New Holland Tractor TT55 TT75 Service Repair Manual (87042097) – New Holland Tractor TT55 TT75

TT55, TT75 REPAIR MANUAL COMPLETE CONTENTS SECTION 00 - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SECTION 10 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SECTION 18 - CLUTCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SECTION 21 - FRONT TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SECTION 23 - FOUR WHEEL DRIVE (FWD) TRANSFER BOX . . . . . . . . . . . 4 SECTION 25 - FOUR WHEEL DRIVE (FWD) FRONT AXLE . . . . . . . . . . . . . . 5 SECTION 27 - REAR AXLE AND TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 5 SECTION 31 - POWER TAKE-OFF (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SECTION 33 - BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SECTION 35 - HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SECTION 41 - STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SECTION 44 - 2WD FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SECTION 55 - ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SECTION 90 - BODYWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

The following pages are the collation of the contents pages from each section and chapter of the TT55, TT75 Repair manual. Complete Repair part # 87042097. 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 TT55, TT75 Tractors.

87042100

12/03

SECTION 00 - GENERAL BOOK 1 - 87042098

Chapter 1 - General CONTENTS Section

Description

Page

General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Ecology and the Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Minimum Hardware Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Tractor System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Speed Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Federal Emissions Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

SECTION 10 - ENGINE BOOK 1 - 87042098

Chapter 1 - Engine Overhaul CONTENTS Section

Description

Page

SECTION 10 - ENGINE BOOK 1 - 87042098

Chapter 1 - Engine Overhaul (Continued) CONTENTS Section

Description

Page

Crankshaft, Main Bearings and Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Camshaft, Tappets and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Valve Guide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Valve Seat In Cylinder Head Refacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Injector Sleeve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Rotating Counterweight Dynamic Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Engine Lubrication System Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Crankshaft Front Oil Seal Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Coolant System Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Fuel System Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Engine Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

SECTION 10 - ENGINE BOOK 1 - 87042098

Chapter 2 - Air Cleaning System CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Inner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 18 - CLUTCHES BOOK 1 - 87042098

Chapter 1 - Clutches CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Clutch Assembly Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Clutch Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Transmission Clutch Pedal Free-Travel and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Adjusting PTO Clutch Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION 21 - FRONT TRANSMISSION BOOK 1 - 87042098

Chapter 1 - Front Transmission CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Transmission Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Inspecting the Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Assembling the Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION 23 - FOUR WHEEL DRIVE (FWD) TRANSFER BOX BOOK 1 - 87042098

Chapter 1 - Four Wheel Drive (FWD) Transfer Box CONTENTS Section

Description

Page

Transfer Box and Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 25 - FOUR WHEEL DRIVE (FWD) FRONT AXLE BOOK 1 - 87042098

Chapter 1 - Four Wheel Drive (FWD) Front Axle CONTENTS Section

Description

Page

Four-wheel Drive Front Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Four-wheel Drive Front Axle Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Four-wheel Drive Front Axle -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Four-wheel Drive Front Axle Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Complete Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Steering Knuckle Pins and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Stub Axle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Bevel Drive Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Front Axle Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Checking the Alignment of Steering-Drive Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

SECTION 27 - REAR AXLE AND TRANSMISSION BOOK 1 - 87042098

Chapter 1 - Rear Axle and Transmission CONTENTS Section

Description

Page

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rear Transmission Housing Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Bevel Drive and Differential Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Reassembling the Bevel Drive and Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Final Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Final Drive Disassembly (Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Final Drive Disassembly (Housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Final Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SECTION 31 - POWER TAKE-OFF (PTO) BOOK 2 - 87042099

Chapter 1 - Power Take-Off (PTO) CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PTO Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Power Take-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 PTO Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SECTION 33 - BRAKE SYSTEM BOOK 2 - 87042099

Chapter 1 - Brakes CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Brake Pedal Free-Travel/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Parking Brake T-Handle Free-Travel/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 35 - HYDRAULIC SYSTEM BOOK 2 - 87042099

Chapter 1 - Hydraulic System CONTENTS Section

Description

Page

Hydraulic Lift Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic System Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remote Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remote Valve Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Quick-fit Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Mid-mount Coupler Relocation Kit [Optional] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Switching Between Single and Double-acting Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hydraulic Power Lift (HPL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulic Lift Main Control Valve Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Hydraulic System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hydraulic Lift Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Hydraulic Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Lift Adjustment on Bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Lift Adjustment and Checks on the Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Relief Valve and Cylinder Safety Valve Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Implement Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Remote Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Dual Remote Valve Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Double Acting Valve with Detent Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Dual Remote Valve System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Hydraulic System with One Remote Valve Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Hydraulic System with Two Remote Valves Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Hydraulic System with Three Remote Valves Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

SECTION 41 - STEERING SYSTEM BOOK 2 - 87042099

Chapter 1 - Steering System CONTENTS Section

Description

Page

Steering System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Steering System Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Determining Front Wheel Toe In/Toe Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydrostatic Steering Motor Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Front Axle Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Steering Cylinder - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Steering Cylinder - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

SECTION 44 - 2WD FRONT AXLE BOOK 2 - 87042099

Chapter 1 - 2WD Front Axle CONTENTS Section

Description

Page

2WD Front Axle and Steering Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Two-Wheel Drive Front Axle and Steering Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Front Axle Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Front Axle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Steering Knuckle Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Axle Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Determining Front Wheel Toe In/Toe Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 55 - ELECTRICAL SYSTEM BOOK 2 - 87042099

Chapter 1 - Description and Operation CONTENTS Section

Description

Page

Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical System -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SECTION 55 - ELECTRICAL SYSTEM BOOK 2 - 87042099

Chapter 2 - Starter CONTENTS Section

Description

Page

Starter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Starter Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Starting System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Resistance In Ignition System Circuit (Voltage Drop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Positive Battery Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Starter Motor Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Battery Ground Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Starter Motor Removal and Re-installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Servicing the Starting Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Armature Shaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Starter Motor Test Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Bench Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 55 - ELECTRICAL SYSTEM BOOK 2 - 87042099

Chapter 3 - Alternator CONTENTS Section

Description

Page

Alternator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 System Testing and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Preliminary Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Alternator Component Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Removal and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Rotor and Regulator Field Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION 55 - ELECTRICAL SYSTEM BOOK 2 - 87042099

Chapter 4 - Battery CONTENTS Section

Description

Page

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Inspection and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION 55 - ELECTRICAL SYSTEM BOOK 2 - 87042099

Chapter 5 - Electrical Circuits -- Wiring Diagrams CONTENTS Section

Description

Page

Linear Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Starting, Charging and Safety diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Thermostart, Injection Pump and Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Main Light Switch and Front Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Rear Lights, Position Lights and Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Lights, Safety Switches and Flasher Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Safety Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

SECTION 90 - BODYWORK BOOK 2 - 87042099

Chapter 1 - Bodywork CONTENTS Section

Description

Page

Engine Hood Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear Wheel Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Roll-over Protection (ROPS) Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 00 -- GENERAL -- CHAPTER 1

SECTION 00 - GENERAL Chapter 1 - General CONTENTS Section

Description

Page

00-1

SECTION 00 -- GENERAL -- CHAPTER 1 WARNING

WARNING

All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND service technicians in strict accordance with the instructions given and using any specific tools necessary.

The Manufacturer and all organizations belonging to the Manufacturerâ&#x20AC;&#x2122;s distribution network, including but not restricted to national, regional or local distributors, will accept no responsibility for personal injury or damage to property caused by abnormal function of parts and/or components not approved by the Manufacturer, including those used for maintenance and/or repair of the product manufactured or marketed by the Manufacturer. In any case, the product manufactured or marketed by the Manufacturer is covered by no guarantee of any kind against personal injury or damage to property caused by abnormal function of parts and/or components not approved by the Manufacturer.

WARNING Anyone who performs the operations described herein without strictly following the instructions is personally responsible for resulting injury or damage to property.

00-2

SECTION 00 -- GENERAL -- CHAPTER 1 GENERAL INSTRUCTIONS IMPORTANT NOTICE All maintenance and repair operations described in this manual should be carried out exclusively by the authorised workshops. All instructions detailed should be carefully observed and special equipment indicated should be used if necessary. Everyone who carries out service operations described without carefully observing these prescriptions will be directly responsible of deriving damages.

Apply silicone/gasket eliminator over the mating surfaces marked with an X. Before applying the sealer, prepare the surface as follows:

To correctly install rotating shaft seals, observe the following instructions:

Thoroughly clean the shaft and ensure that the shaft working surface is not damaged;

•

Place the sealing lip towards the fluid. In case of a hydrodynamic lip, consider the shaft rotation direction and orient grooves in order that they deviate the fluid towards the inner side of the seal;

•

Coat the sealing lip with a thin layer of lubricant (oil rather than grease) and fill the gap between the sealing lip and the dust lip of double lip seals with grease;

•

Insert the seal into its seat and press it down using a flat punch. Do not tap the seal with a hammer or a drift;

To prevent damaging the sealing lip against the shaft, place a suitable protection during installation.

SEALERS

ROTATING SHAFT SEALS

•

Lubricate the O rings before inserting them into their seats. This will prevent the O rings from roll over and twisting during mounting, which will jeopardize sealing.

At each adjustment, select adjusting shims, measure them individually using a micrometer and then sum up recorded values. Do not rely on measuring the whole shimming set, which may be incorrect, or on the rated value indicated for each shim.

Let the seal soak into the same oil as it will seal for at least half an hour before mounting;

Take care to insert the seal perpendicularly to its seat while you are pressing it. Once the seal is settled, ensure that it contacts the thrust element, if required;

O RINGS

SHIMMING

•

remove possible scales using a metal brush;

•

thoroughly degrease the surfaces using one of the following cleaning agents: trichlorethylene, diesel fuel or a water and soda solution.

BEARINGS It is advisable to heat the bearings to 80° to 90°C (176° to 194°F) before mounting them on their shafts and cool them down before inserting them into their seats with external tapping.

SPRING PINS When mounting split socket spring pins, ensure that the pin notch is oriented in the direction of the effort to stress the pin. Spiral spring pins should not be oriented during installation.

00-3

SECTION 00 -- GENERAL -- CHAPTER 1 GENERAL INSTRUCTIONS PRECAUTIONARY NOTICE Only authorized workshops should carry out maintenance and repair operations on the tractor, or tractor components. Carefully observe all instructions, safety precautions, and the use of equipment such as special tools, as detailed in this manual. Damage to the tractor, or injury to personnel is the direct responsibility of anyone who fails to observe these precautions.

EQUIPMENT NOTICE The equipment proposed in this manual is: •

Designed and studied expressly for use on New Holland tractors

•

Necessary for adequate and reliable repair of the tractor

•

Strictly tested for the efficient and long lasting life cycle of the tractor

SPARE PARTS NOTICE Genuine NEW HOLLAND spare parts guarantee the same quality, safety and life cycle as original components. These parts bear the logo:

GENERAL NOTICES In this manual, the description ’FRONT’, ’REAR’, ’RIGHT--HAND’ and ’LEFT--HAND’ refer to the view seen by the operator while in the operator’s seat, looking in the direction in which the tractor normally moves. Wear limits detailed in this manual, although advised, are not binding.

00-4

SECTION 00 -- GENERAL -- CHAPTER 1 HEALTH AND SAFETY CONTENTS Description

Page

HEALTH AND SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ACIDS AND ALKALIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ADHESIVES AND SEALERS -- see Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ANTIFREEZE -- see Fire, Solvents e.g. Isopropanol, Ethylene Glycol, Methanol. . . . . . . . . . . . . . . . . . . . . . . 6 ARC WELDING -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 BATTERY ACIDS -- see Acids and Alkalis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 BRAZING -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CHEMICAL MATERIALS -- GENERAL -- see Legal Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DOâ&#x20AC;&#x2122;S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DO NOTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 CORROSION PROTECTION MATERIALS -- see Solvents, Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DUSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ELECTRIC SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 EXHAUST FUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FIBRE INSULATION -- see Dusts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FIRE -- see Welding, Foams, Legal Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FOAMS -- Polyurethane -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FUELS -- see Fire, Legal Aspects, Chemicals -- General, Solvents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 GAS CYLINDERS -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 GENERAL WORKSHOP TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 LEGAL ASPECTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 LUBRICANTS AND GREASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 PAINTS -- see Solvents and Chemical Materials -- General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SOLDER -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SOLVENTS -- see Chemical Materials -- General Fuels (Kerosene), Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SUSPENDED LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 WELDING -- see Fire, Electric Shock, Gas Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

HEALTH AND SAFETY PRECAUTIONS

precautions necessary to avoid these hazards are identified.

Many of the procedures associated with vehicle maintenance and repair involve physical hazards or other risks to health. This section lists, alphabetically, some of these hazardous operations and the materials and equipment associated with them. The

The list is not exhaustive and all operations and procedures and the handling of materials, should be carried out with health and safety in mind.

00-5

SECTION 00 -- GENERAL -- CHAPTER 1 ACIDS AND ALKALIS -- see Battery acids, e.g.

Provide adequate ventilation and avoid skin and eye contact. Follow manufacturers instructions.

caustic soda, sulfuric acid.

Used in batteries and cleaning materials.

Anaerobic, Cyanoacrylate and other Acrylic Adhesives

Irritant and corrosive to the skin, eyes, nose and 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 ordinary protective clothing. Do not breathe mists.

Skin and eye contact should be avoided and the manufacturers instructions followed.

Ensure access to water and soap is readily available for splashing accidents.

Cyanoacrylate adhesives (super--glues) must not contact the skin or eyes. If skin or eye tissue is bonded cover with a clean moist pad and get medical attention. do not attempt to pull tissue apart. Use in well ventilated areas as vapours can cause irritation of the nose and eyes.

ADHESIVES AND SEALERS -- see Fire Highly Flammable, Flammable, combustible. Generally should be stored in â&#x20AC;&#x153;No Smokingâ&#x20AC;? areas; cleanliness and tidiness in use should be observed, e.g. disposable paper covering benches; should be dispensed from applicators where possible; containers, including secondary containers, should be labelled.

For two--pack systems see Resin based adhesives/ sealers.

Isocyanate (Polyurethane) Adhesives/ Sealers -- see Resin based Adhesives. Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity reactions can occur.

Solvent based Adhesives/Sealers -- See Solvents. Follow manufacturers instructions.

Any spraying should preferably be carried out in exhaust ventilated booths removing vapours and spray droplets from the breathing zone. Individuals working with spray applications should wear supplied air respirators.

Water based Adhesives/Sealers Those based on polymer emulsions and rubber lattices may contain small amounts of volatile toxic and harmful chemicals. Skin and eye contact should 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 released.

Vapours given off from coolant antifreeze (glycol) arise only when heated. Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze if swallowed is fatal and medical attention must be found immediately.

Skin contact with uncured resins and hardeners can result in irritation; dermatitis and absorption of toxic or harmful chemicals through the skin. Splashes can damage the eyes.

00-6

SECTION 00 -- GENERAL -- CHAPTER 1 ARC WELDING -- see Welding.

The effects of excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent; cumulative; superficial; life threatening; or may reduce life--expectancy.

BATTERY ACIDS -- see Acids and Alkalis. Gases released during charging are explosive. Never use naked flames or allow sparks near charging or recently charged batteries.

DOâ&#x20AC;&#x2122;S Do remove chemical materials from the skin and clothing as soon as practicable after soiling. Change heavily soiled clothing and have it cleaned.

BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) -- see Fire. Combustible.

Do carefully read and observe hazard and precaution warnings given on material containers (labels) and in any accompanying leaflets, poster or other instructions. Material health and safety data sheets can be obtained from Manufacturers.

Splashes to the skin and eyes are slightly irritating. Avoid skin and eye contact as far as possible. Inhalation of vapour hazards do not arise at ambient temperatures because of the very low vapour pressure.

Do organise work practices and protective clothing to avoid soiling of the skin and eyes; breathing vapours/aerosols/dusts/fumes; inadequate container labelling; fire and explosion hazards.

BRAZING -- see Welding. CHEMICAL MATERIALS -- GENERAL -- see

Do wash before job breaks; before eating, smoking, drinking or using toilet facilities when handling chemical materials.

Legal Aspects.

Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids, antifreeze, brake fluids, oils and grease should always be used with caution and stored and handled with care. They may be toxic, harmful, corrosive, irritant or highly inflammable and give rise to hazardous fumes and dusts.

Do keep work areas clean, uncluttered and free of spills. Do store according to national and local regulations. Do keep chemical materials out of reach of children.

00-7

SECTION 00 -- GENERAL -- CHAPTER 1 DO NOTS

Cutting -- see Welding.

Do Not mix chemical materials except under the manufacturers instructions; some chemicals can form other toxic or harmful chemicals; give off toxic or harmful fumes; be explosive when mixed together.

De--Waxing -- see Solvents and Fuels (Kerosene).

DUSTS Powder, dusts or clouds may be irritant, harmful or toxic. Avoid breathing dusts from powdery chemical materials or those arising from dry abrasion operations. Wear respiratory protection if ventilation is inadequate.

Do Not spray chemical materials, particularly those based on solvents, in confined spaces e.g. when people are inside a vehicle. Do Not apply heat or flame to chemical materials except under the manufacturersâ&#x20AC;&#x2122; instructions. Some are highly inflammable and some may release toxic or harmful fumes.

ELECTRIC SHOCK Electric shocks can result from the use of faulty electrical equipment or from the misuse of equipment even in good condition.

Do Not leave containers open. Fumes given off can build up to toxic, harmful or explosive concentrations. Some fumes are heavier than air and will accumulate in confined areas, pits etc.

Ensure that electrical equipment is maintained in good condition and frequently tested.

Do Not transfer chemical materials to unlabelled containers.

Ensure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise damaged.

Do Not clean hands or clothing with chemical materials. Chemicals, particularly solvents and fuels will dry the skin and may cause irritation with dermatitis. Some can be absorbed through the skin in toxic or harmful quantities.

Ensure that electric equipment is protected by the correct rated fuse. Never misuse electrical equipment and never use equipment which is in any way faulty. The results could be fatal.

Do Not use emptied containers for other materials, except when they have been cleaned under supervised conditions.

Use reduced voltage equipment (110 volt) for inspection and working lights where possible.

Do Not sniff or smell chemical materials. Brief exposure to high concentrations of fumes can be toxic or harmful.

Ensure that the cables of mobile electrical equipment cannot get trapped and damaged, such as in a vehicle hoist.

Clutch Fluids -- see Brake and Clutch Fluids.

Use air operated mobile equipment where possible in preference to electrical equipment.

Clutch Linings and Pads -- see Brake and Clutch Linings and Pads.

In cases of electrocution:--

CORROSION PROTECTION MATERIALS --

-- switch off electricity before approaching victim

Highly flammable, flammable.

-- if this is not possible, push or drag victim from source of electricity using dry non--conductive material

see Solvents, Fire.

These materials are varied and the manufacturers instructions should be followed. They may contain solvents, resins, petroleum products etc. Skin and eye contact should be avoided. They should only be sprayed in conditions of adequate ventilation and not in confined spaces.

-- commence resuscitation if trained to do so -- SUMMON MEDICAL ASSISTANCE

00-8

SECTION 00 -- GENERAL -- CHAPTER 1 EXHAUST FUMES

Splashes in the eye should be flushed with clean water for at least ten minutes.

These contain asphyxiating, harmful and toxic chemicals and particles such as carbon oxides, nitrogen oxides, aldehydes, lead and aromatic hydrocarbons. Engines should only be run under conditions of adequate extraction or general ventilation and not in confined spaces.

Soiled skin should be washed with soap and water. Inhalation affected individuals should be removed to fresh air immediately.

Gasolene (Petrol) Engine

If swallowed or if effects persist consult a doctor with information (label) on material used.

There may not be adequate warning properties of odour or irritation before immediate and delayed toxic or harmful effects arise.

Do not induce vomiting (unless indicated by manufacturer).

Diesel Engine

FOAMS -- Polyurethane -- see Fire. Used in sound and noise insulation. Cured foams used in seat and trim cushioning.

Soot, discomfort and irritation usually give adequate warning of hazardous fume concentrations.

Follow manufacturers instructions.

FIBRE INSULATION -- see Dusts.

Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles.

Used in noise and sound insulation. The fibrous nature of surfaces and cut edges can cause skin irritation. This is usually a physical and not a chemical effect.

Individuals with chronic respiratory diseases, asthma, bronchial medical problems or histories of allergic diseases should not work with or near uncured materials.

Precautions should be taken to avoid excessive skin contact through careful organisation of work practices and the use of gloves.

The components, vapours, spray mists can cause direct irritation, sensitivity reactions and may be toxic or harmful.

FIRE -- see Welding, Foams, Legal Aspects.

Vapours and spray mists must not be breathed. These materials must be applied with adequate ventilation and respiratory protection. Do not remove respirator immediately after spraying, wait until vapour/ mists have cleared.

Many of the materials found on or associated with the repair of vehicles are highly flammable. Some give off toxic or harmful fumes if burnt. Observe strict fire safety when storing and handling 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 vapours/mists have cleared should not be allowed. Any heat cutting of cured foams or partially cured foams should be conducted with extraction ventilation (see Body Section 44 Legal and Safety Aspects).

Have a suitable fire extinguisher available when using welding or heating equipment.

FIRST AID Apart form meeting any legal requirements it is desirable for someone in the workshop to be trained in first aid procedures.

00-9

SECTION 00 -- GENERAL -- CHAPTER 1 FUELS -- see Fire, Legal Aspects, Chemicals -General, Solvents.

if liquid aspiration into the lungs occurs. Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may be slightly irritating.

Used as fuels and cleaning agents. Gasolene (Petrol). Highly flammable. Swallowing can result in mouth and throat irritation and absorption from the stomach can result in drowsiness and unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs, e.g. through vomiting, is a very serious hazard. Gasolene dries the skin and can cause irritation and dermatitis on prolonged or repeated contact. Liquid in the eye causes severe smarting. Motor gasolene may contain appreciable quantities of benzene, which is toxic upon inhalation and the concentrations of gasolene vapours must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache, depression and symptoms of drunkeness. Very high concentrations will result in rapid loss of consciousness. Ensure there is adequate ventilation when handling and using gasolene. Great care must be taken to avoid the serious consequences of inhalation in the event of vapour build up arising from spillages in confined spaces. Special precautions apply to cleaning and maintenance operations on gasolene storage tanks. Gasolene should not be used as a cleaning agent. It must not be siphoned by mouth.

Kerosene (Paraffin) Used also as heating fuel, solvent and cleaning agent.

In normal circumstances the low volatility does not give rise to harmful vapours. Exposure to mists and vapours from kerosene at elevated temperatures should be avoided (mists may arise in de--waxing). Avoid skin and eye contact and ensure there is adequate ventilation. Gas--Oil (Diesel Fuel) -- see Fuels (Kerosene). Combustible. Gross or prolonged skin contact with high boiling gas oils may also cause serious skin disorders including skin cancer. GAS CYLINDERS -- see Fire. Gases such as oxygen, acetylene, carbon dioxide, argon and propane are normally stored in cylinders at pressures of up to 2000 lb/sq. in. (13,790 kn/m2) and great care should be taken in handling these cylinders to avoid mechanical damage to them or to the valve gear attached. The contents of each cylinder should be clearly identified by appropriate markings. Cylinders should be stored in well ventilated enclosures, and protected from ice and snow, or direct sunlight. Fuel gases (e.g. acetylene and propane) should not be stored in close proximity to oxygen cylinders. Care should be exercised to prevent leaks from gas cylinders and lines, and to avoid sources of ignition. Only trained personnel should undertake work involving gas cylinders. Gases -- see Gas Cylinders.

Flammable. Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises

00-10

Gas Shielded Welding -- see Welding. Gas Welding -- see Welding.

SECTION 00 -- GENERAL -- CHAPTER 1 GENERAL WORKSHOP TOOLS AND EQUIPMENT It is essential that all tools and equipment are maintained in good condition and the correct safety equipment used where required. Never use tools or equipment for any purpose other than that for which they were designed. Never overload equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always immediately apparent and may result in a fatal failure the next time that the equipment is used. Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A damaged grinding wheel can disintegrate without warning and cause serious injury. Wear suitable eye protection when using grinding, chiselling or sand blasting equipment. Wear a suitable breathing mask when using sand blasting equipment, working with asbestos based materials or using spraying equipment. Glues -- see Adhesives and Sealers. High Pressure Air, Lubrication and Oil Test Equipment -- see Lubricants and Greases.

•

The Asbestos Regulations (1969).

•

Highly Flammable Liquids and Liquified Petroleum Gases Regulations (1972).

•

Deposit of Poisonous Waste Act (1972).

•

Control of Pollution Act (1974).

•

Health and Safety at Work Act (1974).

•

The Packaging and Labelling of Dangerous Substances Regulations (1978).

•

Control of Lead Regulations (1981).

Workshops should be familiar, in detail, with these and associated laws and regulations. Consult local factory inspectorate if in any doubt.

LUBRICANTS AND GREASES Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated during service (e.g. routine service change sump oils) are more irritating and more likely to cause serious effects including skin cancer in the event of gross and prolonged skin contact.

Always keep high pressure equipment in good condition and regularly maintained, particularly at joints and unions.

Wash skin thoroughly after work involving oil. Proprietary hand cleaners may be of value provided they can be removed from the skin with water. Do not 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 cause serious injury.

Lubricants and greases may be slightly irritating to the eyes.

LEGAL ASPECTS Many laws and regulations make requirements relating to health and safety in the use of materials and equipment in workshops. Some of these laws which apply in the U.K. are listed. Similar laws exist for other territories:-•

The Factories Act (1961).

00-11

Repeated or prolonged skin contact should be avoided by wearing protective clothing if necessary. Particular care should be taken with used oils and greases containing lead. Do not allow work clothing to be contaminated with oil. Dry clean or launder such clothing at regular intervals. Discard oil soaked shoes.

SECTION 00 -- GENERAL -- CHAPTER 1 Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur. Used oils may only be disposed of in accordance with local regulations, e.g. in the U.K., the Control of Pollution Act. There are publications describing the problems and advising on precautionary measures. For the U.K. these include: SHW 295: SHW 295A: SHW 397:

Those doing small scale repair work in the open shop should wear supplied air respirators. Paint Thinners -- see Solvents. Petrol -- see Fuels (Gasolene). Pressurised Equipment -- see High Pressure Air, Lubrication and Oil Test Equipment. Resistance Welding -- see Welding.

Effects of mineral oil on the skin Cancer of the skin caused by oil Cautionary notice: Effects of mineral oil on the skin

Sealers -- see Adhesives and Sealers. SOLDER -- see Welding.

Noise Insulation Materials -- see Foams, Fibre Insulation. PAINTS -- see Solvents and Chemical Materials -General. Highly Flammable, Flammable. One Pack. Can contain harmful or toxic pigments, driers and other components as well as solvents. Spraying should only be carried out with adequate ventilation. Two Pack. Can also contain harmful and toxic unreacted resins and resin hardening agents. The manufacturers instructions should be followed and the section of page 05--2 on resin based adhesives, isocyanate containing Adhesives and Foams should be consulted. Spraying should preferably be carried out in exhausted ventilated booths removing vapour and spray mists from the breathing zone. Individuals working in booths should wear respiratory protection.

00-12

Solders are mixtures of metals such that the melting point of the mixture is below that of the constituent metals (normally lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is used. Oxy--acetylene flames should not be used, as they are much hotter and will cause lead fumes to be evolved. Some fumes may be produced by the application of any flame to surfaces coated with grease etc. and inhalation of these should be avoided. Removal of excess solder should be undertaken with care, to ensure that fine lead dust is not produced, which can give toxic effects if inhaled. Respiratory protection may be necessary. Solder spillage and filing should be collected and removed promptly to prevent general air contamination by lead. High standards of personal hygiene are necessary in order to avoid indigestion of lead or inhalation of solder dust from clothing.

SECTION 00 -- GENERAL -- CHAPTER 1 SOLVENTS -- see Chemical Materials -- General Fuels (Kerosene), Fire. e.g. Acetone, white spirit, toluene, xylene, trichlorethane. Used in cleaning materials, de--waxing, paints, plastics, resins, thinners etc. Highly Inflammable, Flammable. Skin contact will degrease the skin and may result in irritation and dematitis following repeated or prolonged contact. Some can be absorbed through the skin in toxic or harmful quantities.

When the spraying material contains solvents, e.g. paints, adhesives, coatings, use extraction ventilation or personal respiratory protection in the absence of adequate general ventilation. Do not apply heat or flame except under specific and detailed manufacturers instructions. Sound Insulation -- see Fibre Insulation, Foams. Spot Welding -- see Welding.

SUSPENDED LOADS.

Splashes in the eye may cause severe irritation and could lead to loss of vision.

There is always a danger when loads are lifted or suspended. Never work under an unsupported suspended or raised load, e.g. jacked up vehicle, suspended engine, etc.

Brief exposure to high concentrations of vapours or mists will cause eye and throat irritation, drowziness, dizziness, headaches and in the worst circumstances, unconsciousness.

Always ensure that lifting equipment such as jacks, hoists, axle stands, slings, etc. are adequate and suitable for the job, in good condition and regularly maintained.

Repeated or prolonged exposures to excessive but lower concentrations of vapours or mists, for which there might not be adequate warning indications, can cause more serious toxic or harmful effects.

Never improvise lifting tackle.

Aspiration into the lungs (e.g. through vomiting) is the most serious consequence of swallowing. Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary. Ensure good ventilation when in use, avoid breathing fumes, vapours and spray mists and keep containers tightly sealed. Do not use in confined spaces.

00-13

Underseal -- see Corrosion Protection. WELDING -- see Fire, Electric Shock, Gas Cylinders. Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding. Resistance Welding This process may cause particles of molten metal to be emitted at high velocity and the eyes and skin must be protected.

SECTION 00 -- GENERAL -- CHAPTER 1 Arc Welding This process emits a high level of ultraviolet radiation which may cause eye and skin burns to the welder and to other persons nearby. Gas--shielded welding processes are particularly hazardous in this respect. Personal protection must be worn, and screens used to shield other people. Metal spatter will also occur and appropriate eye and skin protection is necessary. The heat of the welding arc will produce fumes and gases from the metals being welded and from any applied coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and inhalation should always be avoided. The use of extraction ventilation to remove the fumes from the working area may be necessary, particularly in cases where the general ventilation is poor, or where considerable welding work is anticipated. In extreme cases where adequate ventilation cannot be provided, supplied air respirators may be necessary. Gas Welding Oxy--acetylene torches may be used for welding and cutting and special care must be taken to prevent leakage of these gases, with consequent risk of fire and explosion.

00-14

The process will produce metal spatter and eye and skin protection is necessary. The flame is bright and eye protection should be used, but the ultra--violet emission is much less than that from arc welding, and lighter filters may be used. The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work, particularly during cutting away of damaged body parts and inhalation of the fumes should be avoided. In brazing, toxic fumes may be evolved from the metals in the brazing rod, and a severe hazard may arise if brazing rods containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert advice may be required. SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE ON VESSELS WHICH HAVE CONTAINED COMBUSTIBLE MATERIALS, E.G. BOILING OR STEAMING OUT OF FUEL TANKS. White Spirit -- see Solvents.

SECTION 00 -- GENERAL -- CHAPTER 1

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

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

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

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

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

MACHINE SAFETY The precautionary statement (“IMPORTANT”) is followed by specific instructions. This statement is intended for machine safety. IMPORTANT: The word “IMPORTANT” is used to inform the reader of something he needs to know to prevent minor machine damage if a certain procedure is not followed.

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

00-15

SECTION 00 -- GENERAL -- CHAPTER 1

SAFETY PRECAUTIONARY STATEMENTS A careful operator is the best operator. Most accidents can be avoided by observing certain precautions. To help prevent accidents, read the following precautions before operating this equipment. Equipment should be operated only by those who are responsible and instructed to do so. Carefully review the procedures given in this manual with all operators. It is important that all operators be familiar with and follow safety precautions.

THE TRACTOR 1. Read the Operator’s Manual carefully before using the tractor. Lack of operating knowledge can lead to accidents. 2. Only allow properly trained and qualified persons to operate the tractor. 3. To prevent falls, use the handrails and step plates when getting on and off the tractor. Keep steps and platform clear of mud and debris.

5. Use extreme caution and avoid hard application of the tractor brakes when towing heavy loads at road speeds. 6. Any towed vehicle whose total weight exceeds that of the towing tractor must be equipped with brakes for safe operation. 7. Never apply the differential lock when turning. When engaged, the differential lock will prevent the tractor from turning.

4. Do not permit anyone but the operator to ride on the tractor unless a passenger seat is fitted. There is no safe place for extra riders otherwise.

8. Always check overhead clearance, specifically when transporting the tractor. Watch where you are going, especially at low overhanging obstacles.

5. Replace all missing, illegible or damaged safety decals.

9. Use extreme caution when operating on steep slopes.

6. Keep safety decals free of dirt or grime.

10. To avoid overturns, drive the tractor with care and at speeds compatible with safety, especially when operating over rough ground, when crossing ditches or slopes and when turning overturning.

7. Do not modify or alter or permit anyone else to modify or alter the tractor or any of its components or any tractor function without first consulting your dealer. 8. Tractor wheels are very heavy. Handle with care and ensure, when stored, that they cannot fall.

DRIVING THE TRACTOR 1. Always sit in the drivers seat while starting or driving the tractor. 2. When driving on public roads, have consideration for other road users. Pull in to the side of the road occasionally to allow any following traffic to pass. Do not exceed the legal speed limit set in your area. 3. Use low beam lights when meeting a vehicle at night. Make sure the lights are adjusted to prevent blinding the drive of an oncoming vehicle 4. Reduce speed before turning or applying the brakes. Ensure that both brake pedals are locked together when traveling at road speeds or when on public roads. Brake both wheels simultaneously when making an emergency stop.

00-16

11. If the tractor becomes stuck or the tires are frozen to the ground, reverse the tractor out to prevent corners. 12. Keep the tractor in the same gear when going downhill as would be used when going uphill. Do not coast or freewheel down hills.

OPERATING THE TRACTOR 1. Apply the parking brake, place the PTO control in the ‘OFF’ position, the lift control lever in the down position, the remote control valve levers in the neutral position and the transmission lever in neutral before starting the tractor. 2. Do not start the engine or operate controls while standing beside the tractor. Always sit in the tractor seat when starting the engine or operating the controls.

SECTION 00 -- GENERAL -- CHAPTER 1 3. Do not bypass the neutral start switches. Consult your authorized dealer if your neutral start controls malfunction. Use jump cables only in the recommended manner. Improper use can result in a tractor runaway. 4. Avoid accidental contact with the gear shift levers while the engine is running. Unexpected tractor movement can result from such contact. 5. Do not get off the tractor while it is in motion. 6. Shut off the engine and PTO and apply the parking brake before getting off the tractor. 7. Do not park the tractor on a steep incline. 8. Do not run the tractor engine in an enclosed building without adequate ventilation. Exhaust fumes are toxic and can cause death. 9. Always wear a protective mask when working with toxic spray chemicals. Follow the directions on the chemical container. 10. If the power steering or engine ceases operating, stop the tractor immediately as the tractor will be more difficult to control. 11. Stop the engine and relieve pressure before connecting or disconnecting hydraulic, steering or fuel lines. 12. Tighten all connections before starting the engine or pressurizing lines.

a hazard both to the operator and to bystanders. Do not overload or operate with attached equipment which is unsafe, not designed for the particular task or is poorly maintained. 19. The tractor is designed to provide the minimum noise level at the operatorâ&#x20AC;&#x2122;s ears and meets or exceeds applicable standards in this respect. However, noise (sound pressure level) in the workplace can exceed 86 dB(A) when working between buildings or in confined spaces. Therefore, it is recommended that operators wear suitable ear protectors during vehicle operation.

OPERATING THE PTO 1. When operating PTO driven equipment, shut off the engine and wait until the PTO stops before getting off the tractor and disconnecting the equipment. 2. Do not wear loose clothing when operating the power take-off or especially when near rotating equipment. 3. When operating stationary PTO driven equipment, always apply the tractor parking brake and block the rear wheels front and back. 4. To avoid injury, do not clean, adjust, unclog or service PTO driven equipment when the tractor engine is running.

13. Pull only from the swinging drawbar or the lower link drawbar in the lowered position . Use only a drawbar pin that locks in place. Pulling from the tractor rear axle or any point above the axle may cause the tractor to overturn.

5. Make sure the PTO guard is in position at all times and always replace the PTO cap when the PTO is not in use.

14. If the front end of the tractor tends to rise when heavy implements are attached to the threepoint hitch, install front end or front wheel weights. Do not operate the tractor with a light front end.

1. The cooling system operates under pressure which is controlled by the radiator cap. It is dangerous to remove the cap while the system is hot. Always turn the cap slowly to the first stop and allow the pressure to escape before removing the cap entirely.

15. Always select Position Control when attaching implements and when transporting equipment. Be sure hydraulic couplers are properly installed and will disconnect safety in case of accidental detachment of the implement. 16. Do not leave equipment in the raised position when the vehicle is stopped or unattended. 17. Ensure any attached equipment or accessories are correctly installed, are approved for use with the tractor, do not overload the tractor and are operated and maintained in accordance with the instructions issued by the equipment or accessory manufacturer. 18. Remember that your tractor, if abused or incorrectly used, can be dangerous and become

00-17

SERVICING THE TRACTOR

2. Do not smoke while refueling the tractor. Keep any type of open flame away. Wait for the engine to cool before refueling. 3. Keep the tractor and equipment, particularly brakes and steering, maintained in a reliable and satisfactory condition to ensure your safety and comply with legal requirements. 4. To prevent fire or explosion, keep open flames away from battery or cold weather starting aids. To prevent sparks which could cause explosion, use jumper cables according to instructions. 5. Stop the engine before performing any service on the tractor.

SECTION 00 -- GENERAL -- CHAPTER 1 6. Escaping diesel/hydraulic fluid under pressure can penetrate the skin causing serious injury.

5. Do not fill the fuel tank to capacity. Allow room for expansion.

Do not use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. • Stop the engine and relieve pressure before connecting or disconnecting lines. • Tighten all connections before starting the engine. • If fluid is injected into the skin obtain medical attention immediately. 7. Do not modify or alter or permit anyone else to modify or alter the tractor or any of its components or any tractor function without first consulting an authorized dealer.

6. Wipe up spilled fuel immediately.

•

8. The fuel oil in the injection system is under high pressure and can penetrate the skin. Unqualified persons should not remove or attempt to adjust a pump, injector, nozzle or any other part of the injection system. Failure to follow these instructions can result in serious injury. 9. Continuous long term contact with used engine oil my cause skin cancer. Avoid prolonged contact with used engine oil. Wash skin promptly with soap and water.

DIESEL FUEL 1. Under no circumstances should gasoline, alcohol or blended fuels be added to diesel fuel. These combinations can create an increased fire or explosive hazard. In a closed container such as a fuel tank these blends are more explosive than pure gasoline. Do not use these blends.

7. Always tighten the fuel tank cap securely. 8. If the original fuel tank cap is lost, replace it with an approved cap. A non-approved cap may not be safe. 9. Keep equipment clean and properly maintained. 10. Do not drive equipment near open fires. 11. Never use fuel for cleaning purposes. 12. Arrange fuel purchases so that summer grade fuels are not used in the winter.

ROPS The tractor may be equipped with a safety frame (ROPS) which must be maintained in a serviceable condition. Be careful when driving through doorways or working in confined spaces with low headroom. 1. Do not modify, drill, weld or alter the ROPS in any way. 2. Never attempt to straighten or weld the ROPS or retaining brackets, which have suffered damage. By doing so you may weaken the structure and endanger your safety. 3. Do not secure any parts on the ROPS or attach it with other than the special high tensile bolts and nuts specified. 4. Never attach chains or ropes to the safety frame or roll bar for pulling purposes.

2. Never remove the fuel cap or refuel with the engine running or hot.

5. Never take unnecessary risks even though your safety frame or roll bar affords you the maximum protection possible.

3. Do not smoke while refueling the tractor or when standing near fuel. Keep any type of open flame away. Wait for the engine to cool before refueling.

6. Whenever possible, operate with the ROPS in its fully upright and locked position.

4. Maintain control of the fuel filter pipe nozzle when filling the tank.

00-18

SECTION 00 -- GENERAL -- CHAPTER 1

ECOLOGY AND THE ENVIRONMENT Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment of some of the substances which are required by advanced technology, common sense should govern the use and disposal of products of a chemical and petrochemical nature.

2. Avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances which may be harmful to your health.

The following are recommendations which may be of assistance:

4. Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc. Do not mix drained brake fluids or fuels with lubricants. Store them safely or dispose of in a proper way to comply with local legislation and available resources.

â&#x20AC;˘

Become acquainted with and ensure that you understand the relative legislation applicable to your country. Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning agents, etc., with regard to effect on man and nature and how to safely store, use and dispose of these substances. Agricultural consultants will, in many cases, be able to help you as well.

3. Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.

5. Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. Do not allow seepage into the soil. Collect and dispose of safely. 6. Repair any leaks or defects in the engine cooling or hydraulic system immediately. 7. Do not increase the specified operating pressure in a pressurized circuit as this may lead to component failure.

PRECAUTIONS 1. Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems which may cause considerable spillage.

00-19

8. Protect hoses during welding as penetrating weld splatter may burn or weaken the hose, allowing the loss of oils, coolant, etc.

SECTION 00 -- GENERAL -- CHAPTER 1

20033007

GENERAL SPECIFICATIONS 2WD TRACTOR DIMENSIONS

TT55

TT55 L.C.G

TT75

TT75 L.C.G

Standard Front Tires

9.5 -- 15

Standard Rear Tires

14.9 -- 28

16.9 -- 30

14.9 -- 28

A (Height of Exhaust)

mm (in.)

2489 (98.0)

2362 (93.0)

2540 (100.0)

2362 (93.0)

B (Height of Hood High)

mm (in.)

1562 (61.5)

1435 (56.5)

1613 (63.5)

1435 (56.5)

C (Height of Hood Low)

mm (in.)

1397 (55.0)

1270 (50.0)

1448 (57.0)

1270 (50.0)

D (Length from Front Tire to Back of Rear Tire)

mm (in.)

3137 (123.5)

3099 (122.0)

3315 (130.5)

3226 (127.0)

E (Length Between Axle Centers) mm (in.)

2057 (81.0)

2019 (79.5)

2184 (86.0)

2146 (84.5)

F (Height of ROPS)

mm (in.)

2540 (100.0)

2413 (95.0)

2591 (102.0)

2413 (95.0)

G (Height of Steering Wheel)

mm (in.)

1702 -- 1778 (67.0 -- 70.0)

1575 -- 1651 (62.0 -- 65.0)

1753 -- 1829 (69.0 -- 72.0)

1575 -- 1651 (62.0 -- 65.0)

H (Clearance)

mm (in.)

394 (15.5)

267 (10.5)

445 (17.5)

279 (11.0)

I (Front Wheel Track Widths)

mm (in.)

1422 -- 1930 (56.0 -- 76.0)

1422 (56.0)

J (Rear Wheel Track Widths)

mm (in.)

1524 -- 1930 (60.0 -- 76.0)

1829 (72.0)

1880 (74.0)

00-20

SECTION 00 -- GENERAL -- CHAPTER 1

20033008

2 TT55

4WD TRACTOR DIMENSIONS

TT75

Standard Front Tires

9.5 -- 24

11.2 -- 24

Standard Rear Tires

14.9 -- 28

16.9 -- 30

A (Height of Exhaust)

mm (in.)

2489 (98.0)

2540 (100.0)

B (Height of Hood High)

mm (in.)

1562 (61.5)

1613 (63.5)

C (Height of Hood Low)

mm (in.)

1397 (55.0)

1448 (57.0)

D (Length from Front Tire to Back of Rear Tire)

mm (in.)

3264 (128.5)

3467 (136.5)

E (Length Between Axle Centers)

mm (in.)

2057 (81.0)

2184 (86.0)

F (Height of ROPS)

mm (in.)

2540 (100.0)

2591 (102.0)

G (Height of Steering Wheel)

mm (in.)

1702 -- 1778 (67.0 -- 70.0)

1753 -- 1829 (69.0 -- 72.0)

H (Clearance)

mm (in.)

394 (15.5)

432 (17.0)

I (Front Wheel Track Widths)

mm (in.)

1448 -- 1956 (57.0 -- 77.0)

1422 -- 2032 (56.0 -- 80.0)

J (Rear Wheel Track Widths)

mm (in.)

1525 -- 2032 (60.0 -- 80.0)

00-21

SECTION 00 -- GENERAL -- CHAPTER 1 TRACTOR CAPACITIES

TT55

Fuel Tank

TT75 90 liters (23.8 US gallons)

Sump Oil (filter included)

9.0 liters (9.5 US quarts)

11.7 liters (12.3 US quarts)

Cooling System

11.0 liters (2.9 US gallons)

11.6 liters (3.1 US gallons)

Hydrostatic Steering

2.0 liters (2.1 US quarts)

Front Axle -- 4WD

5.5 liters (5.8 US quarts)

Front Hubs -- 4WD

1.2 liters (1.3 US quarts)

Transmission/Rear Axle -- 2WD*

32 liters (33.8 US quarts)

Transmission/Rear Axle -- 4WD*

33 liters (34.9 US quarts)

Final Drives -- 2WD

1.7 liters (1.8 US quarts)

3.5 liters (3.7 US quarts)

Final Drives -- 4WD

3.5 liters (3.7 US quarts)

* Remote cylinders displace up to 7.5 liters (2.0 U.S. gallons) of transmission oil without the requiring additional oil, provided the tractor is on a level surface. Keep the transmission oil up to the fill line. When attaching remote devices, replenish the transmission oil with the same amount of oil displaced by the remote cylinder. RECOMMENDED CONSUMABLES

CONSUMABLE

New Holland Recommended Product

New Holland Specification

International Specification

Fuel

Decanted and filtered diesel fuel

Engine (Sump) Oil

Premium Multigrade Engine Oil

SH / CG--4 API (SAE 15W--40)

API CF--4/SG or CCMC D4 or MIL--L--2104E

Transmission/Hydraulics/ Rear Axle Oil

Multigrade Transmission, Rear Axle and Hydraulic Oil

134--D 85700812

API GL4 or ISO 68 or SAE 10W--30

Front Axle Case Oil, Front Wheel Hub Oil, Rear Final Drives

Multigrade Transmission, Rear Axle and Hydraulic Oil

134--D 85700812

API GL4 or ISO 68 or SAE 10W--30

Coolant

50% Antifreeze Plus 50% Clean, Soft Water

82980516

WSN--M97B18--D

Grease (including front wheel hub)

Multipurpose Grease Extreme Pressure (EP)

82923047

NLGI 2 or ESE--M1C75--B or ESN--M1C137--B

Hydrostatic Steering Oil

Multigrade Transmission, Rear Axle and Hydraulic Oil

134--D 85700812

API GL4 or ISO 68 or SAE 10W--30

00-22

40 min. cetane rating (No.2)

SECTION 00 -- GENERAL -- CHAPTER 1 Choose the correct oil viscosity from the chart

--25°C

--18°C

--12°C

0°C

10°C

32°C

SAE 5W--30 SAE 10W--30 SAE 15W--40 SAE 30 --13°F

0°F

10°F

32°F

50°F

90°F

3 NOTE: In places with prolonged periods of extreme temperature, local lubricant practices are acceptable. For prolonged periods of extreme low temperatures, SAE 5W is acceptable, and for prolonged periods of extreme high temperatures, SAE 50 is acceptable.

The conditions of operation

•

The specific characteristics of the fuel you use

If the tractor operates much of the time in temperatures below --12°C (10°F), or under severe conditions, you should change the oil more frequently. If the diesel fuel you are using has between 0.5 and 1.3 percent sulfur, you should also change the oil more frequently. Do not use a fuel with more than 1.3 percent sulfur. If you are using RME fuel, the recommended change interval is every 150 hours.

After the first 50 hours of operation, the recommended oil change interval is every 200 hours. But how often you change the engine oil and oil filter depends on: •

•

The temperature

2WD TRACTOR WEIGHTS

TT55

TT75

Standard Front Tires

7.50--16

Standard Rear Tires

16.9--28

15.5--38

2194 kg (4837 lbs.)

2579 kg (5686 lbs.)

2657 kg (5857.6 lbs.)

3042 kg (6706 lbs.)

No Ballast (no cast iron support) With Steel Ballasts (6 front & 6 rear; 463 kg [1020.7 lbs.]) Maximum Safe Operating Weight

3500 kg (7720 lbs.)

4WD TRACTOR WEIGHTS

TT55

TT75

Standard Front Tires

9.5--24

11.2--24

Standard Rear Tires

14.9--28

16.9--30

2424 kg (5344 lbs.)

2939 kg (6479 lbs.)

2887 kg (6364.7 lbs.)

3402 kg (7500 lbs.)

No Ballast (no cast iron support) With Steel Ballasts (6 front & 6 rear; 463 kg [1020.7 lbs.]) Maximum Safe Operating Weight

3500 kg (7720 lbs.)

00-23

SECTION 00 -- GENERAL -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN FOOT POUNDS (NEWTON-METERS) FOR NORMAL ASSEMBLY APPLICATIONS

INCH HARDWARE AND LOCKNUTS SAE GRADE 2 NOMINAL UNPLATED SIZE or PLATED SILVER 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

55* (6.2) 115* (13) 17 (23) 27 (37) 42 (57) 60 (81) 83 (112) 146 (198) 142 (193) 213 (289)

SAE GRADE 5

PLATED W/ZnCr

SAE GRADE 8

PLATED W/ZnCr

GOLD

UNPLATED or PLATED SILVER

72* (8.1) 149* (17) 22 (30) 35 (47) 54 (73) 77 (104) 107 (145) 189 (256) 183 (248) 275 (373)

86* (9.7) 178* (20) 26 (35) 42 (57) 64 (87) 92 (125) 128 (174) 226 (306) 365 (495) 547 (742)

112* (13) 229* (26) 34 (46) 54 (73) 83 (113) 120 (163) 165 (224) 293 (397) 473 (641) 708 (960)

GOLD

UNPLATED or PLATED SILVER

LOCKNUTS

PLATED W/ZnCr GOLD

121* (14) 157* (18) 250* (28) 324* (37) 37 (50) 48 (65) 59 (80) 77 (104) 91 (123) 117 (159) 130 (176) 169 (229) 180 (244) 233 (316) 319 (432) 413 (560) 515 (698) 667 (904) 773 (1048) 1000 (1356)

GR.B w/GR5 BOLT

GR.C w/GR8 BOLT

NOMINAL SIZE

61* (6.9) 125* (14) 19 (26) 30 (41) 45 (61) 65 (88) 90 (122) 160 (217) 258 (350) 386 (523)

86* (9.8) 176* (20) 26 (35) 42 (57) 64 (88) 92 (125) 127 (172) 226 (306) 364 (494) 545 (739)

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION CAP SCREWS AND CARRIAGE BOLTS

SAE GRADE 2

SAE GRADE 5

SAE GRADE 8 REGULAR NUTS

SAE GRADE 5 HEX NUTS

SAE GRADE 8 HEX NUTS

LOCKNUTS

GRADE IDENTIFICATION

GRADE A NO NOTCHES

GRADE A NO MARKS

GRADE B ONE CIRCUMFERENTIAL NOTCH

GRADE B THREE MARKS

GRADE C TWO CIRCUMFERENTIAL NOTCHES

GRADE C SIX MARKS MARKS NEED NOT BE LOCATED AT CORNERS GRADE A NO MARK GRADE B LETTER B GRADE C LETTER C

GRADE IDENTIFICATION

00-24

SECTION 00 -- GENERAL -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN FOOT POUNDS (NEWTON-METERS) FOR NORMAL ASSEMBLY APPLICATIONS

METRIC HARDWARE AND LOCKNUTS PLATED W/ZnCr

UNPLATED

PLATED W/ZnCr

LOCKNUT CL.8 W/CL8.8 BOLT

23* (2.6)

30* (3.4)

33* (3.7)

42* (4.8)

16* (1.8)

67* (7.6)

79* (8.9)

102* (12)

115* (13)

150* (17)

56* (6.3)

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)

CLASS 5.8

CLASS 8.8

NOMINAL SIZE

UNPLATED

PLATED W/ZnCr

15* (1.7)

19* (2.2)

51* (5.8)

UNPLATED

CLASS 10.9

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION HEX CAP SCREW AND CARRIAGE BOLTS CLASSES 5.6 AND UP MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS

HEX NUTS AND LOCKNUTS CLASSES 05 AND UP MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS

00-25

CLOCK MARKING

SECTION 00 -- GENERAL -- CHAPTER 1 TRACTOR SYSTEM COMPONENTS POWER TRAIN • Clutch — Twin, dry, single--plate, 11--inch diameter discs with separate controls. One pedal for the transmission and a hand lever for the P.T.O. Organic material for transmission and P.T.O. clutch plate. The free play on the transmission clutch pedal should be about 25 mm (1.0 in.). •

Transmission — Constant mesh, straight-toothed transmission with epicyclic type splitter produces 8 forward and two reverse speeds. Two levers control the transmission, one range selector and one gearshift selector. Shift 3, 4, 7 and 8 are synchronized.

•

Bevel Drive — Central on differential.

•

Differential — Two--pinion with pedal control differential lock.

•

Final Drive — Pinion outboard or cascade drive, single reduction.

AXLES •

2WD Front Axle — Welded beam, center pivoting axle. The TT55 front axle track can be adjusted to 7 widths by lengthening or shortening the front axle, from 1372 to 1981 mm (54.0 to 78.0 in.). The TT75 front axle track can be adjusted the same way to 7 widths, from 1422 to 2032 mm (56.0 to 80.0 in.).

•

4WD Front Axle — Full--floating, center pivoting, unjointed drive shaft and articulations on tractor centerline. The differential is two--pinion with epicyclic reduction gear in the wheel hubs. Track is adjusted by changing the wheel rim relative to the center disc, changing the rim or disc relative to the axle hub, or by swapping the two wheels. The TT55 have 6 widths, from 1448 to 1956 mm (57.0 to 77.0 in.). The TT75 has 7 widths, from 1422 to 2032 mm (56.0 to 80.0 in.).

•

Rear Axle — Track adjusted to five or six possible widths, depending on the tractor. Track adjusted by changing the wheel rim relative to the center disc, changing the rim or disc relative to the axle hub, or by swapping the two wheels. The 2WD TT55 have 5 possible widths, from 1525 to 1930 mm (60.0 to 76.0 in.). The 2WD TT75 and all 4WD have 6 widths, from 1525 to 2032 mm (60.0 to 80.0 in.).

BRAKES •

Service Brakes — Wet disc, oil--bath, axle shaft mounted brakes. Brake pedals, separate or latched, mechanically operate the brakes. The free play on both pedals should be about 38 mm (1.5 in.).

•

Parking Brake — Acting on service brake, a hand lever engages the brake latch, foot pedal pressure supplies the brakes.

