G6030,G6035 SERVICEMANUAL COMPLETECONTENTS
SECTION00-GENERALINFORMATION2 .............................
SECTION10-ENGINEANDFUELSYSTEMS3 ..........................
SECTION25-FOURWHEELDRIVEREARAXLE11
SECTION27-DIFFERENTIAL,AXLE12 .................................
SECTION31-POWERTAKE-OFF(PTO)15 .............................
SECTION35-HYDRAULICSYSTEM17 ..................................
SECTION41-STEERING20 ............................................
SECTION44-WHEELSANDTIRES21 ..................................
SECTION55-ELECTRICAL22 .........................................
Thefollowingpagesarethecollationofthecontentspagesfromeachsectionandchapter oftheG6030,G6035Servicemanual.CompleteServicepart#84203602.
ThesectionsusedthroughoutallNewHollandproductServicemanualsmaynotbe usedforeachproduct.EachServicemanualwillbemadeupofoneorseveralbooks. EachbookwillbelabeledastowhichsectionsareintheoverallServicemanualand whichsectionsareineachbook.
ThesectionslistedabovearethesectionsutilizedfortheG6030,G6035Servicemanual.
© 2009CNHAmericaLLC.AllRightsReserved. NewHollandisaregisteredtrademarkofCNHAmericaLLC. 84203605 6/09 1stPrinting
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SECTION29-HYDROSTATICDRIVESYSTEM14 .........................
SECTION33-BRAKES16 ..............................................
SECTION90-PLATFORM30 ...........................................
2 SECTION00--GENERALINFORMATION BOOK1-84203603 Chapter1--GeneralInformation CONTENTS SectionDescription Page Introduction 2 ................................................................... PrecautionaryStatements3 PersonalSafety 3 MachineSafety 3 Information 3 TechnicalInformation--Hardware4 ................................................ General 4 ................................................................... Plating 4 NutTightening4 Locknuts 4 JamNuts 4 ThreadLubrication4 .......................................................... Safety 5 CommercialMower5 ServicingtheCommercialMower5 DrivingtheCommercialMower6 OperatingthePowerTakeOff(PTO)6 .......................................... OperatingtheMowerDeck7 ................................................... DieselFuel 8 ................................................................ AvoidHigh-pressureFluids8 Safety 9 SafetyDecals 12 InternationalSymbols18 ......................................................... Specifications 19 ................................................................ MinimumHardwareTighteningTorques26 ......................................... SpecialTools 28 Lubricants 29 Touch-upPaint 30 Pre-seasonandPredeliveryService31 ............................................ CheckandAdjustasRequired31 ................................................. InoperativeServiceChecks31 SafetyItemsChecks31 OperativeServiceChecks31
SECTION10--ENGINEANDFUELSYSTEMS
3
BOOK1-84203603
CONTENTS
Page Specifications 6
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PistonSpecifications7
PistonRingSpecifications8
CrankshaftSpecifications10
RockerArmSpecifications13
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................................... MetricBoltTorqueSpecifications--AllModels16 SpecialTools 17 ................................................................ CompressionTest18 DescriptionofOperation--Engine20 .............................................. CylinderBlock21 CylinderHeadandValveTrainComponents21 .................................. Troubleshooting 23 Overhaul--Engine27 ........................................................... Engine 27 Removal27 ............................................................. FuelInjectorandGlowPlug32 Removal32 ValveCover 32 Removal32
Chapter1--EngineSystems
SectionDescription
GeneralEngineSpecifications6
CylinderBlockSpecifications6 CylinderHeadSpecifications7 .................................................
PistonWristPinSpecifications8 ................................................
ConnectingRodSpecifications9 ...............................................
CamshaftSpecifications11 ValveSpecifications12 PushrodSpecifications13
LubricationSystemSpecifications13 CoolingSystemSpecifications14
EngineBoltTorqueSpecifications15 EngineFuelSystemBoltTorqueSpecifications15
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BOOK1-84203603 Chapter1--EngineSystems(Continued) CONTENTS SectionDescription Page OilTransferTube33 Removal33 ............................................................. WaterPumpRemoval33 RockerArm,SupportBracket,andPushrod33 .................................. Removal33 ExhaustManifold34 ......................................................... Removal34 EngineCylinderHead34 ..................................................... Removal34 Lifter(ValveTappet)35 Removal35 FuelShutoffSolenoid35 Removal35 TimingGearCover36 Removal36 ............................................................. TimingGearsandCamshaft37 Removal37 ............................................................. OilPanandPick-up38 Removal38 ............................................................. ConnectingRods,Bearings,andPiston39 Removal39 ............................................................. BackingPlateandOilSeal39 Removal39 ............................................................. FrontCrankshaftGear40 Removal40 ............................................................. CrankshaftandMainBearings40 Removal40 ............................................................. CylinderHead41 Disassembly41 InspectionandRepair41 ValveSeats 42 InspectionandRepair42 ..................................................
