© 2016 CNH Industrial America LLC. All Rights Reserved. SERVICE MANUAL BoomerTM 20 / BoomerTM 25 Compact Tractor Part number 48017684 English June 2016
SER VICE MANUAL Boomer™ Boomer™ 48017684 02/06/2016
Link Product / Engine
Product Market Product Engine Boomer™ Europe S3L2 Boomer™ Europe S3L2 48017684 02/06/2016
14] Mechanical transmission Front axle system
Powered front axle
Front bevel gear set and dif ferential
drive hub, steering knuckles, and shafts
Contents INTRODUCTION Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10] Clutch and
T ransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
components 12] Slip clutch flywheel damper
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [25.100]
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.102]
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 [25.108]
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3 [25.310]
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4 Rear axle system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear bevel gear set and dif ferential Final drive steering and shafts Hydrostatic drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [29.100] T ransmission and steering hydrostatic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1 [29.202] Hydrostatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.2 [29.204] Reservoir , cooler , and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.3 [29.218] Pump and motor components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.4 Power T ake-Of f (PT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [31.101] Rear mechanical control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 [31.104] Rear electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 48017684 02/06/2016
Final
Final drives
Parking brake parking lock Mechanical service brakes Hydraulic systems
Fixed displacement pump
14] hitch control valve
16] hitch cylinder
Remote control valves
Reservoir , cooler , and filters
Safety and main relief valves Hitches, drawbars, and implement couplings
10] rear
[31.120] Central
(PT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.4 Brakes and
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
[35.000]
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.104]
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
Power T f (PT
Power T ake-Of f
controls
10]
Hydraulic systems
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [37.1 10]
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.1 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T rods [41.200] Hydraulic control components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 Cylinders Wheels [44.51 Front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2 Electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.01 Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 48017684 02/06/2016
Rear three-point hitch
Engine oil system
Parking brake electrical system
Rear Power T f (PT control system
Harnesses and connectors
Engine starting system
Cold start aid
Battery
External lighting
External lighting switches and relays
W arning and instruments
Platform, cab, bodywork, and decals
1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [90.120] Mechanically-adjusted operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 48017684 02/06/2016
INTRODUCTION 48017684 02/06/2016 1
Contents INTRODUCTION Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 International symbols 5 Safety rules 6 Safety rules 7 Safety rules - Ecology and the environment 8 Basic instructions hardware 9 T orque - Standard torque data for hydraulic connections Basic instructions - Shop and assembly General specification - T ractors with Hydrostatic T ransmission (HST) General specification - T ractor with mechanical transmission General specification Dimension Consumables Capacities Product identification Product identification machine orientation 48017684 02/06/2016 2
Foreword
This repair manual provides the technical information needed properly service the NEW HOLLAND models Boomer and Use this manual conjunction with the manual for complete and maintenance information
NEW HOLLAND left and right are determined standing behind the looking the direction
INTRODUCTION
48017684 02/06/2016 3
Foreword - Important notice regarding equipment servicing
All repair and maintenance work listed this manual must carried out only qualified dealership strictly complying with the instructions and whenever the special
Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall responsible for any subsequent
The manufacturer and all the organizations its distribution chain, including - without limitationnational, regional, local reject any responsibility for damages caused parts and / components not approved the facturer , including those used for the servicing repair the product manufactured marketed the manufacturer any case, warranty given attributed the product manufactured marketed the manufacturer case damages caused parts and / components not approved the manufacturer
The manufacturer reserves the right make improvements design and changes specifications any time without notice and without incurring any obligation install them units previously and illustrative material herein are accurate known time publication but are subject change without notice.
case refer your NEW HOLLAND Sales and Service
INTRODUCTION
48017684 02/06/2016 4
F
Safety rules
Personal safety
This the safety alert used alert you potential personal injury Obey all safety messages that follow this symbol avoid possible death injury
Throughout this manual you will find the signal words W and CAUTION followed special These precautions are intended for the personal safety you and those working with
Read and understand all the safety messages this manual before you operate service the
DANGER indicates a hazardous situation not will result death serious injury
W
ARNING indicates a hazardous situation not could result death serious injury
CAUTION indicates a hazardous situation not could result minor moderate injury
AILURE T O FOLLOW DANGER, W ARNING, AND CAUTION MESSAGES COULD RESUL T DEA SERIOUS INJUR Y .
Machine safety
NOTICE: Notice indicates a situation that, not avoided, could result machine property damage.
