Manual de Sevicio 5610s

5610S, 6610S, 7610S, 7010, 8010
REPAIR MANUAL
COMPLETE CONTENTS
SECTION 00 - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 10 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 18 - CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 21 - TRANSMISSION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 23 - FRONT AXLE TRANSFER BOX . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 25 - FRONT AXLE -- FOUR WHEEL DRIVE . . . . . . . . . . . . . . . . . . . 10
SECTION 27 - MECHANICAL REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . 10
SECTION 31 - POWER TAKE-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 33 - BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 35 - HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 41 - STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 44 - FRONT AXLE -- TWO WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . 16
SECTION 55 - ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
The following pages are the collation of the contents pages from each section and
chapter of the 5610S, 6610S, 7610S, 7010, and 8010 Tractor Repair manual. Complete
Repair part # 87032901.
The sections used through out all New Holland product Repair manuals may not be
used for each product. Each Repair manual will be made up of one or several books.
Each book will be labeled as to which sections are in the overall Repair manual and
which sections are in each book.
The sections listed above are the sections utilized for the 5610S, 6610S, 7610S, 7010,
and 8010 Tractors.
 2003 NEW HOLLAND NORTH AMERICA, INC. 87032904 4/03

Printed In U.S.A.
SECTION 00 - GENERAL
BOOK 1 - 87032902
Chapter 1 -- General
CONTENTS
Description Page
HEALTH AND SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ACIDS AND ALKALIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADHESIVES AND SEALERS -- see Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ANTIFREEZE -- see Fire, Solvents e.g. Isopropanol, Ethylene Glycol, Methanol. . . . . . . . . . . . . . . . . . . . . . . 3
ARC WELDING -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY ACIDS -- see Acids and Alkalis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRAZING -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHEMICAL MATERIALS -- GENERAL -- see Legal Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DO’S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DO NOTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CORROSION PROTECTION MATERIALS -- see Solvents, Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DUSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRIC SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EXHAUST FUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FIBRE INSULATION -- see Dusts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FIRE -- see Welding, Foams, Legal Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FOAMS -- Polyurethane -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUELS -- see Fire, Legal Aspects, Chemicals -- General, Solvents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GAS CYLINDERS -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL WORKSHOP TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LEGAL ASPECTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LUBRICANTS AND GREASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PAINTS -- see Solvents and Chemical Materials -- General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SOLDER -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SOLVENTS -- see Chemical Materials -- General Fuels (Kerosene), Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SUSPENDED LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WELDING -- see Fire, Electric Shock, Gas Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2
SECTION 10 - ENGINE
BOOK 1 - 87032902
Chapter 1 - Diesel Engines

CONTENTS
Section Description Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Crankshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Cylinder Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Diesel Engine Strip-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Separating the Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Disassembly and Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cylinder Head, Valves, and Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Rocker Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Valve Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
New Valve Guide Stem Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Rocker Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Engine Front Cover and Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Connecting Rods, Bearings, Pistons, and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Connecting Rod Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Rear Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3
SECTION 10 - ENGINE
BOOK 1 - 87032902
Chapter 1 - Diesel Engines (Continued)

CONTENTS

Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Oil Filter Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Balancer Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Camshaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Engine Break-in (Low Hp Application) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Engine Break-in (Other Than Low Hp Application) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
SECTION 10 - ENGINE
BOOK 1 - 87032902
Chapter 2 - Engine Cooling System

CONTENTS

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cooling System Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4
SECTION 10 - ENGINE
BOOK 1 - 87032902
Chapter 3 - Air Cleaning System

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 10 - ENGINE
BOOK 1 - 87032902
Chapter 4 - Fuel System

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fuel Injection Pump – Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maximum No-load Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DPS Fuel Injection Pump -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DPS Fuel Injection Pump Timing (Non-Emissionized Engine) . . . . . . . . . . . . . . . . . . . . . . . 20
DPS Fuel Injection Pump -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DP 200 Series Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DP200 Series Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5
SECTION 10 - ENGINE
BOOK 1 - 87032902
Chapter 4 - Fuel System (Continued)

CONTENTS

DP200 Series Fuel Injection Pump Shaft Lock Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Alternative Method for Removing the DP200 Series Fuel
Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Alternative Method for Installing the DP200 Series Fuel
Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Fuel Injector Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Electric Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Main Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Auxiliary Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
SECTION 10 - ENGINE
BOOK 1 - 87032902
Chapter 5 - Turbocharger
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6
SECTION 18 - CLUTCH
BOOK 1 - 87032902
Chapter 1 - Single Clutches

CONTENTS

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Single Clutch Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 18 - CLUTCH
BOOK 1 - 87032902
Chapter 2 - Servicing Clutch Associated Parts

CONTENTS

Specifications and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clutch Pedal Free-play (Travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Clutch Pilot Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clutch Release Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Clutch Release Shaft Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clutch Pedal Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7
SECTION 21 - TRANSMISSION SYSTEMS
BOOK 1 - 87032902
Chapter 1 - 8 x 2 Transmission
CONTENTS

Specifications, Tightening Torques and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8x2 Non-synchromesh Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tractor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Ground Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transmission - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Introduction to Transmission Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gear Shift Levers and Covers - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Start Inhibitor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Transmission Front End - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

BOOK 1 - 87032902
Chapter 2 - 16 x 4 Dual Command (Dual Power) Transmission

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dual Command Transmission - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Planetary Gear Set Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8
BOOK 1 - 87032902
Chapter 3 - Reduction Gearbox Assembly

CONTENTS

Specifications, Tightening Torqes, and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Reduction Gearbox - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Reduction Gearbox Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 23 - FRONT AXLE TRANSFER BOX

BOOK 1 - 87032902
Chapter 1 - Front Axle Transfer Box

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clearances and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Shim Thickness Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9
SECTION 25 - FRONT AXLE--FOUR WHEEL DRIVE
BOOK 1 - 87032902
Chapter 1 - Four Wheel Drive

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hub and Planetary Reduction Gear Assembly - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Axle Shafts - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Steering Swivel Pin Bearings - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Steering Cylinder and Track Rods – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Front Axle – Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Differential Crown Wheel and Pinion Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . 31
Drive Shaft - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SECTION 27 - MECHANICAL REAR WHEEL DRIVE

BOOK 2 - 87032903
Chapter 1 - Rear Axle

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rear Axle Shaft Bearing Pre-load Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Differential Bearing Pre-load Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10
BOOK 2 - 87032903
Chapter 1 - Rear Axle (Continued)

CONTENTS

Maximum Permissible Rear Axle Loading with Ballast and Mounted Equipment . . . . . . . . . 4
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Final Reduction Gear Assembly (Planetary Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Separating the Tractor Between the Front Transmission and the Rear Axle . . . . . . . . . . . . . 9
Rear Axle Shaft Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Planetary Gear Assembly and Axle Housing – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Differential and Differential Lock Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Differential Lock Control Linkage – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Drive Pinion Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Rear Axle Assembly Final Reduction Drop Trumpet (Drop Box) -- Component
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 31 - POWER TAKE-OFF

BOOK 2 - 87032903
Chapter 1 - Power Take-Off Systems

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PTO -- Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mechanically Operated P.T.O. Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
P.T.O. Clutch Oil Flow – Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
11
BOOK 2 - 87032903
Chapter 1 - Power Take-Off Systems (Continued)

CONTENTS

P.T.O. Clutch Oil Flow - Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
P.T.O. Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Regulating Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cooling and Lubrication Circuit Relief Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
P.T.O. Clutch – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
P.T.O. Shafts and Gears – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Single Speed Shafts and Gears - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Two-speed Shafts and Gears – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
16x4 Dual Command (Power) Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 33 - BRAKING SYSTEM

BOOK 2 - 87032903
Chapter 1 - Braking System

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disc Brake Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Parking Brake Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake Pedal and Linkage – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12
SECTION 35 - HYDRAULIC SYSTEM
BOOK 2 - 87032903
Chapter 1 - Hydraulic Circuits

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Component -- General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

BOOK 2 - 87032903
Chapter 2 - Hydraulic Pumps

CONTENTS

Fixed Displacement Transmission Mounted (Tandem Gear) Type Pump . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fixed Displacement Engine Mounted (Single Gear) Type Pump . . . . . . . . . . . . . . . . . . . . . . 11
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
13
BOOK 2 - 87032903
Chapter 3 - Remote Control Circuit

CONTENTS

Remote Valve Circuit Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remote Control Valve -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Remote Control Valve Coupler -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

BOOK 2 - 87032903
Chapter 4 - Component Overhaul

CONTENTS

Oil Cooler -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Pressure Regulating Valve -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Lift Cover -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Priority Valve Pack -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic Lift Cylinder Assembly -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

BOOK 2 - 87032903
Chapter 5 - Adjustments and Testing

CONTENTS

Draft Control Main Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Draft Control Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Position Control Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remote Control Valve External Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
14
SECTION 41 - STEERING SYSTEM
BOOK 2 - 87032903
Chapter 1 - Hydrostatic Steering System

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

BOOK 2 - 87032903

CONTENTS

Steering Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Steering Cylinder – Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Steering Cylinder – Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Flow Control Valve -- Power Steering Pump (Where Installed) . . . . . . . . . . . . . . . . . . . . . . 23
Transmission Mounted Tandem Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine Mounted Power Steering Pump (Where Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Steering System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
15
SECTION 44 - FRONT AXLE--TWO WHEEL DRIVE
BOOK 2 - 87032903
Chapter 1 - Two Wheel Drive

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Front Axle Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front Wheel Spindle - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Center Steering Arm - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front Axle - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 55 - ELECTRICAL SYSTEMS

BOOK 2 - 87032903
Chapter 1 - Description, Operation and Overhaul

CONTENTS

Specifications -- Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lighting and Instrumentation Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
16
BOOK 2 - 87032903
Chapter 1 - Description, Operation and Overhaul (Continued)

CONTENTS

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical Components -- Description, Operation and Overhaul . . . . . . . . . . . . . . . . . . . . . . 24
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Instrument Panel Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Instrument Panel Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Instrument Panel Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Four--Wheel Drive Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Dual Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Key--Start Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Warning Flasher Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Power Take Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Neutral Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cold Advance Thermostatic Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Air Cleaner Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Fuel/Water Separator Warning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Work Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Oil Pressure Sender Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Stop Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Main Fuel Tank Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Auxiliary Fuel Tank Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Instrument Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fender Mounted Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
External Headlamp Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Tail/Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Work Lamp Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Grille Mounted Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
17
BOOK 2 - 87032903
Chapter 2 - Alternator and Charging System

CONTENTS

Alternator -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Alternator -- Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Alternator -- Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

BOOK 2 - 87032903
Chapter 3 - Starting Motor and System

CONTENTS

Starting System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Starting System Circuit Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Starting Motor -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

BOOK 2 - 87032903
Chapter 4 - Battery, Servicing and Testing

CONTENTS

Battery -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
18
BOOK 2 - 87032903
Chapter 5 - Electrical System Diagrams

CONTENTS

Legend 1 -- Non-Emissionized Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table 1 -- Non-Emissionized Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Legend 2 -- Emissionized Engine Less Fuel/Water Separator Circuit . . . . . . . . . . . . . . . . . . . 3
Table 2 -- Emissionized Engine Less Fuel/Water Separator Circuit . . . . . . . . . . . . . . . . . . . . . 4
Legend 3 -- Emissionized Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 3 -- Emissionized Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 4 -- Electrical Diagram Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
19
20
SECTION 00 -- GENERAL -- CHAPTER 1
GENERAL INSTRUCTIONS
IMPORTANT NOTICE
All maintenance and repair operations described in this manual should be carried out exclusively by New Holland
authorised workshops. All instructions should be carefully observed and special equipment where indicated
should be used.
Anyone who carries out service operations described without carefully observing these prescriptions will be
directly responsible for any damage caused.
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 a 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.
00-1
HEALTH AND SAFETY
CONTENTS
Description Page
HEALTH AND SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ACIDS AND ALKALIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADHESIVES AND SEALERS -- see Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ANTIFREEZE -- see Fire, Solvents e.g. Isopropanol, Ethylene Glycol, Methanol. . . . . . . . . . . . . . . . . . . . . . . 3
ARC WELDING -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY ACIDS -- see Acids and Alkalis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRAZING -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHEMICAL MATERIALS -- GENERAL -- see Legal Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DO’S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DO NOTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CORROSION PROTECTION MATERIALS -- see Solvents, Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DUSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRIC SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EXHAUST FUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FIBRE INSULATION -- see Dusts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FIRE -- see Welding, Foams, Legal Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FOAMS -- Polyurethane -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUELS -- see Fire, Legal Aspects, Chemicals -- General, Solvents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GAS CYLINDERS -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL WORKSHOP TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LEGAL ASPECTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LUBRICANTS AND GREASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PAINTS -- see Solvents and Chemical Materials -- General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SOLDER -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SOLVENTS -- see Chemical Materials -- General Fuels (Kerosene), Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SUSPENDED LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WELDING -- see Fire, Electric Shock, Gas Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HEALTH AND SAFETY PRECAUTIONS precautions necessary to avoid these hazards are
Many of the procedures associated with vehicle identified.
maintenance and repair involve physical hazards or
The list is not exhaustive and all operations and
other risks to health. This section lists, alphabeti-
procedures and the handling of materials, should be
cally, some of these hazardous operations and the
carried out with health and safety in mind.
materials and equipment associated with them. The
00-2
ACIDS AND ALKALIS -- see Battery acids, e.g. Provide adequate ventilation and avoid skin and eye
caustic soda, sulfuric acid. contact. Follow manufacturers instructions.
Used in batteries and cleaning materials.
Anaerobic, Cyanoacrylate and other Acrylic
Irritant and corrosive to the skin, eyes, nose and Adhesives
throat. Causes burns.
Many are irritant, sensitizing or harmful to the skin.
Some are eye irritants.
Avoid splashes to the skin, eyes and clothing. Wear
suitable protective gloves and goggles. Can destroy
Skin and eye contact should be avoided and the
ordinary protective clothing. Do not breathe mists.
manufacturers instructions followed.
Ensure access to water and soap is readily available
Cyanoacrylate adhesives (super--glues) must not
for splashing accidents.
contact the skin or eyes. If skin or eye tissue is
bonded cover with a clean moist pad and get medical
ADHESIVES AND SEALERS -- see Fire attention. do not attempt to pull tissue apart. Use in
well ventilated areas as vapours can cause irritation
Highly Flammable, Flammable, combustible. of the nose and eyes.
Generally should be stored in “No Smoking” areas; For two--pack systems see Resin based adhesives/
cleanliness and tidiness in use should be observed, sealers.
e.g. disposable paper covering benches; should be
dispensed from applicators where possible; contain-
ers, including secondary containers, should be Isocyanate (Polyurethane) Adhesives/
labelled. Sealers -- see Resin based Adhesives.
Individuals suffering from asthma or respiratory
Solvent based Adhesives/Sealers -- See Solvents. allergies should not work with or near these materials
as sensitivity reactions can occur.
Follow manufacturers instructions.
Any spraying should preferably be carried out in
Water based Adhesives/Sealers
exhaust ventilated booths removing vapours and
Those based on polymer emulsions and rubber spray droplets from the breathing zone. Individuals
lattices may contain small amounts of volatile toxic working with spray applications should wear
and harmful chemicals. Skin and eye contact should supplied air respirators.
be avoided and adequate ventilation provided during
use. ANTIFREEZE -- see Fire, Solvents e.g.
Isopropanol, Ethylene Glycol, Methanol.
Highly Flammable, Flammable, Combustible.
Resin based Adhesives/Sealers -- e.g. epoxide
and formaldehyde resin based. Used in vehicle coolant systems, brake air pressure
systems, screenwash solutions.
Mixing should only be carried out in well ventilated
areas as harmful or toxic volatile chemicals may be Vapours given off from coolant antifreeze (glycol)
released. arise only when heated.
Skin contact with uncured resins and hardeners can Antifreeze may be absorbed through the skin in toxic
result in irritation; dermatitis and absorption of toxic or harmful quantities. Antifreeze if swallowed is fatal
or harmful chemicals through the skin. Splashes can and medical attention must be found immediately.
damage the eyes.
00-3
ARC WELDING -- see Welding. The effects of excessive exposure to chemicals may
be immediate or delayed; briefly experienced or
BATTERY ACIDS -- see Acids and Alkalis. permanent; cumulative; superficial; life threatening;
or may reduce life--expectancy.
Gases released during charging are explosive.
Never use naked flames or allow sparks near
charging or recently charged batteries. DO’S
Do remove chemical materials from the skin and
BRAKE AND CLUTCH FLUIDS clothing as soon as practicable after soiling. Change
(Polyalkylene Glycols) -- see Fire. heavily soiled clothing and have it cleaned.
Combustible. Do carefully read and observe hazard and
precaution warnings given on material containers
Splashes to the skin and eyes are slightly irritating. (labels) and in any accompanying leaflets, poster or
Avoid skin and eye contact as far as possible. other instructions. Material health and safety data
Inhalation of vapour hazards do not arise at ambient sheets can be obtained from Manufacturers.
temperatures because of the very low vapour
pressure. Do organise work practices and protective clothing to
avoid soiling of the skin and eyes; breathing
BRAZING -- see Welding. vapours/aerosols/dusts/fumes; inadequate contain-
er labelling; fire and explosion hazards.
CHEMICAL MATERIALS -- GENERAL -- see Do wash before job breaks; before eating, smoking,
Legal Aspects. drinking or using toilet facilities when handling
Chemical materials such as solvents, sealers, chemical materials.
adhesives, paints, resin foams, battery acids,
antifreeze, brake fluids, oils and grease should Do keep work areas clean, uncluttered and free of
always be used with caution and stored and handled spills.
with care. They may be toxic, harmful, corrosive,
Do store according to national and local regulations.
irritant or highly inflammable and give rise to
hazardous fumes and dusts.
Do keep chemical materials out of reach of children.
00-4
DO NOTS Cutting -- see Welding.