SECTION10--ENGINEANDFUELSYSTEMS
SECTION10--ENGINEANDFUELSYSTEMS
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BOOK1-84203603 Chapter1--EngineSystems(Continued) CONTENTS SectionDescription Page Valves 43 InspectionandRepair43 .................................................. ValveGuides44 InspectionandReplacement44 ............................................ ValveSprings45 InspectionandReplacement45 ............................................ RockerArms45 InspectionandReplacement45 ............................................ Pushrods 46 InspectionandReplacement46 CylinderHead46 Assembly46 CylinderBlock47 Inspection47 Pistons 48 .................................................................. DisassemblyandInspection48 PistonRings51 ............................................................. Inspection51 ConnectingRods52 ......................................................... Inspection52 ConnectingRodBearingOilClearanceCheck54 ................................ Pistons,Rings,andConnectingRod55 Assembly55 ............................................................ MainBearingandThrustWasher56 RemovalAndInspection56 ................................................ Crankshaft--AllModels58 Inspection58 ............................................................ MainJournalNumberOneBearing(Bushing)60 Inspection60 Replacement61 CrankshaftFrontGear,MainBearingsandThrustWashers61 Assembly61 ............................................................
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Chapter1--EngineSystems(Continued) CONTENTS SectionDescription Page OilPumpPortBlock62 Removal62 ............................................................. Installation63 TimingGear 63 .............................................................. Inspection63 Camshaft 64 ................................................................ Disassembly64 Inspection64 ............................................................ Assembly65 Flywheel 66 InspectionandRepair66 TimingGearHousing66 FrontOilSealandSteeringPumpSeal66 Replacement66 CrankshaftandBearingHolder67 ............................................. Installation67 RearOilSealandBackingPlate68 ............................................ Installation68 PistonandConnectingRod68 ................................................ Installation68 OilPick-upandPan69 ....................................................... Installation69 CamshaftandTimingGear69 ................................................. Installation69 OilPump,IdlerGear,andInjectionTiming70 .................................... Installation70 TimingGearCover70 ........................................................ Installation70 CrankshaftPulley70 Installation70 FuelInjectionPump71 Installation71 ............................................................
SECTION10--ENGINEANDFUELSYSTEMS BOOK1-84203603
SECTION10--ENGINEANDFUELSYSTEMS
7
CONTENTS SectionDescription Page HeadGasketSelection71 CylinderHead72 ............................................................ Assembly72 ValveClearanceAdjustment73 ................................................ ExhaustManifold73 Installation73 ............................................................ OilTransferTube74 Installation74 ............................................................ WaterPump 74 Installation74 ValveCover/AirIntake74 Installation74 FuelInjectorandGlowPlug75 Installation75 Engine 75 .................................................................. Installation75 LubricationSystemSpecifications81 ........................................... DescriptionofOperation--EngineLubricationSystem82 OilFilter 85 ................................................................. ConstructionandFunction85 Maintenance85 .......................................................... OilPump 85 Removal85 ............................................................. Inspection85 InstallationandAdjustment86 ............................................. EngineOilPressureCheck87 OilPressureReliefValve88 ................................................... Removal88 Installation88 OilConsumption88
BOOK1-84203603 Chapter1--EngineSystems(Continued)
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BOOK1-84203603 Chapter1--EngineSystems(Continued) CONTENTS SectionDescription Page DescriptionofOperation--CoolingSystem89 Specifications91 ............................................................ Maintenance92 Coolant 92 .................................................................. RadiatorCap92 Thermostat 93 .............................................................. WaterPump 93 CoolingFan 93 .............................................................. Overhaul--CoolingSystem94 Radiator 94 Removal94 Inspection96 Installation97 WaterPump 99 Removal99 ............................................................. Inspection100 Installation101 ........................................................... Thermostat102 Removal102 ............................................................ Inspection103 Installation104 ...........................................................
