent cell
gassing and/or damage to internal components.
3. Allow the battery to stand fifteen minutes after 3. Re-check the electrolyte level in each cell and
filling. Recheck the electrolyte level and replenish as necessary.
replenish as necessary.
4. Charge the battery for 4 hours at a rate of 5-8 Recharging a heavily discharged battery
amps, in accordance with the battery instruc- The recommended method of recharging a mainte-
tions. Allow the cells to gas freely. nance free Pb-Ca battery includes using a constant
5. Install the battery cell vent plugs when finished. voltage charger. Charge a heavily discharged battery
for a period of 48 hours at 16 V with a current
Charging the Battery limitation of 40.0 A for 90 Ah.
Before charging a battery:
Table 2 lists recommended current levels and times
1. Thoroughly clean the battery casing, terminals, for constant current chargers:
and cell covers with dilute ammonia or hot water.
Table 2
2. Check the level of the electrolyte, and replenish
if below recommended level. Battery Type Description Current Time
90 Ah Slow Charge 5A 25 hrs
WARNING (800 CCA)
Charging a battery produces an explosive gas. 10 A 12.5 hrs
Do not expose to sparks or flame when checking
the electrolyte level, and never connect or Fast Charge* 18 A 7 hrs
disconnect the charger until turned off. *Fast charge method for emergencies only.

Charging
Battery Testing
1. Charge the battery with a slow charger at a rate
Test equipment required:
of 3-6 amps until the battery reaches full charge.
This may take up to 36 hours or longer for a
heavily discharged battery. A severely sulfated • Hydrometer
battery may not accept a charge at all. When the • Battery Starter Tester
battery has finished charging, the cells will gas • Thermometer
freely and the specific gravity will remain constant. • Battery Charger
Remove the charger after three consecutive
hydrometer readings, taken at hourly intervals;
indicate that specific gravity no loner rises.

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 4
Testing Specific Gravity Example 1
1. Take the hydrometer reading of the electrolyte Temperature below 30 _C (86 _F)
with the float in the vertical position. Electrolyte Temperature 19 _C (66 _F)
Hydrometer Reading 1.270
2. Adjust the hydrometer reading for electrolyte Subtract 11 x 0.004 0.008
temperature variations as follows: 5.5
1) Subtract four points (0.004 specific gravity) Corrected Specific Gravity 1.262
for every 5.5 _C (10 _F) below the
temperature of hydrometer calibration.
2) Add four points (0.004 specific gravity) for Example 2
every 5.5 _C (10 _F) above the temperature Temperature above 30 _C (86 _F)
of hydrometer calibration. Electrolyte Temperature 40 _C (104 _F)
Hydrometer Reading 1.220
The following examples demonstrate specific gravity Subtract 10 x 0.004 0.007
corrections using a hydrometer calibrated at 30 _C 5.5
(86 _F): Corrected Specific Gravity 1.277

Refer to Table 3 to determine the state of change:


Table 3
State of Charge Corrected Specific Corrected Specific Average Battery Voltage
Gravity at 15 _C (59 _F) Gravity at 25 _C (77 _F)
100% 0.295 1.287 12.76 V
75% 1.253 1.246 12.52 V
50% 1.217 1.210 12.30 V
25% 1.177 1.170 12.06 V
Discharged 1.137 1.130 11.84 V

NOTE: Specific gravity must not vary more than NOTE: After adding distilled water, charge the
0.025 points between cells. battery for a short period before testing with the
hydrometer to ensure an accurate reading.
A specific gravity measurement of 1.280 or more
indicates a fully charged battery in good operating NOTE: Charging a battery under static conditions will
condition. Should the corrected specific gravity cause denser electrolyte to accumulate at the bottom
measure below 1.280, charge the battery and of the cells. Periodically shake the battery to mix the
inspect charging system to determine cause of the electrolyte and improve the charge rate. This will
low charge. result in a more accurate hydrometer reading.