Throughout this manual you will find the signal word Notice followed special instructions prevent machine property damage. The word Notice used address practices not related personal safety .
Information
NOTE: Note indicates additional information that clarifies other information this
Throughout this manual you will find the word Note followed additional information about a step, other information the The word Note not intended address personal safety property
INTRODUCTION
48017684 02/06/2016 7
Safety rules - Ecology and the environment
Soil, air , and water quality important for all industries and life general. When legislation does not yet rule the treatment some the substances that advanced technology sound judgment should govern the use and disposal products a chemical and petrochemical
Familiarize yourself with the relative legislation applicable your country , and make sure that you understand this Where legislation obtain information from suppliers anticleaning agents, etc., with regard the fect these substances man and nature and how safely store, use, and dispose these
Helpful hints
• A void the use cans other inappropriate pressurized fuel delivery systems fill Such delivery systems may cause considerable
• avoid skin contact with all Most these products contain substances that may harmful your
• Modern oils contain not burn contaminated fuels and waste oils ordinary heating
• A void spillage when you drain fluids such used engine coolant engine hydraulic brake etc. not mix drained brake fluids fuels with lubricants. Store all drained fluids safely until you can dispose the fluids a proper way that complies with all local legislation and available
• not allow coolant mixtures get into the soil. Collect and dispose coolant mixtures properly .
• The air - conditioning system contains gases that should not released into the Consult airtioning specialist use a special extractor recharge the system properly
• Repair any leaks defects the engine cooling system hydraulic system immediately
• not increase the pressure a pressurized circuit this may lead a component
• Protect hoses during Penetrating weld splatter may burn a hole weaken allowing the loss
Battery recycling
Batteries and electric accumulators contain several substances that can have a harmful fect the environment the batteries are not properly recycled after Improper disposal batteries can contaminate the groundwater , and NEW HOLLAND strongly recommends that you return all used batteries a NEW HOLLAND dealer , who will dispose the used batteries recycle the used batteries properly some countries, this a legal requirement.
Mandatory battery recycling
NOTE: The following requirements are mandatory
Batteries are made lead plates and a sulfuric acid solution. Because batteries contain heavy metals such lead, CONAMA Resolution 401 / 2008 requires you return all used batteries the battery dealer when you replace any not dispose batteries your household
Points sale are obliged to:
• Accept the return your used batteries
• Store the returned batteries a suitable location
• Send the returned batteries the battery manufacturer for recycling
INTRODUCTION
48017684 02/06/2016 8
SER VICE MANUAL Engine Boomer™ Boomer™ 48017684 02/06/2016
Engine - Engine and crankcase
Engine - General specification
Engine Model S3L , S3L2 T ype W ater 4 - stroke cycle diesel No. cylinders 3 Combustion type Swirl chamber V alve mechanism Overhead valve type Cylinder bore x stroke x ( x ) T otal displacement 1.3 l ( in³ ) Compression ratio 22:1 Fuel used JIS Diesel fuel its equivalent (ASTM diesel fuel oil No. 2Firing order 1 - 3 - 2 Direction rotation Counterclockwise viewed from flywheel side Length 512 ( ) Width 453 ( 17.8 ) Height 563 ( 22.2 ) Dry weight Approximately 140 ( 309 ) Inspection point Nominal Standard Limit Remark Maximum rotation speed (rated rotation speed used reference) V aries depending specification destination Minimum rotation speed V aries depending