STEERING •

Type — Hydrostatic Power Steering.

•

Turning Radius (Without Brakes) — 2WD radius is 3.4 m (11 ft., 2 in.); 4WD radius is 4.1 m (16 ft., 1 in.).

00-26

POWER TAKE OFF •

Shaft — Six--spline, 34.9 mm (1.375 in.) diameter shaft.

•

Clutch — Fully independent. The free play on the P.T.O. clutch link should be 4.5 mm (0.18 in.).

•

Designed Operating Speed — 540 RPM.

•

Engine Driven Speed — P.T.O. rotates at 540 RPM when engine speed is 1967 RPM. P.T.O. rotates at 686 RPM when engine speed is 2500 RPM.

•

Direction — When you look at the P.T.O. from behind the tractor, the splined shaft rotates clockwise.

SECTION 00 -- GENERAL -- CHAPTER 1 HYDRAULIC LIFT

BALLASTING

•

Modes — Draft control, position control, and combined draft/position control with manual sensitivity control. Draft control sensed through spring behind top link.

•

Automatic Control — Automatic arm lift control with Touch Command buttons.

•

Pump Drive — Engine timing gears drive the hydraulic gear pump.

•

Oil Source — Hydraulic oil taken from rear transmission oil.

•

Implements — Category 1 and 2 implements attach with a three--point linkage with normal arms.

•

Towing Attachments — Swinging drawbar.

•

Lift Weight Limits —

MAXIMUM LIFT CAPACITIES (Starting with lower links horizontal)

TT55/TT75

At lower link swivel bushings

1745 kg (3847 lbs.)

Center of gravity 610 mm (24.0 in.) from lower link swivel bushing

1340 kg (2954 lbs.)

Maximum lower link end travel with lifting rods fully OUT

785 mm (30.9 in.)

Maximum lower link end travel with lifting rods fully IN

645 mm (25.4 in.)

00-27

•

Front End Steel Weights — Six, eight, ten, or twelve front--end ballast weights and their support are cast iron. The support weighs 49 kg (108 lbs.) and each individual weight is 31 kg (68 lbs.). Six weights would have a total possible front end ballast of 266 kg (586 lbs.), and 10 weights would have 390 kg (860 lbs.).

•

Rear Wheel Cast Iron Plates — Each rear wheel can take three rings, each ring weighing 38 kg (83.0 lbs.), for a maximum of 228 kg (501.6 lbs.) rear cast iron ballast.

ELECTRICAL SYSTEM •

Voltage — 12 Volts.

•

Alternator Power — Integral electronic voltage regulator. Maximum output is 55 amps.

•

Battery — Maintenance--free 12 V with 90 Ah capacity.

•

Starter — Electromagnet operated.

•

Lights — Headlights are 60/55 W (H--4) lamps (white or yellow), with adjustable aiming. Parking lights are 5 W (R5W) lights with yellow front and red rear transluscent covers. Work lamp is a halogen bulb with a separate switch.

•

Instruments and Accessories — Multifunction instrument panel contains all gauges and warning lights. Flasher pulses parking lights for hazard light operation. Thermostart® cold starting device warms the air in the intake manifold.

SECTION 00 -- GENERAL -- CHAPTER 1 Speed Decals Example:

4 Each tractor has a speed decal that shows the ground speed for three engine speeds: 1500, 1967, and 2500 RPM.

00-28

Each tractor model has a specific decal for the engine, transmission, and final drive configuration. Refer to the charts on the following pages for more precise ground speeds at 2500 RPM and 1967 RPM (when PTO is at 540 RPM).

SECTION 00 -- GENERAL -- CHAPTER 1 2WD SPEED CHART Ground Speed in KPH (MPH) at 2500 RPM

RANGE

GEAR

TT55 2WD 14.9--28

TT75 2WD 16.9--30

3.1 KPH (1.9 MPH)

4.7 KPH (2.9 MPH)

4.6 KPH (2.9 MPH)

6.8 KPH (4.3 MPH)

6.7 KPH (4.2 MPH)

8.8 KPH (5.5 MPH)

8.7 KPH (5.4 MPH)

11.2 KPH (6.9 MPH)

11.0 KPH (6.8 MPH)

16.8 KPH (10.5 MPH)

16.6 KPH (10.3 MPH)

24.6 KPH (15.3 MPH)

24.2 KPH (15.1 MPH)

31.8 KPH (19.8 MPH)

31.3 KPH (19.5 MPH)

4.5 KPH (2.8 MPH)

4.4 KPH (2.7 MPH)

16.1 KPH (10.0 MPH)

15.8 KPH (9.8 MPH)

4WD SPEED CHART Ground Speed in KPH (MPH) at 2500 RPM

RANGE

GEAR

TT55 4WD 14.9--28

TT75 4WD 16.9--30

2.8 KPH (1.8 MPH)

3.1 KPH (1.9 MPH)

4.3 KPH (2.7 MPH)

4.6 KPH (2.9 MPH)

6.2 KPH (3.9 MPH)

6.7 KPH (4.2 MPH)

8.1 KPH (5.0 MPH)

8.7 KPH (5.4 MPH)

10.2 KPH (6.3 MPH)

11.0 KPH (6.8 MPH)

15.3 KPH (9.5 MPH)

16.6 KPH (10.3 MPH)

22.4 KPH (14.0 MPH)

24.2 KPH (15.1 MPH)

29.0 KPH (18.0 MPH)

31.3 KPH (19.5 MPH)

4.1 KPH (2.5 MPH)

4.4 KPH (2.7 MPH)

14.6 KPH (9.1 MPH)

15.8 KPH (9.8 MPH)

00-29

SECTION 00 -- GENERAL -- CHAPTER 1 PTO 2WD SPEED CHART Ground Speed in KPH (MPH) at PTO 540 RPM (Engine 1967 RPM)

RANGE

GEAR

TT55 2WD 14.9--28

TT75 2WD 16.9--30

2.4 KPH (1.5 MPH)

3.7 KPH (2.3 MPH)

3.6 KPH (2.3 MPH)

5.4 KPH (3.3 MPH)

5.3 KPH (3.3 MPH)

7.0 KPH (4.3 MPH)

6.8 KPH (4.3 MPH)

8.8 KPH (5.5 MPH)

8.7 KPH (5.4 MPH)

13.2 KPH (8.2 MPH)

13.0 KPH (8.1 MPH)

19.4 KPH (12.0 MPH)

19.1 KPH (11.9 MPH)

25.0 KPH (15.6 MPH)

24.6 KPH (15.3 MPH)

3.5 KPH (2.2 MPH)

12.6 KPH (7.9 MPH)

12.4 KPH (7.7 MPH)

PTO 4WD SPEED CHART Ground Speed in KPH (MPH) at PTO 540 RPM (Engine 1967 RPM)

RANGE

GEAR

TT55 4WD 14.9--28

TT75 4WD 16.9--30

2.2 KPH (1.4 MPH)

2.4 KPH (1.5 MPH)

3.4 KPH (2.1 MPH)

3.6 KPH (2.3 MPH)

4.9 KPH (3.1 MPH)

5.3 KPH (3.3 MPH)

6.3 KPH (3.9 MPH)

6.8 KPH (4.3 MPH)

8.0 KPH (5.0 MPH)

8.7 KPH (5.4 MPH)

12.1 KPH (7.5 MPH)

13.0 KPH (8.1 MPH)

17.7 KPH (11.0 MPH)

19.1 KPH (11.9 MPH)

22.8 KPH (14.2 MPH)

24.6 KPH (15.3 MPH)

3.2 KPH (2.0 MPH)

3.5 KPH (2.2 MPH)

11.5 KPH (7.2 MPH)

12.4 KPH (7.7 MPH)

00-30

SECTION 00 -- GENERAL -- CHAPTER 1

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

Coverage This emission control system warranty applies to the following emission control parts. Fuel Injection Pump Fuel Injectors Turbocharger Intake Manifold Exhaust Manifold Boost Pressure Tubing-connection to Aneroid Device ON F.I.P.

00-31

SECTION 00 -- GENERAL -- CHAPTER 1

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT (North America Only) (California Only)

Your Warranty Rights and Obligations The California Air Resources Board and New Holland are pleased to explain the emission control system warranty on your engine. In California, new 1997 and later heavy-duty off-road engines from 100 to 150 HP must be designed, built, and equipped to meet the State’s stringent anti-smog standards. New Holland must warrant the emission control system on your engine for the periods of time listed below, provided there has been no abuse, neglect, or improper maintenance of your engine. Your emission control system includes parts such as the fuel injection system and the air induction system. Where a warrantable condition exists, New Holland will repair your heavy-duty off-road engine at no cost to you, including diagnosis, parts, and labor.

Manufacturer’s Warranty Coverage: The 1997 and later heavy-duty off-road engines are warranted from the original date of delivery for five years or 3,000 hours of operation, whichever occurs first. If any emission-related part on your engine is defective, the part will be repaired or replaced by New Holland.

Owner’s Warranty Responsibilities: D

As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. New Holland recommends that you retain all receipts covering maintenance on your heavy-duty off-road engine, but New Holland cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

As the heavy-duty off-road engine owner, you should, however, be aware that New Holland may deny you warranty coverage if your heavy-duty off-road engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.

Your engine is designed to operate on commercially available diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with California’s emissions requirements.

You are responsible for initiating the warranty process. The ARB suggests that you present your heavy-duty off-road engine to a New Holland dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible.

If you have questions regarding your warranty rights and responsibilities, you should contact your Branch Office at the address and phone number listed on the Owner Assistance page of your equipments operator manual. D

Prior to the expiration of the warranty, you must give notice of any failure of an emission control warranted part. Such notice must be given to New Holland or an authorized dealer, and you must deliver the engine to the repair location.

You, the owner, are responsible for incidental costs incurred by yourself or your employees as a result of a warrantable failure. Examples of such costs are communication expenses, meals and lodging.

The owner is responsible for any business costs or losses, any “downtime” expenses and any “cargo” damage which result from the failure of a warranted part. New Holland is not responsible for other incidental or consequential damages, including but not limited to fines, theft, vandalism or collisions.

Parts covered: This emission control system warranty applies to the following emission control parts. Fuel Injection Pump Fuel Injectors Turbocharger Intake Manifold Exhaust Manifold Boost Pressure Tubing-connection to Aneroid Device ON F.I.P. Any replacement part, equivalent in performance and durability, may be used in the performance of any maintenance or repairs and must be provided without charge to the owner. The use of these parts does not reduce the warranty obligations of New Holland. However, New Holland recommends the use of new, genuine New Holland service parts or New Holland approved rebuilt parts and assemblies. New Holland also recommends that the engine be serviced by a New Holland authorized dealer.

New Holland Responsibilities Warranty work will be provided at no charge to the owner at any authorized dealer, using new genuine New Holland service parts or New Holland approved rebuilt parts or assemblies.. The owner will not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work was performed at a warranty station. New Holland is liable for damages to other engine components caused by the failure under warranty of any warranted part.

Warranty Limitations New Holland is not responsible for failures resulting from abuse or neglect by owner or operator. New Holland warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built, and equipped so as to conform with all applicable regulations adopted by the Air Resources Board, and that it is free from defects in materials and workmanship which cause the failure of a warranted part. Any warranted part which is not scheduled for replacement as required maintenance, or which is scheduled only for regular inspection to the effect of “repair or replace as necessary” is warranted for the warranty period. Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of time prior to the first scheduled replacement point for that part. New Holland is liable for damages to other engine components caused by the failure under warranty of any warranted part.

00-32

SECTION 00 -- GENERAL -- CHAPTER 1

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

00-33

SECTION 00 -- GENERAL -- CHAPTER 1

00-34

SECTION 10 -- ENGINE -- CHAPTER 1

SECTION 10 - ENGINE Chapter 1 - Engine Overhaul CONTENTS Section

Description

Page

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening Torque Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Engine Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Splitting the tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Engine Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Checks, Dimensions and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Cylinder Block and Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Crankshaft, Main Bearings and Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Camshaft, Tappets and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Valve Guide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Valve Seat In Cylinder Head Refacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Injector Sleeve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Rotating Counterweight Dynamic Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Engine Lubrication System Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Crankshaft Front Oil Seal Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Coolant System Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Fuel System Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Engine Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

10-1

SECTION 10 -- ENGINE -- CHAPTER 1 GENERAL SPECIFICATIONS

ENGINE SPECIFICATIONS Engine

TT55

TT75

55 hp; naturally aspirated; 8035 -- 06 -- 507 (w/BOSCH pump emiss)

70 hp; naturally aspirated; 8045 -- 06 -- 506 (w/BOSCH pump emiss)

Cycle

4-stroke diesel

Fuel Injection Number of Cylinders

Direct 3 cylinders

Cylinder Liners

4 cylinders

Dry, force-fitted on engine block

Bore (Piston Diameter)

100 mm (3.9370 in.)

Stroke

115 mm (4.5276 in.)

2710 cm3 (165 in.3)

3613 cm3 (220 in.3)

Total Displacement Compression Ratio Maximum Power

17 to 1 ratio 40.5 kW (55 hp)

Maximum Output Speed Maximum Torque Speed

55.5 kW (70 hp) 2500 RPM

1500 RPM

Idle Speed

1400 RPM 650 – 700 RPM

Main Bearings

Sump

5 Structural, in cast iron

Balancer

—

10-2

Flyweight, engine sump

SECTION 10 -- ENGINE -- CHAPTER 1 TIMING SPECIFICATIONS Valve Gear

TT55

TT75

Overhead valves; pushrod operated; camshaft driven by the crankshaft through helical gears

Inlet Start: Before TDC

12°

Inlet End: After BDC

31°

Exhaust Start: Before BDC

50°

Exhaust End: After TDC

16°

Valve Clearance for Timing Check

0.45 mm (0.0177 in.)

Valve Clearance Normal Running (Engine Cold) — Inlet

0.30 mm ± 0.05 mm (0.0118 in. ± 0.0020 in.)

Valve Clearance Normal Running (Engine Cold) — Exhaust

0.30 mm ± 0.05 mm (0.0118 in. ± 0.0020 in.)

FUEL SYSTEM SPECIFICATIONS Air Cleaning

TT55

TT75

Dual cartridge dry air filter; clogged filter indicator; centrifugal pre-cleaner; automatic dust ejector

Fuel Tank Capacity

90 liters (23.8 US gallons)

Fuel Supply Pump

Double diaphragm; engine driven; camshaft operated

Fuel Filtering

Strainer in fuel supply pump; Lucas - dual filter;

Strainer in fuel supply pump; dual filters

Bosch - single filter with water separator Minimum Fuel Flow with Pump Shaft Rotating at 1600 RPM

100 liters/hour (26.4 US gallons/hour)

Drive Shaft Eccentricity Injection Pump

3.0 mm (0.1181 in.) Emissioned

Rotary distributor type

Pump All-Speed Governor

Integral; centrifugal counterweights

Pump Advance Regulator

Integral; hydraulic

Injection Pump Rotation

Counterclockwise

Injection Order

1-2-3

1-3-4-2

0.31 mm (0.0122 in.)

Injector Nozzles (Orifices) Nozzle Diameter Injector Release Pressure

230 – 238 bar (235 – 243 kg/cm2, 3340 – 3460 PSI)

10-3

SECTION 10 -- ENGINE -- CHAPTER 1 INJECTOR SPECIFICATIONS Pump Model No.

TT55

TT75

BOSCH 814--1

BOSCH L810

Injection Pump Rotation

Counterclockwise

Shaft Journal Diameter

31.975 to 32.000 mm (1.2588 to 1.2598 in.)

Bushing Installer ID After Reaming

32.050 to 32.075 mm (1.2618 to 1.2628 in.)

Shaft Clearance in Bushing

0.050 to 0.100 mm (0.0020 to 0.0040 in.)

Bushing Interference Install in Housing

0.063 to 0.140 mm (0.0025 to 0.0055 in.)

Inner Washer Thickness

1.45 to 1.50 mm (0.0570 to 0.0590 in)

Outer Washer Thickness

2.93 to 3.00 mm (0.1153 to 0.1181 in)

BOSCH Injector Nozzle

4824165

Nozzle Holder

4791124

Nozzle

4817266

Nozzle Holder

4816070

Fuel Delivery Lines

4797511

4797522

6 x 2 x 475 mm

6 x 2 x 530 mm

TT55

TT75

LUCAS Injector

Fuel Delivery Line Dimensions LUBRICATION SPECIFICATIONS Lubrication System Engine Capacity (filter included)

Force feed; gear pump 9.0 liters (9.5 US quarts)

Oil Fill and Dipstick Location

LH Side Crankcase

Pump Drive

Camshaft

Engine / Oil Pump Speed Ratio

2 to 1 ratio

Oil Filtering Normal Oil Pressure

11.7 liters (12.3 US quarts)

Mesh screen on oil pick-up line; full flow filter cartridge on delivery line 2.9 – 3.9 bar (3.0 – 4.0 kg/cm2, 42.6 – 56.9 PSI)

Relief Valve

Built into pump housing

Shaft Clearance in Bushing

0.016 to 0.055 mm (0.0006 to 0.0022 in.)

Shaft Clearance in Driven Gear

0.033 to 0.066 mm (0.0013 to 0.0026 in.)

Gear Backlash

0.100 mm (0.0039 in.)

Gear Clearance in Pump Body

0.060 to 0.170 mm (0.0024 to 0.0067 in.)

Drive and Driven Gear Thickness

40.961 to 41.000 mm (1.6126 to 1.6142 in.)

Gear Seat in Pump Height

41.025 to 41.087 mm (1.6152 to 1.6176 in.)

Drive and Driven Gear End Float

0.025 to 0.126 mm (0.0009 to 0.0049 in.)

Relief Valve Spring Length — Free

45.0 mm (1.77 in.)

Relief Valve Spring Length — Loaded 45–49 N (4.6–5.0 kg)

37.5 mm (1.48 in.)

Relief Valve Spring Length — Loaded 88–94 N (9.0–9.6 kg)

30.5 mm (1.20 in.)

10-4

SECTION 10 -- ENGINE -- CHAPTER 1 COOLING SPECIFICATIONS

TT55

Cooling System Cooling System Capacity

TT75 Water circulation

11.0 liters (2.9 US gallons)

Pump

11.6 liters (3.1 US gallons)

Centrifugal vane type

Pump / Engine Speed Ratio

1.403 to 1 ratio

Pump Interference Install Between Impeller and Shaft

0.017 to 0.059 mm (0.0007 to 0.0023 in.)

Pump Interference Install Between Fan Hub and Shaft

0.024 to 0.058 mm (0.0009 to 0.0023 in.)

Pump Interference Install Between Seal Bushing and Impeller

0.012 to 0.058 mm (0.0005 to 0.0023 in.)

Radiator

3 or 4 deep core vertical tubes 0.7 bar (0.7 kg/cm2, 10 PSI)

Pressure Cap Rating Fan

Suction; attached to water pump pulley; four steel blades Suction; attached to water pump pulley; four steel blades

Temperature Control

Wax thermostat

Thermostat Starts Opening

79° C ± 2° C (174° F ± 3.6° F)

Thermostat Fully Open

94° C (201° F)

Thermostat Valve Travel

7.5 mm (0.295 in.)

Thermometer Green Range

30° to 105° C (86° to 221° F)

Thermometer Red Range

105° to 115° C (221° to 239° F)

TRACTOR METER SPECIFICATIONS

TT55

Location

TT75 On instrument panel

Drive

Electronic -- “W” terminal on alternator

Hour Meter Rated Speed

3000 RPM

Meter Drive Ratio

1 to 2 ratio

10-5

SECTION 10 -- ENGINE -- CHAPTER 1 FUEL SUPPLY PUMP DATA

mm (inches)

Eccentricity of drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 mm (0.118 in.)

Diameter of drive shaft at bushings . . . . . . . . . . . . . . . . . . . . . . . . . .

31.975 to 32.000 mm (1.2588 to 1.2598 in.)

Internal diameter of installed and reamed bushings . . . . . . . . . . . .

32.050 to 32.075 mm (1.2618 to 1.2628 in.)

Interference between bushings and seats . . . . . . . . . . . . . . . . . . . .

0.063 to 0.140 mm (0.0025 to 0.0055 in.)

Assembly clearance between shaft and bushings . . . . . . . . . . . . .

0.050 to 0.100 mm (0.0020 to 0.0040 in.)

Thickness of internal washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.45 to 1.50 mm (0.0570 to 0.0590 in.)

Thickness of external washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.93 to 3.00 mm (0.1153 to 0.1181 in.) mm (inches)

CRANKCASE/CYLINDER BLOCK DATA

TT55/TT75

Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

cast-iron monobloc with replaceable dry, force-fitted cylinder liners, incorporating seatings for crankshaft bearings, camshaft and pushrod/tappet assemblies

Internal diameter of cylinder liners . . . . . . . . . . . . . . . . . .

100.000 to 100.024 mm (1) (3.9370 to 3.9379 in.) (1)

External diameter of cylinder liners . . . . . . . . . . . . . . . . . .

103.020 to 103.050 mm (4.0559 to 4.0571 in.)

Diameter of cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . .

102.850 to 102.900 mm (4.0492 to 4.0512 in.)

Interference fit between cylinder liners and bores . . . . .

0.120 to 0.200 mm (0.0047 to 0.0079 in.)

Liner internal diameter oversizes . . . . . . . . . . . . . . . . . . .

0.4 and 0.8 mm (0.0157 and 0.0315 in.)

Liner external diameter oversizes . . . . . . . . . . . . . . . . . . .

0.2 mm (0.0079 in.)

Maximum permissible liner ovality or taper due to wear

0.12 mm (0.0047 in.)(2)

Diameter of main shell bearing seats . . . . . . . . . . . . . . . .

84.200 to 84.230 mm (3.3149 to 3.3161 in.)

Diameter of camshaft bearing seats: - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54.780 to 54.805 mm (2.1567 to 2.1577 in.)

- center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54.280 to 54.305 mm (2.1370 to 2.1380 in.)

- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53.780 to 53.805 mm (2.1173 to 2.1183 in.)

Diameter of standard tappet bores in crankcase . . . . . .

15.000 to 15.018 mm (0.5906 to 0.5913 in.)

Tappet oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.1 - 0.2 - 0.3 mm (0.0039 - 0.0079 - 0.0188 in.)

(1) Measured after press-fitting and reaming. (2) Measure in the area swept by piston rings, both parallel and perpendicular to the crankshaft axis.

10-6

SECTION 10 -- ENGINE -- CHAPTER 1 mm (inches)

CRANKSHAFT AND BEARINGS DATA

TT55/TT75

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

balanced with integral counterweights

Standard journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79.791 to 79.810 mm (1) (3.1414 to 3.1421 in.) (1)

Journal undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.254 - 0.508 - 0.762 - 1.016 mm (0.0100 - 0.0200 - 0.0300 - 0.0400 in.)

Standard main bearing shell thickness . . . . . . . . . . . . . . . . . . . . . . .

2.168 to 2.178 mm (0.0854 to 0.0857 in.)

Main bearing shell undersizes (internal diameter) . . . . . . . . . . . . .

0.254 - 0.508 - 0.762 - 1.016 mm (0.0100 - 0.0200 - 0.0300 - 0.0400 in.)

Bearing shell to journal clearance . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.034 to 0.103 mm (0.0013 to 0.0040 in.)

Maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . . . . . . .

0.180 mm (0.0071 in.)

Standard crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63.725 to 63.744 mm (1) (2.5088 to 2.5096 in.) (1)

Crankpin undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.254 - 0.508 - 0.762 - 1.016 mm (0.0100 - 0.0200 - 0.0300 - 0.0400 in.)

Standard big-end bearing shell thickness . . . . . . . . . . . . . . . . . . . .

1.805 to 1.815 mm (0.710 to 0.0715 in.)

Big-end bearing shell undersizes (internal diameter) . . . . . . . . . . .

0.254 - 0.508 - 0.762 - 1.016 mm (0.0100 - 0.0200 - 0.0300 - 0.0400 in.)

Big-end bearing shell to crankpin clearance . . . . . . . . . . . . . . . . . .

0.033 to 0.087 mm (0.0013 to 0.0034 in.)

Maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . . . . . . .

0.180 mm (0.0071 in.)

Standard crankshaft thrust washer thickness . . . . . . . . . . . . . . . . .

3.378 to 3.429 mm (0.1330 to 0.1350 in.)

Thrust washer oversizes (thickness) . . . . . . . . . . . . . . . . . . . . . . . .

0.127 - 0.254 - 0.381 - 0.508 mm (0.0050 - 0.0100 - 0.0150 - 0.200 in.)

Width of main bearing including thrust washers . . . . . . . . . . . . . . .

31.766 to 31.918 mm (1.2506 to 1.2638 in.)

Width of corresponding crankshaft journal . . . . . . . . . . . . . . . . . . . .

32.000 to 32.100 mm (1.2598 to 1.2638 in.)

Crankshaft assembly endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.082 to 0.334 mm (0.0032 to 0.0131 in.)

Max. permitted wear endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.40 mm (0.0160 in.)

Maximum ovality or taper of journals and crankpin after regrinding .

0.01 mm (0.0004 in.)

Maximum ovality or taper of worn journals and crankpin . . . . . . . .

0.05 mm (0.0020 in.)

(1) Crankshafts with 0.1 mm (0.0039 in.) undersize journals and crankpins and consequently undersize bearing shells may be fitted in factory production. (continued)

10-7

SECTION 10 -- ENGINE -- CHAPTER 1 mm (inches)

CRANKSHAFT AND BEARINGS DATA

TT55/TT75

Maximum tolerance for alignment of crankshaft journals with crankshaft supported on the two outer journals . . . . . . . . . . . . . . .

0.10 mm (0.0039 in.)

Maximum tolerance for alignment, in both directions, of crankpins (3-cylinder engines) or each pair of crankpins (4-cylinder engines) relative to crankshaft journals . . . . . . . . . . . . . . . . . . . . . .

0.25 mm (0.0098 in.)

Maximum tolerance for run-out between the outer surfaces of the crankshaft journals and the crankshaft centerline . . . . . . . . . . . . . .

± 0.10 mm (± 0.0039 in.)

Maximum permitted tolerance on run-out of flywheel mounting flange surface relative to the crankshaft centerline, measured with 1/100 mm scale dial gauge resting on front flange surface at a diameter of 108 mm (total gauge reading). . . . . . . . . . . . . . . . . . . . .

0.025 mm (0.0098 in.)

Maximum permitted tolerance on co-axial alignment of flywheel centering seat relative to the crankshaft journals (total gauge reading) . . . . . . . . . . . . .

0.040 mm (0.0016 in.)

mm (inches)

CONNECTING ROD DATA

TT55/TT75

Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

cast-iron with oil way

Diameter of small end bushing seat . . . . . . . . . . . . . . . . . . . . . . . . .

41.846 to 41.884 mm (1.6475 to 1.6490 in.)

Outside diameter of small end bushing . . . . . . . . . . . . . . . . . . . . . .

41.979 to 42.017 mm (1.6527 to 1.6542 in.)

Interference between small end bushing and seat . . . . . . . . . . . . .

0.095 to 0.171 mm (0.0037 to 0.0067 in.)

Inside diameter of small end bushing (measured after fitting) . . . .

38.004 to 38.014 mm (1.4962 to 1.4966 in.)

Diameter of big end shell bearing seats . . . . . . . . . . . . . . . . . . . . . .

67.407 to 67.422 mm (2.6538 to 2.6544 in.)

Max. tolerance for parallelism between the small end and big end axes measured at 25 mm (0.984 in.) . . . . . . . . . . . . . . . . . . . . . . . .

± 0.07 mm (± 0.0028 in)

Max. weight difference between con rods in same engine . . . . . .

25 grams (0.88 oz.)

10-8

SECTION 10 -- ENGINE -- CHAPTER 1 mm (inches)

PISTON DATA

TT55/TT75

Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard piston diameter, measured at 57 mm from base from skirt and perpendicularly to the gudgeon pin axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Light alloy with two compression rings and one oil control ring 99.827 to 99.841 mm (3.9302 to 3.9307 in.)

Piston clearance in cylinder liner . . . . . . . . . . . . . . . . . . . .

0.159 to 0.197 mm (0.0063 to 0.0077 in.)

Max. permissible clearance due to wear . . . . . . . . . . . . .

0.30 mm (0.012 in.)

Piston oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.40 and 0.80 mm (0.016 and 0.032 in.)

Piston protrusion at TDC from cylinder block face . . . . .

0.355 to 0.761 mm (0.014 to 0.030 in.)

Gudgeon pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37.983 to 37.990 mm (1.4954 to 1.4957 in.)

Diameter of gudgeon pin seat in piston . . . . . . . . . . . . . .

37.993 to 8.000 mm (1.4958 to 1.4961 in.)

Gudgeon pin to seat clearance . . . . . . . . . . . . . . . . . . . . .

0.003 to 0.017 mm (0.0001 to 0.0012 in.)

Gudgeon pin to small end bearing clearance . . . . . . . . .

0.014 to 0.031 mm (0.0006 to 0.0012 in.)

Max. permissible clearance due to wear . . . . . . . . . . . . .

0.060 mm (0.0024 in.)

Max. weight difference between pistons in same engine

20 grams (0.70 oz.)

Piston ring groove clearance (measured vertically): . . . . - Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.090 to 0.122 mm (0.0035 to 0.0048 in.)

- Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.060 to 0.092 mm (0.0024 to 0.0036 in.)

- Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.040 to 0.075 mm (0.0016 to 0.0029 in.)

Max. permissible clearance (wear limit): - Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.50 mm (0.0197 in.)

- Second and bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.20 mm (0.0079 in.)

Piston ring end gap (fitted): - Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.35 to 0.55 mm (0.0138 to 0.0216 in.)

- Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 to 0.45 mm (0.1180 to 0.0177 in.)

- Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 to 0.60 mm (0.1180 to 0.0236 in.)

Max. permissible gap (wear limit) . . . . . . . . . . . . . . . . . . .

1.20 mm (0.0472 in.)

10-9

SECTION 10 -- ENGINE -- CHAPTER 1 mm (inches)

VALVE TIMING GEAR DATA

TT55/TT75

Timing gear tooth backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside diameter of intermediate gear bushings (fitted and reamed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.160 mm (0.0093 in.) 37.050 to 37.075 mm (1.4587 to 1.4596 in.)

Diameter of intermediate gear journal . . . . . . . . . . . . . . . . . . . . . . .

36.975 to 37.000 mm (1.4557 to 1.4567 in.)

Journal to bushing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.050 to 0.100 mm (0.0020 to 0.0039 in.)

Max. permissible clearance (wear limit) . . . . . . . . . . . . . . . . . . . . . . Busing interference fit in seat in intermediate gear . . . . . . . . . . . . .

0.15 mm (0.0059 in.) 0.063 to 0.140 mm (0.0025 to 0.0055 in.)

Outside diameter of camshaft bearings: - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54.875 to 54.930 mm (2.1604 to 2.1626 in.)

- center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54.375 to 54.430 mm (2.1407 to 2.1429 in.)

- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53.875 to 53.930 mm (2.1210 to 2.1232 in.)

Interference between bearings and seats in cylinder block . . . . . .

0.070 to 0.150 mm (0.0028 to 0.0059 in.)

Inside diameter of camshaft bearings (fitted and reamed): - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51.080 to 51.130 mm (2.0110 to 2.0130 in.)

- center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50.580 to 50.630 mm (1.9913 to 1.9933 in.)

- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50.080 to 50.130 mm (1.9716 to 1.9736 in.)

Diameter of camshaft journals: - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50.970 to 51.000 mm (2.0067 to 2.0079 in.)

- center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50.470 to 50.500 mm (1.9870 to 1.9882 in.)

- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49.970 to 50.000 mm (1.9673 to 1.9685 in.)

Clearance between camshaft journals and bearings . . . . . . . . . . .

0.080 to 0.160 mm (0.0031 to 0.0063 in.)

Max. permissible clearance (wear limit) . . . . . . . . . . . . . . . . . . . . . .

0.20 mm (0.0079 in.)

Camshaft endfloat between thrust plate and seat on camshaft . .

0.070 to 0.220 mm (0.0028 to 0.0087 in.)

mm (inches)

TAPPET DATA

TT55/TT75

Tappet bore in crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15.000 to 15.018 mm (0.5906 to 0.5913 in.)

Outside diameter of standard tappet . . . . . . . . . . . . . . . . . . . . . . . . .

14.950 to 14.970 mm (0.5886 to 0.5894 in.)

Tappet running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.030 to 0.068 mm (0.0012 to 0.0027 in.)

Max. permissible clearance (wear limit) . . . . . . . . . . . . . . . . . . . . . .

0.15 mm (0.0059 in.)

Tappet oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.1 - 0.2 - 0.3 mm (0.0039 - 0.0079 - 0.0118 in.)

10-10

SECTION 10 -- ENGINE -- CHAPTER 1 mm (inches)

ROCKER ARM - VALVE DATA

TT55/TT75

Diameter of shaft bores in rocker arms . . . . . . . . . . . . . . . . . . . . . .

18.016 to 18.034 mm (0.7093 to 0.7100 in.)

Diameter of rocker arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.982 to 18.000 mm (0.7070 to 0.7087 in.)

Rocker shaft to rocker arm bore clearance . . . . . . . . . . . . . . . . . . .

0.016 to 0.052 mm (0.0006 to 0.0020 in.)

Maximum permissible clearance (wear limit) . . . . . . . . . . . . . . . . . .

0.15 mm (0.006 in.)

Rocker arm spacing springs: - free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59.5 mm (2.3425 in.)

- length under load of 46 to 52 N (4.7 to 5.3 kg [10.3 to 11.7 lbs])

44.0 mm (1.7323 in.)

Valve clearance for timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.45 mm (0.0177 in.)

Valve clearance for normal running (engine cold): - inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 ± 0.05 mm (0.0118 ± 0.0020 in.)

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 ± 0.05 mm (0.0118 ± 0.0020 in.)

Cam lift: - inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.67 mm (0.223 in.)

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.95 mm (0.234 in.)

(*) installed on 4-cylinder engines only (TT75)

ROTATING COUNTERWEIGHT DYNAMIC BALANCER DATA

mm (inches)

Interference fit between bushings and seat in gear . . . . . . . . . . . .

0.063 to 0.140 mm (0.0025 to 0.0055 in.)

Clearance between intermediate gear journal and bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.050 to 0.100 mm (0.0020 to 0.0039 in.)

Interference fit between bushings and carrier . . . . . . . . . . . . . . . . .

0.063 to 0.140 mm (0.0025 to 0.0055 in.)

Clearance between gear shaft and bushings . . . . . . . . . . . . . . . . .

0.050 to 0.100 mm (0.0020 to 0.0039 in.)

Tooth backlash between splined sleeve, connecting drive box gear and counterweight drive gear . . . . . . . . . . . . . . . . . . . . . . . . . .

0.038 to 0.106 mm (0.0015 to 0.0042 in.)

Interference fit between front bushing and bore in housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.063 to 0.140 mm (0.0025 to 0.0055 in.)

Clearance between counterweight drive shaft and front bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.050 to 0.100 mm (0.0020 to 0.0039 in.)

Interference fit between rear bushing of counterweight drive gear and seat in carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.037 to 0.101 mm (0.0015 to 0.0040 in.)

Clearance between counterweight drive shaft and rear bushing . . .

0.013 to 0.061 mm (0.0005 to 0.0024 in.)

Interference fit between bushing and seat in counterweight . . . . .

0.040 to 0.100 mm (0.0016 to 0.0039 in.)

Clearance between counterweight rotation shaft and bushing . . . . .

0.020 to 0.073 mm (0.0008 to 0.0029 in.)

Interference fit between intermediate gear bushing and relative seat in housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.037 to 0.101 mm (0.0015 to 0.0040 in.)

Clearance between intermediate gear shaft and relative bushing . .

0.013 to 0.061 mm (0.0005 to 0.0024 in.)

Tooth backlash between meshed gears . . . . . . . . . . . . . . . . . . . . . .

0.080 mm (0.0031 in.)

10-11

SECTION 10 -- ENGINE -- CHAPTER 1

mm (inches)

CYLINDER HEAD DATA

TT55/TT75

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with valve seats cut directly in the casting and press-fitted steel valve guides.

Original height of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92.0 mm (3.62 in.)

Max. face re-grinding depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.5 mm (0.0197 in.)

Diameter of standard valve guide bores in head . . . . . . . . . . . . . . .

13.950 to 13.983 mm (0.5492 to 0.5505 in.)

Outside diameter of standard valve guides . . . . . . . . . . . . . . . . . . .

13.993 to 14.016 mm (0.5509 to 0.5518 in.)

Guide interference fit in bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.010 to 0.066 mm (0.0004 to 0.0026 in.)

Inside diameter of valve guide (fitted in head) . . . . . . . . . . . . . . . . .

8.023 to 8.043 mm (0.3159 to 0.3166 in.)

Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. 985 to 8.000 mm (0.3144 to 0.3150 in.)

Assembly clearance between valve stem and guide . . . . . . . . . . .

0.023 to 0.058 mm (0.0009 to 0.0029 in.)

Maximum permissible clearance (wear limit) . . . . . . . . . . . . . . . . . .

0.13 mm (0.0051 in.)

Maximum run-out of valve guided on its stem measured through 360_ with dial gauge contact point resting on valve head contact band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.03 mm (0.0051 in.)

Valve guide oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.20 mm (0.0079 in.)

Valve seat angle in head: - inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60o ± 5′

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45o ± 5′

Valve face angle: - inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60o 30’ ± 7′

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45o 30’ ± 7′

Valve head diameter: - inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45.300 to 45.500 mm (1.7835 to 1.7913 in.)

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37.500 to 37.750 mm (1.4764 to 1.4862 in.)

Valve stand-in relative to cylinder head face . . . . . . . . . . . . . . . . . .

0.7 to 1.0 mm (0.0276 to 0.0394 in.)

Max. permissible valve stand-in . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 mm (0.0512 in.)

Inlet and exhaust valve springs: - free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44.6 mm (1.7560 in.)

- length with valve closed, under load of 256 to 284 N (26.1 to 28.9 kg[57.4 to 63.5 lbs.]) . . . . . . . . . . . . . . . . . . . . . . . . .

34.0 mm (1.3386 in.)

- length with valve open, under load of 502 to 544 N (51.2 to 56.6 kg[112.6 to 124.5 lbs.]) . . . . . . . . . . . . . . . . . . . . . . .

23.8 mm (0.9370 in.)

Injector protrusion relative to head face (stand-out): D BOSCH injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 to 1.10 mm (0.0118 to 0.0433 in.)

D LUCAS injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.15 to 0.95 mm (0.0059 to 0.0374 in.)

10-12

SECTION 10 -- ENGINE -- CHAPTER 1 TIGHTENING TORQUE DATA PART

Thread size

Crankshaft hub retaining nut . . . . . . . . . . . . . . . . . . . . . . . . .

Tightening torque Nâ&#x2039;&#x2026;m

kgm

ft. lbs.

M 30 x 1.5

294

217

Fan and alternator pulley bolts . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

5.6

40.5

Additional counterweight retaining bolts . . . . . . . . . . . . . . . .

M 12 x 1.25

110

11.2

Inlet manifold retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . .

2.6

Alternator and belt tension adjustment nut . . . . . . . . . . . . . .

M 10 x 1.25

5.6

40.5

Coolant pump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

5.6

40.5

Nuts for injector mounting studs . . . . . . . . . . . . . . . . . . . . . .

25 (*)

2.6 (*)

Rocker cover nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5

Rocker shaft pedestal bolts . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6

Oil pump and pump cover retaining bolts . . . . . . . . . . . . . . .

2.6

Timing gear case and cover bolts

2.6

Intermediate flanged journal bolts . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

5.6

40.5

Camshaft thrust plate retaining bolts . . . . . . . . . . . . . . . . . .

3.6

Rear crankcase cover bolts

.........................

2.6

Tappet adjuster locknuts . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

Exhaust manifold retaining bolts . . . . . . . . . . . . . . . . . . . . . .

2.6

Injection pump mounting bolts . . . . . . . . . . . . . . . . . . . . . . . .

2.6

Sump pan retaining bolts to - inner rear timing cover and gear case . . . . . . . . . . . . . . . . - cylinder block and flywheel case . . . . . . . . . . . . . . . . . . . .

M 10 X 1.25 M 10 X 1.25

39 to 49 49 to 59

4 to 5 5 to 6

29 to 36 36 to 44

....................

(*) Tighten nuts in two stages.

ANGULAR TORQUE DATA Preliminary torque PART

Th d size Thread i

Cylinder head bolts . . . . . . . . . . . . . .

A l Angle

Nâ&#x2039;&#x2026;m

kgm

ft. lbs.

M 12 x 1.25

7.1

90o + 90o

Main bearing cap bolts . . . . . . . . . . .

M 14 x 1.5

8.2

90o

Big-end rod cap bolts . . . . . . . . . . . .

M 11 x 1.5

4.1

60o

Flywheel mounting bolts . . . . . . . . . .

M 12 x 1.25

4.1

60o

10-13

SECTION 10 -- ENGINE -- CHAPTER 1 ENGINE SPECIAL TOOLS

WARNING The operations described in this section can only be carried out with the essential tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools which are to be made according to the drawings included in this manual. List of specific tools required for the various operations described in this section. X 380000226 Puller for crankshaft pulley hub. X 380000232

Wrench for valve clearance adjustment.

X 380000219

Drift for valve guide extraction/ installation.

X 380000246

Set of grinding tools for regrinding injector seat.

X 380000223

Puller for coolant pump impeller.

X 380000247

Drift for installation of coolant pump impeller seal.

293830

Adaptor for injector removal (with 380000549).

380000617

Dummy injector

380000829

Injector sleeve tap

380000832

Injector sleeve extractor

380000830

Injector sleeve guide bush

380000831

Injector sleeve reamer

380000833

Injector milling cutter

Injection pump bench test

380000612

Centering tool

380000304

Flywheel bolt tightening tool

380000228

Dial gauge (1/100mm scale, 5 mm stroke, â&#x2C6;&#x2026; 40mm with 380000229).

X 380000276

Twist bit for enlarging valve guide bore.

380000229

Device for BOSCH injection pump timing on engine.

X 380000277

8Â° Tapered grinder for swaging exhaust valve guides.

X 380000835

X 380000242

Bush for valve guide installation (with 380000219)

292411

X 292177

Valve guide reamer

10-14

Extractor for injection pump drive gear. Device for CAV injection pump timing

SECTION 10 -- ENGINE -- CHAPTER 1 Mounting for engine lifting hook (No. 50075 measurements in mm). Material UNI C40.

26101

1 Splining tool for assembling the crankshaft front seal (print on the tool no. 50138 - values in mm). Material UNI C40.

26102

2 Splining tool for assembling the crankshaft rear seal (print on the tool no. 50139 - values in mm). Material UNI C40.

26103

10-15

SECTION 10 -- ENGINE -- CHAPTER 1 ENGINE SECTIONAL VIEWS

1 2

7 6

25355

4 1. 2. 3. 4.

Rocker Shaft Pedestal Bolts Cylinder Head Bolts Flywheel Mounting Bolts Main Bearing Cap Bolts

Longitudinal section of 3-cylinder model (TT55) 5. Big-end Cap Bolts 6. Fan and Alternator Pulley Bolts 7. Crankshaft Hub Retaining Nut

10-16

SECTION 10 -- ENGINE -- CHAPTER 1

4 5

1 25356

5 1. 2. 3. 4.

Oil Pan Hydraulic Pump Fuel Injection Pump Engine Air Intake

Cross-section of 3-cylinder model (TT55) 5. Engine Exhaust 6. Engine Oil Filter 7. Breather 8. Oil Pan Dipstick

10-17

SECTION 10 -- ENGINE -- CHAPTER 1

1 2

5 6

6 1. 2. 3. 4.

Rocker shaft pedestal bolts Cylinder head bolts Flywheel mounting bolts Main bearing cap bolts

Longitudinal section of 4-cylinder model (TT75) 5. Big-end cap bolts 6. Fan and alternator pulley bolts 7. Crankshaft hub retaining nut

10-18

SECTION 10 -- ENGINE -- CHAPTER 1

25358

7 1.

Cross-section of 4-cylinder models (TT75) Balancer assembly mounting bolts

10-19

SECTION 10 -- ENGINE -- CHAPTER 1

20035281

8 1. 2. 3. 4.

Lubrication system of 3-cylinder engine (TT55) Oil filler cap 5. Oil filler cap Filter safety valve (opens when oil pressure at 6. Pump filter inlet exceeds the pressure at the outlet by 7. Oil pressure limiting valve 1.5 -- 1.7 bar) 8. Screen filter on pick-up pipe Filter Switch for low engine oil pressure warning (on dashboard)

10-20

SECTION 10 -- ENGINE -- CHAPTER 1

20035282

9 1. 2. 3. 4.

Lubrication system of 4-cylinder engine (TT75) Oil filler cap 5. Oil filler cap Filter safety valve (opens when oil pressure at 6. Pump filter inlet exceeds the pressure at the outlet by 7. Oil pressure limiting valve 1.5 -- 1.7 bar) 8. Screen filter on pick-up pipe Filter Switch for low engine oil pressure warning (on dashboard)

10-21

SECTION 10 -- ENGINE -- CHAPTER 1 c 1

3 4

25363

6 d

1 2 3 4

25364

10 a. b. c. d. 1.

Engine cooling system Coolant circulation with thermostat valve closed 2. Coolant pump Coolant circulation with thermostat valve open 3. Electric thermometer for engine coolant temperature 3-cylinder models (TT55) 4. Temperature sender 4-cylinder models (TT75) 5. Fan Thermostat 6. Radiator

10-22

SECTION 10 -- ENGINE -- CHAPTER 1 ENGINE REMOVAL

DANGER Lift and handle all heavy parts using suitable lifting equipment. Ensure to support load by means of suitable slings and hooks. Ensure no-one is standing in the vicinity of the load to when lifting.

CAUTION Always use suitable tools to align holes in parts. NEVER USE YOUR FINGERS OR HANDS.

Before removing engine: • Disconnect the negative lead (1), from the battery. •

Drain oil from the transmission/gearbox.

•

Drain liquid from cooling system. 40035227

11 On FWD Models:

1. Remove the circlip (2), and slide the sleeve (1) in the direction shown by the arrow until free of the splines on the front axle.

25039

12 2. Remove the circlip (2) and slide the sleeve (1) in the direction shown by the arrow until it is free of the spines on the drive shaft.

2 25040

10-23

SECTION 10 -- ENGINE -- CHAPTER 1 3. Remove the retaining bolts from the central drive shaft support (1) and remove the shaft complete with support.

1 25041

14 Splitting the tractor 1. Disconnect the negative battery lead if not previously done.

2. Place wedges between the front axle and the front axle carries to prevent the assembly from tilting. 3. Disconnect the tractor electrical harnesses. 4. Remove the exhaust pipe and right and left middle hood sections. 5. Remove the steering lines tubes. 6. Remove the suction line from the hydraulic reservoir and cap the reservoir port. 7. Remove the throttle linkage (1) from the injection pump and from the mounting point under rear hood. 8. Disconnect the fuel delivery line from the primer pump and the return line from the tee. 9. Remove bolts holding â&#x20AC;&#x153;Fire Wallâ&#x20AC;? to engine. 10. Remove the hydraulic lift suction and delivery lines from the hydraulic pump. 11. If there is a horizontal exhaust, disconnect or remove exhaust line and muffler. 12. On four-wheel drive tractors, disconnect and drop the front axle driveshaft. 13. Place a hydraulic stand under the clutch transmission case and attach lifting tackle to the engine. 14. Unbolt the engine from the transmission case. 15. Using a crane, separate the engine from the rest of the tractor.

10-24

40035234

SECTION 10 -- ENGINE -- CHAPTER 1 16. Insert centralizer tool (1) 380000612 in the clutch center hole. Unscrew the six bolts securing the clutch to the flywheel and remove complete clutch assembly.

25057

2 16

ENGINE REINSTALLATION

•

Attach the adjustable lifting chain to the eyebolts on the engine.

•

Place wooden wedges under the rear wheels, check that the handbrake is fully on and that the fixed and moving stands are firmly in place.

•

The next operation will require 2 or 3 operatives. Position the engine/front axle unit up to the clutch housing, pushing the front wheels and accompanying the unit with the hoist. Be careful at this stage not to damage the rigid hydraulic oil pipes. Make sure that no electrical leads are trapped between the two units.

To re-install the engine, proceed as follows: •

Attach the three hooks of an adjustable lifting chain to three eye bolts on the engine. Raise the engine from the platform and position it in front of the front axle support. Join the two units using the four securing bolts.

•

Move a rolling jack under the engine sump.

•

Drive wedge blocks between front axle carrier casting and front axle housing.

•

Attach the top radiator hose to the thermostat housing and secure with adjustable hose clamps.

•

Connect the bottom radiator hose to the coolant pump and secure at both ends with adjustable hose clamps.

Next, turn the cooling fan to rotate the clutch disc so it engages with the two shafts of the PTO and transmission.

•

Replace and tighten all the bolts securing the engine to the clutch housing.

•

Install the hydraulic pumps.

•

Detach the lifting chain from the engine.

Lower the stands under the engine sump and the clutch housing.

•

Connect the rigid pipe from the air cleaner to the inlet manifold and secure with the relative clamp.

•

Connect the injector leak-off pipe. Connect the pipes to the glowplug and to the fuel water separator filter.

•

Reconnect all electrical leads: thermostarter glow plug, coolant temperature sensor, air filter clogging sensor, horn, front axle support ground, engine stop on injection pump, leads to the alternator and relay, oil pressure sensor, and starter motor. Secure all leads with plastic ties.

•

Install the fuel filter mounting to the engine. Connect the two semi-rigid pipes to the mounting.

•

Connect the power steering at control valve oil supply and return pipes.

•

Connect the hydraulic oil suction pipe to the pump.

•

Install the clutch using tool 380000612. Fix clutch to the engine flywheel using the six retaining bolts.

10-25

SECTION 10 -- ENGINE -- CHAPTER 1 •

Connect the rigid lift control valve supply pipe to the hydraulic pump, remembering to first fit the O-ring.

•

Reinstall the 4WD transmission shaft and the guard.

•

Secure the two pipes with the adjustable hose clamp.

•

Re-connect the throttle rod to the accelerator mechanism.

•

Connect up all the electrical leads to the connectors.

•

Replace the fan guards.

Connect the two flexible power steering pipes to the union on the right-hand side of the front axle. Secure the two pipes with a special clamp and fix the clamp to the tractor with a screw.

•

Reinstall the front ballast and secure with the lock pin.

•

Fill the transmission/gearbox/power steering bottle with oil.

•

Fill the radiator with coolant mixture.

•

Connect the positive and negative battery leads.

•

Install the tachometer cable and secure the sleeve with the retaining ring.

10-26

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

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes. After removing all relative guards, shields and parts mounted to the engine in the tractor and the engine is â&#x20AC;&#x153;freeâ&#x20AC;? proceed as follows: 1. Loosen the alternator pivot bolt.

2. Loosen the belt tension adjustment bolt (1). 3. Release the belt tension adjustment arm by undoing the retaining nut. 4. Remove the alternator and coolant pump drive belt.

25072

17 5. Unscrew the bolts securing the fan (1) and pulley to the coolant pump and remove the fan and pulley.

1 25073

18 6. Remove the union in order to gain access to the pump retaining bolt.

25077

10-27

SECTION 10 -- ENGINE -- CHAPTER 1 7. Unscrew the coolant pump retaining bolts (1) and remove the pump.

25076

20 8. Unscrew the pump support bolts (1), the internal support bolt and remove the support.

25078

21 9. Loosen the alternator support retaining bolts (1) and remove the complete alternator assembly.

25081

1 22

10-28

SECTION 10 -- ENGINE -- CHAPTER 1 10. Unscrew the bolts (1) securing the exhaust manifold to the cylinder head and remove the manifold.

25082

23 11. Remove the thermostat housing retaining bolts (1) and remove the thermostat housing.

25084

24 12. Unscrew the high pressure fuel line unions (1) on the injection pump and remove the fuel lines.

25085

10-29

SECTION 10 -- ENGINE -- CHAPTER 1 13. Unscrew the bolts (1) securing the inlet manifold to the cylinder head and remove the manifold.

25086

26 14. Unscrew the unions (1) on the fuel supply pump and detach the fuel lines.

25087

10-30

SECTION 10 -- ENGINE -- CHAPTER 1 15. Loosen screws (1) and remove the injection pump drive gear cover.

25089

28 16. Unscrew the nuts (1) securing the injection pump to the timing gear case.

25088

29 17. Unscrew the nut (1) securing the injection pump shaft to the drive gear.

25090

10-31

SECTION 10 -- ENGINE -- CHAPTER 1 18. Remove the injection pump drive gear using tool 380000835 (1) and recover the injection pump and the woodruff key.

25091

31 19. Disconnect the fuel line unions (1) on the fuel filter.

10036159

32 20. Remove the bolts securing the fuel filter support to the engine block and remove the complete filter assembly (1).

10036159

10-32

SECTION 10 -- ENGINE -- CHAPTER 1 21. Drain and remove steering system reservoir (1) and tubes (2). The tube to the steering pump not shown.

1 2

10036136

34 22. Remove the power steering tubes (1) and remove the power steering pump (2). 23. Remove spacer, gasket and the pump drive connector.

10035297

35 24. Remove tubes (1) to the high-pressure (lift) pump. Cap and plug all openings to prevent contamination.

25. Remove the mounting bolts and then remove the pump (2) and filter (3) as one assembly.

10035297

3 36

10-33

SECTION 10 -- ENGINE -- CHAPTER 1 26. Unscrew the retaining nuts (1), remove the fuel pump support complete with the hydraulic pump and recover the gasket.

1 25094

37 27. Remove the cover (where installed), then remove the starter motor solenoid (2) connectors and then the starting motor (1) retaining bolts. Remove the starter and solenoid assembly together.

20035283

38 28. Remove the injector mounting nuts, the underlying spherical washers, then the supports and the injectors themselves.

29. Remove the rocker cover bolts (1), washers and seals, and then the rocker cover and its gasket.

2 25098

10-34

SECTION 10 -- ENGINE -- CHAPTER 1 30. Remove the rocker shaft retaining bolts (2), then remove the entire rocker shaft assembly (1).

25099

40 31. Remove the valve collets (1) and withdraw the pushrods (2).

25100

41 32. Unscrew the cylinder head bolts (1) and remove the head using a hoist and lifting hook. 33. Remove the cylinder head gasket.

25101

1 42

10-35

SECTION 10 -- ENGINE -- CHAPTER 1 34. Unscrew the sump pan retaining bolts (4) and remove the sump pan using a hoist, lifting hook and lifting chain with eyeholes.

35. Remove the half-gaskets (1) and (3) between the crankcase and sump pan and the gasket (2) between the timing gear carrier and sump pan.