Do Not mix chemical materials except under the De--Waxing -- see Solvents and Fuels (Kerosene).
manufacturers instructions; some chemicals can
form other toxic or harmful chemicals; give off toxic
or harmful fumes; be explosive when mixed together. DUSTS
Powder, dusts or clouds may be irritant, harmful or
Do Not spray chemical materials, particularly those
toxic. Avoid breathing dusts from powdery chemical
based on solvents, in confined spaces e.g. when
materials or those arising from dry abrasion
people are inside a vehicle.
operations. Wear respiratory protection if ventilation
Do Not apply heat or flame to chemical materials is inadequate.
except under the manufacturers’ instructions. Some
are highly inflammable and some may release toxic ELECTRIC SHOCK
or harmful fumes.
Electric shocks can result from the use of faulty
Do Not leave containers open. Fumes given off can electrical equipment or from the misuse of equipment
build up to toxic, harmful or explosive concentrations. even in good condition.
Some fumes are heavier than air and will accumulate
in confined areas, pits etc. Ensure that electrical equipment is maintained in
good condition and frequently tested.
Do Not transfer chemical materials to unlabelled
containers. Ensure that flexes, cables, plugs and sockets are not
frayed, kinked, cut, cracked or otherwise damaged.
Do Not clean hands or clothing with chemical
materials. Chemicals, particularly solvents and fuels Ensure that electric equipment is protected by the
will dry the skin and may cause irritation with correct rated fuse.
dermatitis. Some can be absorbed through the skin
Never misuse electrical equipment and never use
in toxic or harmful quantities.
equipment which is in any way faulty. The results
Do Not use emptied containers for other materials, could be fatal.
except when they have been cleaned under
Use reduced voltage equipment (110 volt) for
supervised conditions.
inspection and working lights where possible.
Do Not sniff or smell chemical materials. Brief
Ensure that the cables of mobile electrical equipment
exposure to high concentrations of fumes can be
cannot get trapped and damaged, such as in a
toxic or harmful.
vehicle hoist.
Clutch Fluids -- see Brake and Clutch Fluids.
Use air operated mobile equipment where possible
Clutch Linings and Pads -- see Brake and Clutch in preference to electrical equipment.
Linings and Pads.
In cases of electrocution:--
CORROSION PROTECTION MATERIALS -- -- switch off electricity before approaching victim

see Solvents, Fire.
-- if this is not possible, push or drag victim from
Highly flammable, flammable. source of electricity using dry non--conductive
material
These materials are varied and the manufacturers
instructions should be followed. They may contain -- commence resuscitation if trained to do so
solvents, resins, petroleum products etc. Skin and
eye contact should be avoided. They should only be -- SUMMON MEDICAL ASSISTANCE
sprayed in conditions of adequate ventilation and not
in confined spaces.
00-5
EXHAUST FUMES Splashes in the eye should be flushed with clean

water for at least ten minutes.
These contain asphyxiating, harmful and toxic
chemicals and particles such as carbon oxides, Soiled skin should be washed with soap and water.
nitrogen oxides, aldehydes, lead and aromatic
hydrocarbons. Engines should only be run under Inhalation affected individuals should be removed to
conditions of adequate extraction or general fresh air immediately.
ventilation and not in confined spaces.
If swallowed or if effects persist consult a doctor with
Gasolene (Petrol) Engine information (label) on material used.
There may not be adequate warning properties of Do not induce vomiting (unless indicated by
odour or irritation before immediate and delayed manufacturer).
toxic or harmful effects arise.
Diesel Engine FOAMS -- Polyurethane -- see Fire.

Used in sound and noise insulation. Cured foams
Soot, discomfort and irritation usually give adequate
used in seat and trim cushioning.
warning of hazardous fume concentrations.
FIBRE INSULATION -- see Dusts.
Unreacted components are irritating and may be
Used in noise and sound insulation. harmful to the skin and eyes. Wear gloves and
goggles.
The fibrous nature of surfaces and cut edges can
cause skin irritation. This is usually a physical and Individuals with chronic respiratory diseases,
not a chemical effect. asthma, bronchial medical problems or histories of
allergic diseases should not work with or near
Precautions should be taken to avoid excessive skin uncured materials.
contact through careful organisation of work
practices and the use of gloves. The components, vapours, spray mists can cause
direct irritation, sensitivity reactions and may be toxic
FIRE -- see Welding, Foams, Legal Aspects. or harmful.
Many of the materials found on or associated with the Vapours and spray mists must not be breathed.
repair of vehicles are highly flammable. Some give These materials must be applied with adequate
off toxic or harmful fumes if burnt. ventilation and respiratory protection. Do not remove
respirator immediately after spraying, wait until
Observe strict fire safety when storing and handling vapour/ mists have cleared.
flammable materials or solvents, particularly near
electrical equipment or welding processes. Burning of the uncured components and the cured
foams can generate toxic and harmful fumes.
Ensure before using electrical or welding equipment
but that there is no fire hazard present. Smoking, open flames or the use of electrical
equipment during foaming operations and until
Have a suitable fire extinguisher available when vapours/mists have cleared should not be allowed.
using welding or heating equipment. Any heat cutting of cured foams or partially cured
foams should be conducted with extraction ventila-
tion (see Body Section 44 Legal and Safety Aspects).
FIRST AID
Apart form meeting any legal requirements it is
desirable for someone in the workshop to be trained
in first aid procedures.
00-6
FUELS -- see Fire, Legal Aspects, Chemicals -- if liquid aspiration into the lungs occurs. Liquid
General, Solvents. contact dries the skin and can cause irritation or
dermatitis. Splashes in the eye may be slightly
Used as fuels and cleaning agents. irritating.
Gasolene (Petrol). In normal circumstances the low volatility does not

give rise to harmful vapours. Exposure to mists and
Highly flammable. vapours from kerosene at elevated temperatures
should be avoided (mists may arise in de--waxing).
Swallowing can result in mouth and throat irritation Avoid skin and eye contact and ensure there is
and absorption from the stomach can result in adequate ventilation.
drowsiness and unconsciousness. Small amounts
can be fatal to children. Aspiration of liquid into the Gas--Oil (Diesel Fuel) -- see Fuels (Kerosene).
lungs, e.g. through vomiting, is a very serious
hazard. Combustible.
Gasolene dries the skin and can cause irritation and Gross or prolonged skin contact with high boiling gas
dermatitis on prolonged or repeated contact. Liquid oils may also cause serious skin disorders including
in the eye causes severe smarting. skin cancer.
Motor gasolene may contain appreciable quantities

of benzene, which is toxic upon inhalation and the GAS CYLINDERS -- see Fire.
concentrations of gasolene vapours must be kept
very low. High concentrations will cause eye, nose Gases such as oxygen, acetylene, carbon dioxide,
and throat irritation, nausea, headache, depression argon and propane are normally stored in cylinders
and symptoms of drunkeness. Very high concentra- at pressures of up to 2000 lb/sq. in. (13,790 kn/m2)
tions will result in rapid loss of consciousness. and great care should be taken in handling these
cylinders to avoid mechanical damage to them or to
Ensure there is adequate ventilation when handling the valve gear attached. The contents of each
and using gasolene. Great care must be taken to cylinder should be clearly identified by appropriate
avoid the serious consequences of inhalation in the markings.
event of vapour build up arising from spillages in
confined spaces. Cylinders should be stored in well ventilated
enclosures, and protected from ice and snow, or
Special precautions apply to cleaning and mainte- direct sunlight. Fuel gases (e.g. acetylene and
nance operations on gasolene storage tanks. propane) should not be stored in close proximity to
oxygen cylinders.
Gasolene should not be used as a cleaning agent.
It must not be siphoned by mouth. Care should be exercised to prevent leaks from gas
cylinders and lines, and to avoid sources of ignition.
Kerosene (Paraffin)
Only trained personnel should undertake work
Used also as heating fuel, solvent and cleaning
involving gas cylinders.
agent.
Gases -- see Gas Cylinders.
Flammable.
Gas Shielded Welding -- see Welding.
Irritation of the mouth and throat may result from
swallowing. The main hazard from swallowing arises Gas Welding -- see Welding.
00-7
GENERAL WORKSHOP TOOLS AND • The Asbestos Regulations (1969).

EQUIPMENT
• Highly Flammable Liquids and Liquified Petro-
It is essential that all tools and equipment are
leum Gases Regulations (1972).
maintained in good condition and the correct safety
equipment used where required.
• Deposit of Poisonous Waste Act (1972).
Never use tools or equipment for any purpose other
than that for which they were designed. • Control of Pollution Act (1974).
Never overload equipment such as hoists, jacks, • Health and Safety at Work Act (1974).
axle and chassis stands or lifting slings. Damage
caused by overloading is not always immediately • The Packaging and Labelling of Dangerous
apparent and may result in a fatal failure the next time Substances Regulations (1978).
that the equipment is used.
• Control of Lead Regulations (1981).
Do not use damaged or defective tools or equipment,
particularly high speed equipment such as grinding
wheels. A damaged grinding wheel can disintegrate
Workshops should be familiar, in detail, with these
without warning and cause serious injury. and associated laws and regulations. Consult local
factory inspectorate if in any doubt.
Wear suitable eye protection when using grinding,
chiselling or sand blasting equipment.
LUBRICANTS AND GREASES
Wear a suitable breathing mask when using sand Avoid all prolonged and repeated contact with
blasting equipment, working with asbestos based mineral oils, especially used oils. Used oils
materials or using spraying equipment. contaminated during service (e.g. routine service
change sump oils) are more irritating and more likely
Glues -- see Adhesives and Sealers.
to cause serious effects including skin cancer in the
High Pressure Air, Lubrication and Oil Test event of gross and prolonged skin contact.
Equipment -- see Lubricants and Greases.
Wash skin thoroughly after work involving oil.
Always keep high pressure equipment in good Proprietary hand cleaners may be of value provided
condition and regularly maintained, particularly at they can be removed from the skin with water. Do not
joints and unions. use petrol, paraffin or other solvents to remove oil
from the skin.
Never direct a high pressure nozzle at the skin as the
fluid may penetrate to the underlying tissue etc. and Lubricants and greases may be slightly irritating to
cause serious injury. the eyes.
Repeated or prolonged skin contact should be

