Shop Manual Tt45

REPAIR MANUAL
TT45
TT40
TT35
Tractors
English
NEW
HOLLAND
Service Manual -- TT45 / TT40 / TT35 Tractors
CONTENTS
GENERAL SECTION 00
General Instructions and Health Safety Chapter 1
ENGINE SECTION 10
Engine System Chapter 1
Section Description Page
10 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine stripdown -- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10 001 Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10 100 Engine Disassembly and Overhaul :
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Front Cover and Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Connecting Rods, Bearings, Pistons and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Cylinder Block Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Engine Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Main Bearing and Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10 200 Fuel System Components :
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
10 300 Lubricating System :
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10 400 Cooling System :
Radiator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Thermostat removal, testing and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Water Pump removal, overhaul and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
84261396 - 09 - 2009
Contents Continued:
CLUTCHES SECTION 18
Clutches Chapter 1

18 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
18 100 Clutch Control, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clutch Pedal Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
18 110 Clutch Assembly, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TRANSMISSION SYSTEM SECTION 21

Transmission Chapter 1

21 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General Recommendations for Overhauling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . 11
21 118 Transmission Assembly, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
21 148 Internal Components, Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
External Components, Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
MECHANICAL REAR WHEEL DRIVE SECTION 27

Rear Axle Chapter 1
27 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Description & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
27 100 Rear Wheel Drive, Removal -- Installation -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
27 126 Final Drive Housing, Removal -- Installation -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . 20
84261396 - 09 - 2009
Contents Continued:
POWER TAKE-- OFF SECTION 31

Rear Power Take Off System Chapter 1

31 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
31 110 PTO Shaft Assembly -- Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BRAKING SYSTEM SECTION 33

Tractor Brakes Chapter 1
33 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
33 120 Brake Pedal and External Linkages -- Removal and Installation . . . . . . . . . . . . . . . . . . . . 8
33 120 Brake Assembly, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake Pedal Free Play Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
84261396 - 09 - 2009
Contents Continued:
HYDRAULICS SECTION 35
Introduction Chapter 1

35 000 Introduction and Circuit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Open Centre High Pressure Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Pump Chapter 2

35 000 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
35 104 Hydraulic Lift Oil Pump, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Lift Oil Pump, Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Lift Assembly Chapter 3

35 000 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation of Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Internal Linkage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Functioning of Internal Levers fo Liftomatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
35 110 Mechanical Lift Assembly, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Rear LIft -- External Components, Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . 25
Hydraulic LIft -- Internal Controls, Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . 29
Lift Arm Shaft, Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Distributor, Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Adjustments and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
84261396 - 09 - 2009
Contents Continued:
STEERING SYSTEMS SECTION 41

Mechanical Steering Systems Chapter 1

41 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
41 101 Removal -- Installalation -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydrostatic Steering Systems Chapter 2

41 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
41 101 Steering Motor -- Removal and Installalation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
41 201 Two Wheel Drive Steering Cylinder -- Removal and Installalation . . . . . . . . . . . . . . . . . . . 28
Two Wheel Drive Steering Cylinder -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
FRONT AXLE SECTION 44

Two Wheel Drive Axle Chapter 1

44 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
44 101 Removal -- Installation -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front Wheel Setting Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
84261396 - 09 - 2009
Contents Continued:
ELECTRICAL SYSTEM SECTION 55

Electrical Introduction Chapter 1

55 100 Electrical System and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
55 000 System Precautions For Battery Charging and Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
55 100 Temporary Wiring Harness Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Analogue Instrument Cluster Chapter 2

55 100 Techinical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Starting System Chapter 3

55 100 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
55 201 Starter Motor, Removal -- Installation -- Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Charging System Chapter 4

55 100 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
55 301 Alternator, Removal -- Installation -- Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery Chapter 5

55 100 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
55 301 Battery, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
84261396 - 09 - 2009
Contents Continued:
Schematic Wiring Diagrams Chapter 6
Description Page
Fender lamp front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Aux output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fender lamp rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Main light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Harazd warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Trailer soket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
84261396 - 09 - 2009
SECTION 00 -- GENERAL -- CHAPTER 1 1
GENERAL INSTRUCTIONS
IMPORTANT NOTICE
All maintenance and repair operations described in this manual should be carried out exclusively by New Holland
authorised workshops. All instructions should be carefully observed and special equipment where indicated
should be used.
Anyone who carries out service operations described without carefully observing these prescriptions will be
directly responsible for any damage caused.
NOTES FOR EQUIPMENT

Equipment which NEW HOLLAND proposes and shows in this manual is:
-- studied and designed expressly for use on NEW HOLLAND tractors;
-- necessary to make reliable repair;
-- accurately built and strictly tested to offer efficient and long--lasting working life.
NOTICES
The words “front” , “rear” , “right hand” and “left hand” refer to the different parts as seen from the operator’s seat
oriented to the normal direction of movement of the tractor.
SAFETY RULES
PAY ATTENTION TO THIS SYMBOL

This warning symbol points out important messages involving personal safety.
Carefully read the safety rules contained herein and follow advised precautions to
avoid potential hazards and safeguarded your safety.
In this manual you will find this symbol together with the following key--words:
WARNING - It gives warning about improper repair operations and potential
consequences affecting the service technician’s personal safety.
DANGER - It gives specific warning about potential dangers for personal safety of
the operator or other persons directly or indirectly involved in the operation
TO PREVENT ACCIDENTS A wise and careful service technician is the best

Most accidents and personal injuries taking place in precautions against accidents.
workshops are due from non--observance of some Careful observance of this only basic precaution
essential rules and safety precautions. would be enough to avoid many severe accidents.
The possibility that an accident might occur with any DANGER
type of machines should not be disregarded, no Never carry out any cleaning, lubrication or
matter how well the machine in question was maintenance operations when the engine is running.
designed and built.
84261396-- 09 - 2009
2 SECTION 00 -- GENERAL -- CHAPTER 1
SAFETY RULES • All repair and maintenance operations should be

carried out with greatest care and attention.
Generalities • Disconnect the batteries and label all controls to
• Carefully follow specified repair and warn that the tractor is being serviced. Block the
maintenance procedures. machine and all equipment which should be
raised.
• Do not wear rings, wrist watches, jewels,
unbuttoned or flapping clothing such as ties, torn • Never check or fill fuel tanks or batteries, nor use
clothes, scarves, open jackets or shirts with open starting liquid if you are smoking or near open
zips which could get caught in moving parts. Use flames as such fluids are flammable.
approved safety clothing such as anti--slipping • The fuel filling gun should always remain in
footwear, gloves, safety goggles, helmets, etc. contact with filler neck. Maintain this contact until
• Wear safety glasses with side guards when the fuel stops flowing into the tank to avoid
cleaning parts using compressed air. possible sparks due to static electricity build--up.
• Damaged or frayed wires and chains are • To transfer a failed tractor, use a trailer of a low
unreliable. Do not use them for lifting or towing. loading platform trolley if available.
• Wear suitable protection such as approved eye • To load and unload the machine from the
protection, helmets, special clothing, gloves and transportation means, select a flat area providing
footwear whenever welding. All persons a firm support to the trailer or truck wheels. Firmly
standing in vicinity of the welding process should tie the machine to the truck or the trailer platform
wear approved eye protection. NEVER LOOK and block wheels as required by the transporter.
AT THE WELDING ARC IF YOUR EYES ARE • Always use lifting equipment of appropriate
NOT SUITABLY PROTECTED. capacity to lift or move heavy components.
• Never carry out any repair on the machine if • Chains should always be safely fastened.
someone is sitting on the operator’s seat, except Ensure that that fastening device is strong
they are qualified operators assisting in the enough to hold the load foreseen. No persons
operation to be carried out. should stand near the fastening point.
• Never operate the machine or use attachments • The working area should be always kept CLEAN
from a place other than sitting at the operator’s and DRY. Immediately clean any spillage of
seat or at the side of the machine when operating water or oil.
the fender switches. • Never use gasoline, diesel oil or other flammable
• Never carry out any operation on the machine liquids as cleaning agents. Use non--flammable
when the engine is running, except when non--toxic proprietary solvents.
specifically indicated. Stop the engine and • Do not pile up grease or oil soaked rags, as they
ensure that all pressure is relieved from hydraulic constitute a great fire hazard. Always place them
circuits before removing caps, covers, valves, into a metal container.
etc.
84261396 - 09 - 2009
START UP use a piece of cardboard or a piece of wood for

• Never run the engine in confined spaces which this purpose. If any fluid is injected into the skin,
are not equipped with adequate ventilation for seek medical aid immediately. Lack of immediate
exhaust gas extraction. medical attention may result in serious infections
or dermatitis.
• Never bring your body, arms, legs, feet, hands,
fingers near fans or rotating belts. • Always take system pressure readings using the
appropriate gauges.
ENGINE
WHEELS AND TYRES
• Always loosen the radiator cap very slowly
before removing it to allow pressure in the • Check that the tyres are correctly inflated at the
system to dissipate. Coolant should be topped pressure specified by the manufacturer.
up only when the engine is stopped. Periodically check for possible damage to the
rims and tyres.
• Do not fill up fuel tank when the engine is running.
• Stay a the tyre side when inflating.
• Never adjust the fuel injection pump when the
tractor is moving. Never lubricate the tractor • Check the pressure only when the tractor is
when the engine is running. unloaded and tyres are cold to avoid wrong
reading due to over-- pressure.
ELECTRICAL SYSTEMS • Never cut, nor weld a rim with the inflated tyre
assembled.
• If it is necessary to use auxiliary batteries, cables
• To remove the wheels, block both front and rear
must be connected at both sides as follows : (+)
tractor wheels. Raise the tractor and install safe
to (+) and (--) to (--). Avoid short--circuiting the
and stable supports under the tractor in
terminals. GAS RELEASED FROM
BATTERIES IS HIGHLY FLAMMABLE. During accordance with the regulations in force
charging, leave the battery compartment • Deflate the tyre before removing any object
uncovered to improve ventilation. Avoid sparks caught into the tyre tread.
or flames near the battery area. Do not smoke. • Never inflate tyres using flammable gases as
• Do not charge batteries in confined spaces. they may originate explosions and cause injuries
• Always disconnect the batteries before to bystanders.
performing any type of service on the electrical
system. REMOVAL AND INSTALLATION
• Lift and handle all heavy components using lifting
HYDRAULIC SYSTEMS equipment of adequate capacity. Ensure that
parts are supported by appropriate slings and
• Some fluid coming out from a very small port can
hooks. Use lifting eyes provided to this purpose.
be almost invisible and be strong enough to
penetrate skin. For this reason, NEVER USE Take care of the persons near the loads to be
YOUR HANDS TO CHECK FOR LEAKS, but lifted.
84261396-- 09 - 2009
HEALTH AND SAFETY
CONTENT

HEALTH AND SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ACIDS AND ALKALIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ADHESIVES AND SEALERS -- See Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ANTIFREEZE -- see Fire, Solvents e.g. Isopropanol, Ethylene Glycol, Methanol . . . . . . . 5
ARC WELDING -- see Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BATTERY ACIDS -- see Acids and Alkalis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) -- see Fire . . . . . . . . . . . . . . . . . . . . 6
BRAZING -- see Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHEMICAL MATERIALS -- GENERAL -- see Legal Aspects . . . . . . . . . . . . . . . . . . . . . . . . . 6
DO’S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DO NOTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CORROSION PROTECTION MATERIALS -- see Solvents, Fire . . . . . . . . . . . . . . . . . . . . 6
DUSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRIC SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EXHAUST FUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FIBRE INSTALLATION -- see Dusts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FIRE -- see welding, Foams, Legal Aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FOAMS -- Polyurethane -- see Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUELS -- see Fire, Legal Aspects, Chemicals -- General, Solvents . . . . . . . . . . . . . . . . . . . 8
GAS CYLINDERS -- see Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GENERAL WORKSHOP TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LEGAL ASPECTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LUBRICANTS AND GREASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PAINTS -- see Solvents and Chemical Materials -- Genera . . . . . . . . . . . . . . . . . . . . . . . . . 10
SOLDER -- see Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SOLVENTS -- see Chemical Materials -- General Fuels (Kerosene ), Fire . . . . . . . . . . . . 10
SUSPENDED LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WELDING -- see Fire, Electric Shock, Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
HEALTH AND SAFETY PRECAUTIONS them. The precautions necessary to avoid these
Many of the procedures associated with vehicle hazards are identified.
maintenance and repair involve physical hazards or The list is not exhaustive and all operations and
other risks to health. This section lists, procedures and the handling of materials, should be
alphabetically, some of these hazardous operations carried out with health and safety in mind.
and the materials and equipment associated with
84261396 - 09 - 2009
ACID AND ALKALIS -- See Battery acids, Anaerobic, Cyanoacrylate and other Acrylic
e.g. caustic soda, sulphuric acid. Adhesives
Used in batteries and cleaning materials. Many are irritant, sensitizing or harmful to the skin.
Some are eye irritants.
Irritant and corrosive to the skin, eyes, nose Skin and eye contact should be avoided and the
and throat. Causes burns. manufacturers’ instructions followed.
Avoid splashes to the skin, eyes and clothing. Wear Cyanaocrylate adhesives (super--glues) must not
suitable protective gloves and goggles. Can destroy contact the skin or eyes. If skin or eye tissue is
ordinary protective clothing. Do not breathe mists. bonded cover with a clean moist pad and get medical
Ensure access to water and soap is readily available attention. Do not attempt to pull tissue apart. Use in
for splashing accidents. well ventilated areas as vapours can cause irritation
of the nose and eyes.
For two--pack systems, See Resin based
adhesives/sealers.
ADHESIVES AND SEALERS -- See Fire
Isocyanate (Polyurethane) Adhesives/ Sealers
Highly Flammable, Flammable, combustible.
-- See Resin based Adhesives.
Generally should be stored in “ No Smoking” areas;
Individuals suffering from asthma or respiratory
cleanliness and tidiness in use should be observed,
allergies should not work with or near these materials
e.g. disposable paper covering benches; should be
as sensitivity reactions can occur.
dispensed from applicators where possible;
containers, including secondary containers, should Any spraying should preferably be carried out in
be labelled. exhaust ventilated booths removing vapours and
spray droplets form the breathing zone. Individuals
Solvent based Adhesive/Sealers -- working with spray applications should wear supplied
See Solvents. air respirators.
Follow manufacturer’s instructions.
Water base Adhesive/ Sealers

ANTIFREEZE -- See Fire, Solvents
Those based on polymer emulsions and rubber
e.g : Isopropanol, Ethylene Glycol, Menthol.
lattices may contain small amounts of volatile toxic
and harmful chemicals. Skin and eye contact should Highly Flammable, Flammable, Combustible.
be avoided and adequate ventilation provided during Used in vehicle cooling systems, brake air pressure
use. systems, screenwash solutions.
Follow manufacturers instructions. Vapours given off from coolant antifreeze (glycol)
arise only when heated.
Resin based Adhesives/Sealers -- Antifreeze may be absorbed through skin in toxic or
e.g. epoxide and formaldehyde resin based. harmful quantities. Antifreeze if swallowed is fatal
Mixing should only be carried out in well ventilated and medical attention must be found immediately.
areas as harmful or toxic volatile chemicals may be
released.
Skin contact with uncured resins and hardeners can
result in irritation; dermatitis and absorption of toxic ARC WELDING -- See Welding
of harmful chemicals through the skin. Splashes can
damage the eyes.
Provide adequate ventilation and avoid skin and eye
contact . Follow manufacturers’ instructions.
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.
84261396-- 09 - 2009
BRAKE AND CLUTCH FLUIDS (Polyalkylene DO NOTS

Glycols) -- See Fire Do not mix chemical materials except under the
Combustible. manufacturers’ instructions; some chemicals can
Splashes to the skin and eyes are slightly irritating. form other toxic or harmful chemicals; give off toxic
Avoid skin and eye contact as far as possible. or harmful fumes; be explosive when mixed together.
Inhalation of vapour hazards do not arise at ambient Do not spray chemical materials, particular those
temperatures because of the very low vapour based on solvents, in confined spaces e.g. when
pressure. people are inside a vehicle.
Do not apply heat or flame to chemical materials
except under the manufacturers’ instructions. Some
are highly inflammable and some may release toxic
BRAZING -- See Welding or harmful fumes.
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.
CHEMICAL MATERIALS -- GENERAL --
Do not transfer chemical materials to unlabelled
See Legal Aspects.
containers.
Chemical materials such as solvents, sealers,
Do not clean hands or clothing with chemical
adhesives, paints, resin foams, battery acids,
materials. Chemicals, particularly solvents and fuels
antifreeze, brake fluids, oils and grease should
will dry the skin and may cause irritation with
always be used with caution and stored and handled
dermatitis. Some can be absorbed through the skin
with care. They may be toxic, harmful, corrosive
in toxic or harmful quantities.
irritant or highly inflammable and give rise to
hazardous fumes and dusts. Do not use emptied containers for other materials,
except when they have been cleaned under
The effects of excessive exposure to chemicals may
supervised conditions.
be immediate or delayed; briefly experienced or
permanent; cumulative; superficial; life threatening Do not sniff or smell chemical materials. Brief
or may reduce life expectancy. exposure to high concentrations of fumes can be
toxic or harmful.
Clutch Fluids -- See Brake and Clutch Fluids.
DO’S
Clutch Linings and Pads -- See Brake and
Do remove chemical materials from the skin and Clutch Linings and Pads.
clothing as soon as practicable after soiling. Change
heavily soiled clothing and have it cleaned.
Do carefully read and observe hazard and
precaution warning given on material containers
(labels) and in any accompanying leaflets, poster or CORROSION PROTECTION MATERIALS --
other instructions. Material health and safety data See Solvents, Fire.
sheets can be obtained from manufacturers’. Highly flammable, flammable.
Do organise work practices and protective clothing These materials are varied and the manufactures’
to avoid soling of the skin and eyes; breathing instructions should be followed. They may contain
vapours/aerosols/dusts/fumes; inadequate solvents, resins, petroleum products etc. skin and
container labelling; fire and explosion hazards. eye contact should be avoided. They should only be
Do wash before job breaks; before eating, smoking, sprayed in conditions of adequate ventilation and not
drinking or using toilet facilities when handling in confined spaces.
chemical materials.
Do keep work areas clean, uncluttered and free of
spills.
Do store according to national and local regulations. Cutting -- See Welding
Do keep chemical materials out of reach of children.
De--Waxing -- See Solvents and Fuels (Kerosene).
84261396 - 09 - 2009
DUSTS Diesel Engine

Powder, dusts or clouds may be irritant, harmful or Soot, discomfort and irritation usually give adequate
toxic. Avoid breathing dusts from powdery chemical warning of hazardous fume concentrations.
materials or those arising from dry abrasion
operations. Wear respiratory protection if ventilation
is inadequate.
FIBRE INSULATION -- See Ducts.
Used in noise and sound insulation.
The fibrous nature of surfaces and cut edges can
ELECTRIC SHOCK cause skin irritation. This is usually a physical and not
Electric shocks can result from the use of the faulty a chemical effect.
electrical equipment or from the misuse of Precautions should be taken to avoid excessive skin
equipment even in good condition. contact through careful organisation of work
Ensure that electrical equipment is maintained in practices and the use of gloves.
good condition and frequently tested.
Ensure that flexes, cables, plugs and sockets are not
frayed, kinked, cut, cracked or otherwise damaged.
Ensure that electric equipment is protected by the FIRE -- See Welding, Foams, Legal Aspects.
correct rated fuse.
Many of the materials found on or associated with the
Never misuse electrical equipment and never use repair of vehicles are highly inflammable. Some give
equipment which is in anyway faulty. The results off toxic or harmful fumes if burnt.
could be fatal.
Observe strict fire safety when storing and handling
Use reduced voltage equipment where possible in flammable materials or solvents, particularly near
preference to electrical equipment. electrical equipment or welding processes.
In cases of electrocution:-- Ensure before using electrical or welding equipment
-- switch off electricity before approaching victim but that there is no fire hazard present.
-- if this is not possible, push or drag victim from Have suitable fire extinguisher available when using
source of electricity using dry non--conductive welding or heating equipment.
material
-- commence resuscitation if trained to do so.
-- SUMMON MEDICAL ASSISTANCE
FIRST AID
Apart from meeting any legal requirements its i
desirable for someone in the workshop to be trained
EXHAUST FUMES in first aid procedures.
These contain asphyxiating, harmful and toxic Splashes in the eye should be flushed with clean
chemicals and particles such as carbon oxides, water for at least ten minutes.
nitrogen oxides, aldehydes, lead and aromatic Soiled skin should be washed with soap and water.
hydrocarbons. Engines should only be run under Inhalation affected individuals should be removed to
conditions of adequate extraction or general fresh air immediately.
ventilator and not in confined spaces.
If swallowed or if effects persist consult a doctor with
information (label) on material used.
Gasolene (Petrol) Engine
Do not induce vomiting (unless indicated by
There may not be adequate warning properties of manufacturer)
odour or irritation before immediate and delayed
toxic or harmful effects arise.
FOAMS -- See Fire.

Used in sound and noise insulation. Cured foams
used in seat and trim cushioning.
Follow manufacturers’ instructions.
84261396-- 09 - 2009
Un reacted components are irritating and may be Special precautions apply to cleaning and
harmful to the skin and eyes. Wear gloves and maintenance operations on gasolene storage tanks.
goggles. Gasolene should not be used as a cleaning agent.
Individuals with chronic respiratory diseases, It must not be siphoned by mouth.
asthma, bronchial medical problems or histories of
allergic diseases should not work with or near
uncured materials.
The components, vapours, spray mists can cause Kerosene (Paraffin)
direct irritation, sensitivity reactions and may be Used also as heating fuel, solvent and cleaning
toxic or harmful. agent.
Vapours and spray mists must not be breathed. Flammable.
These materials must be applied with adequate
ventilation and respiratory protection. Do not remove Irritation of the mouth and throat may result from
respirator immediately after spraying, wait until swallowing. The main hazard from swallowing arises
vapour/ mists have cleared. if liquid aspiration into the lungs occurs. Liquid
contact dries the skin and can cause irritation or
Burning of the uncured components and the cured dermatitis. Splashes in the eye may be slightly
foams can generate toxic and harmful fumes. irritating.
Smoking, open flames or the use of electrical In normal circumstances the low volatility does not
equipment during foaming operations and until give rise to harmful vapours. Exposure to mists and
vapours/mists have cleared should not be allowed. vapours from kerosene at elevated temperatures
Any heat cutting of cured foams or partially cured -- should be avoided (mists may arise in de--waxing).
foams should be conducted with extraction Avoid skin and eye contact and ensure there is
ventilation (see Body Section 44 Legal and Safety adequate ventilation.
Aspects).
Gas--Oil (Diesel Fuel) --See Fuels (Kerosene).

FUELS -- See Fire, Legal Aspects, Chemicals --
General, Solvents. Combustible.
Used as fuels and cleaning agents. Gross or prolonged skin contact with high boiling gas
oils may also cause serious skin disorders including
skin cancer.
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 GAS CYLINDERS --See Fire.
can be fatal to children. Aspiration of liquid into the Gases such as oxygen, acetylene, carbon dioxide,
lungs, e.g. through vomiting, is a very serious argon and propane are normally stored in cylinders
hazard. at pressures of up to 2000 Ib/sq. in. (13,790 kn/m2)
Gasolene dries the skin and can cause irritation and and great care should be taken in handling these
dermatitis on prolonged or repeated contact. Liquid cylinders to avoid mechanical damage to them or to
in the eye causes severe smarting. the valve gear attached. The contents of each
cylinder should be clearly identified by appropriate
Motor gasolene may contain appreciable quantities markings.
of benzene, which is toxic upon inhalation and the
concentrations of gasolene vapours must be kept. Cylinders should be stored in well ventilated
very low. High concentrations will cause eye, nose enclosures, and protected from ice and snow, or
and throat irritation, nausea, headache, depression direct sunlight. Fuel gases (e.g. acetylene and
and symptoms of drunkenness. Very high propane) should not be stored in close proximity to
concentrations will result in rapid loss of oxygen cylinders.
consciousness. Care should be exercised to prevent leaks from gas
Ensure there is adequate ventilation when handling cylinders and lines, and to avoid sources of ignition.
and using gasolene. Great care must be taken to Only trained personnel should undertake work
avoid the serious consequences of inhalation in the involving gas cylinders.
event of vapour build up arising from spillages in
confined spaces.
84261396 - 09 - 2009
Gases --See Gas Cylinders. LEGAL ASPECTS

Many laws and regulations make requirements
relating to health and safety in the use of materials
Gas Shielded Welding --See Welding. and equipment in workshops.
Workshops should be familiar, in detail, with
associated laws and regulations. Consult local
Gas Welding --See Welding. factory inspectorate if in any doubt.
GENERAL WORKSHOP TOOLS AND LUBRICANTS AND GREASES

EQUIPMENT Avoid all prolonged and repeated contact with
It is essential that all tools and equipment are mineral oils, especially used oils. Used oils
maintained in good condition and the correct safety contaminated during service (e.g. routine service
equipment used where required. change sump oils) are more irritating and more likely
to cause serious effects including skin cancer in the
Never use tools or equipment for any purpose other event of gross and prolonged skin contact.
than that for which they were designed.
Wash skin thoroughly after work involving oil.
Never overload equipment such as hoists, jacks, Proprietary hand cleaners may be of value provided
axle and chassis stands or lifting slings. Damage they can be removed from the skin with water. Do not
caused by overloading is not always immediately use petrol, paraffin or other solvents to remove oil
apparent and may result in a fatal failure the next time from the skin.
that the equipment is used.
Lubricants and greases may be slightly irritating to
Do not use damaged or defective tools or equipment, the eyes.
particularly high speed equipment such as grinding
wheels. A damaged grinding wheel can disintegrate Repeated or prolonged skin contact should be
without warning and cause serious injury. avoided by wearing protective clothing if necessary.
Particular care should be taken with used oils and
Wear suitable eye protection when using grinding, greases containing lead. Do not allow work clothing
chiselling or sand blasting equipment to be contaminated with oil. Dry clean or launder
Wear a suitable breathing mask when using sand such clothing at regular intervals. Discard oil soaked
blasting equipment, working with asbestos based shoes.
materials or using spraying equipment 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
Glues --see Adhesives and Sealers. accordance with local regulations.
There are publications describing the problems and
advising on precautionary measures.
High Pressure Air, Lubrication and Oil Test
Equipment --See Lubricants and Greases.
Always keep high pressure equipment in good
condition and regularly maintained, particularly at Noise Insulation Materials --See Foams, Fibre
joints and unions. Insulation.
Never direct a high pressure nozzle at the skin as the
fluid may penetrate to the underlying tissue etc. and
cause serious injury.
84261396-- 09 - 2009
PAINTS --See Solvents and Chemical Materials -- which can give toxic effects if inhaled. Respiratory
General. protection may be necessary.
Highly Flammable, Flammable. Solder spillage and filing should be collected and
One Pack. Can contain harmful or toxic pigments, removed promptly to prevent general air
driers and other components as well as solvents. contamination by lead.
Spraying should only be carried out with adequate High standards of personal hygiene are necessary in
ventilation. order to avoid indigestion of lead or inhalation of
Two Pack. Can also contain harmful and toxic solder dust from clothing.
unreacted resins and resin hardening agents. The
manufacturers instructions should be followed and
the section of page 5 on resin based adhesives,
isocyanate containing Adhesives and Foams should SOLVENTS --See Chemical Materials --General
be consulted. Fuels (Kerosene), Fire.
Spraying should preferably be carried out in e.g. Acetone, white spirit, toluene, xylene,
exhausted ventilated booths removing vapour and trichlorethane.
spray mists from the breathing zone. Individuals
working in booths should wear respiratory protection. Used in cleaning materials, de--waxing, paints,
Those doing small scale repair work in the open shop plastics, resins, thinners etc.
should wear supplied air respirators. Highly Inflammable, Flammable.
Skin contact will degrease the skin and may result in.
--irritation and dematitis following repeated or
Paint Thinners --See Solvents. prolonged contact. Some can be absorbed through
the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation and
could lead to loss of vision.
Petrol --See Fuels (Gasolene).
Brief exposure to high concentrations of vapours or
mists will cause eye and throat irritation, drowsiness,
dizziness, headaches and in the worst
Pressurised Equipment --See High Pressure Air, circumstances, unconsciousness.
Lubrication and Oil Test Equipment.
Repeated or prolonged exposures to excessive but
lower concentrations of vapours or mists, for which
there might not be adequate warning indications, can
Resistance Welding --See Welding. cause more serious toxic or harmful effects.
Aspiration into the lungs (e.g. through vomiting) is
the most serious consequence of swallowing.
Sealers --See Adhesives and Sealers. 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
SOLDER --See Welding. tightly sealed. Do not use in confined spaces.
Solders are mixtures of metals such that the melting When the spraying material contains solvents, e.g.
point of the mixture is below that of the constituent paints, adhesives, coatings, use extraction
metals (normally lead and tin). Solder application ventilation or personal respiratory protection in the
does not normally give rise to toxic lead fumes, absence of adequate general ventilation.
provided a gas/air flame is used. Oxy--acetylene Do not apply heat or flame except under specific and
flames should not be used, as they are much hotter detailed manufacturers instructions.
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 Sound Insulation --See Fibre Insulation, Foams.
inhalation of these should be avoided.
Removal of excess solder should be undertaken with
care, to ensure that fine lead dust is not produced, Spot Welding --See Welding.
84261396 - 09 - 2009
SUSPENDED LOADS. applied coatings or contamination on the surfaces

There is always a danger when loads are lifted or being worked on. These gases and fumes may be
suspended. Never work under an unsupported toxic and inhalation should always be avoided. The
suspended or raised load, e.g. jacked up vehicle, use of extraction ventilation to remove the fumes
suspended engine, etc. from the working area may be necessary, particularly
in cases where the general ventilation is poor, or
Always ensure that lifting equipment such as jacks, where considerable welding work is anticipated. In
hoists, axle stands, slings, etc. are adequate and extreme cases where adequate ventilation cannot be
suitable for the job, in good condition and regularly provided, supplied air respirators may be necessary.
maintained.
Gas Welding
Never improvise lifting tackle.
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
Underseal --See Corrosion Protection. and explosion.
The process will produce metal spatter and eye and
skin protection is necessary.
The flame is bright and eye protection should be
WELDING --See Fire, Electric Shock, Gas used, but the ultra--violet emission is much less than
Cylinders. that from arc welding, and lighter filters may be used.
Welding processes include Resistance Welding The process itself produces few toxic fumes, but
(Spot Welding), Arc Welding and Gas Welding. 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.
Resistance Welding
In brazing, toxic fumes may be evolved from the
This process may cause particles of molten metal to
metals in the brazing rod, and a severe hazard may
be emitted at high velocity and the eyes and skin
arise if brazing rods containing cadmium are used.
must be protected.
In this event particular care must be taken to avoid
inhalation of fumes and expert advice may be
required.
Arc Welding SPECIAL PRECAUTIONS MUST BE TAKEN
This process emits a high level of ultraviolet radiation BEFORE ANY WELDING OR CUTTING TAKES
which may cause eye and skin burns to the welder PLACE ON VESSELS WHICH HAVE CONTAINED
and to other persons nearby. Gas--shielded welding COMBUSTIBLE MATERIALS, E.G. BOILING OR
processes are particularly hazardous in this respect. STEAMING OUT OF FUEL TANKS.
Personal protection must be worn, and screens used
to shield other people.
Metal spatter will also occur and appropriate eye and White Spirit --See Solvents.
skin protection is necessary.
The heat of the welding arc will produce fumes and
gases from the metals being welded and from any
84261396-- 09 - 2009
NEW
HOLLAND
CONTENTS - SECTION 10
ENGINE SECTION 10
Engine System Chapter 1

10 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine stripdown -- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10 001 Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Front Cover and Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Connecting Rods, Bearings, Pistons and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Cylinder Block Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Main Bearing and Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
84261396 - 09 - 2009
SECTION 10 -- ENGINE -- CHAPTER 1 1
SECTION 10 -- ENGINE
Chapter 1 -- Engine System
CONTENT
ENGINE SECTION 10

10 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine stripdown -- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10 001 Engine Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Front Cover and Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Connecting Rods, Bearings, Pistons and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Cylinder Block Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Main Bearing and Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
84261396- 09 - 2009
2 SECTION 10 -- ENGINE -- CHAPTER 1
GROUP 10 -- GENERAL FEATURES AND SPECIFICATIONS

GENERAL SPECIFICATIONS
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simpsons
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 stroke, diesel, naturally
aspirated, direct injection,
water cooled
Power
TT45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HP 47 (BS Au 141a:1971)
. . . . . . . . . . . . . TT40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HP 42 (BS Au 141a:1971)
. . . . . . . . . . . . . TT35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HP 35 (BS Au 141a : 971)
No of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bore
TT45/TT40/ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 91.44
TT35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 88.9
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 127
Cubic Capacity
TT45/TT40/ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3 2500
TT35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3 2400
Compression Ratio
TT45/TT40/ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5:1
TT35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5:1
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 2 -- 3
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RPM 650 -- 700
Maximum no Load Speed
TT45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RPM 2530
TT35/TT40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RPM 2000
Rated Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RPM
TT45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RPM 2300
TT35/TT40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RPM
2000
Height of Cylinder Block between Top and Bottom Faces . . . . . . . mm 349.01/349.08
Parent Bore Dia. for Cylinder Sleeves . . . . . . . . . . . . . . . . . . . . . . . . mm 93.66/93.69
Depth of Recess of Sleeves Flange (Cast iron sleeves) . . . . . . . . . mm 3.76/3.86
Dia. Recess of Sleeves Flange (Cast Iron sleeves) . . . . . . . . . . . . . mm 97.16/97.03
Main Bearing Parent Bore Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 74.08/74.10
Camshaft Bore Dia. -- No.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 47.60/47.68
CYLINDER SLEEVES--CAST IRON
Sleeve Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry--Interference Fit
Outside Dia. for Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 93.71/93.74
Interference Fit of Sleeve in Block . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.03/0.08
Inside Dia. of Finished Sleeve in Block
TT45/TT40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 91.48/91.50
TT35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 88.93/88.96
Outside Dia. of Sleeve Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 96.60/96.72
Flange Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 3.76/3.81
Depth of Sleeve Flange relative of Top Face of Cylinder block . . . mm +0.05/--0.10
NOTE: Reboring to oversize is not possible
84261396 - 09 - 2009
PISTONS
Type
TT45/TT40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alfin Piston with Re--entrant
bowl in crown.
TT35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alfin Piston withRe--entrant
bowl in crown
Piston Height in relation to Cylinder Block Top Face . . . . . . . . . . . . mm 0.10 above 0.0254 below
Bore Dia. for Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 31.7525/31.7462
Top and 2nd Ring Groove width
TT45/TT40/ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2.43/2.46
TT35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2.43/2.45
rd
3 Ring Groove width
TT45/TT40/ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 4.81/4.84
TT35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 4.80/4.82
PISTON RINGS
Top Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chrome Inlaid Steel ring --
parralel faced
2nd Compression
TT45/TT40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast Iron -- Taper land,
TT35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast Iron -- internally stepped.
rd
3 Oil Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chrome plated --
Parallel faced conformable oil
control ring.
Top and 2nd Ring Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2.36/2.38
3rd Ring Width
TT45/TT40/ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 4.737/4.763
TT35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 4.724/4.775
Top, 2nd and 3rd Ring Clearance in Groove . . . . . . . . . . . . . . . . . . . mm 0.05/0.10
Ring Gap Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.36/0.61
Ring Gap -- 2nd
TT45/TT40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.28/0.52
TT35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.28/0.51
Ring Gap -- 3rd
TT45/TT40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.36/0.48
TT35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.36/0.46
The ring gaps quoted above are for a bore diameter of 91.48 mm (TT45/TT40 model) & 88.93 (TT35 model).
When checking ring gaps in a worn bore, 0.08 mm should be added to these ring gaps for every 0.03 mm increase
in bore diameter
NOTE: In a worn cylinder, ring gap should be checked at the bottom of cylinder.
PISTON PINS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully Floating
Outside Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 31.74/31.750
Fit in Piston Boss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transition
SMALL END BUSHES
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel Backed, Lead Bronze
Lined
Outside Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 35.01/35.05
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 26.42/26.87
Inside Dia. after Reaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 31.76/31.79
Clearance, Bushing to Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.01/0.04
84261396- 09 - 2009
CONNECTING RODS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . “H” Section
Big End Parent Bore Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 60.83/60.85
Small End Parent Bore Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 34.92/34.96
Big End Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 39.38/39.43
Big End Side Clearence on Crankpin . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.24/0.50
Length Between Bore Centres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 223.81/223.86
Permissible Connecting Rod bend
(measured at a distance of 127 mm)
Without Small End Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . mm + 0.25
With Small End Bush fitted . . . . . . . . . . . . . . . . . . . . . . . . . mm + 0.06
NOTE: The numbered side on connecting rod and cap should be on the fuel injection pump side
CONNECTING ROD BEARINGS

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre--finished, Steel Backed.
Aluminium Tin/ Copper Lead
Inside Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 57.19/57.21
Bearing Running Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.06/0.10
CRANKSHAFT
Main Journal Dia. (std.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 69.81/69.83
Main Journal Length--Nos.2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 30.85/31.06
Main Journal Length--Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 46.80/46.88
Main Journal Fillet Radius (Except Last Main Journal) . . . . . . . . . . mm 3.17/3.56
Last Main Journal Fillet Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 3.97/4.22
Crank Pin Dia. (Std.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 57.11/57.13
Crank Pin Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 39.67/39.88
Crank Pin Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 4.76/5.16
Surface Finish--All Pins and Journals . . . . . . . . . . . . . . . . . . . . . . . . . micron 0.4 (max)
s 0.05/0.38
Crankshaft End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.25, 0.51, 0.76
Re--grind Undersize--Main Journals and Pins . . . . . . . . . . . . . . . . . . mm
CRANKSHAFT THRUST WASHER
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre--finished Steel Backed,
Position in Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aluminium Tin/Copper Lead
Cylinder Block, Rear Main
Thrust Washer Thickness--Standard . . . . . . . . . . . . . . . . . . . . . . . . . mm Bearing Housing
Thrust Washer Thickness--Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . mm 3.07/3.12
3.26/3.31
MAIN BEARING
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre--finished Steel Backed,
Aluminium Tin/Copper Lead
Inside Dia. (Fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 69.90/69.94
Main Bearing Running Clearence . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.686/0.127
84261396 - 09 - 2009
CAMSHAFT
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Polydine
No. 1 Journal Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 47,47/47.50
Running Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.10/0.20
No. 2 Journal Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 47.22/47.24
No.3 Journal Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 46.71/46.74
Cam Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 7.90/7.98
Gear--Spigot Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 50.76/50.79
Oil ways for Rocker Shaft Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . No.2 Cam Journal
CYLINDER HEAD
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 75.82/76.58
Leak Test Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
kgf/cm2 36
Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ 15.86/15.895
Tappet Bore in Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 12.69/12.71
Valve Guide Bore in Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . mm
0.076 (max)
Permissible Cylinder Head Bow--Transverse . . . . . . . . . . . . . . . . . . mm
0.152 (max)
Longitudinal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
0.30 (max)
Skimming Allowance on Head Face . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Provided Nozzle Protrusion
does not exceed 4.67 mm
after Skimming
I,EE,II,E
Valve Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE GUIDES
Inside Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 7.99/8.02
Outside Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 12.73/12.75
Overall Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 56.36
Guide Protrusion above Spring Seating Face . . . . . . . . . . . . . . . . . . mm 9.19/9.55
Interference fit of guide in Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.04/0.08
INLET VALVE
Valve Stem Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 7.90/7.92
Clearance Fit of Valve in Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.071/0.12
Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ 35
Valve Head Depth below Cylinder Head Face . . . . . . . . . . . . . . . . . mm 1.27/1.57
Not to exceed 1.83 mm after
regrinding
EXHAUST VALVE
Valve Stem Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 7.90/7.92
Clearance Fit of Valve in Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.071/0.12
Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ 35
Valve Head Depth below Cylinder Head Face . . . . . . . . . . . . . . . . . mm 1.54/1.88
Not to exceed 2.11 mm after
regrinding.
NOTE: Valve Stem Seal (with metal insert) is fitted in both Inlet and Exhaust Valves.
84261396- 09 - 2009
VALVE SPRINGS
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 45.29/45.80 mm
Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 38.10 mm
Load at Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kg 10.34 + 0.90
TAPPETS
Outside Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 15.80/15.84
Clearance fit in Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.02/0.09
ROCKER SHAFT
Outside Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 15.806/15.845
ROCKER LEVERS
Bore Dia. Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 15.86/15.89
Clearance Fit on Rocker Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.017/0.09
CAMSHAFT GEAR
No. of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Gear Bore Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 50.79/50.83
Clearance Fit of Gear on Spigot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.00/0.06
IDLER GEAR AND HUB
No. of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Gear Bore Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 53.98/54.02
Dia. of Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 53.92/53.94
Clearance of Gear of Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.03/0.09
Gear Hub Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 33.47/33.59
Length of Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 33.72/33.85
Gear End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.13/0.38
CRANKSHAFT GEAR
No. of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Dia. of Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 38.09/38.13
Spigot Dia. of Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 38.10/38.11
Transition Fit of Gear on Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.03/0.03
84261396 - 09 - 2009
FUEL PUMP GEAR

No. of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Dia of Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 44.45/44.47
Pump Adaptor Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 44.21/44.40
Clearence Fit of Gear on Spigot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.058/0.26
TIMING OIL PUMP IDLER GEAR
Inside Dia. of Gear Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 19.05/19.08
Outside Dia. of Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 19.10/19.14
Interference Fit of Bush in Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.03/0.09
Inside Dia. of Bush--Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 16.67/16.69
Dia. of Gear Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 16.63/16.64
Running Clearance of Gear on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.02/0.061
Gear End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.20/0.58
LUBRICATING OIL PUMP DRIVE GEAR
Internal Dia of Gear Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 12.60/12.63
Pump Drive Shaft Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 12.67/12.69
Interference Fit of Gear on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.05/0.08
LUBRICATING OIL PUMP CLEARANCES
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotor
Inner Rotor to Outer Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.01/0.06
Inner Rotor End Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.04/0.08
Outer Rotor End Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.01/0.06
Outer Rotor to Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.28/0.33
LUBRICATING OIL RELIEF VALVE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring Loaded Plunger
Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kgf/cm2 3.52/4.57
LUBRICATING OIL FILTER
Type of Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full flow,
Spin on type element
Bypass Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kgf/cm2 0.91/1.20
LUBRICATING OIL
Capacity -- Oil Sump only
4510/4010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ltrs 7.8
3510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ltrs 7.8
Capacity -- Oil Sump and Filter
4510/4010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ltrs 8.3
3510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ltrs 8.3
Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . API CF4 SAE 20W 40
84261396- 09 - 2009
COOLING SYSTEM
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermo Syphon--Pressurised,
recirculating by--pass
Coolant Capacity--Engine Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ltrs 4.8
Total Capacity -- Engine and Radiator . . . . . . . . . . . . . . . . . . . . . . . . Ltrs 8.7
Radiator Pressure Cap Opening Pressure . . . . . . . . . . . . . . . . . . . bar/p.s.i 0.89/13
THERMOSTAT
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wax / Bellows
Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _C 75 + 2
Fully Open Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _C 89 + 2
WATER PUMP
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal
Pulley Bore Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 15.85 / 15.87
Shaft Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 15.91 / 15.92
Interference Fit of Pulley on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.04 / 0.07
Impeller Bore Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 15.88 / 15.89
Interference Fit of Pulley on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.01 / 0.04
Clearance between Impeller Blades and Body . . . . . . . . . . . . . . . . . mm 0.25 / 0.51
Distance between Impeller Rear Face and Pulley Front Face . . . . mm 140.5 + 0.38
FUEL SYSTEM
Fuel Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel oil should conform to
IS : 1460 / 2000
Special grade or grade A
Fuel Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Filter (spin on type)
Fuel Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plunger type, Flange mounted
on Fuel Injection Pump and
driven by Camshaft
ALTERNATOR
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PMP
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F002 G1B O34
System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V 14 -- 12
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative earth
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Max. Output Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Amp 23
STARTER MOTOR
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MICO
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IF 12V 2.7KW
System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V 12
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
No. of Teeth on Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 or 11
Starter Cable Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ω 0.0017 (max)
84261396 - 09 - 2009
TIGHTENING TORQUES
Description Thread size Torque (kgf)