4 3 25104

43 36. Remove the gasket (1) between the crank seal carrier and the sump pan. NOTE: When relocating gasket, 1, Fig. 41, apply high temperature silicone sealing compound to the mating surfaces.

25105

44 NOTE: Steps 34, 35, 36 are to be carried out on 4-cylinder models only (TT75). For dismantling-assembly of the rotating counterweight dynamic balancer, refer to steps 58 to 66.

37. Turn the engine upside down on the rotary stand. Remove the sump pan bolts, the sump pan (1) and its gasket (2).

25102

2 45

10-36

SECTION 10 -- ENGINE -- CHAPTER 1 38. Unscrew the retaining bolts and remove the oil pick-up pipe (1) complete with the strain filter and seal.

39. Unscrew the retaining bolts (2), and detach the counterweight housing (3) by moving it outward, remove the sleeve coupling (4) and the housing (3).

25103

2 46

40. Remove the rotating counterweight oil seal O-ring (1) installed on the crankcase mating surface.

25106

47 41. Unscrew retaining bolts (1) and remove the complete oil pump unit.

25107

10-37

SECTION 10 -- ENGINE -- CHAPTER 1 42. Unscrew the retaining bolts (2) and remove the crankshaft pulley (1).

2 25108

49 43. Straighten the lock tab, then hold the crankshaft against rotation and unscrew nut (1).

1 25109

50 44. Pull the pulley hub off the crankshaft using tool 380000226 (1) and recover the woodruff key.

1 25110

10-38

SECTION 10 -- ENGINE -- CHAPTER 1 45. Unscrew the retaining bolt (1) and remove the timing cover and gasket.

25111

52 46. Unscrew the retaining bolts and remove the lift pump drive gear carrier (1).

25112

53 47. Remove the circlip (1) and recover the thrust washer and the intermediate gear (2).

NOTE: When installing the intermediate gear, see Synchronizing the Timing Gears.

25113

10-39

SECTION 10 -- ENGINE -- CHAPTER 1 48. Unscrew the retaining bolts (1) and remove the intermediate gear journal.

25114

55 49. Unscrew retaining bolts (4) and withdraw the camshaft (2) complete with the camshaft gear (1) and the end plate (3).

4 3

25115

56 50. Remove circlip (1) and the thrust washer, and remove the gear with fuel supply pump camshaft (2) from the opposite side.

NOTE: This gear transmits drive to the injection pump. On re-assembly, see Synchronizing the Timing Gears.

2 25108

10-40

SECTION 10 -- ENGINE -- CHAPTER 1 51. Unscrew bolts (1) and remove the timing gear case.

25109

58 52. Replace the O-ring seal (1) installed in the lift pump drive shaft lubrication line. 53. Remove the crankcase - timing gear case gasket.

25118

59 54. Rotate the engine on the stand 90_. Unscrew the big-end cap bolts (2) and recover the big-end caps (1) with their half shell bearings.

2 25119

10-41

SECTION 10 -- ENGINE -- CHAPTER 1 55. Slide the pistons (1), complete with rings, gudgeon pins and connecting rods, out of the cylinder liners.

1 25108

61 56. Rotate the engine on the stand 90_ back to the horizontal position. Unscrew the flywheel bolts and remove the flywheel with the aid of a hoist and hook.

57. Unscrew retaining bolts and remove the rear oil seal carrier (1) complete with gasket.

25109

10-42

SECTION 10 -- ENGINE -- CHAPTER 1 58. Unscrew the main bearing cap bolts (1) and remove the main bearing caps with relative bearing shells, and recover the thrust washers located on the penultimate main bearing as shown in the figure. 59. Lift the crankshaft clear of the crankcase using a hoist and nylon sling. Recover the bearing shells, thrust washers and tappets.

60. Unscrew retaining bolts and remove the rear crankcase housing and gasket. 25122

63 NOTE: The following instructions on dismantling of the rotating counterweight dynamic balancer only apply to 4-cylinder models (TT75).

61. Remove the lubricating oil pipe (3). 62. Remove circlip (18). 63. Remove circlip (25) and cover (23) with relative O-ring seal (24). 64. Withdraw gear (22) from sump. 65. Remove circlip (2), gear (26) and the two thrust washers (1). 66. Inspect shaft (27). If it shows signs of scoring or wear it must be replaced. 67. Withdraw spring pins (8) and dismantle the counterweight shafts using a suitable drift. 68. Remove the counterweight drive gear (1) Fig. 61 by removing the circlip (5) and the carrier retaining bolts (6). 69. Remove circlip (3) and intermediate gear (4).

10-43

4 5

25159

SECTION 10 -- ENGINE -- CHAPTER 1

7 8

28 27 26 25 24 23 25160

22 21 11 20 19 18 17 16 15 14 13 12

65 Sectional view of dynamic balancer 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Thrust washers. Circlip. Lubricating oil pipe for bushing (28). Counterweight rotation shaft. Shaft retaining spring pin. Carrier for counterweight drive gear (13). Thrust washer. Counterweight. Counterweight intermediate gear. Bolts securing counterweight housing to sump. Circlip. Counterweight housing. Counterweight drive gear. Screen filter.

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

10-44

Screen filter retaining bolt. Bushing. Rigid coupling sleeve. Circlip. Thrust washer. Carrier for gear (22). Thrust washer. Counterweight drive gear. Cover. O-ring seal. Circlip. Intermediate gear. Shaft for gear (26). Bushing.

SECTION 10 -- ENGINE -- CHAPTER 1 ENGINE -- Assembly • • • •

After dismantling the engine, clean all parts carefully. To re-assemble the engine, carry out the dismantling operations described earlier in reverse order. The following pages concern those assembly operations requiring particular attention. Tightening torques are at the end of the specifications section.

IN ADDITION, MAKE SURE TO: • • •

Replace all seals and gaskets at each complete or partial engine rebuild. Lubricate all rotating parts and oil seals with engine oil before to installation. Lubricate the oil filter mounting seal before installing the filter.

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes.

MOUNTING THE BALANCING DEVICE WITH COUNTER-ROTATING WEIGHTS

(Disassembly Steps 58 to 66) Proceed as follows: •

Assemble counterweight parts in the housing (2) carrying out dismantling Steps 64 to 66 in reverse order. Align the positioning marks on the gear (4) and counterweights (1) (indicated by arrows).

•

The intermediate gear (3) must be installed with the longer side of its hub towards the casing side;

24913

2 66

• •

The holes for the lock pins (1) in the counterweight shafts (2) must be aligned with corresponding holes in the casing. Install the counterweight assembly on the sump carrying out disassembly Steps 58 to 63 in reverse order.

24914

10-45

SECTION 10 -- ENGINE -- CHAPTER 1 MOUNTING THE TAPPETS AND DRIVE SHAFT WITH MAIN BEARING CAPS, BEARINGS AND THRUST RINGS; CHECKING AXIAL PLAY OF DRIVE SHAFT (Disassembly Steps 55 to 56) Proceed as follows: •

Install the tappets in their crankcase bores.

•

Lubricate the main bearing seats with engine oil and install the half shell bearings (3).

•

Stick the semi-circular thrust washers to both sides of the penultimate main bearing with grease.

•

25109

Lubricate the upper surfaces of the main bearing shells with engine oil and lower the crankshaft (1) into position taking care not to dislodge the semi-circular thrust washers installed previously.

24718

69 •

Lubricate the crankshaft journals with engine oil and fit the main bearing caps (3) with the half-shells (4), fitting the top semi-circular thrust washers (2) to the penultimate bearing cap.

•

Rotate the crankshaft (1) a few times to allow the parts to settle into position.

•

Insert the main bearing cap bolts and screw in until the head of the bolt is up against the cap.

25108

10-46

SECTION 10 -- ENGINE -- CHAPTER 1 •

Tighten all cap bolts (1) to a torque of 80 N⋅m (59 ft. lbs.).

24720

71 •

Tighten each cap bolt (1) through 90o.

24744

72 •

Check that crankshaft endfloat does not exceed the specification.

24760

10-47

SECTION 10 -- ENGINE -- CHAPTER 1 MOUNTING THE REAR COVER WITH SEAL, AND ENGINE FLYWHEEL

Proceed as follows: • Install the rear oil seal carrier (3) with the outer seal. Tighten retaining bolts (2) to the torque specifications. Using a feeler gauge (1), check that crankshaft flange is coaxial with the carrier. NOTE: Tightening the two pan bolts that thread into the rear oil seal carrier can pull the seal from coaxial alignment with the crankshaft flanges. After torquing the two pan bolts to 6 N⋅m (4.4 ft. lbs.), it may be necessary to remove the flywheel and check the coaxial clearance of the seal to the crankshaft flange. •

3 2

24752

Install the inner rear oil seal using installer supplied with the seal.

24761

10-48

SECTION 10 -- ENGINE -- CHAPTER 1 •

Install the flywheel and tighten retaining bolts (1) to a torque of 40 N⋅m (4.1 kgm [29.5 ft. lbs.]).

24762

76 •

Using a proper tool, tighten each flywheel bolt (2) through a further 60o.

24763

10-49

SECTION 10 -- ENGINE -- CHAPTER 1 MOUNTING THE PISTONS COMPLETE WITH RINGS, PINS, CONNECTING RODS, BIG END CAPS AND BEARINGS CHECKING PROTRUSION IN RELATION TO CYLINDER BLOCK FACE Proceed as follows: •

Lubricate pistons, rings and cylinder liners with engine oil prior to fitting.

•

Install the piston rings using piston ring pliers. Make sure that the piston ring gaps are offset at 180o apart.

•

Install piston ring clamp (1) to compress the rings, making sure that the piston ring gaps remain in the positions specified in the previous point.

•

Insert the piston/connecting rod into the cylinder liner, checking that the connecting rod number corresponds with the cylinder number and that the number stamped on the connecting rod is facing away from the camshaft.

•

25163

Install the big-end caps (2) complete with shells to the crankpins and tighten the cap bolts (1) to a torque of 40 N⋅m (4.1 kgm [ 29.5 ft. lbs.]).

25164

10-50

SECTION 10 -- ENGINE -- CHAPTER 1 â&#x20AC;˘

Using a proper tool (1), tighten each big-end cap bolt (2) through a further 60o.

25165

80 â&#x20AC;˘

Rotate the engine on the stand 180o and clean the upper face of the cylinder block. Bring the pistons (2) up to TDC and, using a dial gauge with a magnetic base (1), check that the piston protrusion from the cylinder block face is within the tolerance specifications.

25166

10-51

SECTION 10 -- ENGINE -- CHAPTER 1 SYNCHRONIZING THE TIMING GEARS Proceed as follows: •

Remove the cover of the flywheel housing inspection window and gasket.

25167

82 •

Turn the drive shaft to bring cylinder No. 1 to TDC (compression stroke). Look through the inspection window to check that the notch in degrees aligns with the index mark, according to the type of pump installed on the tractor.

NOTE: PMS = TDC.

26107

83 •

Install the timing gears with the various reference marks aligned (indicated by the arrows in the figure).

25169

10-52

SECTION 10 -- ENGINE -- CHAPTER 1 REINSTALLING THE COUNTER-ROTATING WEIGHT BOX TO THE OIL SUMP When installing the counter-rotating weight box, synchronise as follows: •

Bring piston no. 1 to TDC.

•

Position the rotating counterweights so that the timing reference marks are aligned (as shown in the figure).

25170

85 •

Turn the rotating counterweight unit over and insert the locating pin (2) in its hole. The pin holds the counterweights in the correct timing position during installation of the unit.

•

Using the hoist and a lifting chain, lower the counterweight unit onto its seatings in the sump.

25171

86 •

Slide the coupling sleeve (1) over the splines of the counterweight drive gear.

•

Slide the other end of the coupling sleeve (1) over the toothed shaft of the counterweight drive box gear, so that the upper toothed parts coincide with the large gap between the teeth on the shaft (3).

•

Tighten the dynamic balancer housing retaining bolts (1) Fig. 84 to the torque specifications.

25172

10-53

SECTION 10 -- ENGINE -- CHAPTER 1 REINSTALLING THE INJECTION PUMP •

Install the injection pump and proceed with the injection pump timing in the manner described later in this section.

2 25181

INSTALLING THE CYLINDER HEAD GASKET

Proceed as follows: •

Before fitting the cylinder head, carefully clean and degrease the mating surface of the cylinder block. Locate the cylinder head gasket (1) with the word ALTO uppermost.

25173

10-54

SECTION 10 -- ENGINE -- CHAPTER 1 Cylinder head bolts (2, Fig. 4 and 1-6) If the bolts are to be re-used, check that diameter d (measured in area a shown in the figure) is greater than 11.5 mm (0.45 in.); if not, use new bolts.

25343

INSTALLING AND TIGHTENING THE CYLINDER HEAD Proceed as follows: •

Lower the cylinder head onto the block and screw in the cylinder head bolts (1) Fig. 84 so that their heads are brought into contact with the cylinder head.

•

Tightening sequence for cylinder head bolts (1) Fig. 90 on 3-cylinder engines to be followed for each of the four tightening stages (A = fan end).

25174

10-55

SECTION 10 -- ENGINE -- CHAPTER 1 •

Tightening sequence for cylinder head bolts (1, Fig. 90) on 4-cylinder engines to be followed for each of the four tightening stages (A = fan end).

25175

92 •

Tighten the bolts (1) to a torque of 70 N⋅m (7.1 kgm [52 ft. lbs]) in the sequence indicated above (1st stage).

•

Check the torque of all the bolts in the sequence indicated above (2nd stage).

25176

93 •

Using an angular tightening tool (1), tighten each bolt (2) in sequence through 90o (3rd stage) and then through a further 90o (4th stage) in the sequence indicated above.

2 25177

10-56

SECTION 10 -- ENGINE -- CHAPTER 1 ADJUSTING VALVE/ROCKER ARM CLEARANCE •

Before installing the rocker cover, adjust the valve clearances as described later in this section.

•

Tighten the rocker arm adjuster screw locknuts (1) to the torque specifications.

25178

INSTALLING THE INJECTORS Proceed as follows: •

Insert the injectors (2) in their respective bores.

•

Position the injector support brackets and fit the spherical washers.

•

Screw the bracket retaining nuts (1) up to the spherical washers, then tighten to the torque specified in two stages: 1st stage - tighten nuts to 10 N⋅m (1 kgm [7.4 ft. lbs.]); 2nd stage - tighten nuts to 25 N⋅m (2.6 kgm [18.4 ft. lbs.]).

•

Tighten the leak-off pipe unions.

•

Tighten the high-pressure fuel line unions.

10-57

1 2 25179

SECTION 10 -- ENGINE -- CHAPTER 1 CHECKS, DIMENSIONS AND REPAIRS CYLINDER BLOCK AND CYLINDER LINERS

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes. Clean all parts carefully before proceeding with the operations described below. NOTE: Cylinder liner dimensions must only be measured when the liner is installed in the cylinder bore as they are subject to deformation when not fitted. Check liner wear as follows: •

Measure the inside diameter in the area swept by the piston rings X (Fig. 96);

•

Measure the inside diameter at the upper and lower ends of this area both parallel to the crankshaft center line (a) and perpendicular to the crankshaft center line (b);

•

Compare measurements thus determine liner ovality and taper.

obtained

To check piston running clearance, measure the I.D. of each liner in the area Z (Fig. 96) only along the axis perpendicular to the crankshaft center line. If ovality or taper exceed 0.12 mm (0.005 in.) or piston coupling play exceeds 0.3 mm (0.012 in.), rebore and grind (or change) the liners, to bring them up to one of the sizes shown in the specifications. Pair up the cylinder liners with the pistons of the same dimensions. NOTE: if one of the liners is rebored, all of the liners in the engine must also be rebored to the same oversize. After reboring, the 0.5 mm (0.020 in.) 30_ chamfer must be restored on the liner (1). In case of replacement, remove and install the liners in cylinder block cold using a press as follows:

25307

1 97

10-58

SECTION 10 -- ENGINE -- CHAPTER 1 •

Press the worn liner out of the block operating from the bottom of the crankcase using the appropriate plate.

•

Check the ovality of the bore in the block and rebore if necessary to 0.22 mm (0.0087 in.) oversize.

•

Press-fit the new liner (0.22 mm [0.0087 in.] oversize if necessary) from the top of the block, using the appropriate plate.

•

Rebore and ream the liner to the specified inside diameter.

25308

20035284

99 Standard dimensions (mm) of cylinder liners and bores in cylinder block and positions for checking liner wear. a,b. Perpendicular positions of dial gauge to measure liner inside diameter. c. Models TT55 and TT75. C. Dimension to obtain after press-fitting and reaming of liner. Z. Area for measurement of inside diameter of used liner to determine piston running clearance (measured along axis b perpendicular to crankshaft).

X. Area for measurement of inside diameter of worn liner (area swept by piston rings) to determine ovality and taper (measure along axes a and b, respectively parallel and perpendicular to crankshaft). 1,2,3. Points at which to measure inside diameter of new or rebored liners along axes a and b.

10-59

SECTION 10 -- ENGINE -- CHAPTER 1 CRANKSHAFT, MAIN BEARINGS AND FLYWHEEL

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes.

Crankshaft Clean parts carefully before proceeding with operations described below. Carefully inspect the crankshaft. Any cracks, even minor ones, will necessitate replacement of the crankshaft. Inspect the crankshaft journals and crankpins; slight scoring or seizure marks can be removed with very fine grade emery cloth. If scoring, ovality or taper exceeds 0.05 mm, the crankshaft will have to be reground. Measure journal diameter to determine the nearest undersize. After regrinding, restore the journal and crankpin rounds and fillets as shown in the details in Fig. 98 and check that: 25311

â&#x20AC;˘

Main bearing journal and crankpin ovality does not exceed 0.008 mm;

â&#x20AC;˘

Main bearing journal and crankpin taper does not exceed 0.01 mm;

10-60

100

SECTION 10 -- ENGINE -- CHAPTER 1

B c c

25312

25313

101 Standard dimensions (mm) of main bearing journals and crankpins, main bearings and semi-circular thrust washers. A. Models TT55. B. Model TT75. c. Crankpin rounds and fillets.

d. e.

10-61

Normal crankshaft journal rounds and fillets. Rounds and fillets of crankshaft journal with thrust washers.

SECTION 10 -- ENGINE -- CHAPTER 1 •

With the crankshaft resting on parallel gauge blocks, the maximum misalignment of the main bearing journals cannot exceed 0.10 mm (0.004 in.) (D, Fig. 99);

•

The centerlines of the crankpins (TT55) or of each pair of crankpins (TT75) should lie in the same plan as the main bearing journal centerlines, with a maximum deviation of 0.25 mm (0.010 in.) as measured perpendicularly to the same plane (see Fig. 99);

•

The distances between the outer surfaces of the crankpins and the crankshaft centerline should be equal with a tolerance of  0.10 mm (0.004 in.);

•

The run-out measured with the dial gauge contact point resting on surface (A) or (B) cannot exceed the value specified : A - 0.025 mm (0.0010 in.) B - 0.040 mm (0.0010 in.)

•

The oil plugs seal against an oil pressure of 14.7 bar (15 kg/cm2 [213 psi]);

•

If new plugs are fitted, punch-lock in position and re-check oil tightness with the system pressurised.

b A

25314

a 25315

102 Maximum tolerances for alignment of main bearing journals and crankpin relative to crankshaft centerline and alignment of crankpins relative to main bearing journals (a). b. Models TT55. c. Model TT75. A. and B. Dial gauge contact point positions for checking run-out of flywheel mounting flange.

D. Maximum permissible main bearing journal alignment deviation.

10-62

SECTION 10 -- ENGINE -- CHAPTER 1 Bearings Check the clearance between the crankshaft journals and bearing shells using a calibrated wire gauge as follows: •

Make sure that all parts are perfectly clean and remove all traces of oil;

•

Locate the half-shells in their respective seats (5);

•

Install the crankshaft;

•

Position lengths of calibrated wire (6) on the crankshaft journals (4) in correspondence with the crankshaft centerline.

•

Fit the caps (1) complete with half-shells (2) to the respective journals;

•

Lubricate the screws fixing the main bearing caps with engine oil and tighten them to the prescribed torque using a torque wrench;

2 3

5 25316

103

Main bearing cap bolts (4, Figs. 1-4 and 1-6) If the bolts are to be re-used, check that diameter d (measured in area a shown in the figure) is greater than 13.5 mm (0.53 in.); if not, replace the bolts.

25318

104 •

Remove the caps and determine the bearing clearance by comparing the width of the calibrated wire at the widest point against the scale printed on the packet (3) containing the wire Fig. 100;

•

After installing the crankshaft and the bearing caps and bolts, check crankshaft endfloat about the penultimate bearing with a dial gauge (1);

•

If the endfloat exceeds the specified value, replace the existing thrust washers with oversizes ones.

25317

1 105

10-63

SECTION 10 -- ENGINE -- CHAPTER 1 Flywheel If the bolts are to be re-used , check that diameter d (measured in area a shown in the figure) is greater than 11.5 mm (0.45 in.), if not, replace the bolts. The flywheel is fixed to the crankshaft flange by means of self-locking bolts. The starter ring gear is force-fitted after pre-heating to the register on the engine side of the flywheel. If the ring gear is to be replaced, heat in oil to 80o to 90o C (176o to194o F) before fitting and position with the bevel on the teeth facing inward towards the starter motor. The flywheel mounting holes are offset so that the flywheel can only be mounted in one position. â&#x20AC;˘

Lubricate with engine oil the screws fixing the engine flywheel, and tighten them to the prescribed torque using a torque wrench;

10-64

25318

106

SECTION 10 -- ENGINE -- CHAPTER 1 CONNECTING ROD

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and another. Wear the recommended safety clothing, i.e. goggles, gloves and protective shoes. Clean all parts carefully before carrying out the following operations. Check that the bushings in the connecting rod small ends are tight in their bores and are flush with sides of the rods. If necessary, replace the bushings and ream after fitting to the specified diameter (A). Dimensions (mm) of standard connecting rods, bearing shells, bushings and gudgeon pins A. Dimension to obtain by reaming after fitting bushings - L and M Oil ports.

25320

107

Check parallelism of small end and big end axes. Maximum permitted tolerance is ď?§ 0.07 mm (0.003 in.) measured at 125 mm (4.92 in.) from longitudinal axis of the connecting rod. Slightly twisted con rods can be straightened using a press. Severely deformed rods should be replaced. New con rods must be marked with the number of the cylinder in which they are to be fitted. Check that the difference in weight of connecting rods in the same engine does not exceed 25 grams. Also check that the oil ways (L and M) Fig. 104 are not obstructed by scale or impurities.

25321

108

If the rod bearing cap bolts are to be reused, check that diameter d (measured in area a shown in the figure) is greater than 10.5 mm (0.41 in.), if not, replace the bolts.

109

10-65

SECTION 10 -- ENGINE -- CHAPTER 1 PISTONS

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes. Clean all parts carefully before carrying out the following operations. Determine the degree of piston and liner wear. If the piston running clearance exceeds 0.30 mm (0.012 in.), rebore and ream the liners and fit oversize pistons and rings. In case of piston replacement, check that the weight difference between pistons in the same engine does not exceed 20 grams. Check that the piston ring groove clearance (b, Fig. 109) and the end gap (c, Fig. 109) are within the specifications. If the end gap is less than that specified, correct by grinding the ends of the piston ring.

25322

110 Checking pistons and rings. a. b.

Checking piston diameter at a distance (L) from the base of the skirt. Checking piston ring groove clearance.

c. L.

10-66

Checking the end gap with ring in cylinder bore. Distance from base of piston skirt: 57 mm (2.2 in.).

SECTION 10 -- ENGINE -- CHAPTER 1

20035285

111 Dimensions (mm) of standard pistons, gudgeon pins and rings. a. Models TT55 and TT75. A. Measurement to be obtained with ring inserted in cylinder bore.

E. Piston diameter measured at 57 mm (2.2 in.) from the base of the skirt.

Fit rings in grooves in the correct order. When fitting pistons on connecting rods, check that the clearance between the gudgeon pin and its bore in the piston is within the tolerance specifications.

2 25324

112

10-67

SECTION 10 -- ENGINE -- CHAPTER 1 Check that the piston/connecting rod assembly is perfectly square. If not, replace parts causing the problem.

25108

113 NOTES:

Oil the pistons, rings and liners before inserting the pistons in their bores. Before fitting the ring clamp (1) to compress the rings for insertion in the liner, check that the ring end gaps are offset by an angle of 180 o. This will ensure better compression and better oil sealing. 25326

2 114

Big end cap bolts If the bolts are to be re-used, check that diameter d (measured in the area a shown in the figure) is greater than 10.5 mm (0.41 in.); if not, replace the bolts. NOTE: It is advisable to replace the big end cap bolts each time the connecting rods are dismantled.

25327

115

10-68

SECTION 10 -- ENGINE -- CHAPTER 1 CAMSHAFT, TAPPETS AND VALVES

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes. Clean all parts carefully before carrying out the following operations. Valves In the case of minor sealing faults, the valves and their seats in the cylinder head may be re-faced using pneumatic grinder or universal grinder. In case of more serious defects, re-face the seats and grind the valves as shown in the relative chapter. After grinding, check that the step below the valve contact band is no less than 0.5 mm (0.020 in.). Dimensions (mm) of valves and valve guides A. Inlet. B. Distance to be obtained by reaming fitted valve guide. S. Exhaust.

116 Tappets Check that the tappets slide freely in their bores without excessive play. In the case of excessive tappet-to-bore clearance, rebore the seats and fit oversize tappets. Pushrods must be perfectly straight, and the concave contact surface with the rocker arm adjuster screw must not show signs of seizure or excessive wear, otherwise the rod must be replaced. In case of refacing of the contact surfaces, remove as little material as possible.

25329

117

10-69

SECTION 10 -- ENGINE -- CHAPTER 1 Camshaft Place it on two parallel V blocks, and, using a dial gauge with 1/100 mm scale, check that journal run-out relative to the axis of rotation does not exceed 0.02 mm (0.0001 in.). If run-out does not exceed 0.02 mm (0.0001 in.), the camshaft may be straightened using a press; otherwise replace the camshaft. Check cam lift using a dial gauge, which should be as follows: 25328

-- inlet valve = 5.97 mm (0.235 in.);

118

-- exhaust valve = 6.25 mm (0.246 in.). Replace worn bushings using suitable extractors and drifts, and ream to obtain the inside diameter indicated in Fig. 116.

25331

119 Dimensions (mm) of camshaft journals and relative seats in cylinder block. a.

Models TT55.

Model TT75.

NOTE: The value indicated for the bushing inside diameter refers to the fitted part.

10-70

SECTION 10 -- ENGINE -- CHAPTER 1 Valve timing check To check the valve timing after dismantling/assembly or overhaul of the valve timing gear, proceed as follows: Check that the timing reference marks on the timing gears are aligned. Provisionally set valve clearances to 0.45 mm (0.0177 in.). Turn the crankshaft and, using a graduated timing disc, check that valves open and close at the angles indicated in the timing diagram. On completion of timing check, set the valve clearances for normal running as specified later in this section. Valve timing diagram. A. Fixed advance (*). 1. TDC. 2. BDC. 3. Inlet. 4. Exhaust. 5. Injection.

25333

120

(*) According to pump type and engine model.

10-71

SECTION 10 -- ENGINE -- CHAPTER 1 CYLINDER HEAD

Check that the cylinder head mating surface is flat using a straightedge (2) and feeler gauge (1). If deviations of more than 0.15 mm (0.0059 in.) are found, the head must be refaced. NOTE: Remove as little material as possible: the maximum depth of material that can be ground from the cylinder head is 0.5 mm (0.0197 in.). 25108

121 Using a dial gauge with magnetic base (1), check the run-out of the valve head (2) in the guide and the clearance between the valve stem and guide. â&#x20AC;˘

Maximum run-out of valve head - 0.03 mm (0.0012 in.)

â&#x20AC;˘

Maximum clearance between valve stem and guide - 0.13 mm (0.0051 in.)

If the clearance exceeds the specified value, replace the valve and, if necessary, the valve guide. 25108

122

10-72

SECTION 10 -- ENGINE -- CHAPTER 1 VALVE GUIDES -- Replacement

CAUTION Lift and handle all heavy parts using suitable lifting equipment. Make sure that the load is supported by means of suitable slings and hooks. Make sure that no-one is standing in the vicinity of the load to be lifted.

CAUTION Always use suitable tools to align holes in parts. NEVER USE YOUR FINGERS OR HANDS. With the cylinder head on the test bench, proceed as follows: 1. Place the cylinder head on a suitable support and remove the valve guide to be replaced using drift 380000219 (1).

2. Enlarge the bore of the valve guide to be fitted using twist drill 380000276.

25334

123 3. Turn the head upside down, and force fit the new valve guide with the enlarged bore using drift 380000219 (1) and bush 380000242 (2).

1 2 25335

124

10-73

SECTION 10 -- ENGINE -- CHAPTER 1 4. Ream out the valve guide bore (2) using reamer 292177 (1).

1 2

25336

125 NOTE: When replacing exhaust valve guides you must also carry out the following further operations. 5. Measure the distance (L) between the cylinder head face and the base of the valve guide using a caliper gauge and the special plate of tool 380000277.

25337

126

10-74

SECTION 10 -- ENGINE -- CHAPTER 1 The depth of taper milling is given by: B-L=C where: B = depth of taper relative to cylinder head face. L = distance measured between cylinder head face and valve guide base. C = depth of taper milling. Example (4-cylinder engine, TT75) B = 43.1 to 43.6 mm (1.70 to 1.72 in.)

L = 34.0 mm (1.34 in.) = distance measured.

C = (43.1 to 43.6) - 34.0 = 9.1 to 9.6 mm. = ([1.70 to 1.72] - 1.34 = 0.36 to 0.38 in.) Depth of taper milling. 6. From the upper side of the cylinder head, fit guide bush (1) of tool 380000277 on the guide valve to be milled (2).

25109

127 7. Slide the cutter (1) of tool 380000277, complete with depth stop (2), into the previously located guide bush until the cutting head is in contact with the valve guide.

2 25339

128

10-75

SECTION 10 -- ENGINE -- CHAPTER 1 8. Position the plate (3) of tool 380000277 flush against the cylinder head face and slide the depth stop (2) up to the plate. Measure the distance (A) between the depth stop and the end of the cutter shank (1).

25340

129 9. Position the depth stop (1) at a distance (D) = 35.9 to 36.4 mm (1.42 to 1.44 in.) from the end of the cutter shank and fix in place with its set screw. Distance (D) is given by: D=A-C

where: D = the distance determining the end of the taper milling. A = the distance between the end of the cutter shank and the depth stop, with the plate flush against the cylinder head.

25341

130

C = the depth of taper milling. Example A = 45.5 mm (1.80 in.) C = 9.1 to 9.6 mm (0.36 to 0.38 in.) D = 45.5 - (9.1 to 9.6) = 35.9 to 36.4 mm. = (1.80 - [0.36 to 0.38] = 1.42 to 1.44 in.) 10. Turn the cutting tool (2) until the plate (3) is brought up to the cylinder head face by the depth stop (1). NOTE: Before fitting the cylinder head clean it thoroughly to remove all residue from the milling operation.

2 1

25342

3 131

10-76

SECTION 10 -- ENGINE -- CHAPTER 1 VALVE SEATS IN CYLINDER HEAD -Refacing

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes. 11. If the valve seats need refacing to improve valve sealing, use a universal valve grinder (1) and remove as little material as possible.

25343

132 Dimensions (mm) of valve seats and guide valves. A. Inlet. B. Depth of taper on 3 and 4-cylinder engines. S. Exhaust.

25344

133

10-77

SECTION 10 -- ENGINE -- CHAPTER 1 INJECTOR SLEEVES -- Replacement

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes. 1. If the cylinder head face has been reground, check that injector stand-out is within the tolerance limits specified for that injector.

Checking injector and valve height relative to the cylinder head face. a. Checking injector stand-out (check specifications section) b. Checking valve stand-in: 0.7 to 1.0 mm (0.0276 to 0.0394 in.) - max. permissible stand-in = 1.3 mm (0.0512 in.). 25345

134 If injector stand-out exceeds the specified limit, replace the injector sleeve using tool kit 380000246 and proceeding as follows:

2. Set distance (A) on tap (3) 380000829 to 9 mm by means on ring nut (5) and fix ring nut in position by tightening the set screw (4).

3. Cut an internal thread in the sleeve to be removed using tap 380000829 (M12x11.75), making sure that the thread is cut in the sleeve only. 4. Install tool (2, Fig. 133) 380000832 to the injector mounting studs on the cylinder head with the nuts (3) (M8x1.25) under the tool. 5. Screw part (11, Fig. 133) fully into the previously cut thread and turn nut while hammering the tool end (1, Fig. 133) to withdraw the injector sleeve (12, Fig. 133) from the head. 6. Remove any copper residue from inside the head using tool 380000370. 7. Install seals (6, Fig. 133) onto the new injector sleeve and lubricate. Then fit the sleeve into its bore, making sure that the sleeve butts up against the bottom of the seating in the cylinder head. With dressing tool 380000834 (5), seat sleeve in head and swage sleeve into groove (A) at base.

10-78

5 25346

135

SECTION 10 -- ENGINE -- CHAPTER 1 8. Install guide bush 380000830 (10, Fig. 133) in the new sleeve (12, Fig. 133), securing it in position by turning the ring nut (9, Fig. 133) clockwise. Insert reamer (7, Fig. 133) 380000831 in guide bush (10, Fig. 133) and ream the lower part of the sleeve. 9. Remove the reamer (7, Fig. 133) and back-off the ring nut (9, Fig. 133) by about 10 mm (0.39 in.). 10. Press by hand on the ring nut (or tap gently with a rubber mallet) to release the inside of the guide bush (10, Fig. 133) 380000830. 11. Remove the guide bush, and fit the milling cutter (8, Fig. 133) 380000833 in the bush. Install the bush in the sleeve (12, Fig.133) and fix in position by turning the ring nut (9, Fig. 133) clockwise. 12. Work with the cutter to remove material until the seating is perfectly smooth and free from all marks. 13. This done, remove the cutter, fit the injector and check that stand-out is within specifications.

7 2 1

4 3

8 9

25348

136 Disassembly, removal of residue, installation and reaming of injector sleeve in cylinder head using tool kit 380000246. 1,2, and 11. Injector sleeve extractor 380000832. 3. M8x1.25 retaining nuts. 4. Waste removal tool 380000370. 5. Injector sleeve dressing tool 380000834. 6. O-ring seals.

7. 8. 9. 10. 12.

10-79

Reamer 380000831. Milling Cutter 380000833. Ring nut Guide bush 380000830. Injector sleeve.

SECTION 10 -- ENGINE -- CHAPTER 1 ROTATING COUNTERWEIGHT DYNAMIC BALANCER

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes Clean all parts carefully before proceeding with the operations described below. Check component wear and replace any defective parts. If the bushings of the counterweights are to be replaced, pre-heat the new bushings in oil to a temperature of 140o to 160 oC (284o to 320o F) before force-fitting in their bores. Ream the new bushings after fitting using a reamer with expanding cutters to the inside diameter specifications.

28 27 26 25 24 22605

23 22 21 20 19 18 17 16 15 14 13 12

137 Cross-sectional view of rotating counterweight dynamic balancer. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Thrust washers. Circlip. Bushing lubrication tube. Counterweight (28) rotation shaft. Shaft (4) retaining spring pin. Counterweight drive gear (13) carrier. Thrust washer. Counterweights. Intermediate counterweight drive gear. Bolts securing balancer housing to sump. Circlip. Dynamic balancer housing. Counterweight drive gear. Wire screen filter.

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

10-80

Screen filter retaining screw. Bushing. Sleeve coupling. Circlip. Thrust washer. Carrier for gear (22). Thrust washer. Drive box gear for dynamic balancer. Cover. O-ring seal. Circlip. Intermediate gear. Intermediate gear (26) rotation shaft. Bushing.

SECTION 10 -- ENGINE -- CHAPTER 1 LUBRICATION SYSTEM

OIL PUMP Overhaul

To access the oil pump, remove the sump pan. When servicing the pump, check component wear against dimensions specified in the table.

In case of replacement, note that the drive shaft (3) and drive gear are supplied ready assembled, with the gear hot force-fitted on the shaft.

3 4 5

25354

138 Cross-sectional view of engine lubrication oil pump 1. External drive gear. 2. Bushing. 3. Drive shaft and gear. 4. Driven shaft and gear. 5. Pressure relief valve.

10-81

SECTION 10 -- ENGINE -- CHAPTER 1 OIL FILTER Replacement

This mixture also has anti-oxidant, anti-corrosion, anti-foaming and anti-scaling properties to ensure long-term protection of the cooling system.

The oil filter is of the full-flow, integral paper cartridge type, and is installed on the pump delivery line. Should the filter become clogged, the safety valve will open to allow the oil to bypass the filter, thus ensuring that the engine continues to be lubricated, although with unfiltered oil.

The same mixture can be kept in the cooling system for a maximum of 2 years or 1600 operating hours, whichever comes sooner, after which it must be changed.

Replace the cartridge periodically (every 300 operating hours), remembering to: • Oil the outer part of the seal in contact with the mounting on the crankcase; • Screw on the new cartridge until the seal is up against the mounting; • Tighten the cartridge by hand only through a further 3/4 turn.

LOW OIL PRESSURE INDICATOR Functional checks The indicator consists of a control switch and a red warning lamp on the dashboard, which illuminates in the following conditions: • Low oil pressure (the warning lamp also illuminates in normal conditions, without signifying a fault, when the engine is hot and idling at low speed); • Control switch malfunction. If the red lamp fails to illuminate when the engine is stopped and the ignition switch is turned to the power on position, the possible causes are: • Blown fuse; • Blown lamp; • Interruption in wire to the control switch. • During initial startup after the tractor has been sitting for over 4 hours, the lamp may take up to 10 seconds to go out.

CHECKS, DIMENSIONS AND REPAIRS COOLING SYSTEM Clean all parts carefully before proceeding with the operations described below. The cooling system is filled with a permanent coolant mixture consisting of water and antifreeze (up to 50% in volume). This mixture prevents freezing down to the following temperatures: Degrees oC

-8o

-15o

-25o

-35o

Degrees oF

18o

-13o

-31o

% in volume of antifreeze

20%

30%

40%

50%

RADIATORS Flushing and checks Two valves are built into the radiator cap, one compression valve and one depression valve. Check periodically that they are working correctly. When overhauling, remove deposits of lime scale in the radiator by means of a solution of water and de-scaling agent in the proportions shown on the container. It is never advisable to limit flushing to the radiator only - always extend it to the entire cooling circuit and top up the engine with the solution referred to above. Run the engine for about an hour before draining (with the engine off) the solution through the drain plug. If the system is leaking, check the radiator seal by immersing it in a tank of water at the temperature of 20o - 40o C (68o to 104o F), blowing air into the radiator at a pressure of 0.98 bar (1 kg/cm2 [14.2 psi]) for approximately two minutes (repeat the test at least three times).

COOLANT THERMOMETER Testing If malfunction is suspected, immerse the bulb of the thermometer in water and check the readings against a test thermometer (repeat the test a number of times with different water temperatures to be sure).

THERMOSTAT Replacement The thermostat is located in the cylinder head coolant outlet union. The thermostat cannot be adjusted and therefore must be replaced if does not meet the temperature specifications. NOTE: When fitting a new belt, check the tension again after one hour of running.

10-82

SECTION 10 -- ENGINE -- CHAPTER 1 CRANKSHAFT FRONT OIL SEAL Removal/installation

DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that the load is supported by means of suitable slings and hooks. Make sure that no-one is standing in the vicinity of the load to be lifted. 1. Remove the radiator (1) and recover the upper rubber mountings.

25135

139 2. Loosen the alternator pivot bolt (1).

25136

140

10-83

SECTION 10 -- ENGINE -- CHAPTER 1 3. Loosen the belt tension adjuster bolt (1) and remove the belt.

25137

141 4. Remove the radiator fan (1).

1 25138

142 5. Remove the retaining bolts (1) and remove the crankshaft pulley.

25139

143

10-84

SECTION 10 -- ENGINE -- CHAPTER 1 6. Straighten the tab on the lock washer, hold the crankshaft against rotation and unscrew nut (1).

25140

144 7. Remove the pulley hub from the crankshaft using tool 380000226 (1) and recover the woodruff key.

25141

145

10-85

SECTION 10 -- ENGINE -- CHAPTER 1 8. Remove the oil seal (1) from it seat. To install the front oil seal, proceed as follows: a. Install the oil seal. b. Install the crankshaft hub and retaining nut; bend tab over on lock washer. c. Install fan. d. Install the drive belt, adjust tension and tighten alternator bolts. 25142

e. Replace the radiator and secure with the two bolts. f.

Install the two rubber hoses to the coolant pump and the thermostat housing.

g. Reconnect the pipe to the radiator cap. h. Install the hose connecting the air cleaner to the inlet manifold. Install the air filter clogging sensor. i.

Install the hood.

Install the two wire guards around the fan.

k. Fill the radiator with coolant. l.

Reconnect the negative battery lead; close the hood.

10-86

1 146

SECTION 10 -- ENGINE -- CHAPTER 1 COOLANT SYSTEM -- OVERHAUL

Removal - Reinstalling

CAUTION Always use suitable tools to align holes in parts. NEVER USE YOUR FINGERS OR HANDS. 1. Remove the exhaust pipe and open the engine hood. 2. Disconnect the negative battery lead. 3. Remove the wire guards (1) from the left and right-hand sides of the fan.

25028

147

4. Remove the hose clamp, detach the bottom radiator hose (1) and drain off the coolant.

25124

148 5. Remove the fan shroud (1) retaining bolts.

25143

149

10-87

SECTION 10 -- ENGINE -- CHAPTER 1 6. Move the fan shroud towards the engine. 7. Unscrew the three bolts securing the fan to the coolant pump shaft, remove the fan and the fan cowling.

25145

150 8. Loosen the alternator pivot bolt (2). 9. Loosen the belt tension adjustment bolt (1).

1 2

25146

151 10. Remove the coolant pump pulley (1).

25147

152

10-88

SECTION 10 -- ENGINE -- CHAPTER 1 11. Loosen the hose clamp (1) and detach the hose from the coolant pump.

25148

153 12. Unscrew the belt tension adjustment arm retaining nut (1) and move the alternator outward.

25149

154 13. Remove pump connection pipe (1) to gain access to the coolant pump retaining bolt (2).

14. Unscrew the four bolts (1) securing the coolant pump to its mounting.

15. Disconnect the hose from the coolant pump to the thermostat housing, then remove the pump (1).

25150

155

10-89

SECTION 10 -- ENGINE -- CHAPTER 1 To install the coolant pump proceed as follows: a. Install the coolant pump. Be careful not to lose the seals on the vertical hose connecting the pump to the thermostat housing.

b. Install the connection pipe to the pump, and replace the two retaining bolts. c. Install the coolant pump pulley and the fan. Install the fan shroud and fix the belt tension adjustment arm. Tighten the alternator pivot bolt.

25151

156

d. Install the bottom radiator hose to the connection pipe on the coolant pump and the radiator. e. Install the right-hand wire guard. f.

Install the left-hand wire guard.

g. Fill the cooling system from the radiator cap. h. Reconnect the negative battery lead and install the exhaust pipe.

25152

157

10-90

SECTION 10 -- ENGINE -- CHAPTER 1 COOLING SYSTEM THERMOSTAT Removal - Reinstalling

CAUTION Always use suitable tools to align holes in parts. NEVER USE YOUR FINGERS OR HANDS. 1. Remove the hood and brackets. 2. Drain the cooling system. 3. Remove the wire guard (1) from the right-hand side of the radiator.

25028

158 4. Unscrew the hose clamp and disconnect the hose (1) connecting the radiator to the thermostat housing.

25155

159

10-91

SECTION 10 -- ENGINE -- CHAPTER 1 5. Remove the thermostat housing cover screws (1).

25156

160 6. Lever the cover (1) off the housing using a screwdriver and recover the cover.

25157

161 7. Remove the thermostat valve (1).

1 25158

162 To reinstall the thermostat proceed as follows: a. Install the thermostat in its housing and locate the gasket. Install the cover to the housing. b. Connect the top radiator hose to the thermostat housing, and secure with a hose clamp. c. Install the right-hand wire guard to the fan. d. Install the hood. e. Fill the cooling system. Top up if necessary. f. Reconnect the negative battery lead. Close the hood and install the exhaust pipe.

10-92

SECTION 10 -- ENGINE -- CHAPTER 1 FUEL SYSTEM OVERHAUL BOSCH INJECTION PUMP Removal -- reinstalling, timing and air bleeding

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes.

CAUTION

20035286

Always use suitable tools to align holes in parts. NEVER USE YOUR FINGERS OR HANDS.

163

1. Open the hood. 2. Disconnect the negative battery lead. 3. Unscrew the three retaining bolts, and remove the wire guard (1) from the right-hand side of the fan.

25182

164 4. Detach the throttle control spring (1) and remove the throttle lever (2).

2 25183

165

10-93

SECTION 10 -- ENGINE -- CHAPTER 1 5. Unscrew the hose clamp (1) and disconnect the flexible pipe (2) connected to the thermostarter.

2 25184

166 6. Disconnect the electrical lead (1) from the engine stop solenoid.

25185

167 7. Unscrew union (1) on the fuel supply pump and union (2) on the injection pump.

25186

168

10-94

SECTION 10 -- ENGINE -- CHAPTER 1 8. Unscrew the unions on the fuel filter and recover the fuel lines (1) and (2).

2 25187

169 9. Unscrew the unions (1) of the high-pressure feed lines from the injection pump to the injectors and remove the fuel lines.

25188

170 10. Unscrew the retaining bolts (1) of the injection pump gear cover (2).

25189

171

10-95

SECTION 10 -- ENGINE -- CHAPTER 1 11. Remove the cover from the flywheel ring gear inspection window (1).

25190

172 12. Rotate the flywheel, using a screwdriver as a lever, until the two “4” reference marks stamped on the gears (1) and (2) coincide.

2 25191

173 13. Unscrew the nut (1) securing the injection pump drive gear to the pump shaft.

25192

174

10-96

SECTION 10 -- ENGINE -- CHAPTER 1 14. Unscrew the nuts (1) securing the injection pump to the timing gear case.

25193

175 15. Remove the injection pump drive gear (1) using puller 380000835 (2).

1 2

25194

176 16. Lift off the injection pump (1). NOTE: On TT55 models, the fuel filter must be removed prior to removing the injection pump.

25195

177

10-97

SECTION 10 -- ENGINE -- CHAPTER 1 17. Recover gasket (1), spacer (2) and gasket (3).

22650

178 To reinstall the injection pump, proceed as follows: a. Reinstall the drive gear and the injection pump, fitting the gear in its tapered housing and securing with the nut. Secure the pump with the three retaining nuts. b. Reinstall the gear cover. c. Reinstall the two semi-rigid pipes connecting the injection pump to the filter and the fuel supply pump to the filter. This job is made easier if you tighten the unions on the filter first. d. Reconnect the engine stop solenoid lead (1). Reconnect the high-pressure fuel lines to the injection pump and the injectors. e. Reinstall the throttle control lever spring on the injection pump. Reconnect all the flexible hoses previously removed. f.

Replace the flywheel inspection window cover.

g. Reinstall the wire guard to the right-hand side of the fan. h. Reconnect the negative battery lead. Close the hood.

10-98

1 40035234

179

SECTION 10 -- ENGINE -- CHAPTER 1 BOSCH INJECTION PUMP Timing If the engine does not run evenly, or when the timing marks (1) are not visible, or when in doubt as to whether the marks are correct, time the injection pump as follows:

2 25181

180 1. Unscrew the unions of the high-pressure fuel lines connecting the pump to the injectors and remove the fuel lines.

25188

181 2. Remove the injection pump gear cover. 3. Check that â&#x20AC;&#x153;4â&#x20AC;? timing reference marks on gears (1) and (2) are aligned.

1 2

25191

182

10-99

SECTION 10 -- ENGINE -- CHAPTER 1 4. Remove the flywheel inspection window cover (1). 5. Turn the crankshaft to bring cylinder no. 1 to TDC of the compression stroke.

25190

183 6. Check through the inspection window that the pointer is aligned with the degree reference mark.

26107

184 7. With the injection pump in position but with the mounting bolts loose, remove the plug (1) on the pump housing.

8. Install dial gauge 380000228 (1, Fig. 181) and relative tool 380000229 (2) and pre-load the shaft by about 2.5 mm (0.098 in.). 9. Turn the flywheel slowly backwards so as to bring the plunger to BDC at the start of the delivery stroke (the point at which the dial gauge needle stops falling). 25196

185

10-100

SECTION 10 -- ENGINE -- CHAPTER 1 10. Set dial gauge to zero, and slowly turn the flywheel clockwise (as viewed from the fan end of the engine) until the pointer lines up with the degree reference mark. 11. Check on the dial gauge that the plunger has completed a stroke of 1 mm (0.039 in.) up to this point; if not, slacken off the pump mounting bolts. 12. Turn the pump counter-clockwise if the plunger stroke is less than 1 mm (0.039 in.) and clockwise if the stroke is greater than 1mm (0.039 in.), and repeat test until the correct stroke is obtained. 13. Having obtained the correct plunger stroke, secure the pump in position by tightening the mounting nuts (1, Fig. 171) to the torque specified - 25 Nâ&#x2039;&#x2026;m (2.6 kgm, 19 ft. lbs.).

25197

186

14. Stamp pump timing marks on the pump mounting flange and timing gear casing. 15. Remove the dial gauge 380000228 (1) and the relative tool 380000229 (2). Replace the plug and tighten to a torque of 8 to 10 Nâ&#x2039;&#x2026;m (0.8 to 1 kgm, 5.9 to 7.4 ft. lbs.). 16. Reinstall other parts in the reverse of the dismantling order.

INJECTION PUMP

Air bleeding 1. Unscrew the bleed plug (1) on the fuel filter.

10036159

187

10-101

SECTION 10 -- ENGINE -- CHAPTER 1 2. Operate the priming lever (1) on the fuel supply pump until the fuel coming out of the filter bleed plug is free of bubbles, then tighten plug.

25199

188 3. Loosen the fuel line unions (1) on the injectors, crank the engine and then re-tighten the union when the fuel flows out free of bubbles.

25200

189

10-102

SECTION 10 -- ENGINE -- CHAPTER 1 FUEL INJECTORS

Removal -- Reinstalling

CAUTION Always use suitable tools to align holes in parts. NEVER USE YOUR FINGERS OR HANDS. 1. Unscrew the fuel leak-off pipe union (1) on the injector.

25301

190 2. Unscrew the union (1) of the high-pressure fuel line on the injector.

1 25302

191 3. Unscrew the two mounting nuts (1) and remove the injector.

To reinstall the injector, proceed as follows: a. Insert the injector in its seat. b. Replace and tighten the two mounting nuts in two stages. 1st stage: tighten nuts to 10 N⋅m (1 kgm, 7.4 ft. lbs.) 2nd stage: tighten nuts to 25 N⋅m (2.6 kgm, 18 ft. lbs.). c. Reconnect the fuel leak-off pipe union.

25303

d. Reconnect the high-pressure fuel line union.

192

e. Replace hood. f.

Reconnect the negative battery lead.

10-103

SECTION 10 -- ENGINE -- CHAPTER 1 VALVE CLEARANCE ADJUSTMENT

CAUTION Always use suitable tools to align holes in parts. NEVER USE YOUR FINGERS OR HANDS. 1. Unscrew the four rocker cover nuts (1) and remove cover.

25305

193 2. Remove the flywheel inspection window cover (1).

25190

194 3. Adjust the clearance between valves and rocker arms using a feeler gauge, spanner (1) and special tool 380000232 (2).

NOTE: Before adjusting, position the valves as described in the following page.

25306

195

10-104

SECTION 10 -- ENGINE -- CHAPTER 1 Adjusting valve clearances To adjust valve clearances on the 3-cylinder models, proceed as follows (see Figure 1-195): 1. Turn the crankshaft so that the inlet and exhaust valves of cylinder no.1 are balanced (compression stroke). In this position the pointer will be aligned with the reference mark PMS 1 (TDC 1) on the flywheel. 2. Rotate the crankshaft through a full revolution, returning to TDC 1, then check that the valve clearances correspond with the specifications. 3. Repeat this operation for the other valve pairs. Note that the TDC positions of cylinders 2 and 3 are not marked on the flywheel.

Rocker arm screw Rocker arm Valve stem Feeler gauge

196

To check valve clearances on 4-cylinder models, proceed as follows (see Figure 1-196): 1. Turn the crankshaft so that the inlet and exhaust valves of cylinder no. 1 are balanced (compression stroke). In this position the pointer will be aligned with the reference mark PMS 1 (TDC 1) on the flywheel. 2. Check that the clearances between valves and rocker arms on the symmetrical cylinder no. 4 correspond with the values specified in the table on page 1-10. Rotate the crankshaft through 360_ and check valve clearances on cylinder no. 1. 3. Repeat this operation for the other valve pairs. Note that the symmetrical cylinders are 1-4 and 2-3.

197

To reassemble proceed as follows: 1. Install the rocker cover. 2. Install the flywheel inspection window cover. 3. Install the hood. 4. Reconnect the negative battery lead.

198

10-105

SECTION 10 -- ENGINE -- CHAPTER 1 COOLANT PUMP

Overhaul

CAUTION Use the appropriate tools for aligning the holes. NEVER USE YOUR HANDS OR FINGERS.

4 5

NOTE: The bearing (9) forms a single piece with the control shaft (10); it is a sealed unit and requires no lubrication during running.

6 10

14262

199 Overhaul the pump as follows: 1. Remove the cover (4) and the shaft screw (2) retaining the shaft (10) and bearing (9). 2. Gently tap the end of the shaft (10, Fig. 197) on the rotor side (5) to break the film of oxide between the shaft and the rotor; fit extractor 380000223 (1, Fig. 198) and take out the rotor.

3. Remove the front sealing bushing (7, Fig. 197). 4. Use a punch to extract from the pump housing (6, Fig. 197) the shaft (10) complete with bearing (9) and fan hub (1).

5976

200

10-106

SECTION 10 -- ENGINE -- CHAPTER 1 NOTE: Remove the seal (8, Fig. 197) only when it needs to be changed.

Check components for wear, and change any that are in poor condition. Install the parts, proceeding in the following way: 1. Install the shaft (10, Fig. 197) complete with bearing (9) and hub (1) on the pump housing (6) and secure it with the retaining screw (2), having first spread it with LOCTITE 242. 2. In the case of changing, fit the seal (8, Fig. 197) into the seat, using tool 380000247 (1, Fig. 200). 3. Heat the rotor (1) in an air oven, until you reach a temperature difference of 130-150Â° in relation to the shaft (2).

