Beruflich Dokumente
Kultur Dokumente
REPAIR MANUAL
COMPLETE CONTENTS
SECTION 00 - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 10 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 18 - CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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.
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
3
SECTION 10 - ENGINE
BOOK 1 - 87046218
4
SECTION 10 - ENGINE
BOOK 1 - 87046218
SECTION 10 - ENGINE
BOOK 1 - 87046218
5
SECTION 10 - ENGINE
BOOK 1 - 87046218
6
SECTION 10 - ENGINE
BOOK 1 - 87046218
Chapter 5 - Turbocharger
CONTENTS
SECTION 18 - CLUTCH
BOOK 1 - 87046218
7
SECTION 18 - CLUTCH
BOOK 1 - 87046218
Chapter 1 - 8 x 2 Transmission
CONTENTS
8
SECTION 21 - TRANSMISSION SYSTEMS
BOOK 1 - 87046218
9
SECTION 23 - FRONT AXLE TRANSFER BOX
BOOK 1 - 87046218
10
SECTION 27 - MECHANICAL REAR WHEEL DRIVE
BOOK 2 - 87046219
11
SECTION 31 - POWER TAKE-OFF
BOOK 2 - 87046219
12
SECTION 35 - HYDRAULIC SYSTEM
BOOK 2 - 87046219
13
SECTION 35 - HYDRAULIC SYSTEM
BOOK 2 - 87046219
14
SECTION 41 - STEERING SYSTEM
BOOK 2 - 87046219
15
SECTION 44 - FRONT AXLE--TWO WHEEL DRIVE
BOOK 2 - 87046219
16
SECTION 55 - ELECTRICAL SYSTEMS
BOOK 2 - 87046219
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.
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
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
00-5
SECTION 00 -- GENERAL -- CHAPTER 1
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 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.
00-7
SECTION 00 -- GENERAL -- CHAPTER 1
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.
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
00-12
SECTION 00 -- GENERAL -- CHAPTER 1
00-13
SECTION 00 -- GENERAL -- CHAPTER 1
CALIFORNIA
Proposition 65 Warning
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.
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.
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
00-20
SECTION 00 -- GENERAL -- CHAPTER 1
00-21
SECTION 00 -- GENERAL -- CHAPTER 1
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.
Accessory
Turn signals Creeper socket
Fuel level gears
00-23
SECTION 00 -- GENERAL -- CHAPTER 1
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.
00-25
SECTION 00 -- GENERAL -- CHAPTER 1
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.
00-27
SECTION 00 -- GENERAL -- CHAPTER 1
00-28
SECTION 00 -- GENERAL -- CHAPTER 1
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
10-1
SECTION 10 -- ENGINE -- CHAPTER 1
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 HEAD
10-3
SECTION 10 -- ENGINE -- CHAPTER 1
EXHAUST VALVES
INTAKE VALVES
VALVE SPRINGS
VALVE TIMING
10-4
SECTION 10 -- ENGINE -- CHAPTER 1
VALVE INSERTS
VALVE SEATS
10-5
SECTION 10 -- ENGINE -- CHAPTER 1
ROCKER ARM
TAPPETS
CAMSHAFT
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
PISTONS
10-6
SECTION 10 -- ENGINE -- CHAPTER 1
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 BEARING
CRANKPIN BEARINGS
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
CRANKSHAFT BALANCER
FLYWHEEL
OIL PUMP
10-9
SECTION 10 -- ENGINE -- CHAPTER 1
10-10
SECTION 10 -- ENGINE -- CHAPTER 1
LUBRICANTS
Transmission/rear axle hydraulics, four wheel drive
differential casing and front hubs: 134 D Hydraulic Oil
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
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
LOCKNUTS
GRADE A NO MARK
GRADE B LETTER B
GRADE C LETTER C
GRADE IDENTIFICATION
10-13
SECTION 10 -- ENGINE -- CHAPTER 1
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)
MANUFACTURER’S IDENTIFICATION
PROPERTY CLASS
MANUFACTURER’S IDENTIFICATION
10-14
SECTION 10 -- ENGINE -- CHAPTER 1
SPECIAL TOOLS
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.