TT45/TT40 TT35
Cylinder Head Nuts and Setscrews (non retorque type) 7/16 -- 20 UNF 10.8 10.8
Connecting Rod Nuts (cadmium plated) . . . . . . . . . . . . . 7/16 -- 20 UNF 6.1 6.1
--do-- (Phosphated) . . . . . . . . . . . . . . . . 7/16 -- 20 UNF 8.3 8.1
Main Bearing Setscrews . . . . . . . . . . . . . . . . . . . . . . . . . . M14 X 2 15.9 15.6
Balance Weight Setscrews . . . . . . . . . . . . . . . . . . . . . . . . 7/16 -- 20 UNF 7.6 7.5
Idler Gear Retaining Setscrew . . . . . . . . . . . . . . . . . . . . . M12 X 1.5 6.9 6.8
Camshaft Gear retaining Setscrews . . . . . . . . . . . . . . . . M8 X 1.25 2.9 2.9
F.I Pump Gear to Adapter Setscrew . . . . . . . . . . . . . . . . M8 X 1.25 2.9 2.9
Flywheel Setscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 X 1.25 11.1 10.8
Crankshaft Pulley retaining Setscrew . . . . . . . . . . . . . . . M22 X 2.5 15.2 14.9
Injector Securing Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 X 1.00 1.7 1.6
Engine to front support buckle up bolts . . . . . . . . . . . . . M16 X 2 22 22
Engine to clutch housing buckle up bolts . . . . . . . . . . . . M12 X 1.5 9 9
Support Radiator to Engine Setscrew . . . . . . . . . . . . . . . M10 X 1.25 4.5 4.5
Fuel Tank Support Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 X 1.25 8 8
Fuel Tank Support Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 X 1 3.2 3.2
Fan Assembly Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 X 1 2.6 2.6
Hydraulic Pump to Coupler Setscrew . . . . . . . . . . . . . . . M8 X 1 3 3
Hydraulic Pump assy. Bolt . . . . . . . . . . . . . . . . . . . . . . . . Hex. 3/8” 2.5 2.5
Radiator assy. Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 X 1.5 3 3
Air Cleaner to Bracket Set screw . . . . . . . . . . . . . . . . . . . M10 X 1.5 5 5
Air Cleaner Bracket to Shell Nut . . . . . . . . . . . . . . . . . . . M10 X 1.5 3.2 3.2
Starter motor mounting bolts . . . . . . . . . . . . . . . . . . . . . . M10 X 1.5 7.4 7.4
Alternator mounting bracket nuts . . . . . . . . . . . . . . . . . . . M10 X 1.25 4 4
Alternator hinge bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 X 1.5 8 8
Fan belt tension adjusting bolt . . . . . . . . . . . . . . . . . . . . . M8 X 1.25 2.4 2.4
84261396- 09 - 2009
SEALANTS
Equivalent
Loctite
Operation Description Anabond / Other
Specification
specfication
Injector mounting Stud . . . . . . . . . . . . . . . . . . . . . . . . . .
Front lift hook retaining Stud . . . . . . . . . . . . . . . . . . . . .
Water outlet body retaining Stud . . . . . . . . . . . . . . . . . .
Cylinder Block Stud fitment (Cam side) . . . . . . . . . . . .
Cylinder Block Stud fitment (FIP side) . . . . . . . . . . . . .
FIP mounting Stud on timing Case . . . . . . . . . . . . . . . .
Loctite -- 577 Anabond 340
Timing Case joint with cylinder block . . . . . . . . . . . . . .
Alternator lever retaining Stud . . . . . . . . . . . . . . . . . . . .
Timing Case Cover mounting Stud Fitment on Bridge
piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water pump mounting Stud on Timing Case cover . .
Cylinder Block to Sump Fitment Stud . . . . . . . . . . . . . .
Rocker Shaft retaining Stud . . . . . . . . . . . . . . . . . . . . . .
Loctite -- 262 Evertite TL -- 175
Fitment of all water Jacket plugs at rear side . . . . . . .
Water Jacket Plug Fitment . . . . . . . . . . . . . . . . . . . . . . . Loctite -- 603 Anabond 412
Pressure Rail Hole Plug Fitment . . . . . . . . . . . . . . . . . . Loctite -- 262 Epoxite resin
Rear main Bearing cap ‘O’ ring fitment . . . . . . . . . . . . .
Rear End Oil Seal joint with Cylinder Block . . . . . . . . .
Suction Pipe with joint Fitment . . . . . . . . . . . . . . . . . . . .
Loctite -- 596 Anabond 666
Front and rear neck packing corners . . . . . . . . . . . . . .
Timing Case Cover joint on both sides . . . . . . . . . . . . .
Lubrication Oil Filler joint -- both sides . . . . . . . . . . . . .
Fitment of rear end Oil Seal with Crankshaft flange . . OKS -- 1110 Morykote -- 111
Inlet Manifold joint Fitment . . . . . . . . . . . . . . . . . . . . . . .
Loctite -- 205 --
Tapper Cover fitment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water outlet body Allen Plug Fitment . . . . . . . . . . . . . . Loctite -- 577 Shellac
Fitment of Housing with Cylinder Block . . . . . . . . . . . . Loctite 510 --
Seal Air Deflector -- Radiator . . . . . . . . . . . . . . . . . . . . .
Hightack -- 98 D Anabond -- 870
Between Fuel Tank Clamp and protecting . . . . . . . . . .
Fuel Tank Support Bolt on Starter Motor side . . . . . . . Loctite -- 243 --
Buckle up of Engine and Clutch Housing . . . . . . . . . . Loctite -- 574 --
84261396 - 09 - 2009
SPECIAL TOOLS
List of special tools necessary to perform service operations coverd by this section of the Manual. For more
details Special Tools usage, Please refer fo the “SPECIAL TOOLS APPLICATION MANUAL”
CAUTION
Operations described in this section of the manual
must be perfiormed using the following ESSENTIAL
TOOLS, to work safely and achieve the best
technical results with additional saving of time and
effort.
Tool Description Tool Number

Injector Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290284
Sling hook, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290740
Cylinder Head Valve Spring Compressor . . . . . . . . . . . . . . . . . . . . . . . 291050
Tractor splitting Trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292320
Installer rear Main Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9970846
Installer Front Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9970845
Dummy Injector (Compression test kit) . . . . . . . . . . . . . . . . . . . . . . . . . 9970847
Swan Neck Pipe (fuel timing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9970848
Engine mounting bracket (to be used with engine stand 293860) . . . 9970844
Steering Wheel Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82834312
Bushes for Steering Wheel Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9971375
Remover injector . . . . . 9971238
Cylinder pressure test Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Local
Lube pressure check Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Local
Piston Ring Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Local
Piston Ring Expander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Local
84261396- 09 - 2009
TROUBLE SHOOTING
The following table lists problems and their possible causes with recommended remedial action.
IMPORTANT: When attending a repair the cause of the problem must also be investigated and corrected to avoid
repeat failures.
PROBLEM POSSIBLE CAUSES REMEDY
Low cranking 1. Battery capacity low 1. Charge or renew the battery
speed 2. Bad electrical connections 2. Check the connections or renew
electricals
3. Faulty starter motor 3. Overhaul starter motor
4. Lubricating Oil of incorrect grade 4. Drain and refill with specified grade
of oil
Engine does not 1. Low cranking speed 1. See Problem -- Low Cranking
start speed
2. Fuel tank empty 2. Fill the tank with fuel
3. Faulty stop control operation 3. Check the stop control cable
movement and setting
4. Blocked fuel feed pipe 4. Clean the pipe
5. Faulty fuel feed pump 5. Overhaul fuel feed pump
6. Choked fuel filters 6. Renew filter elements
7. Air in fuel system 7. Remove air lock
8. Faulty fuel injection pump 8. Overhaul injection pump
9. Faulty injectors 9. Overhaul injectors
10. Broken fuel injection pump drive 10. Fit new drive
11. Incorrect fuel pump timing 11. Check and reset
12. Incorrect valve timing 12. Check and reset
13. Poor compression 13. See Problem -- Poor Compression
14. Incorrect type or grade of fuel 14. Drain and refill with correct
type / grade of fuel
15. Worn cylinder bores 15. Re--bore/re--sleeve block and fit
new pistons
16. Pitted valve/s and seat/s 16. Replace valve with new standard
or oversize, and/or machine the
valve guide bores
17. Broken, worn or sticking piston 17. Fit new ring/s, check bore and
ring/s pistons for damage
84261396 - 09 - 2009
Difficult starting 1. Low cranking speed 1. See Problem -- Low Cranking

Speed
2. Faulty stop control operation 2. Check the stop control cable
3. Blocked fuel feed pipe 3. Clean
5. Choked fuel filters 5. Renew filter elements
6. Restriction in air cleaner or 6. Check and clean/remove the
induction system restriction
13. Blocked fuel tank vent 13. Clean
14. Incorrect type or grade of fuel 14. Drain the fuel and refill with correct
grade of fuel
15. Exhaust pipe restriction 15. Check and clean/remove the
restrictions
16. Sticking valves 16. Replace valve with new standard
valve guide bores
new pistons
18. Pitted valves and seats 18. Replace valve with new standard
valve guide bores
19. Broken, worn or sticking piston 19. Fit new rings, check bore and
84261396- 09 - 2009
Lack of power 1. Blocked fuel feed pipe 1. Clean the pipe

3. Choked fuel filters 3. Remove Filter components
11. Blocked fuel tank vent 11. Clean
12. Incorrect type/grade of fuel 12. Drain the fuel and refill with correct
grade of fuel
13. Sticking throttle or restricted 13. Check, clean, lubricate and adjust
movement settings
restrictions
15. Cylinder head gasket leaking 15. Check the cylinder head bolts
torque or renew the gasket
16. Overheating 16. See Problem -- Overheating
new pistons
valve guide bores
84261396 - 09 - 2009
Misfiring 1. Blocked fuel feed pipe 1. Clean pipe

3. Choked fuel filters 3. Remove filter elements
9. Poor compression 9. See Problem -- Poor compression
12. Incorrect tappet adjustment 12. Check and reset the adjustment
valve guide bores
14. Incorrect high pressure pipes 14. Renew the pipes of correct
specification
valve guide bores
Excessive fuel 1. Restriction in air cleaner or 1. Check and clean/remove the
consumption induction system restriction
6. Poor compression 6. See Problem -- Poor compression
grade of fuel
movement settings
restrictions
valve guide bores
new pistons
valve guide bores
84261396- 09 - 2009
Black smoke 1. Restriction in air cleaner or 1. Check and clean/remove the

grade of fuel
restrictions
valve guide bores
new pistons
valve guide bores
Blue/white smoke 1. Incorrect grade of lubricating oil 1. Drain and refill with specified grade
of oil
new pistons
9. Worn valve stems and guides 9. Renew valves and guides
10. Piston seized 10. Replace piston assembly and
check the bore for damage
11. Overfilled air cleaner oil or use of 11. Check the oil level and remove as
incorrect grade of oil necessary or refill with correct
grade oil
84261396 - 09 - 2009
Low Engine oil 1. Incorrect grade of lubricating oil 1. Drain and refill with specified grade
pressure of oil
2. Worn or damaged big end bearings 2. Renew the bearings
3. Insufficient oil in sump 3. Top up as necessary
4. Oil gauge faulty 4. Fit new gauge
5. Oil pump worn 5. Renew oil pump
6. Oil pressure relief valve faulty 6. Fit new relief valve
7. Faulty suction pipe 7. Renew the pipe
8. Choked oil filter 8. Replace with new filter
9. Blocked sump strainer 9. Clean the strainer
Engine knocks 1. Faulty fuel feed pump 1. Overhaul fuel feed pump
5. Incorrect type or grade of fuel 5. Drain and refill with correct
grade of fuel
valve guide bores
new pistons
11. Overfilled cleaner or use of 11. Check the level or drain out and
incorrect grade of oil refill with correct grade oil
12. Worn or damaged big end bearings 12. Renew the bearings
14. Broken valve spring 14. Replace new springs
84261396- 09 - 2009
Erratic running 1. Faulty stop control operation 1. Check the stop control cable
2. Blocked fuel feed pipe 2. Clean
4. Choked fuel filters 4. Choked fuel filters
9. Poor compression 9. Renew piston rings or re--sleeve as
necessery
10. Blocked fuel tank vent 10. Clean the vent
movement settings
valve guide bores
15. Incorrect high pressure pipes 15. Renew the pipes of correct
specifications
16. Broken, wornout or sticking piston 16. Fit new rings, check bore and
17. Overfilled cleaner or use of 17. Check the level or drain out and
incorrect grade of oil refill with correct grade oil
19. Broken valve spring 19. Replace with new springs
84261396 - 09 - 2009
Vibration 1. Faulty fuel injection pump 1. Overhaul injection pump

movement settings
valve guide bores
8. Incorrect high pressure pipes 8. Renew with pipes of correct
specifications
9. Broken worn or sticking piston 9. Fit new rings, check bore and
11. Faulty engine mounting 11. Check and redo the installation of
engine
12. Incorrectly aligned flywheel 12. Check and align fly wheel housing
housing, or fly wheel and fly wheel
High oil pressure 1. Incorrect grade of lubricating oil 1. Drain and refill with specified grade
of oil
2. Inaccurate gauge 2. Check and renew gauge
3. Pressure relief valve faulty 3. Fit new relief valve
Overheating 1. Restriction in air cleaner or 1. Check and clean/remove the
3. Faulty injector 3. Overhaul injector
4. Incorrect fuel pump timing 4. Reset the timings
5. Incorrect valve timing 5. Reset valve timings
6. Exhaust pipe restriction 6. Remove the restriction
9. Damaged fan 9. Fit new fan
10. Faulty thermostat 10. Replace with new thermostat
11. Restriction in water jacket 11. Remove the restriction by reverse
flushing entire cooling system
12. Loose fan belt 12. Tighten the fan belt
13. Choked radiator 13. Clean and check for free flow
14. Faulty water pump 14. Overhaul or renew the water pump
15. Coolant level too low 15. Top up as necessery
84261396- 09 - 2009
Excessive 1. Cylinder head gasket leaking 1. Check the cylinder head bolts
crankcase torque or renew the gasket
pressure 2. Worn cylinder bores 2. Re--bore/re--sleeve block and fit
new pistons
5. Piston seized 5. Replace with new piston assembly
and check the bore for damage
6. Choked breather pipe 6. Clean the pipe
Poor 1. Overheating 1. See Problem -- Overheating
compression 2. Incorrect valve timing 2. Reset the timing
valve guide bores
new pistons
valve guide bores
ring/s piston for damage
10. Broken valve springs 10. Fit new springs
Starts and stops 1. Choked fuel filter 1. Fit new filter
2. Restriction in air cleaner or 2. Remove the restriction
induction system
3. Air in fuel system 3. Remove the air lock
84261396 - 09 - 2009
DESCRIPTION AND OPERATION
CYLINDER HEAD ASSEMBLY CONNECTING RODS

The cylinder head incorporates valves and springs, Connecting rods “Wedge” shaped at the small end
with the valve rocker arm shaft assembly bolted to has been designed to reduce the reciprocating
the cylinder block through the cylinder head. Cylinder weight at the piston end. The connecting rods are
head retaining bolts are evenly spaced with a six-- heavy beam construction and are assembled to the
point pattern around each cylinder, this ensures an crankshaft, by means of insert type bearings.
even clamping load across the cylinder head. They are retained in position by the connecting rod
Archetype intake and exhaust manifolds are bolted big end cap and secured by two bolts per rod. The
to the head; the intake manifold is mounted on the small end of the connecting rod is fitted with a
right side of the engine, with the diesel injectors replaceable bushing, through which the free floating
mounted outside the rocker cover. The exhaust piston pin is fitted. The steel pin being held in place
manifold is mounted on the left side of the engine. within the piston by two snap rings (circlip). While
assembling connecting rods to engine numbered
side should come towards fuel injection pump side.
CYLINDER BLOCK ASSEMBLY

The cylinder block is an alloy cast iron with deep PISTONS
cylinder skirts & water jackets for cooling the Pistons are constructed of an aluminium alloy. The
cylinders. The cylinder bores are replaceable types combustion chamber being recessed in to the piston
and oversizing of sleeves is not recommended. crowns.
Cylinders are inline and vertical and numbered from Each piston has two compression rings and one oil
1 to 3 from front of the engine to the rear. The oil pan, control ring, to reduce the friction and increase
which is attached to the bottom of the cylinder block, positive seating. All rings are located above the
is the reservoir for the engine oil lubrication system piston pin.
is mounted on the left hand side of the engine. Water
outlet connections and thermostat being attached to
the front of the cylinder head directly behind the
radiator.
MANIFOLDS
The cross flow design aluminium intake, and cast
iron exhaust manifolds are on opposite sides of the
CAMSHAFT ASSEMBLY cylinder head. This is designed to maintain balanced
heat distribution within the cylinder head. The
The camshaft gear is in mesh with and driven by idler configuration of the manifolds also ensures minimum
gear which is driven by the crankshaft timing gear. heat transfer to the intake manifold.
The camshaft end float is taken up by a steel spring
riveted to the timing case front cover. The intake manifold is connected through hose to air
cleaner.
TIMING GEARS
CRANKSHAFT ASSEMBLY
The crankshaft timing gear is key located and press
The crankshaft is supported in the cylinder block by fitted on to the front of the crankshaft, to a high
4 bearings. degree of accuracy during manufacturing. This
The crankshaft is manufactured from molybdenum enables precise timing being maintained during the
Thrust washers incorporated in the last main bearing life of the engine. The crankshaft gear drives the idler
cap towards the flywheel control end thrust. Front gear, which is attached to the front of cylinder block.
and Rear crankshaft oil sealing is effected by The idler gear then drives the camshaft and the
one--piece oilseals that are designed for long and injection pump and hydraulic pump gears.
durable service life.
84261396- 09 - 2009
COOLING SYSTEM Cored passages also conduct the coolant to the fuel
The function of the water pump mounted at the front injector nozzle locations, before re--entering the
of the engine, is to maintain a continuous flow of water pump below the thermostat.
water around the cooling system. This is essential to
ensure correct engine temperature, and performance The thermostat is located at the top of the water
during vehicle operation. outlet body, and controls the flow of water as
required by temperature changes.
The pump is driven by a “V” Belt from the crankshaft
pulley, when the engine is running. The fan belt NOTE: Do not run engine without a thermostat.
tension can be adjusted by altering the position of
When the thermostat is closed a recirculating
alternator within the adjusting bracket.
by--pass is provided to allow the coolant recirculate
from the head to the block to effect a faster
The cooling system is of the recirculating by--pass warm--up.
type with full length of water jackets for each cylinder.
The coolant is drawn from the bottom tank of radiator
Once the engine has reached its normal operating
by the water pump, which pauses the coolant to the
temperature, the thermostat will open and allow
cylinder block. This coolant then flows through cored
water to be drawn through the radiator by the pump
passages to cool the cylinder walls.
action and cooled water pumped to the engine
system.
Passages in the cylinder head gasket allow coolant
to flow from cylinder block, into the cylinder head.
84261396 - 09 - 2009
LUBRICATION SYSTEM
Lubrication of the engine, Figure 2 is maintained by The main gallery also supplies oil to the crankshaft
a rotor type oil pump mounted in front of the engine main bearings and connecting rod big end bearings.
block, below timing cover. The oil pump is driven by The underside of the pistons and pins, small end
the crank gear and draws oil from the engine oil sump bush are lubricated by splashed oil.
through strainer and delivers it by a pipe inside the
crankcase through a drilling at the side of the
The camshaft journals are lubricated by oil draining
cylinder, to the lubricating filter.
back from rocker assembly to sump.
A spring--loaded relief valve is provided with oil pump

Timing gears are lubricated by overflow oil from the
to prevent overpressurisation of the system.
front of the camshaft tunnel. Further lubrication for
the timing gears is provided by means of a drilling in
A spin on type oil filter is mounted externally to its the block behind idler gear spigot. Oil from the drilling
support housing, on the left hand side of the engine. escapes through a hole in the idler gear boss.
Oil flows from filter to the main gallery, which runs the
length of the cylinder block, which also intersects the
Rocker shaft and rocker lever bushes are lubricated
camshaft follower chamber. Also an inbuilt by--pass
through pipe from camshaft tunnel. As the camshaft
valve is provided in the oil filter to maintain the
revolves, oil is picked up and carried round in the
pressure in the filter at a definite level. If the oil
narrow slot machined on the centre camshaft journal
pressure at the inlet to the filter element increases
until it escapes through the upper drilling in the
(with the oil too thick or the filter contaminated
camshaft tunnel. The oil then flows through a pipe to
excessively). The valve opens and unfiltered oil flows
the hollow rocker shaft.
into the main gallery
ROCKER ASSEMBLY
Camshaft Camshaft Camshaft

Journal--1 Journal--2 Journal--3
Small Small Small

end end end
Bush Bush Bush
Big End Big End Big End

Bearing--1 Bearing--2 Bearing--3
Idler CRANKSHAFT
Gear
Main Main Main Main

Bearing--1 Bearing--2 Bearing--3 Bearing--4
MAIN OIL GALLERY
Oil
Pressure Oil pump Relief Oil Filter
Guage valve
SUMP
84261396- 09 - 2009
FUEL SYSTEM FUEL FILTERS

The diesel fuel system consists of fuel tank, fuel Engine is provided with two spin on type fuel filters.
filters, fuel feed pump, injection pump, injector Primary and secondary, located below fuel injection
nozzles and inter connecting tubes and lines. pump. Fuel first passes primary filter and then
through the secondary filter before entering injection
pump.
The injection pump is located on left side of the
engine, is pressure fed from fuel feed pump. Fuel Primary filter is provided to separate the larger dirt
flows from fuel tank to the fuel feed pump strainer, particles whereas secondary is provided to separate
through feed pump and then through the fuel filters. the particles, which passed through the primary filter
From the filter the fuel passes to the injection pump to the secondary filter.
to supply fuel at high pressure to each injector. Fuel filters are provided with drain plug to drain out
The extra fuel from injection pump and injectors is water.
recirculated by means of the leak offline to the fuel
tank.
FEED PUMP
FUEL SHUT OFF Fuel feed pump draws fuel from the fuel tank via
Supply of fuel to the combustion chamber is stopped strainer and forces the fuel through primary and
by means of a pull type knob provided just below the secondary fuel filters to fuel injection pump.
rear hood.
Fuel Tank
Fuel Overflow
Injector
Fuel Filter Assembly
Primary Secondary
filter filter
FI Pump Assembly
Fuel feed pump

Strainer
84261396 - 09 - 2009
Diesel engine strip down Operations or Repair that can be performed

In the following procedures and illustrations the with the engine still in the tractor.
engine in the main is shown removed from the
tractor. 1. Cylinder head and associated inlet and exhaust
However there are certain operations that can components.
performed with the engine still in the tractor, or 2. Fuel injection pump and associated parts.
separated at the connection to the front axle support,
3. Water pump, thermostat, and associated
or separated from the transmission housing.
components.
The engine overhaul procedure initially describes the
4. Radiator and associated parts.
assembly process for rebuilding an engine using all
new components. Following this section are defined
headings, which describe detailed repair specifications Operations or Repair that are performed with
and procedures, where components are suitable for the engine separated from the front axle
re--use. Refer to the SPECIFICATIONS section to 1. Front oil seal.
ensure components are serviceable. 2. Timing cover and gears.
Where overhaul of components is required without 3. Cam shaft.
engine being removed from the tractor refer to the
4. Oil pump (With oil sump removed).
following headings, and the relevant paragraphs, in
the main overhaul procedure. 5. Oil sump
Operations or Repairs that are performed with

the engine separated from the transmission
housing
1. Rear oil seal / bracket.
Dismantle the engine by referring to the following
removal procedure. Refer to the specification section
as necessary.
NOTE: All gaskets, seals. and ’O’ rings must be
replaced while reassembling. Where new sealant is
to be applied refer to Page 10
84261396- 09 - 2009
ENGINE REMOVAL -- INSTALLATION (OP. 10 001 10)
Separating Engine From Centre Housing

WARNING
Handle all components with the greatest care. Do not
insert hands or fingers between the parts. Wear suit-
able protection clothing, including goggles, gloves
and footwear.
1. Remove the front weight carrier (1)
1
2. Slide the lock (1) to right , hold and lift the handle
(2)( to raise hood
1
2
3. To maintain the hood in raised position a gas strut
(1) is provided underside hood
84261396 - 09 - 2009
4. Dis --connect battery terminals

IMPORTANT: Always disconnect the negative cable
(1) first
4
5. Loosen the silencer mounting clamp bolts(1) and
remove the silencer assembly.
1
5
6. Remove the electrical couplers (1) for rear
lamps, flasher unit, fuse box etc.
7. Remove fuse box
1
6
8. Unscrew hood mounting bracket bolts from
engine frame
9. Unscrew gas strut bolts and remove the front
hood
1
84261396- 09 - 2009
10. Disconnect electric connections to starter motor
8
11. Disconnect hand throttle cable fuel shut--off
cable fuel line and overflow lines and remove fuel
tap bracket bolts.
9
12. Remove the steering wheel cover
10
13. Loosen the steering wheel securing nut and
remove the steering wheel using Tool No.
82834312 and 9971375.
11
84261396 - 09 - 2009
14. Loosen the rear hood securing bolts (1) and (2)
and remove rear hood.
12
15. Unscrew the rear bolts (1) and remove cover
strip
13
16. Remove the accelerator knob(1)
1
14
17. Unscrew all the screws (1) of instrument panel
15
84261396- 09 - 2009
18. Remove the steering boot (1)
16
19. Pull out the instrument panel from rear hood
17
20. Disconnect all electric wire connectionss of the
switches and hourmeter cable from instrument
cluster.Also remove fuel tank cap 1
18
21. Remove pull to stop knob and then centre
panel.Unscrew all rear hood securing bolts lift
and remove rear hood
19
84261396 - 09 - 2009
22. Disconnect diesel overflow hose pipe (1) and fuel

sender electric connection.
1 2
20
23. Remove hand accelerator cable (3).
21
24. Loosen bolts and release fuel tank strap
NOTE: It is advisable to drain diesel from fuel tank
1
if tank is more than half filled.
22
25. Position splitting trolley SST No 292320 with
engine supports in position, also block front
wheels both at front & backusing suitable
wedges.
23
84261396- 09 - 2009
26. Remove knuckle joint nut(1) and disconnect drag

link from control lever (2)
2
24
27. Support the engine at the back of the front axle
and position wedges between axle and support
to prevent articulation.
25
28. Remove the bolts securing the engine to the
centre housing.after removing platform bolts.
26
29. Wheel the centre housing and rear wheels away
from the engine.
27
84261396 - 09 - 2009
Separating Front Axle From Engine
With engine previously separated from Centre

housing
DANGER
Lift and handle all heavy components using lifting
equipment of appropriate capacity. Ensure that units 1 1
or parts are supported by suitable slings or hooks.
Ensure that no one is in the vicinity of the load to be
lifted.
1. Disconnect headlight harness connection (1)

and horn wirings
28
2. Disconnect hose (1) from radiator and drain the

coolant.
jeet
29
3. Loosen the clamps (1) and radiator (2)

4. Remove the radiator bracket& deflector support 1
bracket securing bolt.
30
84261396- 09 - 2009
5. Support the front axle at the front bracket.

6. Support the engine using a suitable hoist.
31
7. Remove buckle up bolts between the engine and
front support carefully prise the engine from the
front axle support ensuring that all wires and
tubes are disconnected. Place the engine onto a
suitable stand for repair
32
ENGINE INSTALLATION
Installation of the engine is reversal of the removal
procedure, noting the following points :
1. Apply thread sealant to bolt
2. Ensure all attaching hardware is tightened to the
correct torque value as detailed in Page 9.
3. Ensure after installation that all fluid levels are
correct prior to start up. Start and run the engine
until correct operating temperature is achieved to
purge air from cooling system. Stop engine,
check for leaks, rectify as required and recheck
fluid levels.
84261396 - 09 - 2009
ENGINE DISASSEMBLY
Cylinder Head, Valves, and Related Parts
(OP 10 101)
CYLINDER HEAD REMOVAL(OP 10 101 20)

NOTE: The cylinder head can be removed with the
engine installed in the tractor.
WARNING
and footwear.
1. Remove the centre panel.

2. Remove drain plug (1) and drain the engine
coolant in to a clean receptacle.
3. Disconnect air cleaner hoses, water hoses.
1
4. Remove the banjo bolt (1) to disconnect oil flow
pipe from camshaft to rocker assembly shaft.
2
5. Remove the fuel injection pipes (1) and overflow
pipes (2).
NOTE: Cover the fuel pump delivery ports and
injector inlet ports with suitable protective caps, to 1
avoid foreign particles ingress
84261396- 09 - 2009
6. Remove the injector securing nuts (1).

1
7. Remove the injectors (1) from cylinder head.
84261396 - 09 - 2009
8. Loosen the clamp (1) and remove the breather

pipe (2) from tappet cover.
9. Remove the self locking nuts (1) and remove the

tappet cover. 1
10. Disconnect the pipe (1) for rocker shaft

lubricating oil circulation by unscrewing the nut
(2).
84261396- 09 - 2009
11. Remove the rocker shaft assembly mounting

bolts (1).
12. Lift off the rocker shaft assembly from cylinder

head.
10
13. Loosen the 18 cylinder head bolts and lift off the
cylinder head from cylinder block.
11
84261396 - 09 - 2009
TAPPET ASSEMBLY REMOVAL

1. Loosen the lock nut (1) by holding the tappet 1
body (2), to prevent rotation.
12
2. Remove the tappets (1) from bottom side of the

cylinder head. 1
Reassembly of Tappets
Installation of tappets is the reverse of the removal
procedure.
13
VALVES AND SPRINGS REMOVAL

1. Using Tool No. 291050 (1), press the spring (2)
and remove the valve retaining cones with the 1
help of magnet .
2. Gently release the spring and remove the tool.
Spring is now free to remove.
14
84261396- 09 - 2009
3. Take out the valves (1) and valve stem seals (2).
NOTE: In case replacement of new valves is not
1
required, put an identification mark on valves, to
assemble valves back in original location.
15
REPAIR AND INSPECTION OF CYLINDER

HEAD
1
1. Clean the cylinder head and remove the carbon
deposits around the valve heads.
2. Scrape all gasket surfaces clean and wash
cylinder head in a suitable solvent, also cleaning
valve guide bores.
NOTE: Ensure injector washers have been removed
prior to cleaning.
1. All studs and bolts on the cylinder head and top
face of the cylinder block should be examined for 2
looseness, damaged threads etc.
2. All joint faces should be examined for pitting and 16
defacement.
3. Wash out and clean the water passages, dry
and clean with pressurised air.
4. Using a straight edge (1) and feeler gauges (2),
check the flatness of the cylinder head in all
directions and it should not exceed:
Transverse : 0.76 mm Max
Longitudinal : 0.15 mm Max
5. If the cylinder head is to be re--machined, then
Max, allowable skimming is 0.30 mm provided
the injector nozzle protrusion does not exceed
4.67 mm after skimming. Ensure all bolts head
face for correct seating, by placing the cylinder
head without gasket, on the cylinder block and
installing bolts hand tight.
84261396 - 09 - 2009
Inspection and Repair of Valves

Critical Valve Points, Figure--17
1). Valve land edge, 2). Valve head, 3). Valve face
angle, 4).Valve face, 5).Valve stem, 6).Valve tip.
Check the valve face angle, valve stem diameter,
valve head face to cylinder head face depth to the
specifications:
ii. Clearance fit of valve in guide
Inlet -- 0.071mm -- 0.12 mm
Exhaust -- 0.071mm -- 0.12 mm
Figure 18
i. Valve seat angle (1)
17
Intake -- 35_
Exhaust -- 35_
2
iii. Valve head face to cylinder head face depth(3)
Intake -- 1.27 mm -- 1.57 m
1
Service limit -- 1.83 mm
Exhaust -- 1.54 mm -- 1.88 mm
Service limit 2.11 mm
18
Inspection and Repair of Valve Guides
Using a telescopic gauge; and micrometer, measure
the valve guide bore and ensure clearance does not
exceed 0.071 -- 0.12 mm.
If new guides are to be replaced, clean the new
guides, removing any burrs.
19
84261396- 09 - 2009
Inspection of Valve Springs

1. Check on a flat surface for squareness, out of
square should not exceed 1.52 mm, between the
square, and spring at the top or bottom.
2. Length of the valve springs should be checked on
both free and loaded lengths.
Free length = 45.29 -- 45.80 mm
Fitted length (at load of 10.34 Kg + 0.90 Kg) = 38.10
mm
20
ROCKER SHAFT -- DISASSEMBLY,

INSPECTION AND REASSEMBLY
Removal
1. To dismantle the rocker shaft, unlock the circlip
(1) on each or one side of rocker shaft and slide
out the parts from the shaft one by one. 1
NOTE: When dismantling rocker shaft assembly,
make careful note of the order of assembly of the
various parts, to facilitate re--assembly in original
position.
21
Inspection and Repair

1. Wash the rocker shaft assembly thoroughly.
2. Examine the rocker bushes for wear, Max.
diameter should not exceed 15.89 mm and the
clearance fit between shaft and bushes should
range from 0.017 mm -- 0.09 mm.
3. If rocker arm bushes are excessively worn,
replace with new bushes and ream to the correct
size.
4. Inspect the rocker arm adjusting screws, and
tappet ends of the rocker arm, for nicks,
damages or excessive wear
5. Inspect the inside diameter of the rocker arm for
damage or wear . If any of these characteristics
are not to specifications replace with new part.
6. Check and inspect the rocker shaft for any kind
of wear or damage to external or internal
diameter. If not to specification, replace with new.
If reused, before re--assembly clean thoroughly,
making sure all oil passages are clear
84261396 - 09 - 2009
Re--assembly of rocker shaft

Re--assembly of rocker shaft is the reverse to the
removal procedure.
CYLINDER HEAD RE--ASSEMBLY

Re--assembly of cylinder head is the reverse of the
removal procedure, but observe the following.
1. Insert the valves into the guides from which they
were removed and lap with a suitable paste.
Ensure that all traces and paste are removed
after lapping
2. Lubricate all components with clean engine oil on
re--assembly. Use a spring compressor to
re--assemble the valves, valve springs and
retainers,.
3. Coat all tappets with clean engine oil prior to
assembly and insert tappet into its original
position.
Installation of Cylinder Head

Installation of cylinder head is the reverse of the
removal procedure, but observe the following:
1. Ensure that the faces of the cylinder head and
cylinder block are perfectly clean.
2. Always fit a new cylinder head gasket. Apply thin
coating of good jointing compound on both sides
of the gasket.
3. Place the cylinder head gasket on top face of the
cylinder block with mark “FRONT TOP” facing
upwards.
4. Place the rockershaft assembly on the cylinder
head
22
5. Torque cylinder head bolts as per specifications
given in section of specifications.
6. Start torquing of cylinder head nuts from the
centre of the cylinder head and move outwards
while tightening in sequence as per Figure 23.
23
84261396- 09 - 2009
TAPPET SETTING
NOTE: Lightly lubricate the bolts prior to assembly
and tighten to the torque specification, with the
engine cold.
1. Rotate the belt pulley and align mark (1) with the
2
pointer (2). In this position, Piston no.1 should be
in TDC. Check both the valve of piston no.1 are
in closed position or rocking (dancing) position. 1
2. If these valves are closed, then check and adjust
the clearance for valves no. 1, 2, 3 and 5. If
rocking then check and adjust the valves no. 4
and 6.
3. Rotate the belt pulley by 360 degree and adjust
the clearance for remaining valves. 24
Inlet valve -- 0.30 mm cold
-- 0.25 mm hot
Exhaust valve -- 0.30 mm cold
-- 0.25 mm hot
To adjust the valve clearance, Hold the tappet (3),

rotate the bolt (2).Check the clearance between
Rocker arm and using bolt (1) using feeler gauge (4).
NOTE: Valve clearance is to be set, only when the
engine is cold. 4
3
25
84261396 - 09 - 2009
ENGINE FRONT COVER AND TIMING

GEAR REMOVAL (OP 10 102 & 106)
WARNING
and footwear.
NOTE: Timing cover and gears can only be serviced

after removing the radiator. 2
1. Loosen the alternator mounting bolt (1) and
remove the fan belt (2).
2. Remove the fan mounting bolts (3) and remove
the fan (4).
3
1
4
3. Loosen the clamps (1) and disconnect the hoses

(2) connected to water pump. 2
4. Remove the water pump mounting bolts (3) and
remove water pump (4) with pulley.
1
3
4
3. Remove the crank pulley dognut and pull out the

pulley (1).
84261396- 09 - 2009
4. Remove engine breather pipe (1).

5. Remove the alternator (2) and alternator
mounting bracket (3). 1
6. Loosen the two bolts in front of the timing cover
and remove the hydraulic pump.
7. Loosen the bolts retaining the front timing cover 2
plate and remove the timing cover.
NOTE: Take care of front oil seal, when removing
this cover.
3
4
FRONT OIL SEAL REMOVAL
Front oil seal can be removed and installed without
removing timing cover.
1. Remove the crank pulley after removing the
dognut.
2. Remove the oil seal (1) using suitable tool.
NOTE: Avoid damage to the crankshaft and oil sump
while removing seal.
5
Timing cover Installation
Installation of timing cover is the reverse of the
removal procedure.
2
Front Seal Installation 1
1. Lubricate the new seal (1) and place on to seal
installer tool (3) (Special Tool No. 9970845),
ensuring the tool shim (2) is installed.
NOTE: Lip of seal should be towards the engine.
6
2. Locate tool on crankshaft. Screw bolt (1) into end
of crankshaft and slowly turn the nut (2) to install 3
2
seal. Continue turning nut until face of tool (3)
almost touches face of front timing cover (4).
NOTE: Ensure that seal is concentric with the outer
diameter of crankshaft for proper sealing.
IMPORTANT: Use the minimum of effort when
turning nut and DO NOT force tool against face of
front cover.
1
4
7
84261396 - 09 - 2009
TIMING GEARS REMOVAL

Removal -- Installation (Op -- 21 118 10)
WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS
Before removing timing gears use a dial indicator or

feeler gauge, Figure 9 to measure the backlash
between each set of gears.
Rotate the gears and check the backlash at four
equal points on the gears. Renew if the backlash
exceeds 0.32 mm
NOTE: It is not possible to remove crankshaft gear
without removing crankshaft. Refer Section
CRANKSHAFT REMOVAL , Page 61 -- for replacing
crankshaft gear.
Idler gear removal
1. Unlock the locking washer (1), and remove the
7 1 3
gear securing bolt (2).
2. Remove the idler gear (3) from its hub. 6
3. Remove the idler gear hub.
Pump gear removal 4
2
1. Remove the fuel injection pump gear securing
bolts (4).
2. Remove the gear (5).
5
Camshaft Gear removal
1. To remove the camshaft gear (6), remove the
bolts (7), coupling camshaft with gear. 8
NOTE: Camshaft gear can also be taken out with
camshaft in fitted condition.
NOTE: Mark ‘D’ is punched on camshaft boss and
gear hub to align in original positions during
assembly.
Repair and Inspection -- Timing gears
Wash the gears using a suitable solvent, and
examine gear teeth for wear, burs or scratches.
Minor marks can be removed using a fine abrasive,
thoroughly clean before re--assembly.
1. Backlash between the timing gears should be
0.08 mm minimum.
2. Backlash between the crank shaft gear and oil
pump gear should range between 0.19 mm --
0.32 mm.
NOTE: Rotate the gears and check the backlash at
four equal points on the gear.
84261396- 09 - 2009
TIMING CASE REMOVAL

1. Remove the rockershaft assembly as explained
in section : CYLINDER HEAD REMOVAL Page 1
33.
2. Remove the sump as explained under section:
SUMP REMOVAL. Page 49.
3. Remove timing case bottom cover.
4. Lift the tappets and remove the camshaft (1)
along with gear , taking care not to damage the
cams or bearing journals.
5. Remove all cables and pipes from fuel injection
pumps. When removing the high pressure pipes
from the pump, release the pipes at the injectors 10
end and remove the pipes.
6. Unscrew the fuel injection pump retaining
nuts(1), and remove the pump.
IMPORTANT: Ensure that all the inlet and outlet 1
connections of the fuel injection system are
effectively sealed against the entry of dust and dirt by
the use of suitable caps or plugs.
7. Remove the set screws and shake proof
washers securing the timing case to the block
and with a light tap, remove the timing case from
the cylinder block.
11
84261396 - 09 - 2009
Installation
1. For the purpose of correct location of the timing
case, it is advisable to fit and fully locate the idler
gear hub (1) to the cylinder block.
2. Thoroughly clean the mating surfaces between
timing case and engine block, using a suitable
solvent cleaner. Carefully apply a 2 mm wide
bead, of the recommended flexible gasket
sealant and replace the timing case.
3. Replace timing case bottom cover ensuring it is
correctly aligned with the front face and the 1
timing case.
4. Secure the fuel injection pump to the back of the
timing case matching the scribed marks. 12
5. Turn the engine crankshaft until No. 1 piston is at
top dead centre (Key on the front of the
Crankshaft vertically upwards.)
6. Fit the fuel pump gear to the fuel pump, locating
the dowel between the gears and pump.
7. Lift the tappets and replace the camshaft, turning
the camshaft as it is being entered into the 1
camshaft tunnel.
8. Replace the idler gear on the hub, with the long
tapered flange of the gear towards the cylinder
block and the timing marks (1) on the crankshaft
gear, fuel pump gear, camshaft gear and idler
should correspond.
13
NOTE: If any of the timing gears are renewed,

ensure that there is a minimum backlash of 0.08 mm
9. Replace the sump as directed in the section --
SUMP REMOVAL, Page 49
10. Fit a new gasket to the timing case and replace
the timing case cover.
11. Refit all fuel pipes and controls.
NOTE: The front seal should be replaced every time
the front plate is removed. Refer Page 44.
14
84261396- 09 - 2009
IMPORTANT: Use the minimum effort when turning belt pulley should be at 12 ‘O’ clock position. This
nut and DO NOT force against face of front cover. ensures that the piston No. 1 is in T.D.C. To ensure
12. Slide the pulley over the key and tighten the compression, check the tappet of both the valves of
securing dognut. cylinder No. 1. Both the valves should be in closed
position.
13. Install fan, fan belts, water pump and alternator
following the reverse of the removal procedure. Fit the camshaft gear ensuring the letter “D” stamped
adjacent to one of the fixing holes is in alignment with
the letter “D” stamped on the camshaft hub.
Timing
Fit the fuel pump gear. This is doweled and will only
The timing or the resetting of the timing can be simply
go in one position.
and quickly carried out if the following instructions
are borne in mind Check that the fuel pump is correctly fitted to the
engine with the scribed line on the mounting flange
It is well to remember that the removal of the cylinder
in line with the scribed line on the rear face of the
head does not in anyway affect the timing of the
timing case.
engine.
With the crankshaft gear fitted, replace the idler gear
ensuring the timing marks coincide .
Timing Marks
After testing the engine, final adjustments may be
When the engine is timed at factory, certain marks
necessary to find the perfect injection point as
are stamped on the gears, so that if for any reason
described under “Re--Timing” Page 65. Adjustment
the timing has to be broken, then the engine can
may be made by releasing the fuel pump securing
easily be reset to it’s original timing.
setscrews and turning the pump in the direction
The method of marking is as follows:-- required.
With the engine timing correctly set, the engine is
turned until No.1 piston is at T.D.C. on its To Check Valve Timing with Valve Timing Case
compression stroke. In this position, scribed lines or Installed
centre punch marks are marked on the idler gear to
Turn the engine until maximum lift is obtained on No.
correspond with lines or centre punch marks on the
3 cylinder exhaust valve.
camshaft, fuel pump and crankshaft gears
respectively. Figure 13, Page 47 In this position, set the clearance between rocker
lever and No. 1 inlet valve to 0.80 mm.
NOTE: With all the timing marks aligned, the
crankshaft will have to be turned 18 times to align all Now turn the engine in the normal direction of
the timing marks again. rotation until the tappet of No.1 inlet valve just
tightens.
Fuel Injection Pump Timing Marks At this point, No.1 piston should be at T.D.C. This can
be checked by examining the T.D.C. mark on the
A scribed line is marked in both fuel pump mounting
engine flywheel. The tolerance for valve timing is +
flange and rear face of the timing case. When the fuel
2 1/2_
pump is fitted, this lines should coincide. Providing
these scribed lines are in alignment and the fuel It should be noted that no adjustment is provided for
pump gear correctly fitted, then the fuel pump timing valve timing. Provided the gear is correctly fitted to
should be correct. the camshaft (see previous remarks) then the timing
can only be one or more teeth out.
To Reset the pump Timing When the timing is found to be correct, adjust the
Remove injectors. valve clearance to 0.30 mm cold.
Bring No.1 piston to T.D.C. in compression stroke.
The front of the crankshaft where the key for the fan
84261396 - 09 - 2009
OIL SUMP REMOVAL (OP 10 102 10)