LEGAL ASPECTS avoided by wearing protective clothing if necessary.
Many laws and regulations make requirements Particular care should be taken with used oils and
relating to health and safety in the use of materials greases containing lead. Do not allow work clothing
and equipment in workshops. Some of these laws to be contaminated with oil. Dry clean or launder such
which apply in the U.K. are listed. Similar laws exist clothing at regular intervals. Discard oil soaked
for other territories:-- shoes.
• The Factories Act (1961).
00-8
Do not employ used engine oils as lubricants or for Those doing small scale repair work in the open shop
any application where appreciable skin contact is should wear supplied air respirators.
likely to occur. Used oils may only be disposed of in
accordance with local regulations, e.g. in the U.K., Paint Thinners -- see Solvents.
the Control of Pollution Act.
Petrol -- see Fuels (Gasolene).
There are publications describing the problems and
advising on precautionary measures. For the U.K. Pressurised Equipment -- see High Pressure Air,
these include: Lubrication and Oil Test Equipment.
SHW 295: Effects of mineral oil on the Resistance Welding -- see Welding.
skin
SHW 295A: Cancer of the skin caused by Sealers -- see Adhesives and Sealers.
oil
SHW 397: Cautionary notice: Effects of
mineral oil on the skin SOLDER -- see Welding.
Noise Insulation Materials -- see Foams, Fibre Solders are mixtures of metals such that the melting
Insulation. point of the mixture is below that of the constituent
metals (normally lead and tin). Solder application
PAINTS -- see Solvents and Chemical Materials -- does not normally give rise to toxic lead fumes,
General. provided a gas/air flame is used. Oxy--acetylene
flames should not be used, as they are much hotter
Highly Flammable, Flammable. and will cause lead fumes to be evolved.
One Pack. Can contain harmful or toxic pigments, Some fumes may be produced by the application of
driers and other components as well as solvents. any flame to surfaces coated with grease etc. and
Spraying should only be carried out with adequate inhalation of these should be avoided.
ventilation.
Removal of excess solder should be undertaken with
Two Pack. Can also contain harmful and toxic care, to ensure that fine lead dust is not produced,
unreacted resins and resin hardening agents. The which can give toxic effects if inhaled. Respiratory
manufacturers instructions should be followed and protection may be necessary.
the section of page 05--2 on resin based adhesives,
isocyanate containing Adhesives and Foams should Solder spillage and filing should be collected and
be consulted. removed promptly to prevent general air contamina-
tion by lead.
Spraying should preferably be carried out in
exhausted ventilated booths removing vapour and High standards of personal hygiene are necessary in
spray mists from the breathing zone. Individuals order to avoid indigestion of lead or inhalation of
working in booths should wear respiratory protection. solder dust from clothing.
00-9
SOLVENTS -- see Chemical Materials -- General When the spraying material contains solvents, e.g.
Fuels (Kerosene), Fire. paints, adhesives, coatings, use extraction ventila-
tion or personal respiratory protection in the absence
e.g. Acetone, white spirit, toluene, xylene, of adequate general ventilation.
trichlorethane.
Do not apply heat or flame except under specific and
Used in cleaning materials, de--waxing, paints, detailed manufacturers instructions.
plastics, resins, thinners etc.
Sound Insulation -- see Fibre Insulation, Foams.
Highly Inflammable, Flammable.
Spot Welding -- see Welding.
Skin contact will degrease the skin and may result in
irritation and dematitis following repeated or
prolonged contact. Some can be absorbed through SUSPENDED LOADS.
the skin in toxic or harmful quantities. There is always a danger when loads are lifted or
suspended. Never work under an unsupported
Splashes in the eye may cause severe irritation and suspended or raised load, e.g. jacked up vehicle,
could lead to loss of vision. suspended engine, etc.
Brief exposure to high concentrations of vapours or Always ensure that lifting equipment such as jacks,
mists will cause eye and throat irritation, drowziness, hoists, axle stands, slings, etc. are adequate and
dizziness, headaches and in the worst circum- suitable for the job, in good condition and regularly
stances, unconsciousness. maintained.
Repeated or prolonged exposures to excessive but Never improvise lifting tackle.
lower concentrations of vapours or mists, for which
there might not be adequate warning indications, can Underseal -- see Corrosion Protection.
cause more serious toxic or harmful effects.
WELDING -- see Fire, Electric Shock, Gas Cylinders.
Aspiration into the lungs (e.g. through vomiting) is the
most serious consequence of swallowing. Welding processes include Resistance Welding
(Spot Welding), Arc Welding and Gas Welding.
Avoid splashes to the skin, eyes and clothing. Wear
protective gloves, goggles and clothing if necessary. Resistance Welding
Ensure good ventilation when in use, avoid breathing This process may cause particles of molten metal to
fumes, vapours and spray mists and keep containers be emitted at high velocity and the eyes and skin
tightly sealed. Do not use in confined spaces. must be protected.
00-10
Arc Welding The process will produce metal spatter and eye and
skin protection is necessary.
This process emits a high level of ultraviolet radiation
which may cause eye and skin burns to the welder The flame is bright and eye protection should be
and to other persons nearby. Gas--shielded welding used, but the ultra--violet emission is much less than
processes are particularly hazardous in this respect. that from arc welding, and lighter filters may be used.
Personal protection must be worn, and screens used
to shield other people. The process itself produces few toxic fumes, but
such fumes and gases may be produced from
Metal spatter will also occur and appropriate eye and coatings on the work, particularly during cutting away
skin protection is necessary. of damaged body parts and inhalation of the fumes
should be avoided.
The heat of the welding arc will produce fumes and
gases from the metals being welded and from any In brazing, toxic fumes may be evolved from the
applied coatings or contamination on the surfaces metals in the brazing rod, and a severe hazard may
being worked on. These gases and fumes may be arise if brazing rods containing cadmium are used.
toxic and inhalation should always be avoided. The In this event particular care must be taken to avoid
use of extraction ventilation to remove the fumes inhalation of fumes and expert advice may be
from the working area may be necessary, particularly required.
in cases where the general ventilation is poor, or
where considerable welding work is anticipated. In SPECIAL PRECAUTIONS MUST BE TAKEN
extreme cases where adequate ventilation cannot be BEFORE ANY WELDING OR CUTTING TAKES
provided, supplied air respirators may be necessary. PLACE ON VESSELS WHICH HAVE CONTAINED
COMBUSTIBLE MATERIALS, E.G. BOILING OR
Gas Welding STEAMING OUT OF FUEL TANKS.
Oxy--acetylene torches may be used for welding and White Spirit -- see Solvents.
cutting and special care must be taken to prevent
leakage of these gases, with consequent risk of fire
and explosion.
00-11
FEDERAL EMISSIONS WARRANTY

(North America Only)
(California owner’s emissions warranty is covered elsewhere)
New Holland warrants that your new 1996 and later heavy-duty off-road diesel engine was designed, built, and equipped to conform to
applicable U.S. Environmental Protection Agency regulations for a period of use of five years or 3,000 hours of operation, whichever occurs
first.
The new model year, class of diesel engine, and emission application determination for your engine are identified on the emission control
information label affixed to the top of your engine’s rocker arm cover. The warranty period begins on the date the new equipment is sold to the
first retail purchaser.
Any emission control system parts which are proven defective during normal use will be repaired or replaced during the warranty period. The
warranty repairs and service will be performed by any authorized New Holland dealer at the dealer’s place of business, with no charge for parts
or labor (including diagnosis).
As the engine owner, you are responsible to perform all the required maintenance listed in your owner’s manual. New Holland will not deny an
emission warranty claim solely because you have no record of maintenance; however, a claim may be denied if your failure to perform
maintenance resulted in the failure of a warranted part. Receipts covering regular maintenance should be retained in the event of questions
and these receipts should be passed on to each subsequent owner of the engine.
It is recommended replacement parts used for maintenance or repairs be New Holland Service Parts to maintain the quality originally
designed into your emission certified engine. The use of non-New Holland parts does not invalidate the warranty on other components unless
the use of such parts causes damage to warranted parts.
New Holland wishes to assure the emission control systems warranty is being properly administered. If you believe you have not received the
service entitled to under this warranty, you should contact the nearest New Holland Branch Office for assistance.
Service Department
New Holland North America, Inc.
500 Diller Avenue
New Holland, PA 17557
(717) 355-1121
Please note that the Emission Warranty does not cover:
1. Systems and parts that were not first installed on the new equipment or engine as original equipment by New Holland.
2. Part malfunctions caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or
inadequate maintenance, or use of non-recommended fuels and lubricating oils.
3. Accident caused damage, acts of nature, or other events beyond New Holland’s control.
4. Replacement of expendable items made in connection with scheduled maintenance.
5. Parts requiring replacement, inspection or adjustment maintenance intervals for reasons other than being defective.
6. Parts which are not New Holland Service Parts.
7. Loss of time, inconvenience, loss of use of equipment/engine or commercial loss.
8. Equipment with altered or disconnected hourmeter where the hours cannot be determined.
9. Equipment normally operated outside the United States.
10. Non-defective parts replaced by other than New Holland dealers.
Coverage
This emission control system warranty applies to the following emission control parts.
Fuel Injection Pump
Fuel Injectors
Turbocharger
Intake Manifold
Exhaust Manifold
Boost Pressure Tubing-connection to Aneroid Device ON F.I.P.
00-12
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

(California Only)
Your Warranty Rights and Obligations
The California Air Resources Board and New Holland are pleased to explain the emission control system warranty on your engine. In California,
new 1997 and later heavy-duty off-road engines from 100 to 150 HP must be designed, built, and equipped to meet the State’s stringent
anti-smog standards. New Holland must warrant the emission control system on your engine for the periods of time listed below, provided there
has been no abuse, neglect, or improper maintenance of your engine.
Your emission control system includes parts such as the fuel injection system and the air induction system.
Where a warrantable condition exists, New Holland will repair your heavy-duty off-road engine at no cost to you, including diagnosis, parts, and labor.
Manufacturer’s Warranty Coverage:
The 1997 and later heavy-duty off-road engines are warranted from the original date of delivery for five years or 3,000 hours of operation,
whichever occurs first. If any emission-related part on your engine is defective, the part will be repaired or replaced by New Holland.
Owner’s Warranty Responsibilities:
D As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance listed in your owner’s
manual. New Holland recommends that you retain all receipts covering maintenance on your heavy-duty off-road engine, but New
Holland cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
D As the heavy-duty off-road engine owner, you should, however, be aware that New Holland may deny you warranty coverage if your
heavy-duty off-road engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.
D Your engine is designed to operate on commercially available diesel fuel only. Use of any other fuel may result in your engine no longer
operating in compliance with California’s emissions requirements.
D You are responsible for initiating the warranty process. The ARB suggests that you present your heavy-duty off-road engine to a New
Holland dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible.
If you have questions regarding your warranty rights and responsibilities, you should contact your Branch Office at the address and phone
number listed on the Owner Assistance page of your equipments operator manual.
D Prior to the expiration of the warranty, you must give notice of any failure of an emission control warranted part. Such notice must be given
to New Holland or an authorized dealer, and you must deliver the engine to the repair location.
D You, the owner, are responsible for incidental costs incurred by yourself or your employees as a result of a warrantable failure. Examples
of such costs are communication expenses, meals and lodging.
D The owner is responsible for any business costs or losses, any “downtime” expenses and any “cargo” damage which result from the
failure of a warranted part. New Holland is not responsible for other incidental or consequential damages, including but not limited to fines,
theft, vandalism or collisions.
Parts covered:
This emission control system warranty applies to the following emission control parts.
Fuel Injection Pump
Fuel Injectors
Turbocharger
Intake Manifold
Exhaust Manifold
Boost Pressure Tubing-connection to Aneroid Device ON F.I.P.
Any replacement part, equivalent in performance and durability, may be used in the performance of any maintenance or repairs and must be
provided without charge to the owner. The use of these parts does not reduce the warranty obligations of New Holland. However, New Holland
recommends the use of new, genuine New Holland service parts or New Holland approved rebuilt parts and assemblies. New Holland also
recommends that the engine be serviced by a New Holland authorized dealer.
New Holland Responsibilities
Warranty work will be provided at no charge to the owner at any authorized dealer, using new genuine New Holland service parts or New
Holland approved rebuilt parts or assemblies..
The owner will not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work was
performed at a warranty station.
New Holland is liable for damages to other engine components caused by the failure under warranty of any warranted part.
Warranty Limitations
New Holland is not responsible for failures resulting from abuse or neglect by owner or operator.
New Holland warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built, and equipped so as to
conform with all applicable regulations adopted by the Air Resources Board, and that it is free from defects in materials and workmanship which
cause the failure of a warranted part.
Any warranted part which is not scheduled for replacement as required maintenance, or which is scheduled only for regular inspection to the
effect of “repair or replace as necessary” is warranted for the warranty period.
Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of time prior to the first scheduled
replacement point for that part.
New Holland is liable for damages to other engine components caused by the failure under warranty of any warranted part.
00-13
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and
other reproductive harm.
Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
00-14
PRECAUTIONARY
STATEMENTS
PERSONAL SAFETY
Throughout this manual and on machine decals, you will find precautionary statements (“DANGER”,
“WARNING”, and “CAUTION”) followed by specific instructions. These precautions are intended for the personal
safety of you and those working with you. Please take the time to read them.
DANGER
This word “DANGER” indicates an immediate hazardous situation that, if not avoided, will result in death
or serious injury. The color associated with Danger is RED.
WARNING
This word “WARNING” indicates a potentially hazardous situation that, if not avoided, could result in
death or serious injury. The color associated with Warning is ORANGE.
CAUTION
This word “CAUTION” indicates a potentially hazardous situation that, if not avoided, may result in minor
or moderate injury. It may also be used to alert against unsafe practices. The color associated with
Caution is YELLOW.
FAILURE TO FOLLOW THE “DANGER”, “WARNING”, AND “CAUTION” INSTRUCTIONS MAY RESULT IN
SERIOUS BODILY INJURY OR DEATH.
MACHINE SAFETY
The precautionary statement (“IMPORTANT”) is followed by specific instructions. This statement is intended for
machine safety.
IMPORTANT: The word “IMPORTANT” is used to inform the reader of something he needs to know to prevent
minor machine damage if a certain procedure is not followed.
INFORMATION
NOTE: Instructions used to identify and present supplementary information.
00-15
SAFETY
PRECAUTIONARY STATEMENTS
A careful operator is the best operator. Most accidents can be avoided by observing certain precautions. To help
prevent accidents, read the following precautions before operating this equipment. Equipment should be
operated only by those who are responsible and instructed to do so.
Carefully review the procedures given in this manual with all operators. It is important that all operators be familiar
with and follow safety precautions.
THE TRACTOR 5. Use extreme caution and avoid hard application