10-16
SECTION 10 -- ENGINE -- CHAPTER 1
10-17
SECTION 10 -- ENGINE -- CHAPTER 1
10-18
SECTION 10 -- ENGINE -- CHAPTER 1
5. Oil loss past the pistons and 5. Replace rings and/or re-bore,
rings or re-sleeve block as
necessary
10-19
SECTION 10 -- ENGINE -- CHAPTER 1
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
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.
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
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
3
Engine Components -- Front
10-24
SECTION 10 -- ENGINE -- CHAPTER 1
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.
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.
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.
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.
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.
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”.
10-33
SECTION 10 -- ENGINE -- CHAPTER 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.
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.
33
10-36
SECTION 10 -- ENGINE -- CHAPTER 1
NOTE: Figure 34 displays an incomplete engine to
facilitate the identification of components. 3 1
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
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
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
44
10-41
SECTION 10 -- ENGINE -- CHAPTER 1
VALVE INSERTS
Cylinder Head Counter Bore
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
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
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
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:
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.
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
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.
62
10-50
SECTION 10 -- ENGINE -- CHAPTER 1
Depending on configuration, proceed as follows:
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.
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.
74
Piston Ring Removal
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.
76
10-57
SECTION 10 -- ENGINE -- CHAPTER 1
T1B10029
77
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.
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”.
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
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.
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
10-64
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.
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
90
Piston Ring Installation
1. Piston Ring Expander
2. Piston Ring
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.
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
94
Connecting Rod Bearing Side Clearance
1. Feeler Gauges
10-68
SECTION 10 -- ENGINE -- CHAPTER 1
95
Balancer Gear Backlash
1. Dial Indicator
2. Backlash Check at Gears
96
Balancer Gears
1. Roll Pin 4. Driven Gears
2. Housing 5. Thrust Washers
3. Thrust Washers 6. Shafts
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
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
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
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
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.
10-73
SECTION 10 -- ENGINE -- CHAPTER 1
105
Rear Cover Plate
1. Sealer Application
2. Retaining Bolts
3. Plate Alignment
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
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
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.
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
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.
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.
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
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
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.
125
Camshaft Tappet Assembly
1. Tappets
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
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:
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:
10-88
SECTION 10 -- ENGINE -- CHAPTER 1
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.
10-90
SECTION 10 -- ENGINE -- CHAPTER 2
SECTION 10 - ENGINE
CONTENTS
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.
SEALANTS
82995776 Sealer--Silicone
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.
12. Hot spot due to rust and scale 12. Reverse flush entire cooling
or clogged water jackets system
14. Extended engine idling 14. Do not allow engine to idle for
long periods
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
10-3
SECTION 10 -- ENGINE -- CHAPTER 2
10-4
SECTION 10 -- ENGINE -- CHAPTER 2
2
Engine Block Drain Plug (left hand side)
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.
Assembly
Assembly of the radiator and associated compo-
nents follows the disassembly procedures with the
following requirements:
Installation
Installation of the radiator follows the removal
procedures in reverse with the following require-
ments:
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.
Installation
Installation of the thermostat follows the removal
procedure in reverse with the following require-
ments: 9
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.
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
10-12
SECTION 10 -- ENGINE -- CHAPTER 3
SECTION 10 - ENGINE
CONTENTS
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
10-2
SECTION 10 -- ENGINE -- CHAPTER 3
10-3
SECTION 10 -- ENGINE -- CHAPTER 3
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.
7
Washing the Element
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
CONTENTS
10-1
SECTION 10 -- ENGINE -- CHAPTER 4
SPECIFICATIONS
FUEL SYSTEM SPECIFICATIONS
Components
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.
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
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
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
10-6
SECTION 10 -- ENGINE -- CHAPTER 4
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
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.
• 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
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
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.
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.
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.
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.
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
CAUTION 10
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.
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.
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
10-17
SECTION 10 -- ENGINE -- CHAPTER 4
10-18
SECTION 10 -- ENGINE -- CHAPTER 4
10-19
SECTION 10 -- ENGINE -- CHAPTER 4
Removal
Refer to Figure 20.
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.
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
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
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
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.
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.
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
WARNING
Fuel spray is flammable. Ensure no open flames
exist in the testing area, and do not generate
excessive vapor.
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.
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.
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
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:
10-38
SECTION 10 -- ENGINE -- CHAPTER 4
Removal
NOTE: Tractors with fuel systems incorporating the
DP203 series fuel injection pump include the electric
lift pump.