NOTE: It is necessary to detach front support from
engine and move forward a couple of inches to allow
removal of the oil sump. Refer to ENGINE
REMOVAL, Page 26.
1. Remove plug (1) and drain oil.
2. Remove bolts securing sump to flywheel
housing. 1
3. Remove bolts securing sump to engine cylinder
block and lower to ground.
1
Inspection and repair
Clean gasket material and clean the sump in a
suitable solvent, inspect for cracks, damaged
threads or damaged sump face.
Installation of sump
Installation process of sump is the reverse of
removal process ensuring the following:
1. Remove all the traces of old joints and cork strips
from timing case bottom cover and rear main
bearing cap.
2. Lightly smear crankcase face with thin coating of
jointing compound and place joints in position
ensuring all holes are aligned.
3. When placing joints in position, it is important that
the mating ends go right up into the recesses of
the timing case bottom cover and rear main
bearing cap.
4. Locate cork joints in the grooves provided in the
timing case bottom cover and rear main bearing
cap.
5. Apply suitable jointing compound on sump rear
and front half moon neck and position sump
through front and rear studs and hand tighten the
nut to hold in position. Install remaining bolts and
tighten all bolts and nuts.
84261396- 09 - 2009
CONNECTING RODS, BEARINGS,

PISTONS AND RINGS REMOVAL
(OP 10 105)
NOTE: Connecting rods and pistons cam be
removed with engine coupled with transmission.
1. Remove cylinder head oil sump and timing cover.
Refer back to corresponding sections for
removal procedure.
2. Remove oil pump as explained in section --OIL
PUMP REMOVAL. Page 68
3. With cylinder head removed clean off any ridge
from the top of the cylinder bore to enable
removal of the pistons, this is essential if old 2
pistons are to be re--used and failure to do so
could result in ring damage when removing.
4. With the piston at the bottom of the stroke
remove the end cap bolts, cap, and sleeve. Using
the handle end of a hammer push the piston
assembly out through the top of the block, and
remove the bearing sleeve from the connecting
rod.
NOTE: Bearing caps and sleeves must be kept with
their respective connecting rods.
5. Turn the crankshaft again and repeat the
process for the remaining pistons.
6. Remove piston pin snap rings from each side of
piston and remove pin. Using Expander remove
the piston rings.
7. Ensure each piston and rod assembly, remains
matched together for re--assembly.
3
1. Clean the piston, and connecting rod assembly,
in a suitable solvent and inspect for damage to
ring lands, skirts, or pin bosses.
2. Check connecting rod components for damage,
and place in the test mandrel to check for
distortion, and ensure that any distortion, is
within specifications.
CONNECTING ROD ALIGNMENT
Large and small end bores must be square and
parallel to each other within the limits of 0.25 mm
measured 127 mm each side of the axis of the rod on
test mandrel as shown in Figure 1. With the small
end bush fitted, the limit of 0.25 mm should reduce 4
to 0.06 mm.
NOTE: Connecting rod nuts should be replaced
whenever the big ends are disturbed.
3. Check connecting rod small end bush and piston
pin for wear.
84261396 - 09 - 2009
Connecting Rod Bush internal Diameter

31.76 -- 31.79 mm
Piston Pin outside Diameter
31.74 -- 31.75 mm
If new bush to be replaced, proceed as follows:

• The small end bushes are press fitted in the
connecting rods.
• Press out the old bushes using a suitable press.
• Remove any sharp edges around the connecting
rod small end parent bores.
• Press in the new bushes using a suitable dolly at
the same time ensuring that the oil holes in the
bushes coincide with the holes in the top of the
connecting rods
• Ream out the new bushes to suit their respective
piston pins, and check parallelism and twist
4. Wash the piston assembly in a suitable solvent

and dry with a clean lint free cloth or compressed
air
5. Inspect the piston ring lands, skirts and pin boses
for damage.
6. Clean the ring grooves and using the ring and
feeler gauge check the piston ring land for wear.
Top, second and third ring clearances -- 0.05 to
0.10 mm.
5
7. Place a new ring into the cylinder bore and check
for gap clearance with the help of a feeler gauge.
Top ring 0.36 to 0.69 mm

Second ring 0.28 to 0.53 mm
Third ring 0.36 to 0.46 mm
NOTE: The ring gaps quoted above are for a bore
diameter of 91.48 mm. When checking ring gaps in
a worn bore, 0.08 mm should be added to these ring
gaps for every 0.03 mm increase in bore diameter.
NOTE: In a worn cylinder, ring gap should be
checked at the bottom of cylinder.
6
84261396- 09 - 2009
Cylinder Bore
1. Check the cylinder bore for scuffing or rings
around the ring frame area. Irregularities can be
felt by running a finger over the surface. To check
out--of--roundness, wear, or taper, use a
telescopic gauge, Figure 7
Specifications
NOTE: ‘Repair Limit’ refers to the tolerance allowed
after a repair has been performed. i.e. the repair
must be within the repair limit. The ’Wear Limit’ is the
tolerance prior to repair.
Taper of cylinder bore,
7
repair limit -- 0.025mm
wear limit -- 0.127mm
Cylinder bore out--of--round,

repair limit -- 0.03mm
wear limit -- 0.127mm
Cylinder bore diameter,

91.48 -- 91.50 mm
2. Where only minor imperfections exist and bores
are to specification, hone the bores prior to
installing new piston rings.
3. Sleeving of the cylinder bores becomes
necessary when.
-- Oil consumption is high.
-- Replacing sleeves, installed in service.
-- Cylinder bore is damaged
REMOVAL OF SLEEVES (OP 10 105 50)
1. Remove the cylinder head studs from the
cylinder block.
2. Press or draw the sleeves out through the top of
the cylinder block ensuring no damage is done to
the parent bores (cast iron production sleeves
are an interference fit and it should be removed
with a heavy duty press).
84261396 - 09 - 2009
Installation of new sleeves

1. Preparation for fitting new sleeves:
• After removal of the old sleeves, the parent bore
must be thoroughly cleaned both in the top
recess off the sleeve flange and in the parent
bore itself.
• A check must be made to ensure that the whole
areas of contact with the sleeves in the cylinder
block are free from burrs, corrosion or damage.
Remove any burrs present.
• Ensure that the sleeve is thoroughly clean before
fitting. If cleaning fluid is used to wash the sleeve,
it is important that the sleeve be thoroughly dried
and well oiled before fitting.
• Throughout the whole operation, extreme
cleanliness is essential as the entry of the
smallest particle or other foreign matter is
sufficient to cause local distortion of the sleeve
bore.
2. Lubricate the outside diameter of the sleeves
with clean oil using spray. The use of brush is not
recommended
3. Press or draw in the new sleeves using a suitable
shouldered metallic disc ensuring that the flange
at the top of the sleeves do not foul the
counter--bore at the top of the parent bore thus
causing distortion at the top of the internal
diameter of the sleeve.
4. In fully pressed condition the top face of the
sleeve should be between 0.05 mm above and
0.1mm below the top face of the cylinder block.
5. Each new sleeves should be checked for internal
diameter in three positions -- top, centre and
bottom; the readings being taken transversely
and parallel to the centre line of the cylinder block
at each position. For service sleeves, the
acceptable limit is 91.48 -- 91.50 mm.
Re--Assembly
NOTE: Pistons that are replaced must be of the
same type that were removed and have the same
identification letters, and numbers, as embossed on
the piston
1. Upon re--assembly with the piston at Top Dead
Centre, ensure that the height between piston
and top face of block is 0.10 mm above and 0.03
mm below using a dial indicator.
NOTE: With most new Pistons, a machining
allowance is provided on the crown of the piston and
the necessary amount must be removed in a lathe to
give clearance quoted above. Some pistons may be
available that do not require topping 8
84261396- 09 - 2009
2. Lubricate all the components with engine oil and

assemble the connecting rod and piston, piston
pin and retainers.
When fitting pistons and connecting rods to the
cylinder block and crankshaft, ensure that the
side of the connecting rod which is stamped with
the number goes to the LH side of the engine.
Ensure that the words “F” marked on the piston
crown is facing towards the front of the engine.
9
3. Check the piston ring end gap width, using a
feeler gauge, in a vertical position at the top,
middle and bottom of the bore,
4. Ensure the correct expander tool is used to
remove or install rings
10
5. Install the piston rings, but note the following:
NOTE: Before installing new pistons and rings into
a used cylinder bore, remove the high polish from the
cylinder walls by honing.
6. Ensure the ring gaps are staggered a minimum
of 120_ from each other on the diameter and with
no gap on the thrust side of the piston.
84261396 - 09 - 2009
PISTON ASSEMBLY INSTALLATION, INTO

BLOCK
1. Select the correct bearing sleeves as in the
following crankshaft section, and install in the rod
and cap, ensure the liner tang locates in the slots
of the rod and cap.
2. Turn the crankshaft to position No.1 crankpin at
the bottom of the stroke, and lubricate all parts
with new engine oil. Using Ring Compressor, and
a soft drive, slide pistons into bores, ensuring “F”
letter on pistons, is towards the front of the
engine.
11
3. Ensure the connecting rod bearing liner, seats on
the crankpin with the bearing cap fitted, to the
connecting rod as a matched assembly. Fit new
bolts lubricated with oil, and tighten to a torque
value of 60 ibf. ft.
4. Using feeler gauges, check the side clearance of
each connecting rod to crankshaft, which should
be within 0.06 -- 0.10 mm
12
5. Refit the oil pump tube/screen and oil sump as
described in the relevant section, refill engine oil
and coolant and run the engine checking for
leaks.
ENGINE COMPRESSION TEST

(OP. 10 001 30)
Test Procedure
1. Be sure battery performance meets
specifications.
2. Warm up the engine by operating for a minimum
of half an hour at 1200 rev / min
3. Stop the engine and remove the injector and seat
washer from No.1 cylinder.
4. Clean the injector bore and crank the engine to
blow out any loose carbon particles.
5. Install an engine compression test gauge. Fit
dummy injector (Special Tool No.9970847 ), into
the injector bore, using a new seat washer and
injector mounting bolts.
6. Connect the gauge and hose to the adapter
dummy injector.
7. Crank the engine with the electric fuel shut off to
prevent engine start up.
8. Observe the gauge reading and repeat the
compression test, steps 5--7 for each cylinder.
84261396- 09 - 2009
Test Readings
1. All cylinder compressions should be uniform or
difference should be within 25 lbf in2 (1.7 bar) of
each other.
2. A reading of more than the 25 lbf in2 (1.7 bar)
below the other cylinders indicates leakage at
the cylinder head gasket, piston rings or valves.
3. A reading of more than 25 lbf in2 (1.7 bar) above
the other cylinders indicates excessive carbon
deposits on the piston and cylinder head.
4. A low even compression in two adjacent
cylinders indicates a cylinder head gasket leak.
Check this item before condemning the rings or
valves.
Test Conclusion
To determine whether the rings or the valve are at
fault, squirt the equivalent of a table spoon of heavy
oil into the combustion chamber. Crank the engine to
distribute the oil and repeat the compression test.
The oil will temporarily seal any leakage past the
rings. If approximately the same reading is obtained,
the rings are satisfactory, but the valves are leaking.
If compression has increased over the original
reading, there is leakage past the rings.
During a compression test, if the pressure fails to
climb steadily and remains the same during the first
two successive strokes, but climbs higher on the
succeeding strokes, or fails to climb during the entire
test, suspect a sticking valve.
84261396 - 09 - 2009
MAIN BEARINGS, FLYWHEEL AND

CRANKSHAFT (OP. 10 103)
NOTE: Replaceable bearings are installed in
production. Ensure correct crankshaft journal to
bearing clearance is maintained in service. The main
bearings can be overhauled with the engine in the
tractor.
To remove the flywheel, the engine requires to be
split from the centre housing.
The crankhaft itself can only be serviced after
removed from the engine, for which engine has to be
separated from the tractor totally.
MAIN BEARING REMOVAL

1. Remove the engine oil sump, to gain access to
the crankshaft.
2. To remove a main bearing, take off the cap of the
bearing to be replaced. For the rear main bearing
cap it will be necessary to remove flywheel and
rear oil seal as described in the following
crankshaft section.
3. Do not remove more than one bearing cap at a
time.
4. Slacken the remaining bearing cap bolts one or
two turns.
5. Remove the lower half of the bearing from the
bearing cap.
6. With a suitable piece of wood push out the top
half of the bearing by rotating it on the crankshaft,
applying the tool to the side opposite the
bearinglip. The locating lips are on the camshaft
side of the engine.
7. Thoroughly clean bearings, journals and caps
and inspect for wear, scores or damage and
replace as required.
NOTE: It is recommended that all the main bearings
should be replaced if it is found necessary to replace
any one set of main bearings.
Installation
1. Coat all parts lightly with new engine oil prior to
assembly.
2. Replace cap and tighten bolts lightly before
proceeding to the next bearing.
1
3. Having replaced all bearings and caps, tighten all
the bolts to a torque of 15.9 Kgf.m. (115 lbf.ft.)
NOTE: Over size thrust washer to be used whenever
crank shaft end float exceeds the service limit.
84261396- 09 - 2009
FLYWHEEL REMOVAL
WARNING
and footwear.
1. To gain the access to the fly wheel separate the

engine from transmission as detailed under
section SEPARATING ENGINE FROM
CENTRE HOUSING Page 26.
2. Prior to removal of flywheel, use dial indicator to
check the flywheel face run out, as described
below. If not to specifications, check crankshaft
to flywheel seating.
3. Unlock the lock washers. Unscrew the flywheel
securing bolts and remove the flywheel.
2
Repair and Inspection
1. Check the flywheel ring gear for damage,
Replace the flywheel if damaged
Installation and Alignment Check
1. Clean the crankshaft gear flange and mating
surface of flywheel.
2. With the flywheel and crankshaft flange perfectly
clean and free from burrs and with two suitable
guide studs fitted in the crankshaft flange,
position the flywheel on the crankshaft.
3. Insert the setscrews complete with locking plates
into the flywheel holes and tighten evenly to a
torque of 11.1 Kgf.m. (80 Ibf.ft.).
4. Secure the base of the “dial gauge” to the
flywheel housing. With the flywheel at top centre,
set the needle of the gauge on the periphery.
3
5. Turn the crankshaft and check the dial gauge, the
flywheel should run truly within 0.30 mm (total
indicator reading).
6. With the base of the “dial gauge” still bolted to the
flywheel housing, adjust the dial gauge so as to
set the needle against the vertical machined face
of the flywheel.
7. Again turn the crankshaft and check the dial
gauge. The flywheel should be truly at right
angles to the crankshaft axis within the limit of
0.025 mm per 25 mm of flywheel radius from the
crankshaft axis to the dial gauge plunger.
8. When the flywheel has been checked for correct
alignment, lock setscrews with locking plates.
84261396 - 09 - 2009
FLYWHEEL HOUSING AND REAR MAIN

OIL SEAL REMOVAL (OP. 10 102)
Rear main oil seal can be changed without removing
flywheel housing. 1
1. Remove flywheel as explained in previous
section.
2. Disconnect starter motor wirings and remove
starter motor (1)
1
3. Remove the rear seal retainer (1).
4. Remove the seal (2) from the retainer. 1
2
6. To fit the new seal in retainer:
i) Fit the retainer first on the engine block.
ii) Fit lip seal in its retainer with the help of Special 1
Tool No. 9970846 (1).
3
NOTE: In service when a new seal is fitted on to the
crank shaft, it should be pressed further in to the
housing to avoid fitting the seal in its original
location.
A -- 0.09 in (2.2 mm)
B -- 0.18 in (4.6 mm)
C -- 0.27 in (6.9 mm)
84261396- 09 - 2009
Installation and Alignment of Flywheel

housing
IMPORTANT: The flywheel housing must be
correctly aligned with the crankshaft. Misalignment
may cause clutch malfunction and difficulty in
changing gear, etc. If the housing has been removed,
as is necessary for a complete overhaul, the greatest
care must be taken on replacement to ensure
accuracy of alignment. The appropriate procedure is
as follows:
1. See that the face of both the rear of the cylinder
block and flywheel housing are perfectly clean
and free from burrs.
2. Set the housing on to the studs and tighten, but
do not overtighten so as to allow adjustment.
3. Flywheel Housing Bore Alignment.
• Secure the base of the dial gauge to the
flange of the crankshaft.
• Set the needle of the gauge to the inside of
the bored hole in the flywheel housing.
• Turn the crankshaft and check that this is
truly central. The housing is adjusted until it
is central.
• For convenience in turning the engine it is
advisable to release (but not remove) the
nuts holding the injectors in place.
• The flywheel housing bore should be truly
central with the crankshaft within the limits
4. Flywheel Housing Face Alignment.
• With the face of the dial gauge secured to the
crankshaft flange, adjust the dial gauge so as
to set the needles against the vertical
machined face of the flywheel housing, and
again turning the crankshaft, check that this
face is perpendicular to the crankshaft axis.
When carrying out this check, the crankshaft
should be pressed forward to take up end
float.
• This facing should be within the
specification.
• All adjustments to bring the flywheel housing
within the limits must be on the flywheel
housing and under NO CONDITIONS must
the rear of the cylinder block be interfered
with.
• When the housing is properly aligned to the
above limits, tighten the securing nuts
evenly.
• Ream the dowel holes and fit the correct
length and size dowels.
84261396 - 09 - 2009
CRANKSHAFT REMOVAL
1 2
(OP 10 103 10)
1. Remove the engine from the tractor as
previously described and place on an engine
stand (Special tool No. 293860).
2. Remove the oil sump, flywheel, flywheel
housing, timing cover as previously described.
3. Remove the oil pump as explained in Section --
OIL PUMP REMOVAL, Page 68
4. Remove rear seal bracket with seal.
5. Remove connecting rod caps (1) and big end 2 1
bearings.
6. Remove main bearing caps (2) and main 5
bearings.
7. Lift out crankshaft.
Repair and inspection
1. If crankshaft timing gear teeth are worn or
damaged it is necessary to replace the complete
crankshaft assembly.
2. Wash the crankshaft and drilled passages in a
suitable solvent. Dress the minor imperfections
using an oil stone but for severely marked
journals machine to next undersize bearing.
3. Measure the diameter of each journal with a

micrometer.
Measuring, A, Compared with B, Indicates
vertical taper.
Measuring, C, Compared with D, Indicates
horizontal taper
Measuring, A and B, Compared with C and D,
indicates journal out of round.
4. Examine the rear seal journal for scoring marks,
remove minor imperfections with fine emery
paper, and if severley damaged renew the
crankshaft.
5. Check for crankshaft end float (0.05 mm -- 0.38
7
mm), if it exceeds the specified limit, replace by
oversize thrust washers.
6. In case balance weights are required to be
replaced, replace them in sets only. In case a
single balance weight requires replacement, this
must be done selectively so that there is no
greater weight variation than 0.028 Kg between
individual weights.
84261396- 09 - 2009
CRANKSHAFT RE--GRINDING
Crankshaft has to be re--ground for fitment of
undersize bearings.
Before proceeding to regrind the crankshaft, the

following points should be checked to ensure it is
suitable for machining.
1. The crankshaft should be crack--detected before
regrinding. It must, of course, be remembered to
demagnetise the crankshaft after crack
detecting, in order to remove any polarisation
which may be present.
2. The main journal and crankpin diameters should
be checked to ascertain the appropriate
undersize to which the crankshaft can be
reground, i.e., 0.25 mm, 0.51 mm or 0.76 mm.
If the crankshaft is to be reground below 0.76 mm it

is recommended that a new crank shaft is fitted.
NOTE: It is important that radii of the main journals
and crankpins are maintained. If these are
neglected, a fatigue failure is liable to occur.
CRANKSHAFT RE--ASSEMBLY
Re--assembly of crank is the reverse of crankshaft
dismantling ensuring the following points:
1. Clean all the oil ways.
2. Check main bearing bolts for damage of threads.
If damaged, replace the bolts.
3. Clean bearing housing and place top half bearing
in position.
4. Place the crankshaft in position.
5. Lightly smear the two upper thrust washers with
lubricating oil and slide in to the recess provided
on either side of the rear main bearing housing,
with the steel side or plain surface of the washers
towards the housing.
6. Fit lower halves of the main bearings to the
bearing cap and place in position ensuring that
the thrust washers on No. 4 bearing cap are fitted
correctly.
7. Renew the rear main bearing cap “O” rings.
8. Lightly coat the rear main bearing cap butt faces
with jointing compound, only coat outboard of the
grooves machined in the cap butt faces and
ensure that the grooves are free from jointing
compounds.
9. Torque the bearing caps and crankshaft pulley to
the specified torques.
84261396 - 09 - 2009
FUEL SYSTEM
1
AIR CLEANER
Removal -- Installation (OP. 10 202 40)
NOTE: It is not necessary to remove the complete air 2
cleaner body, as described below, to service the air
cleaner elements.
Removal
1. Lift the front hood (2).after sliding lock (1 )
towards right
2. Loosen the clamp (1) of air cleaner hose (2).

3. Remove the air cleaner securing bolts (3). 1
4. Remove pre cleaner clamp (4). 4
5 Fly bolt (5) to take out air cleaner bowl.
2
5

1. Check for damage of rubber gaskets, replace if
damaged.
2. Check for oil level and condition, top up or
replace the oil depending on the condition of oil.
3. Clean the wire mesh with the help of diesel and
allow it to dry.
3
Installation of Air Cleaner
Installation of air cleaner is reverse of the dismantling
procedure.
84261396- 09 - 2009
FUEL INJECTION PUMP
REMOVAL -- INSTALLATION(OP. 10 246 26)

WARNING
and footwear.
NOTE: Ensure that the areas around the injection

pump, injectors and front cover access plate are
clean.
1. Remove the fuel pipes (1) to the pump and blank
off all the ports against the ingress of dirt.
2. Remove the throttle cable and stop control rod
from the governor housing of the pump.
1
1
3. Remove the inspection plate (1) from the timing
cover.
4. Carefully remove the three bolts and washers
securing the gear to the fuel pump, great care
must be exercised in removing these bolts to
avoid their falling off in the timing cover. 1
2
5. Release and remove the three nuts, plain and
spring washers(1) securing the flange of the fuel
pump to the back of the timing case.
6. Remove the fuel injection pump from timing

case. Cap all openings to prevent dirt ingress.
3
Inspection
The pump should not be tampered anyway. If the
pump operation is suspectful, it should be taken to an
approved MICO service centre/dealer for testing and
repair.
84261396 - 09 - 2009
Installation
Mounting and Bleeding the pump
1. Mount the pump on the rear side of engine timing
gear case with the help of three nuts, flat washers 2
and spring washers keeping the gasket between 1
the timing case and the pump flange.
2. Connect the respective fuel lines and bleed the
system upto fuel pump gallery by operating the
fuel lift pump manually.
3. Fit the fuel pump drive gear on the pump shaft
and tighten the securing bolts. Ensure that the
pin sits in the groove at the face of the pump
shaft.
4
Re--Timing
To set the timing of the fuel injection pump by spill
cut--off method, proceed as follows:
WARNING
Wear suitable eye and skin protective clothing. Fuel
may be expelled under high pressure.
1. Remove delivery valve holder (1) of No.1

cylinder and remove delivery pin and spring. 1
Keep them in a clean tray.
5
2. Refit delivery valve holder and connect
Swan--neck pipe (1) ( Special Tool No. 9970848).
3. Feed filtered fuel to the pump by gravity or by
operating the feed pump manually.
4. Rotate the crankshaft in the anticlockwise
direction (looking from fan side) to a position
slightly earlier to the commencement of fuel
delivery. In this position, fuel should start flowing
continuously out of the swan--neck pipe. 1
6
5. Now rotate the crankshaft in clockwise direction
and align the injection timing mark (1), Figure 4 Fuel pump timing is as follows
with the pointer(2). In this position, the flow of fuel
from swan--neck pipe should reduce to
approximately one drop in 10 seconds. If this is
Trem III 4510/4010 17 degree
not achieved, swivel the pump towards or away
from the engine to obtain the desired flow rate. Trem III 3510 15 degree
6. Tighten the FIP bolts and recheck the timing.
7. Remove swan--neck pipe and holder. Replace
back delivery valve pin, spring and delivery valve
holder. Connect injector fuel line to holder.
84261396- 09 - 2009
INJECTOR REMOVAL 1
WARNING 4
and footwear. 3
1. Ensure the areas around the injectors and fuel

pump are clean prior to disassembly.
2. Remove the leakoff line(1) retaining bolts (2) and
discard the two copper washers, installed either 2
side of the banjo fittings.
3. Loosen the injector pipe connections(3) at the 7
injection pump end
4. Unscrew the nut (4) and disconnect the high
pressure line from each injector.
. 1
8
Injector Testing and Overhaul
WARNING
The spray from a fuel injector tester can pierce
human skin with fatal results. When an injector is
spraying, the nozzle holder should be turned away
from the operator and any other persons.
During the Nozzle Opening Pressure and Spray

Pattern Tests, collect the spray in a container partly
filled with rags to absorb the spray.
When conducting the Nozzle Seat Leakage Test,
release the injector tester pump pressure before
touching the nozzle tip with a sheet of blotting paper.
9
WARNING
The spray is flammable make sure no open flames
are in the area of the tester and do not generate
excessive vapour.
1. Fit the Injector tester (SpecialTool No. 290284),

with a calibrating type fuel oil and leave the filler
cap loose to prevent a vacuum forming during
testing.
2. Prime the tester until oil is emitted from the tester
line, then connect the injector.
3. Make sure the knob on the right--hand side of the
tester is screwed in to prevent the gauge being
over pressurised if the injector nozzle is blocked.
84261396 - 09 - 2009
4. Pump the tester and check the nozzle is free to Installation

open. Open the pressure gauge valve and begin WARNING
injector testing. If the nozzle is blocked or the
needle jammed, dismantle the injector. Handle all components with the greatest care. Do not
5. Nozzle Opening Pressure setting -- Slowly pump
the injector tester and observe the pressure at
and footwear.
which the needle valve lifts and fuel is injected
form the nozzle tip. The acceptable pressure is
The installation is the reverse of the removal
208 +5 bar .
procedure noting the following points.
6. Spray Pattern-- Pump the tester rapidly (80 to 90
1. A new copper washer to be fitted
strokes per/min) and observe the spray pattern
from the holes. An atomised spray free from 2. Uncouple the fuel pipe altogether before
distortion and irregular streaks of fuel should be attempting to replace the atomiser.
observed. The tester is not regarded as providing 3. Screw the holding down nuts evenly, going from
a suitable test for atomisation under working one to the other, to ensure that the injector sits
conditions, but gives an indication of the working squarely on its seat.
of the nozzle. 4. See that the Union nut threads are clean and that
7. Nozzle Seat Leakage -- Wipe the nozzle tip dry there is no swarf or dirt in the pipe or unions.
and apply a pressure 10 bar(145 lbf/in2) below 5. Offer up the pipe to the delivery valve and injector
the opening pressure. The nozzle tip and bottom unions to check that the pipe fits square at both
face must remain essentially dry and there must ends. Do not fit one end and bend the pipe to
be no tendency for blob of fuel to collect or drip. square it with the other union.
A slight dampness can be ignored. If there is any
6. When fitting the pipes, tighten the union
leakage from the nozzle seat, the nozzle
alternately.
assembly must be cleaned or replaced.
7. If the pipe is square to the unions at each end as
8. Nozzle Back Leakage-- Apply a pressure 10 bar
described above, no force will be needed to
(145 lbf/in2) below the opening pressure, then
make a good joint. NO FORCE SHOULD BE
release the handle and time the pressure drop.
USED.
The pressure should drop 100--150 bar in 5--45
seconds. If below 5 seconds, the nozzle 8. Tighten the retaining bolts to a torque of 1.7
assembly must be replaced, if above 45 Kgf.m. (12 Ibf.ft.)
seconds, check for carbon on the valve and /or 9. It may be necessary to bleed the fuel system of
blocked back leak drillings. air in order to start the engine. Refer to
NOTE: If the injectors meet the tests carried out then “Mounting and Bleeding the pump”
refit the injectors to the engine. If not, it should be
taken to an approved MICO service centre or dealer
for testing and repair.
84261396- 09 - 2009
LUBRICATION SYSTEM (OP. 10 300)
OIL PUMP REMOVAL(OP. 10 304 30)

WARNING
WARNING
and footwear.
1. Remove the timing cover, oil sump as explained

under section -- OIL SUMP REMOVAL ,Page 49
1
2. Remove bottom cover from timing case.
3. Release the lock (1) and remove the idler gear (2)
from oil pump (4).
4. Unscrew the oil pump mounting bolts (3) and
remove the oil pump (4) along with the delivery
2
4
pipe.
NOTE: Delivery pipe can be removed and fitted
along with oil pump only. 3
1
Oil Pump Dis--assembly
1. Remove the setscrews (1) and open the back 1
cover of the oil pump.
2
2. Remove the pump gear with shaft using tool (1).
3. Remove the inner rotor.
84261396 - 09 - 2009

1. Wash all parts in a suitable solvent and inspect
innerside of pump, plate, and body, for excessive
wear or damage. If visually okay, check in the 1
following manner.
2. Clearance between inner rotor (1) max. diameter
and outer rotor (2) min. diameter at all points --
0.01 mm to 0.06 mm
2
4
3. Clearance between outer rotor and pump body
(1) -- 0.28 to 0.33 mm
5
4. Flush off clearance between face of rotors and
face of the pump body.
Inner rotor -- 0.04 -- 0.08 mm
Outer rotor-- 0.01 -- 0.06 mm
NOTE: If not to specification replace the oil pump, as
reduced pump pressure through wear could result in
reduced engine life.
6
Installation
Installation procedure for oil pump is reverse of
removal procedure ensuring the following:
1. Prime oil pump with oil before fitting
2. Crank the engine (Do not start), after assembly
is complete, until the recommended oil pressure
is obtained.
84261396- 09 - 2009
OIL FILTERS
NOTE: The Importance of using clean lubricating oil
in the first place, and providing means to ensure that
it is always clean in use, is hardly second to the
importance of cleanliness in respect of the fuel. It is
imperative, therefore, that lubricating oil filters are
not neglected. Moreover, if the periodical attentions
herein recommended are carried out and the correct
grade of clean oil used, a very long life can be
obtained from the engine.
To ensure cleanliness, the following filters/strainers
are incorporated.
1. Oil Filler strainer
2. Sump strainer.
3. Main (full flow) filter.
The purpose of the oil filler strainer is to prevent large
objects entering the sump when the engine is being
filled with lubricating oil.
The sump strainer consists of a metal screen, which
is fitted over the suction pipe to the oil pump.
This strainer requires no special attention, but it
should be cleaned every time the sump is removed.
Main (Full Flow) Filter
This filter incorporates a screw--on--canister where
the filter element is integral with the canister. This
filter should be renewed at the appropriate time, not
cleaned.
To renew the Oil Filter 7.
1. Unscrew and discard old oil filter
2. Clean the filter head and the threaded adopter.
3. Fill the new filter with clean lubricating oil,
allowing time for oil to fill, through the element.
4. Apply engine oil by hand on top surface canister
rubber seal before fitting.
5. Screw the replacement filter on to the filter head
until the seal just touches the head and then
tighten by hand as detailed in the instructions on
the filter. Where a tool is available, tighten to
15lb.ft. (2.07 Kgf.m.).
6. Run the engine and check for leaks. Check the
oil level after running and top up as necessary.
84261396 - 09 - 2009
COOLING SYSTEM(OP. 10 400)
RADIATOR REMOVAL (OP. 10 406 10)

WARNING
and footwear.
1
1. Loosen the clamp (1) and drain the coolant from
radiator
2. Disconnect the battery connections and loosen

the battery clamping bolts (1). Remove the
battery.
84261396- 09 - 2009
3. Loosen the clamps (1 & 2) and remove the hose

for air cleaner (3) and radiator 3 2
4. Remove the radiator support clamp
6. Remove the couplers for horn and headlamp.
7. Remove the radiator securing shell (1).
84261396 - 09 - 2009
8. Remove the radiator securing bolts (1) below the

front axle support.
9 Remove the radiator assembly.
1 1

1. Check the radiator for leaks, and repair as
required.
2. Inspect the fins for damage and repair as
required, ensuring they are free from any
obstruction.
Installation
Installation procedure of radiator is reverse for
removal procedure.
THERMOSTAT REMOVAL (OP. 10 402 32)

1. Drain the coolant system, below that of the level 2
of the thermostat housing
2 Remove the hoses (1) and bolts securing the
bracket (2)
1
3. Remove top flange (1) by loosening nuts.
3. Withdraw the thermostat (2) from the housing, 1
along with the gasket.
84261396- 09 - 2009
Testing
1. Place the thermostat in a container of water, and
raise the temperature to 100_C. If the thermostat
fails to open when hot, or close properly when
cooled, it must be replaced.
Installation
1. Coat new gasket with sealer and position the
recess on the thermostat housing, prior to
installing the thermostat.
2. Coat the edge of the thermostat with grease and
install.
3. Refit the thermostat housing.
3
WATER PUMP REMOVAL (OP. 10 402 10)
1. Drain the coolant from engine block.
2 Remove the radiator as explained in the previous
section.
3. Remove the coolant fan.
4. Remove the hoses and remove the bolts
securing water pump.
1
Water pump disassembly
1. Remove the back plate (1).
2
2. Remove the pulley using tool (1)
84261396 - 09 - 2009
3. Remove the impeller with bearing assembly.

2. Removes the impeller from bearing assembly
1
NOTE: The shaft and bearings are manufactured as
one component and cannot be serviced separately.
Water pump re--assembly

1. With the shorter end foremost, press the shaft
and bearing assembly into the rear of the water
pump body until the bearing housing end is
flushed with front of water pump body.
2. Fit the seal with the sealing face to the rear and
the flange against machined face of the body.
3. Fit the ceramic counterface seal to the shaft with
ceramic insert towards the seal.
4. Install the impeller on to the shaft
5. Install the pulley.
Installation • After Installation of radiator, refill the cooling

1. Installation of water pump is the reverse of system and run the engine for checking
disassembly, but observing the following leaks.
requirement.
84261396- 09 - 2009
NEW
HOLLAND
CLUTCHES SECTION 18
Clutches Chapter 1

18 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
18 100 Clutch Control, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clutch Pedal Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
18 110 Clutch Assembly, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
84261396 - 09 - 2009
SECTION 18 -- CLUTCHES -- CHAPTER 1 1
SECTION 18 -- CLUTCHES
Chapter 1 -- Clutches
CONTENT

18 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
18 100 Clutch Control, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clutch Pedal Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
18 110 Clutch Assembly, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry plate torsion springs
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical pedal control
Release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diapharam type

Plate material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cerametalic
Plate thickness: 7.5--8.1
Plate with pressure springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tangential springs
84261396-- 09 - 2009
2 SECTION 18 -- CLUTCHES -- CHAPTER 1
TIGHTENING TORQUES
Transmission housing to
M12X1.25 7
fly--wheel housing buckle up bolts (C1)
Clutch assembly mounting bolts (C2) M8X1 2.6
Bolts, Release Fork (C3) M16X1.5 16
C1
C3
C2
84261396 - 09 - 2009
SPECIAL TOOLS
Tool Description Tool No.
Clutch centraliser and finger height setting gauge . . . . . . . . . . . . . . . . 291184
Clutch finger height adjusting wrench (set of 3) . . . . . . . . . . . . . . . . . . 293763
Installer oil seal clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84261387
Installer oil seal in hollow shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84261388
SEALANTS
Operation Description Sealants Specification
Engine to transmission buckle up (S1) . . . . . . . . . . . . . . . . . . . . . . . . LOCKTITE--518
Bolts, release fork (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOCKTITE --243
S1
S2
84261396-- 09 - 2009
SECTIONAL VIEWS -- CLUTCH ASSEMBLY
3
1. Damper springs 3. PTO clutch release fingers
2. Transmission clutch release fingers
84261396 - 09 - 2009
SECTIONAL VIEWS -- CLUTCH PLATE
5 4
4
1. Clutch facing 4. Idle damper spring
2. Facing rivet 5. Main damper spring
3. Hub
84261396-- 09 - 2009
TROUBLESHOOTING
Problem Possible cause Correction
Clutch slips. 1. Clutch disc, pressure plate Replace clutch disc; replace
and/or flywheel wear. clutch if necessary and grind the
flywheel.
2. Damaged or bent or broken Replace finger assembly.
fingers
3 Oil or grease on friction Replace clutch disc; repair leak of
material. lubricant in to clutch housing;
thoroughly clean friction surfaces.
Clutch grabs. 1. Stiff external control linkage. Check and lubricate linkage pivot
points.
2. Warped clutch disc. Replace clutch disc.
3 Clutch disc with damaged Replace clutch disc
damper springs or loose hub.
4. Oil or grease on friction Replace clutch disc; repair leak of
material. lubricant in to clutch housing;
thoroughly clean friction surfaces.
5. Finger springs broken. Replace finger springs.
Clutch fails to disconnect and 1. Warped clutch disc. Replace clutch disc
drags 2. Damaged clutch release Replace clutch release bearing.
bearing
3 Damaged finger spring. Replace finger springs.
Clutch noise at engagement 1. Warped clutch disc. Replace clutch disc
and /or disengagement. 2. Damaged clutch disc damper Replace clutch disc
springs.
3 Excess backlash on clutch Replace clutch disc and shaft, as
disc to hub meshing splines. necessary.
Clutch noise at disengagement. 1. Worn clutch release bearing Replace bearing
Clutch control pedal hardness 1. Hard pedal Check and lubricate linkage.
2. Broken or disconnected clutch Repalce or hook -- up clutch return
return spring. spring.
84261396 - 09 - 2009

The clutch system is double clutch mechanical type. The friction between the clutch disc, flywheel and
It includes two dry clutch discs with non--asbestos, clutch housing transmits the engine power to the
organic material pads. One clutch disc is to connect transmission drive shaft and PTO drive shaft
transmission to engine and another for connecting independently.
PTO directly to engine, independent of transmission. The clutch pedal is connected to the main clutch
As usual, the clutch is located in front of the release bearing by means of mechanical linkage
transmission. The transmission (main) clutch is components.
operated by means of foot pedal and PTO clutch is When the clutch pedal is pressed, the clutch release
operated by hand lever located on right side below bearing moves forward and discharges the main
rear hood panel. The clutch system is composed of clutch fingers. Consequently, the clutch pressure
the clutch housing, clutch pressure plate, disc ring, plate backs off and releases the clutch disc from the
clutch release fingers, clutch release bearings and clutch housing. The transfer of engine power to the
clutch discs. transmission is stopped.
When the clutch pedal is released, the main clutch
OPERATION release bearing disengages the main clutch finger
When both the clutches are engaged, the PTO clutch which acts on the clutch pressure plate and causes
pressure plate pushes the PTO clutch disc against the clutch housing, main clutch discs and pressure
engine flywheel and transmission pressure plate plates to come in contact. The flow of power from the
pushes the clutch housing by the spring action of dish engine and transmission is re--established. Similarly
ring. PTO clutch is engaged and disengaged independent
of transmission clutch by operating PTO clutch
control lever.
84261396-- 09 - 2009
CLUTCH MECHANICAL RELEASE

CONTROL
Removal -- Installation (op. 18--100)
WARNING
and footwear.
Clutch Pedal Removal

6. Remove brake pedal spring (1)
7. Remove split pin (2) and disconnect linkage (3)
8. Remove circlip (4). 3
4
1
9. Loosen Lock screw (1)
2
10. Remove all foot platform bolts as shown
1
2
84261396 - 09 - 2009
11. Remove clutch pedal spring (1)
4
12. Remove split pin (1) and disconnect linkage (2)
from clutch cross shaft. 2
5
13. Jack--up rear LH side of tractor and remove LH
rear wheel.
6
14. Pull out clutch/brake pedal support rod (1) from
the rear axle housing
15. Retreive clutch pedal (2) from the support shaft
84261396-- 09 - 2009
PTO Clutch Lever Removal

To remove the PTO clutch lever (1), proceed as 1
follows:
8
1. Remove pin(1) by releasing lock plate and
disconnect linkage between PTO clutch lever
and PTO clutch cross shaft.
9
2. Remove the split pin lock(1), take out the pin and
remove hand lever from the mounting bracket
3. Remove bolt (2) from the housing to take out the
levers with the bracket.
10
Cross Shafts Removal
1. To remove cross shafts, clutch housing has to be
splited between engine flywheel housing and
transmission housing. See Section 10 Page to
for splitting the tractor.
11
84261396 - 09 - 2009
2. Remove clips (1) from both the forks locking

forks and release bearings & take out release
brgs.
12
3. Slide out both transmission and PTO clutch
release bearings (1) & (2) from the shaft.
1
13
4. Loosen the PTO clutch fork lock screw (1)
1
14
5. Loosen the transmission clutch fork screw.
6. Pull out the PTO clutch cross shaft (1 )from LH
side of the transmision housing and retreive fork
from the housing.
1
1
15
84261396-- 09 - 2009
7. Pull out the transmission cross shaft (1) from LH

side of transmission housing and retrieve fork
from the housing.
16
8. Reassemble the clutch mechanical release
control, taking care of the following:
-- Reassembly follows the disassembly procedure
in reverse.
-- Ensure that lock clips (1) are properly seated on
clutch release forks.
-- Comply with tightening torques indicated on
Page 2.
1
17
-- Apply LOCTITE 243 sealant to clutch release
fork lock--screw and LH brake pedal lock--screw
before tightening.
-- Before buckling up the transmission and engine,
thoroughly clean and degrease mating surfaces
and apply a bead of liquid gasket of approximate-
ly 2 mm of diameter following pattern shown in
the Figure 5 , Page 16
84261396 - 09 - 2009
SINGLE CLUTCH
Removal -- Installation (Op. 18 100)
WARNING
and footwear.
It is necessary to split the tractor between Engine and