specification destination Compression ratio @ 290 RPM bar ( 421 psi ) above bar ( 377 psi ) less When oil and water temperatures( - ) V alve timing Intake - Open BTDC ° - Close ABDC ° Exhaust - Open BBDC ° - Close A TDC ° With 2 ( 0.079 ) clearance valve when V alues are only for checking valve timing and are dif ferent from the actual ones. Rocker arm Rocker arm inside diameter 18.9 ( ) 18.91018.930 ( - ) Rocker shaft outside diameter 18.9 ( ) 18.88018.930 ( - ) Clearance between rocker arm and rocker shaft (oil clearance)( 0.00050.0020 ) ( 0.00 ) Replace rocker arm V alve V alve stem outside diameter - Intake 6.6 ( ) 6.5656.580 ( - ) 6.500 ( ) - Exhaust 6.6 ( 0.260 ) 6.5306.550 ( 0.25710.2579 ) 6.500 ( 0.25 ) V alve guide inside diameter - Intake 6.6 ( 0.260 ) 6.6006.615 ( 0.25980.2604 ) - Exhaust ( 0.260 )( 0.25980.2604 ) Clearance between valve guide and valve stem 48017684 02/06/2016 10.1 [10.001] / 3
Inspection point Nominal Standard Limit Remark - Intake( 0.00080.0020 ) ( 0.00 ) - Exhaust 0.0500.085 ( - ) 0.150 ( ) Replace valve and valve guide V alve seat angle ° V alve sinkage 0 ( 0.00 )( 0.00980.0295 ) ( 0.0591 ) V alve head width 1.6 ( ) 1.301.80 ( - ) 2.50 ( ) V alve margin 1.5 ( 0.059 ) 1.351.65 ( 0.05310.0650 ) 0.50 ( 0.0197 ) V alve guide mounting length ( 0.39 ) 9.510.5 ( 0.374) V alve spring Free length ( 1.85 ) ( 1.81 ) Length @ 131 - 145 N () ( ) - % Length @ 279 - 309 N () ( ) - % Push rod runout 0.3 ( 0.012 ) Replace Cylinder head distortion ( ) ( 0.0039 ) Cylinder Cylinder block distortion (Deck) 0.05 ( 0.0020 ) less 0.10 ( 0.0039 ) Repair Inside diameter ( 3.071 ) ( ) ( 3.079 ) Repair oversize replace Cylindericity 0.01 ( 0.0004 ) less Piston Outside diameter - STD ( 3.0709 ) - (3.0689 ) ( 3.06 )0.25 ( 0.010 ) 78.25 ( ) 78.1878.20 ( 3.0780 - ) 78.05 ( )0.50 ( 0.020 ) 78.50 ( 3.0906 ) 78.4378.45 ( 3.08783.0886 ) 78.30 ( 3.08 ) W eight dif ference within engine + / - 5 g ( ) less Piston pin outside diameter ( 0.91 )( 0.90530.9055 ) Clearance between piston pin bore and piston pin 0.0060.018 ( 0.00020.0007 ) 0.050 ( 0.00 ) Clearance between piston and cylinder - (0.0034 ) ( 0.01 ) Repair oversize replace 48017684 02/06/2016 10.1 [10.001] / 4
Engine - Engine and crankcase
Inspection point Nominal Standard Limit Remark Piston ring Clearance between the piston ring and ring groove - T compression ring 0.090.1 1 ( 0.0035) ( 0.01 ) Replace the rings until the limits are then replace the - Intermediate ring 0.070.1 1 ( 0.00280.0043 ) 0.20 ( ) Replace the rings until the limits are then replace the - Oil ring - (0.0028 ) ( 0.0079 ) Replace the rings until the limits are then replace the Piston ring end gap - T compression ring 0.150.30 ( 0.0059) 1.50 ( ) Replace - Intermediate ring - (0.01 ) 1.50 ( 0.0591 ) Replace - Oil ring 0.200.40 ( 0.0079) ( 0.0591 ) Replace Connecting rod Bend and torsion (over a 100 ( 3.9 ) span ( ) less 0.15 ( 0.0059 ) End play 0.100.35 ( 0.0039) ( 0.0197 ) Replace the connecting rod Crankshaft Crank journal outside diameter ( 2.05 )( 2.04672.0472 ) Crank pin outside diameter ( 1.89 )( 1.88781.8884 ) Crankshaft runout 0.025 ( 0.0010 ) less 0.050 ( 0.00 ) Repair replace Main bearing oil clearance - (0.0030 ) ( 0.00 ) Replace main bearing Connecting rod bearings oil clearance 0.0250.072 ( 0.0010 - ) 0.150 ( ) Replace connecting rod bearings End play - (0.0069 ) 0.500 ( 0.01 ) Replace flanged 3 main bearing T iming gear backlash Between crankshaft gear and idler gear 0.040.12 ( 0.0016) 0.30 ( ) Replace Between idler gear and valve camshaft gear 0.040.12 ( 0.00160.0047 ) 0.30 ( 0.01 ) Replace Between idler gear and pump camshaft gear - (0.0047 ) ( 0.01 ) Replace 48017684 02/06/2016 10.1 [10.001] / 5
Engine - Engine and crankcase
Engine - Engine and crankcase
Engine - T orque