of the tractor brakes when towing heavy loads at
1. Read the Operator’s Manual carefully before road speeds.
using the tractor. Lack of operating knowledge
can lead to accidents. 6. Any towed vehicle whose total weight exceeds
that of the towing tractor must be equipped with
2. Only allow properly trained and qualified persons brakes for safe operation.
to operate the tractor.
7. Never apply the differential lock when turning.
3. To prevent falls, use the handrails and step plates When engaged, the differential lock will prevent
when getting on and off the tractor. Keep steps the tractor from turning.
and platform clear of mud and debris.
8. Always check overhead clearance, specifically
4. Do not permit anyone but the operator to ride on when transporting the tractor. Watch where you
the tractor unless a passenger seat is fitted. are going, especially at low overhanging
There is no safe place for extra riders otherwise. obstacles.
5. Replace all missing, illegible or damaged safety 9. Use extreme caution when operating on steep
decals. slopes.
6. Keep safety decals free of dirt or grime. 10. To avoid overturns, drive the tractor with care and
7. Do not modify or alter or permit anyone else to at speeds compatible with safety, especially
modify or alter the tractor or any of its when operating over rough ground, when
components or any tractor function without first crossing ditches or slopes and when turning
consulting your dealer. overturning.
8. Tractor wheels are very heavy. Handle with care 11. If the tractor becomes stuck or the tires are frozen
and ensure, when stored, that they cannot fall. to the ground, reverse the tractor out to prevent
corners.
DRIVING THE TRACTOR
12. Keep the tractor in the same gear when going
1. Always sit in the drivers seat while starting or downhill as would be used when going uphill. Do
driving the tractor. not coast or freewheel down hills.
2. When driving on public roads, have considera- OPERATING THE TRACTOR
tion for other road users. Pull in to the side of the
road occasionally to allow any following traffic to 1. Apply the parking brake, place the PTO control in
pass. Do not exceed the legal speed limit set in the ‘OFF’ position, the lift control lever in the
your area. down position, the remote control valve levers in
the neutral position and the transmission lever in
3. Use low beam lights when meeting a vehicle at neutral before starting the tractor.
night. Make sure the lights are adjusted to
prevent blinding the drive of an oncoming vehicle 2. Do not start the engine or operate controls while
standing beside the tractor. Always sit in the
4. Reduce speed before turning or applying the tractor seat when starting the engine or operating
brakes. Ensure that both brake pedals are locked
the controls.
together when traveling at road speeds or when
on public roads. Brake both wheels simulta-
neously when making an emergency stop.
00-16
3. Do not bypass the neutral start switches. Consult a hazard both to the operator and to bystanders.
your authorized dealer if your neutral start Do not overload or operate with attached
controls malfunction. Use jump cables only in the equipment which is unsafe, not designed for the
recommended manner. Improper use can result particular task or is poorly maintained.
in a tractor runaway.
19. The tractor is designed to provide the minimum
4. Avoid accidental contact with the gear shift levers noise level at the operator’s ears and meets or
while the engine is running. Unexpected tractor exceeds applicable standards in this respect.
movement can result from such contact. However, noise (sound pressure level) in the
workplace can exceed 86 dB(A) when working
5. Do not get off the tractor while it is in motion.
between buildings or in confined spaces.
6. Shut off the engine and PTO and apply the Therefore, it is recommended that operators
parking brake before getting off the tractor. wear suitable ear protectors during vehicle
operation.
7. Do not park the tractor on a steep incline.
8. Do not run the tractor engine in an enclosed OPERATING THE PTO
building without adequate ventilation. Exhaust 1. When operating PTO driven equipment, shut off
fumes are toxic and can cause death. the engine and wait until the PTO stops before
9. Always wear a protective mask when working getting off the tractor and disconnecting the
with toxic spray chemicals. Follow the directions equipment.
on the chemical container. 2. Do not wear loose clothing when operating the
10. If the power steering or engine ceases operating, power take-off or especially when near rotating
stop the tractor immediately as the tractor will be equipment.
more difficult to control. 3. When operating stationary PTO driven equip-
11. Stop the engine and relieve pressure before ment, always apply the tractor parking brake and
connecting or disconnecting hydraulic, steering block the rear wheels front and back.
or fuel lines. 4. To avoid injury, do not clean, adjust, unclog or
12. Tighten all connections before starting the service PTO driven equipment when the tractor
engine or pressurizing lines. engine is running.
13. Pull only from the swinging drawbar or the lower 5. Make sure the PTO guard is in position at all
link drawbar in the lowered position . Use only a times and always replace the PTO cap when the
drawbar pin that locks in place. Pulling from the PTO is not in use.
tractor rear axle or any point above the axle may
cause the tractor to overturn. SERVICING THE TRACTOR
14. If the front end of the tractor tends to rise when 1. The cooling system operates under pressure
heavy implements are attached to the three- which is controlled by the radiator cap. It is
point hitch, install front end or front wheel dangerous to remove the cap while the system is
weights. Do not operate the tractor with a light hot. Always turn the cap slowly to the first stop
front end. and allow the pressure to escape before
removing the cap entirely.
15. Always select Position Control when attaching
implements and when transporting equipment. 2. Do not smoke while refueling the tractor. Keep
Be sure hydraulic couplers are properly installed any type of open flame away. Wait for the engine
and will disconnect safety in case of accidental to cool before refueling.
detachment of the implement. 3. Keep the tractor and equipment, particularly
16. Do not leave equipment in the raised position brakes and steering, maintained in a reliable and
when the vehicle is stopped or unattended. satisfactory condition to ensure your safety and
comply with legal requirements.
17. Ensure any attached equipment or accessories
are correctly installed, are approved for use with 4. To prevent fire or explosion, keep open flames
the tractor, do not overload the tractor and are away from battery or cold weather starting aids.
operated and maintained in accordance with the To prevent sparks which could cause explosion,
instructions issued by the equipment or use jumper cables according to instructions.
accessory manufacturer. 5. Stop the engine before performing any service
18. Remember that your tractor, if abused or on the tractor.
incorrectly used, can be dangerous and become
00-17
6. Escaping diesel/hydraulic fluid under pressure 5. Do not fill the fuel tank to capacity. Allow room for
can penetrate the skin causing serious injury. expansion.
• Do not use your hand to check for leaks. Use 6. Wipe up spilled fuel immediately.
a piece of cardboard or paper to search for
7. Always tighten the fuel tank cap securely.
leaks.
• Stop the engine and relieve pressure before 8. If the original fuel tank cap is lost, replace it with
connecting or disconnecting lines. an approved cap. A non-approved cap may not
be safe.
• Tighten all connections before starting the
engine. 9. Keep equipment clean and properly maintained.
• If fluid is injected into the skin obtain medical 10. Do not drive equipment near open fires.
attention immediately.
11. Never use fuel for cleaning purposes.
7. Do not modify or alter or permit anyone else to
modify or alter the tractor or any of its 12. Arrange fuel purchases so that summer grade
components or any tractor function without first fuels are not used in the winter.
consulting an authorized dealer.
ROPS
8. The fuel oil in the injection system is under high
The tractor may be equipped with a safety frame
pressure and can penetrate the skin. Unqualified
(ROPS) which must be maintained in a serviceable
persons should not remove or attempt to adjust
condition. Be careful when driving through doorways
a pump, injector, nozzle or any other part of the
or working in confined spaces with low headroom.
injection system. Failure to follow these
instructions can result in serious injury.
1. Do not modify, drill, weld or alter the ROPS in any
9. Continuous long term contact with used engine way.
oil my cause skin cancer. Avoid prolonged
contact with used engine oil. Wash skin promptly 2. Never attempt to straighten or weld the ROPS or
with soap and water. retaining brackets, which have suffered damage.
By doing so you may weaken the structure and
DIESEL FUEL endanger your safety.
1. Under no circumstances should gasoline, 3. Do not secure any parts on the ROPS or attach
alcohol or blended fuels be added to diesel fuel. it with other than the special high tensile bolts and
These combinations can create an increased fire nuts specified.
or explosive hazard. In a closed container such 4. Never attach chains or ropes to the safety frame
as a fuel tank these blends are more explosive or roll bar for pulling purposes.
than pure gasoline. Do not use these blends.
5. Never take unnecessary risks even though your
2. Never remove the fuel cap or refuel with the safety frame or roll bar affords you the maximum
engine running or hot. protection possible.
3. Do not smoke while refueling the tractor or when 6. Whenever possible, operate with the ROPS in its
standing near fuel. Keep any type of open flame fully upright and locked position.
away. Wait for the engine to cool before refueling.
4. Maintain control of the fuel filter pipe nozzle when
filling the tank.
00-18
IDENTIFICATION DECALS
A vehicle identification plate is located under the For convenience, the numbers shown on the plates
tractor hood. In addition, if your tractor is equipped should be recorded and given to your authorized
with optional four wheel drive, a similar plate is New Holland dealer in the event the tractor requires
affixed to the rear surface of the front axle housing. service.
Vehicle Identification Plate Front Axle Identification Plate

20024998
SAFETY DECALS
The following safety decals have been placed on Keep the decals legible. If they are not, obtain
your machine in the areas indicated. They are replacements from your authorized dealer. The decal
intended for your personal safety and for those replacement part numbers are listed with each decal.
working with you. Please take this manual and walk
around your machine to note the content and location
of these warning signs.
00-19
00-20
83929338
85700098
83917224
83958918 81866777 83902321
00-21
81866779
83990357
U.P.I. 83976852
U.P.I. 82980615 U.P.I. 83958726
00-22
ECOLOGY AND THE ENVIRONMENT

Soil, air, and water are vital factors of agriculture and 2. Avoid skin contact with all fuels, oils, acids,
life in general. When legislation does not yet rule the solvents, etc. Most of them contain substances
treatment of some of the substances which are which may be harmful to your health.
required by advanced technology, common sense
3. Modern oils contain additives. Do not burn
should govern the use and disposal of products of a
contaminated fuels and or waste oils in ordinary
chemical and petrochemical nature.
heating systems.
The following are recommendations which may be of 4. Avoid spillage when draining off used engine
assistance: coolant mixtures, engine, gearbox and hydraulic
oils, brake fluids, etc. Do not mix drained brake
• Become acquainted with and ensure that you fluids or fuels with lubricants. Store them safely
understand the relative legislation applicable to or dispose of in a proper way to comply with local
your country. legislation and available resources.
• Where no legislation exists, obtain information 5. Modern coolant mixtures, i.e. antifreeze and
from suppliers of oils, filters, batteries, fuels, other additives, should be replaced every two
antifreeze, cleaning agents, etc., with regard to years. Do not allow seepage into the soil. Collect
effect on man and nature and how to safely store, and dispose of safely.
use and dispose of these substances. Agricultur-
al consultants will, in many cases, be able to help 6. Repair any leaks or defects in the engine cooling
you as well. or hydraulic system immediately.
7. Do not increase the specified operating pressure
in a pressurized circuit as this may lead to
component failure.
PRECAUTIONS
8. Protect hoses during welding as penetrating
1. Avoid filling tanks using cans or inappropriate
weld splatter may burn or weaken the hose,
pressurized fuel delivery systems which may
allowing the loss of oils, coolant, etc.
cause considerable spillage.
00-23
00-24
ALL MODELS
NOTE: When operating remote cylinders, the rear axle oil level will be affected. When topping up the rear axle
to accommodate the oil requirement of remote cylinders, no more than 59 liters (13 Imp. Gallons, 15.5 U.S.
gallons) should be added to bring the oil level up to the upper mark on the dipstick when all rams are fully
extended. Alternatively, remote cylinder with an oil capacity of up to 18 liters (4.1 Imp. Gallons, 4.8 U.S. gallons)
may be connected to the tractor hydraulic system without adding oil, provided the tractor is being operated on
level ground.
LUBRICANTS
Transmission/rear axle hydraulics, four wheel

drive differential casing and front hubs: ESN-M2C86-B, ESN-M2C134-D
Hydrostatic steering: ESN-M2C41-B
Lubrication fittings: ESE-MIC75-B or EXN-M1C137-B
Engine oil: WSE-M2C906A, ESN-M2CI 21 B, C, D, or E
Engine oil should meet A.P.I. (American Petroleum

Institute) quality ‘CF4’ as per the original factory fill.
At minimum, the oil must at least meet A.P.I. quality
level ‘CD’.
Choose the correct viscosity grade from Figure 1.
NOTE: In areas of prolonged periods of extreme

temperatures, local lubricant practices are accept-
able; such as the use of SAE5W in extreme low
temperatures or SAE50 in extreme high tempera-
tures. 358--209
Locally available fuel may have a high sulfur content, 1

in which case the oil change period should be 1. Engine Oil Viscosity Chart
adjusted as follows:
Sulfur Content % Oil Change Period
Below 0.5 Normal

0.5 - 1.0 Half the normal
above 1.0 One quarter normal
00-25
FRONT TIRE PRESSURE AND PERMISSIBLE LOADS (2WD)

The following charts list the carrying capacity of the AXLE at the indicated tire pressures.
Tire Size Ply Inflation Pressure - bar

Rating
1.65 1.8 2.0 2.2 2.5 2.76 3.0 3.1 3.3 3.6 3.7
Load Capacity per AXLE – kg
7.50 X 16 6 900 998 1044 1089 1198 1261 1334 - - - -
8 900 998 1044 1089 1198 1261 1334
7.50 X 18 6 971 1089 1144 1198 1298 1379 1461 1288 1425 1497 1524
7.50 X 20 6 1062 1162 1144 1261 1379 - - - - - -
10.00 X 16 8 1425 1144 1452 1760 1896 1996 - - - - -
Tire Size Ply Inflation Pressures - PSI

Rating
24 28 30 32 36 40 44 45 48 52 54
Load Capacity per AXLE – lbs.
7.50 X 16 6 1980 2200 2300 2400 2640 2780 2940 - - - -
8 1980 2200 2300 2400 2640 2780 2940 2840 3140 3300 3360
7.50 X 18 6 2140 2400 2520 2600 2860 3040 3220 - - - -
7.50 X 20 6 2340 2560 2670 2780 3040 - - - - - -
10.00 X 16 8 3140 2520 3200 3380 4180 4400 - - - - -
The above charts are for tractors operated at speeds damaged tires, always install tires of the same make,
up to 19 MPH (30 Km/h). For exact information model and size as the tires are removed. The
regarding inflation pressures and loads for your installation of other tire combinations will result in
particular tires, consult your authorized New Holland excessive tire wear, loss of useable power or severe
dealer. damage to drive line components. If in doubt, consult
your New Holland dealer. For front tires installed on
IMPORTANT: The tires installed on tractors with four wheel drive tractors, see “Rear Tire Pressures
optional four wheel (4WD) match the gearing of the and Permissible Loads” on the following pages.
transmission and axle. When replacing worn or
00-26
REAR TIRE PRESSURES AND PERMISSIBLE LOADS (CROSS PLY TIRES - INCLUDING
FRONT TIRES ON 4WD TRACTORS)
The following chars give the carrying capacity by TIRE at the pressures indicated.
TIRE LOAD LIMITS AT VARIOUS COLD INFLATIONS PRESSURES