Transmission housing to gain access to the clutch.
1. Loosen the set screw (1) form fork
3
2 Pull out the cross shaft ( 2 )
3 Remove clutch release fork ( 3 )
1
2
1
4. Slide out the clutch release bearing ( 1)
2
5. Loosen the bolts 3 nos. as shown in fig
84261396-- 09 - 2009
6.Unscrew bolts as shown in fig & remove top

cover ( 1 )
1
4
7. Remove lock ( 1 ) as shown in fig. Use plastci
hammer to push out the shaft, shaft will come out
toward gearbox side. & retrieve bearing.
5
8. To remove shaft ( 2 ) towards the clutch side
remove circlip lock ( 1 ) shown in fig Retrieve
bearing & seal.
6
9. Install seal ( 1 ) as shown using SST No. 84261387
84261396 - 09 - 2009
9. Reassemble the clutch mechanical release

control, taking care of the following: 1
in reverse, from step 9 back to step 1.
-- Ensure that spring plates (1) are properly seated
on clutch release fork.
-- Comply with tightening torques indicated on
Page 2.
-- Apply LOCTITE 243 sealant to clutch release
fork setscrew before tightening.
-- Replace key for RH brake pedal on support rod.
84261396-- 09 - 2009
CLUTCH PEDAL SETTING

1
Clutch Pedal free play setting
Clutch pedal free play should be 30--45 mm
measuring at clutch pedal. To adjust the free play,
proceed as follows:
4
1. Remove the split pin (1) and disconnect the
linkage.
2. Loosen the lock nut (2).
3. Rotate the yoke (3) clockwise to reduce the play
and anti--clockwise to increase the play.
3
4. Connect linkage back to cross shaft.
1
2
84261396 - 09 - 2009
P.T.O Clutch Lever Free Play ( Double speed )

Step fig 20
1. Open the parts pin (2) Fork ( 3)&Rod(5)
seperately.
6
2. Keep lever 1 at the right most position such that 1 3 4
the bearing is just touching the clutch fingers.
3. Insert Rod 5 into Fork 6 and tight the threads up 2
to 15mm.
4. Keep end of lever 7 at 30--35mm from edge as
shown in fig. 5
5. Insert Fork 3 into Rod 5 by keeping Rod in static
position. 20
6. Match the hole of Fork 3 with hole of lever 1
without disturbing the initial position of lever 1.
7. Insert pin 2 in matching holes and lock lever 1.
Step 2
7
Figure 21
8. Now tight the nut (4) to lock the fork.
EdgeA
9. We can see the play of Lever 7 between edge A
and end of lever at 30--35 mm from edge A.This
is free play of PTO clutch lever. 30--35 mm
21
84261396-- 09 - 2009
CLUTCH ASSEMBLY
Removal -- Installation (Op. 18 110 10)
WARNING
and footwear.
It is necessary to split the tractor between Engine and

Transmission housing to gain access to the clutch.
1. Seperate the Transmission housing from Engine
as described in Section -- 10, Page -- 23.
1
2. Remove the 10 capscrews (1) which retains the
clutch assembly to the engine fly wheel and
slacken the two remaining capscrews.
2
3. Insert centralising pin Special Tool No.291184 in
clutch plate shaft seats, back off the two
remaining capscrews and remove assembly
completely. Retrieve PTO clutch disc.
84261396 - 09 - 2009
Installation
4. Install the clutch assembly back on flywheel
taking care of the following:
-- Check condition of ball bearing (1) pressed in fly-
wheel. Replace in the event of excessive noise
or binding.
-- Refit old /new bearing packing the seat with
grease
-- Use centralising pin while installing clutch as-
sembly with PTO clutch disc on flywheel. 1
-- Tighten capscrews to specified torque See Page
2.
-- Before buckling up the Transmission housing 4
and engine, thoroughly clean and degrease mat-
ing surfaces and apply a bead of liquid gasket of
approx. 2 mm of diameter following pattern
shown in the Figure 5
84261396-- 09 - 2009
CLUTCH ASSEMBLY,
Disassembly-- assembly
(Op. 18 110 10)
WARNING
and footwear.
1. Remove clutch assembly from tractor as

described earlier in this section.
2. Loosen the PTO clutch release lever locknuts
(1).
IMPORTANT: Since the locknuts are under the load
of disk ring, loosen all these gradually and evenly by
rotating 1/4 to 1/2 turns.
1
3. Remove PTO Pressure plate (1).
2
4. Remove disk ring (1)and lock ring (2)
2
84261396 - 09 - 2009
5. Loosen lock nut (1)
4
6. Remove Transmission clutch pressure plate (1)
5
7. Remove transmission clutch disc (1) from the
housing.
6
Release fingers disassembly
8. Pull--out dowel pin (1)
84261396-- 09 - 2009
9. Pull out pin (1) from the housing and retreive

spring (2).
2
8
10. Remove release fingers from the housing.
84261396 - 09 - 2009
Inspection and Repair -- Clutch housing under cut --‘E’ = 2.5 mm

1. Check clutch driven discs for wear and replace -- Dressing allowance -- ‘F’ = 70 + 0.15 mm
if rivets (2), (Figure 10,) are near or flush with top -- Calculate Dimension ‘F’ as follows
facing. F=A+B+C+S1+S2+P
2. Discs are also to be replaced if the organic Where
facings are found to be soaked with oil. S1 = PTO clutch disc thickness
3. Check condition of clutch housing and pressure S2 = Transmission clutch disc thickness
plate friction surfaces. If necessary dress, noting P = Spring dimensions to restore original load
that dimensions of pressure plates and clutch = 4.5 mm (fixed).
housing must not be reduced below the limits -- Check that value ‘F’ is equal to 70 + 0.15 mm
described below, otherwise replace as -- n restoring value ‘F’ check that clutch housing
necessary. thickness ‘E’ does not fall below 17mm
Refering to Figure 10 i.e. D--F = E > 17mm
-- Fly wheel (1) under cut -- ‘A’ = 2mm -- Check that the undercut ‘E’ on clutch housing is
-- PTO Clutch pressure plate (2) thickness -- ‘B’ = deeper than 2.5 mm and restore as necessary.
22 mm -- If necessary dress friction face on flywheel and
-- Transmission clutch pressure plate (3) thickness restore external undercut ‘A’ of 2 mm.
-- ‘C’ = 24 mm
2
3 4
1
10
84261396-- 09 - 2009
Assembly
Re--assembly follows disassembly procedure in
reverse from step 7 back to step 1.
-- See figure for correct orientation of clutch discs.
11
-- Position Disk springs(1) correctly and lock--ring
(2) on transmission pressure plates as shown in
the figure.
12
-- Using Special Tool No. 291184, centralise clutch
discs.
-- Install the clutch assembly on flywheel and do
release finger adjustments as described under
Clutch release finger settings, Page 21
84261396 - 09 - 2009
Clutch Release fingers settings

For correct function of clutch release mechanism,
the release fingers must be set at the distances D --
96 mm adm D1 -- 121mm relative to flywheel face
from release fingers of transmission clutch and PTO
clutch respectively.
Follow the below described procedure to obtain
these settings.
1. Install the clutch assembly on engine flywheel.
13
2. Insert Centraliser Pin Special Tool No. 291184
along with fingers height setting gauge, drive
shaft seats, ensuring that end is in contact with
flywheel housing.
14
3. First set PTO release fingers by using height
setting gauge (1) as shown in Figure. Gap
between gauge and finger should be between
0.3 mm. Use feler gauge to check the gap.
4. Set the gap by rotating locknut using special Tool
No. 9971365.
5. Similarly set the height setting gauge as shown
in th Figure (b) to set transmission clutch release
fingers. The gap between fingers and gauge
should be 0.3 mm.
6. Adjust the gap by loosening locknut and rotating
screw using Special Tool No. 9971365. a 1 b
15
84261396-- 09 - 2009
Important Points To Be Taken Into Account 5. Ensure the clutch cover is secured to the
While Replacing Clutch: flywheel evenly and sequentially. Use new spring
WARNING washers.
6. After an initial running--in period, any variation
lever height will correct itself.
able protection clothing, including goggles, gloves 7. Before fitting, check the clutch plate for lateral
and footwear. runout.
8. Ensure the clutch plate is fitted the correct way.
1. Check the condition of spigot bearing, replace if Observe the direction as indicated on the driven
necessary plate.
2. Check the condition of the oil seals on the engine 9. Check the gearbox input shaft for damage. Only
and transmission sides for leaks and replace if nonmetallic based high melting point grease
necessary. should be used to lubricate the splines and
3. Check the flywheel face is free from scores and release bearing guide sleeve.
cracks. When machining the surface, follow 10. Check the release bearing guide sleeve for wear
specified tolerances. and replace if necessary.
CAUTION 11. After applying the grease to the gearbox input
shaft, guide the clutch driven plate on to the shaft
Machine the bolting surface to the same amount of
and remove the surplus grease.
the running surface, to maintain original clamp loads.
12. Ensure correct alignment between the engine
and transmission/clutch housing, ensure that the
WARNING
locating dowels are fitted and are secure.
Always use suitable tools to align holes. DO NOT 13. Carefully guide the input shaft into the clutch hub
splines, taking care not to allow the weight of the
transmission to hang on the hub of the driven
4. Ensure correct alignment of the clutch cover to plate, this will prevent irreparable damage to the
the flywheel. Use Special Tool No. 291184 for segments and associated cushion springs.
alignment.
14. Ensure the correct adjustment of clutch pedal
free play.
84261396 - 09 - 2009
NEW
HOLLAND
Service Manual-- TT45 / TT40 / TT35 Tractors
TRANSMISSION SYSTEM SECTION 21

Transmission Chapter 1

21 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
21 118 Transmission Assembly, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
21 148 Internal Components, Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
21 130 External Components, Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
84261396 - 09 - 2009
SECTION 21 -- TRANSMISSION SYSTEM -- CHAPTER 1 1
SECTION 21 -- TRANSMISSION SYSTEM
Chapter 1 -- Transmission System
CONTENT

21 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
21 118 Transmission Assembly, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
21 148 Internal Components, Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
21 130 External Components, Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SPECIFICATION
Gear box type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Constantmesh
Gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spur gears Ist/2nd, Helical3rd/4th

Range gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Constantmesh
Lubrication
Transmission oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . Lts APGL4SAE 20W30 23 Ltrs.
841261396 - 09 - 2009
2 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
35 HP REG 35--37 HP REG 35 HP HX 42 HP REG--HX

HELICAL HELICAL SLOW HELICAL SLOW HELICAL
Engine rpm 2000 2000 2000 2000
Total Reduc.
L1 160.17 181.24 181.24 160.17
L2 106.34 120.34 120.34 106.34
L3 72.03 81.51 81.51 72.03
L4 52.36 59.25 59.25 52.36
H1 44.15 49.96 49.96 44.15
H2 29.31 33.17 33.17 29.31
H3 19.85 22.47 22.47 19.85
H4 14.43 16.33 16.33 14.43
LR 130.51 147.69 147.69 130.51
HR 35.97 40.71 40.71 35.97
Engine Speed
540 rpm (std.) 1747 1747 1747 1747
PTO speed
540E rpm 1227 1227 1227 1227
(economical) PTO
speed
TIGHTENING TORQUES
Gear shift lever cover bolts (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 2.5
Hydraulic housing on transmission retainer bolts (C2) . . . . . . . . . . M10X1.25 6
Hydraulic housing on transmission retainer bolts (C3) . . . . . . . . . . M12X1.25 10
Crown wheel bolts (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 6
Pinion lock nut (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M35 30
Drain plug (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M22 4.5
PTO cover bolts (C7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12X1.25 9
Rear axle to Transmission housing attaching bolts (C8) . . . . . . . . M12X1.25 10
Front cover bolts (C9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12X1.25 10
Transmission housing to Centre housing attaching bolts (C10) . . M12X1.25 9
Differential lock pedal screw (C11) . . . . . . . . . . . . . . . . . . . . . . . . . . M10X1.25 6
84261396 - 09 - 2009
TIGHTENING TORQUES
C1 C2
C5
C6
C4
C3
841261396 - 09 - 2009
TIGHTENING TORQUES
C7
C8
C9 C10
C12
C11
84261396 - 09 - 2009
SEALANTS
Sealant
Operation Description
Specification
Rear axle to transmission housing (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite 518
Gear shft lever cover (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite 518
PTO cover plate (S3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite 518
Crown wheel bolts (S4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite 243
Front cover plate (S5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite 518
Front cover bolts (S6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite 243
Transmission to Centre housing (S7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite 518
Lift housing to Transmission housing (S8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite 518
S3
S8
S2
S7
S5
S1
S6
S4
841261396 - 09 - 2009
SPECIAL TOOLS
Socket pinion check nut ................................................ 84261389
Yoke and Spreader . . . 291051 & 291052
Pinion locking tool . . . . 84261392
Mandrel with exten . . . 9971381
Special snap ring remover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84261393
SECTIONAL VIEW -- TRANSMISSION ASSEMBLY
1 10 12
2 3
17
14
6
16 11
5 7 8
13 9 15
4
SECTIONAL VIEW -- TRANSMISSION ASSEMBLY
84261396 - 09 - 2009
14
17
18
20
19
22
22
21
16
23
5
1. Drive shaft 13. Reverse gear
2. Range shaft 14. Reverse drive gear
3. PTO input shaft 15. Pinion shaft
4. Ist gear 16. Driven shaft
5. 2nd gear 17. Reverse gear shift fork
6. 3rd gear 18. Reverse intermediate gear
7. 4th gear 19. Hi -- Lo gear shift lever
8. Low gear on pinion shaft 20. Range gear shift lever
9. Ist -- 2nd gear coupler 21. 1st -- 2nd gear shift fork
10. 3rd -- 4the gear coupler 22. 3rd -- 4the gear shift fork
11. Hi -- Lo gear coupler 23. Hi -- Lo gear shift fork
12. Low gear on range shaft
841261396 - 09 - 2009
TROUBLESHOOTING
Noisy operation with range in 1. Input and output shaft support Remove transmission housing and
neutral and main lever engaged bearing misadjusted. adjust bearings.
2. Failed or defective inner Remove housing, overhaul
component. transmission and replace faulty
parts.
3. Internal component seizure due Overhaul transmission and top up
to poor lubrication. oil to correct level.
Noisy operation with tractor 1. Faulty clutch plate springs Replace clutch plates
stationery, idling engine and
transmission in neutral
Self disengagement of speed, 1. External linkage and levers Adjust correctly

range gears misadjusted.
2. Failed control rail retaining Replace springs.
springs
3. Partial engagement travel Correct reasons for problem and
restore full travel
Difficult engagement of speed 1. External levers misadjusted Adjust correctly
and range gears 2. External levers stiff or seized Check pivot points and correct
3. Internal control items (rails, Overhaul control items.
forks and sleeves) slide with
difficulty

8 + 2 TRANSMISSION
The transmission has eight forward and two reverse
gears. The gear shift levers, operate in an H--Pattern.
WARNING
Always stop the engine, firmly apply parking brake
and place both transmission levers in neutral before
getting down from the tractor.
84261396 - 09 - 2009
The main gearshift lever (1) is used to select any one

of the four forward gears or one reverse gear. The
Hi--Low selector lever (2) is used to select the high
or low range, which gives double the number of
1 2
available gears.
To change gear range; depress the clutch pedal, stop
the tractor and move the Hi--Low selector lever
backward for high or forward low.
To change the gears in the selected range; depress
the clutch pedal and shift main gear lever in the
normal way
To select reverse gear (R), first stop the tractor.
NOTE: A safety start switch prevents operation of
the starter motor unless the transmission range lever 7
is in neutral position (N).
IMPORTANT: If it is necessary to tow the tractor, the

Hi--Low selector and both main gearshift levers must
be in neutral
Referring to Figures 4, 5, 8 & 9, the transmission has
an input shaft called drive shaft (1) and range shaft(2)
driven shaft ( 16 ) and pinion shaft ( 15 ).1st ( 4 ) 2nd
( 5 ) gears are integral part of the drive shaft &3rd
( 6 ) 4th ( 7 ) gears are integral part of driven shaft.
All gears of input shaft and driven shaft are constant
mesh , high gear is assembled in driven shaft while,
low gear ( 8 ) is fitted on the pinion shaft low drive
gear ( 12 ) is part of the range shaft is in constant
mesh with low gear on pinion shaft.
841261396 - 09 - 2009
The speeds are shifted by meshing gears Ist (4), 2nd range, shifting coupler to left engages cluster gear
(5 ), 3rd ( 6 ) & 4th (7) in succession with the gearbox directly to pinion shaft and pinion shaft receives the
driven shaft. This is done by means of gear couplers rotation from any one of the gears Ist,2nd ,3rd & 4th
(9) and (10). If coupler (9) is shifted, say to the left, depending on the position of gear couplers (9) and
its internal teeth will connect additional gear ring of (10) through driven shaft (16 ) and Range shaft (2 )
Ist gear (4) with toothed bushings secured on the For low gear range coupler (11) have to be shifted
driven shaft. As a result, Ist gear (4) will rotate to right and pinion shaft receives rotation via driven
together with the driven shaft and transmit rotation shaft ( 16) & range shaft ( 2) . Since gear (12) has
to pininion shaft via range shaft ( 2 ) . When gear less number of gears teeth, as a consequence, the
coupler (9) is shifted to the right, the driven shaft will pinion shaft will rotate slower than high range.
become rigidly connected with 2nd gear (5) having a
For high gear range coupler ( 11 ) have to be shifted
larger number of teeth than Ist gear. As a
to the left and pinion shaft receives a rotation directly
consequence, the pinion shaft will rotate faster than
from driven shaft ( 16)
the previous speed.
For engaging reverse gear, shift reverse gear fork to
Similarly by shifting gear coupler (10) to left pinion
right, power flow is from input shaft via drive shaft to
shaft is driven by 3rd gear (6) via range shaft and by
reverse drive ( 14 ) gear ( 18 ) acts as intermediate
shifting to right pinion shaft is driven by 4th gear
gear between reverse drive gear ( 14 ) and Reverse
(7)via range shaft and speed of the pinion shaft
gear ( 13 ) and changes the direction of rotation of
varies according to the number of teeth on the gears
pinion shaft. Depending on the position of range gear
(6) and (7).
coupler (11) high reverse or low reverse are
Range gear can be selected by shifting the range obtained.
gear coupler (11) to left or right. For getting high
84261396 - 09 - 2009
GENERAL RECOMMENDATIONS FOR Bearings

OVERHAULING OPERATIONS Use correct pullers for bearings removal.
Clean, lubricate and inspect well before reassembling
IMPORTANT: Please read this carefully before starting the bearings.
assembly or disassembly operations. The spiral elastic pins do not need such adjustment.
Precaution at flange and tool ends Sealing

While hammering at flange and tool ends during Use sealants as specified. Ensure that parts to be
removal or installation, attention must be paid to the sealed are clean, dry and grease free.
various phases. Functioning and integrity of tool as
well as various components must not be Oil drain
endangered.
Before disassembly, oil should be drained out from
the group.
Reassembling methods
WARNING
Adequate holding equipment should be used for
reassembling group. Disposal of used oil must be done according to the
laws
Lifting system will be necessary for reconnecting,
disassembling and reassembling the ring gear or for
holding the gearbox.
Cleaning
Use cross section drawings to ease assembly and
disassembly operations. • All parts in motion (gears, bearings, etc) are to be
washed accurately with parts cleaning solution.
Recommendations regarding lubrication. • Petrol and watery alkaline solutions are to be
avoided.
It is very important to use proper lubricants and to
maintain a constant level of correct lubrication. • Do not wash with stream or hot water as it will be
very difficult to eliminate surface humidity.
Right operational temperature is to be maintained.
• Dry all parts with a rag or air jet to avoid
scratching from abrasive residuals.
Shaft seals
• All surfaces should be covered with lubricant so
Respect the following recommendations during seal as to protect it from future oxidation.
and gasket assembly:
-- Clean shaft very carefully and ensure that the Inspections
part in contact with the rings is not damaged, cut
or out of roundness. • Examine accurately that all bearings, external
rings which may be still stuck in their position;
-- Assemble the seals so that the lips is fitted pivot pins on which rolls rotate and replace those
towards the oil side. which are worn out or damaged.
-- Lubricate seal lips (use oil ) and fill 3/4 of seal • Gears should not be damaged and toothing
cavity with grease. should not be excessively worn. Teeth
-- Use appropriate driver. Do not use a hammer smoothing should not be deteriorated.
directly on the seals. • Control all grooves: assure that they are not worn
-- Do not damage the seals while assembling the out or damaged.
shaft. • Replace damaged parts with original spare
parts.
O--ring • Replace seals on rotating shaft, after
Lubricate adequately before inserting them at the disassembly.
right place so as to avoid rolling while assembling
shaft.
841261396 - 09 - 2009
TRANSMISSION ASSEMBLY
Removal -- Installation (Op -- 21 118 10)

WARNING
and footwear.
DANGER
equipment of appropriate capacity. Ensure that units
Ensure that no one is in the vicinity of the load to be
lifted.
To remove the Transmission housing from the

tractor, tractor has to be splitted at clutch and
transmission housing and fenders, hydraulic
housing, three point linkage, rear tyres and final drive
housing have to be removed from the tractor.
Remove the transmission assembly from the tractor
as follows:
1. Disconnect battery negative terminal (1) and
insulate. 1
1
2. Detach electric connections (1) under rearhood
connecting rear hood to fender. 1
84261396 - 09 - 2009
3. Detach electric connections (1) between left and

right side fenders.
3
4. Disconnect clutch linkage (1).
4
5. Disconnect foot throttle linkage (1 ) & bracket( 2)
2
1
5
6. Loosen bolts securing foot boards on LH & RH
fenders and transmission housing and remove.
841261396 - 09 - 2009
7. Remove both left and right side wheels
7
8. Loosen the bolts (1) and remove fenders from
both sides.
Drain oil from transmission housing.
1
8
9. Disconnect hydraulic lines (1) connecting pump
and hydraulic distributor
1
9
10. Remove three point linkages from the tractor
10
84261396 - 09 - 2009
11. Place splitting trolley (Special Tool No: 292320)

(1) under the tractorPlace a suitable stand under
both side of the Final drive housing.
jeet
11
12. .Loosen the bolts (1) and remove operator seat
from the hydraulic housing.
1
12
13. Loosen the transmission and centre housing
coupling bolts and lift the assembly using a
suitable hoist.
13
14. Loosen the gear box cover bolts ( 1 ) & remove
cover
14
841261396 - 09 - 2009
< Change Fig >

15. Loosen the bolt ( 1 ) as shown in fig before

Loosen
seperating the transmission housing from clutch
housing. 1
15
16. Seperate the clutch & transmission housing
16
17. Wrap chain or nylon rope on the final drive
housing and connect it to a hoist. Loosen the
attaching bolts and remove the final drive
housing.
18. Repeat for the final drive housing on the other
side.
19. Loosen the bolts securing hydraulic housing on
transmission housing and lift the housing using
suitable hoist.
17
20. Place transmission housing on a suitable stand
18
84261396 - 09 - 2009
21. Remove differential housing along with Crown

wheel from the Transmission Housing as explained
in Section 27 Page 11
19
22. Loosen bolts (1) and remove top cover along with
gearshift levers.
WARNING
20
23. Reinstall the transmission to the engine
observing the following.
-- Reinstallation follows the removal procedure
in reverse, from step 22 to step 1.
-- Refer Section 27, Section 33 & Section 31 for
installing respective components.
-- Before reassembling housings, support and
covers, thoroughly clean and degrease
mating surface and apply a 2 mm bead of
sealant in the Figure 21, Page 18.
-- Tighten to correct torques as detailed on
Page 2.
841261396 - 09 - 2009
21
84261396 - 09 - 2009
TRANSMISSION -- INTERNAL COMPONENTS
Disassembly -- Assembly
REVERSE GEAR & INTERMEDIATE PLATE

(OP 21 148 )
WARNING
WARNING
and footwear.
To remove the Input shaft, transmission assembly

has to be detached from the centre housing, three
point linkage, Hydraulic assembly and PTO
assembly has to be removed from the tractor.
-- Refer page 15 for detaching the Transmission
from centre housing.
-- Refer section 35 for Three--point linkages and
Hydraulic Assembly Removal.
-- Refer section 31 for PTO Shaft Assembly
Removal.
To remove the Intermediate plate & reverse gear
1. Remove PTO shaft ( 1 ) and coupling ( 2 )
2
1
2. Remove all roll pins from gear rails to make
dismantling easy , also remove 3 springs & balls
NOTE: Remove plug ( 1 ) from housing ahown at
( 4 ) from where H/L rail passes, retrieve spring & ball 1
of H/L rail, Retrieve balls & springs from loaction
(2)&(3)
4
2
841261396 - 09 - 2009
3. Remove bolt ( 1 ) of oil feeder pipe
3
4. Remove 4 springs (1) and balls (2) with the help
of a magnetic tool.
Remove all the rails & take out gates, forks
NOTE: Bring all the gears neutral position to remove

rails & retrieve balls 3 nos. from crown side.
4
5. Remove circlip lock (1) of reverse gear stopper
plate (2)
2
5
6. Remove sleeve, hub and fork alongwith reverse
gear railshaft, retrieve gates of reverse shaft,
also retrieve ball.
84261396 - 09 - 2009
7. Remove circlip lock ( 1 ) of reverse gear
7
8. Remove reverse gear ( 1 )
8
9. Remove circlip lock ( 1 ) of reverse drive gear
9
10. Remove reverse drive gear (1) from drive shaft
1
10
841261396 - 09 - 2009
11. Unscrew idler gear shaft locking screw (1) with

the help of screw driver
NOTE: Use thread locker 243 while refitting locking 1
screw.
11
12. Remove idler gear (1)
12
13. Retrieve, spacer, (1) needle bearing (2) and
reverse idler gear pin along with reverse gear. 4
.
13
14. Remove circlip lock ( 1 ) of driven shaft bearing
14
84261396 - 09 - 2009
15. Remove all bolts ( 1 ) of the intermediate plate
15
16. Remove intermediate plate alongwith bearings
16
17. Remove ball bearings from the intermediate
plate by expanding bearing lock ( 1 )
17
NOTE: To fit bearings in the intermediate plate first
fit bearing lock
18. After fiting lock in plate expand lock and slide the
bearing using hammer in such a way lock sits on
the groove of bearing.
NOTE: After fitting driven shaft and drive shaft
assembly fit intermediate plate, then fit reverse gear
assembly.
1
18
841261396 - 09 - 2009
Installation reverse gear

19. Re install the reverse gear observing the
following
-- Re installation follows the removal procedure in
reverse from step
-- Take care of bearings while assembly
-- To avoid sliding of dowels 2 nos ( 2 ) inside first fit
2
intermediate plate and then fit dowels. 1
NOTE: Keep reverse drive gear collar towards
intermediate plate.
19
DRIVEN SHAFT REMOVAL
--INSTALLATION
1. After removing the intermediate plate remove Ist 1
gear ( 1 ) of the driven shaft
1
2. Remove botom rail (1) and take out fork (2) of
Ist/2nd, hub and sleeve ( 3 ) 3
1
2
3. Remove snap ring from the driven shaft before
taking out hub (1 ) of Ist/2nd gear of driven shaft
NOTE: Keep face of hub having cut towards pinion
side.
84261396 - 09 - 2009
4. Remove snap ring ( 1 ) before removing the 2nd

gear
4
5. Remove 2nd gear ( 1 ) from driven shaft
5
Drive shaft removal
6. After removing 2nd gear from the driven shaft 1
remove dive shaft ( 1 ) in assembled form, 1st /
2nd all integral part of the drive shaft.
6
7. Remove snap ring ( 1 ) of 4th gear on range shaft
841261396 - 09 - 2009
8. Remove 4th gear ( 1 )from range shaft
8
9. Remove driven shaft ( 1 ) from the housing
NOTE: 3rd & 4th gears are integral part of the driven
shaft 1
9
DRIVE SHAFT
Dismantling on bench
1. Remove snap ring (1) from the drive shaft to
dismantle hub of 3rd /4th gear also remove 2
sleeve (2)
1
1
84261396 - 09 - 2009
2. Remove snap ring ( 1 )from the drive shaft before

removing the 3rd gear (2) 2
NOTE: Ist /2nd gear are integral part of the drive
shaft
2
Assembly of drive shaft
_ Before assemblly carefully check gears , snap
rings etc. and replace if found faulty
3
DRIVEN SHAFT DISMANTLING ON BENCH
1. Remove snap ring (1) to remove high gear
( 2), bearing ( 3 ) from the driven shaft 1 2
841261396 - 09 - 2009
NOTE: 3rd/4th gears are integral part of the driven

shaft 1
3 2
2
Assembly of driven shaft
_ Before assemblly carefully check gears,needle 1
bearing , snap rings etc. and replace if found faulty
NOTE: Fit oil connector ( 1 ) between driven shaft &

pinion keeping larger dia. towards driven shaft before
fitting driven shaft on pinion
-- Fit drive shaft assembly
_ After fiting driven shaft fit 2nd gear, hub snap ring
on driven shaft
-- To make easy fitment of fork, sleeve of Ist/2nd gear
fit hub,sleeve &fork carefully
Fit bottom rail in fork of Ist/2nd gear.
-- Fit Ist gear on the driven shaft 3
NOTE: Fit high gear (3 ) fig. 2 on driven shaft outside

on bench to make easy fitment.
NOTE: Before fitting intermediate plate first fit 1
bottom & High low rail shaft in housing
RANGE SHAFT REMOVAL--INSTALLATION

1. Remove circlip lock (1 ) of the range shaft
1
2. Remove the range shaft (1 ) from housing and 1
oil feeder cup (2 ) from shaft as shown 2
2
84261396 - 09 - 2009
3. After removing the H/L rail shaft take out high low
fork ( 1 )
NOTE: It is required to take out sapcer( 2 ) spring and 1
ball of H/L rail shaft from the housing
3
4. After the range shaft removal remove snap ring
( 1 ) of range shaft bearing and remove bearing
NOTE: Insert first bearing lock in housing before
fitting bearing for range shaft
Assembly
NOTE: Range shaft to be fitted after fitment of pinion 1
& crown
-- Assembly is reverse of the dismantling
-- Take care of worn out parts if any before
assembling.
PINION SHAFT
Removal -- Installation (Op 21 118 10)

WARNING
and footwear.
To remove the pinion shaft, it is necessary to remove

the transmission housing, from the tractor following
the procedure described under Transmission
Assembly removal Installation, Page 15. Also it is
required to remove PTO cover and related
components.
1. Remove the driven shaft, drive shaft and range
shaft before dismantling pinion shaft
841261396 - 09 - 2009
1. To remove the crown whell loosen allen screws

( 1 ) from the cover plate , remove crown
wheelalong with cover plate , retrieve rubber ring 1
from the housing.
2
2. Remove the crown wheel along with differential
housing following the procedure described in
Section 27, Page 12
3
3. Open the lock of pinion locking check nut with the
help of screw driver
4
4. Fit Pinion locking tool SST no 84261392
84261396 - 09 - 2009
5. Remove the pinion lshaft lock nut using SST no

84261389
6
6. Withdraw pinion shaft from the differential
housing and retrieve low gear,sleeve , coupling
etc from the pinion shaft.
NOTE: Keep deep cut of hub towards pinion check
nut side.
7
7. Remove the circlip lock of the Gama Basasa
1
bearing to remove bearing cone ( 1 ) from the
housing
8
8. Remove bearing from the pinion shaft using SST
no 291051 & 291052 1
841261396 - 09 - 2009
Assembly
9. nstall the bearing on pinion
10
2. Fit the outer cone of Gama Bassa bearing and fit
circlip lock
10
3. Fit pinion shaft along with hubrange,sliding
sleeve, bush and low gear as shown
NOTE: Fit small spacer keeping cuts towards pinion
teeth side, also big spacer cut towards similarly.
NOTE: Keep deep portion of low gear hub, towards
pinion check nut side.After fitment check low gear it
should rotate free.
11
4. After fiting pinion, tighten pinion check nut at 28
Kgm and check pinion breaing preload by
wraping a cord around low gear hub with the help
or spring balance it should be 2.5--3 Kgm.
NOTE: If recomended preload not comes, hammer
pinion using aluminium rod lock pinion check not ,
and check again.
12
84261396 - 09 - 2009
TRANSMISSION RAILS & FORK FITMENT
Removal -- Installation ( 21 148 )

To fit the rail shaft & forks follow the procedure as
mentioned under
1. Insert bottom rail Ist /2nd with fork insert crrclip
on bottom rail & ensure it sits inon seat in
housing.Circlip ensures rail not moves inside
housing. 1
1
2. Rail ( 1 ) and fork,gate etc . of H/L should be
fittted only after pinion & crown settings. 1
NOTE: Keep grooves of rails upward to make easy
fitment of balls & springs.
2
3. Transmission rails can be identified by refering
fig 3. To fit rails Ist/2nd & 3rd/4th rails are similar. Ist/2nd rail ball
After fitting rangeshaft and drive shaft fit fork for
3rd/4th and insert reverse rail paasing thru fork pin
of 3rd/4th gear.
1
H/L rail
3rd/4th rail Reverse rail

3
4. After fitting reverse rail insert ball ( 1 ) applying
some grease in the housing
841261396 - 09 - 2009
5. Insert rail of 3rd/4th with gate , passing thru fork

of 3rd/4th gear as shown in fig 5.
Insert gate of Ist /2nd rail sahft on the notch of Ist

/2nd gear fork.
5
6. Insert ball applying some grease in housing after
removiing bolt as shown in fig 4. Ist/2nd rail ball
pin
7. Insert Ist /2nd rail passing thru gate as shown in
1
fig 5 .
NOTE: Keep grooves of rails upward to make easy H/L rail

fitment of balls & springs.
3rd/4th rail Reverse rail

6
8. Insert ball and pin after removing neutral safety
switch for H/L rail then fit neutral safety switch
and tight it at
7
9. After fitting reverse rail insert ball ( 1 ) applying
some grease in the housing as such it sits in
groove given on reverse rail.
10. Insert balls & springs of the rails & Insert plug
above the spring of H/L rail. Fit roll pins in all rails
& gates.
84261396 - 09 - 2009
External components (OP 21--130 26)
Disassembly -- Assembly
Gear shift lever

WARNING
WARNING
and footwear.
1. Loosen the bolts (1) and remove top cover (2)

from the transmission housing.
1
2. Remove the circlip (1) to remove gear lever
rubber boot (2). 2
1
841261396 - 09 - 2009
3. Remove the split pins ( 1 ) & Take out pin ( 2 ) to

remove lever ( 3 ) from LH /RH side 2
1
3
3
4. Remove circlip lock ( 1 ) from the yoke ( 2 ) from
LH/RH gear shift levers
4
5. Remove the washer ( 1 ) and yoke from LH/RH
gear shift levers
NOTE: Take out springs 2 nos from the range lever 2
1
5
6. Remove expansion plug ( 1 ) from the shifter
cover housing as shown 1
84261396 - 09 - 2009
7. Remove roll pin ( 1 ) from shaft ( 2 ) and remove

fork ( 3 )
1
3
7
Assembly
8. Assemble the levers in the gear shifter housing
and reinstall parts as shown observing following
-- Inspect the rubber bellows for cracks or damage
replace if necessary
-- Use sealant on expansion plug holes before

fitting expansion plugs to avoid possible oil
leakage from pllugs
-- Before fixing cover plate , thoroughly clean and
degrease mating surface and apply a 2mm bead
of sealant following pattern shown
-- Reinstalltion follows the removal procedure in
8
reverse , from step back to step
-- Tighten to correct torque as detailed on page
841261396 - 09 - 2009
Reinstallation
9. Assemble the levers in the cover plate and
reinstall the coverplate on the transmission
housing observing the following:
-- inspect the rubber boot (1) for cracks or damage,
replace if necessary.
9
-- Reinstallation follows the removal procedure in
reverse, from step 7 back to step 1.
-- Before fixing cover plate, thoroughly clean and
degrease mating surface and apply a 2 mm bead
of sealant following the pattern shown in Figure
-- Tighten to correct torque as detailed on Page--2.
10
84261396 - 09 - 2009
DESCRIPTION : 8 X 8 SHUTTLE TRANSMISSION
8 x 8 Shuttle Transmission
A synchronized 8x8 shuttle transmission is available
in TT45 / TT40 / TT35. The synchro shuttle
transmission is ideal for application which require
frequent changes of 4direction. The operator has to 1
press clutch pedal and move shuttle lever to change
direction of travel. Shift lever (1) to front for forward
& rear to get reverse direction.
11
8 X 8 DISMANTLING & ASSEMBLING

PROCEDURE : 1
1. Remove split pins (1) and (2) to release link (3)
3 2
12
2. Remove circlip lock (1)
13
841261396 - 09 - 2009
3. Remove shuttle wire (1) as shown
14
4. Collect spring & pin as shown
15
5. Remove the pin from gate using roll pin remover
16
6. Take out shaft as shown
17
84261396 - 09 - 2009
6. (A) Fork and gates are shown in figure
18
7. Pull out gear assembly (1) as shown
19
8. Retrieve bearing (1) and (2) as shown
2 1
20
9. Remove circlip lock (1) as shown and take out
fork (2)
21
841261396 - 09 - 2009
10. Remove circlip lock (1)

1
22
11. Remove coupler (1) as shown
1
23
12. Using aluminium rod push out input shaft
24
13. Fix the shaft on a bench vice and take out hub (1)
using aluminium rod
25
84261396 - 09 - 2009
13. (A) Remove circlip lock as shown to take out hub

& Sleeve
26
13. (B) Fix the shaft into a bench vice and take out
hub (1)
27
14. Remove sleeve & washer
28
15. Check bearing (1) and (2) as shown
29
841261396 - 09 - 2009
16. Remove circlip lock to remove ball bearing

NOTE: Check all components with great care and
replace if found faulty
30
17. Various components of input shaft are shown in
figure
31
18. Unscrew the plug as shown and retrieve spring
and ball as shown
32
19. Check oil seal (1) replace if found faulty
Assembly : Assembly is reverse of the 1

dismantling procedure
33
84261396 - 09 - 2009
NEW
HOLLAND
MECHANICAL REAR WHEEL DRIVE SECTION 27

Rear Axle Chapter 1

27 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Description & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
27 100 Differential Housing, Removal -- Installation -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
27 126 Final Drive Housing, Removal -- Installation -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
84261396 - 09 - 2009
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE 1
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE
Chapter 1 -- Rear Axle
CONTENT

27 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
27 100 Differential Housing, Removal -- Installation -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
27 126 Final Drive Housing, Removal -- Installation -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
84261396 - 09-- 2009

2 SECTION 27 -- MECHANICAL REAR WHEEL DRIVE
SPECIFICATION
PINION TO CROWN WHEEL AND DIFFERENTIAL

Pinion and crown wheel ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion to crown wheel backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.18--0.23
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 pin
Differential lock control type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical operated with foot pedal
Differential lock free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 106

Compressed spring length, under a load of 36.5 kg/mm2 . . . . . . . mm 82
Side gear to differential gear backlash . . . . . . . . . . . . . . . . . . . . . . . . mm 0.1--0.25
Differential gear pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 21.96--21.939
Bore diameter on differential gears for pin . . . . . . . . . . . . . . . . . . . . mm 22.098--22.065
22.02--22
Bore diameter on differential case for pin . . . . . . . . . . . . . . . . . . . . . mm 0.159--0.04
Pin to differential gear clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.082--0.04
Pin to differential case clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
FINAL DRIVE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Epicyclic
Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 6.55
TIGHTENING TORQUES
Rear axle to Transmission housing attaching bolts (C1) . . . . . . . . M12X1.25 10
PTO cover bolts (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 10
Crown wheel bolts (C3)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 6
Drain plug (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M22 4.5
84261396 - 09 - 2009
TIGHTENING TORQUES
C1
C2
84261396 - 09-- 2009

SEALANTS
Sealant
Specification
Rear axle to transmission housing (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite--518
Lift housing to transmission housing (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite--518
PTO cover plate (S3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite--518
Crown wheel bolts (S4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite--243
S3
S2
S1
S4
SPECIAL TOOLS
84261396 - 09 - 2009

Differential plate check nut tightening tooll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9971349
Installer oil seal wheel side ( Heavy duty ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84261386
Socket allen key 6 mm 84261394
Yoke and Spreader . . . 291051 & 291052
84261396 - 09-- 2009

Sectional View -- CROWN WHEEL AND DIFFERENTIAL ASSY.
3 4
6 2 1
5
3
1. Crown wheel 5. PTO shaft
2. Pinion shaft 6. Differential Assy.
3. Input shaft 7. Brake.
4. PTO Input shaft
84261396 - 09 - 2009
SECTIONAL VIEW -- FINAL DRIVE
1 2
4
1. Trumpet housing 3. Planet gear
2. Rear wheel shaft
84261396 - 09-- 2009

TROUBLE SHOOTING -- PINION, CROWN WHEEL AND DIFFERENTIAL

Noisy rear axle when the 1. Pinion and/or crown wheel Remove rear axle housing and adjust
tractor is moving and also bearing misadjustment. pinion and crown wheel bearings
when transmission in correctly.
neutral (not originationg 2. Excess differential side gears to Remove rear axle housing and
from final drives) half -- shaft spline backlash replace damaged parts.
Noisy rear axle with tractor 1. Excess bevel pinion to crown Remove rear axle housing and adjust
under load and upon wheel backlash bevel pinion and crown wheel
release bearings correctly.
2. Fault or defective inner Remove rear axle housing, replace
components worn parts and adjust differential gear
backlash correctly.
Noisy rear axle with over -- 1. Insufficient pinion and/or crown Remove rear axle housing and adjust
heating wheel bearing backlash bevel pinion and crown wheel
bearings correctly.
2. Insufficient bevel pinion to crown Remove rear axle housing and adjust
wheel tooth backlash crown wheel bearings correctly.
TROUBLE SHOOTING -- FINAL DRIVE

Noisy final drives when the 1. Wheel axle shaft bearing Remove final drive case and adjust
tractor is moving and also misadjusted bearings.
with transmission in 2. Faulty or defective inner Remove final drive case and replace
neutral components. damaged parts.
3. Excess bull and pinion gear Remove final drive case and replace
backlash damaged parts.

The rear axle assembly transfers drive from the The planetary reduction gear set is controlled by the
transmission to the planet drive through a bevel bevel pinion and crown wheel output half -- shaft,
pinion and crown wheel coupling. The bevel gears which also controls the brakes.
are spiral type and are supported by tapered roller Planetary helps in improving traction and increasing
bearings. brakes life. It also gives more ground clearance and
The differential is fitted with four planetary and two it is sealed against water and dust.
side gears and mechanical lock. The differential lock In this cascade arrangement half axle is fitted into
is dog clutch type and operated by foot pedal located two side gears which rotates the planetary gears
below operator’s seat at right hand side. through a ring gear, resulting into reduction of speed,
that turn is transfored to rear axle.
84261396 - 09 - 2009
CROWN WHEEL AND DIFFERENTIAL

HOUSING
Removal -- Installation (Op 27 100)

To remove the crown wheel and differential housing,
Final drive housing, brake assembly and PTO
assembly has to be removed.
Remove the rear axle housing as follows:
1. Detach the negative cable (1) from the battery 1
and insulate.
1
2. Detach rear electric connections (1) under
rearhood 1
2
3. Detach electric connections (1) between left and
right side fenders.
3
4. Loosen the bolts (1) and remove operator seat
from the hydraulic housing.
1
84261396 - 09-- 2009

5. Disconnect hydraulic lines (1) connecting pump

and hydraulic distributor.
5
6. Remove three point linkages from the tractor.
6
7. Loosen bolts (1) securing foot rest to fender on
both sides.
7
8. Place the wedges at front and back on both sides
of front tyres
9. Jack up rear tractor and place two suitable
stands ( 1 ) under transmission housing to raise
the wheels off the ground
84261396 - 09 - 2009
10. Drain oil from the transmission housing.