SECTION10--ENGINEANDFUELSYSTEMS
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BOOK1-84203603 Chapter2--FuelSystems CONTENTS SectionDescription Page Specifications 3 EngineFuelSystemBoltTorqueSpecifications3 ..................................... SpecialTools 3 InjectionPump--DescriptionandOperation4 ........................................ FuelVariationMechanism5 DeliveryValveAssembly6 ..................................................... CTD(CompactTimingDevice)Mechanism6 PumpingElements9 .......................................................... DeliveryValves11 Troubleshooting--General13 Overhaul 14 InjectionPump14 Removal14 Repair 15 Installation16 ............................................................ Spill-TimingandGovernorAdjustments17 NewInjectionPumporDriveComponent17 ................................. Installation17 Spill-TimingProcedure18 .................................................... FuelSystemBleeding23 AutomaticBleeding23 ....................................................... FuelFlowChart23 ManualBleeding24 .......................................................... SmokeScrewandHighIdleAdjustment24 DescriptionandOperation--Governor25 .......................................... Troubleshooting--GovernorSystem27 Governor 30 ................................................................ Disassembly30 Assembly31 GovernorAdjustments33
SECTION10--ENGINEANDFUELSYSTEMS
SECTION10--ENGINEANDFUELSYSTEMS
10
BOOK1-84203603
CONTENTS SectionDescription Page DescriptionandOperation--FuelInjectors34 FuelFilterandShutoffValve35 ................................................ Troubleshooting--FuelInjectors36 Injectors 37 ................................................................. Removal37 Disassembly38 .......................................................... AssemblyandAdjustment38 DescriptionofOperation--EngineBreatherValve39 ................................. EngineBreatherValve40 Removal40 Installation40 Troubleshooting--EngineBreatherValve41
Chapter2--FuelSystems(Continued)
11 SECTION25--FOURWHEELDRIVEREARAXLE BOOK1-84203603 Chapter1--FourWheelDriveRearAxle CONTENTS SectionDescription Page Specifications 2 ReartoFrontAxleRation3 .................................................... MetricBoltTorqueSpecifications5 DescriptionofOperation6 ........................................................ Two-way(Sensitrack™)Clutch9 AutomaticPosition--ClutchEngaged10 .................................... AutomaticPosition--ClutchDisengaged10 FulltimeFWDPosition--ClutchLocked10 ................................... PowerFlow 11 Troubleshooting 12 Adjustment 13 RearWheelToe-In13 Overhaul 14 RearAxle 14 Removal14 ............................................................. DropBox 15 Disassembly15 .......................................................... Inspection21 Assembly21 ............................................................ RearAxleandDifferential29 Disassembly29 .......................................................... Inspection34 Assembly35 ............................................................ Installation40 4WDShiftShaftandTwo-way(Sensitrack™)Clutch42 ........................... Removal42 Disassembly44 .......................................................... Inspection44 Assembly45 Installation46
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BOOK1-84203603 Chapter1-Differential,Axles CONTENTS SectionDescription Page Specifications 3 MetricBoltTorqueSpecifications4 ................................................. SpecialTools 5 DescriptionofOperation6 ........................................................ PowerFlow--RangeGear9 Overhaul 11 ..................................................................... Transaxle 11 Removal 11 .............................................................. Installation17 RearTransmission21 Disassembly21 RangeGearandCountershaft23 Removal23 MainPTOGear25 Removal25 ............................................................. SidePTOGearandShaft25 Removal25 ............................................................. MainShaftandFixedMainGears26 Removal26 ............................................................. Inspection27 Assembly27 ............................................................ MainPTOGear28 Installation28 ............................................................ SidePTOGear29 Installation29 ............................................................ RangeGearandCountershaft30 Installation30 ............................................................ FrontTransmission34 Disassembly34 Inspection36 Assembly37
SECTION27-DIFFERENTIAL,AXLES
SECTION27-DIFFERENTIAL,AXLES
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BOOK1-84203603 Chapter1-Differential,Axles(Continued) CONTENTS SectionDescription Page Axle 40 Removal40 ............................................................. Disassembly41 Inspection44 ............................................................ Assembly44 Installation49 ............................................................ Differential 50 Removal50 ............................................................. Disassembly53 Inspection54 Assembly55 Installation57 DifferentialLock61 Removal/Disassembly61 Inspection61 ............................................................ Assembly/Installation61 Calibration 62 .................................................................. Backlash 62 RingandPinionGearToothContactPattern63 ..................................