Inspection point Nominal Standard Limit Remark Between valve camshaft gear and O gear 0.080.19 ( 0.0031) ( 0.01 ) Replace Between pump camshaft gear and oil pump gear 0.070.20 ( 0.00280.0079 ) 0.30 ( ) Replace Cam height - (1.4102 ) ( 1.36 ) Replace Flywheel flatness 0.15 ( 0.0059 ) less 0.50 ( ) Repair Clearance between tappet and cylinder block bore 0.15 ( 0.0059 ) Replace tappet Clearance between camshaft journal and bushing - (0.0049 ) ( 0.0059 ) Replace Clearance between idler gear bushing and idler shaft 0.020.07 ( 0.0008) 0.20 ( ) Replace idler gear idler shaft
Description Threads Diameter x pitch T orque Cylinder head bolt M10 x - N·m ( - ) Rocker cover bolt x - ( 7 - ) Rocker shaft bracket bolt x - N·m ( 7 - ) Rocker arm adjusting nut x - N·m ( - ) T achometer L joint union nut M22 x - N·m ( - ) Band type hose cramp - 3 - 4 ( 2 - 3 ) Thrust plate x - N·m ( 7 - 9 ) Main bearing cap bolt M10 x - N·m ( - ) Connecting rod cap nut x - N·m ( - ) Flywheel bolt M12 x 1.25 127 - 137 ( - 101 ) Crankshaft pulley nut M18 x 147 - 196 N·m ( 108 - 145 ) Rear plate use mounting bolt - For general use M12 x - N·m ( - ) - For tractor M12 x 1.25 - 103 ( - ) 48017684 02/06/2016 10.1 [10.001] / 6
Engine - Engine and crankcase
Engine - Remove W ARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity . Always support units parts with suitable slings hooks. Make sure the work area clear all bystanders.
Failure comply could result death serious injury
W ARNING
A void injury!
W0398A
Handle all parts carefully not place your hands fingers between Use Personal Protective Equipment (PPE) indicated this manual, including protective goggles, gloves, and safety
footwear
Failure comply could result death serious injury . W0208A
W ARNING
Hot liquid under pressure!
Never remove the filler cap the recovery tank cap while the engine running the coolant
Let the system cool. T urn the filler cap the first notch and allow any pressure escape, and then remove the filler Loosen the recovery tank cap slowly allow any pressure
Failure comply could result death serious injury . W0296A
Engine removal
Open the hood and disconnect the negative ( battery terminal (1)
Open the drain cock (1) under the left hand side the radiator
831 15266 1
831 18786 2 48017684 02/06/2016 10.1 [10.001] / 7
Drain the engine coolant into a clean container (2) .
NOTE: Engine coolant capacity l ( 1 gal )
Loosen the radiator cap (3) accelerate draining all the
Loosen the hose clamp and disconnect the lower coolant hose (1) located the right hand side the
Loosen the hose clamp (2) and disconnect the upper coolant hose.
Engine - Engine and crankcase
831 18785 3
831 18787 4
831 18788 5
831 18789 6 48017684 02/06/2016 10.1 [10.001] / 8
Engine - Engine and crankcase
Remove the x 16mm radiator retaining bracket bolts (1)
Remove the radiator (1) the direction the arrow
Disconnect the electrical connection (1) remove the clip (2)
10. Remove the hood retaining nuts (3) .
1 Remove the engine hood (4)
Disconnect the throttle cable (1) and the fuel line (2)
831 18790 7
831 18791 8
831 18792 9
831 18793 48017684 02/06/2016 10.1 [10.001] / 9
13. Disconnect the engine electrical connectors (1) cated under the left hand side the instrument
Remove the rubber cover (1) , and the connect the positive (+) battery cable from the starter motor .
Disconnect the negative ( ground cable removing bolt (1)
NOTICE: Insure that all necessary hoses and electrical connectors have been disconnected may also necessary disconnect additional items due other optional systems being installed the tractor
Remove the four M14 engine mount retaining nuts (1)
- Engine and crankcase
Engine
831 18794 1 1
831 18795
831 18796
831 18797 48017684 02/06/2016 10.1 [10.001] /
Engine - Engine and crankcase
831 18798 48017684 02/06/2016 10.1 [10.001] / 1 1
17. Use overhead hoist (1) lift the engine (2) . Place engine
a suitable
Engine - Engine and crankcase
Engine - Install W ARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity . Always support units parts with suitable slings hooks. Make sure the work area clear all bystanders.
Failure comply could result death serious injury
W ARNING
A void injury!