11. Loosen the bolts and remove fenders from both
sides
1
9
12. Remove both left and right side wheels.
10
13. Wrap suitable chain or nylon rope on the final
drive housing (1) and connect it to a hoist.
Loosen attaching bolts and remove the entire
final drive.
11
14. Repeat for the final drive housing on the other
side.
15. Remove the cover plate by removing allen screw
(1) and remove cover plate (2).Retrieve oil rings 1 1
2 nos. from the housing & cover plate
respectively.
1
2
12
84261396 - 09-- 2009

16. Loosen the bolts securing hydraulic lift housing

to transmission housing. Lift the hydraulic lift
assembly using suitable hoist and place it on a
flat surfaced table.
17. Remove PTO engaging levers and differential
lock as detailed in Section 31 Page 6
13
18. Loosen the rear PTO cover bolts and pull out the
cover along with PTO shaft and PTO input shaft
assembly.
14
19. Remove PTO drive shaft.
15
20. Take out the differential assembly along with
crown wheel.
1
16
84261396 - 09 - 2009
Installation surfaces and apply a bead of liquid gasket of ap-

21. Re--install the differential housing observing the prox. 2 mm of diameter following the patterns
following shown in the Figure 17.
-- Re--assembly follows the disassembly pro- -- Tighten to correct torques as detailed on page 2.
cedure in reverse, from step 2 back to step 1. -- Preload tapper roller bearings by adding and re-
-- Check seals and replace if damaged. moving shims and set crown pinion backlash by
following the procedure given below.
-- Before reassembling housings, supports and
covers, thoroughly clean and degrease mating
17
Pattern for application of sealant during installation of PTO cover, Final drive housing and
Mechanical lift housing.
Check the backlash with the help of dial gauge . If it is more than 0.18 -- 0.23 mm then first loosen
Permissible backlash is 0.18--0.23 mm, if it is LH ring nut and then tighten RH ring nut
less than 0.18mm, tighten LH ring nut after
slightly loosening RH ring nut
84261396 - 09-- 2009

DIFFERENTIAL ASSEMBLY
Disassembly (Op 27 106 37)

With the assembly removed from the rear axle
housing , proceed as follows :
1
WARNING
insert hands or fingers between the part. Wear suit-
able protection clothing, includes goggles, gloves
and front wear.
1. Loosen the crown wheel attaching bolts (1).

1
2. Detach the crown wheel (1) from the differential
housing .
1
1
2
3. Loosen and remove all the bolts(1) from the
casing
3
4. Lift the cover (1) as shown to get access to
differential gears
84261396 - 09 - 2009
5. Remove the locking pin (1) locking the differential

gear pivot pin
5
6. Remove the pivot pin (1)& withdraw the side
gears from the differential housing along with
trust washer. 1
6
NOTE: Four differential gear (1) and side gear (2)
have thrust washers with same thickness.
2
4
1 3
7
7. Using suitable puller SST No 291051& 291052
remove the bearings from both the sides.
84261396 - 09-- 2009

8. Remove the differentuial lock clutch from the

housing
9
DIFFERENTIAL PINION AND SIDE GEAR
BACKLASH ADJUSTMENT
With reference to figure 7 , Page 15
Fit the two side gears (2 ) in the differential carrier
without the shims ( 4 ).
Install differential pinions (1 ) complete with thrust
washer (3 ) and journal and tighten bolts a few turns
to prevent journal work out.
Bring LH side gear into full contact with differential
pinion.
Using a depth gauge measure dimension (H1) at two
diametrically opposed points and average the two re-
adings. 10
Then push side gear into contact with differential
carrier and measure dimension (H2).
Repeat the same operations on RH side gear.
End float of each side gear without the baulk ring
must be:
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 LH side
gears.
Normal differential pinion and side gear backlash is 11
0.15 mm.
Note that the average ratio normal backlash to the
equivalent side gear end float is 1 to
Side gear end float corresponding to normal back-
lash will be:
0.15 x 1.8 = 0.25 mm
Consequently the shim thickness required in the dif-
ferential carrier is given by:
Ss = Gs -- 0.25 (for LH side gear)
Sd = Gd -- 0.25 (for RH side gear)
Available shims are 1.2 to 2.0 mm; install closest to
calculated thickness.
84261396 - 09 - 2009

Inspect all gears, thrust washers, bearings for any
kind of damages or wear. Replace if necessary.
WARNING
USE HANDS OR FINGERS.
Assembling
9. Re--install all the components of the differential
assembly observing the following
-- Set crown/Pinion backlash and total preload set-
ting as explained in page 18
-- Use suitable tools to fit bearings.
-- Tighten to correct torques as detailed in Page 2.
-- Use thread sealant (Loctite 243) on crown wheel
bolts
-- Sun star backless 0.15 mm procedure as per
procedure on page 16.
84261396 - 09-- 2009

Adjustment of bevel wheel bearings and

Crown pinion backlash adjustment 1
1
NOTE: Place o ring in the housing before fitting cover
plate
1. Fit the locator pins (1) and fit the cover plate ( 2)
tighten the plate with allen screws (3) , Screw out
two allen csrews (4) and remove lock plate from 3
both sides 4
3
NOTE: Place o ring on the housing before fitting 2
cover plate 4 1
12
2. Tighten LH ring nut (1) using SST no 9971349
1
untill minimum backlash between the bevel teeth
is 1mm
13
_ Measure the backlash usingdial gauge and
magnetic stand as shown in fig . Backlash to keep in
between 0.18--0.23 mm
14
3. Measure the torque using a spring balaance and
chord wound around the sleeve of low gear it
should be between 4--5.5 kgm.
15
84261396 - 09 - 2009
4. Fit the lock plate ( 1 ) back on bearing support apply

thread lock sealant locktite 243 to the allen screws
16
Inspect all gears, thrust washers, bearings for any
kind of damages or wear. Replace if necessary.
WARNING
Assembling
5. Re--install all the components of the differential
assembly observing the following
-- Set crown/Pinion backlash and total preload
should be 4--6 kgm after setting backlash check
at hub of H/L
-- Use suitable tools to fit bearings.
-- Tighten to correct torques as detailed in Page 2.
-- Use thread sealant (Loctite 243) on crown wheel
bolts
84261396 - 09-- 2009

FINAL DRIVE HOUSING (LEFT OR RIGHT

HAND SIDE)
1
Disassembly -- Assembly (Op 27 126)
WARNING
insert hands or fingers between the part. Wear suit-
able protection clothing, includes goggles, gloves
and front wear.
1. Wrap chain around final drive housing and

loosen bolts ( 1 ) Remove the final drive housing
1
2. Remove brake disc ( 1 ) and shaft ( 2 )
2
2
3. Remove the brake actuator assembly ( 1 )
1
3
4. Remove dual brake support ( 1 ) as shown
NOTE: Low duty & heavy duty dual brake support
are different
84261396 - 09 - 2009
5. Remove the allen screw (1) holding the cover for

road wheel shaft.
5
6. Remove spacers ( 1 ) planet final drive
6
7. Remove all three planet gears along with needle
bearings as shown
7
8. Remove the circlip lock ( 1 ) of planet carrier sub
assembly
84261396 - 09-- 2009

5. Remove the spacer & shims (1) as shown

1
9
6. Remove panet carrier sub assy ( 1 )
10
7. Check planet gear spacers & needle bearings for
damage , replace if found worn out.
11
8. With the help of hammer wheel axle shaft as
shown
12
84261396 - 09 - 2009
9. Retrieve the taper roller bearing

NOTE: Ball bearings are fitted in low duty trumpet
housing
13
10. Loosen the three bolts ( 1 ) of mud protection
cover from the trumpet housing 1
14
11. Retrieve oil seal from the housing
15
12. Retrieve the taper roller bearing, external spacer
seal & oil seal from the trumpet
NOTE: During fitment insert bearing spacer over
bearing manuallyin Heavy duty drive line.
NOTE: Ball bearing is fitted in low duty trumpet
housing 1
16
84261396 - 09-- 2009

Assembly of Trumpet housing

Reinstall wheel and axle shaft in final drive housing
observing the following :
-- Re assembling follows the removal procedure in
reverse from step 12 back to step 1
-- Refer to Figure 17 for correct orientation of the
shafts, bearings, sleeves and seals.
-- Check seals and replace if damaged
-- Fit trumpet oil seal(1) back, by using the Special

Tool No. 84261386 1
17
-- Check planet carrier after fiting circlip lock on
axle for free play. If notice any free play remove
circlip lock and place suitable shim below the
spacer, so as to eleminate free play completly
NOTE: In low duty trumpet housing bearing preload
is not required
-- Before reassembling housing and covers, thor-
oughly clean and degrease mating surfaces and
apply a 2 mm bead of sealant following the pat-
tern shown in the figure.
18
84261396 - 09 - 2009
19
84261396 - 09-- 2009

FRONT AXLE LS CABLE

Bolt Torque
3
2
1
1
20
Classification Torque (kgf--m) Classification Standard

1 4.0 ~ 5.5 Steering angle Inside 58, outside 45
2 8.5 ~ 9.5 King pin angle 10
3 12.0 ~ 13.5 Camber angle 2.5
3 (reamer bolt) 15.0 ~ 17.0 Caster 0
4 1.0 ~ 2.0 Tow--in 0 ~ 5mm
Used oil Gear oil #80 -- 10 liter
84261396 - 09 - 2009
Knuckle Configuration
3
2
A
B
21
1. wheel axle 2. seal 3. ball bearing 4. gear (38T) 5. ball bearing 6. gear (15T) 7. gear (14T) 8. seal 9. shaft
A. thrust bearingh B. gear (14T) C. taper bearing
Structure of Knuckle Notices in Assembling

It is composed of king pin part and final driving case When assembling knuckle combination and knuckle
and has two functions : driving and steering. arm (H), apply the grease inside. As the compression
may occur, remove grease nipple (J) before
Final gear is driving by bevel gear. assembling.
Oil seal has a strong structure using a special seal When knuckle arm (H) is compressed completely,
against humiidity and dust. measure the distance between knuckle arm (H) and
arm holder (I) and adjust with liner.
The upper cap uses the taper bearing for smooth
steering and has excellent wearing--resistant Liner (2 types) --> 0.1mm, 0.5mm
structure comparing with bushing type.
84261396 - 09-- 2009

KING PIN
1. Apply the fulcrum of the exclusive jig under the
front wheel axle
22
2. Remove front wheel combination
23
3. Loosen the steering angle adjusting bolt before
removing the pin to remove steeing cylinder
When assembling, the length of steering angle

adjusting bolt should be the same.
24
4. For your reference, the recommended
assembling dimension (A) is 43.8mm
25
84261396 - 09 - 2009
5. Remove bolt
26
6. Loosen steering hose
Remove bolt for fixing pin
27
7. Remove pin
Notice : there are two spacer (upper, lower)
28
8. Remove bolt
Remove pin
Remove cylinder
29
84261396 - 09-- 2009

9. Remove tie rod nut fixing split pin
30
10. Remove tie rod fixing nut and draw the tie rod out
Tight torque 5.0 ~ 5.5 kgf--m
31
11. Remove end by using the special tool
32
Special Tool for End Removal
33
84261396 - 09 - 2009
12. Loosen the drain cock from the bottom of king pin
case and drain the oil
34
13. You may remove oil checking plug (1) or the
lubricating plug to drain the oil faster
1
When draining the oil from differential gear,
loosen the plug (2) and drain the oil completely
When lubricating the oil, keep the funnel in 2

horizon and lubricate the oil until the oil flows over
at the oil checking inlet (1)
Oill Gear oil # 80

Amount 10 L
35
NOTICES IN FILLING UP OIL

When fill up oil, remove plug (3) to supply the oil
inside gear case. If fill up oil without loosening this
pug, the oil may not be enough due to the air inside.
36
84261396 - 09-- 2009

Front Wheel Axle

6 7 8 9
3
1 2
4
5
37
1. Ball bearing 2. Gear 3. Snap ring 4. Liner 5. Snap ring 6. Ball bearing 7. Case 8. Seal 9. Wheel axle
Disassembling of Front Wheel Axle

-- Remove fixing bolt of front final driving axle case
Torque 5.0 ~ 5.5 kgf--m
38
Remove wheel axle. -- Attention to the damage of
O--ring
Check O--ring and if damaged, replace it with new

one
39
84261396 - 09 - 2009
Disassembling of Wheel Axle

1. Remove gear (1) and bearing (2) together 2
1
40
2. Remove snap ring and remove liner (4)
The liner shall adjust the clearance, if required 3

Liner (2 types) : 0.1mm, 0.5mm
Backlash 0.1mm ~ 0.3mm
41
3. Remove case (9)
9
Check seal (8) and if damaged, replace it with
new one 8
42
4. Remove snap ring (5) and remove bearing (6)
7 6 A
Remove seal (8) 8
Remove O--ring (A)
Check O--ring or seal and if damaged, replace it

with new one
5
43
84261396 - 09-- 2009

5. Remove grease nipple (due to compressing

force)
When assembling, remove nipple because the

knuckle arm shall be broken due to internal
pressure
44
6. Before loosening the fixing bolt, support or hold
the lower case not to be fallen down and carry out
the following work
Loosen bolt for fixing the knuckle arm
45
7. Remove knuckle arm and O--ring
If O--ring is damaged, replace it with new one
Check number of liner (1) from the bottom of 1

O--ring and when assembling, the same liner
should be inserted
46
8. Remove gear case
Check gear, spacer and bearing to be assembled

in the bottom of the axle, and if damaged, replace
it
47
84261396 - 09 - 2009
9. Loosen bolt and remove knuckle arm holder
Notices in Assembling
-- When assembling, wind the sealing tape to all
bolts
48
10. Remove knuckle arm holder
Notices in Assembling 1
-- After removing the holder, pay attention to the
liner (1) below and when assembling, apply the
grease inside holder and install the liner (1) to the
holder
Before assembling the holder, apply the liquefied

gasket to the contact surface evenly
49
11. Remove driving axle downward
1
Refer to adjustment and checking to adjust the
liner (1)
50
12. Remove reamer bolt (1ea)
When assembling, pay attention to the reamer

bolt not to be changed with other bolt
Torque 13 ~ 15 kgf--m
51
84261396 - 09-- 2009

13. Loosen the fixing bolt for fixing the king pin case
(5ea general bolts)
52
14. Remove king pin case. At this time, remove gear,
spacer and bearing together
-- As it is hard to assemble the spacer, assemble
the gear case and king ping case first before
assembling the spacer
Refer to adjustment & assembling
53
15. Internal parts of king ping case
2
(1) King pin case
5
(2) Taper bearing
(3) Spacer
3
(4) Gear (16T) 1
(5) Axle
4
54
16. Clearance of the group seal use the spacer (3)
Clearance : 1.5+/--0.5mm
Spacer is 2 kinds
0.07mm, 0.2mm
55
84261396 - 09 - 2009
17. Remove driving gear (13T), spacer and liner
Adjust the liner at standard after measuring the

clearance of gear (1) on the above items and
gear (6) on the right figure
liner (2 types) : 0.1mm & 0.5mm
Clearance 0.2 ~ 0.4mm
56
18. Remove driving axle
57
19. Remove connector
Check O--ring and if damaged, replace it with

new one
D49.4 x 3.1
D79.5 x 2.0
58
84261396 - 09-- 2009

5 6
5 6
4
3
2
15
7 8
9
10
16
12
13
11 14
59
(1) Pinion center distance Notices in Adjusting
it means the distance from the gear part of -- When disassembling the differential
pinion gear to the center which is adjusted by liner combination, classify not to change the liner
(15). For more information, refer to next page
-- When changing the case or differential
(2) Pinion assembling revolving force combination, disregard the existing liner and
carry out the readjustment
Assemble pinion only in the state not
-- After completing the checking of pinion revolving
assembling the differential device and check
force, press the grove and fix the nut (14)
revolving force and then adjust it at standard using
completely
the nut (14)
-- When measuring the pinion center distance,
(3) Pinion and differential gear backlash
measure the gap of pinion gear first.--Refer to
“Adjustment of pinion center distance” on next
Adjust to reach standard using liner (5) and
page
(6)
84261396 - 09 - 2009
Adjustment of Pinion Center Distance
1. The adjustment of pinion center distance is

important as this is the adjustment of contact
surface of teeth between differential pre--gear
and pinion gear. If the contact of teeth side is not
good, carry out the readjustment
Measure distance of pinion gear (A)
60
2. In the state that the liner is removed from pinion
axle (1), insert the spacer (2) only and assemble 1
2 3
the bearing (3) on pinion axle (1)
4
Assemble pinion axle (1) combination to the case 5
Assemble taper bearing (3) from backside
Assemble O--ring sheet (4) to the axle
Assemble the nut (5)
At this time, do not assemble the seal and O--ring
Compress the bearing completely and measure
the revolving torque and tighten the nut until the
standard comes out
Pre load 9.0 ~ 13.0 kgf--cm
61
3. Adjust the gauge value to “0” by using the
exclusive jig
62
4. Install the exclusive jig in the differential case the
read the measured value (B)
Liner Adjustment Output

Liner value (mm) = 95 -- (A+measured value)
+/-- 0.05
63
84261396 - 09-- 2009

Pinion Axle Assembling
4 5
3 6
7
2
8 9 A
64
Before Assembling Pinion Axle Assembling
-- Disassemble again the pinion axle assembled -- Disassemble again the pinion axle assembled
when measuring when measuring
Wash the case and each part before assembling If the liner value comes out, assemble the liner
(3) with the measured value backside of the
Replace the seal (7), O--ring (8) and nut (A) with spacer (2)
new one . Check wearing status of seal contact
surface of O--ring sheet (9) and if troubles found, Assemble the bearing to the axle
replace it with new one
Assemble the outside wheel of bearing to the
case and insert the pinion axle
Assemble the bearing (5)
Assemble the coller (6)
Assemble the seal (7)
Apply the grease to the contact surface of seal

and oil (8) and assemble with O--ring sheet (9)
Assemble the nut and check revolving force. If no

problem found, press the grove and fix it
84261396 - 09 - 2009
Assembling of Differential Combination
1
2
65
Assembling of Differential Combination -- But, if there is some problem in pre--gear, replace
-- Assemble the differential combination after it with pinion gear by a set
finishing the pinion assembling -- Insert the differential combination to the case
-- Check troubles or clearance of internal part of -- Fix the snap ring (3) on the left/right
differential gear and if problem found, replace it -- Check clearance and adjust it by the liner until the
with combination standard comes out
84261396 - 09-- 2009

NEW
HOLLAND
FRONT AXLE LS CABLE SECTION 44


44 000 Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Knuckle Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
King Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tool for End Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Notices in filling up oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front Wheel Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembling of Wheel Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Front Wheel Pinion & Differential Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjustment of Pinion Centre Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembling of Differential Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
84261396 - 09 - 2009
SECTION 44 -- FRONT AXLE LS CABLE -- CHAPTER 1 1
FRONT AXLE LS CABLE

Bolt Torque
3
2
1
1
20
Classification Torque (kgf--m) Classification Standard

1 4.0 ~ 5.5 Steering angle Inside 58, outside 45
2 8.5 ~ 9.5 King pin angle 10
3 24 ~ 25 Camber angle 2.5
3 (reamer bolt) 15.0 ~ 17.0 Caster 0
4 1.0 ~ 2.0 Tow--in 0 ~ 5mm
Used oil Gear oil #80 -- 10 liter
84261396-- 09 - 2009
2 SECTION 44 -- FRONT AXLE LS CABLE -- CHAPTER 1
Knuckle Configuration
3
2
A
B
21
1. wheel axle 2. seal 3. ball bearing 4. gear (38T) 5. ball bearing 6. gear (15T) 7. gear (14T) 8. seal 9. shaft
A. thrust bearingh B. gear (14T) C. taper bearing
Structure of Knuckle Notices in Assembling

It is composed of king pin part and final driving case When assembling knuckle combination and knuckle
and has two functions : driving and steering. arm (H), apply the grease inside. As the compression
may occur, remove grease nipple (J) before
Final gear is driving by bevel gear. assembling.
Oil seal has a strong structure using a special seal When knuckle arm (H) is compressed completely,
against humiidity and dust. measure the distance between knuckle arm (H) and
arm holder (I) and adjust with liner.
The upper cap uses the taper bearing for smooth
steering and has excellent wearing--resistant Liner (2 types) --> 0.1mm, 0.5mm
structure comparing with bushing type.
84261396 - 09-- 2009

KING PIN
1. Apply the fulcrum of the exclusive jig under the
front wheel axle
22
2. Remove front wheel combination
23
3. Loosen the steering angle adjusting bolt before
removing the pin to remove steeing cylinder
When assembling, the length of steering angle

adjusting bolt should be the same.
24
4. For your reference, the recommended
assembling dimension (A) is 43.8mm
25
84261396-- 09 - 2009
5. Remove bolt
26
6. Loosen steering hose
Remove bolt for fixing pin
27
7. Remove pin
Notice : there are two spacer (upper, lower)
28
8. Remove bolt
Remove pin
Remove cylinder
29
84261396 - 09-- 2009

9. Remove tie rod nut fixing split pin
30
10. Remove tie rod fixing nut and draw the tie rod out
Tight torque 5.0 ~ 5.5 kgf--m
31
11. Remove end by using the special tool
32
Special Tool for End Removal
33
84261396-- 09 - 2009
12. Loosen the drain cock from the bottom of king pin
case and drain the oil
34
13. You may remove oil checking plug (1) or the
lubricating plug to drain the oil faster
1
When draining the oil from differential gear,
loosen the plug (2) and drain the oil completely
When lubricating the oil, keep the funnel in 2

horizon and lubricate the oil until the oil flows over
at the oil checking inlet (1)
Oill Gear oil # 80

Amount 10 L
35
NOTICES IN FILLING UP OIL

When fill up oil, remove plug (3) to supply the oil
inside gear case. If fill up oil without loosening this
pug, the oil may not be enough due to the air inside.
36
84261396 - 09-- 2009

Front Wheel Axle

6 7 8 9
3
1 2
4
5
37
1. Ball bearing 2. Gear 3. Snap ring 4. Liner 5. Snap ring 6. Ball bearing 7. Case 8. Seal 9. Wheel axle
Disassembling of Front Wheel Axle

-- Remove fixing bolt of front final driving axle case
38
Remove wheel axle. -- Attention to the damage of
O--ring
Check O--ring and if damaged, replace it with new

one
39
84261396-- 09 - 2009
Disassembling of Wheel Axle

1. Remove gear (1) and bearing (2) together 2
1
40
2. Remove snap ring and remove liner (4)
The liner shall adjust the clearance, if required 3

Liner (2 types) : 0.1mm, 0.5mm
Backlash 0.1mm ~ 0.3mm
41
3. Remove case (9)
9
Check seal (8) and if damaged, replace it with
new one 8
42
4. Remove snap ring (5) and remove bearing (6)
7 6 A
Remove seal (8) 8
Remove O--ring (A)
Check O--ring or seal and if damaged, replace it

with new one
5
43
84261396 - 09-- 2009

5. Remove grease nipple (due to compressing

force)
When assembling, remove nipple because the

knuckle arm shall be broken due to internal
pressure
44
6. Before loosening the fixing bolt, support or hold
the lower case not to be fallen down and carry out
the following work
Loosen bolt for fixing the knuckle arm
45
7. Remove knuckle arm and O--ring
If O--ring is damaged, replace it with new one
Check number of liner (1) from the bottom of 1

O--ring and when assembling, the same liner
should be inserted
46
8. Remove gear case
Check gear, spacer and bearing to be assembled

in the bottom of the axle, and if damaged, replace
it
47
84261396-- 09 - 2009
9. Loosen bolt and remove knuckle arm holder
-- When assembling, wind the sealing tape to all
bolts
48
10. Remove knuckle arm holder
Notices in Assembling 1
-- After removing the holder, pay attention to the
liner (1) below and when assembling, apply the
grease inside holder and install the liner (1) to the
holder
Before assembling the holder, apply the liquefied

gasket to the contact surface evenly
49
11. Remove driving axle downward
1
Refer to adjustment and checking to adjust the
liner (1)
50
12. Remove reamer bolt (1ea)
When assembling, pay attention to the reamer

bolt not to be changed with other bolt
Torque 13 ~ 15 kgf--m
51
84261396 - 09-- 2009

13. Loosen the fixing bolt for fixing the king pin case
(5ea general bolts)
52
14. Remove king pin case. At this time, remove gear,
spacer and bearing together
-- As it is hard to assemble the spacer, assemble
the gear case and king ping case first before
assembling the spacer
Refer to adjustment & assembling
53
15. Internal parts of king ping case
2
(1) King pin case
5
(2) Taper bearing
(3) Spacer
3
(4) Gear (16T) 1
(5) Axle
4
54
16. Clearance of the group seal use the spacer (3)
Clearance : 1.5+/--0.5mm
Spacer is 2 kinds
0.07mm, 0.2mm
55
84261396-- 09 - 2009
17. Remove driving gear (13T), spacer and liner
Adjust the liner at standard after measuring the

clearance of gear (1) on the above items and
gear (6) on the right figure
liner (2 types) : 0.1mm & 0.5mm
Clearance 0.2 ~ 0.4mm
56
18. Remove driving axle
57
19. Remove connector
Check O--ring and if damaged, replace it with

new one
D49.4 x 3.1
D79.5 x 2.0
58
84261396 - 09-- 2009

5 6
5 6
4
3
2
15
7 8
9
10
16
12
13
11 14
59
(1) Pinion center distance Notices in Adjusting
it means the distance from the gear part of -- When disassembling the differential
pinion gear to the center which is adjusted by liner combination, classify not to change the liner
(15). For more information, refer to next page
-- When changing the case or differential
(2) Pinion assembling revolving force combination, disregard the existing liner and
carry out the readjustment
Assemble pinion only in the state not
-- After completing the checking of pinion revolving
assembling the differential device and check
force, press the grove and fix the nut (14)
revolving force and then adjust it at standard using
completely
the nut (14)
-- When measuring the pinion center distance,
(3) Pinion and differential gear backlash
measure the gap of pinion gear first.--Refer to
“Adjustment of pinion center distance” on next
Adjust to reach standard using liner (5) and
page
(6)
84261396-- 09 - 2009
Adjustment of Pinion Center Distance
1. The adjustment of pinion center distance is

important as this is the adjustment of contact
surface of teeth between differential pre--gear
and pinion gear. If the contact of teeth side is not
good, carry out the readjustment
Measure distance of pinion gear (A)
60
2. In the state that the liner is removed from pinion
axle (1), insert the spacer (2) only and assemble 1
2 3
the bearing (3) on pinion axle (1)
4
Assemble pinion axle (1) combination to the case 5
Assemble taper bearing (3) from backside
Assemble O--ring sheet (4) to the axle
Assemble the nut (5)
At this time, do not assemble the seal and O--ring
Compress the bearing completely and measure
the revolving torque and tighten the nut until the
standard comes out
Pre load 9.0 ~ 13.0 kgf--cm
61
3. Adjust the gauge value to “0” by using the
exclusive jig
62
4. Install the exclusive jig in the differential case the
read the measured value (B)
Liner Adjustment Output

Liner value (mm) = 95 -- (A+measured value)
+/-- 0.05
63
84261396 - 09-- 2009

Pinion Axle Assembling
4 5
3 6
7
2 10
1. Axle
2. Spacer
3. Liner
4. Taper bearing
5. Taper bearing
6. Coller
7. Seal 8 9 A
8. O--ring
9. O--ring sheet
10. Dust cap
A. Nut
64
Before Assembling Pinion Axle Assembling
-- Disassemble again the pinion axle assembled -- Disassemble again the pinion axle assembled
when measuring when measuring
Wash the case and each part before assembling If the liner value comes out, assemble the liner
(3) with the measured value backside of the
Replace the seal (7), O--ring (8) and nut (A) with spacer (2)
new one . Check wearing status of seal contact
surface of O--ring sheet (9) and if troubles found, Assemble the bearing to the axle
replace it with new one
Assemble the outside wheel of bearing to the
case and insert the pinion axle
Assemble the bearing (5)
Assemble the coller (6)
Assemble the seal (7)
Apply the grease to the contact surface of seal

and oil (8) and assemble with O--ring sheet (9)
Assemble the nut and check revolving force. If no

problem found, press the grove and fix it
Fit dust cap (10) to inhance the oil seal life
84261396-- 09 - 2009
Assembling of Differential Combination
1
2
65
Assembling of Differential Combination -- But, if there is some problem in pre--gear, replace
-- Assemble the differential combination after it with pinion gear by a set
finishing the pinion assembling -- Insert the differential combination to the case
-- Check troubles or clearance of internal part of -- Fix the snap ring (3) on the left/right
differential gear and if problem found, replace it -- Check clearance and adjust it by the liner until the
with combination standard comes out
84261396 - 09-- 2009

NEW
HOLLAND
POWER TAKE-- OFF SECTION 31

Rear Power Take Off System Chapter 1

31 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
31 110 Removal -- Installation -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
84261396 - 09 - 2009
SECTION 31 --POWER TAKE--OFF -- CHAPTER 1 1
SECTION 31 -- POWER TAKE--OFF
Chapter 1 - Rear Power Take Off System
CONTENT

31 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully independent of ground speed
Engagement and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . thru mechanical clutch
Rotation (looking from tractor rear end) . . . . . . . . . . . . . . . . Clockwise
Engine speed
540 rpm (standard) PTO speed . . . . . . . . . . . . . . rpm 1747
540E rpm (economical) PTO speed . . . . . . . . . . . rpm 1227
Output Shaft
Number of splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 28.86--28.96
84261396 - 09 - 2009
2 SECTION 31 --POWER TAKE--OFF -- CHAPTER 1
TIGHTENING TORQUES

PTO case mounting bolts (C1) . . . . . . . . . . . . . . . . . . . M12X1.25 10
PTO lever plate screws (C2) . . . . . . . . . . . . . . . . . . . . . M8 0.9
Differential lock pedal screw (C3) . . . . . . . . . . . . . . . . . M10X1.25 6
C1
C3
C2
84191396 - 09 - 2009
SEALANTS
PTO rear cover (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite--518
Hydraulic to Transmission housing (S2) . . . . . . . . . . . . . . . . . . . . . . . Loctite--518
SPECIAL TOOLS
Installer PTO rear cover seal 84261381

Yoke & spreader . . . . . . 291051 & 291052
S1
S2
84261396 - 09 - 2009
SECTIONAL VIEW
5 4
1
3
2
3
1. PTO input shaft
2. Reduction gear
3. PTO Shaft
4. PTO engaging sleeve
5. Transmission input shaft.
84191396 - 09 - 2009
DESCRIPTION AND OPERATION SINGLE SPEED PTO
The power take--off (PTO) transfers engine power

directly to mounted, semi--mounted or trailed
equipment via a splined shaft at the rear of the
tractor.
The system utilises the standard 6--splines shaft 1
designed to operator at 540 rpm, the speed at which
most PTO driven equipment is designed to run.
The PTO Input shaft front end can be connected and
disconnected to the transmission input shaft by
means of a lever (1) on the left hand side of the
transmission unit.
The rear end of the PTO input shaft is connected to
the PTO output shaft through reduction gears.
IA standard speed of 540 PTO RPM can be obtained 4
at 1747 erpm in 3510/401010/4510 models.Shift WARNING
lever ( 1 ) forward to get normal 540 PTO RPM, and Whenever operating P.T.O. equipment, observe the
shift rearward to get ground speed PTO . 540 following precautions:
Economy RPM can be obtained at 1227 engine • Follow the operator instructions supplied by the
RPM. implement manufacturer.
• Do not wear loose clothing when operating
PTO Engine Lever Application
P.T.O. driven equipment,
RPM RPM position
• Do not approach, clean or adjust P.T.O. driven
540 1747 Forward Rotavator, equipment while the tractor engine is still run-
thresher etc. ning. Stop the engine wait until the P.T.O. and the
540E 1227 Backward Water pump equipment stop turning before getting down from
etc the tractor or before working on the P.T.O., or the
equipment.
DANGER • Apply the parking brake, place both gear shift
To avoid inadvertent movement of the implement, levers in neutral and block all four wheels before
disengage the PTO after each use. operating any stationary P.T.O. equipment.
• To avoid accidental engagement of the imple-
ment, ensure the P.T.O. engagement lever is in
the neutral position.
• Do not cross between the implement and tractor.
• Never allow anyone on or near the implement.
84261396 - 09 - 2009
DESCRIPTION AND OPERATION DOUBLE SPEED PTO
The power take--off (PTO) transfers engine power

directly to mounted, semi--mounted or trailed B
equipment via a splined shaft at the rear of the A
tractor. A C
The system utilises the standard 6--splines shaft
designed to operator at 540 rpm, the speed at which 1
most PTO driven equipment is designed to run.
The PTO Input shaft front end can be connected and
disconnected to the transmission input shaft by
means of a lever (1) on the left hand side of the
transmission unit.
The rear end of the PTO input shaft is connected to
the PTO output shaft through reduction gears.
IA standard speed of 540 PTO RPM can be obtained 5
at erpm1747 In 3510,4040,4510 by shifting lever • If it is required to reverse the direction of PTO
( 1 ) at position A . To obtain economy PTO shift the while keeping the tractor at stationery, then bring
lever at position B keep erpm at 1227..To get ground lever H/L in neutral position, shift lever ( 1 ) at
speed PTO shift lever at position C. positiuon C & engage reverse gear. This feature
can be used in applications like reaper, combine
PTO Engine Lever Application harvesters etc.
RPM RPM position
540 1747 Forward Rotavator,
thresher etc.
540E 1227 Backward Water pump
etc
84191396 - 09 - 2009
PTO SHAFT ASSEMBLY
Removal -- Installation (Op 31 110 08 )

1. Remove hydraulic lift assembly by following the
procedures given in Section 35.
2. Remove PTO lever as explained in Page 7 of this
section.
3. Loosen the bolts (1) securing PTO rear cover to
the differential housing.
1
1
4. Expand snap ring (1 ) with the help of plier. Keep
it expanded to remove PTO shaft rear cover. 1
( Applicable only for economy speed PTO )
2
Disassembly -- Assembly (Op 31 110 58)
5. Remove the PTO shaft assembly from the rear
cover.
1
6. Remove the shaft ( 1 ) and pto engaging coupler
(2) & retrieve the needle roller bearing & pto 2
engage ,disengage pad.
Note: Economy speed PTO coupler is big in 1
size & fit coupler large end towards clutch side of
tractor.
84261396 - 09 - 2009
MAIN PTO LEVERS AND INTERNAL

LINKAGES
Removal -- Installation (Op 31 101 16 ) 2

WARNING
and footwear.
1. Remove the hydraulic lift assembly by following

the procedure given in Section 35, Chapter 3, 1
Page 20 1
2. Push out roll pin (1) and remove main PTO lever
(2) from the shaft.
3. Loosen allen screw and remove plate ( 1 )
4. Remove roll pin holding differential lock fork (1)

and PTO coupler fork.
84191396 - 09 - 2009
5. Press differential pedal by applying some force

with hand to pull out shaft ( 1 ) Removedifferntial
pedal lever (2) by unscrewing two bolts (3)
securing the bracket
1
4
6. Push out the differential lock shaft (1) and PTO
lever shaft. 1
5
7. Remove PTO fork (1).
6
8. Remove differential lock pedal fork (1)
1
84261396 - 09 - 2009
PTO SHAFT ASSEMBLY ( DOUBLE SPEED )
Removal -- Installation ( Op 31 101 20 )

9. Remove ciclip lock ( 1 ) from shaft PTO rear &
remove gear
2
8
10. Remove the circlip lock ( 1 ) to take out hollow
PTO shaft alongwith needle bearing ( 3 ) fig10
9
11. Remove the circlip lock ( 1 ) to take out ball
bearing ( 2 )
1
2
3
10
12. Remove PTO gear aseembly ( 1 ) as shown in fig
11.
1
11
84191396 - 09 - 2009
13. Remove circlip lock from drive shaft assy (540)

from PTO rear cover along with ball bearing. 1
12
14. Remove the drive PTO drive shaft assembly
from the rear cover.
13
15. To dismantle PTO gears assembly use SST no
291051 & 291052 as shown in fig.to remove
bearing.
14
16. Fit the PTO oil seal in the PTO rear cover with the
help of SST no 84261386
15
84261396 - 09 - 2009

Check the gears shaft and bearings,l for wear and
damages. If required replace by new parts.
Assembling
Re--install PTO shaft assembly in differential housing
observing the following:
-- Reassembling follows the removal procedure in
reverse from step 7 back to step 1.
-- Refer to figure for correct orientation of the gears
and sleeve.
-- Check seals and replace if damaged.
-- Before reassembling PTO cover, Thoroughly 16
clean and degrease mating surfaces and apply
a 2 mm bead of sealant following the pattern
shown in the Figure 17.
-- Tighten the rear cover bolts to 50 Nm.
NOTE: Keep bigger collar of the gear towards
bearings
84191396 - 09 - 2009
17
84261396 - 09 - 2009
PTO SHAFT REMOVAL --INSTALLATION

( SINGLE SPEED ) ( OP 31 101 20 )
1. Remove the hydraulic lift assembly by following
1
the procedure given in Section 35, Chapter 3,
Page 20
2. Follow the process given on pages 6--8 for
external leverers removal.
3. Remove the PTOI cover as shown in fiog 1.
4. Retrive needle roller bearing ( 1 )
5. Remove roll pin holding differential lock fork (1)

and PTO coupler fork.
84191396 - 09 - 2009
1. Remove the PTO shaft along with gear ( 1 ) and

take out bearing ( 2 ) if required .
NOTE: Gear is the integhral part of PTO shaft in

single speed PTO.
1
2. Fit PTO shaft seal ( 1 ) as shown in fig.
I
2
Installation
-- Installation follows the reverse of dismantling

procedure.
84261396 - 09 - 2009
NEW
HOLLAND
BRAKING SYSTEM SECTION 33

Tractor Brakes Chapter 1

33 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
33 100 Brake Control, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
33 110 Brake Assembly, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake Pedal Free Play Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
84261396 - 09 - 2009
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 1
SECTION 33 -- BRAKING SYSTEM

Chapter 1 -- Tractor Brakes
CONTENT

33 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
33 100 Brake Control, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
33 110 Brake Assembly, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake Pedal Free Play Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
84261396-- 09 - 2009
2 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil immersed disc brakes acting
on differential axle shaft
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical , independent Pedal
control
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical, Hand lever Pull type
No. of Discs per side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 each side low duty& 3 each

side for heavy duty
Brake Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APGSAE 20W30
Nominal Brake Disc Thickness . . . . . . . . . . . . . . . . . . . . mm 4.65
Service/Parking Drakes Disc discard Thickness . . . . . mm
Brake Pedal Free Play . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 50--55
SPECIAL TOOLS
Description Tool No.
Insaller brake boot in trumpet housing 84261390
Insaller rubber boot outer in brake linkage groove . . . . . . . . . . . 84261391
84261396 - 09 - 2009
TIGHTENING TORQUE
Hand Brake Pawl Assembly mounting Bolt (C1) . . . . . . . . . . . . M12X1.25 10
Clutch housing to transmission (C2) . . . . . . . . . . . . . . . . . . . . . . . M12X1.25 10
Fender Bolts (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16 1.5 20
C1
C2
C3
84261396-- 09 - 2009
SPECIAL TOOLS
Installer brake rubber boot in the brake linkage groove 84261390

Installer brake rubber boot in the trumpet housing 84261391
SEALANTS
Buckle up of Rear Axle Housing to Differential Housing (S1) . . . . . 518
S1
84261396 - 09 - 2009
SECTIONAL VIEWS -- BRAKE CONTROL ASSEMBLY
2 3 5
1
3
1. Brake housing 4. Actuating discs
2. Outer friction plate 5. Inner friction plate
3. Actuator return spring
84261396-- 09 - 2009
TROUBLESHOOTING
Problem Possible causes Correction
Brake actuate only when pedal 1. In correct Pedal adjustment Check and adjust
is depressed fully.
Tractor pulls to one side when 1. Brakes not equally adjusted Adjust
brakes applied 2. Wrong tyre pressure Inflate tyres to correct pressure
3. Wrong liners on one side Replace discs
Brakes noisy 1. Oil contamination Check and change with
recommended oil
2. Wrong brake disc Replace brake discs.
Brakes remain applied when 1. Seized brake actuating Clean and lubricate linkages
pedals are released linkages
Pedals are hard to operate 1. Seized brake actuating Clean and lubricate linkages
linkages
84261396 - 09 - 2009

Oil immersed brakes used, has two brake discs (1) between the brake discs (1), which consists of two
both externally lined with friction material are discs (3) separated by steel balls (4) but connected
supported by brake actuator (2) mounted on brake by short springs (5). Lugs on the discs are attached
housing ( 8 ), An actuating assembly is mounted to a yoke (6) on the operating rod.
7
6
3
4 5
3
3
8
1
2
10
1
5
9
4
10
4
When the tractors moving, the brake discs rotate retracting springs (5) return the plates to their original
with the axle shaft. If brake pedal is depressed, its positions.
associated brake links cause this actuating discs to The force exerted by the driver is transmitted to the
turn in opposite directions. As the pressure plates brake assembly by a system of levers and rods. The
turn, the balls (4) clamped between the actuating actuating system not only connects the pedal with
discs roll over the inclined surfaces of their sockets the brake but also increases the relatively small force
(7). In the plates, thus causing the actuating discs to available at the pedal to the much larger force
move axially outwards to contact the rotating brake required to brake the vehicle. It can also permit the
discs which in turn contact the inner faces of the braking effort to be divided between the axles in the
brake housing (8) and differential support (9) and required proportion.
back--up discs (10). This movement increases the
Left wheel brake pedal can be retained in the applied
axial force on the housing, support back--up disc and
position by means of latch controlled by a hand lever
actuator and produce brake torque. This action
fitted at right hand side, below operator’s seat used
causes the axle shaft, hence the associated driving
as a parking brake.
wheel of the tractor, to slow down and then stop
rotating completely. On release of the brake,
84261396-- 09 - 2009
BRAKE PEDALS AND EXTERNAL

LINKAGES
Removal -- installation (Op 33 120 20)
1. Unlock clip (1) and remove pin (2) on LH and RH 1
side brake linkages.
1
2. Remove brake pedal springs (1).
3. Remove circlip (2),remove the locknut (3) from
the sleeve rod and disconnect linkage (4), 2
remove brake shaft locking conical screw (5).
2
5
3
2
4. Slide out both LH and RH brake pedals (1) from
clutch/brake pedal support rod. 1
5. Remove conical screw (2) & washer from
support rod.
3
PARKING BRAKE LINKAGE REMOVAL
(OP 33 110 30 )
6. Remove split pin from hand brake linkage
7. Pull out hand brake lever along with linkage rod
from the linkage assembly.
84261396 - 09 - 2009
8. Loosen the bolt (1 and remove hand brake pawl

(2))
5
Inspection
Clean the brake pedal assembly thoroughly and
check for bush and support rod wear, replace as
necessary
Installation
Re--install the brake pedals taking the following into
consideration.
in reverse, form step 8 back to step 1.
-- Carry out adjustment as detailed in page 13
84261396-- 09 - 2009
BRAKE ASSEMBLY
To remove brake assembly, rear axle assembly has
to be removed from the transmission.
1. Removetrumpet housing assembly (1) from
differential housing.
1
2. Place the trumpet housing assy on plane surface
2
3. Remove the brake disc ( 1 ) and shaft ( 2 )
3
4. Remove brake actuator assembly ( 1 ) from both
side 1
84261396 - 09 - 2009
5. Remove dual brake support assembly ( 1 )

NOTE: Dual brake assembly for low duty & heavy
duty are different type
5
-- Inspect the brake flange friction face for wear and
damage, replace if necessary.
-- Inspect the inner and outer brake discs, if badly
scored, worn or cracked, replace.
NOTE: Brake discs’ thickness should be minimum
4.30 mm.
Installation
WARNING
USE HAND OR FINGERS.
6. Reinstall the brake assembly and rear axle

housing to the differential housing taking the
following into consideration:
in reverse, form step 5 back to step 1.
-- Refer to Figure to orient the different parts.
-- Use SST no 84261390 to fit the brake rubber
boot in the brake linkage groove & brake rubber
brake boot with SST No 84261391 in trumpet
housing. as shown in fig 6 & 7.
6
-- Before reinstalling the rear axle housing, thor-
oughly clean and degrease mating surfaces and
apply a bead of liquid gasket of approx. 2 mm of
diameter following patterns shown in the Figure
11, page 12.
-- Check seals for wear and damage and replace if
necessary.
-- Tighten to correct torques as detailed on Page 3.
After brake assembly fitted in Differential housing,
check brake discs for free movement between brake
discs
84261396-- 09 - 2009
84261396 - 09 - 2009
BRAKE PEDAL FREE PLAY ADJUSTMENT