21662

201

4. Place the rotor (1) on the shaft (2), easing it onto the end so as not to damage the bearing, until you obtain the operating clearance G = 0.5-0.7 mm (0.02 to 0.03 in.)(see Fig. 197). 5. Install the seal (3, Fig. 197) and the cover (4), securing it with the relevant screws.

2 202

10-107

SECTION 10 -- ENGINE -- CHAPTER 1 ENGINE TESTING

5. Turn the engine over a few times with the starter motor in order to expel any carbon residue;

Compression test In case of poor engine performance, in addition to checking the fuel injection system (injector nozzles and injection pump), also test the compression on each cylinder.

6. Install the dummy injector 380000617 with copper sealing washer in place of the injector removed previously.

DANGER Do not use matches, lighters, blow torches or any naked flame as a source of light when inspecting the engine due to the presence of inflammable fluids and vapour.

Compression ratio The compression ratio is a measure of the quantity of air drawn into the cylinder and provides an indication of the efficiency of the sealing elements in the cylinder (piston rings and valves).

7. Connect a compression test instrument and take readings while turning the engine over with the starter motor. On engines in perfect working order, with the sump oil at approx. 40_C, at sea level (760 mm of mercury) and at an engine speed of 200 to 280 rpm, the compression should be 25.5 to 27.5 bar (26 to 28 kg/cm2 [370 to 400 psi]). 8. Test the compression on the other cylinders, repeating steps 4, 5, 6 and 7, bearing in mind that: The minimum permissible compression on a used engine is 21.6 bar (22 kg/cm2 [313 psi]). The maximum permissible compression difference between cylinders is 3 bar (3 kg/cm2 [43.5 psi]). Every 100 metres above sea level corresponds to a reduction in compression by about 1%.

Uniform compression in all the cylinders ensures that they all perform an equal amount of work, provided of course that each cylinder is injected with the same quantity of fuel at the right time. Low compression not only reduces engine performance, it also causes incomplete fuel combustion due to the lack of available combustion air. The engine therefore gives poor performance with excessive fuel consumption, and consequently exhaust smoke and restriction of the exhaust passages. As the compression ratio varies with the temperature of the engine (cold engines produce lower compression values than hot engines) the compression should only be tested when the engine is at normal operating temperature. Compression should be tested using a compression test kit as follows: 1. Run the engine until it reaches normal operating temperature; 2. Switch off the engine; 3. Disconnect the lead from the engine stop solenoid on the injection pump in order to close the valve and block the flow of fuel to the injectors; 4. Remove the injector from the cylinder to be tested;

CONSIDERATIONS: Uniform compression Although high compression is important, it is more important as regards smooth running that the compression is the same on all cylinders. Low compression readings If very low compression readings are obtained on one cylinder it is advisable to repeat the test. Before testing this time, pour about a spoonful of engine oil into the cylinder through the injector bore. Turn the engine over a few times to distribute the oil evenly over the cylinder walls, and then repeat the test. If the second test readings are significantly higher, suspect worn piston rings, out-of-round or damaged pistons or liners. If the second test readings are not higher, the problem will be the valves. On the other hand, if the second test reading shows only a slight improvement, the problem will be due to both the valves and the rings.

10-108

SECTION 10 -- ENGINE -- CHAPTER 2

SECTION 10 - ENGINE Chapter 2 - Air Cleaning System CONTENTS Section

Description

Page

10-1

SECTION 10 -- ENGINE -- CHAPTER 2 SPECIFICATIONS TORQUE VALUES Description

Nâ&#x2039;&#x2026; m

In.-lb.

Air Cleaner Tube Clamps

2.0

18 in.-lb.

Air Cleaner Retaining Bolts

204 in.-lb.

FAULT FINDING Problem

Possible Cause

Air Cleaner Warning Light illuminates

Air Cleaner Filter Elements Clean or replace elements clogged

Air Cleaner Warning Light illuminates after filter service

Vacuum Switch faulty

10-2

Remedy

Replace switch

SECTION 10 -- ENGINE -- CHAPTER 2 DESCRIPTION AND OPERATION

The air cleaning system consists of a dry-type air cleaner (1) located under the hood assembly, above the battery. The air cleaning system removes impurities from the air, while allowing a sufficient volume of air to enter the engine to ensure complete combustion of the fuel. Air enters the cleaner in a circular direction, and centrifugal force causes the heavier particles to propel to the outside of the container, then collect at the container bottom. A rubber valve provides a provision for removal of the collected particles. The lighter particles in the air collect on the outer (primary) filter element and stay suspended until cleaned during servicing.

40035227

Located within the outer element is the inner (secondary element. The inner element protects the engine from fine dust particles that pass by the outer filter element, and provides filtration if the outer element fails.

The air cleaner restriction warning switch located in the air intake tube (1) detects increases in vacuum caused by an obstructed cleaner. When activated, the switch illuminates a warning light on the instrument panel to notify the operator that the air cleaner requires servicing. 40035227

IMPORTANT: When observing an air cleaner restriction warning light, stop the engine as soon as possible and investigate the cause. Improper air flow to the engine will cause poor engine performance, and the ingestion of dirt and other particles into the engine will cause catastrophic engine failure.

10-3

SECTION 10 -- ENGINE -- CHAPTER 2 AIR CLEANER ASSEMBLY FILTERS

Removal 1. Raise the engine hood assembly.

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

40035227

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

40035293

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

40035294

10-4

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

WARNING Wear a face shield and eye protection when using compressed air to clean a filter element. 4. Use compressed air with a maximum pressure of 2.1 bar (30 psi) to clean the filter element. Insert the air nozzle inside the element and blow the debris from the inside, through the element and out. Blow debris off the outside of the element by holding the nozzle a minimum of 150 mm (6 in.) from the element, Figure 6. IMPORTANT: Never use oil, petrol or solvent to clean a filter element. Only use water warm enough to touch.

6 Cleaning Element with Compressed Air

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

7 Washing the Element

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

10-5

SECTION 10 -- ENGINE -- CHAPTER 2 IMPORTANT: Do not attempt to dry the filter element with compressed air. The element must be thoroughly dry before installation to prevent rupture during operation. 9. Install a new filter element and save the cleaned element for the next service interval. This step is critical in preventing the installation of a filter element that is not completely dry. 10. When the element completely dries, inspect the paper pleats by passing a light through the element, and observing for an even unobstructed pattern of light. Discard element if necessary. 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. Installation Installing the air cleaner assembly follows the removal procedures in reverse with the following requirements: 1. When installing the filter elements, ensure the rubber sealing rings are completely seated and secure. 2. Tighten the air cleaner assembly retaining bolts to a torque of 23 Nâ&#x2039;&#x2026;m (204 in.-lb.). 3. Tighten the air cleaner tube clamps to a torque of 2.0 Nâ&#x2039;&#x2026;m (18 in.-lb.).

10-6

SECTION 18 -- CLUTCHES -- CHAPTER 1

SECTION 18 - CLUTCHES Chapter 1 - Clutches CONTENTS Section

Description

Page

18-1

SECTION 18 -- CLUTCHES -- CHAPTER 1 SPECIFICATIONS CLUTCH

Description

Type

Twin, single dry plate

Control

Mechanical; pedal for transmission; manual lever for PTO

Release Mechanism

Dished spring

Plate with Pressure Springs

Tangential springs

Plate Material

Organic compound

Transmission Plate Thickness

8.8 to 9.6 mm (0.35 to 0.38 in.)

PTO Plate Thickness

8.3 to 8.9 mm (0.33 to 0.35 in.)

Transmission Clutch Control Sleeve Working Clearance

0.050 to 0.151 mm (0.002 to 0.006 in.)

PTO Clutch Control Sleeve Working Clearance

0.072 to 0.205 mm (0.003 to 0.008 in.)

Transmission Clutch Pedal Pin Diameter

35.961 to 36.000 mm (1.416 to 1.417 in.)

Transmission Case and Pedal Supporting Bushing Internal Diameter (fitted, undressed)

36.064 to 36.161 mm (1.420 to 1.424 in.)

Transmission Clutch Pedal Shaft Bushing Play

0.064 to 0.200 mm (0.0025 to 0.0079 in.)

Bushing Internal Diameter (Pedal and Transmission Case)

40.000 to 40.025 mm (1.5748 to 1.5758 in.)

Bushing Outer Diameter

39.928 to 40.097 mm (1.5720 to 1.5786 in.)

Maximum Clearance Between Bushings and Housing

0.097 mm (0.038 in.)

Pedal Bracket / Bushing Interference Fit

0.097 mm (0.038 in.)

TORQUE SPECS

Thread Size

Specification

Capscrews, clutch to flywheel

M8 x 1.25

27 N⋅m (20 ft.lbs.)

Release fork lever bolts

M16 x 1.5

190 N⋅m (140 ft.lbs.)

Capscrews, transmission housing to engine

M12 x 1.25

108 N⋅m (80 ft.lbs.)

Clutch

18-2

SECTION 18 -- CLUTCHES -- CHAPTER 1 CLUTCH ASSEMBLY REMOVAL/ INSTALLATION To remove the clutch assembly from the flywheel: • Remove ten of the capscrews (C2, Fig. 1) holding the clutch in place. •

Loosen the two remaining capscrews.

•

Insert the pilot shaft tool 380000612 through the clutch plate hubs.

•

Back off the two remaining capscrews and remove the clutch assembly, complete with the PTO disc.

1 Removing / Installing 11″/11″ Clutch from Flywheel C2. Capscrews securing clutch to flywheel L1. Centralizer pin 380000612.

18-3

SECTION 18 -- CLUTCHES -- CHAPTER 1 When reassembling, always: • Check the condition of the flywheel pilot bearing (10, Fig. 2). •

Use the pilot shaft tool to install the clutch assembly with the PTO clutch disc against the flywheel.

•

Tighten the capscrews (C2, Fig. 1) to 27 N⋅m (20 ft.lbs.).

•

Connect the transmission to the engine.

6 9

1 2

2 Longitudinal Section Through 11″/11″ Clutch C2. Clutch housing capscrews C3. Release fork lever locknuts C4. Clutch housing capscrews D = 96.0 mm (3.78 in.) nominal distance of transmission clutch release lever (3) from flywheel face D1. = 121.0 mm (4.76 in.) nominal distance of lever (2) from flywheel face L1 = 2.5 mm (0.10 in.) L2 = 2.5 mm (0.10 in.) nominal distance of PTO clutch release levers and transmission clutch release lever 1. Dish spring 2. PTO clutch release levers 3. Transmission clutch release levers 4. Transmission release control sleeve with thrust bearing 5. PTO release control sleeve with thrust bearing 6. PTO clutch release lever adjusting line 7. PTO clutch release lever locknut 8. PTO clutch pressure plate 9. Transmission clutch plate 10. Flywheel pilot bearing 11. PTO sleeve control fork 12. Transmission sleeve control fork 13. Transmission clutch release lever 14. Transmission clutch release adjusting screw 15. Transmission clutch release lever locknut. NOTE: On assembly, thoroughly clean and degrease mating surfaces and apply jointing compound.

18-4

SECTION 18 -- CLUTCHES -- CHAPTER 1 CLUTCH OVERHAUL •

Check clutch driven plates for wear. If rivets are near to or flush with top facing, replace the clutch driven plates. Also replace the plates if the organic facings are soaked with oil.

•

Check the condition of the clutch housing and pressure plate friction surfaces (Fig. 3). If necessary, dress the surfaces and check that the plate dimensions are above the specs shown here: A ≥ 22.0 mm (0.87 in.) 3

B ≥ 24.0 mm (0.94 in.) Clutch Plate Dimensions

C ≥ 87.0 mm (3.43 in.)

1. 2. 3. 4.

E ≥ 2.5 mm (0.10 in.) Calculate dimension “D” using the following formula: D = A + B + S1 + S2 + 6.0 mm (0.24 in.) A and B are the measured dimensions of pressure plates. S1 and S2 are the measured dimensions of PTO and transmission clutch plates. NOTE: Clutch housing thickness should not fall below 17.0 mm (0.67 in.). Make sure that the “C” dimension is always 17.0 mm (0.67 in.) more than the “D” dimension. •

Replace parts that are damaged or worn and dress the plate surfaces and the clutch housing face.

18-5

Flywheel PTO clutch pressure plate Transmission clutch pressure plate Housing.

SECTION 18 -- CLUTCHES -- CHAPTER 1 •

When reassembling the clutch, correctly position dish spring (1, Fig. 4) on PTO clutch pressure plate, making sure that the centralizers register with the slots.

Adjusting the clutch while fitted to flywheel: • Position the PTO clutch disc (8, Fig. 2) so that the widest side of the drive hub faces the transmission. •

Insert centralizer tool, 380000612, in the clutch drive plate shaft seats.

•

Make sure the centralizer end is in contact with the flywheel pilot bearing (10, Fig. 2).

•

Mount the clutch to the flywheel and torque the bolts.

•

Align the clutch release levers to the following specifications. The transmission clutch release lever should have 96.0 mm (3.78 in.) nominal distance (D, Fig. 2) from the flywheel face. The PTO clutch release lever should have 121.0 mm (4.76 in.) nominal distance (D1, Fig. 2) from the flywheel face.

•

Press register against release levers.

4 PTO Dish Spring (1) and Clutch Pressure Plate (2) Alignment 1. 2. 3. 4.

Dish spring Pressure plate Spring dowel Notches

a. Transmission Clutch --

Adjust the clearance (V1, Fig. 5) between the end of the register pins and the release lever to 0.5 mm (0.02 in.).

b. PTO Clutch --

Adjust the clearance (V2, Fig. 5) between the end of the release lever and the register level to 0.5 mm (0.02 in.).

b 5

Checking Clutch Release Lever Alignment on-Flywheel, Transmission Clutch C1. Capscrews L1. Centralizer 380000612 for centering clutch complete with register V1 = 0.5 mm (0.02 in.) clearance between end of register pins (L1) and release lever (2) V2 = 0.5 mm (0.02 in.) clearance between end of release lever (1) and register level (L1) 1. PTO clutch release lever. 2. Transmission clutch release lever.

18-6

SECTION 18 -- CLUTCHES -- CHAPTER 1 TRANSMISSION CLUTCH PEDAL FREE-TRAVEL AND ADJUSTMENT Free-travel is the distance the clutch pedal (1) will travel from the rest [unapplied] position to the moment of resistance. The free-travel distance feels loose on the pedal to the operator and ends when the pedals become more difficult to move, as when the clutch is applied.

It may be necessary to seek assistance when checking the clutch pedal free-travel.

A B

To check the clutch pedal free-travel proceed as follows:

10036149

1. Measure the distance from the bottom of the clutch pedal (A) to the platform.

2. Slowly depress the clutch pedal (1) until feeling resistance (B) and record the amount of travel between point A and point B. The resultant should be 40 mm (1.57 in). If free-travel is less than 20 mm (0.79 in) proceed with the remaining steps. 3. Loosen the lock nut (1) on the pedal control rod (2), located on the left-hand side of the platform under the clutch pedal.

4. Remove the pin and clevis on the rod end (not shown) and turn the rod end counterclockwise to increase free-travel. One complete turn adjusts the clutch pedal free-travel by 10 mm (0.39 in). 5. Reinstall the clevis and pin. Repeat until obtaining the specified free-travel.

1 50035260

ADJUSTING PTO CLUTCH LINKAGE •

Place the PTO clutch control lever in the down, or engaged, position. Move the handle and measure the free play at pin D (Fig. 8) at the bottom of the rod from the PTO clutch control handle as you move the clutch lever handle. The free play should be 4.5 mm (0.18 in.), but adjustment is not required until the free play drops to 2.5 mm (0.10 in.).

•

If the movement is 2.5 mm or less, loosen the locknuts (B, Fig. 8), and turn the sleeve (A, Fig. 8), clockwise until the free play is back to 4.5 mm (0.18 in.). Each rotation of the sleeve will increase the free play 3.0 mm (0.12 in.).

•

8 Adjusting PTO Clutch Control Lever Free Travel

When the PTO clutch lever is correct, retighten the locknuts.

A. B. C. D.

18-7

Adjusting sleeve Locknuts PTO clutch link Pin.

SECTION 18 -- CLUTCHES -- CHAPTER 1 Removing Throw-Out Bearing Actuators • Loosen the lever locknuts (C12, Fig. 9) on the transmission and PTO clutch control rod fork levers. •

Remove the outer PTO clutch control rod and lever (14, Fig. 10) by punching it out from the other side.

•

Remove the PTO clutch sleeve (10, Fig. 9) and fork.

9 Transmission Housing Inside View C12. PTO and transmission fork lever (11) locknuts 10. PTO clutch disengagement sleeve 11. PTO fork lever 12. Transmission clutch disengagement sleeve.

•

Remove the outer transmission clutch control rod and lever (15, Fig. 10) by punching it out from the other side.

•

Remove the transmission clutch sleeve (12, Fig. 9) and fork.

•

Remove the gearbox top cover.

10 Removal (Installation) of Transmission Shaft Front Bearing Shoulder Covers C2. Nuts for cover retaining studs (17 and 18) 14. PTO clutch control rod and lever 15. Transmission clutch control rod 16. PTO Shaft 17. Driving gear cover 18. Driven shaft bearing cover

18-8

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1

SECTION 21 - FRONT TRANSMISSION Chapter 1 - Front Transmission CONTENTS Section

Description

Page

21-1

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 SPECIFICATIONS BEVEL DRIVE AND DIFFERENTIAL

Specification

Bevel Drive Ratio

14 to 47 (1 to 3.357)

Differential Pinion Bore Diameter

23.940 to 24.061 mm (0.9425 to 0.9473 in.)

Differential Pinion Journal Diameter

23.910 to 23.960 mm (0.9413 to 0.9433 in.)

Differential Pinion Running Clearance on Journal

0.030 to 0.122 mm (0.0012 to 0.0048 in.)

Side Gear Boss Housing Diameter in Differential Case

44.080 to 44.119 mm (1.7354 to 1.7370 in.)

Side Gear Boss Diameter

43.961 to 44.000 mm (1.7307 to 1.7323 in.)

Side Gear Boss Clearance in Case

0.080 to 0.158 mm (0.0032 to 0.0062 in.)

Bevel Pinion Bearing Shim Thicknesses (twelve shims, Sp, Fig. 30)

1.00, 1.05, 1.10, 1.15, 1.20, 1.40, 1.50, 1.70, 1.75, 1.85, 1.90, 1.95 mm (0.039″, 0.041″, 0.043″, 0.045″, 0.047″, 0.055″, 0.059″, 0.067″, 0.069″, 0.073″, 0.075″, 0.077″)

Bevel Pinion Positioning Shim Thicknesses (eleven shims, S, Fig. 30)

3.80, 3.90, 4.00, 4.10, 4.20, 4.30, 4.40, 4.50, 4.60, 4.70, 4.80 mm (0.150″, 0.154″, 0.157″, 0.161″, 0.165″, 0.169″, 0.173″, 0.177″, 0.181″, 0.185″, 0.189″)

Side Gear and Differential Pinion Backlash

0.15 mm (0.006 in.)

Side Gear Thrust Washer Thicknesses (five washers, 15, Fig. 29)

1.40, 1.50, 1.60, 1.70, 1.80 mm (0.055″, 0.059″, 0.063″, 0.067″, 0.071″)

Differential Pinion Thrust Washer Thickness

1.50 mm (0.059 in.)

Differential Lock Fork Spring — Free

188.0 mm (7.40 in.)

Differential Lock Fork Spring — Under Load (279 to 309 N, 28.5 to 31.5 kg, 62.7 to 69.3 lbs.)

126.5 mm (4.98 in.)

21-2

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 TRANSMISSION

Specification

Transmission

8 forward speeds, 2 reverse speeds (with creeper – 12 forward, 3 reverse)

Synchromesh

3rd -- 4th and 7th -- 8th

Gears

Spur

Range Selector

Planetary, with three spur pinions

Reduction Ratio

20 to 72 (1 to 3.6)

Transmission and Range Selector Controls

Separate manual levers

Driven Gear Bushing External Diameter

49.925 to 49.950 mm (1.966 to 1.967 in.)

Driven Gear Internal Diameter

50.050 to 50.089 mm (1.970 to 1.972 in.)

Bushing Clearance in Gear

0.100 to 0.164 mm (0.004 to 0.006 in.)

Driven Shaft Diameter

39.166 to 39.191 mm (1.542 to 1.543 in.)

Bushing Internal Diameter

39.200 to 39.239 mm (1.543 to 1.545 in.)

Shaft Clearance in Bushing

0.009 to 0.073 mm (0.0004 to 0.0029 in.)

PTO Clutch Shaft Diameter

24.964 to 24.985 mm (0.983 to 0.984 in.)

Bushing Fitted Internal Diameter

25.040 to 25.092 mm (0.986 to 0.988 in.)

PTO Shaft Clearance in Bushing

0.055 to 0.128 mm (0.002 to 0.005 in.)

Bushing Interference Fit with Drive Shaft

0.037 to 0.091 mm (0.001 to 0.004 in.)

Shim Thickness for Adjusting End Float of Driven Gears

3.70 mm – 4.00 mm – 4.30 mm (0.146 in. – 0.157 in. – 0.169 in.)

Range Selector Washer Thickness

1.470 to 1.530 mm (0.058 to 0.060 in.)

Range Selector Internal and Outer Thrust Washers

1.470 to 1.530 mm (0.058 to 0.060 in.)

Selector Shaft Detent Ball Spring — Free

61.5 mm (2.42 in.)

Selector Shaft Detent Ball Spring — Under Load (50 to 56 N, 5.1 to 5.7 kg, 11.2 to 12.5 lbs.)

48.0 mm (1.89 in.)

21-3

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 Transmission and Range Selector Capscrews securing planetary reduction fixed gear

M12 x 1.5

108 N⋅m (80 ft.lbs.)

Capscrews, transmission housing cover (C3, Fig. 6)

M8 x 1.25

27 N⋅m (20 ft.lbs.)

Capscrew, range selector shift fork rod bracket

M10 x 1.25

68 N⋅m (50 ft.lbs.)

Capscrew securing end of lift pump suction (C11, Fig. 6)

M12 x 1.25

108 N⋅m (80 ft.lbs.)

Locknut for driven gear shaft (C13, Fig. 6)

M32 x 1.5

300 N⋅m (220 ft.lbs.)

Nut, transmission housing to clutch housing (C10, Fig. 6)

M12 x 1.5

108 N⋅m (80 ft.lbs.)

Nut, transmission shaft bearing cover (C2, Fig. 6)

M8 x 1.25

20 N⋅m (15 ft.lbs.)

Range selector control rod support retaining screws (C6, Fig. 11)

M10 x 1.25

47 N⋅m (35 ft.lbs.)

Range selector fixed gear retaining screws (C9, Fig. 11)

M12 x 1.5

81 N⋅m (60 ft.lbs.)

21-4

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 Splitting the Tractor: 1. Disconnect the negative battery lead. 2. Place wedges between the front axle and the front axle carries to prevent the assembly from tilting. 3. Disconnect the tractor meter drive cable. 4. Remove the exhaust pipe and hood. 5. Remove the steering lines. 6. Remove the suction line fromthe hydraulic reservoir and cap the reservoir port. 7. Remove the throttle linkage from the injection pump and from the mounting point under rear hood. 8. Disconnect the fuel delivery line from the primer pump and the return line from the tee. 9. Disconnect the wiring harness 10. Remove the hydraulic lift suction and delivery takes from the hydraulic pump. 11. If there is a horizontal exhaust, remove the exhaust pipe. 12. On four-wheel drive tractors, disconnect and drop the front axle driveshaft. 13. Remove the fire wall attaching bolts. 14. Place a hydraulic stand under the clutch transmission case and attach lifting tackle to the engine. 15. Unbolt the engine from the transmission case. 16. Using a crane, separate the engine from the rest of the tractor.

21-5

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1

1 Eight-Speed Transmission Longitudinal and Cross Sections a. Reverse gear drive shaft section 43. Roller bearing c. Detail of lift pump intake tube end retention 44. 1st and 2nd gear engagement fixed sleeve 47. Range selector driven gear dowel retaining ring A. Drive gear end play adjustment ring 56. Front thrust washer B. 3rd and 4th gear synchromesh C2. Shaft bearing cover retaining nuts 57. Middle thrust washer C3. Top cover capscrews 64. Driven gears support bushings C10. Screws for securing transmission housing to clutch 69. Rear thrust washer housing 72. Gear (37) retaining pin C11. Lift pump intake tube end capscrews 73. 1st and 2nd drive gear C13. Driven gear shaft locknut 74. 3rd drive gear 8. Spacer 75. Drive gear spacer 9 and 10. Seals 76. 4th drive gear 16. Drive gear shaft 77. Seal 28. PTO shaft bushing 82. Hand lever retaining spring 29 and 30. Seals 83. End of lift pump intake tube 31. Ball bearing 84. O ring 32. Roller bearing 85 and 87. Hand lever joint seal and retaining ring. 36. Ball bearing 37. Reverse drive gear NOTE: On installation, fit new seals (9 and 10) after 40. Driven shaft thoroughly cleaning and degreasing the surfaces. 41. Roller bearing

21-6

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 TRANSMISSION REMOVAL AND INSTALLATION •

Separate the engine and front axle (described in front of this section).

•

Drain the oil from the transmission.

•

Remove the right and left-side footboards.

•

Install a mechanical stand under the rear transmission housing.

•

Connect a lift hook to the transmission housing.

•

Remove the stud bolts and nuts securing the transmission housing.

•

Remove the transmission housing by moving it forward slowly and making sure you do not deform the PTO clutch shaft, 1,which goes through the transmission drive shaft to the flywheel. You may have to take the shaft out the back first.

2 Transmission Housing Removal (Installation) from Tractor

NOTE: After overhaul, thoroughly clean and degrease the mating surfaces and properly lubricate the PTO shaft seal, located at the rear of the transmission drive shaft.

1. PTO clutch shaft 8. Spacer 9 and 10. Seals.

NOTE: Be careful not to cut the seal with the PTO shaft splines when sliding the PTO shaft into the shaft seal at the rear of the transmission drive shaft.

21-7

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 Removing Throw-Out Bearing Actuators • Loosen the lever locknuts (C12, Fig. 10) on the transmission and PTO clutch control rod fork levers. •

Remove the outer PTO clutch control rod and lever (14, Fig. 4) by punching it out from the other side.

•

Remove the PTO clutch sleeve (10, Fig. 3) and fork.

3 Transmission Housing Inside View C12. PTO and transmission fork lever (11) locknuts 10. PTO clutch disengagement sleeve 11. PTO fork lever 12. Transmission clutch disengagement sleeve.

•

Remove the outer transmission clutch control rod and lever (15, Fig. 4) by punching it out from the other side.

•

Remove the transmission clutch sleeve (12, Fig. 3) and fork.

•

Remove the gearbox top cover.

4 Removal (Installation) of Transmission Shaft Front Bearing Shoulder Covers C2. Nuts for cover retaining studs (17 and 18) 14. PTO clutch control rod and lever 15. Transmission clutch control rod 16. PTO Shaft 17. Driving gear cover 18. Driven shaft bearing cover

21-8

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 Removing the Shift Rails and Forks • Drive out the roll pins for the shift lever connectors.

5 Removing Roll Pins (arrows indicate orientation of roll pin split) 19. 3rd and 4th speed shifter rod 20. 3rd and 4th speed shifter fork 21. 3rd and 4th speed shifter saddle and lever 22. 1st and 2nd shifter rod 23. 1st and 2nd shifter lever saddle 24. Range selector shifter rod 25. Range selector shifter lever saddle

Removing the Range Planetary Gear • Remove the roll pin for the range selector engagement control fork (78, Fig. 6), and remove the engagement fork with range selector engagement sleeve (49, Fig. 6). •

Remove the shifter rods and remove the collars (Fig. 5).

•

Remove the range selector control rod support and rod by removing the retaining screws (C6, Fig. 6).

•

Remove the range selector and thrust washer by removing the fixed gear retaining screws (C9, Fig. 6).

NOTE: The range selector assembly is held in by a dowel.

6 Transmission Shifter Rod Removal A. C6. C9. 19. 26. 27. 49. 78.

21-9

End float adjustment shim Range selector control rod support retaining screws Range planetary retaining screws 3rd and 4th shifter rod Retaining ring PTO shaft lip seal Range selector engagement sleeve Range selector engagement control fork (A, Fig. 20).

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 â&#x20AC;˘

Remove the range selector control rod from the support and retrieve the detent ball and spring (80 and 81, Fig. 7).

7 Installing Range Selector Shifter Rod (1) and Fork A. 1. 80. 81.

â&#x20AC;˘

Range selector engagement control fork (78, Fig. 4) Range selector shifter rod Detent spring Detent ball.

If the range selector assembly needs servicing, disassemble and check the parts in Fig. 8 for wear or damage. If any parts are damaged, replace and reassemble. Check that the thicknesses of the internal thrust washer (47, Fig. 8) and the gear shim washers (52, Fig. 8) are between 1.470 and 1.530 mm (0.058 to 0.060 in.).

8 Range Selector Components 45. Range selector support internal thrust washer 46. Range selector fixed gear 47. Internal thrust washer and retaining pins (50) 47a. Outer thrust washer 48. Range selector engagement sleeve 49. Sliding range star gear 50. Range selector driven gear pins 51. Rollers 52. Gear (53) shim washers 53. Range selector planet gears 54. Range selector support.

21-10

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 Removing the Top Shaft • Remove the back retaining ring (26, Fig. 6) and the end float adjustment shim (A, Fig. 6). If necessary, pull the lip seal (27, Fig. 6) from its seat on the top shaft. •

Remove the front end plate, or shaft bearing cover, over the drive shaft retaining nut by loosening the retaining screws (C2, Fig. 4).

•

Remove the top shaft bushing (28, Fig. 1). If necessary, use a slide hammer.

•

Drive out the top shaft (16, Fig. 9) using a suitable driver and retrieve the gears inside the housing.

9 Top Shaft (16) Removal Using a Punch 16. Transmission top shaft 27. Lip seal.

Removing the Reverse Side Shaft • Remove the circlip around the reverse drive shaft on the back of the assembly. •

Pry the end of the reverse drive shaft to remove it from the assembly. The reverse drive shaft is tightly fit. Use a wedge to move the shaft forward enough so you can use a punch from inside the front of the housing. If you have difficulty, you may want to tap the shaft with a drill and use a puller.

•

Retrieve the reverse idler gear (37, Fig. 10) and the retaining pin (72, Fig. 1) inside the housing.

10 Reverse Side Shaft (35) Removal 33. 34. 35. 36. 37. 38. 39.

21-11

Retaining ring Thrust washer Reverse drive shaft Rear ball bearing Reverse idler gear Transmission shifter forks Shifter fork (38) rod.

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 •

Remove the roller bushing (1, Fig. 11).

11 Reverse Drive Shaft Roller Bushing (1) Removal Using a Slide Hammer Punch 1.

Roller bushing.

Removing the Bottom Shaft • Remove the transmission 3rd and 4th synchro shifter forks (38, Fig. 12), pulling out the shifter rod (39, Fig. 12) and retrieving the balls and spring (70 and 71, Fig. 12). •

Engage two gears and loosen the drive shaft locknut (C13, Fig. 1). Remove the bearing shoulder covers and retrieve the seals (30, Fig. 8).

•

Remove circlip and outer ball bearing (43, Fig. 1).

•

Support the gears and synchronizers from inside the housing to keep them together for removal.

•

Drive the bottom shaft (40, Fig. 1) out of the front together with the roller bearing (41, Fig. 1), with a soft mallet on the rear end with a suitable punch.

12 Installing 3rd and 4th Synchro Shifter Rod (39) for Fork (38) 38. 39. 70. 71.

21-12

Shifter rod fork Shifter rod Shifter rod detent ball Shifter rod detent spring.

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 INSPECTING THE TRANSMISSION NOTE: When reassembling, replace the PTO top shaft seal in the top drive shaft. •

Check the condition of all the seals, making sure there is no scoring, lip damage or noticeable deformation. Replace as necessary.

•

Check the synchromesh spring (60, Fig. 13) by seeing if it still has a good gradual curve to its shape. Place the springs on a flat surface as in detail a, Fig. 13. Depress the springs in the center with a small load (P, Fig. 13) and check that the spring deflects about 1.5 mm (0.06 in.).

•

Inspect the synchronizer cone gap. A new transmission should have 2.7 mm (0.11 in.) clearance, and the minimum tolerance is 0.5 mm (0.02 in.).

•

Check that the shifting plates (61, Fig. 13) are not deformed or dented, especially on the center relief (R, Fig. 13).

13 Installing Shift Springs (60) and Corresponding Shift Plates (61) of Synchronizer a. Checking shift plate spring d. Detent pips P = 13.7 to 15.2 N (1.40 to 1.55 kg, 3.10 to 3.41 lbs.) test load R. Shift plate relief 58. Synchronizer cone 59. Synchrohub 60. Synchromesh spring 61. Shift plate for spring (60) 62. Sliding sleeve.

ASSEMBLING THE TRANSMISSION Installing 3rd / 4th Synchronizer • Fit the synchronizer cone (58, Fig. 14) and synchrohub (59) on the 3rd driven gear (63) complete with baulk ring so that the threetoothed sectors match the recesses in the baulk ring, and the lead-in chamfer on the splines faces toward the gear. •

Install a sliding sleeve (62, Fig. 14) so that the three-toothed synchrohub sectors (59) are included in the width spanning stepped teeth (D).

•

Position springs (60, Fig. 13) on shifting plate (61) as shown and refit in their recesses.

•

Install the second synchronizer cone with the three front fins in register with those of the first synchronizer cone previously fitted, and position the 4th driven gear.

•

Test the synchromesh effectiveness by operating the sliding sleeve by hand in both directions.

21-13

14 Synchromesh Sliding Sleeve (62) Installation D. V. 58. 59. 62. 63.

Stepped teeth Recess for spring shifting plate Synchronizer cone Synchrohub Sliding sleeve Driven gear.

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 Installing Bottom Shaft, Gears, and Complete Synchromesh • Install the outer ball bearing (43, Fig. 1) complete with circlip in transmission housing and fit the corresponding cover using the two single nuts. •

Upend the transmission housing so that the bottom end is at the top.

•

Place the front thrust washer (56, Fig. 1) in the housing and mount the complete synchronizer (B, Fig. 15), middle thrust washer (57, Fig. 1), second speed gear (63, Fig. 15) complete with internal ring, synchrohub (44, Fig. 15), reverse gear (67, Fig. 15), first speed gear (68, Fig. 15) complete with internal ring and rear thrust washer (69, Fig. 15), as shown Fig. 1.

•

Prefit the rear roller bearing (41, Fig. 15) to the shaft by heating it in oil at 80° to 90° C (176° to 194° F), and place it in position as shown in Fig. 1.

•

Insert the transmission drive shaft and its gears (40, Fig. 15) at the top.

•

Return the transmission to a horizontal position, install the front cover, and tighten the locknut (C13, Fig. 1).

Installing the Reverse Idler Gear and Shaft • Support the reverse idler gear (37, Fig. 1) inside the housing and insert the shaft complete with the bearing from the rear. •

Make sure that the retaining pin (72, Fig. 1) mates with the corresponding spline.

21-14

15 Installing Eight-Speed Transmission Driven Gear Shaft (40) B. 40. 41. 44. 63. 67. 68.

3rd and 4th speed synchronizer assembly, complete. Driven gear shaft Rear roller bearing 1st and 2nd speed synchrohub 2nd speed gear Reverse gear 1st speed gear.

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 Installing the Drive Shaft and Gears • Install the transmission top shaft complete with lip seal (27, Fig. 6), PTO shaft bushing (28, Fig. 1), and ball bearing (31, Fig. 1), and secure with circlip. •

Fit the external race of the roller bearing (32, Fig. 1) in the transmission housing and slide the complete transmission drive shaft in from the front end.

•

Fit the top shaft components in Fig. 1 in the following order: 1) 4th drive gear (76) 2) Drive gear spacer (75) 3) 3rd drive gear (74) 4) 1st and 2nd drive gear (73) 5) Then fit the internal race of the rear roller bearing (32) in the position shown.

•

Mount the front cover (17, Fig. 4) complete with gasket, making sure that the roller bearing (32, Fig. 1) is in perfect alignment. Fit shim (A, Fig. 6), selected in thickness to reduce the end float of the gear and bearing assembly to a minimum. Then mount the circlip (26, Fig. 6).

•

Shift the sliding sleeves and lock two gears at the same time. Then tighten the driven gear shaft locknut (C13, Fig. 1) to 300 N:m (220 ft.lbs.), peen it, and fit the driven shaft bearing cover (18, Fig. 4) together with the corresponding gasket.

21-15

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 Installing 3rd and 4th Synchro Shifter Rod • Replace detent spring and ball (70 and 71, Fig. 16). •

Install 3rd and 4th synchro shifter rod and range selector fork as shown in Fig. 16.

16 Installing 38. 39. 70. 71.

3rd

4th

and Synchro Shifter Rod (39) for Fork (38)

Shifter rod fork Shifter rod Shifter rod detent ball Shifter rod detent spring

Installing Shifter Rods • Insert roll pins into the saddles on the shifter rods as shown in Fig. 17.

17 Installing Roll Pins (arrows indicate orientation of roll pin split) 19. 3rd and 4th speed shifter rod 20. 3rd and 4th speed shifter fork 21. 3rd and 4th speed shifter saddle and lever 22. 1st and 2nd shifter rod 23. 1st and 2nd shifter lever saddle 24. Range selector shifter rod 25. Range selector shifter lever sadd;e

21-16

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 Installing the Range Selector Shifter Rod and Fork • Replace detent ball and spring (80 and 81, Fig. 18). •

Install the range selector shifter rod (1) as shown in Fig. 18.

18 Installing Range Selector Shifter Rod (1) and Fork A. 1. 80. 81.

Range selector engagement control fork (78, Fig. 4) Range selector shifter rod Detent spring Detent ball.

Installing the Range Selector • Fit the range selector planet gears (53, Fig. 19) to the range selector support bracket (54, Fig. 19) with recommended grease to seat the balls in each gear.

19 Range Selector Components 45. Range selector support internal thrust washer 46. Range selector fixed gear 47. Internal thrust washer and retaining pins (50) 47a. Outer thrust washer 48. Range selector engagement sleeve 49. Sliding range star gear 50. Range selector driven gear pins 51. Rollers 52. Gear (53) shim washers 53. Range selector planet gears 54. Range selector support.

21-17

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 Range Shifter Rod Installation • Install the remaining items according to Fig. 1, and tighten the retaining screws (C9, Fig. 20) to 98 N:m (72 ft.lbs.).

20 Range Shifter Rod Installation A. C6. C9. 26. 27. 49. 78.

End float adjustment shim Range selector control rod support retaining screws Range planetary retaining screws Retaining ring PTO shaft lip seal Range selector engagement sleeve Range selector engagement control fork

Installing the Transmission Shift Cover NOTE: After overhaul, thoroughly clean and degrease the mating surfaces, install new seals (9 and 10, Fig. 1), and properly lubricate the PTO shaft seal. •

Coat studs and capscrews securing the shifter levers with jointing compound for a proper seal.

•

Prefit the assembly on the bench, noting that you have to compress the detent spring (7, Fig. 21) with the detent lever (4) using a screwdriver, as shown in Fig. 21.

•

When positioning the cover of the transmission housing, make sure that the end of the gear shift lever and the pad on the internal reverse gear shift lever seats in the lever connectors (23 and 25, Fig. 17) and in the reverse idler gear (37, Fig. 1).

21 Installing Internal Reverse Shifter Lever C4. 2. 4. 7. 13. 46.

21-18

Capscrew securing brackets for spring (13) Reverse shifter lever. Detent lever Lever detent (4) spring Segment return spring Shifter segment.

SECTION 23 -- FOUR WHEEL DRIVE (FWD) TRANSFER BOX -- CHAPTER 1

SECTION 23 - FOUR WHEEL DRIVE (FWD) TRANSFER BOX Chapter 1 - Four Wheel Drive (FWD) Transfer Box CONTENTS Section

Description

Page

Transfer Box and Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

23-1

SECTION 23 -- FOUR WHEEL DRIVE (FWD) TRANSFER BOX -- CHAPTER 1 Section Through Axle Drive Control C12. Drive shaft center bearing capscrew C13. Axle drive housing capscrew 30. Drive shaft 31. Retaining ring 32. Rear spline sleeve 33. Center support complete with ball bearing 34. Retaining ring 35. Dust seal disc 36. Seal 37. Retaining ring 38. Ball bearing 39. Dust excluder 40. Driven gear 41. Splined driven shaft 42. Ball bearing 43. Intermediate shaft 44. Roller bearing 45. Intermediate gear 46. Drive gear keyed on bevel pinion 47. Pad 48. Inner relay lever 49. Plunger 50. Plunger spring 51. Plug 52. O ring 53. Axle drive control lever 54. Hand lever vertical link 55. Hand lever hingepin 56. Hand lever.

TRANSFER BOX AND AXLE SHAFT To remove the drive shaft: • Remove the shaft guard. •

Back off capscrews (C12) from the center mounting bracket.

•

Unseat the retaining ring (31).

•

Withdraw drive shaft (30) complete with the center support (33), moving the splined sleeve (32) inward.

•

Carefully inspect the splines of the shaft and sleeves.

•

Check the condition of the bore bearing in the center support (33).

23-2

SECTION 23 -- FOUR WHEEL DRIVE (FWD) TRANSFER BOX -- CHAPTER 1 Transfer box disassembly: • Remove the transfer box from the tractor by first removing the drive shaft and shaft guard. Drain the oil from the transmission case, detach the lift hand lever vertical link (54) from the axle drive control lever (53), remove the capscrews (C13), and remove the complete transfer box. •

Remove the retaining disk (35) of from the transfer box housing, along with the seal (36) and retaining ring (37).

2 Removing Driven Shaft (41) • Remove the driven shaft (41) with ball bearing (38) and dust excluder (39). •

Remove the driven gear (40) casing, unscrew the plug (51), remove the plunger spring (50), plunger (49) and extract the inner relay lever (48) by removing its spring plug.

3 Removing the Bearing Cup of Ball Bearing (42) • If necessary, remove the rear ball bearing (42) of the intermediate shaft housing using a universal extractor tool. •

If necessary, remove the intermediate gear (45) with the roller bearing.

Transfer box reassembly: • Reverse the disassembly procedure: •

Mount the new seal retaining disc (35), taking care to not distort the disc.

•

When refitting the transfer box housing, tighten the screws to their proper torque and check the condition of the transmission shaft.

23-3

SECTION 23 -- FOUR WHEEL DRIVE (FWD) TRANSFER BOX -- CHAPTER 1

23-4

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1

SECTION 25 - FOUR WHEEL DRIVE (FWD) FRONT AXLE Chapter 1 - Four Wheel Drive (FWD) Front Axle CONTENTS Section

Description

Page

25-1

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 FOUR-WHEEL DRIVE FRONT AXLE SPECIFICATIONS FRONT WHEEL DRIVE Type Bevel Gear Pair Differential Pinion to Crown Gear Ratio Backlash Between Bevel Gear Pair

TT55

TT75

Class 1 9 to 29 (1 to 3.22) 0.18 to 0.23 mm (0.007 to 0.009 in.) 9.5 - 24 11.2 - 24 1448 - 1956 mm 1422 - 2032 mm (57.0 - 77.0 in.) (56.0 - 80.0 in.) 4 inches; 2 inches each axle (101.6 mm; 50.8 mm each axle)

4WD Standard Front Tires 4WD Front Track Widths Track Width Intervals

BEVEL GEAR DIFFERENTIAL Thickness of Pinion Position Adjustment Spacer Thickness of Pinion Bearing Adjustment Spacer Thickness of Crown Wheel Position Adjustment Spacer Backlash Between Planet Pinions and Side Gears Thickness of Planet Pinion Thrust Washers

Specification 2.50 to 3.70 mm — 0.10 mm steps (0.098 to 0.146 in. — 0.004” steps) 2.50 to 4.80 mm — 0.05 mm steps (0.098 to 0.188 in. — 0.002” steps) 0.90 to 2.00 mm — 0.10 mm steps (0.035 to 0.079 in. — 0.004” steps) 0.15 mm (0.006 in.) 1.47 to 1.53 mm (0.058 to 0.060 in.) 1.40 to 1.80 mm — 0.10 mm steps (0.098 to 0.146 in. — 0.004 in. steps) 21.939 to 21.960 mm (0.8637 to 0.8646 in.) 22.040 to 22.061 mm (0.8677 to 0.8685 in.) 0.080 to 0.122 mm (0.0031 to 0.0048 in.)

Thickness of Side Gear Thrust Washers Diameter of Cross Pin for Planet Pinions Diameter of Cross Pin Bore in Planet Pinions Clearance Between Cross Pin and Bores

25-2

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 AXLE SHAFTS & STEERING KNUCKLES

Specification

Diameter of Outer Axle Shafts in Correspondence with Bushings

44.975 to 45.000 mm (1.7707 to 1.7717 in.)

Inside Diameter of Installed Bushings (Measurement taken without reaming)

45.100 to 45.175 mm (1.7756 to 1.7785 in.)

Clearance Between Axle Shafts and Bushings

0.100 to 0.200 mm (0.0039 to 0.0079 in.)

Interference Fit Between Bushings and Respective Bores

0.064 to 0.129 mm (0.0025 to 0.0051 in.)

Thickness of Steering Knuckle Bearing Adjusters

0.10 to 0.30 mm — 0.05 mm steps (0.004 to 0.012 in. — 0.002 in. steps)

EPICYCLIC FINAL DRIVES Gear Ratio Thickness of Driven Gear Shims

Specification 12 to 72 = 1 to 6 0.77 to 0.83 mm (0.030 to 0.033 in.)

AXLE PIVOT Endfloat at Pivot Between Axle Casing and Relative Supports Wear Limit Endfloat

Specification 0.30 to 1.10 mm (0.012 to 0.043 in.) 2.00 mm (0.079 in.) 52.652 to 52.671 mm (2.0729 to 2.0737 in.) 52.720 to 52.790 mm (2.0756 to 2.0783 in.) 0.049 to 0.138 mm (0.0019 to 0.0054 in.) 99.020 to 99.050 mm (3.8984 to 3.8996 in.) 99.146 to 99.221 mm (3.9034 to 3.9063 in.) 0.096 to 0.201 mm (0.004 to 0.008 in.) 4.90 to 5.00 mm (0.193 to 0.197 in.)

Diameter of Front Pin of Axle Pivot Inside Diameter of Installed Front Bushing (Without Reaming) Clearance Between Pin and Bushing Outside Diameter of Rear Bushing Installed in Bevel Pinion Support Inside Diameter of Rear Bushing Installed in Axle Pivot Support (Without Reaming) Clearance Between Two Bushings Thickness of Front and Rear Thrust Washer of Front Axle

SPECIAL TOOLS Tool to be made for adjustment of bevel drive pinion; to be used in conjunction with tool 380000248 (mark tool n. 50118 - measurement in mm). Made from material UNI C40.

25-3

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 FOUR-WHEEL DRIVE FRONT AXLE SPECIAL TOOLS 380000251

Front axle overhaul stand

380000255

Overhaul support for front axle differential casing

380000268

Wrench for threaded adjustment ring of front bevel drive pinion

380000248

Pinion bearing adjustment tool

380000257

Front bevel drive pinion lock key wrench

380000249

Universal gauge for positioning of front bevel drive pinion

380000252

Wrench for front differential case bearing threaded adjustment ring

380000295

Wrench for front axle wheel hub bearing retaining nut

380000548

Dowel studs (M12 x 1.25) for front axle and cover removal

380000265

Front axle pivot pin removal tool

380000234

Front axle pivot bearing outer ring removal tool

380000235

Tool for measurement of rolling drag torque of front axle bearing

380001633

Torque wrench for pinion lock key (crown wheel/pinion bearings)

Tool to be made for adjustment of bevel drive pinion; to be used in conjunction with tool 380000248 (mark tool n. 50118 - measurement in mm). Made from material UNI C40.

25-4

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1

3 FRONT WHEEL DRIVE TORQUES Crown Wheel to Differential Cage Retaining Bolt (C1) Bevel Pinion Shaft Lock Nut (C3) Final Drive Assembly Support to Axle Casing Retaining Bolt (C4) Steering Knuckle Pin Retaining Bolt (C5) Wheel Hub Bearings Lock Nut (C6) Epicyclic Final Drive Case Retaining Bolt (C7) Front Axle Support to Engine Retaining Bolt (C8) Front Axle Front and Rear Pivot Support Bolt (C9) Differential Cage Support Cap Bolt (C10) Nut For Rim to Disc Securing Bolt

25-5

Thread Size M12 x 1.25 M35 x 1.5 M12 x 1.25

Specification 113 N⋅m (83 ft.lbs.) 294 N⋅m (127 ft.lbs.) 113 N⋅m (83 ft.lbs.)

M10 x 1.25 M70 x 2 M10 x 1.25 M18 x 1.5 M18 x 1.5 M12 x 1.25 M16 x 1.5

64 N⋅m (47 ft.lbs.) 392 N⋅m (289 ft.lbs.) 64 N⋅m (47 ft.lbs.) 314 N⋅m (232 ft.lbs.) 314 N⋅m (232 ft.lbs.) 113 N⋅m (83 ft.lbs.) 245 N⋅m (181 ft.lbs.)

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 FOUR-WHEEL DRIVE FRONT AXLE DESCRIPTION AND OPERATION This front axle has a centrally pivoting front axle with the pivot and the drive shaft coaxial with the longitudinal axis of the tractor. The drive shaft has no universal joints.

The differential has two planet pinions; drive is transmitted to lateral epicyclic final drive units (installed on the wheel hubs) through universal joints which do not require any maintenance.

4 Cross-sectional view of front axle 95 mm. = Nominal distance between crown wheel axis 9. Shims for driven gears of epicyclic unit. and greater diameter of the pinion. 10. Steering knuckle adjustment plates. 1. Thickness of side gear thrust washers. 11. Thickness of bevel pinion position adjustment 2. Side gears. spacer. 3. Planet pinions. 12. Thickness of bevel pinion bearing adjustment spacer. 4. Thicknesses of crown wheel bearing adjustment shim. 13. Gasket. 7. Axle shaft. 14. Cross pin for planet pinions. 8. Axle shaft bush. 15. Crown wheel bearings adjustment nut.

NOTE: On assembly, apply a bead of silicone/gasket eliminator to the surface X.

25-6

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1

26131

5 1. 2. 3. 4.

Axle pivot front bush. Front thrust washer. Axle pivot front pin. Rear thrust washer.

Cross-sectional view of front axis pivot 5. Rear bush installed in axle support. 6. Rear bush installed in bevel drive-differential support.

25-7

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 FOUR-WHEEL DRIVE FRONT AXLE REPAIR COMPLETE FRONT AXLE Removal-Installation

DANGER Lift and handle all heavy parts using suitable lifting equipment with a sufficient lifting capacity. Check that the assemblies or parts are held firmly and supported by suitable slings and hooks. Make sure nobody is standing near to the load. Proceed as follows: NOTE: The front axle assembly can be removed from the tractor either with or without previously removing the drive shaft. The description below refers to removal of the front axle with the drive shaft installed on the tractor. 1. Unscrew bolts and remove the drive shaft guard. 2. Remove the circlip (2), and slide the sleeve (1) in the direction of the arrow and detach the drive shaft from the front axle.

3. Pass two nylon slings around the front axle and attach them to the lifting hook. 4. Lift the tractor with the lifting hook and place a stand under the sump pan.

25584

6 5. Unscrew unions (1) of rigid pipes (2) of the power steering cylinders and detach the two flexible hoses (3).

25578

25-8

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 6. Unscrew the wheel bolts and remove the front wheels.

25582

8 7. Unscrew the retaining bolts (1) of the rear support of the front axle.

25585

9 8. Unscrew the retaining bolts support of the front axle.

(1) of the front

25586

25-9

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 9. Using a lifting hook and two nylon cables (one for each side) detach the front axle from the tractor. 10. Install the front axle following the instructions below.

WARNING Always use appropriate tools to align fixing holes. NEVER USE YOUR FINGERS OR HANDS.

24864

11 •

Install the axle, and bolt the front and rear supports in position.

•

Reconnect the power steering pipes.

•

Install the front wheels.

•

Raise the front of the tractor using the lifting hook and hoist.

•

Remove the fixed stand.

•

Detach the nylon cables.

•

Reconnect the drive shaft and refit the drive shaft guard.

•

Reconnect the negative battery lead.

•

Adhere to the tightening torques indicated in the specifications.

25-10

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 FRONT AXLE Disassembly/Assembly

WARNING Handle all parts with care. Do not insert hands or fingers between one part and another. Wear suitable safety clothing, i.e. safety goggles, gloves and shoes.

25587

12 1. Unscrew plug (1) and drain off the oil from the axle casing.

1 25588

13 2. To drain the final drive oil, unscrew plug (1) on the left-hand epicyclic final drive casing; repeat the same operation on the right-hand casing.

25589

25-11

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 3. Remove the rear support (1) of the front axle; remove the front support and retrieve the washer.

25590

15 4. Unscrew the two track rod retaining bolts (1).

25591

16 5. Using a removal tool, withdraw the pins from their bores in the stub axle housing, and recover the track rod.

24080

25-12

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 6. Remove the circlips (2) from the cylinder rod pivot pins, unscrew the pin retaining bolts of the cylinder (1), withdraw the pins and detach the cylinder. Recover the two pins, washers, spacers and the cylinder complete with hoses.

25593

18 7. Unscrew the retaining bolts of the left-hand final drive casing cover (1). Screw in the two dowels 380000548 (2) and, using a sliding impact driver screwed into the oil drain plug, detach the cover (1) from the casing.

25594

19 8. Remove the circlip (1) securing the driving gear outside (2) and recover the gear.

25595

25-13

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 9. Remove the circlip (1) securing the driving gear inside (2, Fig. 19).

25596

21 10. Remove the staking (1) on the wheel hub bearing lock ring (2).

25597

22 11. Remove the wheel hub bearing lock ring using wrench 380000295 (1).

25598

25-14

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 12. Remove the wheel hub (1) with the ring gear (2). Recover all disassembled parts.

25599

24 13. Unscrew the three retaining bolts (1) of the lower pivot pin of the stub axle housing. Recover the lower pivot pin and the relative adjustment shims.

25600

25 14. Unscrew the three retaining bolts of the upper pivot pin. 15. Withdraw the upper pivot pin (1) and detach the stub axle housing (2). Recover the disassembled parts.

25602

25-15

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 16. Unscrew the retaining bolt (2) of the axle shaft (1).

25603

27 17. Using a crowbar, pry the axle shaft out of the casing. 18. To disassemble the right-hand final drive unit, repeat the above steps 7 to 17.