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 4
Battery Performance Test 3. Turn the charger timer past a ‘3 minutes’ charge
The performance test determines if the battery indication and then back to the ‘3 minutes’ mark.
contains adequate capacity to turn the engine. The
4. Set the charging rate as close as possible to 40
voltage reading obtained determines the condition of
amperes.
the battery.
5. After 3 minutes of fast charge, record the
The battery must contain the correct electrolyte level Voltmeter reading.
and an open circuit voltage of 12.5 V before testing. A reading over 15.5 V signifies a sulfated or worn
battery. Replace the battery.
CAUTION
Recovery of a mildly sulfated battery is possible by
Do not leave the high discharge load on the
using a multiple battery type charger, with an
battery for more than 15 seconds.
open-circuit, upper voltage limit of 50 volts. The high
resistance of a sulfated battery will require a high
1. Set the current control switch on the battery voltage setting to overcome the sulfated plates.
starter tester to the ‘OFF’ position. Initially, no charge acceptance will be visible. After a
2. Set the voltage selector switch equal to, or few minutes of inactivity, a small charge will become
slightly higher than the rated battery voltage. apparent, followed by a rapid increase in the charge
rate. The charge rate must not exceed 14 amperes,
3. Connect the positive cable of the tester to the or an electrolyte temperature of 50 _C (122 _F).
positive terminal of the battery. When the ampere rate stabilizes, reset the volts until
4. Connect the negative cable of the tester to the the charge rate steadies at 5 amperes. Continue at
negative terminal of the battery. this rate until the electrolyte specific gravity stops
rising at approximately 1.265-1.270 at 27 _C (80 _F),
5. Turn the current control switch until the Ammeter which may take up to 48 hours of charging. Stand the
reads half the CCA rating of the battery. Record battery for 24 hours and then conduct the “Capacity
the voltage reading. Test” as described in this chapter.
A reading of 9.6 V or greater after 15 seconds
signifies that the battery will provide an acceptable With a reading below 15.5 V test the specific gravity
output, as well as readily accept a normal charge. of each cell and recharge the battery to the following
scale:
A reading below 9.6 V signifies a battery
unsatisfactory for service. Use the “Test Charging” Table 4
procedures described in this chapter for a battery
that fails the capacity test. Specific Slow Charge Fast Charge
Gravity Only Up To

Test Charging 1.150 or less 60 minutes


Use the test charging procedure for batteries that fail 1.151-1.175 45 minutes
the capacity test. 1.176-1.200 30 minutes
1.201-1.225 15 minutes
1. Connect the positive lead of the battery starter
tester (with high rate discharge) to the positive
terminal of the battery. NOTE: When determining the cause of battery
2. Connect the negative lead of the battery starter problems, check the fan belt tension and charging
tester to the negative terminal of the battery. system.

55-8
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 4
Common Causes of Battery Failure Crystal growth occurs whenever batteries stand
• Internal open or short circuit discharged. High temperatures and extended
discharge periods increase this condition. At room
• Loss of electrolyte
temperature after one week, the battery may not
• Separation of active materials from grids recover while on the vehicle. Recharge will require a
• Accumulation of sulfate crystals too large to higher constant voltage. After three weeks, the
disperse battery will suffer permanent degradation, and the
• Failure of inter-cell components procedures for charging a heavily discharged battery
will be required.
• Separators punctured by excessive crystal
growth, causing short circuit When fully charged, batteries have a long shelf life.
• Excessive over-charging The lead--calcium type battery discharges at 3% per
• Electrolyte freezing month. It will take 16 months to drop to 50% charged.
On the tractor, the quiescent load is approximately 50
mA. To predict rundown on a static vehicle, add 8 Ah
A fully charged battery will not freeze until –65 _C per week.
(--85 _F). A 50% charged battery freezes between
–17 _C and –27 _C (1.4 _F and --16.6 _F). Fully When cranking the engine, if the battery starts to
discharged electrolyte freezes between –3 _C and fade, stop cranking and allow the battery to stand for
–11 _C (26.6 _F and 12.2 _F). Excessively high boost two minutes to recover. The recovery time required
charging and gassing will cause separation of active increases as the temperature decreases.
materials from the grids. Separation destroys the
chemical function of the battery.

55-9
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 4

55-10

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