Measure free play of the brake pedals as shown in
Figure 9 and should be 50--55 mm. With the brake
pedals locked together, the tractor should stop in a
straight line when brakes are applied.
Adjustment is made to the brake pull rods beneath
the tractor. Block the wheels , front and rear, unlock
the brake pedals and release the parking brake lever.
Release locking clamp (1), loosen locknut(2) and
rotate the yoke (3) clockwise to reduce the play and
anticlockwise to increase the play fig 10.
Repeat the same procedure for the left brake pull rod.
Lock the brake pedals together and road test to 9
ensure that the brakes are balanced and will stop the
tractor in a straight line. Any further adjustment
necessary to balance the brakes should be carried 1
out on the right brake.
10
84261396-- 09 - 2009
NEW
HOLLAND
HYDRAULICS SECTION 35
Introduction Chapter 1

35 000 Introduction and Circuit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Open Centre High Pressure Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Pump Chapter 2

35 000 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
35 104 Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Lift Assembly Chapter 3

35 000 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation of Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Internal Linkage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Functioning of Internal Levers of Lift--O--Matic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adjustment and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
84261396 - 09 - 2009
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 1
SECTION 35 -- HYDRAULIC SYSTEMS
Chapter 1 -- Hydraulic System
CONTENT

35 000 Introduction and Circuit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Open Centre High Pressure Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INTRODUCTION AND CIRCUIT

IDENTIFICATION
The hydraulic system on 4510/4010/3510 model
tractor is for mechanical lift assembly to raise and
lower the lift arms in turn three point linkages.
The high pressure hydraulic circuit is of open centre
load sensing type.
In this system hydraulic lift is connected to the hydraulic
pump and pump flow is continuously circulating
through the hydraulic system even when the circuit are
not being operated.
The open centre high pressure hydraulic circuit with
mechanical lift is shown in Figure 7 and includes the
components shown on the following pages. 1
Pump
Open centre hydraulic pump assembly is of high
pressure gear pump (1). See Chapter 2 of this
Section for more details on pump.
1
Filter
Full--flow spin on type filter (1) mounted on right side
of the engine on suction pump.
1
1
84261396-- 09 - 2009
2 SECTION 35 -- HYDRAULIC SYSTEMS-- CHAPTER 1
Mechanical Hydraulic Lift Assembly

Mounted on top of transmission housing comprising
1
of following components:
-- Position control lever (1), Draft control lever (2), 2
3
-- Distributor (3), Response control valve (4),
Sensitivity control valve (5), Diverter valve (6),
3
5 6
4
4
-- Lift--O--Matic switch (7),
5
-- Draft sensing unit (8), Lift arms (9), and internal
linkages and cylinder assembly.
8
6
84261396 - 09-- 2009

OPEN CENTRE HYDRAULIC CIRCUIT AND All excess oil flow produced by the hydraulic pump is
MECHANICAL LIFT returned direct to the Gear box through the control
valve spool located in the distributor.
With reference to figure 7, 8 and 9.
High pressure pump is directly connected on rear Also located within the distributor is the lift cylinder
safety valve, which protect the lift cylinder and seals
side of engine timing gear. Oil is drawn from
from excessive peaks of pressure durng operation.
transmission case through filter. The pump supplies
constant oil flow according to engine speed. High For further details on operation of the mechanical
pressure oil enters the distributor valve located at the hydraulic lift assembly refer to the Chapter 3 in this
front of the lift assembly, which controls the raising Section of the Repair Manual.
and lowering of the lift.
SCHEMATIC VIEW OF HYDRAULIC SYSTEM
1 6
3
2 4
7
1. Mechanical Lift 4. Delivery Line
2. Oil sump (Transmission Housing) 5. Pump
3. Suction line 6. Filter
84261396-- 09 - 2009
4 SECTION 35 -- HYDRAULIC SYSTEMS-- CHAPTER 1
HYDRAULIC CIRCUIT DIAGRAM
4
5
8
1. System safety relief valve 6. Diverter valve
2. Cylinder safety valve 7. Cylinder rockshaft
3. Check valve 8. Pump
4. Discharge valve 9. Sump
5. Control valve
84261396 - 09-- 2009

SECTIONAL VIEW -- HYDRAULIC OIL DISTRIBUTOR
Drain Oil
Pressurised Oil
84261396-- 09 - 2009
Chapter 2 -- Hydraulic Pump
CONTENT

35 000 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATION 4510/4010/3510
FILTER Full-- flow spin on type

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On suction pipe before pump
intake,on the R.H side of engine
PUMP Gear type , drawing oil from
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . transmission housing
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On the RH side of engine

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitted on engine timing case and
driven by timing gears
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mico/Dynamatic
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine timing gears
Rotation (from drive end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Engine / Pump rpm ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1.56
Max. speed (with engine running at max. power rated speed) . . . . rpm 3125 for 4510/4010/3510
Corresponding normal flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/min 20 for 4510/4010/3510
Max -- Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 210
84261396 - 09-- 2009

2 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
TIGHTENING TORQUES
Nut, pump drive gear (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/16” -- 20 UNF2B 3
Screw pump mounting on timing case (C2) . . . . . . . . . . . . . . . . . 3/8” -- 16 UNC2B 2.5
Screw Delivery pipe to pump (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . M6X1.25 10--13
Screw suction pipe to pump (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . M8X1.25 25--30
Pump and cover nuts (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8X1.25 25--30
C1
C4
C5
C3
C2
10
SPECIAL TOOLS
Adopter Hydraulic pressure checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 990877
84261396 - 09 - 2009

Hydraulic pumps are spur gear and fixed prevents oil leakage. The pump is flange mounted
displacement according to e rpm. and the drive coupling is keyed to the tapped shaft by
Pump is mounted on the engine timing gear case. a wood ruff key and secured by a nut and tap washer
to the threaded shaft end.
It is driven by engine timing gears. Oil is drawn by
pump from the transmission housing by pump via oil Inlet is cast on the body to identify the inlet port.
filter. The bush/gear assembly is pressure loaded against
Pump comprises of four main components: the end the end cover and the bushes once pressure
cover, the body, the bush/gear assembly and the balanced to prevent tilt. These features ensure that
mounting flange, the whole being held together by internal leakage is kept to a minimum, enabling the
four tie bolts. pump to operate at high efficiency. The condition of
the bush faces adjacent to the gears is an important
The bush gears are housed in the body and consist
factor in maintaining this efficiency and during any
of a pair of meshing gears with integral journals
dismantling on assembly operations, the bushes
supported in two matched pairs of composite
must be handled carefully to prevent damage. It is
bushes.
essential that the pump be operated only in a clean
One of the drive gear journals extends through the system. Any foreign matter in the oil will score the
mounting flange to form the pump drive shaft, and an bush faces, and this will lead to shortened service life
oil seal located in housing surrounding the shaft and eventual failure.
17 16 9
6 7
11
15
10
18 14
12 8 5
4
8
10
13
9 7 6 3 2 1
11
1. Coupling gear nut 10. Composite bush
2. Tab washer 11. Composite bush
3. Shaft oil seal 12. Woodruff key
4. Bolt 13. Drive shaft & gear -- Taper
5. Mounting flange 14. Driven gear
6. Body seal ’O’--ring 15. Body
7. Backing washer 16. End cover
8. Backing washer 17. Spring washer
9. Lobe seal 18. Nut
84261396 - 09-- 2009

HYDRAULIC LIFT OIL PUMP

Proceed as follows:
WARNING
and footwear.
1. Loosen retaining screws and remove the supply

pipe (1) between pump and filter 1
2. Loosen retaining screws (2) and disconnect
delivery pipe from pump.
1
3. Loosen pump retaining screws (1)
4. Withdraw the pump from the timing case along
with sprocket.
2
Installation
5. Reinstall the hydraulic lift pump following the
removal procedure in reverse.
84261396 - 09 - 2009
HYDRAULIC LIFT OIL PUMP COMPONENTS
17 16 9
6 7
11
15
10
18 14
12 8 5
4
8
10
13
9 7 6 3 2 1
1
Disassembly -- Assembly with the pump 5. Remove the nuts and spring washer (18 and 17)
removed (OP 35 104 30) and tap out the square--headed tie bolts (4).
Proceed as follows: 6. Remove the end cover (16) and carefully lift out
WARNING the two backing washers (7 and 8), the bush lobe
seal (9) and the body seal (6).
7. Make sure there are no burrs on the keyway in
the shaft. Lightly tap the mounting flange clean
of the two hollow dowels in the pump body and
and footwear.
slide it squarely to the shaft.
1. Bend back the ears of the tap washer (2) and 8. Carefully lift out the body seal (6), the two
screw back the nut (1) until its outer face is one backing washers (7 and 8) and the lobe seal (9)
turn beyond the end of the shaft thread . 9. Hold the pump body vertically with the mounting
2. Attach the puller tool to that it bears against the flange end downwards and with one hand
face of the nut. Withdraw the gear as far as the underneath to prevent the bushes dropping out.
nut will allow. Tap the side of the body with a hide--faced
hammer to dislodge the lower bushes (10 and
3. Remove the tool, nut, tap washer and gear.
11), and slide these carefully out of the body.
Retain the Woodruff key (12).
NOTE: Keep the bushes as a pair and place them on
IMPORTANT: Do not attempt to remove the coupling
the mounting flange.
by hammering on levering, as this will damage pump
internally. 10. Invert the body and lift out the driver and driven
gears (13 and 14).
4. Lightly mark the end cover, body and mounting
flange (5, 15 and 16) to ensure reassembly in the 11. Remove the remaining pair of bushes as already
correct relationship and take note of the direction described and place on the end cover.
of rotation of the pump.
84261396 - 09-- 2009

Inspecting the parts Gears

IMPORTANT: : It is likely that wear of the internal Examine the gears for discoloration, indicating,
parts will be uniform and it may be more economical overheating. Check the journals for scoring. Ensure
to obtain a service replacement unit than to fit several that the contract marks on the teeth are evenly
new parts. distributed across each tooth surface and ensure
Wash all metal parts thoroughly in a proprietary that none of the teeth are chipped.
cleaning fluids, such as Belco cleaning solvent. If the pump has suffered overheating this may have
Inspect in the order set out below, for wear and been caused by a fault in the hydraulic system, such
damage. as a defective relief valve, and this must be
investigated.
Body NOTE: Bushes are gears are mated for width to
To obtain high efficiency the design allows for the tips within 0.0002 in (0.005 mm) and can be renewed only
of the gear teeth to wipe the walls of the body bores in pairs.
when the pump is running. Pressure will force the
gears against the inlet side of the bores and a witness End Cover
mark will be visible in this area. If excessive wear of Ensure that the flat, inner surface of the cover is free
the bush inserts or gear journals occurs this witness from scoring or pitting.
mark will deepen to form a wear track, causing a step
in the bore. Examine the body bores and if a
Mounting Flange
pronounced step is felt the body must be rejected. It
is inadvisable to fit worn bushes in a new body. Check Examine for damage and check the condition of the
the security of the two dowels. drive shaft oil seal
Composite Bushes Seals and Tie Bolts

Examine the bearing inserts for signs of wear and Inspect all seals and renew if necessary. Check the
bush faces adjacent to the gears for scoring or condition of tie bolt threads.
pitting. Ensure that the holes and slots in the bushes IMPORTANT: Once the internal condition of the
are unobstructed. Light scoring on the bush faces pump has been assessed it may be considered more
can be polished out on a lapping plate. feasible to renew the complete unit than to fit several
NOTE: If new bushes are to be fitted into an old body; new parts.
check for the presence of a burr at the edges of the
wear track. If present, this burr must be polished out
otherwise it will hold the bush faces away from the
gears and increase the internal leakage
84261396 - 09 - 2009
Re--assembling the Pump

Ensure that all parts are perfectly clean and lubricate
them with the oil to be used in the pump.
1. Refer to Figure 2 and prepare the bushes for the
mounting flange end of the body for insertion as
follows:
Place the bushes on the bench with their lobes
uppermost and the flats in contact. Lubricate the
1
’spectacle’ lobe seal (1) with mineral--base
grease and fit it around bush lobes. Fit the
2
backing washers inside the ’eye--pieces’ of the
lobe seal. When fitted correctly the backing
washers (2) must be level and flush with top
surface of the bush lobes. 2
2. Prepare the bushes for the cover end of the body
for insertion in a similar manner.
3. Pack the space between the lips of the oil seal (3)
with high melting point mineral--base grease.
4. Pick up the body and hold it with the hollow
dowels uppermost and with the fingers of one
hand inside ready to support the bushes.
5. Pick up the mounting flange bushes complete
with lobe seal and backing washers, and slide
them into the body bore with the lobes facing
outwards and away from the flat formed by the
removal of the cusp at the intersection of the
body bores. The bushes must be entered
squarely into the bore and must be kept square
to each other. No force must be used; the bushes
should slide in easily. If the bushes jam in the
bore, remove them and examine for bruising.
Light bruising can be stone out with fine--grit
hand stone.
6. Lubricate the body seal (6), Figure 1 with
mineral--base grease and place it in the body
recess.
7. Refer to Figure 3 to find the position of the drive
gear bore for the direction of rotation required.
Lay the pump body on its side and slide the drive
gear (12), Figure 1 through this bore so that the
shaft protrudes from the hollow dowel end of the 1
body. 1
8. Check that the bushes are flush against the
mounting flange face and that the lobe seal and
backing washers have not become dislodged.
Check that the arrow on the body adjacent to the 2 2
word ROTATION indicates the direction of
rotation required.
9. Mesh the driven gear (14), Figure 1 with the drive A B
gear. If the original gears are being refitted, 3
ensure that the marked sides of the teeth are in • A. -- Cover end
contact so that the bedded--in position is
• B. -- Mounting flange end
maintained.
1. Bush lobes
2. Bore for drive gear
84261396 - 09-- 2009

3. Pick up the cover bushes, complete with lobe 3. Run the pump at this speed for a period of 10
seal and backing washers or off--load ring, and minutes at minimum pressure, that is, with the
slide them over the gear journals with the lobes hydraulic system unloaded.
facing outwards and away from the removed 4. By progressively increasing the work load on the
cusp. Again the bushes must be entered machine, increase the pressure upto full working
squarely and without force. requirement over the first hour of operation.
4. Lubricate and fit the body seal (6) into its recess. 5. During this period make frequent checks of the
5. Place the end cover (16) in position, aligning the pump casing temperature, or the oil
marks previously made. feed in the tie bolts (4), temperature. The temperatures should not
locating the square heads in the mounting flange exceed that experienced under normal working
recesses. Fit the spring washers (17) and screw conditions.
on the nuts (18) finger tight. If the temperature does not rise excessively then it
6. Tighten the nuts in a diagonal sequence to pull is possible that the pump has been assembled
the pump together squarely and finally apply a incorrectly and it must be dismantled to check this,
torque load of 2.5 to 2.75Nm If no fault is found then a further period of running--in
7. Pour a small quantity of hydraulic oil into the at low pressure, as in (3), must be carried out.
ports and check the pump for freedom of
rotation. Renewing the Drive shaft oil seal
8. Fit a new tab washer (2) to the shaft and screw 1. Dismantle the pump as far as step 7 of the
on the nut (1).Tape the Woodruff key (12) to the dismantling sequence and clamp the mounting
shaft until the pump is required for installation. flange securely in a soft jammed vice.
2. The seal can then be drifted out using a cranked
Running--in drift. Take care that the drift does not damage the
A pump that has been re--assembled with new gears, inner edge of the shaft bore leading to the seal.
bushes or body must be carefully run--in before it is 3. Ensure that the seal housing in the pump
subjected to full load working conditions. mounting flange is clean and free from burrs
Where test rig facilities are not available the following To fit a new oil seal, proceed as follows :
procedure must be carried out: 4. Pack the space between the lips of the seal with
1. Install the pump on the application. high melting point, mineral--base grease.
2. Where the pump speed is variable, set the speed 5. Put the oil seal squarely into the housing, with the
to 1500 rev/min; otherwise run the pump at its garter spring facing inwards and press home to
normal operation speed. the full depth of the recess.
84261396 - 09 - 2009
Pump Pressure Test

IMPORTANT: Before performing any pressure or
flow testing, operate the tractor until the oil in the
transmission is at normal operating temperature of
75_C
1
1. Remove plug (1) of external supply port and fit
adapter (Special Tool No. 990877)
2. Install 0--300 for Pressure gauge into adapter.
4
3. Set engine speed at 1500 rev/min.
4. Screw in diverter valve Knob (2) and raise the
draft control lever (3) gradually.
3
5
5. The pressure reading should be 185 + 5 bar.
6. If the pressure reading is below 185 + 5 bar, then
unlock -- locknut and tighten allen screw. If the
pressure reading is higher then 185 + 5 bar then
unlock -- locknut and loosen allen screw. Check
the pressure once again after adjustment and
repeat until you get correct pressure setting.
84261396 - 09-- 2009

Chapter 3 -- Hydraulic Lift Assembly
CONTENT

35 000 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation of Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Internal Linkage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Functioning of Internal Levers of Lift--O--Matic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adjustment and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
84261396 - 09 - 2009
SPECIFICATION
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With seperate position or draft
control,Mixed position/draft control plus
draft sensitivity and float control
Contol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Through two independent levers external

Lift sensitivity adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . knob on control valve
Lift--O--Matic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For fast raise/lower using the draft or
position control levers
Response/drop rate adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Through external knob on control valve
Single--acting cylinder 85x88 (4510/4010/3510),

Bore and stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 500cc (4510/4010/3510),
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3
190
Pressure regulating valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar
220
Cylinder safety valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar
Piston diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Piston to bore clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Cross shaft dia at the bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RH side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
LH side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Shaft end play (with lift arms installed) . . . . . . . . . . . . . . . . . . . . . . . mm
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 3--Point hitch
Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I & II
Draft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Through top link
Maximum lifting capacity at hitch point . . . . . . . . . . . . . . . . . . . . . . . Kg 1100 ( 4510/4010/3510)
Max lifting capacity at link ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kg 1300 (4510/4010/3510) (Optional)
Maximum lift capacity at standard frame . . . . . . . . . . . . . . . . . . . . . . Kg 990
Maximum lower link displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 636
Vertical lift rods fully extended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 520
84261396 - 09 - 2009
TIGHTENING TORQUES
Bolts, lift to housing (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10X1.25,M12X1.25 23.6--42
Bolts, Distributor to lift housing (C2) . . . . . . . . . . . . . . . . . . . . . . . . M8X1.25 3
Banjo bolts, Delivery pipe to Distributor (C3) . . . . . . . . . . . . . . . . . . M22X1.25 7.5
Hydraulic cylinder to lift housing (C4) . . . . . . . . . . . . . . . . . . . . . . . . M12 & M14X1.25 7.5
Bolts, top link support (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8X1.25 5
C5
C4
C1
C2
C3
84261396 - 09 - 2009
SEALANTS
Sealant
Specification
Lift housing to transmission housing (S1) . . . . . . . . . . . . . . . . . . . . . 518
S1
SPECIAL TOOLS
Installer lift arm seal with protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9970873
Socket for spool height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9970874
Adopter Hydraulic pressure checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 9970877
84261396 - 09 - 2009
LIFT LONGITUDNAL -- SECTIONAL VIEW
5 4
10
1
3
8
9
9
1. Distributor 6. Lift arm
2. Response control valve. 7. Top link support (sensing unit)
3. Sensitivity control valve 8. Draft sensing rod
4. Lift--O--Matic button 9. Internal linkages (for position/draft/lift--o--matic)
5. Lift--O--Matic release button 10. Housing--lift
84261396 - 09 - 2009
LIFT HYDRAULIC CONTROL VALVE -- SECTIONAL VIEW
10
1. Control valve 7. Cylinder
2. Differential valve 8. System safety valve
3. Check valve 9. Cylinder safety valve
4. Discharge valve 10. Response control valve
5. OIl discharge hole 11. Sensitivity valve
6. Oil inlet
84261396 - 09 - 2009
TROUBLE SHOOTING
The rockshaft support loads 1. Piston gasket worn Replace the gasket
with difficulty; there is a 2. Discharge valve not adjusted Adjust the sensitivity of control
rhythmic oscillation when the valve or substitute the valve
motor is on: the load descends
3. Oil leakage from safety valve Remove control valve and adjust
when the motor is off.
valve
4. Oil leakage from check valve Remove control valve and adjust
valve
With the arms raised at 1. Incorrect adjustment of position Adjust the position control lever
backstop and with the engine control lever which at maximum
on , we have verified a rhythmic raised height, cause the
oscillation ; with the engine off internal automatic back--stop to
the load does not lower function
Working with the draft control, 1. Sensitivity of the control valve is Adjust the sensitivity of the control
the implement drops too much badly adjusted valve
or doesn’t stay in the groove.
The draft control does not 1. Draft control lever is adjusted Adjust the draft control lever
function; the rock shaft raises badly
and lowers only with the
position lever
The position control does not 1. Position control lever is Adjust the position control lever
function; the rock shaft raises adjusted badly
and lowers only with the draft 2. Internal levers damaged Overhaul the rockshaft
lever
Rockshaft does not lift and the 1. Preselector is fully closed Unscrew the preselector “P” fully
relief valve acts with the
possibility to damage the pum
The rockshaft lifts jerky. 1. Insufficient oil level in the tank. Top up the level.
2. Pump inlet filter clogged. Clean or replace the filter.
3. Infiltration of air into the pump Check the inlet pipe, any coupling
inlet pipe and gasket.
Rockshaft does not operate. 1. Differential valve blocked or Remove the control valve and
dirty. unblock the regulator piston.
The rockshaft starts to lift, but 1. Tension rod measurement “L” is Adjust the draft control lever
it stops as soon as it feels the not correct
load, without the functioning of
the overpressure valve.
The rockshaft does not 1. Faulty adjustment of the Adjust position control lever
descend over its entire travel. position control lever (1)
2. Sensibility adjusted badly. Adjust sensitivity of control valve
The rocker shaft does not 1. Discharge valve blocked Remove control valve unblock or
descend. clean discharge valve.
Lifting capacity does not match 1. Deterioration of the control Remove control valve and replace
that prescribed. valve seal rings. the external seal rings.
2. Relief and safety valves out of Control calibration of the valves.
calibration
3. Poor pump efficiency. Replace the pump.
4. Excessive loss of oil from Overhaul the control valve.
control valve.
84261396 - 09 - 2009

HYDRAULIC SYSTEM
This is a live hydraulic system, where gear type
hydraulic pump is mounted directly to timing case.
transmission lubrication oil is used also as hydraulic
oil. This system described here mechanically senses
changes in the draft loading via the top link of the 3
three point linkage. The system allows the operator
to select Position control, Draft control, Mixed control
and Float. 1
2
CAUTION
Hydraulic filter is to be changed at regular intervals
as recommended. Hydraulic and Transmission parts
may get damaged if filter is choked. Always use 1
Genuine New Holland Filters.
The system is operated by Draft control lever (1),

Position control lever (2), Lift--O--Matic buttons (3),
Response control (4), Sensitivity control (5) and
Diverter valve (6).
Pre--operation checks
5
DANGER 6
Before starting the engine, always ensure that the
Lift--O--Matic fast raise button is pushed in, to prevent 4
inadvertent raising of three point linkage.
2
IMPORTANT: Some mounted or semi--mounted
equipment may interfere with and cause damage to
tractor sheetmetal. To avoid damage check for
clearance between tractor and implements.
Position Control Operation
Position control provides accurate control of
implements such as sprayers, rakes, rotary tillers
etc. that operate above the ground. Once set,
Position control will maintain the selected implement
height.
2
IMPORTANT: Always set the system to Position
control at any time when not actually operating in 3
Draft control, such as when attaching or transporting
equipment or when no equipment is attached. 1
Fully open the Diverter valve( 6) Figure 2 and move
the Draft control lever (1) fully forward in the
quadrant. Set the required implement height/depth
3
using the Position control lever (2). Pull the lever
back to raise the implement, push forward to lower.
Implement height/depth is relative to the position of
the lever in quadrant.
An adjustable stop (3) is provided to enable the lever
to be returned to the required working position.
84261396 - 09 - 2009
Draft Control Operation

Draft control is most suitable for mounted or
1
semi--mounted implements operating in the ground.
Changes in the working depth or changes in soil
resistance will cause draft loading on the implement
to increase or decrease.
When starting work, fully open the diverter valve and

move the Position control lever (2) fully forward. 2
Lower the implement in to the work using Draft
control lever (1). Push the lever forward to increase
the draft loading. Pull rearwards to reduce the draft
loading. Forward movement of the Draft control lever
will increase the implement depth and rearward 4
movement will reduce the depth.
Once set, tractor hydraulic system will automatically

adjust the implement depth to maintain an even pull
on the tractor and minimise wheel slip
Combined Position and Draft control

Operation
On very light soil or varying soil types in the same
2
field, it may be necessary to use the Draft control and
Position control in combination. When starting work, 1
lower the implement to the required depth by means
of the Draft control lever (1), as previously described.
When the implement reaches the required depth,

raise the Position control lever (2) back until the lift
arms tends to rise. The lift linkage is now operating
in Draft control but the implement is prevented, by
the Position control function, from sinking too far
when draft reduces. 5
Float Operation
Move the Position control lever (2) and the Draft
control lever (1) fully forward. The 3--point linkage will
now be free to ‘float’ or follow the ground contour, a
feature useful for scraper blades etc.
84261396 - 09 - 2009
Lift--O--Matic
The Lift--O--Matic is used for automatic repositioning
of implement after turn. It helps in saving the time and
adds comfort to the operator. Further it maintains
2
uniform depth and prepares a better seedbed.
To raise the implement at the end of each pass, or 3

whenever required, move the latch (1) rearward to
release the fast raise button (2). The 3--point linkage
(and implement) will raise to the full height without
need to move either the Position or Draft control 1
lever. Use liftomatic button lock (3) to ensure more
safety as required during usages.
7
To lower the implement, simply press the fast raise
button (1) fully in, and the implement will lower to the
preset depth, set by the Position control lever or Draft
control lever.
1
CAUTION
When transporting equipment on 3--point linkage,
raise the implement using the Position control lever.
The hydraulic system will maintain the equipment
height set by the Position control lever and prevent
the equipment lowering and becoming damaged.
8
Sensitivity Control
To adjust the sensitivity of hydraulic system when
working in Draft control, knob (1) needs to be
adjusted.
CLOCKWISE rotation -- Reduces sensitivity
ANTICLOCKWISE rotation -- Increases sensitivity
84261396 - 09 - 2009
Response Control
The response control knob (1) varies the speed of
drop of the lower links.
CLOCKWISE rotation -- Decreases speed of drop
ANTICLOCKWISE rotation -- Increases speed of
drop
IMPORTANT: To lock implements in transport
position when driving on road, fully raise Position
control lever (2) Figure 4 and screw in (rotate
clockwise) knob (1) Figure 10.
1
10
Use of Diverter Valve and External Supply Port

The Diverter valve (1) is used to divert oil, normally
flowing to the left cylinder of the 3 point linkage, to the
external supply port. A single acting cylinder can be
connected to this external port and be operated by
the Draft control lever.
1
2
2
11
84261396 - 09 - 2009
OPERATION OF DISTRIBUTOR: The oil coming from the pump enters the annular duct
The Distributor is Pre--set to perform three Phases : (8) and moves the differential valve (2) upwards
which then opens the discharge hole (7) and enables
A) Neutral Phase the oil to go to the tank.
B) Lifting Phase The oil contained in the cylinder (9) is kept under
C) Lowering Phase pressure by the check valve (3), by the discharge
valve (4) and safety valve (10) connected to the
A. NEUTRAL PHASE : cylinder (9) by the annular duct (11) thus holding the
In this phase the control valve keeps pressure on the load applied to the lifting arms.
oil contaiined in the cylinder thus allowing the oil The safety valve (10) secures protection from any
coming from the pump to flow freely to the tank. possible over--pressure during the implement
In this phase the control spool (1) is in such a position movement.
to connect the chamber (5) of the differential valve
(2) directly to the discharge through hole (6)
7
1
10
8
6
8
3
11
9 11
4 5
RS
RD
12
84261396 - 09 - 2009
B. LIFTING PHASE : The oil from the pump finding the differential valve (2)
During this phase, the Control Valve supplies the oil closed goes to cylinder, pass the hole (14) opens the
under pressure to the cylinder (9) and it consequently check valve (3) enters in the annular duct (11) and
lifts the arms. enters the chamber (9).
The control spool (1) is in such a postion to connect The lifting speed depends on the pump RPM.
the chamber (5) of the differential valve (2) with the In this phase the maximum lifting pressure is
oil coming from the pump through annular duct (8) controlled by the safety valve (15) that is connected
and holes (12) and (13) making in this way the valve to annular duct (8) through hole (14) and then to the
itself to close. oil inlet
7
1
13
10
15
8 12
14
3
11
11
9 2
5
4
RS
RD
13
84261396 - 09 - 2009
C. LOWERING PHASE : From Chamber (9) the oil goes into the annular duct
During this phase, the control valve supplies at the (11) passing the lowering speed regulation valve (16)
same time the oil coming from the pump and the oil through the connecting hole (17) enter into the
contained in the cylinder to the discharge causing the discharge valve (4) that is kept open from the spool
lowering of the arms. (1) and goes to discharge from hole (18)
The control spool (1) is in such a position to connect In this phase the lowering speed of the implement
chamber (5) of differential valve directly to the can be adjusted with lever RD.
discharge through hole (6). By screwing the lever the lowering speed is reduced,
The oil coming from the pump enters the annular duct by screwing totally the valve (16) is closed on the
(8) and moves the differential valve (2) upwards seat and therefore the arms are locked for transport
which then opens the discharge hole (7) and enables safety.
the oil to go to the tank.
At the same time the pressure oil contained in the
cylinder (9) flows to the tank therefore causing the
lowering of the arms.
18
7
1
11
16
17 5
4
RS
RD
14
84261396 - 09 - 2009
INTERNAL LINKAGE SYSTEM absorber (8), to the transmission lever (9) that will
A) Functioning of Position Control bring distributor shaft (21) into delivery position (C),
thus causing the arms to be lifted.
B) Functioning of Draft Control
During the lifting movement of the arms, crank (13)
C) Combined functioning of Position and Draft Control with pin (10) will rotate in an anti--clockwise direction,
and by means of the link (14) will cause position cam
Functioning of Position Control (6) to rotate clockwise.
With reference to Figure 15 When the roller (5) meets the inclined plane of the
By positioning the draft control lever (2) against the cam (6), it allows the anti--clockwise rotation of the
backstop (E) (Fig. Page 14) the roller (11), which flywheel (7) that by means of a friction shock
slides on the flywheel (7) of draft cam (12), will be absorber (8) rotates the lever (9) in a clockwise
moved away completely. direction, which is pushed by the spring of the control
In this way the draft levers will not in any way interfere valve shaft (21) which moves to position (N) (neutral
with the operation of the position control. phase) and thus blocking the movement of the lifting
arms.
The arms are raised by moving the position control
lever (1) upward, and the leverage system will act in During the lowering phase of the arms the
the following way: movements of the levers indicated above will occur
in the opposite sense.
Crank (4) being an integral part of shaft (3) turns in
a clockwise direction and causes roller (5) to slide on The position of the arms, during lifting and lowering,
the position cam (6), in turn causing the clockwise correspond to a specific position of the position
rotation of flywheel (7). The flywheel will transmit an control lever (1).
anticlockwise rotation, by means of friction shock
1
14
10
5
6
2 4
13
9
21 8 11 12
3 7
15
84261396 - 09 - 2009
Functioning of Draft Control The crank (15), being an integral part of the draft
With reference to Figure 16 shaft (16), rotates counter--clockwise and by means
of tension rod (17) causes roller (11) to slide on
By positioning the control lever (1) for position control
flywheel (7).
against the backstop (E) the crank (4) (Figure 14)
reaches its maximum position of anti--clockwise The roller (11), when it meets the inclined plane of the
rotation. In said position the roller (5) is totally draft cam (12), permits the counter--clockwise
lowered from the inclined plane of position cam (6) rotation of flywheel (7) which by means of shock
allowing the anti--clockwise rotation of flywheel (7) as absorber (8) will rotate transmission lever (9) in a
well as the clockwise rotation of the transmission clockwise manner thus leaving distributor shaft (21)
lever (9) that is pushed by the spring of shaft (21) free to move into neutral position (N) and continuing
which in turn will position itself for the discharge the movement of lever (2), in the discharge position
position (S). In this way the position levers will not (S), causing the arms to lower.
interfere with the functioning of the draft control In fact, during the initial part of the movement toward
levers. backstop (E), of draft control lever (2) the
With reference to Figure 16 corresponding lowering of the arms does not happen
yet.
By positioning the draft control lever (2) against
backstop (F) (Fig. Page 14), draft control shaft (16) The traction force on the top link point (20) acts on
is caused to rotate clockwise. tension rod (18) in the direction indicated by the
The crank (15) being an integral part of shaft (16), will arrow ¨ (positive) causing flywheel (19) to rotate
reach its extreme position of clockwise rotation, and clockwise together with draft cam (12) which is
by means of tension rod (17) will move roller (11), the fastened to the same pin.
latter acting on the draft cam (12). This causes When the inclined plane of draft cam (12) meets
flywheel (7) to rotate clockwise which by means of roller (11), a clockwise rotation of flywheel (7) is
function shock absorber (8) produces the achieved which by means of shock absorber (8) will
anti--clockwise rotation of transmission lever (9) thus cause transmission lever (9) to rotate counter--
setting the distributor shaft (21) in delivery position clockwise thereby moving the distributor shaft (21)
(C) and consequently lifting the arms. into neutral position (N) and stopping the movement
The arms will come to a stop only as soon as the of the arms.
piston comes into contact with the pin of the limit stop As the traction force is increased, draft cam (12) will
(22). further move roller (11) thus incrementing the
This limit stop, by means of tension rod (23) causes movement as described above.
lever (9) to rotate clockwise, thereby compressing The distributor shaft (21) will move from neutral
the spring of friction shock absorber (8) and thus position (N) to delivery position (C) causing the arms
releasing shaft (21) which now can move to the to be lifted. When the traction force diminishes, shaft
neutral position (N) where it is pushed outward by its (21) will return to the neutral position or to the
spring. lowering position which will mean an inverse
Moving the draft control lever (2) toward backstop (E), movement of the leverage systems to what is
the leverage system will function in the following described above.
manner:
84261396 - 09 - 2009
16 20
2
19
18
9 8 23
21 22 11 12
7
15
16
84261396 - 09 - 2009
Combined functioning of Position and Draft entering the lowering position (S) and therefore the
control arms cannot sink even though the traction force
With reference to Figure 15 & 16 acting on the top link point (20) will tend to diminish
and putting stress on the tension rod (18) in the
To utilise the lifting device in this condition it is
necessary to observe the following instructions: direction of arrow © (negative).
• Move the position control lever (1) upwards with This condition will not prevent the rockshaft from
respect to the backstop (E) (Fig. page 12) until operating with the draft control when, in the presence
the maximum working depth has been attained. of more consistent soil, the traction force on the top
link (20) will tend to increase, exerting pressure on
• Determine the desired minimum working depth
by operating the draft control lever and raising it the tension rod (18) in the direction of arrow ¨
from its zero position so that roller (11), acting on (positive).
the draft cam (12) , will move the distributor shaft Consequently the combined operation of position
(21) into the lifting position (C) and causing a and draft control will limit variations in height towards
further upward movement of the lifting arms. the ground, as happens during the use of the draft
Due to the position previously established by position control, and at the same time ensuring the maximum
control lever (1), flywheel (7), roller (4) and position possible depth desirable.
cam (6), the distributor shaft (21) is prevented from
16 20
2
19
18
9 8 23
21 22 11 12
7
15
17
84261396 - 09 - 2009
USE OF CONTROL LEVERS Draft Control

A) Position Control Move the position control lever 1 fully down, have the
B) Draft Control implement penetrated into the ground till reaching
the desired depth by gradually moving the lever 2
C) Combined operation for position and draft control
down.
The implement depth reached is proportional to the
The above operations may be chosen in draft determined by soil hardness.
consideration of the work to be carried out, the
In this condition the rockshaft keeps the draft
implement type and the soil superficial hardness.
required automatically constant.
Once the draft is regulated at the end of the rope is
Position Control possible to lift the implement with position lever 2 in
Move the draft control lever 2 fully down. Fix the order to keep in memory the draft.
implement position, inside or outside the soil, by
During last movement stroke of lever 2 a floating
moving the lever 1 up for raising and down for
function is obtained and the rockshaft does not
lowering.
control the draft.
The implement movement is proportional to the
movement range fixed by means of lever 1.
18
Combined Operation for Position and Draft When the desired depth is reached, gradually move
Control up the lever 1 till the lower links slightly start raising.
In case of workings carried out under draft control on The rockshaft operates under controlled draft, but at
not--homogeneous soils, during which excessive the same time it prevents the implement from
implement penetration may occur, it is convenient to excessively penetrating into the ground causing a
use the combined position and draft control. not very uniform work, when coming up against a
Have the implement penetrated into the ground and less hard ground.
search for the desired working depth in the way
described for the draft control.
84261396 - 09 - 2009
For raising and moving the implement penetrated at This can be on neutral--positive--negative--position
the end and beginning of each pass, acting on depending on the draft force, or to the changement
position lever 1 only. of force on the top link bracket depending on the
implement weight.
IMPORTANT : It is not correct to find the position with
the draft lever 2 because the lifting and lowering of
arms with this lever changes with the top link
position.
84261396 - 09 - 2009
FUNCTIONING OF INTERNAL LEVERS OF internal lever (L1) which are attached to the same
LIFT--O--MATIC shaft.
In this way the lever (L1) moves away from the pin
(R) which is fixed to the return lever (9) and this
With reference to Figure 19 and 20
allows the internal levers of the rockshaft to function
The Lift--o--matic system is used for the lifting and normally as explained in pages 7--8--9. The
lowering of the rockshaft arms in order to avoid clockwise movement of the lever (L1) compresses
altering the set--up of the rockshaft already the spring (M) which allows the external lever (L) to
determined by the two control levers. remain always in contact with the button (A).
The rockshaft functions normally--the same as the The position of the rockshaft arms, when the button
version without the Lift--o--matic when the button (A) is in a fixed downward position, depends on how the
is in a fixed downward position (see figure page two control levers (1) and (2) (fig. page 14) are
11.1). positioned and the rockshaft rms lower completely
In this case the external lever (L) reaches its only if the position control lever is completely
maximum clockwise rotation together with the lowered.
19
To completely raise the rockshaft arms all that is oil under pressure to the rockshaft cylinder which
needed is to release the button (A) by rotating raise the arms of the rockshaft.
clockwise the lever (B) (see figure page 11.2). The rockshaft arms stop at the maximum raised
The external lever (L), which is pushed by the spring position only when the piston comes out of the
(M), remains in contact with the button (A) and cylinder and makes contact with the backstop pin
rotates the internal lever (L1) in a counter--clockwise (22) which, by means of the link (23) fitted to the pin
direction. (R) creates a clockwise rotation of the lever (9).
When the lever (L1) touches the pin (R), which is The movement of the lever (9) leaves the spool (21)
pushed by the spring (M), it rotates the lever (9) in a free to exit until the control valve reaches the neutral
counter-- clockwise direction which in turn moves the (N) phase and blocks the flow of oil to the cylinder.
spool (21) of the control valve. This causes the
delivery phase (C) of the control valve which sends
84261396 - 09 - 2009
The clockwise rotation of the lever (9) which is and the internal lever (L1) rotate in the same direction
attached to the pin (R) makes the external lever (L) and compress lightly the spring (M).
20
84261396 - 09 - 2009
MECHANICAL LIFT ASSEMBLY

Remove the hydraulic lift from the rear axle housing
as follows:
WARNING
and footwear.
1. Disconnect delivery pipe (1) from distributor.
1
2. Loosen the bolts (1) and remove the operator’s
seat from the Hydraulic lift. 1
2
3. Remove three--point linkages (Top link, lower link
and lift rod) from the tractor.
4. Loosen the bolts securing hydraulic lift housing
to transmission housing
5. Lift the hydraulic lift assembly using suitable
hoist and place it on a flat surfaced table.
84261396 - 09 - 2009
IMPORTANT: Never lift the housing by holding

distributor knobs and delicate parts.
Installation
6. Refit the hydraulic lift on the transmission
housing as follows.
WARNING

reverse
4
-- Before refitting the hydraulic lift in the rear trans-
mission casing, clean and degrease the mating
surfaces thoroughly and apply a strip of sealing
compound of about 2 mm diameter as shown in
the Figure 4
-- Apply the torque settings listed on Page 3.
84261396 - 09 - 2009
REAR LIFT EXTERNAL CONTROLS

WARNING
and footwear.
Lift external controls can be disassembled and

reassembled only with the lift on a work bench or on
a rotary stand. With the lift on the tractor only position
control lever can be removed.
Proceed as follows :
1. Remove the lift from the transmission housing
and place on a work bench or fix on a rotary
stand. 1
1
2. Loosen allen bolts (1) and remove position
control lever hub along with nylon washer.
NOTE: Nylon washers ) can be removed from hub by
loosening allen screw
2
3. After loosening allen key bolts remove position
control lever (1 ) Remove bolts (2) to take out
sector plate
84261396 - 09 - 2009
4. Remove draft control lever hub by loosening

allenkey bolts (1) long with the nylon washer also
remove sector plate.
4
5. Draft control lever is welded on Draft control
shaft. To remove the draft control lever internal
linkages on position control shaft and draft
control shaft have to be removed.
Remove allen screw (1) and (2) and remove
linkages from the shafts
NOTE: To remove allen screw (2) hydraulic linkages
have to be removed. See REAR LIFT INTERNAL
CONTROLS -- Disassembly--Assembly, Page 26 for
removal procedure
5
6. Remove allen key bolts ( 1 )to remove shaft
6
Reassembly
7. Reassemble the lift external controls following
the disassemble procedure in reverse.
8. Check the ’O’ rings on draft control shaft for any
damage. If required, replace by new ’O’ rings.
1
84261396 - 09 - 2009
DRAFT SENSING UNIT
Disassembly -- Assembly (Op 35 112 18 )

WARNING
and footwear.
NOTE: Draft sensing unit and related external

linkages can be disassembled and assembled with
lift unit mounted on the tractor.
1. Loosen the bolts (1) from the sensing unit.
1
2. Remove the lock ( 1 ) and remove draft link (2)
2
3. Loosen bolts (1) & allen key bolt.
84261396 - 09 - 2009
4. Remove the pin as shown in fig.