25604

28 19. Unscrew two of the bolts fixing the bevel drive-differential support to the axle casing. Screw in the two dowels 380000548 (1). Remove the remaining bolts and separate the bevel drive-differential support from the axle casing. Attach a cable (2) to the support and take up the strain with the hoist. Remove the bevel drive-differential support (3) from the axle casing.

25606

25-16

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 20. Unscrew the two bolts (2) of the crown wheel-differential support caps (1). Remove the crown wheel-differential assembly from the housing.

25612

30 21. Remove the circlip (1) from the splined shaft (2).

25614

31 22. Straighten the locking tab on the splined shaft lock nut (1).

25615

25-17

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 23. Unscrew the nut using wrench 380000268 (1) while holding the bevel drive pinion shaft against rotation with wrench 380000257.

25616

33 24. Recover the splined shaft detent ball (1).

25617

34 25. Remove the bevel drive pinion shaft (1) from the rear of the casing and recover the spacer, the adjustment shims and the bearing.

25618

25-18

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 26. Using a screwdriver, detach and recover the dust seal, the seal ring (1) and the rear bearing.

25619

36 27. Reassemble the front axle adhering to the following instructions: • Respect the tightening torques. •

Install the rear bearing, the seal, the dust seal, the adjustment shims, the spacer and the bevel drive pinion shaft complete with front bearing.

•

Position the detent ball, screw in the bevel drive pinion lock nut and secure in position by staking. Finally, replace the circlip.

•

Install the crown wheel-differential assembly, the support caps and tighten the relative bolts.

•

Install the bevel drive-differential housing on the front axle casing.

•

Install the axle shaft and relative bolt.

•

Install the stub axle, the adjustment shims, the upper and lower pivot pins.

•

Install the wheel hub, the ring gear of the final drive unit and the lock ring and tighten to the prescribed torque value, while simultaneously turning the wheel hub to ensure that the bearings are correctly seated.

•

Install the securing and stop circlips, the driving gear and the cover of the final drive unit.

•

Install the pins, washers, spacers and steering cylinders.

•

Install the track rod, the front and rear supports and the oil drain plugs.

25-19

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 STEERING KNUCKLE PINS AND BEARINGS Replacement In the event that the steering knuckle pins prove difficult to remove, proceed as follows. 1. Remove the grease nipples and the steering knuckle pin retaining bolts. 2. Install the bolts (1) of tool 380000265. 3. Install the plate (2) of the tool and fix it to the three bolts with nuts (5). 4. Install the central tie bolt (4) screwing it fully into the grease nipple bore on the pin (6). 5. Screw in the nut (3) to drive the pin out of its bore.

37 6. Using extractor tool 380000234 (1) remove the steering knuckle bearings. 7. Re-install the steering knuckle bearings using a suitable drift.

25-20

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 STUB AXLE ADJUSTMENT

WARNING Handle all parts with great care. Do not put your fingers or hands between one piece and another. Wear suitable safety clothing, i.e. safety goggles, gloves and footwear. Install the front axle on a stand and proceed as follows. 1. Smear grease on the outer races of the bearings and fit the upper cover, without the adjustment plate, but with tool 380000235 (2). Tighten the retaining bolts to a torque value of 64 N⋅m (47 ft.lbs.).

24076

39 2. Install the lower cover without adjustment plate, lubricate the three retaining bolts with engine oil. 3. Gradually tighten the lower cover bolts in sequence, while simultaneously rotating the casing to allow the excess grease to escape.

24077

40 4. Using a torque wrench and tool 380000235 (1), check that the torque required to rotate the casing is 2.9 N⋅m (2.1 ft.lbs.) (with torque increment of 0.98 N⋅m (0.7 ft.lbs.), without considering the peak starting value. If not, adjust by way of the lower cover bolts.

5. Measure the gap (H) created between the low cover and the casing in correspondence with the three bolts.

24078

25-21

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 6. Calculate the average of the three value measured. The total thickness of the adjustment shims to be fitted under the lower cover is to be calculated as follows: S3= H If necessary, round up the value to the next 0.05 mm. 7. Partially unscrew the bolts of the lower cover, insert the shims and tighten the bolts (C5, page 6-3) to a torque value of 64 Nâ&#x2039;&#x2026;m (6.5 kgm, 47 ft.lbs.). 8. After having rotated the casing a few times to allow the components to bed down, check that the torque necessary to rotate the casing is 2.9 - 7.8 Nâ&#x2039;&#x2026;m (2.1 - 5.8 ft.lbs.), without considering the initial peak torque. 9. If the torque value measured is greater than the prescribed value, increase the thickness of the shims, if the measured value is less than the prescribed value, reduce the thickness of the shims. 10. Install the grease nipples in the upper and lower covers and grease the assembly.

24079

25-22

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 BEVEL DRIVE ADJUSTMENTS Adjustment of the preload of the pinion shaft bearings

WARNING Handle all parts with care. Do not insert hands or fingers between one part and another. Wear suitable safety clothing, i.e. safety goggles, gloves and footwear. Proceed as follows. 1. Clamp tool 380000248 (1) in the vice, fit the inner races of the bearings (2 and 4) and the bearing spacer (3) and tighten the nut of the tool fully home. NOTE: Interpose tool 50118 between tool 380000248 (1) and the bearing (2).

43 2. Using a micrometer, measure distance (H1) between the upper surface and the pin of tool 380000248 (1). 3. Disassemble the above parts, lubricate the bearings with engine oil and then re-assemble the parts, excluding the bearing spacer, in the bevel drive-differential housing, complete with outer bearing races, held in the clamp by way of tool 380000255.

24585

25-23

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 4. Tighten the nut of tool 380000248 (1) (see Note above) fully home, while turning the tool to ensure that the bearings are seated correctly. 5. Using a micrometer, measure distance (H2) assumed by the tool in this condition. 6. The thickness of the adjustment shim required is given by: S = H2 - H1 + 0.05 mm

24586

45 If necessary, round the value thus obtained up to the nearest 0.05 mm. NOTE: On completing the adjustment, do not remove the adjustment tool from the bevel drive-differential housing: leave in place for adjustment of the drive pinion position.

25-24

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 BEVEL DRIVE ADJUSTMENTS Determining the thickness of the drive pinion position adjustment shim. Proceed as follows. 7. Install tool 380000249 (1) in the bevel drive-differential housing complete with outer bearing rings, crown wheel bearings adjustment ring, crown wheel bearings adjustment shim, circlip and differential support caps. 8. Screw the cones (3) of tool 380000249 (1) in or out in order to orientate the micrometer shaft in the direction of the inner bearing ring and eliminate end float between the cones and the outer rings of the crown wheel bearings. 9. Adjust the micrometer so that the shaft is in contact with inner bearing race and measure the distance (H3) thus obtained. 10. Determine the correct distance (H5) between the crown wheel axis and the large diameter base of the pinion: H5 = H4 Âą C where: H4 = 95 mm nominal distance between the crown wheel axis and the large diameter base of the pinion. C = correction value stamped on pinion preceded by a + or - sign, (if other than 0), to be added to or subtracted from the nominal distance (H4) according to the sign. 11. The thickness of the adjustment shim will be given by: S = H3 - H5 where: H3 = the distance measured using the micrometer; H5 = corrected nominal distance between the crown wheel axis and the large diameter base of the pinion. 12. Remove tools 380000248 and 380000249 from bevel drive housing. 13. Install the drive pinion complete with: inner bearing races, spacer and adjustment shims of the previously determined thickness.

25-25

24588

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 14. Install the O-ring seal (1) on the drive pinion shaft.

15. Then insert the spacer and then the detent ball, after having carefully lubricated the outer surface.

24589

47 16. Install the pinion lock tool 380000257 (2). 17. Install wrench 380000268 on the threaded adjustment ring. 18. Using a wrench on the pinion lock tool (2), hold the pinion against rotation, and using a torque wrench positioned exactly as shown in the figure on the threaded adjustment ring wrench (1), tighten the adjustment ring (C3, Fig. 3) to a torque value of 294 N⋅m (217 ft.lbs.), while simultaneously rotating the pinion shaft to ensure that the bearings are seated correctly.

24589

48 19. With a torque wrench (1) on the pinion lock tool 380000257 (2), check that the pinion rolling torque, without oil seal (13, Fig. 4) and relative dust seal ring, is 0.5 - 1 N⋅m (0.37 - 0.74 ft. lbs.). If the rolling torque is less than the prescribed value, fit a thinner adjustment shim (12, Fig. 4), if the torque is greater than the prescribed value, fit a thicker adjustment shim.. 20. Unscrew the threaded adjustment ring and fit the oil seal (13, Fig. 4) and the relative dust seal ring. Tighten the threaded ring to a torque of 294 N⋅m (217 ft. lbs.), while simultaneously rotating the pinion shaft to ensure that the bearings are seated correctly. 21. With a torque wrench (1) on the pinion lock tool 380000257 (2), check that the pinion rolling torque with the oil seal and relative dust seal ring is ≤ 0.50 N⋅m (0.37 - 0.74 ft. lbs.). Finally, carefully stake the threaded ring and fit the circlip on the drive pinion shaft.

25-26

24587

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 BEVEL DRIVE ADJUSTMENTS Adjustment of the crown wheel bearings and checking the backlash between the pinion and crown wheel. Proceed as follows. 1. Install the differential assembly complete with crown wheel and inner crown wheel bearing rings in the bevel drive/differential housing. 24112

50 2. Insert the outer bearing rings in the bevel drive/differential housing, fit the differential support caps, tighten the relative bolts to a torque of 59 N⋅m (44 ft.lbs.), then slacken them off and re-tighten to a torque of 20 N⋅m (15 ft.lbs.).

24591

51 3. With the bearings lubricated, rotate the crown wheel and at the same time tighten the threaded adjustment ring using wrench 380000252 (1) to a torque of 39 - 59 N⋅m (29 - 44 ft. lbs.) to take up the axial play between the components. 4. Measure the backlash between pinion and crown wheel, using a dial gauge perpendicular to the outer edge of a tooth on the crown wheel (1, Fig. 51).

24592

25-27

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 5. Repeat the measurement in a further two positions 120° apart and compare the average of the three values (Gm) with the prescribed normal backlash: 0.18 - 0.23 mm average value 0.20 mm (0.007 - 0.009 in., 0.008 average). If the measured backlash exceeds the prescribed value, adjust the threaded adjustment rings by screwing one of the rings in and the other out by the same amount to correct the axial preload and thus obtain the prescribed backlash.

24593

53 6. With a dial gauge positioned perpendicular to the outside edge of one of the crown wheel teeth, check that the backlash between the pinion and crown wheel is within the prescribed tolerance limits of 0.18 - 0.23 mm ( 0.007 -0.009 in.). 7. Using a wrench 380000252 (1), turn the threaded adjustment ring and check, using torque wrench (1), that the rolling resistance torque of the crown wheel and pinion bearings, as measured in the same conditions as used to check the pinion only, is:

24592

54 A2 = A1 + 1.0 - 1.5 N⋅m (0.74 - 1.11 ft. lbs.) where: A2 = pinion-crown wheel rolling resistance torque; A1 = rolling resistance torque of pinion only as measured previously; 1.0 - 1.5 N⋅m (0.74 - 1.11 ft. lbs.) = rolling resistance torque of crown wheel only measured at the end of the pinion using wrench 380000257 and a torque wrench.

24594

25-28

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 8. Tighten the cap bolts ( C10, Fig. 1) to a torque of 113 Nâ&#x2039;&#x2026;m (11.5 kgm, 83 ft.lbs.). 9. Install the safety plate, screwing the threaded adjustment ring in or out up to the nearest notch. 10. Attach the bevel drive/differential to the axle casing after having carefully cleaned and degreased the mating surfaces and applied a bead of silicon approx. 2mm (0.08 in.) wide along the line shown in the figure below.

24591

56 Silicone/gasket eliminator application diagram for assembly of bevel drive unit and epicyclic final drive unit.

24595

25-29

SECTION 25 -- FOUR WHEEL DRIVE (FWD) FRONT AXLE -- CHAPTER 1 FRONT AXLE DIFFERENTIAL Overhaul In case of differential assembly overhaul it is necessary to adjust the backlash between the teeth of the planet pinions and side gears. Proceed as follows: 1. Thoroughly clean the components of the differential to remove any traces of oil which would otherwise prevent accurate backlash measurement. 2. Install the two side gears without thrust washers. 3. Install the planet pinions complete with thrust washers and pins and screw the pin retaining bolts in by a few turns to hold the pins in place. 4. Position a dial gauge on the differential housing. 5. Move the left-hand the side gear to bring it into full contact with the planet pinion and then push it up against the differential housing, reading the endfloat (Gs) on the dial gauge.

24597

58 6. Repeat the above operations to measure the endfloat on the right-hand side gear (Gd). The endfloat should be 0.25 mm (0.010 in.). Therefore the shims to be inserted in the differential housing are given by: Ss = Gs - 0.25 mm for the left-hand side gear; Sd = Gd - 0.25 mm for the right-hand side gear. 7. Install shims as near as possible to the calculated value, and, using a dial gauge and following the procedure described above, check that the endfloat of the left and right-hand side gears is approximately 0.25 mm (0.010 in.).

24598

25-30

SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1

SECTION 27 - REAR AXLE AND TRANSMISSION Chapter 1 - Rear Axle and Transmission CONTENTS Section

Description

Page

27-1

SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1 TORQUES

Thread Size

Specification

M12 x 1.25

122 N⋅m (90 ft.lbs.)

M40 x 1

300 N⋅m (220 ft.lbs.)

Differential bearing carrier bolts

M10 x 1.25

68 N⋅m (50 ft.lbs.)

Capscrews securing differential lock pedal bracket

M10 x 1.25

68 N⋅m (50 ft.lbs.)

Differential bearing carrier

M10 x 1.25

61 N⋅m (45 ft.lbs.)

Capscrews, final drive cover

M10 x 1.25

68 N⋅m (50 ft.lbs.)

Retaining screws for bracket securing driven gear outer bearing

M10 x 1.25

68 N⋅m (50 ft.lbs.)

Capscrews securing final drive housing to transmission housing

M12 x 1.5

108 N⋅m (80 ft.lbs.)

W12-28 and W13-38 wheel rim retaining screws

M16 x 1.5

190 N⋅m (140 ft.lbs.)

W11-32 wheel rim retaining screws

M16 x 1.5

235 N⋅m (175 ft.lbs.)

Wheel disc to axle flange retaining screws

M16 x 1.5

237 N⋅m (195 ft.lbs.)

Driven gear locknut

M55 x 1.5

950 N⋅m (700 ft.lbs.)

Bevel Drive and Differential Self-locking nuts for bolts securing ring gear Nut locking bevel pinion shaft

Final Drive

FINAL DRIVES

Specification

Type

Single reduction

Gears

Spur

Small Final Drive Reduction Ratio (2WD TT55)

11 to 62 (1 to 5.636)

Large Final Drive Reduction Ratio (All 4WD and 2WD TT75)

11 to 68 (1 to 6.180)

Small Final Drive Backlash (2WD TT55)

0.15 to 0.25 mm (0.006 to 0.010 in.)

Large Final Drive Backlash (All 4WD and 2WD TT75)

0.15 to 0.25 mm (0.006 to 0.010 in.)

27-2

SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1

1 a. b. C1. C2. C3. C4. C5. C7. T.

Longitudinal Section Through LH Final Drive for 3-disc models (2WD 3010 and 2WD 4010) 1. Wheel disc for 4-disc models (all 4WD and 2WD 5010) 2. Wheel shaft and flange Final drive housing cover capscrews 3. Final drive housing cover Retaining screws for bracket securing driven gear 4, 5 and 6. Ball bearings outer bearing 7. Roller bearing Capscrew securing driven housing to transmission 8. Final drive driven gear housing 9. Axle shaft Wheel rim retaining screws 10. Final drive Wheel disc retaining screws 11. Disc brakes Driven gear locknut 12, 13 and 14. Seals Drain plug 17. Retaining ring.

27-3

SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1 SPECIAL TOOLS 380000612 Clutch centering pin 293101/1

Bevel pinion taper bearing adjustment

293510

Bevel drive universal tool for pinion bearing adjustment

380000249 Gauge for bevel pinion position 293632

Bevel drive bushing

290061

Driven gear retaining nut removal wrench

290240

Nut removal wrench extension

292904

Set with driven gear puller

292911

Set with roller bearing internal ring puller/separator

2 Ring Gear/Differential Support Bearing Adjustment B = 54.7 to 55.0 mm (2.15″ to 2.16″) C = 62.0 mm (2.44″) D = 10.0 mm (0.40″) E = 29.8 to 30.0 mm (1.17″ to 1.20″) F = 110.0 mm (4.33″) G = 20.0 mm (0.79″) H = 15.0 mm (0.59″) L = 5.0 mm (0.20″) M = 10.0 mm (0.40″) N = 5.0 mm (0.20″) P = chamfer 1.0 mm (0.04″) x 30°.

27-4

SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1 REAR TRANSMISSION HOUSING REMOVAL/INSTALLATION •

Disconnect the negative battery lead.

•

Drain the transmission housing oil.

•

Remove the ROPS frame, the fenders, the floorboards, the hydraulic lift complete with suction and delivery piping, the implement mounting attachments and towing features.

•

Remove the final drives.

•

Position the PTO control lever to “Engine Driven” and remove the corresponding cover and lever.

•

Connect the transmission housing to a lifting tackle with hook.

•

Undo the studs and nuts securing the transmission housing, and detach by slowly lifting it, taking care to avoid damaging the PTO shaft.

3 Detaching Rear Transmission Housing 1.

•

PTO shaft.

If possible, mount the rear transmission housing to a rotary stand.

4 Rear Transmission Housing Mounted in Rotary Stand 1.

27-5

PTO clutch shaft.

SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1 BEVEL DRIVE AND DIFFERENTIAL REMOVAL

4 9

b1. Section through differential lock control C2. Bevel ring gear retaining screw nuts C3. Bevel pinion shaft nut H = 128 mm (5.0”) nominal distance between ring gear centerline and back of pinion S. Bevel pinion positioning shim Sp. Bevel pinion bearing shims T. Plug 3. PTO ground drive gear 6. RH differential bearing carrier 7. LH differential bearing carrier 15. Thrust washer 16. Differential side gear 17. Thrust washer 18. Differential pinion gear 19. Differential pinion gear journal 20. Bevel pinion shaft 25. Side gear journal (19) retaining screw. 26. Allen screw 27. Bearing lock ring 28. Differential lock spring 29. Differential lock fork 30. Differential lock spindle 31. Front bevel pinion bearing 32. Rear bevel pinion bearing 49. Sliding range star gear

3 1 3

3 2

2 0

2 7

1 7

6 1 6

1 8

2 8

2 9

2 6

3 0 5

Sections Through Bevel Drive

•

Remove the brakes from both sides of the housing.

•

Remove the two Allen screws and remove the lock ring to the differential bearing backlash adjuster.

•

Unscrew the six 17 mm bolts retaining the differential bearing carrier on both sides of the rear axle.

27-6

SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1 •

Remove the rear PTO cover complete with PTO input and output gears and shafts, removing the sliding gear (2, Fig. 6) from the PTO input shaft (1) through the top side of the housing.

•

Unscrew the capscrews (C1, Fig. 7) and remove the plate (3).

•

Tap the PTO clutch shaft end (1, Fig. 7) with a lead mallet and remove it from the rear, complete with bearing (4).

•

Remove the bevel drive and differential supports.

•

Detach the differential lock pedal and the pedal bracket.

•

Remove the plug (T, Fig. 5).

•

Collect the spring (28, Fig. 5), and differential lock shift fork (29). Check that all parts are in good condition, and within specifications.

•

Remove the spindle using a punch and mallet, if necessary, from the left hand side of the transmission housing.

•

Remove the complete bevel drive and differential assembly.

•

Separate the ring gear from the differential case by undoing the studs (C2, Fig. 5).

•

Remove the journal retaining screw (25, Fig. 5) from the side gear journal (19), collecting the differential pinions and the side gears.

•

Loosen and remove the bevel pinion shaft nut (C3, Fig. 5).

•

Drive the bevel pinion shaft (20, Fig. 5) out rearward with a suitable driver.

•

Collect the front and rear bevel pinion bearings and corresponding shims, along with the PTO ground drive gear.

1 2

6 Bevel and Differential Longitudinal and Cross-Sections 1. PTO input shaft 2. PTO sliding gear 3. PTO ground drive gear S. Bevel pinion shim Sp. Pinion bearing shims 20. Bevel pinion 21 and 24. Taper roller bearings NOTE: On assembly, thoroughly clean and degrease mating surfaces, and apply a jointing compound.

NOTE: The rear bevel pinion bearing inner race must be heated to remove and install.

7 Disassembling (Assembling) PTO Engagement Sliding Gear C1. 1. 2. 3. 4.

27-7

Capscrews securing plate (3) PTO input Sliding gear Plate retaining bearing (4) Ball bearing.

SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1 REASSEMBLING THE BEVEL DRIVE AND DIFFERENTIAL Bevel Drive Shaft Bearing Preload Adjustment (shim thickness, SP, Fig. 5) NOTE: Tool 293101 sets the preload with an internal spring, but the rolling torque should be 0.8 N:m (10 in.lbs.). Follow the bevel pinion bearing adjustment and shim thickness calculation (Sp, Fig. 5) using tool 293101/1 (R, Fig. 8): •

Fit the bearing inner rings (1 and 3, Fig. 8) on tool 293101/1 (R).

•

Fit the spacer (2) and PTO drive gear (4) on two-wheel drive tractors with ground speed PTO (a, Fig. 8). Fit the double drive gear (5) for four-wheel drive tractors with ground speed PTO and front axle drive (a, Fig. 81).

•

Tighten the locknut (M) on the tool and take the reading (H1) using a depth gauge.

•

Disassemble, lubricate the bearings and fit the tool in the housing.

•

Tighten locknut (M, Fig. 8) once more, turning the tool at the same time to settle the bearings.

•

Take the reading (H2). Shim thickness (Sp) will be given by: Sp = H2 – H1 + 0.05 mm (0.002″) where: 0.05 mm = correcting required to compensate increased preload on bearings caused by tightening pinion shaft locknut. If necessary, round off Sp upwards to nearest 0.05 mm (0.002″).

NOTE: On completion of adjustment, do not remove tool from housing before performing bevel pinion position adjustment.

Bevel pinion taper bearing adjustment and shim thickness calculation (Sp) using tool 293101/1 (R) a. Two-wheel drive tractors with ground speed PTO. a1. Four-wheel drive tractors with ground speed and front axle drive. H1 and H2. Distance to measure using depth gauge M. Locknut R. Adjustment tool 293101/1 1. Bearing inner ring 2. Spacer 3. Bearing inner ring 4. PTO drive gear 5. PTO and live front axle drive double drive gear 7. Transmission housing.

27-8

SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1 Bevel Pinion Shaft Depth Adjustment (shim thickness, S, Fig. 5) • Install tool 380000249 (D, Fig. 9) on differential supports as shown in Fig. 9. •

Tighten or slacken the two centering cones (1, Fig. 9) to bring micrometer (2) to bevel pinion shaft bearing inner race (3).

NOTE: Use tool mandrel marked 125 mm – 150 mm. •

Turn the centering cones by hand and tighten the tool slightly against bearing cups to eliminate tool end play.

•

Lock micrometer gauge with the screw (5, Fig. 9).

•

Bring micrometer feeler in contact with bearing inner race and take reading (H5).

•

Establish correct nominal distance (H6) between ring gear centerline and back of pinion: H6 = H +/– C, where:

•

H = 128 mm (5.0”) nominal distance between ring gear centerline and back of pinion.

Measurement of distance (H5) with universal tool (D) and specific tool (R)

C = correction factor stamped on pinion head, expressed in mm preceded by + or – sign (if other than 0) to be summed with or subtracted from the nominal value (H) depending on the sign indicated.

D. Universal tool 380000249 R. Specific tool 293101/1 1. Centering cones 2. Micrometer mandrel 3. Bevel pinion shaft bearing inner race 4. Micrometer gauge 5. Micrometer screw

The shim thickness (S) will be given by: S = H5 – H6, where: H5 = distance measured by micrometer gauge. H6 = corrected nominal distance between ring gear centerline and back of pinion. Example: Micrometer reading H5 = 132.0 mm. Nominal distance between ring gear centerline and back of pinion H = 128.0 mm. Correction factor C = – 0.2 mm Corrected nominal distance H6 = 128.0 – 0.2 = 127.8 mm Shim thickness = S = 132.0 – 127.8 = 4.2 mm.

Assembling the Bevel and Pinion Shaft • Tap new bearings into place using a suitable punch or heat up the inboard races of the bearings in oil at 80° to 90° C (176° to 194° F). •

Assemble the pinion shaft and lock the nut down.

27-9

SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1 Differential Bearing Adjustment and Bevel Drive Backlash Check NOTE: To install lock rings, make tool as specified in Fig. 10. •

With bevel pinion installed, install the differential assembly, with bevel ring gear.

10 Tool for Ring Gear / Differential Support Bearing Adjustment B = 54.7 to 55.0 mm (2.15″ to 2.16″) C = 62.0 mm (2.44″) D = 10.0 mm (0.40″) E = 29.8 to 30.0 mm (1.17″ to 1.20″) F = 110.0 mm (4.33″) G = 20.0 mm (0.79″) H = 15.0 mm (0.59″) L = 5.0 mm (0.20″) M = 10.0 mm (0.40″) N = 5.0 mm (0.20″) P = chamfer 1.0 mm (0.04″) x 30°.

•

Fit the LH lock ring (Gs, Fig. 11) and tighten to ensure minimum backlash of about 1.0 mm (0.04″) between the sides of the bevel gear teeth.

11 Installing LH Lock Ring (Gs) for Ring Gear/ Differential Support Bearing Adjustment A. Adjustment Tool Gs. LH lock ring 1. LH support.

27-10

SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1 •

Fit the RH bearing (Gd, Fig. 12) and tighten to obtain pinion ring gear assembly rolling torque of 9.8 to 14.7 N⋅m (7.2 to 12.3 ft.lbs.). This torque is measured using a spring balance and cord wrapped around the differential carrier, and corresponds to a spring balance pull of 98 to 147 N (10 to 15 kg, or 22 to 33 lb.).

•

Check bevel drive backlash using a dial gauge, taking measurements at three equidistant points and comparing the average of the three readings to the backlash value expected — 0.18 to 0.23 mm, with an average of 0.21 mm (0.007″ to 0.009″, average of 0.008″). To compensate for excessive or insufficient backlash, note that the average ratio of normal backlash to equivalent ring gear displacement is 1 to 1.4. Ring gear end play will therefore be:

12 Installing RH Lock Ring (Gd) for Ring Gear/ Differential Support Bearing Adjustment A. Adjustment Tool (Fig. 5) Gd. RH lock ring 2. RH support.

Z = (G – 0.21 mm) x 1.4 where: G = bevel gear backlash as measured previously. •

Adjust the rings, first unscrewing the RH one and then screwing in the LH one to the same degree, until you obtain the specified backlash — 0.18 to 0.23 mm, with an average of 0.21 mm (0.007″ to 0.009″, average of 0.008″).

NOTE: One complete turn of the lock ring corresponds to 2.00 mm (0.079″) ring gear axial displacement (Z). Consequently, a 60° turn of the lock ring, equivalent to one side of the lock ring hexagon, corresponds to 0.33 mm (0.013″) axial displacement.

•

13 Adjusting Ring Gear Bearings 60° = Lock ring (Gs or Gd) rotation = 0.33 mm (0.013″) displacement.

Fit the lock washer (R, Fig. 14) on the lock rings so that the washer tab is aligned with a notch on the differential support.

14 Lock Washer (R) Installation

27-11

SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1

15 a. Measuring dimension (H1)

Determining Side Gear Shim Thickness b. Measuring dimension (H2).

Using a depth gauge, measure dimension H1 (Fig. 15) at two diametrically opposed points and average the two readings.

Side gear end float corresponding to normal backlash will be:

•

Then push the side gear into contact with differential carrier and measure dimension H2 (Fig. 15).

Consequently, the thrust washer thickness required in the differential carrier is given by:

•

Repeat the same operations on RH side gear.

•

End float of each side gear without the thrust washer must be:

•

0.15 X 1.7 = 0.25 mm (0.010″)

Ss = Gs – 0.25 (for LH side gear) Sd = Gd – 0.25 (for RH side gear) Available shims are 1.5 and 1.6 mm (0.059 and 0.063 in.) — install closest to calculated thickness.

Gs or Gd = H1 – H2 where: Gs = LH side gear end float. Gd = RH side gear end float. H1 and H2 = Dimensions measured on LH or RH side gears. •

Normal differential pinion and side gear backlash is 0.15 mm (0.006″).

NOTE: The average ratio of normal backlash to the equivalent side gear end float is 1 to 1.7.

27-12

Differential Pinion and Side Gear Backlash Adjustment • Fit the two side gears (16, Fig. 5) in the differential carrier without the thrust washers (15). •

Install differential pinions (18, Fig. 5) complete with thrust washer (17) and journal (19).

•

Tighten retaining screws (25, Fig. 5) a few turns to prevent journal work out.

•

Bring LH side gear into full contact with differential pinion.

SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1 FINAL DRIVE FINAL DRIVE REMOVAL

CAUTION Raise and handle all heavy components using a suitable lift. Ensure that units or parts are supported by suitable slings or hooks. Ensure that there is no one in the vicinity of the load to be lifted. Remove final drives as follows: •

Drain oil from rear transmission and final drive housing.

•

Position a support stand under transmission housing and remove the ROPS frame, the wheels, the fenders and the platform.

•

Take out capscrews and remove final drive assembly, Fig. 16.

FINAL DRIVE DISASSEMBLY (COVER)

CAUTION Handle all parts with care. Do not put hands and fingers between parts. Wear safety items such as goggles, gloves and safety shoes. Disassemble as follows: •

Take off capscrews (C1, Fig. 7) and remove the final drive housing cover (3) with final drive driven gear (8). There are two dowels holding the driven gear cover in place.

27-13

16 Final Drive Assembly Removal (Installation)

SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1 •

Tighten two M16 x 1.5 screws (C5, Fig. 17) into two of the wheel disc holes on the hub and clamp the wheel shaft in a vice.

•

Unscrew the driven gear locknut, Figure 17.

17 Driven Gear Locknut Removal B. Wrench 290061 C. Extension for wrench 290240 C5. M16 x 1.5 screws for retaining cover in vice.

•

Withdraw driven gear (8, Fig. 18) from wheel shaft (2) using puller.

18 Driven Gear Removal Using Puller 2. 8.

27-14

Wheel shaft Final drive driven gear

SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1 •

Withdraw spacer (18, Fig. 19), and knock out wheel shaft by beating with a soft hammer in the direction shown by arrow in Fig. 19.

•

Use puller to withdraw the outer roller bearing (7) from the cover (3).

•

Remove the retaining bracket (19).

•

Withdraw the ball bearing (4) from the cover.

19 Wheel Shaft (2) Removal (Installation) (Arrow indicates shaft removal direction) C2. 2. 3. 4. 7. 18. 19.

Bracket (19) retaining screw Wheel shaft Cover Ball bearing Roller bearing Spacer Ball bearing (4) retaining bracket.

FINAL DRIVE DISASSEMBLY (HOUSING) •

Remove the ball bearing (5, Fig. 20) from the final drive housing (10) using a suitable puller.

•

Remove the bearing retaining ring (17) and withdraw axle half shaft (9) together with ball bearing (6), in the direction shown by the arrow.

20 Final Drive Housing (Arrow indicates half shaft, 9, removal direction.) 5 and 6. Ball bearings 7. Roller bearing internal ring 9. Half shaft 10. Final drive housing 17. Bearing (6) retaining ring.

27-15

SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1 •

Remove the roller bearing (7, Fig. 21) internal race from the axle shaft, using puller (as shown in Fig. 21).

•

Remove the ball bearing (6, Fig. 20) from the axle shaft (9), having first removed the lock ring (17).

•

Check and replace bearings as required, and replace damaged or worn parts.

•

Check lip seals and replace if necessary.

NOTE: The seal separates the final drive hub oil from the rear axle oil. If there’s excessive noise, use EP80 or EP90 in the external hubs.

FINAL DRIVE ASSEMBLY Carry out the above operations in the reverse order, bearing in mind the following: •

Place the roller bearing (7, Fig. 21) in its seat in the final drive cover with the mark on the outside.

•

Install the other bearings, using appropriate installers.

•

Fit the half shaft and wheel shaft, taking care not to damage the seals.

•

Fit the roller bearing internal ring (7, Fig. 20) on the half shaft (9), having heated it in oil to 80°-90° C (176°-194° F).

•

Tighten the gear locknut using the wrench (B, Fig. 17) and extension (C, Fig. 17), previously used for disassembly.

•

Tighten all the nuts and screws to the torque values in the specifications section.

•

Clean and degrease the surfaces in contact between the housing (10, Fig. 20) and the cover (3, Fig. 19), inserting a new seal (14).

•

Applying a surfaces.

jointing

compound

mating

27-16

21 Roller Bearing (7) Internal Ring Removal from Axle Shaft D. Puller/separator 7. Roller bearing.

SECTION 31 -- POWER TAKE-OFF (PTO) -- CHAPTER 1

SECTION 31 - POWER TAKE-OFF (PTO) Chapter 1 - Power Take-Off (PTO) CONTENTS Section

Description

Page

31-1

SECTION 31 -- POWER TAKE-OFF (PTO) -- CHAPTER 1 SPECIFICATIONS

POWER TAKE-OFF (PTO)

Specification

Type

Independent engine driven only or engine driven and ground driven

Control

Hand lever

Output Shaft Clutch Control

Hand lever on transmission cover

Rotation as Viewed from Rear

Clockwise

Engine Speed with PTO at 540 RPM

1967 RPM

PTO Speed at Rated Engine Speed (2500 RPM)

686 RPM

Output Shaft Splines

Six splines 34.925 mm (1.375 in., 13/8″)

Output Shaft Diameter Output Shaft Speed / Rear Wheel Revolution Ratio (2WD TT55)

14.2 to 1

Output Shaft Speed / Rear Wheel Revolution Ratio (All 4WD and 2WD TT75)

15.5 to 1

TORQUE SPECS

Thread Size

Specification

Capscrews securing cover to rear transmission housing

M12 x 1.5

108 N⋅m (80 ft.lbs.)

Capscrews securing cover to rear transmission housing

M16 x 1.5

230 N⋅m (170 ft.lbs.)

Capscrews securing PTO bearing cover for power output and pulley

M14 x 1.5

163 N⋅m (120 ft.lbs.)

Nut securing PTO shaft driven gear to shaft

M22 x 1.5

258 N⋅m (190 ft.lbs.)

Power Take-Off

31-2

SECTION 31 -- POWER TAKE-OFF (PTO) -- CHAPTER 1 NOTE: A safety interlock, or neutral switch prevents the starter motor from operating when the PTO control lever is in the engaged position.

PTO Attachments

WARNING When operating PTO equipment, always observe these precautions: •

Follow the equipment operator’s manual instructions.

•

Do not wear loose clothing when operating PTO-driven equipment.

•

Stop the engine and wait for the PTO and the equipment to stop before getting off the tractor or working on the equipment.

•

Never approach, clean or adjust PTO-driven equipment with the tractor engine still running -- turn the engine off and wait for all movement to stop.

•

Make sure the PTO guard is on when using any PTO-driven equipment.

•

Apply the parking brake firmly, place both transmission levers in neutral, and block all four wheels before operating any stationary PTO equipment

•

DANGER Before working on any attached PTO equipment, disengage the clutch and move the selector lever to neutral.

WARNING Before operating PTO-driven equipment, check that the shaft-mounted implement safety clutch is operating efficiently. The safety clutch is operating correctly if it slips under overload.

CAUTION To quickly disengage the PTO, pull the control lever rearward and lock it in place.

CAUTION When the PTO is not in use, always keep the control lever in neutral and replace the threaded cap over the splined shaft.

When not in use, disengage the PTO with the control lever to avoid any unexpected movements of the equipment.

31-3

SECTION 31 -- POWER TAKE-OFF (PTO) -- CHAPTER 1 PTO OPERATION

WARNING

Follow all safety precautions concerning the operation of the PTO to prevent damage to equipment, or serious personal injury. Ensure the PTO is in the disengage position, or the engine will not start. The PTO is disengaged when the lever (1) is not in the forward left-hand position (A). 10036150

1 To operate the PTO: A

1. Start the engine.

2. If the PTO lever is in position (D), pull the lever to the rear to position (C), then across to position (B), then to the forward left-hand side of the divider, position (A). If latched on the rear bar, position (B) or (C), press down on the button (1), Figure 1, on top of the lever to unlock, and move the lever to the forward left-hand side of the divider, position (A). B

C 50035233

2 NOTE: When operating the PTO throughout the day, move the PTO lever between the forward left-hand position (A) to engage, and the rearward latched position (B) on the inward side to disengage. This will ensure the coupler remains engaged, and that only the clutch is disengaged. When not expecting to operate the PTO, keep the lever in the forward right-hand position (D) to disengage the coupler and the clutch. Refer to the chart below for more details on the PTO lever operation.

82987623

3 PTO Shaft

Clutch

Coupler

Forward left-hand Side (position A, Fig. 2)

Turning

Engaged

Rearward latched Position (position B, Fig. 2)

Stopped

Disengaged

Engaged

Forward right-hand Side (position D, Fig. 2)

Stopped

Disengaged

Lever Position

NOTE: Moving the PTO Control Lever left to right (inward to outward) disengages the coupler. Moving the lever forward to rearward disengages the clutch.

31-4

SECTION 31 -- POWER TAKE-OFF (PTO) -- CHAPTER 1 POWER TAKE-OFF PTO REMOVAL AND INSTALLATION To remove the PTO assembly, proceed as follows: Refer to Figure 5 •

Drain oil from the transmission housings.

•

Position lever to position to prevent the gear (1, Fig. 5) from dropping when removing the PTO cover complete with the corresponding drive shaft (2).

•

Undo capscrews securing cover on power output and powered pulley (5).

•

Undo capscrews securing rear transmission cover (9) and remove cover from rear transmission housing, complete with PTO.

•

For correct disassembly, install PTO housing on rotary stand (see Fig. 4) and refer to longitudinal section as shown in Fig. 5.

4 PTO Assembly (assembly shown complete with drawbar)

31-5

SECTION 31 -- POWER TAKE-OFF (PTO) -- CHAPTER 1

5 Longitudinal Section Through PTO C1 and C2. Capscrews securing cover to rear 6. Seal transmission housing 7. PTO driven gear C3. Capscrew securing cover (5) 8. Spacer C4. Nut securing PTO shaft driven gear 9. Rear transmission cover L. PTO lever 10. PTO release lever 1. Sliding gear for PTO engagement 11. Pad for lever (10) 2. Drive shaft 12 and 13. Plain roller bearing 3. Drive gear for PTO synchronized to transmission 14. Ball bearing 4. Driven shaft 15. PTO shaft guard. 5. Cover for power output and powered pulley

•

Remove top cover from transmission housing to permit removal of sliding gear (1, Fig. 3).

•

Replace any damaged bearings using universal extractor and suitable drifts.

•

When refitting the PTO items, refer to the longitudinal section of the assembly and keep to the tightening torques as listed in the specifications section. When reassembling, maneuver the splined end of the driven shaft to facilitate splining the drive shaft (2, Fig. 3) with the sliding gear (1, Fig. 3).

Use new gasket seal (6, Fig. 3) as necessary.

NOTE: Prior to refitting the PTO cover to the rear transmission housing, carefully clean and degrease the coupling surface and apply jointing compound.

31-6

SECTION 33 -- BRAKE SYSTEM -- CHAPTER 1

SECTION 33 - BRAKE SYSTEM Chapter 1 - Brakes CONTENTS Section

Description

Page

33-1

SECTION 33 -- BRAKE SYSTEM -- CHAPTER 1 SPECIFICATIONS

SERVICE BRAKES

Specification

Type

Wet disc, oil bath, axle shaft mounted

Control

Mechanical; two suspended pedals

Parking Brake

Engages service brakes

Disc Material

Copper brake

Discs Per Brake

2WD TT55 — Three discs 2WD TT75 & all 4WD — Four discs

Disc Thickness

4.65 to 4.80 mm (0.183 to 0.189 in.)

33-2

SECTION 33 -- BRAKE SYSTEM -- CHAPTER 1 SERVICE BRAKE MEASUREMENTS

Specification mm (in.)

Right Pedal Inner Diameter

26.970 -- 27.00 (1.0619 -- 1.0629)

Right Pedal Bushing Thickness When Pressed 26.987 (1.0625 in.) Dia Ring Gauge

1.651 -- 1.346 (0.0650 -- 0.0530)

Parking Brake Bushing Thickness When Pressed in 26.987 (1.0625 in.)

1.651 -- 1.346 (0.0650 -- 0.0530)

Right Pedal Bushing Fitted Inner Diameter Reaming

22.552 -- 25.578 (1.0060 -- 1.0070)

Right Pedal Bushing / Shaft Clearance

Max. -- 1.828 (0.072)

Left/Right Pedal Shaft Diameter

23.750 -- 23.950 (0.9351 -- 0.9429)

Left Pedal Shaft / Hub Clearance

1.850 -- 1.600 (0.0728 -- 0.0629)

Left Pedal Inner Diameter

25.550 -- 25.600 (1.006 -- 1.007)

Parking Brake Shaft Diameter

23.750 -- 23.950 (0.9351 -- 0.9429)

Support Assy Pedals Inner Diameter with Bushing

25.5650 (1.0065)

Support Assy Pedals Diameter without Bushing

26.9875 (1.0625)

Diameter of Bushing Housing in Transmission Casing

40.000 to 40.025 mm (1.5748 to 1.5758 in.)

Inner Diameter of Left Brake Shaft Support Bushing in Transmission (without reaming)

36.064 to 36.161 mm (1.4198 to 1.4236 in.)

Thickness Left Brake Shaft Support Bushing in Transmission Casing

1.932 to 1.968 mm (0.0761 to 0.0775 in.)

Maximum Clearance Between Bushings and Transmission Casing

0.097 mm (0.038 in.)

Service Clutch Measurements Pedal Shaft Diameter

23.750 -- 23.950 (0.9351 -- 0.9429)

Hob Pedal Inner Diameter

38.246 -- 38.272 (1.5058 -- 1.5067)

Pedal Clutch Inner Diameter with Bushing

35.281 -- 35.414 (1.3891 -- 1.3942)

Support Assy Pedals Outer Diameter

35.165 -- 35.205 (1.3845 -- 1.3860)

TORQUE SPECS

Thread Size

Specification

Capscrew securing inner lever

M16 x 1.5

206 N⋅m (152 ft.lbs.)

Capscrew securing left brake pedal

M16 x 1.5

122 N⋅m (90 ft.lbs.)

Setscrews retaining brake actuator lever

M16 x 1.5

217 N⋅m (160 ft.lbs.)

Brakes

33-3

SECTION 33 -- BRAKE SYSTEM -- CHAPTER 1 DESCRIPTION AND OPERATION

An actuating assembly within each brake assembly consists of two actuating discs (3), three springs (4) five steel balls (5), and two actuating links (6). The actuating discs contain ramp pockets in which the steel balls ride during the braking process. The springs hold the actuating discs together, while the actuating links transmit input from the connecting rod to the actuating assembly.

The brake system consists of two mechanically operated brake assemblies installed in the left and right rear axle housings. The brake pedals, located on the forward right-hand side of the platform transmit operator input to the brake assemblies via mechanical linkage. A T-handle with rod and ratchet mechanism, mounted below the steering column, functions with the left brake pedal to lock the pedals for parking.

When the brake pedals are depressed, rotation of the actuating discs relative to one another, force the steel balls to ride up the ramps, resulting in the actuating disks moving apart. Upon moving apart, the actuating discs force the brake discs to provide a braking action on the intermediate shaft.

Brake Assemblies Each brake assembly consists of brake discs (1), and intermediate discs (2). The number of discs varies depending on model as shown below: Brake Disc

Intermediate Disc

2WD TT55

2WD TT75

ALL FWD

1 3

4 6 5 6

1. 2. 3.

Brake Discs Intermediate Discs Actuating Discs

4. 5. 6.

33-4

Springs Steel Balls Actuating Links

SECTION 33 -- BRAKE SYSTEM -- CHAPTER 1 Parking Brake T-handle The parking brake consists of a T-handle (1) and rod assembly. The rod assembly functions as a ratchet mechanism in conjunction with the left brake pedal to lock the brakes in the applied position.

CAUTION Never operate the T-handle to stop a moving tractor except in an emergency. After such an event, inspect all transmission and parking brake components for damage. Always release the parking brake before moving the vehicle.

10024307

2 Brake Pedals The left and right brake pedal assemblies (1) operate independently to aid in turning the tractor in confined spaces, or together for normal stopping. A locking tab (2) latches the pedals together for simultaneous operation. When unapplied [foot pressure released], two springs return the pedals to the upright position.

During field operation, the pedals may be unlocked, but due to the close proximity of the pedals to one another, it is still possible to apply both brakes simultaneously when required.

1 10036166

WARNING

Always lock the brake pedal assemblies together when traveling at transport speeds, or when operating the tractor with an attached trailer.

33-5

SECTION 33 -- BRAKE SYSTEM -- CHAPTER 1 BRAKE PEDAL FREE-TRAVEL AND ADJUSTMENT

WARNING Owners should be aware of local regulations concerning the braking system. Regularly maintain the brakes to ensure compliance with the law and to ensure your safety. If in doubt, contact your New Holland dealer. Free-travel is the distance the brake pedals will travel from the rest [unapplied] position to the moment of resistance. The free-travel distance feels loose on the pedals to the operator and ends when the pedals become more difficult to move, as when the brakes start to apply. It may be necessary to seek assistance when checking brake pedal free-travel. To check for brake pedal free-travel proceed as follows:

1. With the left and right-hand brake pedals (1) positioned level with one another, slide the locking tab (2) by hand to the latched position. The brakes will now operate together as one assembly. A

2. From the resting position (A), slowly depress the brake pedals until feeling resistance (B), and then record the amount of travel from the released position. Compare the result to a maximum of 40 mm (1.6 in). If not within the specified value, adjust the brake pedal linkage.

1 10036166

Adjusting Brake Pedal Linkage 1. Unlock the left and right-hand pedals from each other. 2. Remove the clevis pin (1) and loosen the lock nut (2) to the right-hand brake pedal linkage on the rear underside of the tractor, near the rear axle. 3. Turn the adjustable end of the linkage clockwise to shorten or counterclockwise to lengthen the linkage. Reinstall the clevis pin and recheck free-travel of the right brake pedal. Continue to adjust the linkage until obtaining a maximum of 40 mm (1.6 in) free-travel.

2 1 10036162

4. Reinstall the pedal linkage and tighten lock nut.

5. Perform steps 1 through 4 for the left-hand brake pedal. 6. After obtaining the correct free-travel for the left and right-hand brake pedals, check the free-travel again with the pedals locked together.

33-6

SECTION 33 -- BRAKE SYSTEM -- CHAPTER 1 7. Start the tractor and drive in a straight line. Apply the brakes and observe that the tractor stops in a straight line with no pull. If the tractor pulls to one side, readjust the right-hand pedal linkage until the brakes apply evenly.

PARKING BRAKE T-HANDLE FREE-TRAVEL AND ADJUSTMENT Always check brake pedal free-travel before adjusting the parking brake handle. 1. Pull the brake handle rearward.

10036165

6 2. Twist the handle (1) 90ยบ to the locked position. The pedals must lock within 2 to 4 clicks of pulling the parking brake handle rearward.

10036164

7 3. If needed, adjust the parking brake handle linkage by repositioning the brake indicator switch in the mounting slots.

10036159

33-7

SECTION 33 -- BRAKE SYSTEM -- CHAPTER 1 BRAKE DISASSEMBLY •

Remove the trumpet housing by unscrewing the capscrews.

NOTE: One brake disc comes off and remains with the trumpet housing. •

Remove the bottom cover plate.

•

Unscrew the setscrews retaining the brake actuator lever.

•

Remove the actuating arm and shaft with its bushing. Arm and shaft can be removed separately.

•

Remove the actuator assembly and its two inner plates and separator.

When reassembling: • Check the friction plates for wear. •

Tighten the setscrews to 217 N⋅m (160 ft.lbs.).

9 a. b.

33-8

Disc Brake Units (2WD TT55) Disc Brake Units (All 4WD and 2WD TT75)

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

SECTION 35 - HYDRAULIC SYSTEM Chapter 1 - Hydraulic System CONTENTS Section

Description

Page

35-1

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 HYDRAULIC LIFT SPECIFICATIONS HYDRAULIC LIFT COMPONENTS

SPECIFICATION

Type

Position Control, Draft Control and Combined Position/Draft Control

Control

Two independent levers

Variospeed (Lift Sensitivity)

External 4-position lever

Touch Command

Permits automatic up and down movement with push buttons

Response Adjustment (lowering speed and lockout)

Knob on control valve

Single-Acting Cylinder Bore

90 mm (3.54 in.)

Single-Acting Cylinder Stoke

110 mm (3.94 in.)

Single-Acting Cylinder Displacement

700 cm3 (42.7 in3)

Relief Valve Release Pressure

186 to 191 bar (2700 to 2770 PSI)

Cylinder Safety Valve Release Pressure

210 to 215 bar (3060 to 3130 PSI)

HYDRAULIC LIFT MEASUREMENTS

SPECIFICATION

Lift Piston Diameter

89.980 to 90.000 mm (3.5425 to 3.5433 in.)

Lift Cylinder Bore Diameter

90.036 to 90.071 mm (3.5447 to 3.5461 in.)

Piston Working Clearance

0.036 to 0.091 mm (0.0014 to 0.0036 in.)

RH Cross Shaft Journal Diameter

47.975 to 48.000 mm (1.8888 to 1.8898 in.)

LH Cross Shaft Journal Diameter

54.970 to 55.000 mm (2.1642 to 2.1653 in.)

RH Bushing Fitted ID in Lift Body (Not Reamed)

48.100 to 48.184 mm (1.8937 to 1.8970 in.)

LH Bushing Fitted ID in Lift Body (Not Reamed)

55.100 to 55.184 mm (2.1693 to 2.1726 in.)

RH Cross Shaft Working Clearance in Bushings

0.100 to 0.209 mm (0.0039 to 0.0082 in.)

LH Cross Shaft Working Clearance in Bushings

0.100 to 0.214 mm (0.0039 to 0.0084 in.)

RH Bushing Interference Fit in Housing

0.065 to 0.161 mm (0.0026 to 0.0063 in.)

LH Bushing Interference Fit in Housing

0.065 to 0.161 mm (0.0026 to 0.0063 in.)

Cross Shaft End Float With Lift Arms in Position

0.200 to 1.400 mm (0.0079 to 0.0051 in.)

Draft Control Shaft Outside Diameter

21.967 to 22.000 mm (0.8648 to 0.8661 in.)

Shaft Housing Bore Diameter in Lift Body

22.020 to 22.072 mm (0.8669 to 0.8690 in.)

Shaft Clearance in Body

0.020 to 0.105 mm (0.0008 to 0.0041 in.)

35-2

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 HYDRAULIC LIFT MEASUREMENTS

SPECIFICATION

Position Control Shaft Diameter

13.973 to 14.000 mm (0.5501 to 0.5512 in.)

Shaft Housing Bore Diameter on Control Shaft

14.016 to 14.059 mm (0.5518 to 0.8661 in.)

Shaft Clearance in Body

0.016 to 0.086 mm (0.0006 to 0.0034 in.)

Draft Control Lever Pin and Draft Control Inner Lever Hinge Pin Diameter at Needle Roller Bearings

13.973 to 14.000 mm (0.5501 to 0.5512 in.)

Control Valve Link Arm and Draft Control Inner Lever ID at Needle Roller Bearings

19.985 to 20.006 mm (0.7868 to 0.7876 in.)

Valve Spool Clearance in Body

0.008 to 0.012 mm (0.0003 to 0.0005 in.)

Lift Valve Clearance in Control Valve Body

0.008 to 0.012 mm (0.0003 to 0.0005 in.)

Valve Spool Return Spring — Free

50.5 mm (1.99 in.)

Valve Spool Return Spring — Under Load (31.7-35.0 N, 3.23-3.27 kg, 7.1-7.9 lb.)

34.0 mm (1.34 in.)

Control Valve Return Spring — Free

44.0 mm (1.73 in.)

Control Valve Return Spring — Under Load (103.0-114.7 N, 10.5-11.7 kg, 23.1-25.8 lb.)

29.0 mm (1.14 in.)

Response Adjustment Valve Spring — Free

13.0 mm (0.51 in.)

Response Adjustment Valve Spring — Under Load (1.7-2.3 N, 0.17-0.23 kg, 0.4-0.5 lb.)

9.8 mm (0.38 in.)

Sensitivity Adjustment Valve Spring — Free

14.5 mm (0.57 in.)

Sensitivity Adjustment Valve Spring — Under Load (15.8-17.6 N, 1.61-1.79 kg, 3.5-3.9 lb.)

11.0 mm (0.43 in.)

Check Valve Return Spring— Free

23.5 mm (0.92 in.)

Check Valve Return Spring — Under Load (35.3-39.2 N, 3.60-4.00 kg, 7.9-8.8 lb.)

18.0 mm (0.71 in.)

Sensitivity Adjustment Pin Lever Outer Spring — Free

20.5 mm (0.81 in.)

Sensitivity Adjustment Pin Lever Outer Spring — Under Load (61.8-67.7 N, 6.3-6.9 kg, 13.9-15.2 lb.)

13.8 mm (0.54 in.)

35-3

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 LIFT PUMP SPECIFICATIONS

TT55

Filter Type

TT75 Paper cartridge

Filter Location

On pump body, suction side

Pump Type

Gear, drawing from rear trans housing

Pump Location

Behind timing cover

Pump Body Width

71.93 mm (2.832 in.)

Pump Make

BOSCH

Pump Model

814--1

L810

Drive

Valve timing gear driven

Rotation (as seen from drive end)

Counterclockwise

Engine Speed / Pump Drive Ratio

1 to 0.931

Max. Rated Pump Speed (engine at 2750 RPM)

2500 RPM

Max. Rated Output

35.6 liters/min. (9.4 US gallons/min.)

Output at 1450 RPM and 166 bar (2418 PSI) — New or Reconditioned

19.0 liters/min. (5.0 US gallons/min.)

Used

13.3 liters/min. (3.5 US gallons/min.)

Test Oil Temperature

55° to 65° C (131° to 149° F)

Test Oil Grade

SAE 20

Pump Gear Journal Diameter

17.400 to 17.418 mm (0.6850 to 0.6857 in.)

Journal Housing Bore Diameter in Bearing

17.450 to 17.470 mm (0.6870 to 0.6878 in.)