TIRE kPa 12 14 16 18 20 22 24 26 28 30 32
SIZE Psi 80 100 110 120 140 150 170 180 190 210 220
7.50 kg 450 500 530 580 615(4)
lbs. 990 1100 1170 1280 1360(4)
8.3-16 kg 290 325 345 375 400 425(4) 437 462 487 500 515 545 @ 230(6)
lbs. 640 715 760 825 880 935(4) 965 1020 1070 1100 1140 1200 @ 34(6)
8.3-22 kg 355 412 437 450 500 530 560 580 600 630 650
lbs. 785 910 695 990 1100 1170(4) 1230 1280 1320 1390 1430 1760 @ 36(6)
8.3-24 kg 400 437 462 500 530 560(4)
lbs. 880 965 1020 1100 1700 1230(4)
9.5-16 kg 375 412 437 475 500(4) 530 560 580 615 630(6)
lbs. 825 910 965 1050 1100(4) 1170 1230 1280 1360 1390(6)
9.5-22 kg 450 515 545 560 615 650 690 710 750 775 800
lbs. 990 1140 1200 1230 1360(4) 1430 1520 1570 1650 1710 1760(6)
9.5-24 kg 500 545 580 630 670(4) 710 750 775 825 850(6)
lbs. 1100 1200 1280 1390 1480(4) 1570 1650 1710 1820 1870(6)
9.5-32 kg 560 615 670 710 750(4) 800 850 875 925 950 1000 2830 @ 50(10)
lbs. 1230 1360 1480 1570 1650(4) 1760 1870 1930 2040 2090 2200 2470 @ 40(8)
9.5-36 kg 600 650 710 750 800(4)
lbs. 1320 1430 1570 1650 1760(4)
9.5-42 kg 650 710 750 825 875(4) 925 975 1030 1060 1090 1150 1320 @ 280(8)
1450 @ 330(10)
2910 @ 40(8)
lbs. 1430 1570 1650 1820 1930(4) 2040 2150 2270 2340 2400 2540 3200 @ 48(10)
11.2-24 kg 600 650 710 750(4) 800 850 900 950(6) 975 1030 1060 1150 @ 250(8)
lbs. 1320 1430 1570 1650(4) 1760 1870 1980 2090(6) 2150 2270 2340 2450 @ 36(8)
11.2-28 kg 630 690 750 800(4)
lbs. 1390 1520 1650 1760(4)
11.2-36 kg 710 800 850 925(4)
lbs. 1570 1760 1870 2040(4)
11.2-38 kg 750 800 875 950(4)
lbs. 1650 1760 1930 2090(4)
12.4-16 kg 545 600 650(4) 690 750 775 825(6) 875 900 950 975(8) 1250 @ 330(12)
lbs. 1200 1320 1430(4) 1520 1650 1710 1820(6) 1930 1980 2090 2150(8) 2760 @ 48(12)
12.4-24 kg 710 775 850(4) 900 975 1030 1090(6) 1120 1180 1215 1285(8)
lbs. 1570 1710 1870(4) 1980 2150 2270 2400(6) 2470 2600 2680 2830(8)
12.4-28 kg 775 850 900(4)
lbs. 1710 1870 1980(4)
12.4-36 kg 875 950 1030(4) 1090 1150 1215 1285(6) 1360 1400 1450 1550(8) 1750 @ 280(10)
lbs. 1930 2090 2270(4) 2400 2540 2680 2830(6) 3000 3080 3200 3420(8) 3860 @ 40(10)
12.4-38 kg 900 975 1060(4) 1120 1180 1250 1320(6) 4770 @ 56(14)
lbs. 1980 2150 2340(4) 2470 2600 2760 2910(6) 3470(8) 4360 @ 40(12)
12.4-42 kg 925 1030 1120(4) 1180 1250 1320 1400(6) 1450 1550 1600 1650(8) 1900 @ 280(10)
lbs. 2040 2270 2470(4) 2600 2760 2910 3080(6) 3200 3420 3520 3640(8) 4180 @40(10)
12.4-46 kg 975 1060 1150 1250 1320 1400 1500(6) 1550 1600 1700 1750(8) 2000 @ 280(10)
lbs. 1250 2340 2540 2760 2910 3080 3300(6) 3420 3520 3740 3860(8) 440 @40(10)
13.6-16 kg 650 710(4)
lbs. 1430 1570(4)
13.6-24 kg 1870 2040(4) 2200 2340 2540 2680(6) 2830 2910 3080(8)
lbs. 850 925(4) 1000 1060 1150 1215(6) 1285 1320 1400(8)
13.6-26 kg 1930 2090(4) 2270 2470 2600 2750(6) 2910 3000 3200(8)
lbs. 875 950(4) 1030 1120 1180 1250(6) 1320 1360 1450(8)
13.6-28 kg 1980 2200(4) 2340 2540 2680 2830(6) 3000 3080 3300(8) 3420 3520 3740 @ 36(10)
lbs. 900 1000(4) 1060 1150 1215 1285(6) 1360 1400 1500(8) 1550 1600 1700 @ 250(10)
00-27
TIRE LOAD LIMITS AT VARIOUS COLD INFLATIONS PRESSURES - Continued

TIRE kPa 12 14 16 18 20 22 24 26 28 30 32
SIZE Psi 80 100 110 120 140 150 170 180 190 210 220
13.6-38 kg 2340 2540(4) 2760 2910 3080 3300(6)
lbs. 1060 1150(4) 1250 1320 1400 1500(6)
13.6-46 kg 2540 2830(4) 3000 3200 3420 3640(6) 3860 3960 4180(8)
lbs. 1150 1285(4) 1360 1450 1550 1650(6) 1750 1800 1900(8)
13.9-36 kg 2270 2470(4) 2680 2830 3000(6)
lbs. 1030 1120(4) 1215 1285 1350(6)
14.9-24 kg 2200 2400(4) 2600 2830 3000(6) 3200 3300 3520(8) 3640 3740 3960 4400 @ 38(12)
lbs. 1000 1090(4) 1180 1285 1350(6) 1450 1500 1600(8) 1650 1700 1800 2000 @ 260(12)
420/70-24 kg 2340 2540 2760(6) 2910 3080 3300(8) 3520 3640(10)
lbs. 1060 1150 1250(6) 1320 1400 1500(8) 1600 1650(10)
14.9-26 kg 2270 2540 2680 2910 3080(6) 3300 3420 3640 3740 3960 4080(10)
lbs. 1030 1150 1215 1320 1400(6) 1500 1550 1650 1700 1800 1850(10)
14.9-28 kg 2340 2600(4) 2830 3000 3200(6) 3420 3520 3740(8) 3860 4080 4180(10)
lbs. 1060 1180(4) 1285 1360 1450(6) 1550 1600 1700(8) 1750 1850 1900(10)
14.9-30 kg 2470 2680 2910 3080 3300(6) 3520 3640 3860(8) 3960 4180 4300(10)
lbs. 1120 1215 1320 1400 1500(6) 1600 1650 1750(8) 1800 1900 1950(10)
14.9-38 kg 2760 3000 3300 3520 3740(6)
lbs. 1250 1360 1500 1600 1700(6)
15.5-38 kg 2600 2830 3080 3300 3520(6) 3740 3860 4080(8)
lbs. 1180 1285 1400 1500 1600(6) 1700 1750 1850(8)
16.9-24 kg 2680 2910 3200 3420(6) 3640 3860 4080(8) 4300 4400(10)
lbs. 1215 1320 1450 1550(6) 1650 1750 1850(8) 1950 2000(10)
16.9-26 kg 2760 3080 3300 3520(6) 3740 3960 4180 4400 4540(10)
lbs. 1250 1400 1500 1600(6) 1700 1800 1900 2000 2050(10)
16.9-28 kg 2910 3200 3420 3640(6) 3860 4080 4300(8) 4540 4580(10)
lbs. 1320 1450 1550 1650(6) 1750 1850 1950(8) 2060 2120(10)
16.9-30 kg 3000 3300 3520 3740(6) 3960 4180 4400(8) 4680 4940(10)
lbs. 1360 1500 1600 1700(6) 1800 1900 2000(8) 2120 2240(10)
16.9-34 kg 3200 3420 3740 3960(6) 4300 4540 4580(8) 4940 5200(10)
lbs. 1450 1550 1700 1800(6) 1950 2060 2120(8) 2240 2360(10)
16.9-38 kg 3300 3640 3960 4180(6) 4540 4800 4940(8)
lbs. 1500 1650 1800 1900(6) 2060 2180 2240(8)
18.4-16.1 kg 2150 2340 2540(6) 2680 2910(8) 3080 3200 3300(10)
lbs. 975 1060 1150(6) 1215 1320(8) 1400 1450 1500(10)
18.4-24 kg 3200 3520 3860(6) 4080 4400(8) 4540 4800 5080(10) 5360 5520 5680(12)
lbs. 1450 1600 1750(6) 1850 2000(8) 2060 2180 2300(10) 2430 2500 2575(12)
18.4-26 kg 3300 3640 3960(6) 4180 4540(8) 4800 4940 5200(10)
lbs. 1500 1650 1800(6) 1900 2060(8) 2180 2240 2360(10)
18.4-28 kg 3420 3740 4080(6) 4400 4680(8) 4940 5200 5360(10) 5680 5840 6150(12)
lbs. 1550 1700 1850(6) 2000 2120(8) 2240 2360 2430(10) 2575 2650 2800(12)
18.4-30 kg 3520 3860 4180(6) 4540 4800(8) 5080 5360 5520(10)
lbs. 1600 1750 1900(6) 2060 2180(8) 2300 2430 2500(10)
18.4-34 kg 3740 4180 4400(6) 4800 5080(8) 5360 5680 6000 6150 6400 6600(12)
lbs. 1700 1900 2000(6) 2180 2300(8) 2430 2575 2725 2800 2900 3000(12)
18.4-38 kg 3960 4400 4880(6) 5080 5360(8) 5680 6000 6400(10) 6600 6800 7150(12) 7600(14)
lbs. 1800 2000 2120(6) 2300 2430(8) 2575 2725 2900(10) 3000 3075 3250(12) 3450(14)
To avoid the possibility of tire creep (movement if the The above tables are for guidance only. For exact
tire on the rim), tire pressures below (1.0 bar) 14 PSI information regarding inflation pressures and loads
should not be used with cross ply tires for operations for your particular tires, consult your authorized New
having a high torque requirement, e.g. sub-soiling, Holland dealer.
ploughing, etc. When mounted implements are used,
rear tire loads may be increased by up to 20% with
no increase in inflation pressures when operated at
speeds below 20 km/h (12 MPH).
00-28
REAR TIRE PRESSURE AND PERMISSIBLE LOADS (RADIAL TIRES - INCLUDING FRONT
TIRES ON 4WD TRACTORS)
Radial tire performance is now denoted by a Load
Index and Speed Symbol replacing the Ply Rating
commonly found on cross ply tires. Figure 2 shows
typical markings to be found on the side wall of radial
ply tires.
Figure 2 - Typical Tire Data Marking

1. Oil ply rating mark
2. Maximum inflation pressure (in bar)
3. Maximum load at 40 km/h (25 MPH)
4. Load Index
5. Speed Symbol
358--110
NOTE: All tires installed on New Holland tractors
have a Speed symbol ‘A8’ and are suitable for 2
speeds up to 40km/h (25 MPH).
The maximum load that may be carried by the tire is

dependent upon the Load Index shown on the side
wall. In the following charts the loads given are for
individual tires operated at speeds up to 30 Km/h (19
MPH). The right-hand (shaded) column indicates the
maximum load at speeds up to 40 km/h (25 MPH).
00-29
LOAD INDEX CHART
Load Index kg lbs. Load Index kg lbs. Load Index kg lbs.

80 450 990 110 1060 2340 140 2500 5520
81 462 1020 111 1090 2400 141 2575 5680
82 475 1050 112 1120 2470 142 2650 5840
83 487 1070 113 1150 2540 143 2725 6000
84 500 1100 114 1180 2600 144 2800 6150
85 515 1140 115 1215 2680 145 2900 6400
86 530 1170 116 1250 2760 146 3000 6600
87 545 1200 117 1285 2830 147 3075 6800
88 560 1230 118 1320 2910 148 3150 6950
89 580 1280 119 1360 3000 149 3250 7150
90 600 1320 120 1400 3080 150 3350 7400
91 615 1360 121 1450 3200 151 3450 7600
92 630 1390 122 1500 3300 152 3550 7850
93 650 1430 123 1550 3420 153 3650 8050
94 670 1480 124 1600 3520 154 3750 8250
95 690 1520 125 1650 3640 155 3875 8550
96 710 1570 126 1700 3740 156 4000 8800
97 730 1610 127 1750 3860 157 4125 9100
98 750 1650 128 1800 3960 158 4250 9350
99 775 1710 129 1850 4080 159 4375 9650
100 800 1760 130 1900 4180 160 4500 9900
101 825 1820 131 1950 4300 161 4625 10200
102 850 1870 132 2000 4400 162 4750 10500
103 875 1930 133 2060 4540 163 4875 10700
104 900 1980 134 2120 4680 164 5000 11000
105 925 2040 135 2180 4800 165 5150 11400
106 950 2090 136 2240 4940 166 5300 11700
107 975 2150 137 2300 5080 167 5450 1200
108 1000 2200 138 2360 5200 168 5600 12300
109 1030 2270 139 2430 5360 169 5800 12800
00-30
Inflation Pressure - bar