14 SECTION29--HYDROSTATICDRIVESYSTEM BOOK1-84203603 Chapter1--HydrostaticDriveSystem CONTENTS SectionDescription Page Specifications 2 MetricBoltTorqueSpecifications3 ................................................. SpecialTools 4 DescriptionofOperation--HydrostaticTransmission5 ................................ VariableDisplacementPumpOperation6 FixedDisplacementMotorOperation7 .......................................... HydraulicFluidFlow8 NeutralPosition8 ............................................................ ForwardPosition9 ReversePosition10 HydrostaticTransmissionFilter11 Troubleshooting 12 PressureTesting14 HighPressureRelief14 ChargePressureRelief17 .................................................... Overhaul 18 HydrostaticTransmission19 .................................................. Removal19 Disassembly26 .......................................................... Inspection37 Assembly42 ............................................................ Installation54 HydrostaticTransmissionAdjustment60 ........................................ NeutralPosition60 DirectionalControlPedalLinkage63 ........................................ HSTNeutralSafetySwitch65
15 SECTION31-POWERTAKE-OFF(PTO) BOOK1-84203603 Chapter1-PowerTake-Off(PTO) CONTENTS SectionDescription Page Specifications 3 MetricBoltTorqueSpecifications4 ................................................. SpecialTools 4 DescriptionofOperation5 ........................................................ Troubleshooting 8 Overhaul 9 ...................................................................... PTORemoval9 RearTransmissionDisassembly9 ........................................... MainPTOGearRemoval10 SidePTOGearandShaftRemoval10 FrontTransmission11 Disassembly11 Inspection13 Assembly13 RearTransmissionAssembly16 ............................................... MainPTOGearInstallation16 SidePTOGearInstallation17 .............................................. PTOClutch 18 Disassembly18 .......................................................... Inspection21 Assembly21 ............................................................ Installation26 AutomaticPTODisengagementSystem28 ..................................... Removal29 Disassembly30 .......................................................... Assembly31 Installation32 ............................................................ Adjustment 33 PTOControlLeverLinkage33 PTODisengagementCableAdjustment34
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BOOK2-84203604 Chapter1-Brakes CONTENTS SectionDescription Page Specifications 2 BrakeDiscs 2 ................................................................ Stators 2 MetricBoltTorqueSpecifications3 ................................................. DescriptionofOperation--Brakes4 ParkingBrake6 .............................................................. Troubleshooting 7 Overhaul 8 ...................................................................... Brakes 8 Removal 8 Disassembly8 Inspection11 Assembly11 Installation14 BrakeAdjustment15 ............................................................ FreeTravel 15 ParkingBrake16 ............................................................
SECTION33-BRAKES
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BOOK2-84203604 Chapter1-HydraulicSystem CONTENTS SectionDescription Page Specifications 4 BoltTorqueSpecifications5 ....................................................... SpecialTools 5 DescriptionofOperation--HydraulicSystem6 ....................................... HydraulicSystemPriority/FlowChart7 HydraulicFluidFilter8 ........................................................ WeightTransferValve8 LiftControlValve9 ........................................................... OilFlow 10 NeutralPosition10 RaisePosition11 LowerandFloatPosition12 SystemPressureReliefValve13 FlowRestrictor13 HydraulicLiftCylindersandLiftArms14 ........................................ HydraulicFluidCooler14 Troubleshooting 15 .............................................................. Overhaul 16 HydraulicLiftCylinders16 .................................................... Removal16 Disassembly18 .......................................................... Inspection19 Assembly22 ............................................................ Installation24 HydraulicLiftControlValve26 ................................................. Removal26 Disassembly27 .......................................................... Inspection29 Installation32
SECTION35-HYDRAULICSYSTEM
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BOOK2-84203604 Chapter1-HydraulicSystem(Continued) CONTENTS SectionDescription Page WeightTransferValve33 Removal33 ............................................................. Disassembly33 Inspection33 ............................................................ Assembly34 Installation35 ............................................................ HydraulicSystemReliefValve35 Removal35 ............................................................. Disassembly36 Inspection37 Assembly37 Installation38 HydraulicSystemRestrictorValve39 Removal39 Inspection40 ............................................................ Installation40 LiftArms 41 ................................................................. Removal41 Disassembly42 .......................................................... Inspection42 Assembly43 ............................................................ Installation43 HydraulicFluidCooler44 ..................................................... Removal44 Inspection45 ............................................................ Installation45 DescriptionofOperation--HydraulicPump46 ...................................... Overhaul 47 HydraulicPump47 Removal47 Disassembly48
SECTION35-HYDRAULICSYSTEM
SECTION35-HYDRAULICSYSTEM
Chapter1-HydraulicSystem(Continued) CONTENTS
SectionDescription
DoubleActing--Neutral57 ....................................................
DoubleActing--SpoolMovedIn58
HydraulicSystemReliefValvePressureTest66 .................................
HydraulicSystemReliefValvePressureAdjustment68
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BOOK2-84203604
Page Inspection49 Assembly50 ............................................................ Installation51
DescriptionofOperation--RemoteValves53 ....................................... SingleActing--Neutral54
SingleActing--SpoolMovedIn55 ............................................. SingleActing--SpoolMovedOut56
Inspection63 Assembly64 Installation65
DoubleActing--SpoolMovedOut59 Removal60 Disassembly61
............................................................ PressureTesting66
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