61
Installation
Installation of the electric lift pump assembly follows
the removal procedures in reverse with the following
requirement:
62
10-39
SECTION 10 -- ENGINE -- CHAPTER 4
10-40
SECTION 10 -- ENGINE -- CHAPTER 5
SECTION 10 - ENGINE
Chapter 5 - Turbocharger
CONTENTS
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
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
10-5
SECTION 10 -- ENGINE -- CHAPTER 5
TURBOCHARGER
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
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.
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.
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:
10-11
SECTION 10 -- ENGINE -- CHAPTER 5
Thrust Bearing Axial Clearance Check
Check the thrust bearing axial clearance as follows:
Assembly
NOTE: When replacing parts during overhaul,
transfer scribe marks made during disassembly from
the old part to the new part.
• 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
13
10-13
SECTION 10 -- ENGINE -- CHAPTER 5
Installation
Installation of the turbocharger follows the removal
procedures in reverse with the following require-
ments:
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
18-1
SECTION 18 -- CLUTCH -- CHAPTER 1
SPECIFICATIONS
Components
TORQUE VALUES
Components lb.ft. Nm
18-2
SECTION 18 -- CLUTCH -- CHAPTER 1
SPECIAL TOOLS
FAULT FINDING
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.
18-3
SECTION 18 -- CLUTCH -- CHAPTER 1
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
Difficulty engaging gears Clutch Dragging (not fully 1. Check clutch adjustment
disengaging)
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
18-4
SECTION 18 -- CLUTCH -- CHAPTER 1
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:
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
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.
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.
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
50025060
18-9
SECTION 18 -- CLUTCH -- CHAPTER 1
[BEFORE ASSEMBLY
LUBRICATE DISC SPLINES]
10024891
18-10
SECTION 18 -- CLUTCH -- CHAPTER 2
SECTION 18 - CLUTCH
CONTENTS
18-1
SECTION 18 -- CLUTCH -- CHAPTER 2
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
Chapter 1 - 8 x 2 Transmission
CONTENTS
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)
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
21-3
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
TABLE 2
Ground Speeds in Miles Per Hour (16.9 -- 34 Rear Tires)
21-4
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
21-5
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
21-6
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
21-7
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
21-8
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
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
Inspection
1. Inspect the neutral start switch for wear or
damage. Replace as necessary.
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
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.
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
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.
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.
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.
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.).
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
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
CONTENTS
21-1
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2
SPECIFICATIONS
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.
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
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
21-3
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2
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
21-4
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2
1
Power Underdrive
With reference to Figure 2.
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.
Refer to Figure 5.
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
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
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
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
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.
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.
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.
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
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.
21-18
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3
CONTENTS
21-1
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3
SPECIFICATIONS
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)
TIGHTENING TORQUES
Components ft.-lb. Nm
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
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.
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).
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.
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
CONTENTS
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
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
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
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
6
Idle Gear Shaft Retainer
1. Shaft
2. Socket Head Bolt
3. Idler Gear
4. Shouldered Anchor Nut
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
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
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
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
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
18
Output Shaft Front End Plate
1. End Plate
2. Felt/Lip Seal
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)
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
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
26
Installing Output Shaft Rear End Plate
1. End Plate
2. Bearing Assembly
3. Oil transfer Tube
4. O-ring Seal
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
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
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
33
Measuring Width of Idler Gear Mounting Lugs in
Transfer Box Casing
Example:
Then B - A = C
0.2 mm ÷ 2 = .1 mm
(0.01 in. ÷ 2 = 0.005 in.)
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:
23-19
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1
23-20
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
CONTENTS
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
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
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
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.
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.
25-8
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
4
Planetary Carrier Retainers
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
7
Ring Gear and Carrier Retaining Bolts
1. Axle Shaft
2. Ring Gear and Carrier
3. Retaining Bolts
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
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.
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
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.
15
Hub Oil Seal Wear Journal
1. Swivel Casing
2. Wear Journal
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:
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.
18
Installing Sun Gear Components
1. Thrust Washer
2. Spacer
3. Sun Gear
4. Snap Ring
19
Installing Planetary Carrier Retainers
1. Socket Screws
2. Shouldered Studs
25-16
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
20
Hub and Swivel Assembly Supported by Sling
21
Upper Swivel Pin and Retaining Bolts
1. Swivel Pin
2. Retaining Bolts
3. Lever Slot
4. Greaser
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
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
27
Installing Axle Shaft Bushing in Swivel Casing
1. Bushing Installer Special Tool
2. Driver Handle
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.