5. Remove the sensing unit from the lift housing
4
Disassembly
6. Loosen allen screws (1) 5
7. Disassembly roller (2), springs (3), cover (4),
flange (5) from the sensing unit 4
3
2
5
8. Assemble and reinstall sensing unit on hydraulic
housing observing the following:
-- Assembly and reinstallation follows the removal
procedure is reverse from step 7 to step 1.
-- Tighten all fasteners to correct torque as ex-
plained on page 3
-- The top face of spring roller
i) should be 1mm above the top face of flange
ii) In case if it is less add shims and if more
remove shims.
-- Refer to page for correct settings.
84261396 - 09 - 2009
REAR LIFT INTERNAL CONTROLS

WARNING
and footwear.
1. Remove the lift assembly from the transmission
housing and fix on a rotary stand.
See Page 22 for Removal procedure.
1
2. Loosen the allen screws (1)
2
3. Remove the cylinder (1) from hydraulic lift
housing 1
84261396 - 09 - 2009
NOTE: Retrieve the seal (1) from head of cylinder.
4
4. Remove the Piston (1) from the cylinder by
pushing with a suitable aluminium rod from the
front side.
5
5. Loosen the bolts (1) and remove lift--o--matic
linkage (2) 1
6
6. Remove dowel pin (1) and remove lift--o--matic
lever (2)
2
84261396 - 09 - 2009
7. Loosen nut (1) and remove lift--o--matic lever (2).
8
8. Remove locks and disassemble lever (1)
9
9. Remove linkage (1)
10
10. Remove the lock (1 ) from the compensator pin
11
84261396 - 09 - 2009
11. Unscrew the compensator pin untill face of the

pin comes out of the compensator.
1
12
12. Remove linkages as shown in fig.
13
13. Remove link ( 1 )
14
14. Unscrew locking screrw ( 1 ) and remove position
control cam ( 2 ) and bracket (3 )
1
3
2
15
84261396 - 09 - 2009
15. Remove dowel pin (1).
16
16. Remove cam ( 1 )
1
17
17. Remove lock ( 1 ) and disassemble link ( 2 )
2
18
18. Unscrew locking screw ( 1 ) and disassemble
lever (2 ) alongwith link ( 3 ) 1
Re--assembly
19. Re--assembling follows disassembly procedure
in reverse from step 18 back to step 1.
-- Check the settings of push rod and lift--o--matic.
See page 37 for details
3 2
19
84261396 - 09 - 2009
LIFT ARM SHAFT

WARNING
and footwear.
1. Remove lift assembly from the tractor and fix it on
a rotary stand. See Page 22 for Removal
procedure.
1
2. Remove the circlip (1) from lift arm shaft.
1
2
IMPORTANT: Before removing lift arm punch a mark
(1) on both lift arm and shaft to facilitate the assembly
in original position
3. Remove the lift arm from the shaft
84261396 - 09 - 2009
4. Repeat the same for the other side lift arm

5. Remove the locking sensor (1) locking crank and
shaft.
4
6. Push the shaft from left side towards right side by
hammering gently using aluminium or copper
rod.
5
Installation
7. Reinstall the shaft and lift arm in the lift housing
observing the following :
reverse from step 6 to step 1
-- Refer Page 21 for reinstallation of lift assembly
on tractor.
-- Check the seals (1) and replace if required.
-- Use Special Tool No. 9970873 to fix the seal.
-- Tighten all fasteners to correct torque as detailed
in Page 3. 1
84261396 - 09 - 2009
DISTRIBUTOR ASSEMBLY

WARNING
and footwear.
1. Loosen the bolts (1) and remove distributor

assembly from lift housing.
NOTE: Distributor assembly is not serviceable.
Replace complete assembly if found defective.
2. Insert the distributor assembly back on the lift
assembly and tighten the bolts (1).
1
IMPORTANT: Check the ’O’--rings (1) for any
damage on distributor assembly before installing and
replace if required.
84261396 - 09 - 2009
USE OF PRESELECTOR (P) AND • For safety fully lower the lift arms by putting down
AUXILIARY PORT (PA) both draft and position levers.
• Screw completely the preselector (P) in order to
block the oil passage to the rockshaft cylinder.
The preselector (P) is used to connect the auxiliary
port--thread M18x1,5--and send the oil to a single • To obtain the acting of external cylinder move up
acting cylinder--for example a wagon dump--and slowly the draft lever (2). If the top link bracket is
moving it with the draft lever (2). in neutral position (without any implement
attached) the effect starts when the lever (2) is
In this way the oil that normally is filling the rockshaft
between numbers 9--6 on the sector.
cylinder is deviated to the external cylinder.
• Connect the port (PA) to the single acting
usage--e.g. Wagon dump cylinder.
3
• To obtain the stop of the acting move back down possibility to damage the pump if the system is left
a little the draft lever. for a long time in this position.
• To obtain the discharge -- cylinder closing -- lower Therefore after having reached the required
down fully the draft lever (2). movement of the cylinder it is important to not forget
to move back down a little the lever (2) in order to stop
IMPORTANT : In the acting phase--external cylinder the cylinder or to discharge the oil.
opening--if the single acting arrives to the end of the
stroke the relief valve enters in action with the
84261396 - 09 - 2009
ADJUSTMENTS AND SETTINGS :

In case of complete disassembly of the lift it is
necessary to make the following adjustments:
A) Control valve sensitivity setting
B) Position control lever setting
C) Draft control lever setting
D) Reaction spring setting
E) Internal push rod setting
A) Control valve sensitivity setting
With reference to Figure 3
After having first carried out a rough adjustment of
position control place the lift arms with the weight
applied at about the middle of the stroke so that the
control valve is in the neutral phase. Operate the
control valve by rotating the sensitivity register (RS)
counter--clockwise until the lifting arms begin jerking.
Should this not happen when register (RS) is set to
position 1, screws 3 must be loosened so that
register (RS) can be turned clockwise, together with
the threaded locking ring for sensitivity adjustment;
said ring nut is covered by a rubber cap (4). The
register should be moved to position (2). Block the 4
movement of the nut ring by tightening screw (3), and
find again the position where the jerking movement
starts by carefully turning the register (RS)
counter--clockwise.
NOTE: Keep repeating the operation as described
above until you have reached the goal. Once the
jerking position has been determined, slowly keep
turning the register (RS) clockwise until the arms
come to a complete standstill and from that position
on continue rotating for 1/4 of a turn.
Now lower the implement load and loosen screws 3
so that register (RS) can be turned clockwise,
together with the sensitivity adjusting ring nut, until
the register reaches position (1) against the
backstop (RD).
Then the sensitivity ring nut covered by its rubber cap
(4) is firmly blocked by tightening screws (3).
In this manner the control valve is adjusted to its
maximum sensitivity.
To reduce the degree of sensitivity the register (RS)
should be rotated clockwise until the desired effect
has been obtained.
84261396 - 09 - 2009
B) Position Control lever setting position which is determined by the internal hydraulic
With reference to Figure 5 limit stop.
The adjustment is carried out in order to establish the Since during the functioning of the position control
maximum raised position of the rockshaft’s lifting the hydraulic limit stop must not be triggered it is
arms. necessary to have a safety margin of ~ 10--15 mm.
Completely lower the arms and apply a light weight In order to do this, rotate slowly in a clockwise
which creates a pressure in the cylinder of 50--60 bar. direction the shaft (5) until the arms are lowered by
the required safety margin.
Loosen the fastening screw (6) so as to free the
position control lever (1) from the shaft (5). At this point keep the shaft (5) fixed and with lever (1)
against the backstop (F) keep the lever fixed with the
With the draft control lever (2) at its lowest position
shaft by tightening fully the fastening screw (6).
against the backstop (E) raise the position control
lever (1) against the backstop (F). To control, raise completely the arms by moving the
position control lever (1) against the backstop (F)
Maintaining fixed the levers (1) and (2) and with a 13
raising completely the draft control lever (2) there is
mm. open end wrench rotate slowly in an
a further movement upwards of the rockshaft arms.
anticlockwise direction the position control shaft (5)
This movement should be contained within 15--20
so as to raise the arms to their maximum raised
mm.
84261396 - 09 - 2009
C) Draft control lever setting The adjustment of the draft lever (2) is correct when
With reference to Figure 6 it is moved upward to the (6--8) sign on the sector and
this allows the arms to be completely raised.
The adjustment of the draft control lever must be
carried out to have a correct synchronisation If the lever (2) raises completely the arms before
between this lever and the stroke (positive and arriving at the (6--8) sign on the sector then the
negative) of the top link bracket in order to make full measurement (L) of the rod (T) must be shortened.
use of the reaction spring. If the lever (2) raises completely the arms after
The adjustment must be carried out without passing the (6--8) sign on the sector then the
implements or loads applied to the three point measurement (L) of the rod (T) must be lengthened.
linkage (20) (i.e. in a neutral position). NOTE: The position of the lever (1) establishes only
Position the two control levers (1) and (2) in the the position of the arms but does not influence the
lowest position. adjustment of the draft control lever (2).
With the motor running at minimum RPM slowly raise
the draft control lever (2).
84261396 - 09 - 2009
D) Reaction spring setting Before assembling the complete reaction assembly

With reference to Figure 6 to the rockshaft housing a pre--assembly of the
spring (M) is needed in order to obtain a
For a correct functioning of the rockshaft the top link
measurement of about 8,4 mm.
bracket, when it is not working, must not have an
axial play in the positive + and negative --. After carrying out the reaction assembly a definitive
adjustment is made:
After having carried out a correct assembly, the
spring holder (2) must rest against the rockshaft Keep the screw (V) fixed with an 8mm wrench and
housing (1), while the spring holder cover (4) must adjust the self--locking nut (D) by tightening or
rest against the flange (3). loosening it gradually in order to eliminate the axial
play completely.
In this condition the spring (M) is preloaded by about
0.3--0.6 mm.
84261396 - 09 - 2009
E) Internal push rod setting With the rockshaft’s arms completely lowered and
With reference to Figure 7 without loads or implements on the three point
linkage (neutral position), position the two control
If the rockshaft is disassembled and if the regulator
levers (1) and (2) at their lower position against the
(R) must be changed it is advisable to control the
backstop (F) (see Fig. page 14).
measurement “X” (~10,5) in order to re--assemble
the push rod in the same position. In this position push the push rod and verify with the
appropriate gauge that the distance of 112 0/+0,5 is
Ensure also that the measurement of the spring is 46
correct.
0/+0,3 mm.
NOTE: If the measurement “X” is changed it is
The control of the measurement of the push rod with
obligatory to carry out again the adjustment of the
respect to the control valve face is carried out after
position and draft control levers.
making all the adjustments (sensitivity of control
valve -- position control lever -- draft control lever).
7
Adjustment of Button for the Lift--O--Matic The adjustment of the button (A) is carried out as
With reference to Figure 8 & 9 follows (see figure page 12.2).
The adjustment of the button (A) for the lift--o--matic The two control levers -- position and draft control --
should be made after having first carried out all of the are completely lowered (rockshaft arms completely
other adjustments foreseen for the standard version. lowered) and the button (A) is released from the lever
These should be carried out when the button (A) is (B). Due to the effect of the spring (M) which pushes
fixed in a downward position (see figure page 12.1) against the lever system (L--L1--9) the lever (L) remains in
and the external lever (L) is rotated in a clockwise; contact with, the button (A), which is released
direction in order to have a space of about 4mm completely. This causes the spool (21) to be pushed
between the internal lever (L1) and the pin (R). In this to the delivery phase (C) which causes the raising of
condition the, spring (M) is compressed and the the rockshaft arms.
levers for the lift--o--matic do not interfere with the If this does not happen then move in small steps the
levers of the rockshaft. complete assembly of the button (A) along its sector
If the spring group is disassembled and the by loosening and tightening the two screws (VF)
anti--rotation nut (DA) is loosened then it is The button (A) is adjusted correctly when the
necessary that the distance 64.5mm is maintained rockshaft arms are slowly lowered by pressing the
between the two pins Ø8mm when the spring (M) is button gradually downwards for about 10mm. By
reassembled (see figure page 12.2). letting go of the button the arms are completely
raised.
84261396 - 09 - 2009
84261396 - 09 - 2009
DRAWBACKS CAUSES REMEDIES

The Rockshaft lifts jerkily. Insufficient oil level in the tank. Top up the level.
Pump inlet filter clogged. Clean or replace the filter.
Infiltration of air into the pump inlet Check the inlet pipe and any
pipe. coupling and gasket.
Rockshaft does not operate. Differencial Valve blocked or dirty Remove the control valve and
(page 5.1 pos. 2). unblock the regulator piston.
The rockshaft starts to lift, but it Tension rod measureement (L) is Adjust the draft control lever (page
stops as soon as it feels the load, not correct (page 16). 16).
without the functioning of the
over--pressure valve.
The rockshaft does not descend Faulty adjustment of the position Adjust position control lever (page
over its entire travel. control lever (1). 15).
Sensibility adjusted badly. Adjust sensitivity of Control Valve
(page 14.1).
The rockshaft does not descend. Discharge Valve blocked (page 6.1 Remove Control Valve and unblock
pos. 16) . or clean discharge valve.
Lever RD closed. Turn lever RD in anticlockwise.
Lifting capacity does not match Deterioration of the Control Valve Remove Control Valve and replace
that prescirbed. seal rings. the external seal rings.
Relief and Safety valves out or Control calibration of the valves.
calibration.
Poor pump efficiency. Replace the pump.
Excessive loss of oil from Control Overhaul the Control Valve.
Valve.
The rockshaft supports loads with Piston gasket worn. Replace the gasket.
difficulty.
There is a rhythmic oscillation when Discharge Valve not adjusted (page Adjust the sensitivity of Control
the motor is on; the load descends. 4.1, pos. 4). Valve or substitute the valve.
When the motor is off.
Oil leakage from Safety Valve Remove Control Valve and adjust
(page 4.1 pos. 10). valve.
Oil leakage from Check Valve Remove the Control Valve and
(page 4.1 pos. 3). adjust valve.
With the arms raised at backstop Incorrectly adjusted of position Adjust the position control lever
and with the engine on, we have control lever which, at maximum (page 15).
verified a rhythmic oscillation; with raised height, causes the internal
the engine off the load does not automatic backstop to function.
lower.
Working with the draft control, the Sensitivity of the Control Valve is Adjust the sensitivity of the Control
implement drops too much or badly adjusted. Valve (page 14.1).
doesn’t stay in the groove.
The draft control does not function; Draft control lever is adjusted badly. Adjust the draft control lever (pages
the rockshaft raises and lowers 16).
only with the position lever.
The position control does not Position control lever is adjusted Adjust the position control lever
function; the rockshaft raises and badly. (page 15).
lowers only with the draft lever.
Rockshaft does not lift and the relief Preselector i s fully closed. Unscrew fully the preselector (P)
valve acts with the possibility to (page 13).
damage the pump.
84261396 - 09 - 2009
NEW
HOLLAND
STEERING SYSTEMS SECTION 41
Hydrostatic Steering Systems Chapter 2

41 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
41 101 Steering Motor -- Removal and Installalation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
41 201 Two Wheel Drive Steering Cylinder -- Removal and Installalation . . . . . . . . . . . . . . . . . . . . . 28
Two Wheel Drive Steering Cylinder -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
84261396-- 09 - 2009
SECTION 41 -- STEERING SYSTEMS -- CHAPTER 2 1
SECTION 41 -- STEERING SYSTEMS
Chapter 2 -- Hydrostatic Steering Systems
CONTENT

41 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
41 101 Removal -- Installalation -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
41 000 -- SPECIFICATIONS -- TIGHTENING TORQUES -- SPECIAL TOOLS -- TROUBLESHOOTING --

SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DANFOSS
Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Independent, separate pump
Oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparent plastic on
RH side of engine
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in oil reservoir, gauze
Hydraulic Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--25
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dowty
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . From engine valve gear
Rotation (seen from rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Drive ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 to 0.931
Rated speed (at engine governed speed) . . . . . . . . . . . . . . . . . . . . . rpm 2328
Rated output at maximum rated speed . . . . . . . . . . . . . . . . . . . . . . . Itrs/min 26.4
On--bench output at 1450 rpm (70 102 kg/cm@):
-- new or reconditioned pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Itrs/min 15.3
-- used pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Itrs/min 10.7
-- test oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _C 55 to 65
-- test oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 20
84261396 - 09 - 2009
2 SECTION 41 -- STEERING SYSTEMS -- CHAPTER 2
Drive/driven gear journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 17.400 to 17.418

Bearing bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 17.450 to 17.470
Gear journal clearance in bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.032 to 0.070
Maximum wear clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.1
Gear clearance in pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.020 to 0.064
Maximum wear clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.1
Bearing width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 19.812
Gear width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 18.348
Pump body width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 58.072 to 58.122
Bearing and gear end clearance in pump body
(to be restored on overhaul) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.1 to 0.2
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DANFOSS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with steering column operated rotary
valve (permitting steering also in
case of pump failure)
Outfit code:
-- DANFOSS (with valves in control valve) . . . . . . . . . . . . . . . . . . . . . OSPC 1 00
Relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 100 --110
Power cylinder overload valve setting . . . . . . . . . . . . . . . . . . . . . . . . bar 200
Power Cylinder:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double acting, located front of front
axle
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEBER, or SIMA ERBER
Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 48
Piston rod diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 22
Maximum piston stroke with cylinder make: . . . . . . . . . . . . . . . . . . . . 214
84261396 - 09 - 2009
TIGHTENING TORQUES
Capscrew, control valve support (C1) . . . . . . . . . . . . . . M16 x 1.5 15
Capscrew, control valve to tractor (C2) . . . . . . . . . . . . 3/8”--16 UNC 4.5
Capscrew, cover to control valve(C3) . . . . . . . . . . . . . M8 x 1 3.5
Nut, power cylinder pivot pin(C4) . . . . . . . . . . . . . . . . M18 x 1.5 30
Nut, power cylinder piston rod to steering arm(C5) . . M16 x 1.5 21
Nut, piston to rod(C6) . M16 x 1.5 10
Capscrew, steering pump to engine (C7) . . . . . . . . . . M12 x 1.25 0.8
Nut, cover to pump body (C5) . . . . . . . . . . . . . . . . . . . . M6 x 1 5
Nut, drive sleeve to pump drive shaft(C5) . . . . . . . . . 7/16”--20 UNF--2B 2.8
SPECIAL TOOLS
DESCRIPTION Tool No.
Steering Wheel Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82834312
Adopter, Power Steering Pressure Check . . . . . . . . . . . . . . . . . . . . . . . 291318
(includes in the set of Hydraulic pressure kit 292870)
Installer, Power Steering Rotor Spring . . . . . . . . . . . . . . . . . . . . . . . . . . 292927
TROUBLESHOOTING
Problem Possible Causes Correction
Steering wheel is heavy to turn 1. No or insufficient oil pressure
a) Pump does not run Start up pump (loose V--belt)
b) Pump defective Repair or replace pump
c) Pump runs in the wrong Correct direction of rotation of
the direction pump or replace pump
d) Pump is worn out Replace pump
e) Pump is under Install a larger pump (examine
dimensioned pressure need and flow)
2. Pressure relief valve is stuck in Repair or clean pressure relief
open position or setting valve. Adjust the valve to the
pressure is too low. correct pressure.
3. Priority valve is stuck in open Repair or clean the priority valve.
position.
4. Too much friction in the Lubricate bearings and joints of
mechanical parts of the vehicle. steering gear or repair if necessary.
Check steering column installation.
5. Emergency steering balls Install new balls.
missing.
6. Combination: Downstream Change cylinder type (through
system + steering unit with going piston rod). If necessary use
suction valve and differential two differential cylinders.
cylinder are inexpedient.
84261396 - 09 - 2009
Regular adjustments of the 1. Leaf spring without spring force Replace leaf springs
steering wheel are necessary or broken.
(“Snake--like driving”) 2. Spring in double shock valve Replace shock valve.
broken.
3. Gear wheel set worn. Replace gear wheel set.
4. Cylinder seized or piston seals Replace defective parts.
worn
Neutral position of steering 1. Steering Colunm and steering Align the steering column with
wheel cannot be obtained, i.e. unit out of line. steering unit.
there is a tendency towards 2. Too little or no play between Adjust the play and, if necessary,
“Motoring” steering colunm and steering shorten the splines journal.
unit input shaft.
Contact your Authorised New
3. Pinching between inner and
Holland Dealer
outer spools.
“Motoring” effect. The steering 1. Leaf springs are stuck or Replace leaf springs.
wheel can turn on its own. broken and have therefore
reduced spring force.
2. Inner and outer spools pinch, Clean steering unit or Contact your
possible due to dirt. Authorised New Holland Dealer
3. Return pressure in connection Reduce return pressure, change
with the reaction between cylinder type or use a non--reaction
differential cylinder and control unit.
steering unit too high
Backlash 1. Cardan shaft fork worn or Replace cardan shaft
broken.
2. Leaf springs without spring Replace leaf springs.
force or broken.
3. Worn splines on the steering Replace steering column
column.
“Shiny”--effect. The 1. Air in the steering cylinder. Bleed cylinder. Find and remove
steeredWheels vibrate. (Rough 2. Mechanical connections or the reason for air collection.
tread on tyres gives vibrations) wheel bearings worn. Replace worn parts.
Steering wheel can be turned 1. Oil is needed in the tank. Fill with clean oil and bleed the
the whole time without the system.
steered wheels moving. 2. Steering cylinder worn. Replace or repair cylinder.
3. Gear wheel set worn. Replace gear wheel set.
4. Spacer across cardan shaft Install spacer.
forgotten.
Steering wheel can be turned 1. One or both anti--cavitation Clean or replace defect or missing
slowly in one or both valves are leaky or are missing valves.
directions without the steered in OSPC or OVP/OVR.
wheels turning. 2. One or both shock valves are Clean or replace defective or
leaky or are missing in OS PC missing valves.
or OVP/OVR
84261396 - 09 - 2009
Steering is too slow and heavy 1. Insufficient oil supply to Replace pump or increase number
when trying to turn quickly. steering unit, pump defective or of revolutions.
number of revolutions too low.
2. Relief valve setting too low. Adjust valve to correct setting.
3. Relief valve sticking owing to Clean the valve.
dirt.
4. Spool in priority valve sticking Clean the valve, check that spool
owing to dirt. moves easily without spring.
5. Too weak spring in priority Replace spring by a stronger
valve. (There are 3 sizes: 4,7 and 10 bar)
“Kick--back” in steering wheel 1. Fault in the system Contact your Authorised New
from system. Kicks from Holland Dealer or Danfoss
wheels.
Heavy kick--back in steering 1. Wrong setting of cardan shaft Correct setting as shown in Service
wheel in both directions. and gear wheel set. Manual.
Turning the steering wheel 1. Hydraulic hoses for the steering Reverse the hoses
activates the steered wheels cylinders have been switched
opposite. around.
Hard point when starting to 1. Spring force in priority valve too Replace spring by a stronger one
turn the steering wheel. weak. (4, 7 and 10 bar).
2. Air in LS and /or PP pipes. Bleed LS and PP pipes.
3. Clogged orifices in LS or PP Clean orifices in spool and in
side priority valve. connecting plugs for LS and PP .
4. Oil is too thick (cold). Let motor run until oil is warm.
Too little steering force 1. Pump pressure too low. Correct pump pressure.
(possibly to one side only). 2. Too little steering cylinder. Fit a larger cylinder .
3. Piston rod area of the Fit cylinder with thinner piston rod or
differential cylinder too large 2 differential cylinders
compared with piston diameter
Leakage at either input shaft, 1. Shaft defective Replace shaft seal,
end cover, gear--wheel set, 2. Screws loose. Tighten screws Torque 3--3, t daNm
housing or top part OR steering unit (2, 5--3 daNm).
3. Washers or O--rings defective Replace washers and O--rings
84261396 - 09 - 2009
SYSTEM TESTING -- (OP 41 000)

When the hydrostatic steering system is in operation,
the pressure of oil supplied by the steering pump, to
the steering motor, can rise towards the maximum
setting of the steering motor relief valve, which is 120
bar depending on tractor model.
Steering Pump
There is no relief valve in the steering/low pressure
pump. The following practical test will determine if
steering pump output is sufficient to allow
satisfactory operation of the steering system.
Steering Test
1. Set engine speed to 1000 rev/min.
2. Turn steering quickly from lock to lock. If steering
is operating correctly the reaction of the steering
should be immediate with no time delay between
turning the steering wheel and movement of the
wheels. At full lock the relief valve in the steering
motor should be heard to blow and the engine
speed should drop to approximately 970 rev/min.
1
Steering Relief Valve Pressure Test
IMPORTANT: There is no relief valve in steering 1
pump and the following pressure test must only be
performed as specified below. Failure to observe this
precaution may result in severe damage to the
hydraulic pump.
1. Turn steering onto full left hand lock.
2. Disconnect left hand turn feed hose at steering
cylinder.
3. Install Power steering pressure checking kit
(Special Tool No.292870 with adapter 271318). 3 2
As shown in Figure
4. Start tractor and set engine speed to 1450
2
rev/min. Turn steering wheel to the left with a pull
of apporximately 22 N (2.25 kgf, 5lbf) and
observe the pressure reading.
NOTE: The use of a force greater than 5 lbf. at the
rim of the steering wheel may lead to slightly
inaccurate readings due to the pumping action of the
hydrostatic steering motor.
If the steering test was satisfactory but pressure
readings are away from specification the relief valve
in the steering motor must be adjusted
The pressure reading should be 110--125 bar
5. If the system pressure is not to specification
proceed to Relief Valve Adjustment.
84261396 - 09 - 2009
Relief Valve Adjustment -- All models 3. Block the plug connections to steering cylinder
With reference to Figure 3 with suitable blanking cap.
NOTE: To adjust the steering system relief valve it is 4. Connect the return hose normally. If required
necessary to remove the steering motor from the connect with extra hose and suitable adopter.
steering bracket, to gain access to the hexagon 5. Start the engine and idle between 1450 and 1500
headed adjusting screw. rev/min. Run the tractor until the transmission oil
1. Disconnect the steering motor from the steering reaches normal working temperature.
bracket, as detailed previously in this Chapter 6. With the engine running, turn the steering motor
and remove from the tractor. shaft to obtain full lock. The pressure gauge
2. Fabricate suitable test hose to connect pump reading should read 120 bar.
pipeline to steering motor. Connect locally 7. If the pressure readings are not correct, reset the
procured ‘T’ joint between test hose and steering adjuster (11), using an 8 mm hexagon key.
motor and Install pressure gauge as shown in the
Figure.
1
11
2
10
3
7
6
3
1. Plug 7. Pressure gauge 0--5000 lbf.in2
2. Steering shafst 8. Swivel running Tee
3. Relief valve 9. Blanking Cap
4. Fabricated Steering Motor Output Hose 10. Spring
5. Tractor tubes to steering cylinder 11. Adjuster
6. Fabricated hose for pump supply to steering motor
84261396 - 09 - 2009

V S T
26
27
D1
P
Oil Pressure to power cylinder

H
Oil pressure to rotor
Inlet, low pressure or return oil
Trapped oil
1
D1 -- Control valve P -- Hydraulic pump
E -- Filter Catridge S -- Return to tank
H -- Power cylinder T -- Reservoir
M -- Pump outlet line V -- Steering wheel
84261396 - 09 - 2009
Oil Pressure to power cylinder
Oil pressure to rotor
Inlet, low pressure or return oil
Trapped oil
2
A. Operation in straight--ahead driving position b. Sections through control unit with valve (5) in R.H. steer position (for 12. Spacer 25. Washer
B. R.H. (Sd) and L.H. (Ss) steer L.H. steer, valve rotation is symmetrical in opposite direction) 13 and 14. Oil ports 26. Oil passage to L.H. power cylinder chamber
C. R.H. and L.H. emergency steer (Sed and Ses) G1, G2. Gap between pin (1) and rotary valve (5) 15. Rotor inlet passages (6 off) 27. Oil passage to R.H. cylinder chamber, piston rod side
d. Operation diagram for straight--ahead driving r1, r2. Sections through DANFOSS OSPC 100 control valve 16. Connecting port (12 off) communicating with passages (15 and 17) 29. Thrust bearing
e, f. Operation diagram for two--stage R.H. steering 1. Drive pin alternatively 31. Seals
E. Filter cartridge 2. Sleeve return springs 17. Pressure passages (6 off) to power cylinder communicating with the 32. Dust excluder
g. Steering system schematics 3. Control valve body rotor recesses and ports (18 and 20)
33. Cylinder safety valves
H. Power cylinder 4. Check valve 18. R.H. power cylinder chamber outlet or exhaust ports (6 pairs)
34. Make--up valves
M. Pump outlet line 5. Rotary valve 19. Power cylinder exhaust passages (6 off) communicating with ports (18
35. O--rings
6. Valve seat sleeve and 20)
P. Hydraulic pump 36. Valve adjusting screw
7. Rotor drive shaft 20. L.H. power cylinder chamber outlet or exhaust ports (6 off)
S. Return to tank 37. Plugs
8. Rotor cam ring 21. Oil passage from ports (16) to rotor recesses
T. Reservoir 38. Valve adjusting screw.
9. Rotor 22. Supply ports for passages (15)
V. Steering wheel 24. Relief valve
10. Thrust ring 23. Check valve
23. Check valve 33. Power cylinder safety valves
11. Cover 24. Relief valve
a. Section through control unit with valve (5) in neutral 34. Make--up valves.
84261396 - 09 - 2009
Hydrostatic steering system is powered (when the RH Steer (B, Sd, b, e, f).
engine is running) by steering pump mounted on the Upon turning steering wheel (V) clockwise, springs
front side of the engine timing gear. (2, Section A--A) deflect allowing valve (5) to rotate
Hydrostatic steering system incorporate a steering relative to sleeve (6) until gap (G,, section B--B) is
pump (1) pressurises the steering column operated taken up.
control valve (2). The pressurised oil from the control Thus:
valve operates the axle mounted double acting
steering cylinder (3). -- Ports (13 and 14, Section C--C) go out of align-
ment to discontinue oil return.
The control valve is bolted to a bracket mounted on
transmission housing and connected to the steering -- Six passages (15, Section D--D) line up with an
column by a spindle shaft. equal number of ports (16) connected instant by
instant with the rotor recesses during the inlet
The steering cylinder is fixed at one end to the front phase.
axle beam and at the other to an eye on the spindle
arm. -- Six pressure passages (17, Section E--E) line up
with ports (18) communicating with the power
The pressure relief value for the system is contained cylinder. Moreover, the oil pressure passages
within the steering control valve itself communicate with the remaining ports (16, Sec-
tion D--D) connected instant by instant with the
Operation rotor recesses during the actuation phase.
Oil is drawn from the reservoir (4) and into the pump -- Six exhaust passages (1 9) line up with ports (20,
through a filter (3) , pressurised by the rotation of the Section E--E) communicating with the power cyl-
gears and expelled through the pump outlet port to inder.
the steering control valve. The pressurised oil when Once the gap (G,) is eliminated valve (5) positively
received at the control valve is directed to the transmits steering wheel input to both sleeve (6) and
steering actuating cylinder when the steering wheel rotor (9) through pin (1) and shaft (7). Diagrams (e
is truned. and f) show the principle of operation at start of RH
The control valve incorporates a metering unit which steer and after a certain amount of wheel rotation.
regulates the volume of oil supplied to the cylinder so
The flow of oil pressure from pump to rotor during
that it is propotional to the angular movement of the
inlet, and from rotor to power cylinder line during the
steering wheel. The metering unit in combination
power actuation phase, is provided instant by in-
with the check value also allows the steering to be
stant.
operated MANUALLY without pressurised oil being
supplied from the pump.
The system is fully hydrostatic and as such there is LH Steer (B, Ss).
no mechanical connection between the steering Upon turning the steering wheel anti--clockwise, a re-
column and the steering wheels. versal of the above sequence is obtained and deliv-
ery passages (17, Section E--E) supply ports (20) to
bring about LH steering.
Straight--ahead Driving (A, a, d).
With steering wheel (V) stationary, rotary valve (5)
takes neutral position relative to sleeve (6). This Emergency Hydraulic Steer (C, Sed, Ses).
position is maintained through the action of springs Steering is possible even in cases of loss of hydraulic
(2, section A--A) and the following conditions exist: pressure. Upon turning the steering wheel, valve (5)
takes up the normal operating position, whilst the
-- Pin (1, section B--B) is central in the valve (5) ap-
rotor functions as a hand pump directing oil pressure
erture.
to the power cylinder,
-- Ports (13 and 14) are in alignment (Section C--C)
and the oil pressure from pump (P) is returned to Check valve (4) opens, thereby permitting the flow of
tank. oil from tank to rotor by--passing the pump. Valve
(23) remains closed preventing leakage in connect-
-- Passages (15, 17 and 19) on the valve (Sections ing line between pump and control unit.
D--D and E--E) are off register relative to ports (1
6, 1 8 and 20) on the sleeve (i.e. all ports in com-
munication with the power cylinder remain
closed).
84261396 - 09 - 2009
Power Cylinder Safety and Make--up Valves which are not sufficient to open cylinder safety valve,
(N2). is exhausted through normal leakage past control
As of safety valves open (33), pressure created by valve (D,), while vacuum in the opposite chamber is
piston (H) is exhausted in one cylinder chamber compensated through make--up (34), as shown in
under the action of strong external stress on wheels. detail N2, for DANFOSS OSPC 100 control valve.
Simultaneously, vacuum in the opposite chamber is Operation of the above valves eliminates continuous
compensated by oil flow through the opening of the steering wheel correction and prevents front wheel
associated make up valve (34). Pressure in one cyl- shimmy, hydraulic circuit failure and damage to the
inder chamber deriving from small external stress steering linkage.
33
33
D1
34
84261396 - 09 - 2009
STEERING MOTOR
Removal -- installation
(Op. 41 204)
Removal
1. Position the tractor on a hard level surface and
apply the parking brake.
WARNING
and footwear.
2. To gain access to the Steering motor:

-- Remove tractor rear hood
-- Remove fuel tank.
For Removal procedure, Please refer to Section 10
3. Disconnect the four supply/return tubes and ’O’
ring seals from the steering motor and cap the L
ends of the tubes and steering motor to prevent T
entry of foriegn particles. R
T -- To Tank
P -- From Pump
L -- Left Port P
R -- Right Port
1
4. Remove the four bolts(1) at the base of the
steering column and slide out the steering motor
from the steering column remove bolts ( 2 ) from 3
bracket to take out stg motor ( 3 ) Disconnect
pipes 4 nos. .
1
Installation of Steering Assembly 2

5. Reinstall the steering motor following the
removal procedure in reverse. 2
84261396 - 09 - 2009
Disassembly--Reassembly
1. Hold the steering securely in a vice.
2. Remove the end cover bolts (6 plus one special
screw)
3
3. Remove the end cover, sideways
4
4. Lift the gear wheel set (with spacer fitted) off the
unit. Take out the two O--rings.
5
5. Remove cardan shaft
84261396 - 09 - 2009
6. Remove distributor plate
7
7. Screw out the threaded bush over the check
valve
8
8. Remove O--ring
9
9. Shake out the check valve ball and suction valve
pins and balls.
NOTE: Replace pins prior to the reassembly
10
84261396 - 09 - 2009
10. Take care to keep the cross pin in the sleeve and
spool horizontal. The pin can be seen through the
open end of the spool. Press the spool inwareds
and the sleeve, ring, bearing races and needle
bearing will be pushed out of the housing
together.
11
11. Take ring, bearing races and needle bearing from
sleeve and spool. The outer (thin) bearing race
can sometimes “stick” in the housing, therefore
check that it has come out.
12
12. Press out the cross pin. Use the special screw
from the end cover.
13
NOTE: Asmall mark has been made with pumice
stone on both spool and sleeve close to one of the
slots for the neutral position springs (see Figure)
If the mark is not visible, remember to leave a mark
of your own on sleeve and spool before the neutral
position springs are dismantled.
14
84261396 - 09 - 2009
13. Carefully press the spool out of the sleeve.
15
14. Press the neutral position springs out of their
slots in the spool.
16
15. Remove dust seal and O--ring/kin--ring/Roto
Glyd.
17
16. The steering unit OSPB is now completely
dismantled.
18
84261396 - 09 - 2009
Cleaning
Clean all parts carefull in Shellsoi K or the like.
Inspection and replacement

Replace all seals and washers. Check all parts
carefully and make any replacements necessary.
Lubrication
Before assembly, lubricate all parts with hydraulic oil.
84261396 - 09 - 2009
ASSEMBLY
WARNING
and footwear.
WARNING
1. Place the two flat neutral position springs in the

slot. Place the curved springs between the flate
ones and press them into the place
1
2. Line up the spring set.
2
3. Guide the spool into the sleeve. Make sure that
spool and sleeve are placed correctly in relation
to each other
84261396 - 09 - 2009
4. Assemble spool and sleeve
4
NOTE: When assembling spool and sleeve, only two
possible ways of positioning the spring slots are
correct.
There are three slots in the spool and three holes in
the sleeve in the end of the spool/ sleeve, opposite
to the end with speing slots. Place the slots and holes
opposite each other so that parts of the holes in the
sleeve are visible through the slots in the spool.
5
5. Press the springs together and push the neutral
position springs into place in the sleeve.
6
6. Line up the springs and centre them.
84261396 - 09 - 2009
7. Guide the ring dwon over the sleeve

NOTE: The ring should be able to move -- free of the
springs.
8
8. Fit the cross pin into the spool/sleeve
9
9. Fit bearing races and needle bearing as shown
on below drawing.
10
84261396 - 09 - 2009
Assmbly Pattern for standard bearing
4
* 1. Outer bearing race
2. Needle bearing
3. Inner bearing race
5
4. Spool
5. Sleeve
11
* The inside chamfer on the inner bearing reace must face the inner spool
Installation of O--ring
1. Turn the steering unit until the bore is horizontal
in position. Guide the outer part of the sasembly
tool into the bore for the spool/sleeve.
12
2. Grease O--ring and king ring/roto Glyd with
hydraulic oil and place them on the tool.
13
84261396 - 09 - 2009
3. Hold the outer part of the assembly tool in the bottom

of the steering unit housing and guide the inner part
of the tool right to the bottom.
14
4. Press and turn the O--ring /kin--ring into position
in the housing.
15
5. Draw the inner and outer parts of the assembly
tool out of the steering unit bore, leaving the guide
from the inner part in the bore.
16
Installation of Lip seal
WARNING
1. Lubricate the lip seal with hydraulic oil and place

it on the assembly tool.
17
84261396 - 09 - 2009
2. Guide the assembly tool right to the bottom.
18
3. Press and turn the lip seal into place in the
housing.
19
4. With a light turning movement, guide the spool
and sleeve into the bore.
NOTE: Fit the spool set holding the cross pin
horizontal.
20
5. The spool set will push out the assembly tool
guide. the O--ring and kin ring/roto Glyd are now
in position.
21
84261396 - 09 - 2009
6. Turn the steering unit until the bore is vertical

again. Put the check valve ball into the hole
indicated by the arrow.
22
7. Screw the threaded bush lightly into the check
valve bore. the top of the bush must lie just below
the surface of the housing.
23
8. Place a ball in the two holes (1).
1
24
9. Place a new pin in the same two holes.
25
84261396 - 09 - 2009
10. Grease the ‘O’ ring with mineral oil approx.

viscosity 500 mm2/s at 20_C.
26
11. Place the distributor plate so that the channel
holes match the holes in the housing.
27
12. Guide teh cardan shaft down into the bore so that
the slot is parallel with the connection flange.
28
13. Place the cardan shaft as shown -- so that it is
held in position by mounting fork.
29
84261396 - 09 - 2009
14. Grease two O--rings with mineral oil approx.

viscosity 500 mm2/s at 20_C and place them in
the two grooves in the gear rim. Fit the gearwheel
and rim on the cardan shaft.
30
IMPORTANT: Fit the gearwheel (rotor ) and cardon
shaft so that a tooth base in the rotor is positioned in
relation to the shaft slot as shown. Turn the gear rim
so that the seven through holes match the holes in
the housing.
31
15. Fit the spacer, if any.
32
16. Place the end cover in position.
33
84261396 - 09 - 2009
17. Fit the special screw with washer and place it in

the hole (1)
1
34
18. Fit the six screws with washers and insert them.
Cross--tighten all the screws and the rolled pin
with a torque of 3.0 + 0.6 daNm. The steering
motor can now be function tested.
35
19. Fit the dust seal ring in the housing using Suitable
Tool and a plastic hammer
36
20. Press the plastic plugs into the connection ports.
DO NOT USE A HAMMER!.
37
84261396 - 09 - 2009
TWO WHEEL DRIVE STEERING CYLINDER REMOVAL -- INSTALLATION

(OP 41 216 20)
1
Steering Cylinder
Removal 4. Remove the nut securing the steering cylinder on

1. Stand the tractor on a hard level surface and front axle beam.
position the front wheel in the straight ahead 5. Remove the steering cylinder from the tractor
position. and retrieve washer, spacer and bolt (Pivot pin).
2. Disconnect flexible pipes, cap the open pipe
ends and remove hose clamps. Installation
IMPORTANT: Position of flexible pipes and 6. Installation is the reversal of the removal
orientation of connectors must be the same upon procedure.
re--assembly.
3. Remove the nut securing the cylinder rod ball
joint to the steering arm and separate the joint,
Figure 1.
84261396 - 09 - 2009
STEERING CYLINDER OVERHAUL -- (OP 41 216 28)
2
Steering Cylinder Assembly
1. Seeger ( 5 & 7 also) 5. Ball joint
2. assembled rod 6. Head
3. Piston 7. Nut
4. Lock nut 8. Seal kit
1. Fix the body taking care not to scratch it

2. Push the rod to the end of the stroke ( in the
welded side)
3. Use the seeger clamp to remove the head
seeger.
4. Use the head bell and the plastic hammer to push
the head inside the body 20--30mm
3
5. Remove the internal retaining ring with screw
driver.
6. Remove the head hammering the rodRemove
the piston after unscrew the self locking nut.
NOTE: Check that oil ports are not plugged and
remove internal oil.
84261396 - 09 - 2009
7. Extract the rod pulling it. Seal on the piston could

require energic action. Clamp the rod paying
special attention to not sctatch its surface.
8. Remove with the screwer driver piston seal and
o--ring under the seal.
5
9. Throw away used seal and open the seal kit &
clean the piston.
6
10. Apply piston seal mounting bell against piston
and insert the o--ring having it slipping on the bell.