Load
L d 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.6
Index
Load Capacity per TIRE - kg
107 680 725 770 815 860 910 955 1000 1050 975
109 720 765 815 860 910 960 1005 1055 1100 1030
114 830 885 940 990 1050 1100 1155 1210 1260 1180
116 885 940 995 1055 1115 1170 1225 1280 1340 1250
119 965 1020 1090 1145 1210 1270 1335 1390 1455 1360
121 1020 1080 1150 1220 1285 1355 1420 1485 1555 1450
122 1045 1120 1185 1265 1330 1400 1465 1535 1605 1500
123 1070 1145 1220 1295 1365 1430 1515 1585 1660 1550
124 1105 1180 1260 1335 1410 1490 1565 1640 1715 1600
126 1170 1250 1335 1415 1495 1580 1660 1740 1820 1700
127 1200 1285 1370 1450 1535 1620 1710 1780 1875 1750
128 1230 1320 1410 1495 1580 1670 1755 1840 1926 1800
134 1445 1550 1655 1760 1855 1965 2065 2165 2270 2120
135 1510 1615 1720 1825 1920 2030 2130 2230 2335 2180
136 1550 1660 1765 1875 1975 2080 2185 2290 2395 2240
137 1605 1710 1820 1925 2035 2140 2245 2350 2460 2300
139 1715 1825 1935 2050 2155 2270 2380 2495 2600 2430
141 1820 1935 2055 2170 2290 2410 2520 2640 2760 2575
142 1875 1990 2115 2230 2355 2480 2595 2710 2836 2650
144 1980 2110 2240 2360 2490 2615 2745 2975 3000 2800
146 2085 2225 2370 2510 2650 2790 2930 3070 3210 3000
153 2525 2700 2875 3045 3215 3390 3565 3755 3905 3650
155 2675 2865 3045 3225 3415 3595 3780 3960 4150 3875
157 2835 3035 3235 3430 3630 3825 4020 4260 4415 4125
159 3000 3210 3420 3635 3845 4060 4260 4475 4685 4375
166 3695 3945 4190 4435 4685 4935 5180 5425 5675 5300
Use this table for guidance only. For exact information regarding inflation pressures and loads for a particular
tire, consult an authorized New Holland dealer.
00-31
REAR TIRE PRESSURE AND PERMISSIBLE LOADS (RADIAL TIRES - INCLUDING FRONT
TIRES ON 4WD TRACTORS) (CONTINUED)
Inflation Pressure - PSI
Load
L d 12 13 15 16 17 18 20 22 23 23
Index
Load Capacity per TIRE - lbs.
107 1500 1600 1695 1795 1895 2005 2105 2205 2315 2150
109 1585 1685 1795 1895 2005 2115 2215 2325 2430 2270
114 1830 1950 2070 2180 2315 2425 2545 2665 2780 2600
116 1950 2070 2195 2325 2460 2580 2700 2820 2955 2755
119 2125 2250 2405 2525 2665 2800 2945 3065 3205 3000
121 2250 2380 2535 2690 2830 2985 3130 3275 3430 3195
122 2305 2470 2610 2790 2930 3085 3230 3385 3540 3305
123 2360 2525 2690 2855 3010 3150 3340 3495 4135 3860
124 2435 2600 2775 2945 3110 3285 3450 3615 3780 3525
126 2580 2755 2945 3120 3295 3485 3660 3835 4010 3745
127 2645 2830 3020 3195 3385 3570 3770 3925 4135 3860
128 2710 2910 3110 3295 3485 3680 3870 4055 4245 3970
134 3185 3415 3650 3880 4090 4330 4550 4770 5005 4675
135 3330 3560 3790 4025 4230 4475 4695 4915 5145 4805
136 3415 3660 3890 4135 4355 4585 4815 5050 5280 4940
137 3538 3770 4010 4245 4485 4715 4950 5180 5425 5070
139 3780 4025 4265 4520 4750 5005 5245 5500 5730 5355
141 4010 4265 4530 4785 5050 5315 5555 5820 6085 5675
142 4133 4385 4660 4915 5190 5465 5720 5975 6250 5840
144 4365 4650 4940 5200 5490 5765 6050 6560 6615 6170
146 4595 4905 5225 5535 5840 6150 6460 6770 7075 6615
153 5565 5950 6340 6715 7085 7475 7860 8280 8610 8045
155 5895 6315 6715 7110 7530 7925 8335 8730 9150 8540
157 6250 6690 7130 7560 8000 8430 8860 9390 9735 9095
159 6615 7075 7535 8015 8475 8950 9390 9865 10330 9645
166 8145 8695 9235 9775 10330 10880 11420 11960 12510 11685
Use this table for guidance only. For exact information regarding inflation pressures and loads for a particular
tire, consult an authorized New Holland dealer.
GROUND SPEEDS
4 1
A decal similar to that shown in Figure 3 is affixed to
the instrument console, immediately below the
instrument panel.
The decal illustrates the gear shift pattern and the
approximate ground speed in all forward and reverse
ratios at three alternative engine speeds. The
example shown is for a tractor having a rated engine
speed of 2100 rev/min.
Figure 3 - Ground Speed Decal
1. Gearshift lever positions 2 3
2. Tire size
3. Ground speeds 3
4. Engine speed range
The right-hand side of the decal represents the range
and main shift lever positions. To the left are columns
representing the gear ratios selected.
00-32
SECTION 10 -- ENGINE -- CHAPTER 1
SECTION 10 - ENGINE
Chapter 1 - Diesel Engines

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Crankshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Cylinder Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Diesel Engine Strip-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Separating the Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Disassembly and Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cylinder Head, Valves, and Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Rocker Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Valve Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
New Valve Guide Stem Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Rocker Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Engine Front Cover and Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Connecting Rods, Bearings, Pistons, and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Connecting Rod Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Rear Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Oil Filter Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Balancer Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Camshaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Engine Break-in (Low Hp Application) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Engine Break-in (Other Than Low Hp Application) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10-1
ENGINE SPECIFICATIONS
Model Unit 5610 S 6610 S 7610 S 7010 8010

Turbocharged Engine No No Yes Yes No
Cylinders 4 4 4 4 6
Bore mm 111.8 111.8 111.8 111.8 111.8
in 4.4 4.4 4.4 4.4 4.4
Stroke mm 111.8 127.0 127.0 127.0 127.0
in 4.4 5.0 5.0 5.0 5.0
Displacement cu cm 4392 4987 4987 4987 7480
cu in 268 304 304 304 456
Compression Ratio 17.5:1 17.5:1 17.5:1 17.5:1 17.5:1
Cylinder Bore Compression bar 25.85 25.85 25.85 25.85 25.85
(at cranking speed of 200 rpm)
psi ± 50 375 375 375 375 375
Firing Order 1⋅3⋅4⋅2 1⋅3⋅4⋅2 1⋅3⋅4⋅2 1⋅3⋅4⋅2 1⋅5⋅3⋅6⋅2⋅4
Low-Idle Speed rev/min ± 25 750 750 750 750 750
High-Idle Speed rev/min ± 25 2350 2350 2250 2250 2250
Maximum No-Load Speed rev/min 2375 2375 2375 2250 2250
Rated Engine Speed rev/min 2200 2200 2100 2200 2100
CYLINDER BLOCK
Cylinder Bore Taper maximum wear limit 0.127 mm 0.005 in.

maximum repair limit 0.025 mm 0.001 in.
Cylinder Bore Out-of-Round maximum wear limit 0.127 mm 0.005 in.
maximum repair limit 0.030 mm 0.001 in.
Cylinder Bore Diameter 110.017-110.080 mm 4.331-4.334 in.
Rear Oil Seal Diameter 140.77-140.87 mm 5.542-5.546 in.
Head-to-Block Surface Flatness any 152 mm (6 in.) area 0.080 mm 0.003 in.
Limit any 25.40 mm (1 in.) area 0.030 mm 0.001 in.
overall 0.127 mm 0.005 in.
CYLINDER HEAD
Valve Guide Bore Diameter 9.469-9.495 mm 0.3728-0.3738 in.
10-2
EXHAUST VALVES
Face Angle relative to valve head 44°15′-44°30′

Stem Diameter Std 9.401-9.421 mm 0.3701-0.3709 in.
0.076 mm 0.003 in.
oversize 9.477-9.497 mm 0.3731-0.3739 in.
0.381 mm 0.015 in.
oversize 9.781-9.802 mm 0.3851-0.3859 in.
0.762 mm 0.030 in.
oversize 10.163-10.183 mm 0.4001-0.4009 in.
Head Diameter 42.88-43.13 mm 1.688-1.698 in.
Stem-to-Guide Clearance 0.048-0.094 mm 0.0019-0.0037 in.
Lash Clearance cold 0.43-0.53 mm 0.017-0.021 in.
Valve Head-to-Cylinder Head Face Depth 1.2-1.6 mm 0.047-0.063 in.
INTAKE VALVES
Face Angle relative to valve head 29°15′-29°30′

Stem Diameter Std 9.426-9.446 mm 0.3711-0.3719 in.
0.076 mm 0.003 in.
oversize 9.502-9.522 mm 0.3741-0.3749 in.
0.381 mm 0.015 in.
oversize 9.807-9.827 mm 0.3861-0.3869 in.
0.762 mm 0.030 in.
oversize 10.188-10.208 mm 0.4011-0.4019 in.
Head Diameter 47.37-47.63 mm 1.865-1.875 in.
Stem-to-Guide Clearance 0.023-0.069 mm 0.0009-0.0027 in.
Lash Clearance cold 0.36-0.46 mm 0.014-0.018 in.
Valve Head-to-Cylinder Head Face Depth 0.86-1.32 mm 0.034-0.052 in.
VALVE SPRINGS
Free Length 60.7 mm 2.4 in.

Length loaded at 28-31 kg (62-68 lbs.) 48.3 mm 1.9 in.
Length loaded at 61-69 kg (135-152 lbs.) 35.7 mm 1.4 in.
VALVE TIMING
Intake Opening before top dead center 12°

Intake Closing after bottom dead center 38°
Exhaust Opening before bottom dead center 48°
Exhaust Closing after top dead center 12°
10-3
VALVE INSERTS
Insert Oversize 0.25 mm 0.010 in.

0.50 mm 0.020 in.
0.76 mm 0.030 in.
Exhaust valve Insert 44.17-44.20 mm 1.739-1.740 in.
Cylinder Bore Diameter in Head 44.42-44.45 mm 1.749-1.750 in.
44.68-44.70 mm 1.759-1.760 in.
Intake Valve Insert 50.01-50.04 mm 1.969-1.970 in.
Cylinder Bore Diameter in Head 50.27-50.29 mm 1.979-1.980 in.
50.52-50.55 mm 1.989-1.990 in.
VALVE SEATS
Exhaust Valve 45°00′-45°30′

Intake Valve 30°00′-30°30′
Interference Valve Face Angle-to-Valve Seat Angle 0°30′-1°15′
Valve Seat Concentricity with Valve Guide Total Indicator Reading 0.051 mm 0.002 in.
Bore
Seat Width Exhaust Valve 1.8-2.3 mm 0.071-0.091 in.
Intake Valve 1.9-2.5 mm 0.075-0.098 in.
CAMSHAFT IDLER GEAR
End-Play 0.076-0.35 mm 0.003-0.014 in.

Bushing Inside Diameter 50.81-50.83 mm 2.000-2.001 in.
Adapter Outside Diameter 50.76-50.77 mm 1.998-1.999 in.
Backlash with Crankshaft Gear 0.025-0.23 mm 0.001-0.009 in.
Backlash with Camshaft Gear 0.025-0.38 mm 0.001-0.015 in.
Backlash with Fuel Injection Pump 0.10-0.15 mm 0.004-0.006 in.
CAMSHAFT GEAR
Timing Gear Backlash 0.025-0.38 mm 0.001-0.015 in.
ROCKER ARM SHAFT
Shaft Diameter 25.40-25.43 mm 1.000-1.001 in.

Shaft Support Internal Diameter 25.45-25.50 mm 1.002-1.004 in.
10-4
ROCKER ARM
Inside Diameter 25.48-25.50 mm 1.003-1.004 in.
TAPPETS
Clearance-to-Bore 0.015-0.053 mm 0.0006-0.0021 in.

Tappet Diameter 25.11-25.13 mm 0.988-0.989 in.
Tappet Bore Diameter 25.15-25.17 mm 0.990-0.991 in.
CAMSHAFT
Bearing Journal Diameter 60.693-60.719 mm 2.389-2.390 in.

Bearing Clearance 0.025-0.076 mm 0.001-0.003 in.
End-Play 0.051-0.018 mm 0.002-0.007 in.
CONNECTING RODS
Small-End Bushing
g Internal Diameter Naturally Aspirated 38.113-38.120 mm 1.500-1.501 in.
Turbocharged 41.288-41.295 mm 1.625-1.626 in.
Bushing-to-Piston Pin Clearance 0.013-0.025 mm 0.0005-0.001 in.
Side Float 0.13-0.33 mm 0.005-0.013 in.
Twist Limit maximum 0.30 mm 0.012 in.
Bend Limit maximum 0.10 mm 0.004 in.
PISTON PIN
Outside Diameter Naturally Aspirated 38.095-38.100 mm 1.499-1.500 in.

Turbocharged 41.270-41.275 mm 1.624-1.625 in.
PISTONS
Skirt-to-Cylinder Clearance Naturally Aspirated 0.14-0.17 mm (new engine) 0.0055-0.0067 in.

0.14-0.28 mm (run engine) 0.0055-0.011 in.
Turbocharged 0.17-0.19 mm (new engine) 0.0067-0.0075 in.
0.17-0.28 mm (run engine) 0.0067-0.011 in.
Taper out-of-round 0.063-0.127 mm 0.0025-0.005 in.
Grading Diameters at right angles to piston pin 111.64-111.74 mm 4.395-4.399 in.
in increments of 0.0127 mm 0.0005 in.
Piston Pin Clearance at 21°C (70°F) 0.003-0.014 mm 0.00012-0.00055 in.
Piston Crown-to-Block Naturally Aspirated 0.28-0.58 mm 0.011-0.023 in.
Face Turbocharged 0.0-0.3 mm 0.0-0.012 in.
10-5
PISTON RINGS (87802355 THRU 87802360)
Compression
p Rings
g Number 2 off
Location 1st and 2nd from piston top
Naturallyy Aspirated
p Top Ring Chrome Plated Internal Chamfer
2nd Ring Napier Ductile Iron Taper Face with Step
Turbocharged
g Top Ring Keystone Tapered Internal Chamfer
2nd Ring Napier Ductile Iron Taper Face with Step
Oil Control Rings
g Number 1 off
Location directly above piston pin Chrome Plated Symmetrical
Gap
p Clearances Top Ring 0.29-0.53 mm .012-.021 in.
2nd Ring 0.49-0.63 mm .020-.029 in.
0.4200.76 mm .017-.030 in. 0.015-0.033 in.
PISTON RINGS
Compression
p Rings
g Number 2 off
Location 1st and 2nd from piston top
Naturallyy Aspirated
p Top Ring Parallel Sides Inner Chamfer
Engine 2nd Ring Straight Face Inner Step
Turbocharged
g Top Ring Keystone Tapered Internal Chamfer
Engine 2nd Ring Straight Face Inner Step
Oil Control Rings
g Number 1 off
Location directly above piston pin Slotted with Expander
Side Face Clearance-to- Top Ring 0.112-0.155 mm 0.0044-0.0061 in.
Ring Groove 2nd Ring 0.099-0.142 mm 0.0039-0.0056 in.
Oil Ring 0.061-0.104 mm 0.0024-0.0041 in.
Gap
p Width Top Ring 0.38-0.84 mm 0.015-0.033 in.
2nd Ring 0.66-1.12 mm 0.026-0.044 in.
Oil Ring 0.38-0.84 mm 0.015-0.033 in.
10-6
CRANKSHAFT
Main Journal Diameter 85.631-85.644 mm 3.3713-3.3718 in.