25-20
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
29
Hub and Swivel Assembly Supported by Sling
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
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
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.
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)
Or
Then,
Or
25-25
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
41
Steering Cylinder End Plate/Retaining Bolts
1. Retaining Bolts
2. End Plate
3. Cylinder Rod
4. Hydraulic Hose
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
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
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
50
Rear Support Pillar Retaining Bolts
1. Support Pillar
2. Retaining Bolts
3. Flange Coupling
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.
Installation
Installation of the axle follows the removal
procedures in reverse with the following require-
ments.
25-32
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
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
56
Differential Unit Bearing Adjuster Locking Plates
1. Locking Plates
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
59
Crown Wheel Retaining Bolts
1. Retaining Bolt
2. Crown Wheel
3. Differential
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
62
Removing Differential Side Gear and Clutch Pack
1. Side Gear
2. Clutch Pack
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
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
67
Side Gears and Clutch Packs
1. Side Gears
2. Interfacing Drive Plate
3. Internally Splined Driven Friction Plate
4. Inner Thrust Plate
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
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
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
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
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.
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.
25-45
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
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.
25-46
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
CONTENTS
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)
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
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
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
27-5
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
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.
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.
27-8
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
MTG27009
5
Rear Axle Half Shaft Assembly
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.
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.
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
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:
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:
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
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
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:
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:
Installation
Installation of the differential and differential lock
follows the removal procedures in reverse with the
following requirements:
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:
27-20
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
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
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”.
Installation
Installation of the drive pinion assembly follows the
removal procedures in reverse with the following
requirement:
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)
Example:
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.
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)
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.
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
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
WARNING
Tractor wheels are very heavy. Handle with care
and ensure, when stored, that they cannot topple 1626 mm
and cause injury. (64 in.)
27-35
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
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.
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.
27-36
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
CONTENTS
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
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)
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
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)
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)
31-9
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
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
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.
12
Clutch and Valve Assembly
1. Piston
2. Return Spring
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
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:
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:
31-15
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
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
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
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.
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
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
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.
31-24
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
CONTENTS
33-1
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
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.
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.
33-3
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
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.
33-5
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
33-6
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
CONTENTS
35-1
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
SPECIFICATIONS
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
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)
35-3
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
SPECIAL TOOLS
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
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.
35-7
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
35-8
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
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
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
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.
35-16
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
7
Control Valve Oil Flow in Neutral
(Tractors with Fixed Displacement Hydraulic Pump)
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.
35-18
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
R8--333
8
Control Valve Oil Flow in Lowering Position
(Tractors with Fixed Displacement Hydraulic Pump)
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.
35-20
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
9
Control Valve Oil Flow in Slow Raising Position
(Tractors with Fixed Displacement Hydraulic Pump)
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.
35-22
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
10
Control Valve Oil Flow in Fast Raising Position
(Tractors with Fixed Displacement Hydraulic Pump)
35-23
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
Fixed Displacement Engine Mounted
(Single Gear) Pump - Oil Flow
Refer to Figure 11.
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)
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.
35-26
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
Hydraulic System Control
Two distinct systems are incorporated:
• Draft Control
• Position Control
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
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.
35-33
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
35-34
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2
CONTENTS
35-1
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2
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.
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).
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.
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
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
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:
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.
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.
35-10
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2
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.
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.
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
CONTENTS
35-1
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
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.
Neutral Position
Refer to Figure 3.
35-3
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
24
25
26
28 27
2
Double Spool Remote Control Valve
35-4
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
3
Single Remote Control Valve Operation--Neutral
35-5
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Raise Position
Refer to Figure 4.
35-6
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
4
Single Remote Control Valve Operation--Raising
35-7
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Lowering Position
Refer to Figure 5.
35-8
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
5
Single Remote Control Valve Operation--Lowering with Slow Flow Control Setting
35-9
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Cylinder Overload
Refer to Figure 6.
35-10
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
6
Single Remote Control Valve Operation--External Cylinder Overload
35-11
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Double Remote Valve Oil Flow
Refer to Figure 7.
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
35-13
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Oil Flow in Float
Refer to Figure 8.