Journal Clearance in Bearing

0.032 to 0.070 mm (0.0013 to 0.0028 in.)

Maximum Wear Clearance

0.100 mm (0.0039 in.)

Gear in Pump Body

0.020 to 0.064 mm (0.0008 to 0.0025 in.)

Maximum Pump Body Wear on Suction Side

0.100 mm (0.0039 in.)

Gear Flank Width

24.000 to 24.015 mm (0.9449 to 0.9454 in.)

Bearing Width

24.490 to 24.510 mm (0.9642 to 0.9650 in.)

Pump Body Width

73.153 to 73.160 mm (2.8793 to 2.8803 in.)

Gear and Bearing End Float (for new or reconditioned pumps)

0.100 to 0.180 mm (0.0039 to 0.0071 in.)

35-4

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 LIFT TORQUE SPECIFICATIONS

Thread Size

Specification

Capscrew, Lift Cover to Rear Trans. Housing (C1, Fig. 12)

M14 x 1.5

147 N⋅m (108 ft.lbs.)

Capscrew, Control Valve Body to Lift (C3, Fig. 14)

M8 x 1.25

26 N⋅m (19.5 ft.lbs.)

Capscrew, Lift Arm End Plates (C2, Fig. 12)

M14 x 1.5

147 N⋅m (108 ft.lbs.)

Plug, Maximum Rise Adjustment (T1, Fig. 24)

M12 x 1.25

103 N⋅m (76 ft.lbs.)

Nut, Position Control Shafts (26, Fig. 13)

M10 x 1.25

15 N⋅m (10.8 ft.lbs.)

Nut, Lever Bracket Studs (C4, Fig. 13)

M8 x 1.25

25 N⋅m (19 ft.lbs.)

Capscrew, Draft Spring to Top Link Support (27, Fig. 12)

M14 x 1.5

215 N⋅m (160 ft.lbs.)

Capscrew, Draft Spring to Lift Body (28, Fig. 12)

M14 x 1.5

215 N⋅m (160 ft.lbs.)

Capscrew, Pivot Shaft to Top Link Support

M16 x 1.5

195 N⋅m (145 ft.lbs.)

M6 x 1

8 N⋅m (5.8 ft.lbs.)

Nut, Pump Draw Bolt (11, Fig. 31)

M10 x 1.25

41 N⋅m (30.4 ft.lbs.)

Nut, Pump Drive Gear (12, Fig. 31)

7/16″--20 UNF--2B

27 N⋅m (20 ft.lbs.)

Nut, Chain Support

M14 x 1.5

145 N⋅m (108 ft.lbs.)

Nut, Chain Rear Arms

M18 x 1.5

315 N⋅m (230 ft.lbs.)

Top Retaining Bolt, Drawbar Hanger

M20 x 1.5

470 N⋅m (350 ft.lbs.)

Bottom Retaining Bolt, Drawbar Hanger

M20 x 1.5

390 N⋅m (290 ft.lbs.)

Nut, Handle Shaft

M10 x 1.25

35 N⋅m (25 ft.lbs.)

Capscrew, Valve to Adapter

M10 x 1.25

35 N⋅m (25 ft.lbs.)

Capscrew, Adapter to Mount

M10 x 1.25

5 N⋅m (36 ft.lbs.)

3/8”

41 N⋅m (30 ft.lbs.)

Capscrew, Mounting Stud to Housing

M12 x 1.5

34 N⋅m (25 ft.lbs.)

Capscrew, Mounting Nut to Stud

M12 x 1.5

98 N⋅m (72 ft.lbs.)

Lift Cover

Hydraulic Pump Capscrew, Pump Mount (11, Fig. 31)

Implement Attachment & Towing Devices

Single Remote Control Valve

Dual Remote Control Valves Nut, Drawbolt

35-5

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 SINGLE REMOTE VALVE Type Application Control Pressure Relief Valve Crack-Off Setting

Specifications Rotary spool For single- or double-acting cylinder Independent hand levers 172 to 180 bar (2500 to 2600 PSI) 0.007 to 0.015 mm (0.0003 to 0.0006 in.)

Spool Clearance in Control Valve Body

The single remote is the only factory installed remote valve. A second rotary spool valve or two linear spool valves are available to provide a total of 2 or 3 remotes, respectively. Information about them is given in the â&#x20AC;&#x153;DIA KITSâ&#x20AC;?.

SPECIAL TOOLS 293849

Connection fitting for testing control valve main spool

380001628 Driver for fitting seals in the lift assembly 292547

Guide ring for installing piston

380000261 Driver for installing roller bearing on control valve spool lever 380000260 Driver for installing roller bearings on draft control inner lever 380000267 Wrench for adjusting lift control valves 380000264 Adjustment tool for lift positions 293872

Fitting for compressed air supply

380000479 Lever for lift adjustments 380000215 Hand pump for testing safety and relief valves 380000217 Safety valve fitting for testing safety and relief valves 380000218 Safety valve fitting for testing safety and relief valves 380000231 Wrench for relief valve adjustment 380000230 Wrench for cylinder safety valve adjustment 380000240 Kit for checking relief valve setting 291326

Fitting for relief valve setting

380000554 Fitting for relief valve setting 380000266 Protection device for fitting rings

35-6

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 HYDRAULIC SYSTEM PRECAUTIONS

WARNING Never use your hands to locate a leak. Hydraulic leaks under pressure may penetrate the skin and possibly cause severe injury, or death. A piece of cardboard or a rag usually will sufficiently identify a leak without risking personal injury.

WARNING Always turn-off the engine and bleed any remaining hydraulic pressure before connecting or disconnecting hydraulically operated equipment, components or connectors. Hydraulic oil under pressure may cause severe injury or death.

WARNING Ensure all hydraulic connections remain tight before starting the engine or pressurizing the hydraulic system. Hydraulic oil under pressure may cause severe injury or death.

WARNING Always stand clear of equipment raised with a hydraulic system, as a failure, leak or sudden loss of pressure will cause the equipment to drop. Severe injury or death may occur from unexpected falling equipment.

WARNING Stand clear of all moving parts when starting the engine or pressurizing the hydraulic system.

CAUTION Contamination of the hydraulic oil will lead to premature failure of components, or catastrophic failure of the entire system. Use protective closures, and keep work areas clean before, during and after maintenance on the hydraulic system.

CAUTION Operating the hydraulic system above recommended operating temperature for long periods will destroy O-rings and seals, as well as break down the lubricating properties of hydraulic oil. This will result in internal corrosion or leakage, which will lead to component and/or system failure.

35-7

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 DESCRIPTION AND OPERATION The hydraulic system supplies oil for the operation of the hydraulic lift and remote control valves to provide accurate and sensitive control of implements over a wide range of operating conditions. The hydraulic oil flows in an open-center type circuit, which allows for the continuous flow of oil through the system and back to return. An open-center system reduces wear on the control valve seals, and prevents damage to components caused by prolonged static pressure. The TT55/TT75 series tractor is equipped with an implement (lift) pump (1) and a steering pump (2). For more information on the steering system, refer to Section 41.

A filter assembly (3), located on the right-hand side of the engine below the implement pump, cleans the oil before it enters the valves.

The implement pump mounts on the right-hand side of the engine. It is a fixed displacement, open-center, gear type pump driven by the engine timing gear. The pump supplies oil a rate of 35.6 l/m (9.4 g/m) at 2500 pump rpm.

3 10035297

1 The implement pump pressurizes oil from the rear axle housing, which functions as a reservoir. The pressurized oil exits the pump at the delivery port (1) and flows through tubing routed along the right-hand side of the transmission until entering the rear remote valve(s).

The rear remote valves have oil priority over the hydraulic power lift (HPL). When operated, oil flows from the remote valve to the actuated cylinder. Return oil from the cylinder flows back through the remote valve assembly and into the top of the lift cover, then back to sump. The hydraulic lift is not operable during operation of a remote control valve.

10036144

An adjustable relief valve (1), installed in the rear remote valve block, protects the system from overload conditions.

10036148

35-8

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 REMOTE CONTROL VALVES

REMOTE VALVE CONTROL LEVERS

Simple Self-centering The simple self-centering valve operates within extend, retract and neutral positions. After releasing the control lever, the self-centering valve springs back to neutral, and the cylinder remains in the position selected.

The remote control lever (1) on the right-hand side of the operator’s seat provides for mechanical control of the valve. With more than one valve installed, color markings on the control levers correspond with colors of the remote valve couplings for quick identification. Depending on the type of remote valve installed, the control lever functions within three or four positions as follows: Lifting – Pulling the lever rearward extends the corresponding cylinder to lift or raise the implement.

Simple Self-centering Float The simple self-centering valve with float operates within extend, retract, neutral and float positions. Remote valves with float setting capabilities contain a mechanical detent, which holds the control lever engaged in position until the operator returns the lever to the neutral position.

Neutral – Pushing the lever forward returns the valve to the neutral position and the deactivated cylinder stops moving the implement. Rear remote valves, incorporating the detent-releasing feature, will automatically return the valve to the neutral position when the cylinder reaches the end of the stroke.

Detent with Auto-release and Float The detent with auto-release and float remote valve operates within extend, retract, neutral and float positions. Remote valves with automatic release contain a mechanical detent, which holds the control lever in the extended or retracted position. The automatic release mechanism returns the control lever to neutral when the cylinder reaches the end of travel. For a single-acting valve, the automatic release mechanism only works in the raise position. Remote valves with float setting capabilities contain a mechanical detent, which holds the control lever engaged in position until the operator returns the lever to the neutral position.

Lowering – Pushing the lever forward past the neutral position retracts the cylinder and the implement lowers. Float – Pushing the lever full forward past the lowering position selects the float function. This position allows the cylinder to extend and retract freely, which permits the implement to follow the contour of the ground.

TABLE 4 -- CONTROL LEVER POSITIONS Operation Performed

Control Lever Position

Description

Lifting

Full Rearward

Lifts the Implement

Lowering

Forward

Lowers the Implement

Neutral

In-between Rearward and Forward

Stops Lifting or Lowering

Float (where installed)

Full Forward Beyond Lowering

Implement Follows Terrain Under Own Weight

35-9

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 QUICK-FIT COUPLERS

WARNING Before connecting or disconnecting quick-fit couplers, stop the tractor, and lower any attached implement.

Each remote control valve contains two-Â½ inch push-pull type couplers (1), which provide for easy installation and removal of external equipment. The couplers contain plastic caps (2) for the prevention of contamination when not in use.

IMPORTANT: Clean the area around the coupler before connecting or disconnecting to reduce the ingestion of contaminates such as dirt into the hydraulic system.

4 Remote Control Valve Assembly (Rear)

MID-MOUNT COUPLER RELOCATION KIT [OPTIONAL]

For front loader applications, install a mid-mount (1) coupler relocation kit. The kit, available through parts, requires a minimum of two remote valves on the tractor. The removal and relocation of the rear remote couplers to a mid-vehicle location on the tractor is required.

10035239

SWITCHING BETWEEN SINGLE AND DOUBLE-ACTING CYLINDERS To switch a single-acting cylinder to a double-acting cylinder, tighten the switching valve adjustment screw completely. To switch a double-acting cylinder to a single-acting cylinder, unscrew the adjusting screw.

20036218

6 1. 2. 3. 4.

35-10

Switching Between Single and Double-Acting Cylinders Switching Valve Adjustment Screw Seal Retaining Plug Seal

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 HYDRAULIC POWER LIFT (HPL) The Hydraulic Power Lift system contains four distinct methods of controlling the 3-point linkage system, which includes: • Draft Control • Position Control • Float • Draft and Position Control Combined Selection of a control system depends on the type of implement in use and the operating conditions that exist. Selection is accomplished through a position control lever (1) and a draft selector lever (2) in a quadrant on the right-hand side of the operator’s seat.

The lower lift arms and corresponding control rods connected to the flex bar provide for draft control. Principles of Draft Control The Draft Control system manages the working depth of soil engaging implements to maintain an even pull on the tractor, and to reduce wheel slippage. When lowering a soil-engaging implement, e.g. a plow, into the ground, the draft forces applied to the implement tend to make the plow pivot at the point where it attaches to the lower links. The HPL senses the force on the lower link arms via a torsion bar. Without the top link, the plow would tip up. Due to the top link resistance, the plow stays level in the ground. This demonstrates compressive force acting on the top link against the tractor. The draft force will alter according to the depth of work and soil type. Move the position control lever full forward and set the implement depth in the ground by gradually shifting the draft control lever. The depth reached by the implement is proportional to the traction power determined by the soil consistency. The lift automatically maintains drive power required of the tractor at a constant level. Principles of Position Control Position control allows for pre-setting and maintaining the working depth or height of an implement, relative to the tractor. Move the draft control lever full forward and set the position of the implement by shifting the position control lever forward to lower the implement, and backwards to raise the implement. Movement of the implement is proportional to movement of the lever.

35-11

40035231

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 In addition to the position control lever, movement of the implement is possible by pressing the touch command button (2) to raise the implement, and lever (1) to lower the implement.

Principles of Float The float position enables the lower link arms to move freely. Shift both the position control lever and the draft control lever full forward. Principles of Draft and Position Control Combined In this configuration the lift operates in draft control, and at the same time prevents the implement from protruding deep into soil of less resistance, thereby preventing soil unsuitable for crop growing from reaching the surface Set the desired draft control of the implement and gradually shift the position control lever until the lower link arms rise.

35-12

40035292

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 HYDRAULIC LIFT MAIN CONTROL VALVE SETTINGS

The hydraulic lift has two control adjustments that affect all hydraulic lift functions: the lift sensitivity control lever (2) and the lift arm lowering speed control knob (1). Sensitivity Control Lever The lift sensitivity control lever (2) has four positions. The top position is the lowest sensitivity, with the longest reaction times. The lowest sensitivity means that the weight transfers to the rear wheels more gradually, so traction is not lost and there are fewer jolts. The bottom position is the highest sensitivity, with the shortest reaction times. Move the lever by loosening the knob at the end of the lever, and then retightening it in its new position. Lift Arm Lowering Speed Control Knob The lowering speed control knob (1) increases and decreases the lowering speed of the hydraulic lift. Turning the knob counterclockwise (â&#x20AC;&#x201C;) makes the lowering speed slower, taking more time. Turning the knob clockwise (+) makes the lowering speed faster, taking less time. NOTE: When the knob is all the way counterclockwise, or all the way out, the hydraulic lift will not lower.

35-13

40035252

9 1. 2.

Hydraulic Lift Sensitivity Controls Lowering speed control knob. Lift sensitivity control lever

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 HYDRAULIC SYSTEM OPERATION

F. P. 1. 2. 3. 6. 9. 12. 14. 16. 27. 28. 29.

Draft control lever Position control lever Lift control valve Spool main control Maximum lift kickout adjusting screw Main spool control lever Main spool control lever link Position control lever roller Position control inner cam Rod Position control lever shaft Cam ring Piston.

NOTE: Solid arrows indicate linkage movements in arm raising phase. During arm descent, linkage moves in opposite direction.

10 Lift Linkage Operation in Position Control Mode

Lift Linkage Operation: Position Control When lever (P) moves back, cam on end of shaft (27) moves cam (14), located between roller (12) and cam ring (28), upwards. As the cam ring (28) on arm shaft is stationary at the beginning of operation, lever (14) reacts against it and pushes roller (12) forward. This moves link (9) and lever (6) in the direction indicated by the solid arrows to set control valve (1) in the arm lift position (Fig. 9). Arms rise until cam ring (28) turns far enough to permit lever (6), link (9) and lever (14) to move under the action of spool return spring (4, Fig. 11) in the direction indicated by the clear arrows. The control valve (1) therefore returns to neutral and the arms stop in the neutral phase.

35-14

Maximum arm upward travel is limited by rod (16). When rod (16) contacts piston (29), the control valve returns to neutral through adjusting screw (3) before the piston reaches the rear of the lift housing. The same movements occur in reverse when lever (P) moves forward to lower arms (Fig. 11). Float Position With position control lever (P) and draft control lever (F) fully forward : â&#x20AC;˘

The draft control linkage is not activated;

â&#x20AC;˘

Lever (14) link (9) and lever (6) are moved in the direction opposite to that indicated by the solid arrows, and control valve is held in lowered position (Fig. 11), thereby letting arms swing freely and associated implement float on the surface of the soil.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

F. P. 5. 6. 9. 13. 15. 17. 18. 20. 21. 22. 25. 26.

Draft control lever Position control lever Maximum lift kick-out control rod spring Main spool control lever Main spool control lever link Draft control lever roller Draft control inner cam Draft control link Lever. Top link draft control spring Draft control spring support Draft control outer lever Draft control adjustable link Draft control hollow shaft.

(Move position control lever fully forward. Levers traced lightly do not operate and concern position control only.) NOTE: Solid arrows indicate linkage movements in arm raising phase. During arm descent, linkage moves in opposite direction.

11 Lift Linkage Operation in Draft Control Mode

Lift Linkage Operation: Draft Control When the implement has been set to the desired working depth by means of lever (F), and if the implement then hits a stretch of harder or more compact soil, its draft on the lower arms will then increase. This will then cause a greater top link thrust against the spring (20) which, when compressing, transmits motion in the direction of the solid arrows, through lever (22), lever (18), link (17), lever (15), link (9) and the main spool control valve lever (6), thereby setting the main spool in the arm lifting position (Fig. 9). The arms will rise until the resulting draft reduction on the lower links reduces the compression of spring (20) and causes lever (22) to rotate in the opposite direction, allowing lever (6) to move rearwards, pulled by the main spool spring (4, Fig. 11). Main spool returns to neutral and arms stop.

35-15

Once the hard stretch has been left behind, the draft control spring (20) returns completely to its original position and lever (6) moves further back. The main spool moves to the discharge position so that the arms lower the implement to its original working position. If the control lever (F) is positioned further back on quadrant (increased draft), the hollow shaft (26) pushes cam (15), roller (13), link (9) and lever (6) to act against the control valve main spool, setting the valve in raise position (Fig. 9). If the lever (F) moves forward (reduced draft), operation is the same but in the opposite direction.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 F. P. 6. 7. 8. 9. 10. 11. 15. 17. 18. 20. 21. 22. 25.

Draft control lever Position control lever Main spool control lever Main spool control lever link pin Locknut Main spool control lever link Link lever Link lever spring Draft control cam Draft control link Lever Top link draft control spring Draft control spring support Draft control outer lever Draft control adjustable link.

(Lift arms rise momentarily. When obstacle has been overcome, the draft control spring returns to its normal position and permits the arms to drop).

12 Lift Linkage Operation with Increasing Draft

Lift Linkage Operation: Combined Draft and Position Control With position control lever (P) fully forward, and moving the draft control lever (F) forward from the fully back position, the working depth is established as described above. When lever (P) is then shifted backwards, lever (14), link (9) and main spool control lever (6) move in the direction indicated by the solid arrows in the position control diagram, placing the control valve in the raise position and causing a slight upward movement of the lift arms.

35-16

This condition permits lift to operate in draft control mode when the lift goes over patches of hard or compact soil. Combined draft and position control therefore limits the changes in working depth that occur when operating in draft control alone.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

13 Lift Hydraulic System Schematic B. C. D. F. P.

Lift arm Remote control valve Main control valve assembly Paper cartridge oil filter Engine valve gear driven hydraulic pump

1. 2. 4. 7. 8.

Suction line drawing from transmission housing Delivery line to control valve Oil discharge pipe from lift body Remote control valve lines Dip stick in rear-end housing

Hydraulic Lift Control Valve Schematic 1. 2. 5. 8. 9. 13. 15. 17. 19. 20. 22. 25. 28. 29.

Spool - main control Spool seat - main control Phase control valve plunger Phase control valve piston seat Piston Plug Cylinder safety valve Lowering speed control valve Lowering speed control pin Oil delivery fitting to lift cylinder Check ball Sensitivity adjustment lever Sensitivity adjustment pin Lowering speed control knob.

35-17

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

15 Main Control Valve Schematic in Arm Lifting Phase F. Filter P. Hydraulic pump T. Implement lift arm control piston T1 and T2. Ports in control valve piston seat (8) T3. Draft sensitivity valve port V. Relief valve (installed on lift body or on remote control valves, where applicable)

1. 5. 6. 8. 9. 22. 25.

When valve spool (1, Fig. 9) moves inward, oil flow to control valve piston (9) is cut off and plunger (5) is forced to the left by spring (6), thus closing discharge port. Oil under pressure opens check valve (22) and operates piston (T) to raise arms. NOTE: Draft sensitivity may be adjusted through lever (25), which controls position of valve seat (8). When seat (8) moves to the right, piston (9) covers ports (T1 and T2 ) and oil in valve may be discharged through the draft sensitivity valve port (T3 ). Since discharge there takes longer, lift reaction time increases with a consequent decrease in sensitivity. When seat (8) moves to the left, ports T1 and T2 are open and oil may be discharged quickly through all three ports (T1 , T2 , and T3 ), with consequent short reaction time resulting in increased sensitivity.

35-18

Spool - main control Phase control valve plunger Phase control valve plunger spring Phase control valve piston seat Phase control valve piston Check valve Adjusting pin lever

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

16 Main Control Valve Schematic in Neutral Phase F. P. V. 1. 5. 6.

Filter Hydraulic pump Relief valve (installed on lift body or on remote control valves, where applicable) Spool - main control Phase control valve plunger Phase control valve plunger spring

9. 12. 15. 17. 18. 22. 29.

With spool (1) in neutral position, oil is delivered through sensitivity control valve (12) to piston (9) which overcomes plunger spring (6) reaction and moves plunger (5) to the right, thus opening discharge port and conveying pressurized oil to tank in rear transmission housing rather than to cylinder. The oil in the lines is held by the check ball (22). Cylinder safety valve (15) protects lift cylinder pressure circuit while relief valve (V) protects the pump circuit. NOTE: When traveling on the road with implements attached, fully unscrew knob (29, Fig. 23) to block implement in desired position; oil contained in cylinder remains trapped by check valve (22) and lowering speed control valve (17). Arms therefore remain blocked, even if operator accidentally moves lift control levers.

35-19

Phase control valve piston Sensitivity control valve Cylinder safety valve Lowering speed control valve Ball Check valve Lowering speed control knob

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

17 Main Control Valve Schematic in Arm Lowering Phase F. F1. P. T. V. 1.

Filter Port in control valve spool (1) Hydraulic pump Implement lift arm control piston Relief valve (installed on lift body or on remote control valves, where applicable) Main Control spool

4. 5. 9. 12. 17. 29. F2

When return spring (4) pushes spool (1) to the right, cylinder oil is discharged under piston pressure (T) through lowering speed control valve (17) and the port uncovered by spool port (F2). NOTE: Arm lowering speed is determined by knob (29). Slackening this knob restricts exhaust passage between the lowering speed control valve (17) and control valve body, thus increasing the time taken to lower the implement (low response). Tightening knob (29) increases effective area of discharge port and the implement drops more quickly (high response).

35-20

Spool return spring Phase control valve plunger Phase control valve piston Phase control valve piston seat Lowering speed control valve Lowering speed control knob. Port for cylinder discharge oil

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 HYDRAULIC LIFT DISASSEMBLY

WARNING Lift and handle all heavy parts using suitable lifting equipment with sufficient hoisting capacity. Check that all assemblies or parts are held firmly and supported by slings and hooks. Make sure no one is standing too near to the load.

CAUTION Do not put hands or fingers between moving parts. Wear proper safety items such as glasses, gloves and safety shoes. NOTE: Lift disassembly, assembly and adjustments are simplified by mounting the lift assembly on a rotating stand with the draft spring attaching bolts. •

Before placing the lift on a stand you must: --

Remove the three-point linkage.

Remove the top link sensing spring (A, Fig. 12).

Disconnect the power-beyond pressure line from the remote control valve.

Disconnect the return-to-sump line from the remote valve.

•

Stand can be mounted in four holes at rear top link attaching point.

•

Remove the control valve assembly (B, Fig. 12) from the lift body.

18 Section Through Lift A. Draft control top link sensing spring B. Control valve assembly B1. Lift sensitivity adjustment lever B2. Lowering speed control knob C1. Lift capscrews C2. Thrust plate retaining screw G = 0.2 to 1.4mm, shaft end float 1. Inner arm 2. Lift control arm shaft (rock shaft) 3. Lifting arms 4. Arm thrust plates 5. RH seal 6. LH seal 7. RH bushings 8. LH bushings 10. Thrust washers 11. Top link support 12. Piston rod pin 13. Travel limit adjusting screw 14. Travel limit adjustment screw locknut 15. Travel limit control rod 16. Control valve linkage pivot pin 17. Lift relief valve (tractors without remote control valves) 18. Draft control inner lever pivot 19. Setscrew 20. Front cover 27. Screw retaining spring to top link support 28. Screw retaining spring to lift body.

35-21

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 •

Remove the control lever quadrant by removing the lever quadrant bracket (21, Fig. 13) attaching nuts and the nut on the position control lever base.

•

Remove the position control lever, the draft control lever, and the clutch plates (23).

•

Take off the lift front cover (20, Fig. 12) and remove the cylinder and piston.

•

Remove the piston from the cylinder.

NOTE: Before removing lifting arms (3), lift control arm shaft (2) and inner arm (4), mark each with an index reference mark so each can be assembled in correct relation to each other. •

Remove the cross shaft by removing both side arm thrust plates (4, Fig. 12) and the thrust plate retaining screws (C2, Fig. 12). Then remove the piston connecting arm and the internal linkage control cams eccentric by tapping on the right-hand end of the cross shaft itself.

•

Remove the control valve internal linkage pivot pins (16, Fig. 12) to allow removal of the linkage assembly. 19 Section Through Lift Levers and Controls C1. C4. P. F. 21. 22. 23. 24. 25. 26.

35-22

Lift capscrews Lever quadrant bracket nuts Position control lever Draft control lever Lever quadrant bracket Springs Clutch plates Position control lever pin Draft control lever inner shaft Nut.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

20 Lift Control Valve Sections a. C3. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Detail of backup ring (32) and O ring (33) Capscrew Main spool Valve spool seat Plug Valve spool return spring Valve plunger Plunger spring Plug Piston seat Valve piston Spring cup Draft sensitivity adjusting valve spring Draft sensitivity adjusting valve Plug Spool seat ring Cylinder safety valve Lowering speed control valve spring Lowering speed control valve Ball

23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.

NOTE: Install O ring (33) and back-up ring (32) as shown in detail “a”, using protector 380000266 and heating ring (32) in oil at 50° C (122° F). Take care to install ring (32) with flat surface upwards and concave surface facing O ring (33).

CONTROL VALVE DISASSEMBLY •

• •

Lowering speed control pin Oil delivery fitting Check valve spring Check valve ball Check valve seat Detent ball Adjusting pin lever Sector Plug Adjusting pin Lowering speed control knob Retaining ring Roll Pin Pin (19) backup ring O ring

Remove the lowering speed control knob (29, Fig. 14) from the front, take off the cylinder safety valve (15) from the back, and remove the lowering speed control valve (17), spring (10) and pin (19). Remove the oil delivery fitting (20) to the lift cylinder from the back, retrieving the check valve ball (22), spring (21) and seat (23). Remove the phase shuttle control valve plugs from the back and front. Retrieve the main spool (1), valve spool return spring (4) and piston.

35-23

Retrieve the draft sensitivity valve plunger (5) and spring (6). • Drive out the draft sensitivity lever roll pin (31) and remove the lever and quadrant. • Remove the draft sensitivity lever shaft and nut. Retrieve the phase shuttle control valve piston sleeve (8) and piston (9). • Remove the main spool plug (3) from the front. Remove the spool (1) and carefully drive out its sleeve (2). NOTE: The main spool and its sleeve are serviced as one unit due to the tolerance between both parts.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 CONTROL VALVE ASSEMBLY Assembly is in reverse order of disassembly. NOTE: When installing the main spool sleeve, lubricate the external O rings and backup rings. Then carefully drive in the sleeve, taking care not to cut the O rings. Inspect the seals, and replace if necessary. Check the valves for wear and clearance in their seats. To check the efficiency of the control valve main spool and seat: •

Install seat with O ring and spool in connection fitting 293849, checking that seals in bottom of seat prevent leakage through the connection fitting itself and connect the fitting to the hand pump.

•

Push the spool into contact with associated seat.

•

While operating the hand pump, tighten the screw on the connection fitting to discontinue oil flow through the seat outlet.

•

Tighten the screw two more turns.

•

Operate the pump to bring the oil pressure in the system to 245 bar (3556 PSI). Watch the pressure drop and time how long it takes for the pressure to drop from 196 bar (2845 PSI) to 98 bar (1422 PSI) — it should take more than six seconds. Replace spool if necessary; these spools come together with their associated seats.

NOTE: Before reinstalling the lift, thoroughly clean and degrease the mating surfaces and apply 2 mm (0.08 in.) diameter bead of jointing compound on the transmission housing.

CAUTION Always use the proper tools for aligning holes. Never use your hands or fingers.

35-24

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 HYDRAULIC LIFT ASSEMBLY Reverse the disassembly procedures and note the following: •

If replacement is necessary, press-fit cross shaft bushings from the outside to the inside of the lift body, ensuring that the dimensions (A, B, C, Fig. 15) match the figure. Bushings do not require reaming after installation.

•

Couple the lift control arm shaft (2, Fig. 12) to inner arm (1) and lifting arms (3), lining up reference marks on parts.

•

Remove left side seal (6) and replace if you replace the right side seal (5).

•

With the lift control arm shaft (2) installed, fit seals using driver 380001628 to insert them correctly in seats.

•

When completing assembly, check cross shaft end float measurement (G, Fig. 12) is 0.2 to 1.4 mm (0.008 to 0.055 inches).

•

To prevent seal damage, install the piston in the cylinder using guide ring 292547.

•

Reassemble control linkage using driver 380000261 to install roller bearing on control valve spool lever and use driver 380000260 to install roller bearings on draft control inner lever and control valve control link.

•

Reassemble control valve as shown and install the lift body only after carrying out the lift adjustments specified below.

21 Cross Shaft Bushing Fitted Details A = 55mm (2.16”) B = 67mm (2.64”) C = 15mm (0.59”) 7. RH outer bushing 8. LH bushings.

NOTE: Before reinstalling the lift, thoroughly clean and degrease the mating surfaces and apply 2 mm (0.08 in.) diameter bead of jointing compound on the transmission housing.

22 Applying Jointing Compound to Transmission Housing

35-25

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 LIFT ADJUSTMENT ON BENCH The following adjustment procedures are for a lift without the lift control valve, using a bench or rotary stand with a holding bracket. The order of these adjustments is important — always follow this order. When the lift is on the tractor, only maximum lift arm height kick-out and external draft spring adjustments are possible. IMPORTANT: Before beginning these procedures, disconnect Touch Command control by removing the internal touch command lever spring. Adjusting Position Control • Disconnect the draft control external link (25, Fig. 21) to the rear draft spring. •

Move the draft control lever fully forward on the quadrant (fully lowered position).

•

Move the position control lever fully back on the quadrant (fully raised position).

•

Rotate lift control arm shaft (2, Fig. 12) to bring lift arms to the fully raised position. Raise the lift arms so that piston connecting arm comes into contact with lift body. Make two marks corresponding to this position — one on the arm and one on the body.

35-26

23 Adjusting Position Control F. Draft control lever F1. = 4.0 to 4.5 N (kg, 9 to 10 lb.), force applied to lever end (7) by tool 380000264 L1. Distance between end of lever (7) and lift body front face. P. Position control lever 6. Maximum lift arm height kick-out adjusting screw 7. Main spool control valve lever 8. Turnbuckle locknut 9. Control valve lever cap 10. Maximum lift arm height kick-out adjusting screw locknut.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 •

Using wrench 380000267 (C, Fig. 18), slacken the locknut (10, Fig. 17) and unscrew the maximum lift arm height kick-out adjusting screw (6) until it is no longer in contact with the main spool control valve lever (7).

•

Install tool 380000264 (A, Fig. 18) on the lift body.

•

Using two wrenches, back off the turnbuckle locknut (8, Fig. 17) and adjust the turnbuckle so that the plunger (P1, Fig. 18) is aligned with the outer register (R1) of tool 380000264.

NOTE: This condition corresponds to a gap of 82.0 to 82.1 mm (3.228 to 3232 in.) between the main spool control lever and the lift body front face while applying a force of 4.0 to 4.5 kg (9.0 to 10.0 lbs.) to the main spool control lever end. •

Tighten the locknut and verify plunger (P1) is still aligned with the outer register (R1).

•

Bring the position control lever fully forward on the quadrant (fully lowered position).

•

Rotate the cross shaft to bring piston fully forward (fully lowered position) and check that movement of rod (P1) of tool 380000264 is no more than 1.3 - 1.7 mm (0.051 - 0.067 in.) back from the inner register (R2) of the tool.

NOTE: This condition corresponds to a gap of 86.3 to 86.7 mm (3.398 - 3.413 in.) between the main spool control lever and the lift body front face while applying a force of 4.0 to 4.5 kg (9.0 to 10.0 lbs.) to the main spool control lever end. Maximum lift arm height kick out adjustment on the bench •

With tool 380000264 (A, Fig. 18) installed on the lift body, install connection fitting 293872 (D).

•

Put position control lever (P) fully back on the quadrant (fully raised position).

•

Connect the fitting 293872 (D, Fig. 18) to the shop air supply (T).

•

Rotate the lift control arm shaft (2, Fig. 12) to bring the lift arms to beyond the fully raised position, until the piston connecting inner arm (1) comes into contact with the lift body.

35-27

24 Adjusting Position Control and Maximum Lift Arm Travel A. C. D. P1. R1. R2. T.

Tool 380000264 Wrench 380000267 Fitting 293872 Plunger of tool 380000264 Tool 380000264 outer register Tool 380000264 inner register Compressed air line.

•

Through fitting 293872, introduce air into the cylinder so that the piston moves through the full lift stroke and maintain the air pressure to hold this position.

•

Using wrench 380000267 (C, Fig. 18), tighten the maximum lift arm height kick-out adjusting screw (6, Fig. 17) until plunger (P1, Fig. 18) is not more than 1.3 to 1.7 mm (0.051 - 0.067 in.) back from the inner register (R2) of the tool 380000264.

NOTE: This condition corresponds to a gap of 86.3 to 86.7 mm (3.398 - 3.413 in.) between the main spool control lever and the lift body front face. •

Secure the locknut (10, Fig. 17) and verify the above specification.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 LIFT ADJUSTMENT AND CHECKS ON THE TRACTOR Adjusting Draft Control Spring NOTE: This adjustment can only be made while the lift is on the tractor. Check this adjustment before removing lift. •

Flip over the lock-out block to remove block from between the draft control “U” spring ends.

•

With no load on the spring, measure the distance between the inside of the tractor side spring end surface and the inside of the top link support mounting plate surface on the top side. The distance should be between 12.7 and 13.0 mm (0.500 and 0.512 in.). To adjust the distance, add or subtract shims between the back of the top link support mounting plate and the inside surface of the implement end of the draft control spring.

•

Open the draft control “U” spring completely with tool 380000479 applied to top link support.

•

Again measure the distance between the inside of the tractor side spring end surface and the inside of the top link support mounting plate surface on the top side. It should be between 19.2 and 19.7 mm (0.76 and 0.78 in.). To adjust the distance, add or delete shims between the outside surface of the implement end of the draft control spring and the inside surface of the top link support.

35-28

25 Draft Control Spring Travel Adjustment Controlling distance (L2) with spring free Controlling distance (L3) with spring in total traction by means of tool 380000479 (A) A. Lever 380000479 connected to the top link support holes to stretch control spring (push lever downwards) H1 and H2. Shims for dimensions (L2) and (L3) L2 = 12.7 – 13mm (0.5 – 0.51 in.) L3 = 19-2 – 19.7mm (0.756 – 0.776 in.) 16. Plate 17. Top Link support 29. Spring travel stop block 94. Draft control spring. a. b.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 Adjusting Draft Control Linkage NOTE: Make the following adjustments only after the draft control external spring has been adjusted. •

Fit the outer draft control link (25, Fig. 21).

•

Move the position control lever fully forward on quadrant (fully lowered) and pull back the draft control lever on the quadrant 184 to 186 mm (7.24 to 7.32 in.), as measured from the beginning of the draft lever quadrant slot and the lower edge of the draft lever (L2, Fig. 20).

•

Adjust the internal draft control adjustable link (22, Fig. 20) so that the distance (L3) between the centerlines of the turnbuckle end fulcrums is 70.0 to 70.5 mm (2.76 to 2.77 in.).

•

Adjust the outer draft control link so that the plunger (P1, Fig. 18) is aligned with the outer register (R1) of tool 380000264 (A).

NOTE: This condition corresponds to a gap of 82 mm (3.23 in.) between the main spool control lever and the lift body front face while applying a force of 4.0 to 4.5 kg (9.0 to 10.0 lbs.) to the main spool control lever end.

•

Tighten the turnbuckle locknut (23, Fig. 21).

•

Install the control valve.

26 Draft Control Adjustment F. Draft control lever F1 = 4 – 4.5 N (kg, or 9 – 10 lbs.), force exerted by tool 380000264 on lever (7) L1 = 82 – 82.1mm (3.228 – 3.232 in.), distance between end of lever (7) and front face of lift body L2 = 184- 186mm (7.24 – 7.32 in.), distance from beginning of slot and edge of lever (F) L3 = 70 – 70.5mm (2.76 – 2.77 in.), distance between tie (22) fulcrum centerlines P. Position control lever 7. Control valve lever 14. Draft control internal lever 22. Draft control adjustable link.

27 Draft Control Adjustment On Tractor 23. 24. 25. F. P.

35-29

Locknut Threaded sleeve Draft control external link Draft control lever Position control lever.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 Adjusting Touch Command Descent Button Free Play: • Apply a 50 kg (110 lbs.) load to the bottom lift arms. •

Run the engine at medium speed (1200 to 1500 RPM).

•

Put position and draft control levers fully forward on quadrant.

•

Adjust the position of the quadrant mounted by loosening screw (21) and sliding touch command assembly forward or backward on quadrant.When you press the button to lower the lift, the lift starts to lower 9.0 to 12.0 mm (0.35 to 0.47 in.) before the button’s fully pushed limit (L5, Fig. 22).

28 Touch Command Device Adjustment F. P. 21. Q. L5.

Draft control lever Position control lever Retaining screw Arm descent button Arm descent button free play.

Maximum Lift Arm Height Kick-Out • Move position and draft control levers fully forward on quadrant. •

Operate the lift with the Touch Command buttons several times. Make a reference mark on the lift housing (S1) and straight across to the lift arm at the cross shaft at maximum raise (A).

•

Pick up the bottom lift arms until the piston arm hits the back of the lift.

•

Make another mark on the lift arm (B) straight across from lift housing mark (S1).

•

Measure the distance between the two notches on the lift arm. The distance should be between 2.0 to 4.0 mm (0.79 to 0.16 in.).

35-30

29 Notches for Arm Top Travel End Control

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 •

Adjust the maximum lift height kick out by removing the plug (T, Fig. 24) on the front of the control valve block. With tool 380000267, unscrew the locknut (10), and adjust the setting screw (6) until the distance is between 2.0 to 4.0 mm (0.79 to 0.16 in.).

NOTE: It is possible that torque on the above lock nut from the factory is greater than tool 380000267 can release. If this is the case, remove the lift control valve to release the locknut. Before retorquing the locknut, apply Loctite 242. •

Tighten the locknut (10).

•

Tighten the plug (19).

1431-2-01

30 Top Travel End Adjustment T. Plug 6. Setting screw 10. Locknut

31 Adjusting Lifting Arm Lift C. Wrench 380000267

Start-to-Lift Check • Place the position control lever in its fully forward position on the quadrant. •

Push the Touch Command switch to its lowered position.

•

Place the draft control lever at 185 mm (7.28 in.) from the start of its slot.

•

Operate the lift with the raise switch of the Touch Command. If the lift fails to rise, adjust the draft control external link turnbuckle (25, Fig. 21) to make the lift rise.

35-31

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 RELIEF VALVE AND CYLINDER SAFETY VALVE CHECKS You can check the relief valve either on the bench or on the tractor. You must check the cylinder safety valve on the bench. To bench test the relief valve or cylinder safety valve, use a hand pump with safety valve fittings 380000218 (C, Fig. 26) and 380000217 (B). The relief valve crack-off pressure should be 186 to 191 bar (2702 to 2775 PSI). The cylinder safety valve crack-off pressure should be 210 to 215 bar (3058 to 3129 PSI). If the valve does not meet these specs, adjust it or discard the valve and replace it. NOTE: This relief valve bench-testing procedure is for guidance only. In-factory adjustment of relief valves uses oil under pressure. You can adjust these valves through threaded plugs after raising the peened area. Use wrench 380000231 for the relief valve and use wrench 380000230 for the cylinder safety valve.

32 Cylinder Safety and Relief Valve On-Bench Equipment a. b. A. B. C. 1. 7.

Section through relief valve Section through cylinder safety valve Hand pump 380000215 Safety valve fitting 380000217 Safety valve fitting 380000218 Relief valve Cylinder safety valve.

40035252

33 Lift Control Valve Front View 1. 2.

35-32

Lift sensitivity adjustment lever Lowering speed control knob

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 To test the relief valve on a tractor with remote control valves: •

Tap a hydraulic pressure/flow rater with a scale from 0 to 245 bar (0 to 3556 PSI) into the remote couplers.

•

Run the engine to bring the hydraulic system oil up to between 47° and 53° C (117° and 127° F).

•

Actuate the remote valve lever. As pump flow is being restricted on the hydraulic pressure/flow rater, relief valve crack-off occurs at the pressure reading at the instant the pump flow begins to drop. At this instant, the pressure gauge on the hydraulic pressure/flow rater should read between 186 and 191 bar (2702 and 2775 PSI). The pressure will continue to climb to a maximum of 242 bar (3500 PSI) before flow will reach 0 GPM.

•

34 Checking Lift Relief Valve Setting F. Fitting 380000554 M. Pressure gauge with 0 to 250 bar (0-3560 PSI) scale

If the valve adjustment is incorrect, discard the valve and replace it or adjust it. Adjust the valve by releasing the peen and turning the adjustment screw clockwise to increase crack-off pressure or counterclockwise to decrease crack-off pressure.

To test the pump backpressure: •

Tap a hydraulic pressure flow/rate with a scale from 0 to 245 bar (0 to 3500 psi) into the pressure side at the pump using fitting 291326 (R, Fig. 29).

•

With all valves in neutral, pump backpressure should be between 2.0 and 10.4 bar (30 and 150 psi).

35 Checking Pump Backpressure with all Valves in Neutral M. P. R. 2.

35-33

Pressure gauge with 0 to 245 bar (0-3500 PSI) scale Hydraulic pump Fitting 291326 Oil delivery pipe.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

36 Lift Pump Components a. M. R. 1. 2. 3. 4. 5.

Seal assembly detail Pump delivery port Gear bearing fittings (delivery side) Gear bearings Cover seals Pump body Rear cover Front cover

6. 7. 8. 9. 10. 11. 12. 13.

Drive shaft rotary seals Seal retaining ring Drive gear shaft Driven gear shaft Spacer Anti-extrusion ring Shaft nut and associated tab washer Cover retaining nuts.

Disassembly/Overhaul • Mark the position of the internal parts to remember how to reassemble them back into their original positions. •

Check gear shafts and bearings for wear, referring to the specifications.

•

Check side face flatness and squareness relative to bearings, smearing the surfaces in question with carbon black. Wet zero-grade emery cloth may rectify small defects.

37 Section Through Pump Drive 1. 2. 3. 4. 5. 6. 7. 8. 11. 12.

35-34

Centralizer Pump drive sleeve Sleeve drive ring Retaining ring securing ring (3) Seal Pump driven gear Thrust washers Gear bushings Pump capscrews Sleeve nut.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 •

Check that gear end clearance (Fig. 32) in the pump body with bearings in position is 0.09 to 0.16 mm (0.0003 to 0.0060 in.). If necessary, dress using wet zero-grade emery cloth, removing as little material as possible.

•

Lubricate the parts using the same grade of oil as the hydraulic lift system.

When reassembling, remember to : •

Use the marks made during disassembly.

•

Position the plastic anti-extrusion ring (11, Fig. 30) inside the central cover seals (2).

•

Position the bearings by hand so that delivery side gear bearing fittings (R) face towards the pump delivery port (M), with the frontal surfaces with lubrication slots flush with the gears.

•

Fit the drive shaft rotary seals (6) on the rear cover (4) complete with associated spacer (10), turned as shown in Fig. 30, detail “a”, and pack lip cavity with grease.

•

Progressively tighten the cover nuts and the capscrew to pump body to the specified torque. Cover nuts Capscrew

•

4.2 N⋅m (30.4 ft.lbs.) 0.8 N⋅m (5.8 ft.lbs.)

When installing the hydraulic pump on the tractor, fill the suction line and pump body with oil to facilitate priming and prevent seizure during initial service.

OIL FILTER The oil filter is a paper cartridge that should be replaced every 400 operating hours. The filter is on the hydraulic pump suction line, on the right-hand side of the engine. When replacing the oil filter, clean the area around the filter, unscrew the filter casing, and discard it the old filter. Clean the inlet channel and the face of the filter mounting. Smear clean oil around the rubber seal of the new filter and screw the filter onto the engine. Screw the filter up until the faces meet, then tighten another three-quarter turn. Do not over tighten. NOTE: Check filter base mounting allen head screws for tightness.

35-35

38 Checking Gear End Clearance in Pump Body Dimension X to be smaller than dimension Y by 0.09 to 0.16 mm (0.002 to 0.006”).

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 IMPLEMENT ATTACHMENT The implement attachment is a three-point linkage with adjustable link rods, top link, and check chains. The linkage may also have optional adjustable links or lower check blocks. Right-Hand Lifting Rod Disassembly To remove the right-hand lifting rod: •

Straighten the tab washer (13, Fig. 33) and unscrew the cover (4).

•

Remove the cover with the driven gear (8).

•

Back off the drive pinion support capscrew (14), and remove the drive pinion support (15) with the drive pinion (7).

•

Unscrew the lower housing (10) and remove the driven gear and thrust bearing (9).

•

Remove the lifting rod adjustment handle (1) and roll pin (2), retrieving the drive pinion.

When reassembling, pack the top and bottom recesses with grease. Insert shims (S) between the driven gear pin (12) and the driven gear (8) to obtain 0.1 to 0.3 mm (0.004 to 0.012 in.) end float. Measure the end float by inserting a feeler gauge between the fixed pin (11) and the driven gear pin (12).

S. 1. 2. 3. 4. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Section Through RH Lifting Rod End float shims Lifting rod adjustment handle Roll pin Top housing Cover Grease zerk Drive pinion Driven gear Thrust bearing Lower housing Fixed pin Driven gear pin Tab washer Drive pinion support capscrew Drive pinion support

REMOTE CONTROL VALVES These tractors are fitted with either a single rotary double acting remote valve or a dual double-acting in line block-type remote valve. The remote control valve uses the same hydraulic fluid as the hydraulic lift unit, but operates independently by means of the control lever. It is not possible, however, to operate the remote control valve and the hydraulic lift unit at the same time.

Single Remote Control Valve Assembly (Front) 1. Remote control valve handle 2. Remote control valve

35-36

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 Testing remote operation of single valve doubleacting:

Connect the raise hose to the top port (1, Fig. 35) and the lower hose to the lower port (2) on the remote valve. Moving the main control lever to the rear will raise the implement. Moving the control lever forward will lower the implement. The rate of lift or lower can be changed by feathering the lever in either direction.

2 41 Remote Control Valve Assembly (Rear)

42 Hydraulic Oil Flow for Single Remote Valve A. Stop B. Lift C. Lower

P1. Remote control valve spool 1. Pressure relief valve 41. Adapter for double-acting cylinder control.

Oil is supplied to the remote valves from the main pump. In the neutral position oil is supplied to the top cover via the power beyond port in the rear of the attaching manifold. If the three point lift is not being used the oil will return to sump.

Single remote valve removal: 1. Remove the two 13 mm bolts connecting the pump pressure line to the remote valve and remove the line.

If the lift circuit is operating, oil will be supplied to the lift cylinder until it reaches the end of its stroke at which point the main control spool will return to neutral. The relief valve protects the pump. The relief pressure is set at 186 to 191 bar (2700 to 2770 PSI). The relief valve will blow if the load is too heavy for the three point lift allowing oil to return to sump via the oil return port in the side of the lift cover. This is also the path that return oil takes during the lowering cycle.

35-37

2. Undo the 30 mm bolt securing the return line banjo fitting to remove valve. 3. Undo the 27 mm bolt securing the power beyond banjo fitting to the remote valve. 4. Remove the four 17 mm bolts securing the valve to the support bracket and remove the valve.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 Single remote valve disassembly: To access the main control spool: 1. Undo the 17 mm nut and remove the main control lever. 2. Remove the main lever return spring. 3. Remove the three 17 mm bolts and remove the spool retaining end plate. 4. Remove the spool. The spool has a regular O ring and a back up ring seal, which can be replaced. The valve spool and housing are only available as a complete assembly and will need to be replaced if worn. Single remote valve reassembly: Reassembly is the reverse of disassembly. When reinstalling the valve, the keyway must be in the vertical position to assure correct alignment of the internal oil galleries.

35-38

Single remote valve system tests: NOTE: All tests should be carried out with oil at 55-65º C (131-149º F). Test data was achieved using SAE 20 oil. Pressure Test: To test the system pressure put a 3000 PSI gauge in the raise port of the remote outlet. Pressurize the remote valve by stroking the lever and observe the pressure. Pressure should be between 186-191 bar (2700-2770 PSI). Flow Test: To test pump output connect the flow meter to both ports on the remote valve. Open the restrictor valve fully. Stroke the remote control lever and run the tractor at maximum speed, 2500 RPM. Pump flow should be 35.6 liters/min. (9.4 US gallons/min.) with a new pump and as low 23.0 l/min. (6.3 US gallons/min.) with a used pump. NOTE: For information see “DIA” Dual Remote Valves.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 DUAL REMOTE VALVE DESCRIPTION AND OPERATION The linear spool-type hydraulic remote control valves can be used for single and double-acting ram applications, and float operation is possible. For single acting cylinder operation, screw (1, Fig. 37) should be fully backed off, while for double-acting operation, should be fully in. Remote controlled valves are installed in banks (two maximum) on special brackets on the RH final drive. Operation is by means of the hydraulic lift oil with separate control by means of hand levers (A and B). Simultaneous operation of a remote control valve and the lift is only possible with the control valve in float position. The relief valve (setting 186 - 191 bar or 2702 - 2775 PSI), normally housed in the hydraulic lift control valve, is on the control valve retaining plate when remote control valves are installed. Oil circulates through the two remote control valves with associated control levers in the neutral position. In this position, the oil coming from the pump passes through the valve bodies in the direction indicated by the arrows and flows into the lift control valve.

35-39

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 Convertible Valve – Double Acting a. Raising – When lever A is pulled back, spool (2) opens inlet (E) and cylinder lower chamber through check valve (3) and port (G) and between cylinder upper chamber and exhaust port (L) through port (H), preventing oil delivery to lift control valve. If the control lever is held back, the raising phase continues until relevant cylinder reaches the end of its travel. On release, the lever springs back to neutral and the entire pump output is directed to the lift control valve through ports (M). b. Lowering – To lower implement, push control lever A forward. Spool (2) moves as shown in detail “b” and permits oil contained in cylinder lower chamber to flow to discharge (L) through port (G), while upper chamber is placed in communication with outlet port (E) through port (H) and check valve (3). Convertible Valve – Single Acting c. Raising – When lever B is pulled back, spool (2) opens inlet (E) and cylinder lower chamber through check valve (3) and port (G). Port (H), used for double-acting cylinders, is not used in this phase since it is permanently connected to discharge (L) when conversion valve (1) is open.

d. Lowering – When lever B is pushed forward, the spool (2) moves as shown in detail “d.” The oil in the cylinder, pushed by weight of lifted implement, flows to discharge (L) through port (G) through entire pump output is directed to discharge (L) through check valve (3) and port (H).

d 43 Double-Acting Cylinder (fig. a, fig. b) and Single-Acting Cylinder (fig. c, fig. d) Remote Control Valve Operation NOTE: For double-acting cylinder operation, screw (1) should be fully screwed in, and fully backed off for single-acting cylinders.

35-40

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 DOUBLE ACTING VALVE WITH DETENT FLOAT e. Raising – When lever B is pulled back, spool (2) opens inlet (E) and cylinder lower chamber through check valve (3) and import (G) and between cylinder upper chamber and exhaust port (L) through port (H), preventing oil delivery to lift control valve. If the control lever is held back, the raising phase continues until relevant cylinder reaches the end of its travel. On release, the lever springs back to neutral and the entire pump output is directed to the lift control valve through ports (M). f.

Lowering – To lower implement, push control lever B forward. Spool (2) moves as shown in detail “f” and permits oil contained in cylinder lower chamber to flow to discharge (L) through port (G), while upper chamber is placed in communication with outlet port (E) through port (H) and check valve (3).

g. Float – for implement float operation, push lever B fully forward. Spool (2) takes up position shown in detail “g” where it is held by ball (30) retained in place by pin (31) and spring (32) and establishes communication between ports (M) directing entire pump output to lift control valve, and between discharge port (L) through ports (H, G) and upper and lower chambers respectively, Implement may therefore follow ground contour as lift arms are free. Lift may be operated in float control.

g 44 Remote Control Valve Operation for Double-Acting Cylinder (fig. e, fig. f) and Detent Float (fig. g).

35-41

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

b a. Single-acting cylinder remote control valve b. Double-acting cylinder remote control valve c. Float double-acting cylinder remote control valve d. Outlet cover e. Inlet cover 1. Single/double action conversion valve 2. Spool 3. Check valve 4. Caps 5. Cups 6. Spool spring 7. Spacer 8. Actuating lever support 9. Valve (1) plug 10. Check valve seat 11, 12, 13, 14, 15 and 16. O ring 17. Seal 18. Rear plate 19. Oil outlet connection to lift 20. O ring 21. Front plate 22. inlet port 23. Outlet port 24. Relief valve body 25. Plug 26. Relief valve plunger 27. Shim 28. Spacer 29. Relief valve spring 30. Spool detent balls 31. Ball (30) retaining pin 32. Spring 33. Bushing.

45 Section Through Remote Control Valves

To disassemble dual remote control valves: Refer to the drawings and note the following: • Remove caps (4), springs (6) and cups (5) and withdraw spools from actuating side of each valve body (with float double-acting cylinder control valve (detail c), also retrieve spool detent ball (30), pin (31), and spring (32). • For control valves with single/double action conversion valve (detail a and b), back off plug (9) and remove valve (1). • Remove check valve seat (10) using pliers. Take out check valve (3) and retrieve spring.