Main Journal Length except thrust, rear or inter- 36.96-37.21 mm 1.455-1.465 in.
mediate
Main Journal Wear 0.127 mm 0.005 in.
Main and Crankpin Fillet Radius 3.048-3.556 mm 0.12-0.14 in.
Thrust Bearing Journal Length 37.06-37.11 mm 1,459-1.461 in.
Intermediate Bearing Journal Length 36.96-37.21 mm 1.455-1.465 in.
Rear Bearing Journal Length 37.97-38.48 mm 1.495-1.515 in.
Crankpin Journal Length 42.62-42.72 mm 1.678-1.682 in.
Crankpin Diameter 69.840-69.850 mm 2.749-2.7500 in.
End-Play 0.10-0.20 mm 0.004-0.008 in.
Crankpin Out-of-Round Total Indicator Reading 0.005 mm 0.0002 in.
Taper Surface parallel to center of Main 0.005 mm 0.0002 in.
Journal
Crankshaft Rear Oil Seal Journal Diameter 122.12-122.28 mm 4.808-4.814 in.
Crankshaft Pulley Journal Diameter 44.45-44.48 mm 1.750-1.751 in.
Crankshaft Timing Gear Journal Diameter 46.23-46.25 mm 1.820-1.821 in.
Crankshaft Flange Run-Out 0.038 mm 0.0015 in.
Cankshaft Drive Gear Teeth 26
MAIN BEARING
Liner Length without thrust liner 27.94-28.19 mm 1.10-1.11 in.

Liner Length with thrust liner 39.91-39.96 mm 1.453-1.455 in.
Bearing Clearance assembled, vertical 0.055-0.117 mm 0.0021-0.0046 in.
CRANKPIN BEARINGS
Liner Length 35.56-35.81 mm 1.40-1.41 in.

Bearing Clearance assembled, vertical 0.035-0.094 mm 0.0014-0.0037 in.
NOTE: Reduce the main and crankpin journal diameters the same amount as the undersize bearings used,
when regrinding a crankshaft. The rear end of the crankshaft should be located on the 60° chamfer of the pilot
bearing- bore.
10-7
CRANKSHAFT REGRINDING
Undersize Bearings Available Main Journal Diameters

0.051 mm 0.002 in. 85.580-85.593 mm 3.3693-3.3698 in.
0.254 mm 0.010 in. 85.390-85.402 mm 3.3618-3.3623 in.
0.508 mm 0.020 in. 85.136-85.148 mm 3.3518-3.3523 in.
0.762 mm 0.030 in. 84.882-84.894 mm 3.3418-3.3423 in.
1.016 mm 0.040 in. 84.628-84.640 mm 3.3318-3.3323 in.
Undersize Bearings Available Crankpin Journal Diameters
0.051 mm 0.002 in. 69.789-69.799 mm 2.7476-2.7480 in.
0.254 mm 0.010 in. 69.956-69.606 mm 2.7400-2.7404 in.
0.508 mm 0.020 in. 69.342-69.352 mm 2.7300-2.7304 in.
0.762 mm 0.030 in. 69.088-69.098 mm 2.7200-2.7204 in.
1.016 mm 0.040 in. 68.834-68.844 mm 2.7100-2.7104 in.
CRANKSHAFT BALANCER
Gear Backlash at 90° Intervals 0.05-0.25 mm 0.002-0.010 in.

Shaft-to-Bushing Clearance 0.012-0.038 mm 0.0005-0.0015 in.
Shaft Diameter 25.133-25.400 mm 0.9895-1.000 in.
Backlash Between Balancer Drive Gear and Crankshaft Gear 0.05-0.20 mm 0.002-0.008 in.
End Float of Assembled Gears 0.20-0.51 mm 0.008-0.20 in.
FLYWHEEL
Ring Gear Run-Out 0.63 mm 0.025 in.

Flywheel Run-Out 0.27 mm 0.011 in.
Skimmed Face Maximum Depth 3 mm 0.118 in.
OIL PUMP
Rotor Clearance 0.025-0.15 mm 0.001-0.006 in.

Rotor-to-Pump Housing Clearance 0.15-0.28 mm 0.006-0.011 in.
Rotor End-Play 0.025-0.089 mm 0.001-0.0035 in.
Oil Pressure minimum at idle speed 1.24 bar 18 psi
minimum at rated speed 2.76 bar 40 psi
Pump Gear-to-Camshaft Gear Backlash 0.40-0.56 mm 0.016-0.022 in.
10-8
OIL FILTER SUPPORT
Relief Valve Operating Pressure 4.0 bar 59 psi

Flow rate 68-75 liters/min 18-20 gal/min
Relief Valve Spring
p g Free Length 52.8 mm 2.08 in.
Compressed Length with 15.6 kgs (34.3 lbs.) 37.0 mm 1.46 in.
OIL SERVICING
Oil &
Filter Quantity Quantity
API Change 4 Cylinder 6 Cylinder
Temperature Oil Type/Viscosity Class Interval (with filter) (with filter)
Below SAE 5W Supplement 1 or
--12°C (10°F) SAE 5W/20 Supplement 1 11.4 liters 20.8 liters
or SAE 10W-30 SG/CF 150 (12.0 qt) (22.0 qt)
--12°C to 4° C SAE 10W Series 3 11.4 liters 20.8 liters
(10°F to 40°F) or SAE 10W-30 SG/CF 300 (12.0 qt) (22.0 qt)
0°C to 32°C SAE 30W Series 3 11.4 liters 20.8 liters
(32°F to 90°F) or SAE 10W-40 SG/CF 300 (12.0 qt) (22.0 qt)
Above 24°C SAE 30W Series 3 11.4 liters 20.8 liters
(75°F) or SAE 15W-40 SG/CF 300 (12.0 qt) (22.0 qt)
NOTE: When using diesel fuel with a sulfur content below 1.0%, use Series 3 engine oil with a (CD) API
classification. In addition, reduce he oil and filter change interval to 150 hours. When using diesel fuel with a sulfur
content between 1% and 1.3%, use only the oils listed above, and reduce the oil and filter change interval to 75
hours.
Fuel Injection Pump 5610S 6610S 7610S 7010 8010
8920A360W/361W X
8920A421W X
8920A431W X
8921A481W X X
10-9
TORQUE VALUES
Description N⋅ m Ft.-Lb.
Main Bearing Bolts 197 145
Connecting Rod Bolts 149 110
Cylinder Head Bolts (engine cold) Final Torque 217 160
Intake Manifold-to-Cylinder Head 35 26 (312 in.-lb.)
Exhaust Manifold-to-Cylinder Head 38 28 (336 in.-lb.)
Exhaust Pipe-to-Flange 31 23 (276 in.-lb.)
Flywheel-to-Crankshaft 197 145
Oil Pan Drain Plug 41 30
Valve Rocker Cover Bolts 24 18 (216 in.-lb.)
Crankshaft Pulley-to-Crankshaft 284 210
Valve Rocker Arm Self Locking Screw 24 18 (216 in.-lb.)
Injector Attachment Bolts 23 17 (204 in.-lb.)
Cover Bolts 31 23 (276 in.-lb.)
Oil Pump-to-Block 23 17 (204 in.-lb.)
Water Pump-to-Cylinder Block 35 26 (312 in.-lb.)
Water pump Cover-to-Pump 27 20 (239 in.-lb.)
Oil Pan-to-Cylinder Block (cast) 38 28 (336 in.-lb.)
Injector Line Banjo Bolts 24 18 (216 in.-lb.)
Leak-Off Tube Banjo Fitting Bolts 11 8 (96 in.-lb.)
Injection Pump-to-Front Cover 24 18 (216 in.-lb.)
Camshaft Idler Drive Gear-to-Block 237 175
Front Cover-to-Cylinder Block 24 18 (216 in.-lb.)
Thermostat Housing Bolts 24 18 (216 in.-lb.)
Camshaft Gear Bolt 69 51
Camshaft Rear Gear Plate Bolts 47 35
Oil Filter Adapter Bolts 42 31
Oil Filter Mounting Bolt Insert 34 25 (300 in.-lb.)
Starting Motor-to-Rear Adapter Plate 31 23 (276 in.-lb.)
Injection Pump-to-Gear Nut (4-cylinder) 79 58
Oil Pressure Switch Assembly 31 23 (276 in.-lb.)
Turbocharger-to-Exhaust Manifold Nut 44 33
Fan Blade-to-Support Body 27 20 (239 in.-lb.)
Crankshaft Rear Oil Seal Retainer Initial Torque 12 9 (108 in.-lb.)
Crankshaft Rear Oil Seal Retainer Final Torque 23 17 (204 in.-lb.)
Belt Tension Pulley 54 40
Temperature Senders 20 15 (180 in.-lb.)
Tensioner-to-Water Pump Bolt 54 40
Idler Pulley Bolt 54 40
Pump Connector-to-Block 24 18 (216 in.-lb.)
Dynamic Balancer-to-Cylinder Bore 117 86
Cylinder Block Plugs (1/4 in-27 NPT) 11 8 (96 in.-lb.)
10-10
SPECIAL TOOLS
Description Tool Number Other Tool Number

Puller, Crankshaft Pulley FNH09539 NUDAY 9539
Protector, Shaft (set of 6) 380000564 FNH09212
Adapter, Step Plate (set of 11) FNH09210 NUDAY 9210
Driver, Bushing FNH09514 NUDAY 9514
Kit, Valve Stem Guide Reamer 380000319 FNH02136
Handle, Driver Camshaft 380000501 FNH01442
Driver, Camshaft FNH01255 NUDAY 1255
Installer, Water Pump Seal 380000321 FNH04672
Tool, Connecting Rod Bushing FNH00053
Replacer, Front Crank Seal T87T-6019-A
Tool, Crank Gear Alignment FNH00881
Installer, Crankshaft Rear Main Seal FNH01301 NUDAY 1301
Kit, Fuel Injection Pump Timing 380000081
SEALANTS/LUBRICANTS
The table below list recommended sealers and lubrications.
Nomenclature Description/Type Part Number

A Grease NLG1 Grade 2
B Grease Silicone (light consistency) ESF-M1C43-A
C Sealant Anaerobic (low strength) ESE-M4G194-B
D Sealant Silicone ESE-M4G195-A
E Sealant Polyester Urethane SP-M4G9112-A
F Sealant Polyester Urethane SP-M4G9112-C
G Sealant Anaerobic ESE-M4G217-A
H Sealant Silicone RTV (rubber) SP-M2G9121-B
10-11
FAULT FINDING
IMPORTANT: Investigate and correct the causes of malfunctions during the repair cycle. This will prevent repeat
failures.
NOTE: Quantify all complaints of excessive oil consumption before initiating repairs. Maximum (North American)
engine oil consumption should be no more than three tenths of one percent (0.3%) of the fuel consumed by
volume, or no more than 1 quart of oil for every 83 gallons (US) of fuel usage. Record fuel and engine oil usage
for a minimum of 50 engine hours before calculating the rate of oil consumption. Oil consumption less than that
specified is not considered excessive.
The following table lists problems, their possible causes, and recommended remedial action.
PROBLEM POSSIBLE CAUSES REMEDY

Engine does not develop 1. Clogged air cleaner 1. Clean or replace element
full power
2. Fuel line obstructed 2. Remove obstruction
3. Faulty injectors 3. Clean and reset or replace
4. Incorrect valve lash adjustment 4. Check and reset
5. Burnt, worn or sticking valves 5. Replace valves or oversize,

and/or machine the valve guide
bores
6. Blown head gasket 6. Check head flatness and

replace gasket
7. Incorrect fuel delivery 7. Check injectors and fuel pump
8. Low cylinder compression 8. Replace piston rings or

re-bore/re-sleeve as necessary
Excessive exhaust 1. Oil leak on compressor or 1. Overhaul turbocharger
smoke turbine side of turbocharger,
(where installed)
2. Exhaust leak on exhaust 2. Install new gasket

manifold side of turbocharger,
(where installed)
3. Air cleaner dirty or restricted 3. Clean
4. Excessive fuel delivery 4. Overhaul injection pump and

injectors, check timing
Water temperature gauge 1. Faulty temperature sender 1. Replace sender switch
fails to reach normal oper-
ating temperature 2. Incorrect or faulty thermostat 2. Replace thermostat
3. Faulty water temperature 3. Replace temperature gauge

gauge
10-12

Engine knocks 1. Diluted or thin oil 1. Check crankshaft bearings for
damage, change as required.
Drain and refill with specified
oil and replace filter. Ascertain
cause of dilution
2. Insufficient oil supply 2. Check oil level and top up as
necessary. Overhaul or replace
pump as necessary. Check oil
filter is not clogged
3. Low oil pressure 3. Overhaul pump or relief valve
as necessary
4. Excessive crankshaft end--play 4. Install new thrust bearing liner
5. Flywheel or ring gear run-out 5. Skim flywheel or install new
excessive ring gear
6. Excessive connecting rod or 6. Install new bearing inserts and/
main bearing clearance or regrind crankshaft
7. Bent or twisted connecting 7. Replace connecting rods
rods
8. Crankshaft journals out-of- 8. Regrind crankshaft and install
round undersize bearing inserts
9. Excessive piston-to-cylinder 9. Re-bore/re-sleeve block and fit
bore clearance new pistons
10. Excessive piston ring 10. Install new pistons and rings
clearance
11. Broken rings 11. Install new rings, check bore
and pistons for damage
12. Excessive piston pin clearance 12. Install new piston or pin
13. Piston pin retainer loose or 13. Install new retainer, and check
missing bore/pistons for damage
14. Excessive camshaft play 14. Install new thrust plate
15. Imperfections on timing gear 15. Replace timing gear
teeth
16. Excessive timing gear 16. Replace timing gear
backlash
10-13