35-14
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
8
Single Remote Control Valve Operation--Float
35-15
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
Remote Valve Coupler Oil Flow
Refer to Figure 9.
35-16
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
9
Remote Valve Coupler Operation
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.
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.
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.
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
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
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
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
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
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
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:
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
35-29
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3
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
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:
35-32
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4
CONTENTS
35-1
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4
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
35-5
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4
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
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.
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.
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
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.
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.).
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)
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
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
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
35-18
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4
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
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:
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
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
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
CONTENTS
35-1
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5
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.
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:
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
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
22
IMPORTANT: Do not allow the drop poppet valve
and spring to fall from the lift cylinder housing.
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:
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
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.
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.
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.
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
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.
35
Checking Main Hydraulic Pump Pressure
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).
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
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
CONTENTS
41-1
SECTION 41 -- STEERING SYSTEM -- CHAPTER 1
SPECIFICATIONS
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
41-3
SECTION 41 -- STEERING SYSTEM -- CHAPTER 1
SPECIAL TOOLS
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
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
CONTENTS
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.
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.
4
Refer to Figure 5.
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.
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.
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.
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.
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.
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
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
R-8-493
30
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.
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:
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.
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
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
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.
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.
41-23
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Assembly
Refer to Figure 53.
Installation
Installation of the steering cylinder follows the remov-
al procedures in reverse with the following require-
ments:
41-24
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Steering Stops - Adjustment
Refer to Figure 54.
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
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.
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.
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:
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.
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.
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.
41-32
SECTION 41 -- STEERING SYSTEM -- CHAPTER 2
Steering Motor Pressure Relief Valve
Adjustment
Refer to Figure 59.
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
CONTENTS
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.
LUBRICANT
Grease, High Temperature 82923047 (AMBRA GR9)
44-2
SECTION 44 -- FRONT AXLE--TWO WHEEL DRIVE -- CHAPTER 1
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
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:
44-5
SECTION 44 -- FRONT AXLE--TWO WHEEL DRIVE -- CHAPTER 1
44-6
SECTION 44 -- FRONT AXLE--TWO WHEEL DRIVE -- CHAPTER 1
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
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.
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
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
CONTENTS
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.
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.
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:
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.
• 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
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.
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
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.
55-20
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
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.
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.
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.
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
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:
Installation
Installation of the oil pressure sender switch follows
the removal procedures in reverse with the following
requirement:
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
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.
32
Key--Start Ignition Switch
The five positions of the key-start ignition switch
include:
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.
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:
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.
Installation
Installation of the PTO switch follows the removal
procedures in reverse with the following require-
ments: 20030995
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.
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:
Installation
Installation of the air filter restriction switch follows
the removal procedures in reverse with the following
requirement:
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
Installation
Installation of the work lamp switch follows the
removal procedures in reverse with the following
requirement:
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
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
55-35
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
DIAGRAMS -- DESCRIPTION
(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
55-36
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
(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
55-38
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
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:
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
CONTENTS
55-1
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
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.
4
Fan Belt Tensioner
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.
20031417
55-4
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
7
Alternator Charging Circuit
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
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
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:
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:
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
55-10
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Alternator Plug Connection Test
Refer to Figure 16.
55-11
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Alternator Charging Current and Controlled
Voltage Tests
Refer to Figure 17.
55-12
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Charging Circuit Voltage--Drop Test
Refer to Figure 18.
55-13
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Ground Voltage--Drop Test
Refer to Figure 19.
55-14
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Alternator Maximum Output Performance Test
Refer to Figure 20.
55-15
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Rectifier Assembly -- Positive/Negative Diode
Test
Refer to Figure 22.
24
55-16
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Stator-Winding Continuity Test
Refer to Figure 25.
20031436
26
55-17
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 2
Field-Winding Insulation Test
Refer to Figure 27.
27
Table 1
55-18
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 3
CONTENTS
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.
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
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.
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.
20031440 3
6
55-6
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 3
Field Coil Insulation Test
Refer to Figure 7. 2
Assembly
Assembly of the starting motor follows the
disassembly procedures in reverse with the following
requirements:
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.
55-8
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 4
CONTENTS
55-1
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 4
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.
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.
Installation
Installation of the battery follows the removal
procedures in reverse. Follow all safety precautions
when installing the battery. Observe the following
requirements:
55-4
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 4
55-5
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.
55-6
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
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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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
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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.
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