W0398A
Handle all parts carefully not place your hands fingers between Use Personal Protective Equipment (PPE) indicated this manual, including protective goggles, gloves, and safety footwear
Failure comply could result death serious injury . W0208A
W ARNING
Hot liquid under pressure!
Never remove the filler cap the recovery tank cap while the engine running the coolant Let the system cool. T urn the filler cap the first notch and allow any pressure escape, and then remove the filler Loosen the recovery tank cap slowly allow any pressure
Failure comply could result death serious injury . W0296A
Use overhead hoist (1) lift the engine (2)
Place the engine the chassis mounts.
Install four M14 engine mount retaining nuts (1) .
NOTICE: Ensure that all necessary hoses and electrical connectors have been connected may also necessary connect additional items due other optional systems being installed the tractor
831 18798 1
831 18797 2
48017684 02/06/2016 10.1 [10.001] /
Connect the negative ( ground cable installing bolt (1)
Connect the positive (+) battery cable the starter tor Install the nut and the rubber cover (2)
Connect
Engine - Engine and crankcase
831 18796 3
831 18795 4
831 18794 5
the engine electrical connectors (1) located under the left hand side the instrument
831 18793 6 48017684 02/06/2016 10.1 [10.001] /
Connect the throttle cable (1) and the fuel line (2)
Install the engine hood (2) , install the mounting
(3) . Connect the electrical connection (4) , install the clip (5) 831 18792 7 Install the radiator (1) the direction the arrow 831 18791 8 1
831 18790 9 Install
831 18788 48017684 02/06/2016 10.1 [10.001] /
Engine - Engine and crankcase
nuts
Install the x 16mm radiator retaining bracket bolts (1) .
the lower coolant hose (1) , and tighten the clamp (2) .
Engine - Engine and crankcase
Fill the coolant the proper use Ethylene Glycol coolant
NOTE: Engine coolant capacity 3.8 l ( 1 gal ) Connect the negative ( battery terminal (1)
831 18789 1 1
831 18786
13. Install the upper coolant hose (3) . T ighten the hose clamp (4)
Close the drain cock under the left hand side the radiator (1)
831 15266
831 18787 48017684 02/06/2016 10.1 [10.001] /
Install the radiator cap (1) and run the engine until the thermostat opens, ensuring that all the air
Clutch - Clutch and components
Clutch and components - Dynamic description
NHIL16CT00305F A 1
(1) Clutch cover (4) Release bearing (7) Clutch release lever (10) Flywheel
(2) Clutch disc (5) Release bearing hub (8) Clutch lever shaft Diaphragm boss (3) Diaphragm spring (6) Clutch main shaft (9) Pressure plate
The clutch assembly bolts the flywheel and the clutch main shaft (6) connects the diaphragm boss the clutch assembly with The pressure plate will compress the clutch the force the diaphragm spring (3) When the engine the clutch assembly , clutch disc and clutch main shaft rotate together When the operator depresses clutch the clutch lever (7) pushes the release bearing hub (5) toward the the release bearing (4) installed the end the release bearing hub pushes the center the diaphragm spring (3) the clutch assembly . a result, the edge the diaphragm separated from the pressure plate (9) which then separated from the clutch disc (2) the clutch disc between the flywheel and pressure plate loses the clutch disc and diaphragm stop but the flywheel and clutch cover continue the rotating force the flywheel not transferred the clutch main resulting the interruption power from the
48017684 02/06/2016 18.1 [18.1 10] / 4
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Clutch - Clutch and components
Clutch and components - Exploded view
Main shaft (5) M12 x x Qty:5 (9) Bolt / washer , M10 x x Qty:2 (13) Lock washer , Qty:2 (17) Bolt / washer , x x Qty:6 (2) Release bearing (6) Lock washer , Qty:7 (10) Clutch lever shaft (14) x x Qty:1 (18) Clutch cover assembly (3) Release bearing hub (7) M12 x x 1 Qty:2 Clutch housing (15) Clutch shift lever (19) Pin (4) Bushing (8) M10 x Qty:1 (12) Cotter pin (16) Lock M12 x 1.25, Qty:1 (20) Clutch disc assembly 48017684 02/06/2016 18.1 [18.1 10] / 5
NHIL16CT0031 A 1 (1)
Clutch control mechanism - Detailed view
NHIL16CT00312F
(1) Clutch pedal (Mechanical transmission)
(2) Pin
(3) W asher
(4) Cotter pin
(5) Clutch rod assembly
(6) Return spring
(7) Pedal pad (Rubber)
(8) Clutch pedal
(9) Spring pin
Clutch - Clutch and components
A 1
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Clutch - Clutch and components
Clutch and components - Disassemble the clutch W ARNING
A void injury!