35-42

•

Unscrew relief valve body (24) to remove relief valve from retaining plate; on the bench, remove plug (25) and retrieve spring (26), shims (27 and 28) and plunger (29). Check seal for wear, replacing as required.

If spool replacement is necessary, note that spare spools are supplied complete with associated control valve body. To install control valves, reverse the disassembly procedure and tighten control valve link nuts to 20 N⋅m (14.5 ft.lbs.).

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 DUAL REMOTE VALVE SYSTEM TESTS NOTE: All tests should be carried out with oil at 55-65Â° C (131-149Â° F) Test data was achieved using SAE 20 oil. Pressure Test: To test the system pressure, put a 3000 PSI gauge in the raise port of the remote outlet. Pressurize the remote valve by stroking the lever and observe the pressure. Pressure should be between 186-191 bar (2700-2770 PSI). Flow Test: To test pump output connect a flow meter to both ports on the remote valve. Open the restriction valve fully. Stroke the remote control lever and run the tractor at maximum speed, 2500 RPM. Pump flow should be 32.8 l/min. (8.7 US gallons/min.) for a new pump and as low 23.0 l/min. (6.3 US gallons/min.) with a used pump. Remote control valve spool leakage test: Take a porta-power and fill with oil. Connect the porta-power to either the raise or lower port of the remote valve and pressurize the system to 150 bar (2091 PSI). Maintain the pressure for one minute and relieve the pressure on the porta-power. Measure the amount of oil required to bring the porta-power back to the full level. The amount of leak down should be within 25 cc/min. (1.526 in.3/min.) with new control valves and 60 cc/min. (3.66 in.3/min.) with used ones. Repeat the test on each remote control valve, testing each of the two cylinder delivery ports in turn.

35-43

46 Remote Control Valve Piping Connection Diagram A. Single/double-acting convertible remote control valve lever B. Float double-acting remote control valve lever C. Single/double action conversion valve F1. Threaded hole (M22x1.5) for oil inlet line fitting F2. Threaded hole (M22x1.5) for oil discharge line fitting F3. Threaded hole (M20x1.5) for oil delivery connection to lift control valve F4 and F5. Threaded holes for oil delivery connections to single-acting or double-acting cylinders.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 Hydraulic System with One Remote Valve Installed

50037333

35-44

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 Hydraulic System with Two Remote Valves Installed

50037332

35-45

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 Hydraulic System with Three Remote Valves Installed

50037331

35-46

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1

SECTION 41 - STEERING SYSTEM Chapter 1 - Steering System CONTENTS Section

Description

Page

41-1

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 STEERING SYSTEM SPECIFICATIONS

HYDROSTATIC STEERING Type Oil Filter Control Valve Make Control Valve Type

Control Valve Model Code Pressure Relief Valve Setting

Specification Independent hydrostatic control With metal cartridge; built into oil reservoir DANFOSS ORBITROL; rotary valve controlled directly by the steering column; the steering continues to function even if the pump is damaged OSPC 100 OR 140 to 145 bar (2025 to 2100 PSI)

HYDROSTATIC STEERING PUMP Type Make, Model Rotation (viewed from control side) Engine RPM / Pump RPM Ratio Maximum Pump RPM with Engine at 2500 RPM Rated Pump Output at Maximum Rated Pump RPM Diameter of Driven and Driving Gear Shafts Diameter of Shaft Bore in Bearings

Gear type BOSCH Clockwise 1 to 0.931 2328 RPM 26.4 liters/min. (7.3 US gallons/min.) 18.938 to 18.956 mm (0.7456 to 0.7463 in.) 18.988 to 19.006 mm (0.7476 to 0.7483 in.) 0.032 to 0.070 mm (0.0012 to 0.0027 in.) 0.10 mm (0.004 in.) 0.020 to 0.064 mm (0.0008 to 0.0025 in.) 0.10 mm (0.004 in.) 19.796 to 19.812 mm (0.7794 to 0.7800 in.) 18.323 to 18.348 mm (0.7213 to 0.7223 in.) 58.072 to 58.122 mm (2.2863 to 2.2882 in.) 0.10 to 0.20 mm (0.004 to 0.008 in.)

Shaft / Bearing Clearance Maximum Wear Clearance Radial Clearance of Gears in Pump Housing Maximum Wear on Pump Housing on the Intake Side Near Gears Bearing Width Gear Width Pump Body Width for Gear Seats and Supports Bearing / Gear End Clearance in Pump Body (restored during overhaul)

41-2

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 STEERING TORQUE SPECS

Thread Size

Specification

Capscrew, Control Valve Support

M16 x 1.5

147 N⋅m (108 ft.lbs.)

Capscrew, Control Valve to Tractor

3/8”-16 UNC

44 N⋅m (32 ft.lbs.)

Capscrew, Cover to Control Valve

M8 x 1

34 N⋅m (25 ft.lbs.)

Nut, Cylinder Pivot Pin

M8 x 1.5

294 N⋅m (217 ft.lbs.)

Nut, Cylinder Piston Rod to Steering Arm

M16 x 1.5

206 N⋅m (151 ft.lbs.)

Nut, Piston to Rod

M16 x 1.5

98 N⋅m (72 ft.lbs.)

M6 x 1

8 N⋅m (6 ft.lbs.)

M10 x 1.25

49 N⋅m (36 ft.lbs.)

7/16”-20 UNF-2B

28 N⋅m (20 ft.lbs.)

Capscrew, Steering Pump to Engine Nut, Cover to Pump Body Nut, Drive Sleeve to Pump Drive Shaft

SPECIAL TOOLS 380000305 Bush guide

380000618 Hydraulic union

380000307 Driveshaft guide

380000613 Hydraulic union

41-3

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1

24725

1 Hydrostatic steering control valve components Dust seal Reflux valve balls Reflux valve pins Body, rotary valve and rotary valve seat sleeve of control valve 5. Check valve ball 6. Threaded plug of check valve 7. O-ring seal 8. Support ring for O-ring (7) 9. Thrust bearing components 10. Retaining ring for springs (11) 11. Springs for returning sleeve to neutral position 1. 2. 3. 4.

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

41-4

Rotor control shaft - sleeve trim pin Cover fixing screws Check valve seat screw Washers Cover O-rings Rotor and fixed ring for rotor Thrust washer O-ring Rotor control shaft Pressure relief valve complete with spring

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 DESCRIPTION AND OPERATION The steering system controls the direction of the front wheel assemblies with pressurized hydraulic oil. There is no mechanical linkage connecting the steering column to the wheels, thereby making the steering system hydrostatic. The steering system includes the following components: • • • • • • •

Reservoir Tank with Filter Steering Pump Hoses and Tubes Steering Motor Check Valve Pressure Relief Valve Steering Cylinder(s)

The reservoir tank (1), located on the upper right-hand side of the engine, stores hydraulic oil for the steering system. An opening on top of the tank, covered by a large plastic cap (2) provides a provision for replenishing oil as needed. In addition, the reservoir contains an integral metal cartridge type filter to remove contaminates from the oil.

10036136

The reservoir tank mounts higher than the steering pump, which allows gravity fed oil to enter the suction port (1) of the pump through the supply tube (2). This configuration reduces pump wear by preventing cavitation at first start up.

10036137

41-5

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 The steering pump (1), located on the lower right-hand side of the engine, mounts forward of the high-pressure system hydraulic pump. It is an engine driven fixed displacement, gear type pump, which delivers 7.3 g/m at 2500 engine rpm. The pump draws oil from the reservoir tank and filter, pressurizes the oil, and then directs the oil to the steering motor.

10036138

4 The steering motor (1) mounts at the base of the steering column just forward of the rear engine firewall. The steering wheel and column adjusts to vary the angle of tilt.

10036139

5 The steering wheel, when turned, rotates a spline shaft within the steering motor. The motor reacts by directing hydraulic oil under pressure from the steering pump, through tubing (1) to the steering cylinder (2WD shown) or the 2 steering cylinders (FWD) to drive the front wheels.

10036160

41-6

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 The steering motor consists of a metering unit for regulating the volume of oil to the steering cylinder(s), proportional to the angular movement of the steering wheel. This controls the rate of turn. A check valve functions in combination with the metering unit to allow manual operation of the steering system in the absence of pressurized oil from the pump. The pressure relief valve, mounted in the steering motor, protects the system from over pressurization, by maintaining pressure at 140-145 bar (2030-2103 psi). The single steering cylinder on 2WD models is a double acting, balanced type valve with the cylinder end opposite the rod end connected to the front axle support (1, 2WD shown).

10036140

7 The rod end (1) of the steering cylinder connects to the right-hand wheel steering arm (2). When the steering cylinder extends and retracts, the movement transfers to the left-hand wheel through the tie rod (3) connected to both wheel steering arms (2WD shown).

2 1

10036141

3 8

41-7

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 FWD

2WD

9 a 1. 2. 3. 4.

2WD models Steering cylinder(s) Metering valve Check valve Pump

Diagram of hydrostatic steering operation 5. Filter 6. Return line to reservoir 7. Pressure relief valve 8. Control valve external rotor 9. Control valve internal rotor

Passages in the spool and sleeve allow oil from the opposite side of the steering cylinder(s) to flow back to return by way of the steering motor housing.

Steering System Oil Flow With the steering wheel stationary, springs in the steering motor maintain the control valve spool and sleeve in the neutral position, stopping the flow of oil to the steering cylinder(s). The sleeve traps oil in the steering cylinder(s), thus keeping the wheels in position. Trapped oil within the cylinder transfers between the left and right sides of the cylinder as the wheels react to the ground, which provides feedback to the operator.

Manual Steering Manual steering provides a means of controlling the tractor when a loss of pump pressure occurs. When turning the steering wheel for a right-hand turn, the metering unit forces oil into the steering cylinder. On the suction side of the metering unit, return oil flows from the steering cylinder through a check valve to feed the metering unit. In this action, the steering motor functions as a hand pump. The same occurs for left-hand turns.

Turning the steering wheel causes movement of the control valve spool within the sleeve to form a series of passages. When turned right, oil flows through the sleeve along a groove in the spool and into the steering motor housing to the metering unit. The drive shaft rotates the metering unit, directing oil through another passage within the spool and sleeve until reaching the steering cylinder(s).

Returning oil flow from the steering motor reenters the reservoir tank, where it redistributed to the steering pump suction port.

41-8

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 STEERING SYSTEM TESTING AND ADJUSTMENT Steering Motor Relief Valve Pressure Check With all steering system components installed on the tractor, proceed as follows: 1. Start the engine and run until the hydrostatic steering oil temperature reaches app 50ยบ C (122ยบ F), then shut off engine.

3 1

2. Disconnect the tube from the steering cylinder rod end (1) and remove the fitting from the port.

3. Install union (2) in place of the fitting previously removed from the cylinder rod end. The testing union must accommodate the connector of a 0-150 bar (0-2175 psi) pressure gauge. 4. Connect a 0-150 bar (0-2175 psi) pressure gauge to the test fitting with the original oil tube. 24915

CAUTION

Do not hold the wheels in the full left or full right position for more than 10 seconds. Oil exiting the relief valve heats up rapidly, which may cause damage to internal seals and components.

1. 2. 3. 4. 5.

5. Start the engine and run engine speed up to 1500 rpm. Apply a full right hand turn to extend the steering cylinder rod completely. In this condition, the pressure relief valve will open and the pressure gauge must read 140-145 bar (2030-2103 psi). If the value observed deviates from the specified relief pressure, adjust the relief valve opening pressure by way of the adjuster screw. 6. After obtaining the correct relief valve setting, remove the test equipment and install the original fitting back into the steering cylinder rod end. 7. Reconnect the steering cylinder tube. Ensure all connections are tight. 8. Check the steering reservoir oil level and replenish if necessary. 9. Start the tractor and check the steering system for proper operation and leakage.

41-9

Pressure gauge Union 293874 to be fitted in place of original union Union 291318 Hydraulic cylinder oil feed pipe Hydraulic cylinder.

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 Checking for Steering Motor Wear With all steering system components installed on the tractor, proceed as follows: 1. Start the engine and run until the hydrostatic steering oil temperature reaches app 50ยบ C (122ยบ F). Set the engine speed to 1000rpm. 2. Turn the steering wheel quickly from stop to stop. The reaction of the front wheels must be immediate. If no problem is evident shut-off the engine and proceed with step 3. 3. Remove the center cap from the steering wheel and place an inch-pound torque wrench on the steering wheel mounting nut. Turn the wheel to full lock. 4. Apply a torque of 6.8 Nm (60 in-lb) and hold for one minute. The motor must not turn more than three-quarter of a revolution in one minute. If the motor turns more than specified, repair or replace due to excessive leak-by. Steering Motor Return to Neutral (Static) Check With all steering system components installed on the tractor, proceed as follows: 1. Start the engine and run until the hydrostatic steering oil temperature reaches app 50ยบ C (122ยบ F), then shut off engine. 2. Turn the wheels full left or full right and then release the steering wheel. The wheels must remain locked in position as system pressure reduces.

41-10

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 DETERMINING FRONT WHEEL TOE IN / TOE OUT To determine the correct toe-in, refer to the following procedures: 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. 3. Measure the distance between the two marks and note as Dimension A.

4. Maintain a straight-ahead position and move the tractor forward to rotate the wheels 180ยบ with the marks of Dimension A at the rear. 5. Measure the distance between the two marks and note as Dimension B. NOTE: If Dimension A is larger than Dimension B, the toe-out is A minus B. If Dimension B is larger than Dimension A, the toe-in is B minus A. 6. To ensure accurate results, repeat the procedure three times with different marks equally spaced around each wheel rim, and take the average dimension for toe-in/toe-out. This method minimizes inaccuracy due to wheel rim run-out. Compare the front wheel toe-in to a specification of 0-6.0 mm (0-0.24 in), i.e. the difference in the measurement between the front and rear rim measurement must not exceed 6 mm (0.24 in). Proceed with steps 7 through 11 if not within specification. To determine toe-out, subtract Dimension B from Dimension A. Check for a result of 0-13 mm (0-0.5 in).

41-11

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 Front Wheel Toe-in/Toe-out Adjustment For best operation, configure the front wheels parallel to one another, or with a slight toe-in. To adjust the toe-in proceed as follows: 1. Park the tractor on a flat level surface with the front wheels facing straight ahead.

2. Loosen the lock nut on the left-hand side of the tie rod (1, 2WD shown).

3. Remove the nut to the tie rod-to-steering arm bolt (2, 2WD shown). Remove the bolt.

10036142

12 4. Turn the threaded portion (3, 2WD shown) of the tie rod clockwise or counterclockwise until obtaining the correct toe-in measurement. Place the tie rod-to-steering arm bolt back into position to check measurement, and remove the bolt if the tie rod requires further adjustment. See item 1, Figure 13 for FWD.

5. After obtaining the correct toe-in, reinstall the tie rod-to-steering arm bolt and tighten.

10035242

41-12

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 HYDROSTATIC STEERING MOTOR OVERHAUL Disassembly-Assembly with the control valve removed To disassemble the hydrostatic steering control valve, proceed as follows: 1. Remove the cover fixing screws.

24701

14 2. Remove the cover by sliding it sideways.

24702

15 3. Remove the fixed ring for the rotor, the rotor and the internal spacer. 4. Remove the two O rings on the fixed ring for the rotor.

24703

41-13

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 5. Take out the rotor control shaft.

24704

17 6. Take out the thrust washer.

24705

18 7. Remove the threaded plug from the check valve seat.

24706

41-14

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 8. Take out the O ring from the control valve body.

24707

20 9. Turn the control valve body and take out the ball of the check valve, the two balls with the pins, and the springs of the reflux valve.

24708

21 10. Position the control valve body and the rotor control shaft in such a way that the sleeve-control shaft trim pin is in a horizontal position. 11. Push the rotary valve inwards, so that you can take the valve, the valve seat sleeve and the thrust bearing out of the control valve body.

24709

41-15

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 12. Take out the thrust bearing of the rotary valve complete with the two external rings and take the spring retaining ring out of the valve seat sleeve.

24710

23 13. Take out the valve-sleeve pin.

24711

WARNING At the time of assembly, two reference marks were made on the rotary valve and the sleeve, corresponding to the neutral position maintained by the spring. Before removing the springs, make sure that the reference marks are clearly visible, otherwise renew them.

24712

41-16

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 14. Take the rotary valve out of the valve seat sleeve.

24713

26 15. Remove the neutral position springs, withdrawing them from their seats.

24714

27 16. Remove the dust ring and the O-ring from their seats on the control valve body.

24715

41-17

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 17. Using a 6 mm Allen key, remove the threaded plug of the pressure relief valve and take out the washer.

24721

29 18. Remove the adjuster screw of the pressure relief valve.

24722

30 19. Turn the control valve body over and complete disassembly by taking out the spring and the pressure relief valve piston.

24723

41-18

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 Pressure relief valve components (order of disassembly-assembly).

24724

32 20. Thoroughly clean all the component parts of the control valve. 21. Change the washers and seals. 22. Thoroughly check the mechanical parts, and renew any that show clear signs of wear. 23. Before refitting, lubricate the components with hydraulic oil. 24. Refit the rotary valve on the sleeve, checking that the reference marks indicated in the figure coincide.

24726

41-19

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 25. Use tool 293389 to insert the flat and curved springs (11, Fig. 1). Diagram for fitting springs (11, Fig. 1 for neutral position for OSPC 100 ON-150N).

24728

34 26. After inserting the springs in their seat, align them and centre them as shown in the figure.

24729

41-20

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 27. Fit the neutral position spring retaining ring on the valve seat sleeve, bearing in mind that the ring must rotate freely without being impeded by the spring.

24730

36 28. Insert the sleeve-rotor control shaft pin.

24731

37 29. Fit the thrust bearing, following the sequence and warnings shown in the figure below.

24732

41-21

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 1. 2. 3. 4. 5.

Bearing external ring Thrust bearing Internal ring of bearing, with bevel facing contact surface of part (5) Rotary valve Rotary valve seat sleeve.

1 2 3 4 5 24733

39 30. Arrange the control valve body in such a way that the seat for the sleeve of the rotary valve is in a horizontal position, then insert the guide bushing (1) of tool 293388.

24734

1 40

41-22

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 Support head for support and seal rings (part of tool 293388). 31. Lubricate the support ring (1) and O ring (2) with hydraulic oil and fit them on the head (3) of tool 293388 as shown in the figure.

2 3

24735

41 32. Insert the complete punch in the guide bushing previously installed.

24736

42 33. Holding the external bushing with your hands, press the punch fully down and turn simultaneously so as to facilitate the entry of the seal ring into its seat on the control valve body.

24737

41-23

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 34. Take out the components of tool 293388 (external bushing and punch). NOTE: The support head of the support and seal rings remains on the control valve body (Fig. 32).

24738

44 35. Insert the parts previously fitted in steps 24 - 29 into the control valve body, and hold the sleeve-rotor control shaft trim pin in a horizontal position, so as to prevent it from slipping out and jamming in the slots inside the control valve body.

24739

45 36. Press the rotary valve so as to bring the thrust bearing into contact with the control valve body; this operation simultaneously expels the head (1) of tool 293388 (see Fig. 32) and inserts the rings (1) and (2) into the seat of the control valve body (see step 31).

24740

1 46

41-24

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 37. Turn the control valve body and insert the check valve ball into the seat indicated by the arrow.

24741

47 38. Screw the threaded plug into the check valve seat until the upper surface is below the coupling surface of the control valve body.

24742

48 39. Insert the reflux valves balls into the two seats indicated by the arrows.

24743

41-25

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 40. Fit the pins complete with spring into the reflux valve seats indicated by the arrows.

24745

50 41. Lubricate the O ring and fit it into its seat on the control valve body.

24746

51 42. Fit the thrust washer, so that the holes coincide with the holes in the control valve body.

24747

41-26

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 43. Make a reference mark at the top of the teeth (1), near the seat (2), to indicate the exact position of the valve-sleeve trim pin.

24748

53 44. Fit the rotor control shaft into the control valve body, insert tool 293390 for retaining and centering the rotor drive shaft between the rotor drive shaft and the thrust washer, and turn the shaft so as to facilitate coupling of the seat (2) and the trim pin installed on the sleeve.

24749

54 45. Proceed with fitting the rotor, taking account of the following warnings: â&#x20AC;˘

â&#x20AC;˘

each time the hydrostatic steering is dismantled, turn the rotor over so as to limit wear to the splined coupling over time; in the figure below, the rotor shaft has been removed, in order to show the phasing between the rotor, rotor control shaft and trim pin.

41-27

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 â&#x20AC;˘

fit the rotor on the drive shaft, bearing in mind that phasing is achieved by aligning, on the plane of the trim pin axis, the teeth (1) shown in Fig. 45 with the centre line of one compartment of the rotor.

24750

55 46. Lubricate the two O-rings (1) with hydraulic oil and fit them in the seats of the rotor fixed ring; fit the latter so that the fixing holes (2) coincide with the holes in the thrust washer.

24751

56 47. Fit the cover so that the fixing holes coincide with the holes in the rotor fixed ring.

24753

41-28

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 48. Remove retaining tool 293390 and fit the special screw and washer in the check valve seat shown in the figure.

24754

58 49. Tighten steering motor gyrotor in the pattern shown in three steps. • • •

Tighten until resistance. Tighten until snug. With torque wrench, tighten to 8 N⋅m (6 ft.lbs)

1 6

2 5

24755

59 50. Turn over the control valve body and insert (see components in Fig. 22) the piston of the pressure relief valve in the seat indicated in the figure.

24756

41-29

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 51. Insert the spring of the pressure relief valve.

24757

61 52. Using an 8 mm Allen key, insert the screw for setting the pressure relief valve. NOTE: Setting will be carried out subsequently on the bench or on the tractor to 140 to 145 bar (2025 to 2100 PSI)

24758

41-30

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 53. Tighten the plug (1) with the relative seal, using an 8 mm Allen key, and execute setting on the workbench or on the machine; tighten to the envisaged torque of 40-60 Nm (4.1 to 6.1 kgm, 29.5 to 44 ft.lbs.).

24763

63 54. When the unit has been assembled, insert the dust ring into its seat on the control valve body.

24764

41-31

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1

65 C1. C3. C4. P1. 1. 2.

Pump Capscrews Sleeve Nut Cover Nut Hydraulic Pump Gear Bushings Shims

Section Through Steering Pump Drive 3. Pump Drive Gear 4. Drive Collar 5. Drive Sleeve 6. Retaining Ring 7. Gasket 8. Centralizer

41-32

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 FRONT AXLE STEERING CYLINDERS STEERING CYLINDER - 2WD Removal -- Installation

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and another. Wear the recommended safety clothing such as goggles, gloves and safety boots. To remove the axle steering cylinder, proceed as follows: 1. Unscrew the unions fixing the oil delivery and return hoses (1) to the cylinder (2).

24768

2. Remove the nut fixing the cylinder rod ball end to the lever (1).

24858

67 3. Using the extractor (1), separate the ball end of the cylinder rod.

24859

41-33

SECTION 41 -- STEERING SYSTEM -- CHAPTER 1 4. Remove the pin fixing the cylinder to the axle body and remove the cylinder (1).

226 52

5. To refit the cylinder, follow the removal procedures in reverse order.

24860

STEERING CYLINDER - 4WD Removal -- Installation

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and another. Wear the recommended safety clothing such as goggles, gloves and safety boots. To remove the steering cylinder of the front axle, proceed as follows:

2 1

1. Remove the unions fixing the delivery and return hoses to the cylinder. 2. Remove the snap ring (1) and remove the cylinder rod articulation pin (2) connected to the stub axle box.

24861

70 3. Remove the retaining screw, remove the pin (1) fixing the cylinder to the axle body and remove the cylinder.

4. Remove the two cylinders complete with supply pipes.

24862

41-34

SECTION 44 -- 2WD FRONT AXLE -- CHAPTER 1

SECTION 44 - 2WD FRONT AXLE Chapter 1 - 2WD Front Axle CONTENTS Section

Description

Page

44-1

SECTION 44 -- 2WD FRONT AXLE -- CHAPTER 1 2WD FRONT AXLE 2WD FRONT AXLE

TT55

Type

TT75

Inverted U; telescoping center pivot

2WD Standard Tires 2WD Front Wheel Track Widths (Seven Possible Widths) Track Width Intervals

7.50-16

1372 - 1981 mm (54.0 - 78.0 in.)

1422 - 2032 mm (56.0 - 80.0 in.)

4 inches; 2 inch each axle (101.6 mm; 50.8 mm each axle)

2WD FRONT AXLE TORQUE SPECS

Thread Size

Specification

Capscrew, front axle carrier to engine (C3, Fig. 5-1)

M18 x 1.5

315 N⋅m (232 ft.lbs.)

Capscrew, axle pivot (C4, Fig. 5-1)

M10 x 1.25

59 N⋅m (43 ft.lbs.)

Nut, axle end

M16 x 1.5

221 N⋅m (163 ft.lbs.)

Capscrew, wheel to hub (C2, Fig. 5-2)

M18 x 1.5

315 N⋅m (232 ft.lbs.)

Nut, track rod ball joint

M14 x 1.5

98 N⋅m (72 ft.lbs.)

Nut, RH and LH levers on knuckles (C1, Fig. 5-2)

M14 x 1.5

147 N⋅m (108 ft.lbs.)

2WD FRONT AXLE SPECIAL TOOLS 380000549 Slide hammer puller

380000305 External bushing and punch

380000541 Slide hammer puller adapter

293390

293389

Spring fitting tool

44-2

Retaining and centering tool

SECTION 44 -- 2WD FRONT AXLE -- CHAPTER 1 FRONT AXLE REPAIR

1 Front Axle Pivot C3. Axle support capscrew C4. Axle pivot capscrew 9. Axle support

10. Axle pivot 11. Axle pivot bushings

FRONT AXLE REMOVAL AND INSTALLATION

•

Support the front axle with an overhead crane or hoist.

CAUTION

•

Handle all parts with care. Do not put hands or fingers between parts. Wear safety items such as goggles, safety shoes and gloves.

Position an axle stand under the axle support, raise the tractor and remove the front wheels.

•

Remove the capscrew (C4, Fig. 1) and withdraw the axle pinion (10) using a slide hammer puller 380000549 with adapter 380000541. Remove the axle assembly and install it on a suitable axle overhaul stand.

•

Replace the axle pivot bushings (11) if worn, using suitable pullers and drivers.

•

When refitting, grease the axle pivot with recommended lubricating grease.

To remove the front axle assembly: • Apply the parking brake, chock the rear wheels and remove the front ballast weights and ballast support. •

On models with power steering, remove the power cylinder from the axle.

44-3

SECTION 44 -- 2WD FRONT AXLE -- CHAPTER 1 STEERING KNUCKLE OVERHAUL NOTE: You can remove and disassemble steering knuckles without removing the axle from the tractor. To disassemble each steering knuckle: •

Remove the hub cap (8, Fig. 2) and slacken the adjusting nut (D).

•

Loosen the wheel hub capscrews (C2).

•

Apply the parking brake, chock the rear wheels, jack up the front of the tractor, and support the front axle on two stands.

•

Remove the front wheel.

•

Remove the nut (C1) and withdraw the steering spindle together with the wheel hub.

•

Disassemble the spindle on a bench.

•

Before reassembling, replace any inefficient seals or worn bushings and bearings. Grease the bushings with recommended lubricating grease.

•

When reassembling, pack the wheel hub with recommended grease.

•

Adjust taper roller bearings with the bearing adjusting nut (D, Fig. 2). Use a new nut for each new adjustment. Tighten the nut to a torque of 68 N⋅m (51 ft.lbs.) while simultaneously rotating the wheel hub (7, Fig. 2) to settle the bearings. Slacken the nut, then tighten to a torque of 9.8 N⋅m (7.2 ft.lbs.) while rotating the wheel hub. Stake the nut in place.

2 C1. C2. D. 1. 2. 3. 4. 5. 6. 7. 8. 12. 13.

44-4

Section Through Steering Knuckle Steering arm (1) nut Wheel hub capscrew Bearing adjusting nut Steering arm King pin Bushings Dowel Bronze thrust washer Seal Wheel hub Hub cap Steel washer Cup.

SECTION 44 -- 2WD FRONT AXLE -- CHAPTER 1 1. Remove 3 bolts and withdraw the steering arm. 2. Remove bolt and nut that hold to the pin. 3. Remove pin and withdraw spindle together with the spacer bearing.

3 1. 2. 3. 4. 5. 6. 7. 8.

Steering Arm Axle Shaft Assy (LH and RH) Center Beam Spindle Pin Bolt Nut and Flat Washer Spacer Bearing

AXLE CHECKS To check the steering geometry: â&#x20AC;˘

Place the wheels in the straight-ahead driving position.

â&#x20AC;˘

Measure the camber at the wheel rim edges as shown in Fig. 4, detail a. The difference between the top and bottom readings should be near 15 mm (0.59 in.) for 16 inch (406 mm) rims. This is equal to a two degree camber setting.

B + (0 -- 5 mm)

4 Front Wheel Geometry a. Wheel camber check b. Front toe-in check. X = Approximately 15 mm (0.59 in.) for 16 inch (406 mm) rims.

44-5

SECTION 44 -- 2WD FRONT AXLE -- CHAPTER 1 DETERMINING FRONT WHEEL TOE IN / TOE OUT To determine the correct toe-in, refer to the following procedures: 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. 3. Measure the distance between the two marks and note as Dimension A.

44-6

SECTION 44 -- 2WD FRONT AXLE -- CHAPTER 1 Front Wheel Toe-in/Toe-out Adjustment For best operation, configure the front wheels parallel to one another, or with a slight toe-in. To adjust the toe-in proceed as follows: 1. Park the tractor on a flat level surface with the front wheels facing straight ahead.

2. Loosen the lock nut on the left-hand side of the tie rod (1). 3. Remove the nut to the tie rod-to-steering arm bolt (2). Remove the bolt.

4. Turn the threaded portion (3) of the tie rod clockwise or counterclockwise until obtaining the correct toe-in measurement. Place the tie rod-to-steering arm bolt back into position to check measurement, and remove the bolt if the tie rod requires further adjustment.

10036142

1 6

5. After obtaining the correct toe-in, reinstall the tie rod-to-steering arm bolt and tighten.

44-7

SECTION 44 -- 2WD FRONT AXLE -- CHAPTER 1

44-8

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

SECTION 55 - ELECTRICAL SYSTEM Chapter 1 - Description and Operation CONTENTS Section

Description

Page

55-1

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 FAULT FINDING IMPORTANT: To avoid repeat failures, investigate and correct the cause of the defect when making repairs to the electrical system.

LIGHTING AND INSTRUMENTATION SYSTEMS Problem

Probable Cause

Several or all lights g do not illuminate Battery discharged

Remedy Recharge battery

Battery cables/terminals loose or Clean cables/terminals, tighten defective connections, or replace defective component

Individual lights g do not illuminate

Harness connections loose

Check connections for tightness

Fuse burned out

Check circuit and replace fuse

Wiring defective

Check circuit wiring and repair

Light switch defective

Repair or replace switch

Bulbs burned out

Check voltage regulator

Bulb faulty or burned out

Replace bulb

Bulb contacts defective or cor- Clean contacts or repair roded

Lights g burn-out repeatedly p y

Warning g lights g and g gauges g inoperative

Fuse burned out

Check circuit and replace fuse

Wires loose or broken

Repair or replace wiring

Ground connection poor

Clean and tighten ground connection

Wire corroded or loose

Repair or replace wiring

Bulb or mounting bracket loose

Tighten bulb or bracket

Voltage regulator faulty

Replace voltage regulator if necessary

Key-start ignition switch faulty

Replace switch

Fuse burned out

Check circuit and replace fuse

Key-start ignition switch connec- Tighten connectors on back of tors loose switch Gauge g erratic or inoperative p

Wiring defective

Check wires and repair

Wiring defective

Check wires and repair

Connectors loose

Tighten connectors on back of instrument panel

Gauge defective

Replace gauge

Sender defective

Replace sender

Voltage stabilizer defective

Replace voltage stabilizer

55-2

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 STARTING SYSTEM Problem Probable Cause Engine g will not crank and starting g motor Battery discharged relay or solenoid will not engage Key-start ignition switch defective Starting system relay defective Neutral start switch defective Starting circuit open, or high resistance Engine will not crank with starting motor Engine seized relay or solenoid engaged

Remedy Charge battery Check circuit, replace switch Check circuit, replace relay Check circuit, replace switch Check circuit connections and repair Check engine crankshaft. If binding, 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 Starting motor defective Starting motor relay or solenoid contacts burnt Engine will not crank with starting motor Starting motor drive assembly turning g defective

Tighten connections or replace Overhaul or replace starting motor Check circuit and replace relay or solenoid Overhaul or replace starting motor

Solenoid or pinion engagement levers Replace defective component defective Engine g cranks slowlyy

Flywheel ring-gear defective Battery discharged Starting circuit operates under excessive resistance

Replace defective component Charge battery Check system components and replace defective part

Starting motor defective

Overhaul or replace starting motor

CHARGING SYSTEM Problem Battery y low in charge g or discharge g

Battery y overheats

No alternator output p

Intermittent or low alternator output p

Probable Cause

Remedy

Drive belt loose or worn Battery electrolyte low Connections loose causing high resistance

Adjust tension or replace belt Replenish electrolyte Tighten loose connections

Temperature sensor defective Voltage regulator defective Alternator defective Battery defective Temperature sensor defective Voltage regulator defective Alternator defective Drive belt loose, worn or broken Connections loose or broken Temperature sensor defective Voltage regulator defective Alternator defective Drive belt loose, worn or broken Connections loose or broken Temperature sensor defective Voltage regulator defective Alternator defective

Replace sensor Replace voltage regulator Overhaul or replace alternator Service battery or replace Replace sensor Replace voltage regulator Overhaul or replace alternator Adjust tension or replace belt Tighten or repair connection Replace sensor Replace voltage regulator Overhaul or replace alternator Adjust tension or replace belt Tighten or repair connection Replace sensor Replace voltage regulator Overhaul or replace alternator

55-3

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 ALTERNATOR Problem

Probable Cause

Warning light dims and/or battery Charging circuit connection faulty low

Remedy Repair or replace defective connection

Rotor slip-rings or brushes defective

Replace slip-rings or brushes

Warning g light g extinguishes g but brightens with increased speed

Rectifier defective

Repair or replace rectifier

Charging circuit connection faulty

Repair or replace defective connection

Warning g light g out with batteryy hot

Voltage regulator defective

Replace voltage regulator

Temperature sensor defective

Replace temperature sensor

Voltage regulator defective

Replace voltage regulator

Stator defective

Replace stator

Rectifier or diodes defective

Replace rectifier or diodes

Drive belt loose or broken

Adjust tension or replace belt

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 defective

Replace slip-rings or brushes

Voltage regulator defective

Replace voltage regulator

Stator defective

Replace stator

Rectifier or diodes defective

Replace rectifier or diodes

Bulb burned out

Replace bulb

Alternator connection faulty

Repair connection

Rotor slip-rings or brushes defective

Replace slip-rings or brushes

Voltage regulator defective

Replace voltage regulator

Stator defective

Replace stator

Alternator connection faulty

Repair connections

Charging system defective

Check circuit and repair

Rotor slip-rings or brushes defective

Replace slip-rings or brushes

Voltage regulator defective

Replace voltage regulator

Warning g light g out with batteryy discharged

Warning g light g illuminates continuously

Warning g light g extinguished g continuously

Warning g light g flashes intermittentlyy Warning light dims continuously

55-4

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 PRECAUTIONARY STATEMENTS

IMPORTANT: Note the routing of the wiring, position of the wiring clamps, and terminal connections before removing components to facilitate installation.

Observe the following precautions to avoid damage to equipment, personal injury, or death.

IMPORTANT: Do not allow wiring and clamps to come in contact with sharp edges, exhaust system components or moving parts.

WARNING Batteries contain sulfuric acid. Avoid contact with the skin, eyes and clothing. Wear protective clothing and face shield when working on batteries.

IMPORTANT: Check conductors for exposure, and terminal connections for correct engagement. IMPORTANT: Check circuit current draw before applying power to a new wire harness.

WARNING Do not make or break electrical connections, including the battery terminals, with the engine running.

ELECTRICAL SYSTEM -DESCRIPTION AND OPERATION The electrical system features a 12-volt battery, 90-amp alternator, key-start ignition, neutral start and PTO safety switches. The wiring, lights, and instrumentation specifications of the tractor will vary by model.

WARNING Do not short-circuit any charging components to ground.

WARNING

The standard lighting configuration includes:

Disconnect the battery negative (ground) cable before installing or removing electrical components, performing maintenance on electrical components, or when using a battery charger.

• • •

WARNING

Dual Beam Halogen Headlamps Halogen Working Lamp Red/Amber Tail Lamps

Supplemental lighting combinations available (not in all markets), which satisfy local governmental regulations, operational requirements, and operator preferences, include:

Observe correct polarity when installing batteries or using a single slave battery to jump-start the engine. Follow the instructions in the operator’s manual, as well as the battery manufacturer’s recommendations.

• • • • • •

WARNING Always replace fuses with the correct type and correct rating. IMPORTANT: Check terminals and connections for continuity and tightness before operating electrical components.

55-5

Utility Lamp Turn Indicator Lamps Stop Lamps Implement Lamp License Plate Lamps Position Lamps

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 WIRE HARNESSES

The electrical system incorporates various components, which provide for the operation, regulation and protection of the electrical system. The standard electrical configuration will contain all, or several of the following components: • • • • • • • • • • • • • • • • • • • • • •

The wire harnesses form an electrical circuit, which directs power to the components of the electrical system by location. The harnesses attach with connectors, and route from the front of the tractor to the rear, and up the fenders. Each harness removes independently of one another to facilitate maintenance.

Instrument Panel Key-Start Ignition Switch Lights/Horn Switch Power Take Off (PTO) Safety Switch Start Inhibitor Switch Thermostart Switch Air Filter Restriction Sensor Brake Switch Turn Signal Switch Work Lamp Switch Warning Flasher Switch Warning Flasher Unit Engine Oil Pressure Switch Engine Coolant Temperature Sender Fuel Tank Sender Fuse Box Relays/Diodes Battery Temperature Sensor Seat Presence Switch Hand Brake Switch Fuel Shut-off Solenoid 7-Pole External Socket

55-6

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 The electrical system of the TT series tractor consists of the following harnesses: •

Front Headlamp Harness

•

Front Main Harness

•

Rear Main Harness

•

Rear Lights Harness

Each harness contains the necessary connectors for attaching electrical components over a wide range of models. When a component is uninstalled for any reason, secure the unattached harness connector away from hot engine components, and moving parts. Front Headlamp Harness The headlamp harness (1) connects to the rear-main harness at the firewall of the engine compartment with a 4-pin connector.

20031383

1 The harness clamps to the hood assembly and connects to each headlamp (1).

1 10024968

55-7

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 Front Main Harness The front main harness connects to the rear main harness with a 4-pin and a 9-pin connector. The harness routes along the top of the engine and clamps to the rocker cover, then branches at the forward and rear ends of the engine to the following components: •

Horn

•

Air Filter Restriction Switch

•

Engine Coolant Temperature Sensor

•

Alternator

•

Engine Oil Pressure Switch

•

Starter Solenoid

•

Thermostart Element

•

Fuel Shut-off Solenoid

•

Thermostat Switch

•

Battery Temperature Sensor

Rear Main Harness The rear main harness connects to the front main harness with a 4-pin and a 9-pin connector, and to the front headlamp harness at the engine firewall with a 4-pin connector. Most of the rear main harness routes inside the operator’s console and behind the steering column panels. The components listed below receive power from the rear main harness. Fuse Box

•

Instrument Panel/Cluster

•

Ignition Key-switch

•

Turn Signal Switch

•

Cigarette Lighter

Flashers Switch

•

Lights Switch/Horn

•

Buzzer Connection

•

Flasher Unit

•

Handbrake Switch

•

Start Inhibitor Switch

Rear Lights Harness The rear lights harness connects to the rear main harness and routes along the transmission on the left-hand side of the tractor. This harness provides power to the following components:

In addition, the front main harness grounds to the tractor frame.

•

PTO Neutral Safety Switch

•

Seat Presence Switch

•

Fuel Tank Sender

•

7 Pole External Socket

•

Working Lamp Switch

•

Left-hand Tail Light

•

Right-hand Tail Light

•

Ground

Each tail lamp assembly includes a connector for attaching to the rear lights harness.

55-8

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 COMPONENT LOCATION •

Horn Assembly (1), located in front of the radiator, Figure 3.

10036146

3 •

Air Filter Restriction Switch (1), located in the air intake tube at the rear of the engine.

10036136

4 •

Engine Coolant Temperature Sender (1) located in the thermostat housing.

20031379

55-9

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 •

Alternator (1), located at the front, left-hand side of the engine.

10036153

6 •

Engine Oil Pressure Sender (1), located on the left-hand side of the engine block.

10035298

7 •

Starter Solenoid (1), located on the top of the starting motor (2) on the right-hand side of the engine block.

20035283

55-10

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 •

Thermostart Element (1), located on the air intake manifold.

20035238

9 •

Fuel Shut-off Solenoid (1), located on the fuel injection pump (2), on the right-hand side of the engine block.

40031375

10 •

Cold Advance Thermostatic Switch (1), located in the thermostat housing.

40025673

55-11

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 •

Battery Temperature Sensor (1) located on the right-hand side of the battery tray.

10035295

12 •

Fuel Injection Pump Wax Plug (1), located on the right-hand side of the engine block. The wax plug mounts to the DP200 Series fuel injection pump.

1 40025681

13 • •

Relays (2 and 3), located at the rear of the engine compartment in the fuse box. Fuse Box (1), located on the rear of the engine compartment behind the instrument console panel.

1 2 3 40035228

55-12

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 •

Start Inhibitor Switch (1), located on the transmission top cover.

10036157

15 •

Fuel Tank Sender (1), located on the main fuel tank probe.

10036163

55-13

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 •

Flasher Unit (1), located on the rear engine firewall.

10036156

17 •

The Turn Signal Switch (1), Key-Start Ignition Switch (2), Lights/Horn Switch (3), Flasher Switch (4), and the Cigarette Lighter (5), located on the steering column cover.

1 2

3 4 5

10036149

55-14

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 INSTRUMENT PANEL B

3 1

10 19

A. B. C. 1. 2. 3. 4.

Fuel Gauge Tachometer and Hourmeter Engine Coolant Temperature Gauge Alternator Charge Air Filter Restriction Engine Oil Pressure Left Turn

5. 6. 7. 8. 9. 10.

55-15

PTO “ON” High Beams “ON” Lights “ON” Warning Light Thermostart Parking Brake Right Turn

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 INSTRUMENT PANEL DESCRIPTION The instrument panel, provides gauges and warning lights for monitoring system performance, operational limits and malfunctions, which may occur while operating the tractor. The instrument panel illuminates with the lights switch in the ‘ON’ position.

Fuel Gauge (A) A Needle-type gauge indicating the level of fuel remaining in the fuel tank. The needle enters the red colored area of the gauge when the combined fuel level reduces to less than 1/4 of the tank capacity. The gauge receives input from electrical fuel senders attached to the fuel probe of the tank, and receives power from the key-start ignition switch. Tachometer and Hour Meter (B) A needle-type gauge indicating engine revolutions per minute on a scale of 100 rev/min. Two symbols on the tachometer scale identify engine speeds at which the PTO obtains 540 rev/min for standard PTO operation. The hour meter records operating time for guidance on determining service intervals and is calibrated to record one hour at constant engine speed of 1800 rev/min.

Engine Coolant Temperature Gauge (C)

Engine Oil Pressure Warning Light (3) A red colored light, which Illuminates when engine oil pressure in the main gallery falls below minimum oil pressure specifications during engine operation. During start up, it is normal for the warning light to briefly illuminate, then extinguish.

Left Turn Light (4) A green colored light, which illuminates upon activation of the left turn signal.

Power Take Off Light (5) An amber colored light, which illuminates upon activation of the Power Take-off (PTO) system.

High Beams ‘ON’ Light (6) A blue colored light, which illuminates upon activation of the high beams.

Lights ‘ON’ Light (7)

A Needle-type gauge Indicating coolant temperature with the engine in operation. The needle enters the red colored area when the coolant temperature rises dangerously above the normal operating temperature of the engine. The coolant temperature gauge retains a random position with the key-start ignition switch off.

A blue colored light, which illuminates upon activation of the main lights.

Thermostart Warning Light (8) A red colored light, which illuminates when a fault in the Thermostart system occurs.

Alternator Change Warning Light (1) A red colored light, which illuminates when the alternator charging circuit is defective. At first start up, it is normal for the light to briefly illuminate, then extinguish as the engine speed increases above idle.

Air Cleaner Warning Light (2)

Parking Brake Light (9) A red colored light, which illuminates upon activation of the parking brake.

Right Turn Light (10)

A red colored light, which illuminates when an increase in vacuum occurs in the air admission system during engine operation, as detected by the switch in the air intake tube. This usually indicates a dirty or obstructed air filter.

55-16

A green colored light, which illuminates upon activation of the right turn signal.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 Changing Instrument Panel Bulbs Remove the instrument panel by unscrewing the four securing screws, 1, around the panel.

1 20 You can get to all the warning and panel light bulbs from the back of the instrument panel board. Replace the blown bulbs, 1, and resecure the instrument panel with the four screws.

21 Take care to assure bulbs are placed in their proper, respective sockets. (Crossing the bulb/socket locations will result in erroneous information being presented on the instrument panel).

55-17

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 CONTROL SWITCHES The control switches provide a means for the operator to activate and deactivate various electrical systems. A brief description of these switches follows:

1 5

2 4

1. TURN SIGNAL SWITCH The turn signal switch (1) toggles left for LEFT turn signal, centered for turn signal OFF, and toggles right for RIGHT turn signal, and is located on the left-hand side of the steering wheel.

10036149

2. LIGHTS / HORN SWITCH A knob on the lower left side of the steering column, 2, operates the lights/horn switch, The rotary type switch consists of five positions, which closes and opens a series of contacts to turn on or turn off different lights. When the operator presses the knob inward, the horn will sound, and will continue to sound until the knob is released.

Rotating the lights/horn knob left or right selects the following circuits: Lights OFF (1) Tail Lights ON (2) Includes instrument lights and parking lights -

Low Beam Headlamps ON (3) Includes instrument lights, tail lights and parking lights -

High Beam Headlamps ON (4) Includes instrument lights, tail lights and parking lights -

Parking Lights ON (5) Includes instrument lights -

3. CIGARETTE LIGHTER Located on the lower, right side of the steering wheel, the cigarette lighter activates a heating element when pressed in. 4. HAZARD WARNING LIGHTS SWITCH When pressed in, the hazard warning lights switch activates the warning flashers. The switch, red in color, is located above the cigarette lighter on the right side of the steering wheel.

55-18

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 5. KEY-START IGNITION SWITCH The key-start ignition switch rotates clockwise to five positions in 1/16 increments. The following systems activate in each position: • •

•

Position 1 -- OFF [parking lights, headlamps and work light operable] Position 2 -- Accessories ON [instrument panel gauges and warning lights activated; hazard warning lights operable] Position 3 -- Engine ON [the engine runs in this position after start-up; horn operable]

WARNING Operating the key-start ignition switch in Position 4 for longer than 20 seconds with the engine OFF, will over-charge the Thermostart system, and may lead to the failure of the Thermostart heating element. • •

Position 4 -- Thermostart ON [Thermostart heating element is activated] Position 5 -- Engine Start -- The full clockwise position activates the starting motor to start the engine.

55-19

20033056

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 Diagnostic Testing Use a Multi-meter for the following test:

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 and terminal D.

4. Move the switch to Position 3. 5. Check that continuity exists between terminals A and terminal D, between terminals B and terminal D, and between terminals A and terminals B.

40025961

E 25

6. Move the switch to Position 4. 7. Check that continuity exists between terminals A and terminal C. 8. Move the switch to Position 5. 9. Check that continuity exists between terminal C and terminal E, and between terminals A and terminal C, and between terminals A and terminal E. Replace switch if continuity test fails at any point. Key-Start Ignition Switch Terminal Continuity Testing Terminals

Positions 1 2

Installation Installation of the key-start ignition switch follows the removal procedures in reverse with the following requirements: 1. Tighten the key-start ignition switch retaining nut to a torque of 8 Nâ&#x2039;&#x2026;m (72 lb. in.). 2. Check wires and connections for interference with hand throttle linkage.

55-20

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 Air Filter Restriction Switch An obstructed air cleaner (1) increases the vacuum within the air intake tube to the engine.

40035227

26 As vacuum increases, the air cleaner restriction switch (1), completes a circuit, which illuminates a warning light on the instrument panel.

10036136

27 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 attempt to remove by twisting. This will cause damage to the switch.

1 40025972

55-21

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 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

29 Removal 1. Disconnect the battery negative (ground) cable. 2. Remove work lamp lens-cover screws. 3. Remove lens-cover.

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:

40025974

1. Move the lights switch to Position 2.

2 30

2. Press the work lamp switch to the ‘ON’ position. 3. Check for +12 V at the bulb connector (1), Figure 91. 4. Press the work lamp switch to the ‘OFF’ position. 5. Check for zero voltage at the bulb connector. 6. Move the lights switch to Position1 ‘OFF’. Replace switch if voltage test fails. Installation Installation of the work lamp switch follows the removal procedures in reverse with the following requirement: 1. Operate the work lamp switch to ensure correct installation.

55-22

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 LAMPS A lamp assembly mounts to each Roll Over Protection (ROP) bar of the tractor. The lens cover contains 4 screws (1) to access the bulbs for service. 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 as the flasher/hazard lights.

1 2 4 3

50024305

31 The headlamp assemblies (1) mount to the inside of the engine hood. The lamps produce either a high or low beam. The lights switch turns the headlamps ON and OFF, or selects either low or high beam.

55-23

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 HEADLAMP ASSEMBLY The headlamps mount to the front of the engine hood panel above the grille. The headlamp harness connects the right and left headlamps to the rear main-harness. The light switch, which is located on the rear hood panel, controls the headlamps in the OFF, LOW BEAM and HIGH BEAM positions. After removing or installing a headlamp assembly, adjust the position of the headlamps to prevent the light beam from blinding oncoming drivers.

HEADLAMP ADJUSTMENT 1. Park the tractor on a flat surface at a distance of 6 meters (20 ft) from a wall. The center of the light beam must shine 100-200 mm (4-16 in) lower than the center of the headlamp assembly lens. 2. Loosen or tighten the two inside mounting screws for each headlamp until obtaining the desired measurement. See figure.

HEADLAMP BULB REPLACEMENT 1. Raise the engine hood panel. 2. Remove the battery negative (ground) cable.

CAUTION Gently pull the harness connectors off the back of the headlamps to prevent damage to the harness wires or the bulb sockets. 3. Pull the harness connector off the bulb socket on the back of the headlamp assembly. 4. Remove the rubber cap that protects the bulb socket on the back of the headlamp assembly. 5. Remove the socket and discard the bulb. Replace with a bulb of the same specification. 6. After installing a new bulb, clip the socket back into the headlamp assembly. 7. Reinstall the rubber cap. 8. Reinstall the harness connector. 9. Operate the headlamps and check that the low and high beams function properly, and for correct adjustment of the light beam. If required, refer to the headlamp adjustment procedures in this section.

55-24

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 FUSES AND RELAYS The fuse box (1), connected to the rear main-harness, mounts on the front of the firewall, on the left-hand side of the engine compartment. A plastic cover [not shown] prevents dirt and moisture from entering the box. The fuse box contains two relays: the fuel shut-off solenoid relay (2) located on the right side and the starting solenoid relay (3) located on the left side.

1 2 3 40035228

34 The fuse box contains two rows of four fuses to protect the various electrical circuits from overload conditions. See the following table for fuse and circuit identification.

3 4

TABLE 1 FUSE IDENTIFICATION Fuse

Rating

Color

Circuit

10 A

Red

Starting System

15 A

Blue

Headlamp High Beams

15 A

Blue

Starting System Relay, Blinker

10 A

Red

Position, Instrument and Brake Lights

10 A

Red

Fuel Shut-off Relay, Horn

10 A

Red

Blinker

10 A

Red

Tail/Fender Lights, Work Lamp

10 A

Red

Instrument Gauges, Warning Lights

8 6

40035228

CAUTION Always replace a blown fuse with one of the same rating. Installing a fuse not within the specified rating may cause damage to the electrical system. When checking fuses, inspect the element for breaks. If required, replace a blown fuse with one of the same rating. Ensure to reinstall the cover over the fuse box to prevent the entry of dirt and moisture. To remove a fuse, firmly grasp fuse and pull directly out. Install a new fuse by pushing the fuse evenly into the fuse box until fully seated. Test the protected circuit after replacing a fuse.

55-25

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 SENDERS, SENSORS AND SWITCHES A

B D

36 ELECTRICAL COMPONENTS A. B. C. D. E.

F. G. H. I. J. K.

Dry Air Cleaner Restriction Thermostart® Engine Coolant Temperature Sensor Engine Stop Solenoid Alternator “W” Terminal for Tachometer

55-26

Transmission Range Selector Neutral Start PTO Selector Neutral Start Engine Oil Pressure Sensor Auxiliary Light Connector Sender Battery Seat Presence

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

SECTION 55 - ELECTRICAL SYSTEM Chapter 2 - Starter CONTENTS Section

Description

Page

55-1

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

STARTER SPECIFICATIONS

Marelli MT71 (TT55)

Bosch A007C04096 (TT75)

Power

2.5 kW

3.1 kW

60 Amps at 11.6 Volts and 8600 RPM

150 Amps at 11.7 Volts and 7000 RPM

9 to 11

15 to 10

45.0 mm (1.77 in.)

61.5 mm (2.42 in.)

Maximum Armature Shaft End Play

0.1 to 0.4 mm (0.004 to 0.016 in.)

0.1 to 0.5 mm (0.004 to 0.020 in.)

STARTER TIGHTENING TORQUE

N⋅m

Ft. Lbs.

Starter Motor / Engine Block Fastening Bolts

34 N⋅m

25 ft.lbs.

Box on Starter Motor / Ground Wire Side

16 N⋅m

12 ft.lbs.

Solenoid Wire Nuts

7 N⋅m

5.0 ft.lbs.

Box Nuts on Starter Motor Side

10 N⋅m

7.5 ft.lbs.

Solenoid Fastening Nuts

5 N⋅m

4.0 ft.lbs.

Maximum Current Drain Without Load

Starter Drive Ratio Minimum Armature Commutator Diameter

STARTER DESCRIPTION AND OPERATION All systems consist of an ignition key switch, heavy-duty wiring, a starter motor with solenoid, a start-up relay and a neutral start switch. These are the basic circuit components used on versions with mechanical gearbox.