WARNING
11. ubricate the lip seal with hydraulic oil and place
84261396 - 09 - 2009
12. Insert the external ring of the piston seal over the
o--ring just mounted in this way.Position the ring
over the bell ,take the pushing tool and overpass
with it in the piston. The seal will fit its groove
automatically.
8
13. Callibrate the seal with the appropriate tool
WARNING
IMPORTANT: use the screwdriver with care avoiding
scratches on seal grooves.
9
14. .Remove seals on the head with the screw driver
15. Wash the head and verify to noyt have generated
rags during disassembling and working.
10
84261396 - 09 - 2009
16. Manual mount rod seal taking care about the

orientation of the lips.( oriented to reytain oil).
11
17. Mount manually the wiper (taking care about lip
orientation) and the static seal (External )
12
18. Draw the inner and outer parts of the assembly
tool out of the steering unit bore, leaving the
guide from the inner part in the bore.
19. Lubricate the lip seal with hydraulic oil and place

WARNING
13
84261396 - 09 - 2009
20. Insert the head and piston on rod.screw

selflocking nut at torque (Nm) .Grease every seal
on body,head and piston.Grease the internal wall
of body(20--30mm) entrance zone
14
21. nsert the assembled rod. Taking care to not
damage piston seal. Hammer the rod to end of
stroke.Unscrew the rod bell and screw on the
other side.
15
22. .nsert the head manually up to 20--30mm inside
84261396 - 09 - 2009
NEW
HOLLAND
FRONT AXLE SECTION 44


44 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
44 511 Front wheel Camber and Toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
84261396 - 09 - 2009
SECTION 44 -- FRONT AXLE -- CHAPTER 1 1
SECTION 44 -- FRONT AXLE
Chapter -- 1 Two Wheel Drive Axle
CONTENT

44 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
44 511 Front wheel Camber and Toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS
Type
4510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrally pivoted U --type centre
beam with telescopic outer sections.
4010/3510 . . . . . . . . . . . . . . . . . . . . . . . . . . Centrally pivoted U --type centre

beam without telescopic outer
section
Track settings
4510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1250 -- 1350 -- 1450 --1550 -- 1650 --
1750
4010/3510 . . . . . . . . . . . . . . . . . . . . . . . . . mm 1350
Wheel camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2_ corresponding to approx.
15 mm with 16” rims.
Wheel toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0 to 5
Swivel Pin Assembly
Swivel pin (3, fig.2 ) diameter at the bushes . . . . . . . . . . . mm 29.967 / 30.00
Press--fit bush (4) inner diameter . . . . . . . . . . . . . . . . . . . . mm 30.140 / 30.060
Swivel pin to bush clearance . . . . . . . . . . . . . . . . . . . . . . . . mm 0.060 to 0.173
Axle Pivot Pin Assembly
Pivot pin (9, Fig. 2) diameter . . . . . . . . . . . . . . . . . . . . . . . . mm 29.967 / 30.00
Press--fit bush (4) inner diameter . . . . . . . . . . . . . . . . . . . . mm 30.140 / 30.060
Pivot pin to bush clearance . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.060 to 0.173
84261396-- 09 - 2009
2 SECTION 44 -- FRONT AXLE -- CHAPTER 1
TIGHTENING TORQUES

Capscrew, front axle carrier to engine (C1) . . . . . . . . . M16 x 2 22
Capscrew, axle pivot (C2) . . . . . . . . . . . . . . . . . . . . . . . . M10 x 1.25 6
Capscrew, wheel to hub (C3) . . . . . . . . . . . . . . . . . . . . . M14 x 1.5 15
Nut, track rod ball joint (C4) . . . . . . . . . . . . . . . . . . . . . . M10 x 1 2.5
Nut, track/ drag link, ball joint(C5) . . . . . . . . . . . . . . . . M14 x 1.5 10
Nut, RH and LH control lever (C6) . . . . . . . . . . . . . . . . M12 x 1.25 9
Axle Extension securing bolts (C7) . . . . . . . . . . . . . . . . M16 x 1.5 11.8
C1
C2
C4
C5
C3
C7
C6
84261396 - 09-- 2009

SPECIAL TOOLS
Slide hammer for centre pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292927
Adopter for Slide hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290793
SEALANTS
Sealant
Specification
Front wheel hub sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite -- 638
King pin thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loctite -- 638
TROUBLESHOOTING
Premature tyre wear 1. Wrong inflation pressure. Inflate tyres to correct pressure refer
to values suggested in the Operator’s
Manual. Always comply with values
specified by the tyre manufacture.
2. Wrong front wheel toe--in Adjust toe--in (refer the procedure

explained in this section under
adjustment)
Poor tractor stability 1. Wrong inflation pressure. Inflate tyres to correct pressure
The adjustable front axle is composed of a reversed The centre beam is attached to the front axle carrier
‘U’ type centre beam (2) with telescopic sections (1) by means of a single pivot which allows to swing on
at each end. both sides.
A number of holes at 50 mm (2 in) intervals are The front axle is controlled by the mechanical
provided in the telescopic sections for track width steering through swivel pin control lever. The two
adjustment purpose. Adjustment of the front wheel swivel pins are connected by telescopic track control
track width is affected by extending or retracting both rod, which contain adjustment for toe--in
ends of the axle equally.
NOTE: This feature is available only in 4510 model.
In 4010/3510 model the track width is
non--adjustable and fixed at 1350 mm.
84261396-- 09 - 2009
Sectional View -- Front axle support
3
1
2 4
1
1. Grease fitting 4. Thrust washers
2. Axle centre beam 5. Axle pivot pin
3. Axle pivot pin bushings 6. Front axle carrier
84261396 - 09-- 2009

Sectional View -- Stub assembly
2
20
3
19
16 17 18
4
5
6
15
7
14
12 9
13
8
10
11
2
1. Dust cover 11. Grease nipple
2. Oil seal 12. Bearing
3. Bush upper 13. Thrust washer
4. Bush lower 14. Castle nut
5. Thrust washer 15. Split pin
6. Seal 16. Dust cover
7. Dust cover 17. ‘O’ ring
8. Bush (sleeve) 18. Thrust washer pin
9. Seal 19. Grease nipple
10. Bearing 20. King pin
84261396-- 09 - 2009
FRONT AXLE ASSEMBLY

DANGER
equipment of appropriate capacity. Ensure that units
Ensure that no--one is in the vehicle of the load to be
lifted
Remove the front axle assembly from the tractor as

follows:
1. Open and raise front hood .
2. Disconnect the negative cable from the battery
and insulate.
3. Safely block rear wheels.
4. Remove front weights and weight support, where 1
fitted.
5. Jack up front tractor and place a stationary stand
(1) under the sump.
1
6. Loosen retaining bolts (1) and remove the front
wheels.
2
7. Remove knuckle joint nut (1) and disconnect
drag link (2) from control lever.
2
84261396 - 09-- 2009

8. Remove the axle pivot pin locking bolt (1).
4
9. Using a Slide Puller (Special Tool No.292927)
with adapter(Special Tool No. 290793) withdraw
the pivot pin (1) and recover thrust washers and
shims provided between axle carrier and centre
beam.
10. Remove front axle using a hoist.
5
INSTALLATION
Reinstall the front axle assembly to carrier observing
the following:
• Reassembly follows disassembly procedure in
reverse, from step 10 back to step 1.
WARNING
• Check the pivot pin play. It should not exceed

0.25 mm. If play is more, add shims between axle
carrier and centre beam.
• Check for correct toe--in setting. Refer ’FRONT
WHEEL SETTING TESTS’ for details.
• Tighten all fasteners to correct torques as
detailed on Page 2.
84261396-- 09 - 2009
FRONT WHEEL HUB

WARNING
insert hands or fingers between the parts. Wear
suitable protection clothing, including goggles,
gloves and footwear.
Wheel hubs can be removed with the front axle on

the tractor. Proceed as follows for each hub:
(1) under the sump.
3 Loosen retaining bolts and remove front wheels.
1
1
4. Remove wheel hub bearing grease cup (1).
2
5. Remove split pin (1).
84261396 - 09-- 2009

4. Using the socket spanner loosen the wheel hub

bearing. Adjust castle nut.
4
5. Remove wheel hub (2) and recover bearing ( 1& 3)
2
1
5
6. Remove seal (1) and nyloc ring (2) using suitable
tool.
6
INSTALLATION
1. Replace faulty seals and worn bearing using 2
1
suitable pullers and drifts.
2. Fill the wheel hub with specified grease. 3
3. Re--assemble the wheel hub (2) complete with
the bearings (1 & 3).
84261396-- 09 - 2009
4. Using a torque wrench and socket spanner (1),

tighten the castel nut while turning the wheel hub
(1) to settle the bearing. Tighten the nut until
wheel hub gets slightly tight to rotate.
5. Loosen the castel nut and torque it again to 9.8
Nm continuing to turn the wheel hub.
8
6. Insert split pin (1).
9
7. Reassemble the wheel hub dust cap (1)
NOTE: Check the ’O’--ring provided on the dust cap
for any cut or damage. If required replace the
’O’--ring.
10
84261396 - 09-- 2009

SPINDLE ASSEMBLY

WARNING
Handle al components with greatest care. Do not
insert hands and fingers between the parts. Wear
suitable protection clothing, including goggles,
gloves and foot wear.
Swivel pins can be removed and overhauled with the

front axle on the tractor. Proceed as follows for each
wheel:
(1) under the sump.
3 Loosen retaining bolts and remove front wheels.
1
1
4. Remove swivel pin control lever retaining bolt (1).
5. Slide out the control lever (2) from the spindle 2 1
assembly.
2
4. Pull out the swivel axle and hub assembly (1)
from axle outer section.
84261396-- 09 - 2009
5. Remove the axle outer section (1) attaching

bolts.
4
6. Remove the axle outer section (1)
5
Overhaul
1. Fix the axle outer section in a vice and remove
the upper seal using suitable tool.
6
2. Remove the bottom seal using suitable tool and
recover thrust washer.
3. Check the swivel bearing bushes for wear. See
specifications in page 1 . If bushes require
replacement, remove the bushes using suitable
tool.
4. Using a suitable drift install new bushings on the
axle outer section.
5. Check the swivel pin for wear. If required replace
new spindle.
6. Ream the new bushings to suit the swivel pin.
84261396 - 09-- 2009

Installation
Reinstall the spindle assembly to the front axle
following the disassembly procedure in reverse.
NOTE: Ensure that the slot (1) in the thrust washer
fits on the notch provided on the axle outer section
FRONT WHEEL SETTING TESTS
Wheel Camber Test

Check the front wheel camber considering that when
the tractor moves along a straight line, wheels should
be tilted by 2 degrees relative to the ground,
corresponding to a difference (X) of approximately
15 mm between the rim edges.
Front Wheel Toe--in Test

When the tractor moves along a straight line, wheels
should be parallel to the tractor centre line or slightly B+ 0to5mm
toe--in until a max. of 0.5 mm, measured between the
rim edges.
Check the correct toe--in as follows:
1. Inflate front tyres to a pressure of 25 Psi.
2 Place the steering wheel at mid--travel, with one
spoke along the tractor centre line.
3. Check if wheels are parallel to the tractor centre
line.
4. Measure the distance (B) between the wheel
inner rims at hub height at the front of the wheels. 10
5. Measure the distance between the wheel inner
rims at hub height at the rear of the wheels. The
measurement taken should be the same as (B)
or greater by up to 5 mm max.
84261396-- 09 - 2009
6. If necessary to adjust the front wheel toe--in,

proceed as follows:
-- Loosen the clamp (1) on both end of the track
control rod.
-- Turn the track control rod (2) in or out to 2
shorten or lengthen the track control rod until
0.5 mm toe--in is achieved.
-- Tighten the clamp (1).
11
84261396 - 09-- 2009

NEW
HOLLAND
ELECTRICAL SYSTEM SECTION 55

Electrical Introduction Chapter 1

55 100 Electrical System and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
55 000 System Precautions For Battry Charging and Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
55 100 Temporary Wiring Harness Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Analogue Instrument Cluster Chapter 2

55 100 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Starting System Chapter 3

55 100 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
55 201 Removal -- Installation -- Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Charging System Chapter 4

55 100 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
84261396 - 09 - 2009
Contents Continued
Battery Chapter 5

55 100 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
55 301 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Battery testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wiring Diagrams Chapter 6
Description Page
Centre harness circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Front harness circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rear harness circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Instrument cluster circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Starting and Charging system circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
84261396 - 09 - 2009
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 1
SECTION 55 -- ELECTRICAL SYSTEM
Chapter 1 -- Electrical Introduction
CONTENT

55 100 Electrical System and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
55 000 System Precautions For Battery Charging and Welding . . . . . . . . . . . . . . . . . . . . . . . . . . 3
55 100 Temporary Wiring Harness Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84261396-- 09 - 2009
2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
FUSES -- SPECIFICATIONS
Eight fuses housed in one box.
Protected Circuit Amp
1. Left/Right Indicators, (Turn) . . . . . . . . . . . . . . . . . . . . . . . 15
2. Instrument cluster (Guages & Charge Indicator) Horn . . . . 10
3. Head Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4. ACC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5. Stop Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6. Plough Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Description and operation

The electrical system of 4510 / 4010 / 3510 tractor
consists of various wiring harnesses, lights,
switches, battery, alternator, starter and instrument
cluster.
Fuses protect electrical circuits with thin pieces of
wire, which heat up and melt when too much current
flows through them. This opens circuit and protects
the wiring from burning. This can occur in the event
of a ‘short circuit’, or by connecting equipment which
demands a current greater than the circuit, designed
to carry. The fuse is specially designed and in the
event of failure, a new fuse of the same rating, 10
Amps, should be fitted.
IMPORTANT: The fuse should never be repaired or 1
replaced by a fuse of a higher rating.
If the fuse repeatedly ’blows’ the cause must be
investigated and repaired
Fuses are all located under.
84261396 - 09 - 2009
PROTECTING THE ELECTRICAL SYSTEMS DURING CHARGING OR WELDING

Precautions tractor or on any implement attached to the
To avoid damage to the electrical systems, always tractor.
observe the following: 6. Remove positive cable during charging latter with
1. Never make or break any of the charging circuit external charging.
connections, including the battery connections, WARNING
when the engine is running.
Batteries contain sulphuric acid. In case of contact
2. Never short any of the charging components to with skin, flush the affected area with water for five
earth minutes. Seek medical attention immediately. Avoid
3. Do not use a slave battery of higher than 12 volts contact with skin, eyes or clothing. Wear eye
nominal voltage. protection when working near batteries.
4. Always observe correct polarity when installing
the battery or use a slave battery to jump charge IMPORTANT: Failure to disconnect the earth cable
the engine. connections at the battery prior to charging the
5. Always disconnect the earth cable from the batteries or welding on the tractor or attached
batteries before carrying out arc welding on the implement will result in damge to the electrical
system.
84261396-- 09 - 2009
TEMPORARY WIRING HARNESS REPAIR

The following method to repair wiring is a temporary
expedient only. Wiring should be replaced as soon as
possible. Replacement of temporary repaired cables
with new is particularly important if the tractor is to be
used for puddling, spraying etc, as water/chemicals
can enter the repaired area, travel up the cable and
damage electrical components. Do not attempt to
repair the wire on any system sensors as these are
sealed and should only be replaced with a new
component.
NOTE: When conducting a cable repair it is
important that only RESIN CORED SOLDER is
used. Use of other types of solder may result in
further cable damage.
To carry out a temporary repair, proceed as follows:--
1. Locate damaged portion of cable then cut away
outer protective cover on both sides of the
damaged area.
2
2. Peel back the cable from both ends of the
damaged area and carefully cut away the inner
cable cover at the damaged area and strip about
13 mm (1/2 inch) of insulation from the wires. Do
not cut away any wire strands.
3. Using a suitable solvent, clean about 50 mm (2
inches) from each cover end. Clean the grey
cable cover and the individual leads.
4. Twist two bare leads together for each damaged
lead, being careful to match wire colours, then
solder the leads using resin cored solder. Tape
each repaired lead with vinyl insulation tape,
Figure 3.
3
84261396 - 09 - 2009
5. Wind a layer of vinyl insulation tape up to the grey

cable cover at each end of the repair section.
Make a paper trough, Figure 4, then apply silicon
rubber compound (non hardening sealant) over
the repaired section up to the cover ends.
Sufficient sealant must be used to fill the ends of
the cut away area.
4
6. Allow the compound to cure then cover the area
with insulating tape taking the tape well over
each end of the repair. An overlap of at least 2
inches (50 mm) of tape at each end is necessary,
Figure 5.
7. Check to ensure the repair is satisfactory and
secure the repaired cable so that repeat damage
is avoided.
NOTE: This is a temporary repair only. Ensure the
damaged cable is replaced as soon as possible to
prevent ingress of water or chemicals.
84261396-- 09 - 2009
Chapter 2 -- Analogue Instrument Cluster
CONTENT

55 100 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
84261396-- 09 - 2009
LIGHTS, SIGNALS & ACCESSORIES -- SPECIFICATION

Head Lamps
Reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Asymmetric
Bulb (double filament) . . . . . . . . . . . . . . . . . . . . . . . . W 35/35
Fender lights
Front lights (left and right)
Parking light
Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White
Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W 5
Turn signal light
Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Amfer
Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W 21
Rear lights (left and right)
Parking light + License plate light (RH side
only)
Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W 5
Turn signal light
Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Amfer
Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W 21
Stop signal light
Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W 21
Reflex reflector RED . . . . . . . . . . . . . . . . Integral to stop light lens
Plough Lamp
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integral
Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White
Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W 55
Guages and Warning lights
Charge indicator light
TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W 1.7
Oil Pressure guage bulb . . . . . . . . . . . . . . . W 1.7
High beam indicator
TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue
Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W 1.7
Turn signal indicator
TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green
Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W 1.7
Water temperature guage bulb . . . . . . . . . . W 3
Fuel guage bulb . . . . . . . . . . . . . . . . . . . . . . W 3
Hour meter module . . . . . . . . . . . . . . . . . . . . LCD type
TT = Tell Tales
84261396 - 09 - 2009
TROUBLESHOOTING
Warning lights and gauges 1. Faulty key start switch Inspect and renew.
in--operative 2. Fuses burned out Inspect and renew, check circuit
3. Loose or broken wiring before reconnecting power.
Inspect circuit, tighten connections/
renew wiring
Gauges erratic or inoperative 1. Loose or broken wiring Inspect circuit, tighten connectors /
renew wiring.
Gauges always show maximum 1. Sender line short circuited Check the circuit.
reading (fuel gauge and water
temperature gauge)
Oil pressure gauge showing in 1. Pressure switch faulty Check and renew.
Green zone without starting 2. Connection not ok Check and correct.
tractor with ignition switch in
Position -- 2
INSTRUMENT CLUSTER
Figure 1 5. Battery Charging Indicator 10. Tachometer

Instument cluster consists of the following 6. Right Turn Indicator 11. Fuel gauge
1. Position lights 7. High Beam -- Head Light iIndicator
2. Left Turn Indicator 8. Hour Meter
3. Oil Pressure gauge 9. Temerature meter
4. Trailer Light
3 5
4 6
2
1 7
8
11
9
10
84261396-- 09 - 2009
Engine Oil Pressure gauge

Figure 2
A pressure sensor (1) is installed on left hand side of
engine into the main oil gallery. Change in oil
pressure affect the resistance of this sensor. The
gauge then measures the resultant current in the
circuit and indicates it on the dial as oil pressure.
Below 0.5 bar, the sensor switch closes fully and the
gauge will enter the red zone.
1
2
Battery Charging Indicator
This is used to indicate if the alternator is operating
correctly. A 1.7 Watt bulb is connected into the key
switch alternator circuit. This will illuminate when key
switch is turned to position 2. It should go off once
engine is started and alternator begins to change the
battery.
Left/Right Indicator Lights
Left and Right turn, 1.7 Watts lamps are mounted in
the instrument console. These are connected to the
left/right turn indicator circuit and flash whenever the
turn signals are operated. Both the indicator lights
flash when Hazard Warning Switch is used.
High Beam Indicator Light
A 1.7 Watt lamp is connected to the head light high
beam circuit. When high beam is selected the lamp
should illuminate.
Digital Hour Meter
LCD type hour meter indicates hours engine worked.
Reading will be displayed at all positions of key
switch. Meter is connected to alternator through
tacometer.
NOTE: Not required as meter glows reading even
when start switch on off position.
84261396 - 09 - 2009
Temperature Gauge
Figure 3
A temperature sensor (1) installed at the cylinder
head water jacket outlet, changes in resistance 1
according to the temperature of the water. The gauge
indicates the water temperature according to the
electrical current flowing through the sensor and
displays it on the dial.
3
Tachometer
Figure 4
Electrically operated through alternator, indicates
engine speed. Meter is connected to alternator at (1).
NOTE: Tachometer will work only when engine is
started.
4
Fuel Level Gauge
A Sensor inside the fuel tank changes its resistance
according to the fuel level. The gauge measures the
resultant current and indicates it as fuel level on the
dial
84261396-- 09 - 2009
CONTROL SWITCHES
5
6
4
1
2
3
6
1. Horn switch 4. Left/Right Turn Switch
2. Key start switch This is used to switch on, the left or right turn signal
3. Engine shut off circuits. It has 3 positions
4. Turn indicator 1. Forward Right turn
5. Hazard switch 2. Centre Off
6. Headlight switch 3. Backward Left turn
5. Hazard Light Switch
1. Horn Switch
This is used on both left and right turn signal circuits.
A push button switch is used to complete the horn This allows to operate as a warning to other road
signal circuit traffic
2. Key Start Switch

Figure 7
A Key Switch is used to distribute electrical power to
various circuits. It has 4 positions
Position 1 Electrical Equipment Off
Position 2 Head Lights, Horn, Instrument
cluster and gauges
Position 3 All of position 2 plus Brake
lights, Turn signal
Position 4 Starter motor engaged
3. Fuel Shut Off 7
Knob (4) is used to shut off the engine, Pull the knob
to shut off, then push in.
84261396 - 09 - 2009
6.Light Switch
Figure 8
A turn type switch is used to switch the light circuits
Position 1 Off
Position 2 Parking Lights and Instrument
panel lights.
Position 3 Low beam
Position 4 High beam
8
Neutral Start Switch
Figure 9
A two position ‘bal plunger type’ switch (1) mounted
on left hand side of transmission housing, operated
by the high/low range lever.
NOTE: Not required as NSS has only two terminals
with wiring harness soldered.
9
Brake Light Switch
Figure 10
The brake pedal switch (1) is located below the right
foot board near the foot brake. It is actuated while
applying brake and is indicated by the light provided
on the fender.
1
10
84261396-- 09 - 2009
Chapter 3 -- Starting System
CONTENT

55 100 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
STARTING SYSTEM -- SPECIFICATIONS

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mico
Voltage rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V 12
Rated output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kw 2.7
Rotation (viewed from the driver’s end) . . . . . . . . . . . . . Clockwise
No. of teeth on pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
No of poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Field winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical excitation
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting switch on vechicle
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre--engaged direct drive solenoid
Pinion travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 18
Solenoid Details
Winding resistance at 20_C
Pull--in winding . . . . . . . . . . . . . . . . . . . . . . . . . . Ω 0.24
Hold--on winding . . . . . . . . . . . . . . . . . . . . . . . . Ω 1.05
Current consumption at 12 V
Pull--in + hold--on -- instantaneous (max.) . . . Amp. 60
Hold--on -- continuous (max.) . . . . . . . . . . . . . Amp. 12
TIGHTENING TORQUE
Starter motor mounting bolts . . . . . . . . . . . . . . . . . M12X1.5 7.4
84261396 - 09-- 2009

TROUBLESHOOTING
Engine will not crank and 1. Battery discharged. Check battery charge or renew.
starting solenoid does not 2. Key start switch, safety start Check the circuit and repair or
engage switch, starter solenoid. renew faulty components.
3. Starting circuit open or high Check circuit connections and
resistance repair or renew faulty wire
connections.
Engine will not crank but 1. Battery discharged Check battery charge or renew.
solenoid engages 2. Defective starter motor Check, clean and tighten
connections or loose battery connections.
connections.
3. Starting motor faulty. Inspect, repair or renew.
Starting motor turns but not 1. Defective starter motor drive Inspect and repair / renew.
engages assembly.
2 Defective solenoid or pinion Inspect and repair / renew.
engagements levers.
3. Defective flywheel ring gear Inspect and repair / renew.
Engine crank slowly 1. Discharged battery. Check the battery charge or renew.
2. Excessive resistance in Check circuit connections and
starting circuit. repair or renew faulty wiring.
3. Defective starter motor. Inspect and repair / renew.

Tractor is fitted with a 12 Volt, solenoid operated switch connecting the battery directly to the starter
pre--engaged type starter. motor. This switch directs battery power directly to
the starter motor; which causes it to rotate and as a
When the key is turned to the strart position, an consequence, the engine is cranked to start.
electrical circuit is made, from the key switch,
through gearbox mounted safety start switch to the When the key switch is released, battery power to the
starter solenoid. The electricity in this circuit solenoid is removed. The solenoid plunger returns to
energises the solenoid coils and the solenoid plunger rest position (aided by the solenoid plunger spring)
is magnetically attracted into the solenoid core. This and the starter pinion is released from the flywheel
movement, transmitted through a mechanical ring gear, this also breaks the battery connection.
linkage pulls the drive pinion to mesh with the To protect the starter motor from high engine speed,
flywheel ring gear. When the pinion gear is fully an over run clutch is fitted between the starter motor
meshed with the ring gear the solenoid plunger and pinion gear.
reaches the end of its travel and contacts with a
84261396 - 09 - 2009
1
50
1 3 2
30
15a
5 4
6 8
7
9
1.Ignition/starter switch or driving switch

2.Solenoid switch 2 3
3.Return spring
4.Excitation winding series winding
5.Engaging lever
6.Roller--type overrunning clutch
7.Pinion
8.Battery
9.Armature
1
1. Rest position 3. Unfavourable meshing position
No current to starter, pinion demeshed A pinion tooth meets a ring gear tooth. Engaging
2. Favourable meshing position. lever in end position., meshing spring compressed,
pull--in winding not energized. Main current flows,
Pull --in and hold--in windings are energized. A pinion
armature rotates. Pinion attempts to mesh with ring
tooth meets a gap in the ring gear, and the pinion
gear.
meshes immediately. Shown is starter position just
before main current is switched on. 4. End Position.
Engaging lever in end position, pull--in winding not
energized. Main current flows, pinion is fully meshed.
Engine is cranked
84261396 - 09-- 2009

Starter Motor -- Removal, Installation and

Testing (Op. 55 201) 1
Removal 2
1. Disconnect battery from electric circuit. 3
4
2. Disconnect connections (1), (2) and (3).
3. Lossen the three bolts (4) and remove starter

motor from the tractor.
IMPORTANT: Starter motor should be serviced and
reparied only by Authorised MICO Dealer.
Installation of starter motor is reversal of removal
procedure. 2
L
System test
IMPORTANT: Before carrying out any starting
system test, ensure that the battery is fully charged
and in good condition.
Starter Solenoid Feed Voltage Test

1. Connect voltmeter between starter solenoid
battery terminal and chasis ground.
2. If voltmeter shows less than battery voltage,
check battery connections to solenoid or chasis
ground connections.
3
Solenoid ‘On Load’ Feed Voltage Test
1. Connect voltmeter between starter solenoid
battery terminal and chasis ground.
2. Crank engine on starter with Fuel shut--off knob
pulled to prevent engine starting.
3. If during cranking voltmeter shows less than 9.6
volts, check battery, if battery is good, check for
poor connections between battery and starter or
a fault in starter motor.
4. If voltage is higher than 11.0 volts and cranking
speed is low, check for fault in starter.
84261396 - 09 - 2009
Safety Start Circuit Test

1. Connect voltmeter between solenoid safety start
connection and chasis ground,
2. Crank engine over on starter with fuel shut off
knob pulled.
3. If reading is less than 8.5 volts, check key switch,
safety start switch and connections.
84261396 - 09-- 2009


Chapter 4 - Charging System
CONTENT

55 100 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHARGING SYSTEM -- SPECIFICATIONS

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PMP
Rated voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V 12
Rotation (seen from pulley side) . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Cut--in speed at12V and 25_C . . . . . . . . . . . . . . . . . . . . . . . . . . . RPM 975Max.
Output at 12V across battery after warm--up with fully
bedded in brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Amp. 35Amp @5000RPM
Rotor winding resistance between both
collector rings (20_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ω 5.4
Alternator speed on tractor (at engine governed speed) . . . . . . RPM 6000
Drive ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 to 2.06
Torque requirement for nut securing alternator pulley . . . . . . . . Nm 6--6.5kgm
Voltage Regulator
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIP Control Electronic Regulator
Alternator--test speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RPM 5000
Voltage setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V 13.6 to 14
TIGHTENING TORQUES
Alternator mounting bracket nuts . . . . . . . . . . . . . M10X1.25 4
Alternator pivot bolt . . . . . . . . . . . . . . . . . . . . . . . . . M10X1.5 8
Belt tension adjusting screw . . . . . . . . . . . . . . . . . M8X1.25 2.4
84261396 - 09 - 2009
TROUBLESHOOTING
Alternator charging at high rate 1. Defective alternator /Voltage Check and renew
(battery overheating) regulator.
No out put from the alternator 1. Alternator drive belt broken. Tension correctly (renew)
2. Loose connection in the Check, clean and tighten
charging circuit. connections.
3. Defective alternator Check and renew.
Intermittent or low alternator 1. Alternator drive belt slipping. Check and adjust tension and
output renew
2. Loose of broken connection in Inspect the circuit tighten the
the charging circuit. connections.
3. Defective alternator. Check and renew

The Alternator is fitted on the right side of the engine
and driven by the fan belt. The two electrical cables
(1&2) connects the alternator to the electrical
system. The small wire (1) is connected from the key
start switch through the battery warning light. The 2
other larger wire (2) is connected to the battery.
The wire (3) is connected to the tachometer.
3
Alternator Function 1
When the key switch is turned on, a 12 Volt electrical
circuit is made through a 1.7 watt bulb, used as the
battery warning light, to the alternator. This circuit
illuminates the bulb and supplies a small electrical
current, which partially magnetizes the rotor of the 1
alternator.
When the engine starts and begins to drive the
alternator, electricity will be produced. Once the
Voltage produced rises above battery voltage, the
circuit through the battery--warning bulb is
disconnected and light extinguished. As the
alternator voltage is now above battery voltage,
electricity starts to flow through the large wire (B & D
terminal) connected directly to the battery. An inbuilt
regulator is used to limit the maximum voltage to 14
volts.
84261396 - 09 - 2009
Alternator Removal -- Installation -- Testing

(Op 55 301)
Removal
5
1. Disconnect battery from electric circuit.
2
2. Disconnect connections (1), (2) and (3).
3. Loosen bolts (4) and (5) and remove belt guard. 1
3
4
1
4. Slacken and remove the nut and bolt (1)
fastening the alternator to the belt stretcher (2).
5. Move the alternator to reduce belt tension and
remove it from the alternator pulley.
6. Unscrew the bolt (3) Figure 3 completely and
remove the alternator.
IMPORTANT: Alternator should be serviced and
repaired only by Authorised PMP Dealer.
3 2
2
Installation
Installation is reversal of removal procedure. Tighten 3
the belt to 10--13 mm deflecion when moderate finger
pressure is applied to the longest run of the belt.
2
10--13 mm
84261396 - 09 - 2009
Alternator Testing
IMPORTANT: Ensure that the battery is at least 75%
charged before commencing alternator test.
Quick Test 2
1. Battery warning light should illuminate when the
key switch is turned to position 2. 3
If the warning light does not fully illuminate when
the key switch is turned on, check the fuse and 1
bulb. If the fuse or bulb was not the cause, check
the wiring connections to the alternator.
To do this, disconnect the lead from the
Alternator ‘D’ terminal. Touch the lead to a
good/clean chassis ground with the ignition 4
switch in position 2. 1. D -- Terminal
2. B+ -- Terminal
3. W -- Terminal
-
Result Possible Remedy

cause
Bulb Alternator Repair or Replace
illuminates faulty Alternator
Bulb doesnt Faulty Check fuse, bulb and
illuminate circuit wiring from key
switch to alternator
2. If result from test shows that wiring is Result Possible Remedy
satisfactory, but alternator performance is still cause
doubtful, check alternator output.
12.5 volts (or System None
3. To do this, connect a voltmeter between battery good
Alternator ‘B+’ terminal and chassis ground, voltage) &
leaving all connections intact. increasing
Less than Faulty Check wiring
battery circuit between battery and
voltage & not alternator
increasing
If Battery voltage is shown, start the engine.
Result Possible Remedy
cause
13.6 to 14 System None
volts good
Battery
warning light
extinguished.
Less/more Engine Increase engine
than 13.6 to RPM low. RPM.
14 volts. Check belt tension
Battery Alternator Repair or replace
warning light faulty. alternator.
illuminated Faulty Check fusible link
circuit and wiring to battery.
84261396 - 09 - 2009
Full Test
Check battery condition and Alternator belt as
previously described.
Ignition circuit test

1. Battery warning light should illuminate when the
key switch is turned on.
If the warning light is not fully illuminated, check the
bulb and fuse. If the bulb or fuse is not the cause,
check the wiring connections to the alternator. + -
V
a Disconnect lead from Alternator ‘D’ terminal,
connect voltmeter between ‘D’ lead and chasis
ground. With ignition switch on voltmeter should
5
show 12 volt.
If less there is a fault with the ignition or warning light
circuit.
b. If meter shows 12 volt, test the alternator
connection.
With D lead connected to alternator terminal,
connect voltmeter between ‘D’ terminal and chasis
ground. With key switch on voltmeter should show
between 1--1.5 volt.
If less there may be a high resistance fault in the key + -
switch / warning light circuit or a fault with the V
alternator.
If considerably more than 1.5 volt, fault is with the
alternator. 6
Repair or replace as required
84261396 - 09 - 2009
Alternator output test

2. Alternator should supply DC current at 13.6 to 14
volts in order to charge the battery and power
accessories.
a. To test. connect voltmeter between alternator
‘B+’ terminal and chasis ground, leaving wiring
intact. With the engine off, voltmeter should
show battery voltage.
If less. there is a fault with the charging circuit.
+ -
V
7
Start the engine with connections as above, increase
engine speed until battery warning light
extinguishes.
Voltmeter should show 13.6 to 14 volts.
If less, then Alternator is faulty. If considerably more,
then regulator is faulty.
Alternator Amp. test

Remove lead from Alternator terminal B lead (2),
connect an Amp--meter (min 30 amp capacity)
between + terminal B lead (2) and + lead (2).
Crank engine on starter (with fuel shut--off). Start
engine, switch on all electrical loads.
Amp--meter should show 20--23 amps initially, at
2000 RPM appx. gradually reducing as battery is
charged.
If Alternator output is low, ensure connections A
between battery and alternator are good.
If connections are good, but Alternator output is low,
repair or replace Alternator as required.
8
84261396 - 09 - 2009
Chapter 5 -- Battery
CONTENT
55 100 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
55 301 Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BATTERY SPECIFICATION
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lead Acid
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V 12
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ah 75
at 20 hrs. rating
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In front of radiator
TROUBLE SHOOTING
Battery low or discharged 1. Loose or worn out alternator Check and adjust tension or renew.
drive belt.
2 Defective battery, do not Check the condition of the battery
accept or hold charge. or renew.
3. Excessive resistance due to Check, clean and tighten
loose charging system connections.
connections.
4. Defective voltage regulator / Check and renew.
Alternator

New Holland tractors feature a 12--Volt, negative Construction
ground, lead acid type battery of 6 cells connected Battery is constructed in such a manner that each
in series. cell consists of one +ve and one --ve plates and each
These cells are assembled in a polypropylene case cell is separated by porous material all +ve plates are
and covered with a hard plastic top. Each cell welded together to form a +ve terminal and similarly
contains a group of positive and negative plates a --ve terminal is formed. These plates are
insulated from one another by separator plates. The submerged in an electrolyte solution i.e. Sulphuric
plates are alternately arranged in assembly to form acid.
an element. When the element is immersed in
electrolyte, the voltage created is slightly higher than Functions
2 volts.
• To provide a source of current for starting lighting
The series connection adds the voltage, so and instruments
producing slightly over 12 volts at the battery
• Helps to control voltage in the electrical system.
terminals.
84261396 - 09 - 2009
BATTERY
Removal--Installation (Op 55 301)

1. Slide the handle (1 ) and raise front hood
1
2. Keep the front hood in lidting position with gas
strut ( 1 )
2
3. Disconnect battery terminals (1)
4. Lift and remove positive terminal the battery from
the tractor.
Installation of Battery
Installation of battery is reversal of removal
procedure, but observe the following:
• Clean the battery case, and battery terminals
and clamps before installation, by using a
solution of sodiam bicarbonate (baking soda)
and water.
IMPORTANT: Cover vents while cleaning.
• Connect positive terminal last.
• Do not over tighten the battery securing clamp as
this may damage the battery case.
84261396 - 09 - 2009
Battery Testing draw in enough electrolyte to raise the float in the

Condition of the battery could be checked by these barrel with the bulb fully expanded.
different methods NOTE: Do not draw in much electrolyte , as float may
1. Hydrometer test (Specific Gravity) get contact with the top of the barrel.
2. Voltmeter test Read and record the specific gravity of each cell.
The average specific gravity of all cells should be
3. Load test (Voltmeter whilst Cranking)
between 1.230 -- 1.250. If the average value of all
4. Current drain test cells is less than 1.230, recharge the battery.
If the average specific gravity of all cells is above
1. Hydrometer Test
1.230, but the variation between cells is more than
The Hydrometer test indicates the battery state of 0.050, the battery may be faulty. Recheck after fully
charge by measuring the specific gravity of the charging the battery.
electrolyte in the battery cells. Using a hydrometer
1.300 1.300 1.300 1.300 1.300 1.300

1.280 1.280 1.280 1.280 1.280 1.280
1.260 1.260 1.260 1.260 1.260 1.260
1.240 1.240 1.240 1.240 1.240 1.240
1.220 1.220 1.220 1.220 1.220 1.220
1.200 1.200 1.200 1.200 1.200 1.200
1.180 1.180 1.180 1.180 1.180 1.180
1.160 1.160 1.160 1.160 1.160 1.160
1.140 1.140 1.140 1.140 1.140 1.140
1.120 1.120 1.120 1.120 1.120 1.120
1.100 1.100 1.100 1.100 1.100 1.100
4
2. Voltmeter Test
The open circuit voltmeter test indicates the battery
‘state of charge’ by measuring the voltage stored in
the battery. Connect a voltmeter across the battery + -
V
terminals and read the voltage.
NOTE: The battery must have been disconnected
from any charge for at least 10 hours before checking
and the temperature has to be 25 degree centigrade.
Due to this restrictions it is not common to measure
battery condition this way. + -
The table below shows the open circuit voltage and

specific gravity readings relative to the state and
charge
5
State of Open circuit Specific
Charge Voltage (25_
_C) Gravity
100% 12.78 V 1.260 -- 1.280
75% 12.53 V 1.230 -- 1.250
50% 12.28 V 1.200 -- 1.220
25% 12.02 V 1.1700 -- 1.190
0% 11.71 V 1.100 -- 1.130
84261396 - 09 - 2009
3. Load Test
IMPORTANT: The battery must be fully charged
before carrying out a load test.
Never carryout this test on a battery, which is less
than 75% charged. Connect a voltmeter across the
battery terminals. Read the battery voltage whilst
cranking the engine for 20 seconds. Voltmeter
should not show less than 9.6 volts over the 20
seconds period.
CAUTION
Pull the fuel shut of knob and hold while cranking to
prevent engine from starting during this process.
If battery does not maintain 9.6 volts over 20

seconds, fully charge the battery as described in the
Battery Charging , Page 5 . Make another load test,
as above. if battery again fails to maintain 9--6 volts
replace the battery.
4. Current Drain Test

To Electrical System
The current drain test is used in a situation where the
battery and charging system test is OK and yet the
battery is continually in a low state of charge. This
may be due to a circuit continually drawing current
from the battery. To identify, disconnect the cable + -
from the battery negative terminal. Connect the A
Ammeter between battery negative port and the
battery negative cable.
Please note amp. will not be zero fill hour meter
shows display , as hour meter display is directly + -
connected. If meter shows more than 0.5 Amps.
Remove fuses one by one until reading drops to 0.5
Amps and the faulty cuircuit is identified. 6
84261396 - 09 - 2009
Battery Charging
Charging current requirements of batteries:

Model 4510/4010/
3510
Current 7.5 Amps
Hrs. for charging 15 Hrs
CAUTION
When batteries are being charged an explosive gas
mixture forms beneath the cover of each cell.
Do not disconnect live circuits at the terminals of the
batteries on charge, a spark will occur where the live
circuit is broken, which may ignite the gas and cause
an explosion.
Similarly do not smoke, use welding/grinding
equipment near to batteries on charge.
A slow charge is the only method to fully charge a

battery. A high rate charger can be used to quickly
boost the capacity of a battery, but must be followed
by slow charge to bring the battery to full capacity.
Observe the following when slow charging the
battery:
• If the battery is to remain in the tractor,
disconnect the cables at the battery to prevent
damage to the electrical system during charging.
• Thoroughly clean the battery.
• Make sure the electrolyte is at the correct level.
Battery is fully charged when 3 specific gravity
readings taken at 1--hour intervals indicate no
increase in specific gravity.
84261396 - 09 - 2009
Battery Maintenance • Maintain the electrolyte level midway between

During scheduled maintenance checks of tractor, the plates and top cover. Add distilled water if
battery should also be given careful attention. necessary. Do not use well/tap water. Do not top
Battery life can be extended by regularly performing up with acid.
the following maintenance procedure. • Battery securing clamps must be used to keep
• Loosen the battery terminal clamps and the battery secure. Do not over--tighten, as this
disconnect the cables from the battery. Always may damage the battery case.
disconnect the positive cable first and reconnect • Ensure vent caps are tightened and wipe down
last. the battery. Battery should be kept clean and dry.
• Clean the battery case, battery terminals and • Coat the terminal and cable clamps with
cable clamps using a solution of Sodium Petroleum Jelly (Vaseline) to prevent corrosion.
Bicarbonate (baking soda) and water. Do not use grease.
IMPORTANT: Cover vents while cleaning. • Batteries should not be allowed to discharge
• Heavy corrosion of battery terminals and cable completely. If the tractor is to be stored for a
clamps may be cleaned with a wire brush. period of more than 2 weeks, the battery should
be removed from the tractor and stored in a dry
• Inspect cable condition and cable connections.
location on a wooden platform. Trickle charge
Pay attention to both ends of cables. Remove
every 2 to 3 weeks to maintain the battery in good
any corrosion and ensure clean contact.
condition.
Check both negative to chasis and positive to
starter cables.
84261396 - 09 - 2009
Chapter 6 -- Schematic Wiring Diagrams

Description Page
Fender lamp front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Aux output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fender lamp rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Main light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Harazd warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Trailer soket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
84261396 - 09-- 2009

84261396-- 09 - 2009
84261396 - 09-- 2009

84261396-- 09 - 2009
84261396 - 09-- 2009

84261396-- 09 - 2009
84261396 - 09-- 2009

84261396-- 09 - 2009
84261396 - 09-- 2009

84261396-- 09 - 2009

Shop Manual Tt45

Uploaded by

Copyright:

Available Formats

You might also like

Shop Manual Tt45

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Shop Manual Tt45

Uploaded by

Copyright:

Available Formats

REPAIR MANUAL

Section Description Page

TRANSMISSION SYSTEM SECTION 21

Section Description Page

MECHANICAL REAR WHEEL DRIVE SECTION 27

POWER TAKE-- OFF SECTION 31

Section Description Page

BRAKING SYSTEM SECTION 33

Section Description Page

Section Description Page

Hydraulic Pump Chapter 2

Hydraulic Lift Assembly Chapter 3

STEERING SYSTEMS SECTION 41

Section Description Page

Hydrostatic Steering Systems Chapter 2

Section Description Page

FRONT AXLE SECTION 44

Section Description Page

ELECTRICAL SYSTEM SECTION 55

Section Description Page

Analogue Instrument Cluster Chapter 2

Section Description Page

Starting System Chapter 3

Section Description Page

Charging System Chapter 4

Section Description Page

Section Description Page

Schematic Wiring Diagrams Chapter 6

NOTES FOR EQUIPMENT

PAY ATTENTION TO THIS SYMBOL

TO PREVENT ACCIDENTS A wise and careful service technician is the best

SAFETY RULES • All repair and maintenance operations should be

START UP use a piece of cardboard or a piece of wood for

HEALTH AND SAFETY

Section Description Page

Water base Adhesive/ Sealers

BRAKE AND CLUTCH FLUIDS (Polyalkylene DO NOTS

Clutch Fluids -- See Brake and Clutch Fluids.

DUSTS Diesel Engine

FOAMS -- See Fire.

Gas--Oil (Diesel Fuel) --See Fuels (Kerosene).

Gases --See Gas Cylinders. LEGAL ASPECTS

GENERAL WORKSHOP TOOLS AND LUBRICANTS AND GREASES

SUSPENDED LOADS. applied coatings or contamination on the surfaces

Section Description Page

Chapter 1 -- Engine System

Section Description Page

GROUP 10 -- GENERAL FEATURES AND SPECIFICATIONS

CONNECTING ROD BEARINGS

FUEL PUMP GEAR

Description Thread size Torque (kgf)

Tool Description Tool Number

Difficult starting 1. Low cranking speed 1. See Problem -- Low Cranking

Lack of power 1. Blocked fuel feed pipe 1. Clean the pipe

Misfiring 1. Blocked fuel feed pipe 1. Clean pipe

Black smoke 1. Restriction in air cleaner or 1. Check and clean/remove the

Vibration 1. Faulty fuel injection pump 1. Overhaul injection pump

DESCRIPTION AND OPERATION

CYLINDER HEAD ASSEMBLY CONNECTING RODS