Handle all parts carefully . not place your hands fingers between parts. Use Personal Protective Equipment (PPE) indicated this manual, including protective goggles, gloves, and safety footwear
Failure comply could result death serious injury .
Prior operation: Engine - Remove (10.001)
Install a 380003436 (1) into the center hole the clutch assembly (2)
Remove the six x x mounting bolts (3) from the clutch assembly (2)
Remove the clutch assembly (2)
NOTICE: During assembly torque these bolts29.4 N·m (0.0 )
Remove the clutch cover (1) and the clutch disc (2)
NOTICE: Replace the clutch disc assembly with a new one
• Engine side (1)
• T ransmission side (2)
• Clutch (3)
NOTICE: Make sure that the boss the clutch disc with the short end facing the engine assembly
W0208A
NHIL16CT00275AA 1
NHIL16CT00274AA 2
NHIL16CT00260AA 3 48017684 02/06/2016 18.1 [18.1 10] / 7
Clutch - Clutch and components
NOTICE: When installing the clutch disc the flywheel fit the clutch disc clutch aligning 380003436 tool (A) and insert the center hole the flywheel housing (B) Make sure that the longer boss section the clutch disc (C) facing the clutch
NHIL16CT00276AA 4 48017684 02/06/2016 18.1 [18.1 10] / 8
Clutch - Clutch and components
Clutch and components - Remove release fork and release bearing
Remove the clutch release fork mounting bolt (1)
Remove the clutch lever (2) , pulling the direction the arrow
Remove the clutch release fork (3) .
Remove the clutch release bearing (1) and the release hub (2) together
• When installing the clutch bearing (1) the hub sembly , make sure install the correct
• Make sure that the bearing number (2) the hub side (A) .
• When installing the make sure use a - 555 - 4 and careful not deform its
• Lubricate the bearing and check the bearing for ease
NHIL16CT00279AA 1
NHIL16CT00278AA 2
NHIL16CT00280AA 3 48017684 02/06/2016 18.1 [18.1 10] / 9
NHIL16CT00281AA 4
5
(4)
(2)
(5)
(3)
(6)
48017684 02/06/2016 18.1 [18.1 10] /
Clutch - Clutch and components
NHIL16CT00282AA
(1) Clutch disc
Clutch release fork
Clutch cover
Release bearing
Clutch lever
Release hub
Clutch - Clutch and components
Clutch and components - Install the release fork and release bearing
Insert the fork pin (1) into the clutch lever shaft shown the figure and assemble with the release fork (2)
Apply L OCTITE ® 242® adhesive the mounting bolt (1) when installing the release fork (2)
NOTICE: T orque the release fork bolt (1) ( )
Install the release bearing (1) onto the clutch release hub (2)
NOTICE: Check the release bearing for damage before installing Replace necessary
Apply grease the inner groove (3) the clutch lease hub (2)
NOTICE: Application too much grease can contaminate the clutch which shortens the discs usable move any excess grease around the release hub groove.
Install the release hub (1) , and the release fork (2)
NHIL16CT00283AA 1
NHIL16CT00285AA 2
NHIL16CT00284AA 3
NHIL16CT00287AA 4 48017684 02/06/2016 18.1 [18.1 10] / 1 1
Clutch and components - Assemble the clutch W ARNING
A void injury!
Handle all parts carefully . not place your hands fingers between parts. Use Personal Protective Equipment (PPE) indicated this manual, including protective goggles, gloves, and safety footwear
Failure comply could result death serious injury .
NOTICE: Make sure that the boss the clutch disc with the short end facing the engine assembly
NOTICE: When installing the clutch disc the flywheel fit the clutch disc clutch aligning 380003436 tool (A) and insert the center hole the flywheel housing (B) Make sure that the longer boss section the clutch disc (C) facing the clutch
• Engine side (1)
• T ransmission side (2)
• Clutch (3)
Join the clutch cover (1) and the clutch disc (2)
Clutch - Clutch and components
W0208A
NHIL16CT00276AA 1
NHIL16CT00260AA 2
NHIL16CT00274AA 3 48017684 02/06/2016 18.1 [18.1 10] /