At this stage, one end of the pull-in coil is connected to the positive battery pole through the starter switch, while the other end is connected to the positive pole through the solenoid contacts. The pull-in coil is thus bypassed, without absorbing power, and the hold-in coil alone keeps the plunger in position.

The starter has four poles, four brushes with integrated solenoid and positive mesh engagement control. The starter motor solenoid consists of two coils connected in parallel. The low resistance pull-in coil is grounded via the engine, while the high resistance hold-in coil is grounded via the solenoid body.

The starter motor includes a series of contacts and a two-part solenoid plunger which completely closes the contacts even if the pinion teeth are not perfectly in line with the ring gear. When this happens, a clutch spring compresses the pinion, forcing it to connect completely as soon as the starter motor starts turning.

When the ignition switch is closed with the range lever and PTO lever in neutral, the coils are energized and the plunger is magnetically drawn inside the solenoid. This movement, transmitted by means of an orientable joint mechanism, makes the driving pinion engage the flywheel ring gear. The moment the pinion touches the ring gear, the plunger closes a series of contacts and powers all four field windings directly from the battery, thus giving full power to the starter motor.

When the key ignition switch is released, power is taken from both the solenoid and the motor. The solenoid return spring, acting on the orientable joint mechanism, frees the driving pinion from the gear and opens the solenoid contacts again. A roller type clutch is incorporated to the driving pinion group. This prevents the pinion from overspeeding if it stays engaged with the flywheel ring gear after the engine has been started.

55-2

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 STARTING SYSTEM TESTING Use a high rated Battery Starter Tester, a Voltmeter (0--20 V), and an Ammeter (0--1,000 A) for the most conclusive test result, as well as a rapid diagnosis of the starting system. When using test equipment, follow the manufacture’s recommended procedures. If the test equipment recommended above is not available, use standard equipment providing the same ratings to determine if the starting system operates correctly. Before testing: •

Check the battery for full charge.

•

Check entire starting system wiring for frayed, broken or loose wires and connections.

Starting Motor Circuit Current Draw Refer to Figure 1. 1. Disconnect the battery (3) negative (ground) cable. 2. Disconnect the battery positive cable from the starting motor solenoid (4). IMPORTANT: When testing the starting system, only use an Ammeter, which has a maximum capacity of 1000 A or greater, or damage to the Ammeter will occur.

20031438

3. Connect the positive side of an Ammeter (1) to the positive terminal of the battery.

4. Connect the negative side of the Ammeter to the starting motor solenoid input-terminal. 5. Reconnect the battery negative (ground) cable to the battery negative terminal. 6. Connect the positive side of a Voltmeter (2) to the positive terminal of the battery. 7. Connect the negative side of the Voltmeter to the negative terminal of the battery.

55-3

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 8. Disconnect the wire from the shut-off solenoid, on the fuel injection pump. 9. Start the engine. 10. Observe the readings on the Voltmeter and Ammeter. Check that voltage remains steady at 12 V and amperage remains 250--300 A. Overhaul or replace the starting motor when: â&#x20AC;˘

Current measures less than specification.

â&#x20AC;˘

Current measures greater than specifications, and all other starting system circuit tests produce satisfactory results.

If drawn current remains within specification, but a voltage drop occurs, test the starting system circuit resistance. Refer to this chapter.

RESISTANCE IN IGNITION SYSTEM CIRCUIT (VOLTAGE DROP)

If there is higher than necessary power absorption, check the circuit to find the cause of the voltage drop occurring within circuit components.

V 3

IMPORTANT: Disconnect the injection pump solenoid fuel closing wire.

POSITIVE BATTERY CABLE 1. Connect the positive voltmeter point (1) to the positive battery terminal clamp (2).

26631

2. Connect the negative voltmeter point to starter motor solenoid terminal (3). 3. Run the engine and check readings on the voltmeter. If voltage is higher than 0.2 V., check and tighten wire connections. Check voltage again and if it is still high install a new cable.

55-4

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 STARTER MOTOR GROUNDING

1. Connect the positive voltmeter point (1) to starter motor casing (2). 2. Connect the negative voltmeter point to the engine block (3). 3. Run the engine and check the readings on the voltmeter. If voltage is higher than 0.2 V., check grounding connections between motor flange and rear engine cover.

26632

BATTERY GROUND CABLE

1. Connect the positive voltmeter point (1) to the engine block (2).

2. Connect the negative voltmeter point to the negative battery terminal clamp (3). 3. Run the engine and check the readings on the voltmeter. If voltage is higher than 0.2 V., check and tighten the grounding cable connections. Check the voltage again and if it is still higher, then install a new grounding cable.

26633

STARTER MOTOR REMOVAL AND RE-INSTALLATION

1. Disconnect ground (negative) battery cable. 2. Remove starter motor protection cover. 3. Remove the protective plastic cover (1) from the front of the starter solenoid (2). 4. Unscrew the nut and remove battery cable and solenoid wire. 5. Remove starter motor mounting bolts and remove the starter motor.

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6. To re-install the starter motor, reverse the order of removal.

55-5

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

26635

6 1. 2. 3. 4. 5. 6.

Solenoid Solenoid bolts Bolt and stud group Control side support Lever Reducer

Starter motor components 7. 8. 9. 10. 11.

SERVICING THE STARTING MOTOR Disassembly 1. Place the starter motor in a vice with protected jaws. 2. Disconnect the biggest braided wire which runs from the field winding casing to the solenoid. 3. Remove the three screws from front casing and remove the solenoid. Note that the plunger will remain connected to the control lever. 4. Remove solenoid plunger from the control lever by holding and lifting it at the front in order to unclip it from the lever.

55-6

Field windings and casing Brush holder Brush plate Armature Clutch

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 5. Remove the two nuts from rear casing and the two screws which fasten rear cover and brush plate to the casing. Remove clamp and armature shaft end play spacers, leaving the brush gear on the commutator. Remove the thin metal washer on the commutator side of the armature.

Reassembly To reassemble the starter motor, reverse the removal procedure. Before reconnecting, test the armature shaft end play and test the starter motor without load.

6. At this stage of the procedure, check brushes and commutator. Check the brushes are not stuck and, if necessary, clean the brushes and the respective channels with a rag and solvent. Check the brushes are not worn. If they are worn and minimum length is less than that shown in the technical information table, it will be necessary to change the starter motor.

ARMATURE SHAFT END PLAY 1. Place the starter motor in a vice with protected jaws and connect a dial gauge to the flange on the control side of the casing. Position the dial gauge pointer on the end of the armature shaft. 2. Push the armature forward and reset gauge. Push the armature back as far as it will go and note gauge readings.

NOTE: The brushes cannot be serviced separately. They are, in fact, welded to their support and will not be changed for the whole operating life of the starter motor.

3. Readings must fall within the limits specified in the technical information table. If the value is higher, check that armature and brush plate are not worn. Change the worn components, as necessary, and check end play again.

7. Remove motor casing from the armature and the control side bracket. 8. Remove control lever knuckle pin from the control side of the casing. 9. Remove the retaining ring which holds the control group and the inner plate from the armature shaft, by first removing the pressure collar perpendicularly from the retaining ring support by means of an appropriately sized tube. Then lever the retaining ring from the groove. 10. Remove armature and control group.

55-7

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 STARTER MOTOR TEST WITHOUT LOAD

NOTE: A fully charged battery and a battery/starting tester (high discharge multitester) with carbon battery (variable load resistance) are needed to carry out this test.

7 1

1. Place the starter motor in a vice with protected jaws. 2. Connect negative battery cable (4) to starter motor flange.

3. Bridge solenoid contacts (6) with a short wire (7).

26636

4. Connect the positive voltmeter point (3) to the positive battery terminal clamp (4) and the negative voltmeter point to the negative battery terminal clamp. Connect the ammeter positive point (1) to the positive battery clamp (4) and the negative point to the battery or to the starter motor terminal clamp.

5. Place a manual tachometer (5) on the end of the armature shaft. Check maximum power. This value is specific for each starter motor: 2.5 kw for the Marelli starter, 3.1 kw for the Bosch starter. Regulate carbon battery voltage (2) and armature RPM according to the information in the technical information table. 6. If the starter motor does not work according to technical information specifications, then check if there are grounded field windings, if the armature scrapes or if the shaft is scored. BENCH TESTS Armature 1. The commutator surface must be clean and not burnt. If burning needs to be removed, use fine sandpaper and not abrasive fabric. Finally, clean the commutator with a rag and solvent. 2. If the commutator needs refacing, check it is not smaller than the minimum specification: 45.0 mm (1.77 in.) for the Marelli starter, and 61.5 mm (2.42 in.) for the Bosch starter. After refacing, the commutator must be polished with sandpaper and cleaned with a rag and solvent. NOTE: Do not cut the armature metal when making insulation slots.

55-8

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 3. Armature insulation can be checked by connecting an ohmmeter (1) between commutator segments and armature shaft. This reading should show infinity, in other words there should be no continuity.

4. To test there are no short circuits, use an appropriate testing device. The only alternative is to try changing the armature. 5. If the armature circumference has obviously been in contact with pole pieces, the pole bearings are probably too worn. First check the pole pieces are fixed and that the armature spins well in a lathe. If necessary, change the armature bearing.

26637

Field Windings 1. To test field winding insulation, connect an ohmmeter to each of the coil brushes in turn and to a clean and unpainted area of the casing. There should be no readings, that is, there should be no continuity. 2. To test coil continuity, connect an ohmmeter to each of the coil brushes in turn and to the main power clamp (biggest braided wire). The reading should be 1 â&#x201E;Ś. 3. If there is a failure in the field windings, then it will be necessary to change the whole box and field winding system.

26638

1 9

Bearing Bushings Check if the bushing on the brush plate and in the box on the pinion side are worn. Assemble the armature shaft and note play. Change the bushing if there is too much play. Check the field poles to see if there are any signs of scraping against the casing. This can also be caused by a worn bushing. Driving Pinion Check the roller clutch operation. The pinion must spin clockwise only. If the pinion is either blocked, or spins in both directions, or if the pinion teeth are damaged, assemble a new control group. If there is clear evidence of damage to pinion teeth, check flywheel ring gear, as described in section 1, Engine.

55-9

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

55-10

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM Chapter 3 - Alternator CONTENTS Section

Description

Page

55-1

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 ALTERNATOR

ALTERNATOR SPECIFICATIONS

Bosch 23 / 55A

Polarity

Grounded Negative

Temperature Compensated with Battery Sensor

12.9 -- 15.6 Volts

Maximum Rotation Speed

15,000 RPM

Maximum Output

55 Amps

Regulator Controlled Voltage

14.1 Volts

Rotor Field Winding Resistance

2.6 Ohms

Stator Field Winding Resistance

0.069 Ohms +/- 0.0069 Ohms

New Brush Length

13.5 mm (0.53 in.)

Minimum Brush Length

12.0 mm (0.47 in.)

Brush Spring Force

3.9 N (0.40 Kg, 0.90 lbs.)

ALTERNATOR TIGHTENING TORQUE

N⋅m

Ft.Lbs.

Alternator Fastening Bolts

5.5 N⋅m

4.0 ft.lbs.

Pulley Fastening Nut

70 N⋅m

52 ft.lbs.

Rectifier Fastening Screws

4.0 N⋅m

3.0 ft.lbs.

Brush Box and Regulator Screws

2.7 N⋅m

2.0 ft.lbs.

Terminal Nuts

2.7 N⋅m

2.0 ft.lbs.

55-2

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

1 A B

3 5

26640

1 G1. Battery M1. Starter Motor G2. Alternator B1. Battery Temperature Sensor

Alternator charging circuit S3. S2. K1. S1.

Transmission Inhibitor Switch PTO Inhibitor Switch Ignition Relay To Start Inhibitor Switch

1. 2. 3. 4.

Rotor(1) Stator (2) Rectifier Pack (3) Regulator/Brush Box (4)

DESCRIPTION AND OPERATION The charging system consists of a storage battery, alternator with an internal regulator, and circuit wiring. The alternating current (AC) produced by the alternator provides a higher maximum output than a direct current (DC) producing generator, and increases the charge rate at lower engine speeds. In addition, the alternator operates safely at high engine speeds and requires no commutator, unlike a DC generator. The alternator mounts to the front of the engine on the left-hand side, and contains the following components:

Refer to Figure 22.

55-3

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 Rotor The engine crankshaft drives the alternator by way of a belt-driven pulley (1) attached to the rotor shaft. The rotor shaft rotates within a heavy--duty, sealed roller bushing. An integral fan (2) adjacent to the pulley draws air through the alternator for cooling. The rotor field coil receives current via two carbon brushes, which bear against slip rings on the rotor shaft. Current flowing through cooper wire in the rotor field produces a magnetic field. The configuration of the armature, formed into pole shoes, ensures the concentration of the magnetic field.

Stator The moving magnetic field created by the rotor and brushes induces current into the windings of the stator. The stator, fabricated from laminations of thin steel pressings wrapped by wound wires, collects and concentrates the magnetic field. The stator windings contain currents, which pass from one direction to another with each complete revolution of the rotor. This activity creates an S-phase alternating current. Alternating current generates in a series of pulsation. To smooth output, the rotor features six pairs of poles. For every revolution of the rotor, the output characteristic of each stator winding completes six cycles. The battery requires pure direct current (DC) for charging, making alternating current (AC) unsuitable. Therefore, the stator windings connect to a rectifier pack, which converts the AC current to DC current. Rectifier The rectifier consists of six diodes (1) and a module (2) containing field diodes. The diodes check current flow in one direction only. Three diodes mount in a positive plate, and three diodes in a negative plate (3). Terminal links connect each of the three stator output wires to a different diode on each plate. As the rotor revolves, the diodes convert the AC current from the stator to DC current, which effectively charges the battery. The three field diodes contained within the field diode module connect to the stator output wires and supply DC current to the rotor field winding.

55-4

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 Regulator and Brush Box The internal regulator (1) maintains output voltage at a safe working level. The regulated output voltage level, preset during manufacturing, requires no adjustment. A sealed assembly houses the regulator components within the brush-box. The regulator, regulator components, and brush-box require service as a complete assembly. Alternator Operation Turning the key-start switch to the â&#x20AC;&#x2DC;ONâ&#x20AC;&#x2122; position directs a small current flow from the battery, through the rotor field winding. A circuit establishes through the charge indicator warning light, alternator D+ terminal, rotor field winding, alternator regulator and ground. The charge indicator warning light illuminates and the rotor partially magnetizes. When the engine starts, the partially magnetized rotor revolves within the stator windings and generates 3-phase AC current. A constant portion of the current converts to DC current by the three field diodes incorporated in the rectifier pack. The DC current feeds back to supplement current flowing through the rotor field winding. This action results in an ever-increasing magnetic influence of the rotor along with an associated rise in generated output current and voltage.

5 1. 2. 3. 4. 5.

During the rise in generated output voltage (reflected at the D+ terminal), the brilliance of the warning light reduces. When voltage at the D+ terminal equals that of the battery side of the warning light, the lamp extinguishes. The rising voltage continues until reaching the predetermined regulated voltage level. If the drive belt fails, voltage will not build up within the alternator, and the charge indicator warning-light remains on to indicate failure.

55-5

Rectifier Pack Tachometer W Terminal Terminal Protection Sheath Battery B+ Terminal Alternator Indicator D+ Terminal

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 SYSTEM TESTING AND TROUBLESHOOTING Precautions To avoid damaging alternator charging system components, take the following precautions: •

DO NOT MAKE OR INTERRUPT any charging circuit connection, including battery, while the engine is running.

•

NEVER SHORT-CIRCUIT the alternator positive terminal to check if it is working.

•

ALWAYS DISCONNECT battery cables when recharging the battery in the tractor with a battery charger.

•

ALWAYS CHECK battery polarity when installing a battery or using a supplementary battery to start the engine.

•

DO NOT SHORT-CIRCUIT regulator input/ output terminals when the alternator is working.

•

CONNECT POSITIVE TO POSITIVE AND NEGATIVE TO NEGATIVE.

PRELIMINARY CHECKS Before carrying out these electrical tests, carefully inspect the charging system and the electrical system in general. Check continuity in all conductors and connections. Check they are all well fastened.

1. CHECKING THE BATTERY

Check all battery cells for specific gravity with a hydrometer. The battery must be at least 70% charged and efficient.

2. CHECKING THE DRIVING BELT

Inspect the alternator driving belt and pulley, checking that they are both clean, with no traces of oil or lubricant and in good condition. Check the alternator driving belt tension regularly. If you suspect the belt is not tight, check the stretcher as follows: • slacken the nut (3) which fastens the alternator to the stretcher bracket (2). • with a lever, move the alternator (1) on the stretcher bracket (2) to reach correct belt tension and fasten the fastening nut (3) to 55 N⋅m (40 ft.lbs.) screw. Correct deflection values, measured by applying loads to the middle of the belt. A load of 78 to 98 N should produce a deflection of 10 to 11 mm (0.39 to 0.43 in.).

4 1

26641

6 Ventilator belt stretcher

Belt for versions without air conditioning 1. Alternator 2. Belt stretcher 3. Belt stretcher fastening nut 4. Belt

55-6

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 3. CHECKING THE WARNING LIGHT Turn the ignition key and check the warning light is completely lit. If the warning light does not light completely, check the light bulb. If the light bulb has not blown, carry out the alternator wiring connection tests as described in the paragraph “PRELIMINARY TESTS” below. If the light is on, start the engine and run it at 1500 -- 1800 RPM. The warning light should go out. If the warning light does not go out, stop the engine and disconnect the D+ terminal wire. If the warning light goes out now, one of the alternator components is malfunctioning. Carry out “ALTERNATOR COMPONENT TESTS” described later in this section. If the warning light stays on, check there is no grounded short circuit between D+ wire ending and warning light. PRELIMINARY TESTS These preliminary tests can be carried out without removing any components from the tractor charging circuit. These tests check: •

the alternator wire connections

•

alternator charging current and controlled voltage

•

voltage drop in the alternator charging circuit

•

maximum alternator output

The following testing devices are required: •

0-30V mobile coil voltmeter

•

0-1V millivoltmeter

•

0-110 A mobile coil ammeter

•

1.5 ohm, 110 A varying load resistance

NOTE: Most testing devices on the market today include several devices in the same case. When using these devices, follow the manufacturer’s instructions.

55-7

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 1. Alternator Wire Connections Test 1. Disconnect the battery. 2. Disconnect B+ (2) and D+ (3) alternator terminals. 3. Reconnect the battery and turn the ignition key into position ON but without starting the engine. Connect a voltmeter (4) between each terminal lead and ground (1). There must be voltage at each lead. If there is no voltage, locate the open circuit in the external wire circuit. See circuit diagram in Fig. 2-23.

20035301

4. Connect D+ terminal, warning light wire (red) and ground. The warning light should come on. 5. Disconnect the battery and reconnect the connection previously disconnected to the alternator. NOTE: If the warning light does not light up when the wire is connected to the alternator, this means that there is a fault either in the alternator regulator circuit or in the rotor circuit. Check D+ terminal is clean and then test the alternator components as described in this section. 2. Charging Current and Regulated Voltage Tests 1. Check that all tractor electrical devices are switched off and the ignition key is in OFF position. 2. Disconnect the negative battery terminal clamp and the D+ negative alternator terminal. 3. Connect an ammeter (1) between the disconnected lead (red) (4) D+ and the B+ alternator terminal. 4. Connect a voltmeter (2) between the B+ alternator terminal and ground.

20035300

5. Reconnect the battery. Start the engine and run it at 2000 RPM. Note the readings on the voltmeter and the ammeter.

The voltmeter reading should be higher than the battery voltage and when the ammeter reading falls below 10 A, the voltmeter reading should stabilize at 13.6 - 14.4 V.

55-8

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 If the voltmeter reading is higher than 14.4 V, the alternator regulator must be changed, as described in this section. (After installing a new regulator, carry out tests 4 and 5). If the voltmeter reading is less than 13.6 V, there is either a faulty component in the alternator or a failure due to excessive resistance in external charging system connections. If the ammeter reads zero, then one of the alternator components is malfunctioning. Turn the engine off and carry out the alternator component test, as described in this chapter. 3. Charging Circuit Voltage Drop Tests (a) Insulated side voltage drop test Check the ignition key is in OFF position. 1. Disconnect the negative battery cable and the B+ alternator wire (1). 2. Connect a millivoltmeter (5) between the positive battery terminal clamp and D+ lead (3) (positive side of the wire) 3. Connect a ammeter (2) between the B+ alternator terminal and the D+ terminal (negative side of the wire).

20035302

4. Reconnect the negative battery cable and connect a varying load resistance (4) with cursor in minimum current absorption position (maximum resistance) through the battery terminal clamps. 5. Start the engine and increase speed to 2000 RPM. 6. Increase the resistance current load (decreasing resistance) slowly until the ammeter reads 55 amps. 7. Note the reading on the millivoltmeter. This must not be higher than 400 millivolt. A reading higher than 400 millivolt indicates malfunctioning due to excessive resistance on external circuits. If the alternator does not output required power and the millivoltmeter reading is less than 400 millivolt, there is a malfunctioning component in the alternator. Carry out the alternator component tests, as described in this section.

55-9

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 (b) Ground side voltage drop test 1. Check the ignition key is in OFF position. 2. The circuit is the same as that described in the previous test, except that the millivoltmeter (4) is now connected between the negative battery terminal clamp and the alternator casing (negative side of casing). NOTE: check the varying load resistance (3) is in minimum current absorption position (maximum resistance). 3. Start the engine and increase speed to 2000 rpm. 4. Increase resistance current load (decreasing resistance itself) slowly until the ammeter (2) reads 55 A. 5. Note the reading on the voltmeter. This must not be higher than 200 millivolt. A reading higher than 200 millivolt indicates malfunctioning due to excessive resistance on external circuits. If the alternator does not output required power and the millivoltmeter reading is less than 200 millivolt, there is a malfunctioning component in the alternator. Carry out the alternator component tests as described in this section.

55-10

20035303

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 4. Maximum Alternator Output Test 1. Check the ignition key is in OFF position. 2. Disconnect the negative battery cable and the B+ alternator lead (4). 3. Connect an ammeter (5) tightly between B+ alternator terminal (4) and D+ lead (1) (negative side of the wire). 4. Connect a voltmeter (4) between the B+ alternator terminal (5) and ground. 5. Reconnect the negative battery cable. Start the engine and increase speed to 2000 RPM. 6. Increase resistance current load (2) (decreasing resistance) slowly until the ammeter reads 55 A. 7. Note the reading on the voltmeter. This must not be less than 13.6 V. A reading lower than 13.6 V shows there is a malfunctioning component in the alternator. Carry out the alternator component tests, as described in this section. ALTERNATOR COMPONENT TESTS These alternator tests must be carried out only if the PRELIMINARY TESTS have shown a malfunctioning alternator component. These tests check: •

the regulator,

•

rotor field winding continuity,

•

rotor brushes, springs and contact rings.

NOTE: The previously described component tests can be carried out with the alternator installed in the tractor. In order to carry out the other alternator tests, it will be necessary to remove the alternator from the tractor. Refer to the section “FUNCTIONAL TESTS” in this section.

55-11

20035304

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 REMOVAL AND SERVICING IMPORTANT NOTE: Before disconnecting the alternator wires, check the ignition key is in OFF position. Removing The Alternator 1. Disconnect the negative battery cable. 2. Disconnect B+ (1) and D+ (2) wires from the alternator. 20035305

12 3. Slacken and remove the nut and bolt (3) fastening the alternator to the belt stretcher (4). 4. Move the alternator to reduce belt (5) tension and remove it from the alternator pulley (6). 5. Unscrew the nut (7) completely and remove it with its bolt. Remove the alternator.

20035306

13 Firmly fix the alternator horizontally to an appropriate holder with internal surfaces protected with soft material. Before dismantling the alternator completely, carry out the operations and tests described on the following pages.

55-12

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 ROTOR AND REGULATOR FIELD CIRCUIT TEST The following testing devices are required: •

12 volt battery

•

multitester

•

2 watt test lamp

1. Disconnect all alternator wires. 2. Connect a 12 V battery and a 2.2 watt test lamp (2) in series to D+ (1) and alternator casing (negative side of the casing).

20035307

3. The test lamp should light up. If the test lamp does not light up, then the rotor circuit is faulty. Check brushes, contact rings and rotor field winding continuity. If the test shows these components are satisfactory, then the regulator may be faulty. Protecting the Alternator Whenever you are working on the electrical system of the tractor, you can protect the alternator and charging system by following these guidelines: •

Never make or break any charging circuit connection, including the battery, when the engine is running.

•

Never short circuit any of the charging components to ground.

•

Never use an auxiliary battery of higher than 12 volts nominal voltage.

•

Always observe correct polarity when installing a battery or using an auxiliary battery to jump start the engine.

•

Always disconnect the battery ground, or negative, cable before performing any arc welding on the tractor or on any implement attached to the tractor.

55-13

•

Always disconnect the battery ground, or negative, cable when charging the battery in the tractor using a battery charger.

•

Always disconnect the battery ground, or negative, cable before performing any operations on the tractor that could result in an accidental contact with any positive terminal or circuit.

WARNING Always wear eye protection when charging the battery or starting the tractor with an auxiliary battery. Always connect positive to positive and negative to negative.

CAUTION When disconnecting or replacing a batter, always disconnect the negative battery cable first.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

55-14

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

SECTION 55 - ELECTRICAL SYSTEM Chapter 4 - Battery CONTENTS Section

Description

Page

55-1

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 BATTERY TECHNICAL INFORMATION BATTERY SPECIFICATIONS

Specification

Capacity

90 Amp/hours

Rating (Cold Cranking Amps)

800 CCA

Reserve Capacity

170 min.

Number of Cells

6 cells

Number of Plates per Cell

15 plates/cell

Case Material

Polypropylene

Terminal Type

STUD SAE

BCI Code

31P

Overall Dimensions Length

329.5 mm (12.97 in.)

Height

239.1 mm (9.40 in.)

Width

171.5 mm (6.75 in.)

DESCRIPTION AND OPERATION

Each element of the battery consists of positive and negative plates, positioned alternatively, one next to the other. Each positive plate is separated from negative plates by means of a porous insulating spacer. If one of the positive plates touches a negative plate in the element, the element will short-circuit and be irreversibly damaged. The positive plates are welded to a collecting bar and form a positive terminal. The negative plates are welded to a similar collecting bar and form a negative terminal.

The battery is a “sealed, maintenance-free” type, rated at 90 amp hours. The battery is positioned in front of the radiator, in the front axle support compartment. The four main functions of a battery are: •

to supply a source of electricity for starting, ignition and instrument lighting and functioning.

•

to control voltage in the electrical system.

•

to supply electricity when the power required is higher than that produced by the alternator.

•

to support inactive loads from radio and microprocessor memory.

Each positive plate consists of a lead grid with lead peroxide pasted to the grid holes. The negative plates consist of a lead grid with lead sponge pasted to the grid holes. The plates are covered by electrolyte which consists of diluted sulphuric acid solution. The battery box is made of polypropylene.

55-2

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 BATTERY REMOVAL

CAUTION When disconnecting the battery for any reason, always disconnect the negative (ground) cable first.

1. Unlatch and raise the engine hood panel (1) to gain access to the battery.

20033049

CAUTION When removing the battery terminals for any reason, do not allow the negative and positive cables to touch, or to make contact with the battery.

2. Remove the negative cable (1) from the negative terminal on the battery. 3. Remove the positive cable (2) from the positive terminal on the battery.

4. Remove the nut, bolt and bracket (3), which secures the battery to the tractor frame.

40035227

5. Slide the battery from the tractor frame and remove.

55-3

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 INSTALLATION The installation of the battery follows the removal procedures in reverse with the following requirements: •

Check the battery for cleanliness, especially around the terminals. Clean the area where the battery mounts to the tractor frame to prevent debris from piercing the body of the battery.

•

Seat the battery squarely into position before installing mounting strap.

•

Check the vent caps for proper installation and tightness.

•

Ensure that no leakage occurs from the battery.

•

Connect the positive terminal first, then the negative terminal.

•

Coat the battery terminal clamps with petroleum jelly or equivalent. Do not use conventional lubricants as electrolyte corrosion may occur.

•

Check battery terminal connections for correct polarity and tightness. Do not over-tighten. Install dust covers over terminals (where installed).

55-4

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 INSPECTION AND SERVICING

Servicing the Battery

WARNING

Battery ‘State of Charge’ The specific gravity of the battery electrolyte indicates the ‘state of charge’. The specific gravity of a fully charged battery at 25 _C (77 _F) is 1.265 minimum.

Batteries contain sulfuric acid, which generates a highly explosive mixture of hydrogen and oxygen gas during charging.

The approximate state of charge may also be determined using an accurate digital Voltmeter (+/-0.01 V) as follows: Less than 10.5 V

Battery unserviceable*

Less than 11.8 V

Battery discharged

Less than 12.3 V

Battery 1/2 charged

Greater than 12.6 V

Battery fully charged

WARNING Never use equipment that generates flames or sparks when controlling the electrolyte level.

WARNING Do not remove the battery cover plugs without protection for eyes and hands.

*See “Performance Test” for possible recovery of a mildly sulfated battery.

When servicing a battery, observe the following steps.

Measure voltage of an unloaded battery only. Rest the battery for a minimum of four hours before unloading. For recently operated tractors, or a battery recently charged, turn on the headlamps for 2 minutes.

1. Maintain the electrolyte to the recommended level, approximately 5 mm (0.25 in) above the plates in a standard battery. Failure to maintain a proper level of electrolyte may result in a high concentration of acid and will damage the separators and impair the performance of the plates.

When a battery discharges, sulfuric acid in the electrolyte combines chemically with the plates, which lowers the specific gravity of the solution.

2. Use only distilled or de-mineralized water. Never use tap water. Do not overfill.

A battery hydrometer will determine the specific gravity of the electrolyte in a cell, while the amount of unused sulfuric acid in the solution measures the degree of change of that cell.

3. Always keep the battery at least 75% charged to prevent the plates from becoming sulfated, which causes loss of efficiency and possible damage to plates at lower temperatures.

A battery operating in a lower temperature requires a greater charge, and the lower the temperature, the more necessary it is that the battery be in a fully charged condition. For example, a battery with a specific gravity of 1.225 at 27 _C (80 _F) will operate the starter motor at warm ambient temperatures but may not, at lower ambient temperatures due to low battery efficiency. Correct care and periodic inspection will maintain long battery life.

4. Avoid overcharging the battery. Excessive charging will create high internal heat that will expand and warp the plates, distort the battery case, or displace the sealing compound. Excessive charging will also cause plate grid deterioration and produce water loss. 5. When fast charging the battery, ensure the battery temperature remains below 50_C (122_F).

Table 1 shows the effect of temperature on the efficiency of a typical battery:

6. Do not add sulfuric acid to a cell unless loss of electrolyte occurred through spilling. Before replenishing, ensure the correct specific gravity of the solution.

Table 1

Temperature

Fully charged battery performance

Engine power demand

27.0_C (80.6_F)

100%

0_C (32_F)

65%

155%

--18_C (0_F)

40%

210%

--29.0_C (--20.2_F)

20%

250%

7. When fully charging a battery, use only a slow charge rate. A high charge rate will rapidly boost the battery capacity, but must be followed by a slow charge to bring the battery to full capacity.

55-5

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 2. When using a fast or high rate of charge, follow the manufactureâ&#x20AC;&#x2122;s instructions for the battery and the charger. High rated charging raises the temperature of the electrolyte. Unless the charger consists of an automatic time or temperature device, the electrolyte temperature may exceed 50_C (122_F), which will result in violent cell gassing and/or damage to internal components.

Dry-Charged Batteries 1. Remove the battery cell vent plugs. 2. Fill each cell with electrolyte to the recommended level with electrolyte of 1.260 specific gravity. NOTE: The electrolyte must be diluted with sulfuric acid preferably at a temperature of 21-32_ C (70-90_ F). 3. Allow the battery to stand fifteen minutes after filling. Recheck the electrolyte level and replenish as necessary.

3. Re-check the electrolyte level in each cell and replenish as necessary.

4. Charge the battery for 4 hours at a rate of 5-8 amps, in accordance with the battery instructions. Allow the cells to gas freely.

Recharging a heavily discharged battery To recharge a Pb--Ca maintenance-free battery we recommend using a variable charge battery charger. For very flat batteries, charge for 48 hours, at 16 V, with current limitation (40 A for 90 Ah).

5. Install the battery cell vent plugs when finished. Charging the Battery Before charging a battery:

This method is self-regulating. High current is provided at the beginning (when the battery voltage is very low). Current decreases progressively when the battery is fully charged (and the voltage is high).

1. Thoroughly clean the battery casing, terminals, and cell covers with ammonia diluted with hot water.

If only constant voltage battery chargers are available, we recommend using voltage levels and timing shown in Table 2. These figures refer to very flat batteries. If the battery is only 50% charged, use half the time shown (slow charging programs). For other conditions, reduce charging time proportionally. When feasible, use the slowest charging program to increase battery life.

2. Check the level of the electrolyte, and replenish if below recommended level.

WARNING Charging a battery produces an explosive gas. Do not expose to sparks or flame when checking the electrolyte level, and never connect or disconnect the charger until turned off.

If violent boiling occurs during charging, due to gas formation or liquid leakage, or if the battery box is hot (50Â°C [122Â°F] or higher), temporarily reduce or stop battery charging to avoid damaging the battery.

Charging 1. Charge the battery with a slow charger at a rate 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 battery may not accept a charge at all. When the battery has finished charging, the cells will gas freely and the specific gravity will remain constant. Remove the charger after three consecutive hydrometer readings, taken at hourly intervals; indicate that specific gravity no loner rises.

Table 2 lists recommended current levels and times for constant current chargers: Table 2 Battery Type 90 Ah (800 CCA)

Description Slow Charge

Fast Charge*

Current

Time

25 hrs

10 A

12.5 hrs

18 A

7 hrs

*Fast charge method for emergencies only.

55-6

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 TESTS

NOTE: Relative density should not vary more than 0.025 points between cells.

Before carrying out battery tests, check the breathers are not blocked, there is no rust, the breather caps are not open and the box is not cracked.

4. If relative density is 1.265 or higher, the battery is fully charged and in good working condition.

Required testing equipment:

5. If the correct relative density is less than 1.265, charge the battery and check the charging system, to find the cause of low battery load.

•

Hydrometer

•

Battery starter tester (high amperage tester)

•

Thermometer

•

Battery charger

NOTE: If distilled water has recently been added, the battery must be charged for a short period of time to obtain precise densimeter readings. If the battery has been loaded and kept still, the battery liquid will be thicker at the base of the elements. The battery must be shaken periodically to mix the liquid. This will improve charging amperage and allow more precise hydrometer readings during tests.

Relative density: This test shows the charge level of a battery. 1. With the float in vertical position, note the reading. 2. Regulate the hydrometer reading for battery liquid temperature variations subtracting 4 points (relative density 0.004) for every 5.5°C (10 °F) below the temperature the densimeter is calibrated at and adding 4 points (relative density 0.004) for every 5.5° C (10° F) above this temperature. Example 1: Temperature below Battery liquid temperature Hydrometer reading Subtract 11.0 x 0.004 5.5 Correct relative density =

Performance tests Performance tests help to understand if a battery can adequately start the engine. Voltage readings show battery condition. Before carrying out the test, check the battery liquid level is correct and the open circuit voltage is 12.5V or more. The battery can be tested in the tractor or removed.

30°C (86 °F) 19°C (66 °F) 1.270 0.008

1. Switch the battery start tester current control to “off” (high amperage discharge tester). Calibrate the voltage selection switch to the nominal battery voltage or slightly higher. Connect the positive tester conductors to the positive battery terminal and the negative conductors to the negative battery terminal.

1.262

Example 2: Temperature above 30°C (86 °F) Battery liquid temperature 40°C (104 °F) Hydrometer reading 1.220 Add 10.0 x 0.004 0.007 5.5 Correct relative density = 1.227 The following examples have been calculated with a hydrometer calibrated at 30°C (86 °F).

2. Turn the current control knob until the ammeter reading reaches half the cold cranking amperage and note the voltage reading. • If the reading shows 7.2 V or higher after 30 seconds, the battery has adequate power output and can easily be charged following the normal procedure.

3. Use the following table to determine charge level. Charge condition

Correct relative density at 26°C (80°F)

Average battery voltage

100%

1.265

12.70

75%

1.225

12.45

50%

1.190

12.24

25%

1.155

12.06

Flat

1.120

11.90

•

If the reading is lower than 7.2 V, battery is not satisfactory for use and the charge must be tested as follows.

WARNING Do not leave high discharge on the battery for more than 30 seconds.

55-7

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 Amperage must not exceed 14.0 A and the battery liquid temperature must not exceed 50°C (122 °F). When amperage stabilizes, set the voltage until amperage corresponds to 5 A. fixed. Continue this amperage until the relative density of battery liquid stops increasing (1.265 - 1.270 at 26.6°C or 80 °F). This could take approximately 48 hours. Let the battery rest for 24 hours and then carry out the previously described performance test.

Test charging: This test is only for those batteries which have not passed the performance test above. 1. Connect the positive battery charger tester conductors (high amperage discharge tester) to the positive battery terminal and the negative conductors to the negative battery terminal. 2. Connect the positive battery charger conductor to the positive battery terminal and the negative conductor to the negative battery terminal.

•

3. Turn the battery charger timer to more than 3 minute charge and then back to 3 minute charge. 4. Set the charging amperage as close as possible to 40 A. 5. After 3 minute fast charge, read the voltmeter. If the total voltage is higher than 15.5 V, the battery is not satisfactory. It is probably sulphurized or worn and must be changed. NOTE: A slightly sulphurized battery can be renewed using a multiple type battery charger, with upper open circuit voltage limit of 50V. A sulphurized battery has high resistance and for this reason it will be necessary to set high voltage at the beginning to overcome resistance due to sulphurization. At the beginning there may be no visible sign of charging. After some minutes of inactivity, a low charge will show. This is followed by a fast rise in amperage. •

If the total voltage is less than 15.5 V, check the relative density of each element and recharge the battery according to the following scale:

Relative density

Fast charge up to:

1.150 or less

60 minutes

from 1.151 to 1.175

45 minutes

from 1.176 to 1.200

30 minutes

from 1.200 to 1.225

15 minutes (slow charge only)

NOTE: When there are problems with a battery, check fan belt tension and complete charging system.

55-8

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 Crystal growth occurs whenever batteries stand discharged. High temperatures and extended discharge periods increase this condition. At room temperature after one week, the battery may not recover while on the vehicle. Recharge will require a higher constant voltage. After three weeks, the battery will suffer permanent degradation, and the procedures for charging a heavily discharged battery will be required.

Common Causes of Battery Failure • Internal open or short circuit • Loss of electrolyte • Separation of active materials from grids • Accumulation of sulfate crystals too large to disperse • Failure of inter-cell components • Separators punctured by excessive crystal growth, causing short circuit • Excessive over-charging • Electrolyte freezing

When fully charged, batteries have a long shelf life. The lead--calcium type battery discharges at 3% per 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 per week.

A fully charged battery will not freeze until –65 _C (--85 _F). A 50% charged battery freezes between –17 _C and –27 _C (1.4 _F and --16.6 _F). Fully discharged electrolyte freezes between –3 _C and –11 _C (26.6 _F and 12.2 _F). Excessively high boost charging and gassing will cause separation of active materials from the grids. Separation destroys the chemical function of the battery.

When cranking the engine, if the battery starts to fade, stop cranking and allow the battery to stand for two minutes to recover. The recovery time required increases as the temperature decreases.

55-9

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

55-10

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

SECTION 55 - ELECTRICAL SYSTEM Chapter 5 - Electrical Circuits -- Wiring Diagrams CONTENTS Section

Description

Page

55-1

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 LINEAR WIRING DIAGRAMS Refer to Figure 1 Linear wiring diagrams, such as the ones used in this manual, break down large, complex electrical diagrams into smaller sections, or pieces. This type of diagram allows easier navigation through the various circuits while troubleshooting a system failure. Linking all the linear wiring diagrams together will form the entire electrical circuit. For definition of symbols and wire color, refer to the legends at the beginning of the diagram section. Turn the diagrams sideways to read. The linear wiring diagram pages contain a title (1), which identifies the circuit illustrated. The title appears at the bottom of the diagram. A unique reference number (2) allows quick identification of each component. Each component and connector pin appears only once throughout the linear wiring diagram. When the component crosses over to several circuits, such as a processor or multi--function switch, it appears on a separate page or within the circuit the component influences most. . Two wires run across the top of every linear wiring diagram. The upper most wire (3) represents the constant power wire. The lower wire (4) represents the ignition power wire. The lower wire (5) running along the bottom of the diagram represents the ground wire.

55-2

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 A reference line (6) at the very bottom of the diagram contains numerical numbers in increments of ten for locating components from one diagram to another. Example: A wire (7) which has no ending has the number 1440 assigned. Refer to Figure 2 Find the diagram with the reference number 1440 on the reference line (1) and look in that area of the diagram to find the continuation of the wire (2).

55-3

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

55-4

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

55-5

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 Symbol

Drawing Location

Description

(A) Gauges A1

1070

Tachometer/Hour meter

1120

Temperature Gauge

1180

Fuel Gauge

160

Battery Temperature Sensor

1530

Fuel Tank Sender

1580

Engine Coolant Temperature Sensor

1600

Engine Oil Pressure Sensor

1650

Air Filter Restriction Sensor

1680

Horn

430

Stop Fuse

460

Turning Light Fuse

2160

High Beam Fuse

2160

Low Beam Fuse

2310

Lamp RH Fuse

2310

Lamp LH Fuse

2310

Flasher Fuse

2310

Horn Fuse

1080

Air Filter Restriction Warning Light

1080

Engine Oil Pressure Warning Light

1080

Alternator Charge Warning Light

1370

High Beam Warning Light

1370

Left Turn Warning Light

(B) Sensors & Senders

(F) Fuses

(H) Lamp & Lights

1370

Right Turn Warning Light

1370

PTO On Warning Light

H10

1370

Thermostart Warning Light

55-6

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 Symbol

Drawing Location

Description

H14

1370

Parking Lamp Warning Light

H15

1170

Cluster Light

H16

1170

Rear Lamp Warning Light

H17

2030

Head Lamp RH

H18

2030

Head Lamp LH

HTD

2800

Assy Rear Indicator Lamp RH

H19

2800

Right Turn & Flasher

H20

2800

Right Turn & Flasher Additional

H21

2800

Position Rear Lamp RH

H22

2800

Stop Lamp RH

HTI

2800

Assy Rear Indicator Lamp LH

H23

2800

Stop Lamp LH

H24

2800

Position Rear Lamp LH

H25

2800

Left Turn & Flasher Additional

H26

2800

Left Turn & Flasher

H27

2800

Work Lamp

Battery

150

Alternator

260

Ignition Relay

800

Fuel Engine Shut Down Relay

3270

Flasher Unit Relay

3810

Buzzer

Starter Motor

870

Cigar Lighter

1620

Thermostart

(G) Charging

(K) Relays

(M) Motors M1 (R) Resistors

55-7

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 Symbol

Drawing Location

Description

(S) Switches S1

380

Ignition Switch

280

PTO Inhibitor Switch

210

Transmission Inhibitor Switch

2170

Lights & Horn Switch

3050

Turn RH and LH Switch

S10

3160

Brake Switch

S11

3410

Flasher Switch

S12

3750

Seat Switch

S13

3900

Parking Brake Switch

2940

7 Pole Socket

540

Fuel Shut Off Solenoid

(X) Power Sockets X1 (Y) Solenoid Values Y1

55-8

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STARTING, CHARGING AND SAFETY DIAGRAM Starting G1 M1 S1

Battery Starter Motor Ignition Switch

Charging G2

Alternator

Safety B1 S2 S3 F1 F2 K1

Battery Temperature Sensor PTO Inhibitor Switch Transmission Inhibitor Switch Stop Fuse Turning Light Fuse Ignition Relay

Wire Colors Codes B

Black

Red

Light Green

Pink

Brown

Orange

Blue

White

Light Brown

Yellow

Turquoise

Slate

Green

Purple

55-9

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

55-10

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 THERMOSTART, INJECTION PUMP AND TRANSFER PUMP Thermostart K2 R1

Fuel Shut Off Relay Cigar Lighter

Injection Pump Y1

Fuel Shut Off Solenoid

Wire Colors Codes B

Black

Red

Light Green

Pink

Brown

Orange

Blue

White

Light Brown

Yellow

Turquoise

Slate

Green

Purple

55-11

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

55-12

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 CLUSTER Cluster A1 A2 A3 H2 H3 H4 H6 H7 H8 H9 H10 H14 H15 H16

Tachometer and Hour Meter Temperature Gauge Fuel Gauge Air Filter Restriction Warning Light Engine Oil Pressure Warning Light Alternator Charge Warning Light High Beam Warning Light Left Turn Warning Light Right Turn Warning Light PTO On Warning Light Thermostart Warning Light Parking Lamp Warning Light Cluster Light Rear Lamp Warning Light

Wire Colors Codes B

Black

Red

Light Green

Pink

Brown

Orange

Blue

White

Light Brown

Yellow

Turquoise

Slate

Green

Purple

55-13

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

55-14

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 SENDERS Senders B2 B3 B4 B5 B6 R2

Fuel Tank Sender Engine Coolant Temperature Sensor Engine Oil Pressure Sensor Air Filter Restriction Sensor Horn Thermostart

Wire Colors Codes B

Black

Red

Light Green

Pink

Brown

Orange

Blue

White

Light Brown

Yellow

Turquoise

Slate

Green

Purple

55-15

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

55-16

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 MAIN LIGHT SWITCH AND FRONT LIGHTS Light Fuses F3 F4 F5 F6 F7 F8

High Beam Fuse Low Beam Fuse Lamp RH Fuse Lamp LH Fuse Flasher Fuse Horn Fuse

Front Lights H17 H18

Head Lamp RH Head Lamp LH

Lights Interrupter S5

Lights and Horn Switch

Wire Colors Codes B

Black

Red

Light Green

Pink

Brown

Orange

Blue

White

Light Brown

Yellow

Turquoise

Slate

Green

Purple

55-17

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

55-18

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 REAR LIGHTS, POSITION LIGHTS AND WARNING LIGHTS Rear Lights, Position Lights, and Warning Light HTD H19 H20 H21 H22 HTI H23 H24 H25 H26 H27 X1

Assy Rear Indicator Lamp RH Right Turn and Flasher Right Turn and Flasher Additional Position Rear Lamp RH Stop Lamp RH Assy Rear Indicator Lamp LH Stop Lamp LH Position Rear Lamp LH Left Turn and Flasher Additional Left Turn and Flasher Work Lamp 7 Pole Socket

Wire Colors Codes B

Black

Red

Light Green

Pink

Brown

Orange

Blue

White

Light Brown

Yellow

Turquoise

Slate

Green

Purple

55-19

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

55-20

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 LIGHTS, SAFETY SWITCHES AND FLASHER UNIT Lights Interruptors S9 S10 S11 K4

Turn RH and LH Switch Brake Switch Flasher Switch Flasher Unit Relay

Wire Colors Codes B

Black

Red

Light Green

Pink

Brown

Orange

Blue

White

Light Brown

Yellow

Turquoise

Slate

Green

Purple

55-21

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

55-22

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 SAFETY CIRCUIT Safety Circuit K5 S12 S13

Buzzer Seat Switch Parking Brake Switch

Wire Colors Codes B

Black

Red

Light Green

Pink

Brown

Orange

Blue

White

Light Brown

Yellow

Turquoise

Slate

Green

Purple

55-23

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

55-24

SECTION 90 -- BODYWORK -- CHAPTER 1

SECTION 90 - BODYWORK Chapter 1 - Bodywork CONTENTS Section

Description

Page

90-1

SECTION 90 -- BODYWORK -- CHAPTER 1 ENGINE HOOD PANEL ASSEMBLY 1 Removal 1. Unlatch and raise the hood panel (1). 2. Disconnect the headlamp harness from the headlamp assemblies, and from the clamps that run along inside the right side of the hood panel. 3. Support the hood panel with a suitable hoist or sling. When a hoist or sling is not available, enlist the help of several people to hold the hood panel while detaching.

20033049

WARNING

The hood panel is heavy, and when left unsupported, will fall with mounting hardware removed. It is critical to support the hood panel with a hoist or sling, or with several people assisting to prevent serious personal injury, or damage to the engine. 4. Disconnect the strut at the actuator rod-end (1), where it attaches to the hood panel.

40035267

2 5. While supporting the hood panel, remove the hood panel mounting bolts and nuts (1) at the engine compartment firewall on the left and right-hand sides. Remove the hood panel off the tractor. 6. If required, remove the headlamp assemblies by removing the four mounting screws on each lamp.

40035268

90-2

SECTION 90 -- BODYWORK -- CHAPTER 1 7. If required, remove the grille from the front of the hood panel by removing the mounting bolts and nuts (1), on the left and right-hand sides.

CAUTION When completely removing the hood panel from the tractor, ensure not to damage the vertical exhaust [where installed]. Carefully set the hood panel down on a non-abrasive surface. Handling the hood panel too roughly may cause damage to the headlamp assemblies. 40035266

Installation Installation of the engine hood panel follows the removal procedures in reverse with the following requirements:

1 4

WARNING The hood panel is heavy, and when left unsupported, will fall with mounting hardware removed. It is critical to support the hood panel with a hoist or sling, or with several people assisting to prevent serious personal injury, or damage to the engine. 1. After attaching the strut, carefully open and close the hood panel to verify proper operation of the strut. A malfunctioning strut will allow the hood panel to fall. 2. If previously removed, install the headlamp assemblies. 3. If previously removed, install the grille. 4. After connecting the headlamp harness, check for proper operation of the high and low beams. 5. â&#x20AC;&#x2DC;Check that the headlamp harness does not contact hot engine parts, or get pinched in the hood panel when closed. 6. Tighten all mounting hardware.

90-3

SECTION 90 -- BODYWORK -- CHAPTER 1 REAR WHEEL FENDERS Removal 1. Remove the six mounting bolts and nuts (1, three shown) that secure the right or left rear fender to the ROPS. The figure shows three of the six bolts.

2. Remove the bolts and nuts that attach the forward edge of the fender to the platform and fuel tank 40035261

1 5

The rear fenders consist of a number of sub-assembly parts as shown in Figure 6. Remove the attaching hardware to separate these parts from the fender when necessary. 1. 2. 3. 4. 5. 6.

Handle Assembly Rear Extension Fender Wall Lower Wall [Long] Extension Lower Wall [Short] Extension Crown Extension

Installation Installation of the right and left rear fender assemblies follows the removal procedures in reverse with the following requirements:

20035290

1. Ensure to install hardware exactly as removed. Check lock-washers and flat washers for the proper placement as removed. 2. Tighten all bolts and nuts.

CAUTION When installing a rear fender, always ensure that no contact exists between the fender and the tire, or damage may occur to the fender or tire from chaffing.

90-4

SECTION 90 -- BODYWORK -- CHAPTER 1 ROLL-OVER PROTECTION (ROPS) BAR 1

Folding The ROPS bar (1) folds down to allow parking of the tractor in spaces with height limitations. The operator has the capability to pull down and lock the ROPS handle (2), which provides enough advantage to lower the heavy ROPS from the operator’s seat. The operator then relocates a pin (3) through a bracket (4) to lock the ROPS down.

40035289

7 Removing 1. Remove the upper half of the ROPS bar as follows:

WARNING Do not allow the ROPS to fall. Support the ROPS with a suitable hoist or sling before removing attaching hardware. If the hoist or sling is unavailable, enlist the help of several people. The ROPS is heavy enough to cause irreparable damage to the tractor, or cause serious personal injury or death. •

Support the ROPS with a suitable hoist or sling.

•

Remove the large bolt and nut (1). Do not allow the ROPS to fall.

•

Remove the pin (2). Hoist the upper half of the ROPS to the ground.

40035289

2. Remove the lower half, or the ROPS bar as a complete assembly as follows:

Support the ROPS with a suitable hoist or sling.

•

Remove the rear fenders as previously described in this section.

90-5

SECTION 90 -- BODYWORK -- CHAPTER 1 • •

Disconnect the working lamp harness. Remove the working light with mounting bracket (1).

40035222

9 3. Remove the light harness (1).

40035264

90-6

SECTION 90 -- BODYWORK -- CHAPTER 1 â&#x20AC;˘

Remove the attaching bolts and nuts (1) at the lower end of the ROPS for both the left and right-hand sides. Hoist the ROPS to the ground.

Installation Installation of the ROPS bar follows the removal procedures in reverse with the following requirements:

WARNING Do not allow the ROPS to fall. Support the ROPS with a suitable hoist or sling before attaching hardware. If the hoist or sling is unavailable, enlist the help of several people. The ROPS is heavy enough to cause irreparable damage to the tractor, or cause serious personal injury or death.

40035262

1. Position the ROPS and insert all mounting bolts. Do not torque the lower mounting bolts and nuts at this time. 2. Tighten the mounting bolts in a cross pattern. After tightening all bolts, torque each bolt to a final value of 399-502 Nâ&#x2039;&#x2026;m (250-370 lb-ft). 3. Install the fenders as described in this section. 4. Install the work lamp and bracket. 5. Install the light harness. 6. Check the work lamp and rear lights for proper operation.

90-7

SECTION 90 -- BODYWORK -- CHAPTER 1 BATTERY REMOVAL

CAUTION When disconnecting the battery for any reason, always disconnect the negative (ground) cable first. 1. Unlatch and raise the engine hood panel to gain access to the battery. 2. Disconnect the battery sensor (2) and move it away from the tractor frame.

CAUTION When removing the battery terminals for any reason, do not allow the negative and positive cables to touch, or to make contact with the battery.

3. Remove the negative cable (1) from the negative terminal on the battery.

4. Remove the positive cable (2) from the positive terminal on the battery.

5. Remove the nut, bolt and bracket (3), which secures the battery to the tractor frame.

40035227

6. Slide the battery from the tractor frame and remove.

90-8

SECTION 90 -- BODYWORK -- CHAPTER 1 INSTALLATION The installation of the battery follows the removal procedures in reverse with the following requirements: •

Check the battery for cleanliness, especially around the terminals. Clean the area where the battery mounts to the tractor frame to prevent debris from piercing the body of the battery.

•

Seat the battery squarely into position before installing mounting strap.

•

Check the vent caps for proper installation and tightness.

•

Ensure that no leakage occurs from the battery.

•

Connect the positive terminal first, then the negative terminal.

•

Coat the battery terminal clamps with petroleum jelly or equivalent. Do not use conventional lubricants as electrolyte corrosion may occur.

•

Check battery terminal connections for correct polarity and tightness. Do not over--tighten. Install dust covers over terminals (where installed).

90-9

SECTION 90 -- BODYWORK -- CHAPTER 1

90-10