Engine overheats 1. Hose connection leaking or 1. Tighten hose connection or
collapsed replace damaged hose.
2. Radiator cap defective or not 2. Replace radiator cap
sealing
3. Radiator leakage 3. Repair/replace radiator
4. Improper fan belt adjustment 4. Readjust fan belt
5. Radiator fins restricted 5. Clean with compressed air
6. Faulty thermostat 6. Replace thermostat
7. Internal engine leakage 7. Check for source of leakage,
replace gasket or defective
parts
8. Water pump faulty 8. Overhaul water pump
9. Exhaust gas leakage into 9. Replace cylinder head gasket.
cooling system Check head for damage or
distortion
10. Coolant aeration 10. Tighten all connections and
check coolant level is correct.
Ensure cylinder head gasket
has not blown
11. Cylinder head gasket 11. Replace cylinder head gasket
improperly installed
12. Hot spot due to rust and scale 12. Reverse flush entire cooling
or clogged water jackets system
13. Obstruction to radiator air flow 13. Remove the obstruction
14. Extended engine idling 14. Do not allow engine to idle for
long periods
15. Oil cooler tube blocked 15. Clean
16. Radiator core tubes blocked 16. Check free flow
10-14

Low oil pressure 1. Engine oil level low 1. Top off as necessary
2 Wrong grade of oil 2. Drain and refill with correct

grade of oil
3 Blocked oil pump sump screen 3. Clean pump screen
4 Oil pressure relief valve faulty 4. Install new relief valve
5 Oil pump worn 5. Replace Oil Pump
6 Excessive oil pump rotor and 6. Overhaul pump

shaft assembly clearance
7 Excessive main or connecting 7. Install new bearing inserts and/

rod bearing clearance or regrind crankshaft
Excessive oil 1. Engine oil level too high 1. Reduce oil level
consumption
2. External oil leaks 2. Replace gaskets and seals,
where necessary. Check
mating surfaces for damage or
distortion
3. Worn valves, valve guides or 3. Replace defective parts

bores
4. Cylinder head gasket leaking 4. Replace gasket. Check head

for damage or distortion
5. Oil loss past the pistons and 5. Replace rings and/or re-bore,
rings or re-sleeve block as
necessary
6. Oil cooler leak 6. Repair/replace oil cooler

assembly
7. Overfilling engine crankcase 7. Reduce oil level
8. Plugged crankcase breather 8. Remove obstruction
9. Failed turbocharger 9. Replace seal

compressor seal
10-15

Engine tends to keep 1. Air cleaner dirty or restricted 1. Clean or replace element
firing after fuel is shut
2. Oil leak on compressor side of 2. Overhaul turbocharger
off
turbocharger (where installed)
Engine power poor or 1. Intake manifold leaking at joint 1. Replace gasket
runs roughly face.
2. Replate manifold
2. Intake manifold cracked
Excessive exhaust 1. Exhaust leak on exhaust 1. Clean or replace element
smoke manifold side of turbocharger.
10-16
DESCRIPTION AND OPERATION A helical gear mounted on the rear of the camshaft,
This chapter describes the overhaul and repair of the drives the engine oil lubrication pump located
new series direct injection diesel engines. These forward of the flywheel.
engines are available in 4-cylinder or 6-cylinder
Naturally Aspirated models. The 4-cylinder is CRANKSHAFT ASSEMBLY
available in Turbocharged form. The engines are of Five main bearings on the 4-cylinder engine, and
similar design, and service procedures are common seven main bearings on the 6-cylinder, support the
throughout the range. A design difference within the crankshaft in the cylinder block.
4-cylinder engine includes the installation of a
dynamic balancer assembly. Manufacturing of the crankshaft involves two types of
materials, depending on the model:
All engines feature cross-flow cylinder heads, with
the intake and exhaust manifolds on opposite sides • Nodular iron with rough cast crank webs
of the cylinder head. The fuel and air combustion
process takes place in the specially designed bowl in • Steel with machine finished crank webs
the crown of the pistons.
A thrust bearing incorporated in the center main
bearing of the crankshaft, controls end-thrust.
CYLINDER HEAD ASSEMBLY
The cylinder head incorporates valves and springs, A heat-shrunk gear on the crankshaft transmits drive
with the valve rocker arm shaft assembly bolted to from the crankshaft, through meshed gears, to the
the cylinder block through the cylinder head. Cylinder dynamic balancer assembly bolted to the bottom of
head retaining bolts are evenly spaced with a the cylinder block. The dynamic balancer ensures
six-point pattern around each cylinder. This ensures smooth engine performance throughout the life cycle
an even clamping load across the cylinder head of 4-cylinder engines. The crankshaft gear also
area. provides timing to the balancer assembly.
Bolted to the head on the right-hand side of the The external damper and the internal balancer attach
engine is the intake manifold, and on the left-hand to the crankshaft pulley. The 6-cylinder engine only
side, is the exhaust manifold. Installed on the outside requires the external damper for smooth running
of the rocker cover are the diesel injectors. Located performance.
behind the radiator in front of the cylinder block, is the
water outlet connections and thermostat. CONNECTING RODS
The valve guides function as an integral part of the Each engine contains a matched set of heavy beam
cylinder head. The valve ports contain special constructed connecting rods, designed with a wedge
replaceable cast alloy valve seats, pressed into each shaped end to reduce reciprocating weight at the end
of the pistons. The connecting rods attach to the
port during manufacture. Repair includes valves with
oversized stems, and oversized valve seats where crankshaft with insert-type copper lead or aluminum
available. tin alloy bearings.
The connecting rods, held in place by an end cap and

Installed with the exhaust valves are positive valve
rotators. Both intake and exhaust valves contain two bolts, contain replaceable bronze bushings on
(umbrella) type oil seals. Adjustment of a self-locking the wedge shaped end, allowing attachment of the
free-floating piston pin.
screw mounted in each rocker arm maintains valve
lash.
PISTONS
CAMSHAFT ASSEMBLY Pistons constructed of aluminum silicon alloy with an
The camshaft operates within replaceable bearings, iron insert for the top ring increase in weight and
three for the 4-cylinder, and five for the 6-cylinder. strength. The combustion chambers recess into the
piston crowns. Each piston contains two compres-
The camshaft idler and timing gears mesh with and
drive, the camshaft drive gear. sion rings and an oil ring, which reduce friction and
increase positive sealing. The rings install above the
A thrust plate bolted to the block, between the piston pin.
camshaft gear and the front camshaft journal,
controls the camshaft end-thrust.
10-17
MANIFOLDS
A cross-flow design aluminum intake and cast iron
exhaust manifold, are on opposite sides of the
cylinder head. This design ensures a balance of heat
distribution within the cylinder head. The configura-
tion of the manifolds minimizes heat transfer to the
intake manifold.
Tubing connects the intake manifold to the air

cleaner. A trapped hole at the rear of the manifold
allows for the installation of ‘thermostart’, or other
cold starting aids.
NOTE: Tightly plug the intake manifold on tractors

that do not have cold start equipment installed, to
prevent ingestion of contaminants. Entry of grit or
other foreign materials will cause considerable
damage to the cylinder bores. In addition, dirt and grit
may enter through the air cleaner connections if not
properly secured.
CYLINDER BLOCK ASSEMBLY

The cylinder block, manufactured from alloy cast
iron, incorporates deep cylinder skirts and water
jackets for cooling the cylinders. The block contains
cylinder bores machined during the manufacturing
process.
The cylinders are vertical, in line, and numbered from

1 to 4 or 6 from the front of the engine to the rear.
Boring of the cylinders will allow the installation of
sleeves and oversized pistons (where available).
The oil pan, which functions as the reservoir for the

engine oil lubrication system, mounts to the bottom
of the cylinder block.
An aluminum cover attaches to the front engine

adapter-plate to protect the timing gear.
TIMING GEARS
During manufacturing the crankshaft timing gear is
heated and press fit onto the front of the crankshaft
with a high degree of accuracy. This enables precise
timing during the life of the engine. The crankshaft
gear drives the camshaft idler gear attached to the
front of the cylinder block. The idler gear then drives
the camshaft and the fuel injection pump via meshing
helical gears. A keyed camshaft gear, bolted to the
front of the camshaft, maintains position. It is
possible to check timing by observing punch marks
on all the gears.
10-18
LUBRICATION SYSTEM camshaft bearing and aligns to a hole in the cylinder

Installed on the rear of the engine block, forward of head. The rotation of the camshaft allows a
the flywheel left side, is a rotor type pump, which controlled intermediate flow of lubrication.
provides engine lubrication, Figure 1. The camshaft
The oil filter support housing supplies oil to the
drives the oil pump, which draws oil from the engine
turbocharger (where installed).
oil pan through a tube and screen assembly.
The oil filter body mounted on the left side of the DIESEL ENGINE STRIP-DOWN
engine block incorporates an integral spring-loaded Certain operations can be performed with the engine
relief valve to prevent over pressurization of the still in the tractor, or unattached at the connection to
system. the front axle support, or separated from the
transmission housing.
The spin-on type oil filter mounted to the support
housing allows easy access at service intervals. Oil Overhaul and repair procedures with the engine
flows from the filter to the main oil gallery, which runs still in the tractor:
the length of the cylinder block and intersects the
camshaft follower chamber. Cylinder head and associated inlet and exhaust
components
The main gallery also supplies oil to the crankshaft
Fuel injection pump and related parts
main bearings and connecting rods. The underside
of the pistons and pins are lubricated by oil pressure Water pump, thermostat, and associated compo-
jets mounted adjacent to each main journal housing. nents
The camshaft drive gear bushing is pressure Oil pump relief valve
lubricated through a drilled passage from the front Oil pan and gasket
main bearing. The gear has small oil passages
Turbocharger
machined on both sides allowing excess oil to
escape. Overhaul and repair procedures with the engine
separated from the front axle:
The pressure lubricated camshaft drive gear
bushing, and oil splashed from the cam follower Front timing cover/timing gear removal
chamber, lubricates the timing gears. Oil pan removal for access to crankshaft and
balancer, bearing shells, piston removal, and oil
A drilled passage from the cylinder block crankshaft pump suction tubing
thrust bearing web to the balancer housing lubricates
the dynamic balancer on 4-cylinder engines. Oil Front pulley and damper assembly
flows through the balancer housing to the drilled
Overhaul and repair procedures with the engine
balancer gear shafts, and onto the bushings in the
separated from the transmission housing, and
balancer gears.
the oil pan removed:
A drilled passage on the cylinder block directs an Crankshaft rear oil seal and carrier removal
intermittent flow of oil to the valve rocker arm shaft
assembly. This is located vertically above the no. 1 Oil pump and drive gear removal
10-19
Engine Oil Flow
1
Engine Lubrication System with Turbocharger Installed
10-20
SEPARATING THE TRACTOR 8. Disconnect the front and rear harness assem-
blies and ground wires. Remove and retain clips.
Separating the engine from the front 9. Disconnect the hydraulic oil cooler tubing at the
transmission center housing. Cap and plug all exposed
1. Raise the right-hand hood assembly and support openings to prevent contamination. Remove and
with rod. Disconnect the battery. retain brackets and clamps for piping.
2. Remove the vertical exhaust muffler (where 10. Disconnect the wires at the starter motor.
installed) to facilitate removing the left-hand 11. Remove the starter motor, and the battery
hood assembly. grounding cable from the retaining bolt.
3. Completely remove the left and right-hand side 12. Remove the bolts securing the fuel tank to the
hood assemblies, Figure 2, by removing center support bracket at the front of the tank.
retaining bolts.
13. Disconnect the throttle control rod from the fuel
4. Remove the exhaust piping on the left-hand side injection pump.
of the engine (where installed) at the clamp
below the auxiliary engine mounted hydraulic 14. Close the fuel shut-off valve and disconnect the
pump. fuel tank-to-fuel filter tube at the tank.
5. Remove the hydraulic piping at the auxiliary 15. Disconnect the fuel filter hose from the fuel
engine mounted pump (where installed). Cap auxiliary tank (where installed).
and plug all exposed openings to prevent 16. Release the fuel leak-off tube from the neck of
contamination. Remove and retain brackets for the filler tube (where installed).
piping.
17. Remove the engine flywheel access cover.
6. Remove the hydraulic steering piping on the
left-hand side of the engine. Cap and plug all 18. Remove the drive shaft guard assembly (where
exposed openings to prevent contamination. installed).
Remove and retain brackets for piping. 19. Remove the drive shaft-to-axle drive flange
7. Disconnect the rear hood assembly from the left, retaining bolts, and remove drive shaft (where
right and center brackets by removing the installed).
retaining bolts.
20026052
10-21
20. Position the tractor Splitting Tool No. 201387,
Figure 3.
21. Remove the engine-to-front transmission buckle
up bolts and pull the front of the tractor away from
the rear of the tractor.
20026053
3
Reconnecting the engine to the front
transmission
Reconnecting the engine to the front transmission
follows the separation procedures in reverse with the
following requirements:
1. When aligning the front of the tractor with the

rear, ensure the correct positioning of all
components to prevent damage from bending,
pinching or crushing.
2. Tighten the top two and bottom two engine
to-transmission buckle up bolts to 373-460 N⋅m
(275-339 ft.-lb.). Tighten the two lower side bolts
to 224-271 N⋅m (165-200 ft.-lb.), and the upper
two side bolts to 190-230 N⋅m (140-170 ft.-lb.),
see Figure 4.
3. Tighten the starter motor to a torque of 27-34 N⋅m
(240-300 in.-lb.).
4. Check for proper installation of all washers,
spacers, brackets and clamps.
5. Check all fuel connections for proper tightening.
6. Bleed air from fuel system and leak check piping.
4
7. Check all hydraulic connections for proper
tightening.
8. Check level of hydraulic oil and replenish as
necessary.
9. Bleed air from hydraulic system and leak check
piping.
10. Perform check of the steering system.
10-22
Separating the engine from the front axle 12. Disconnect the oil cooler piping (7). Cap and plug
assembly all openings to prevent contamination.
1. Correctly discharge the refrigerant from the air 13. Loosen the clamps and disconnect the upper
conditioning system (where installed). (12) and lower (5) hoses from the radiator.
2. Raise the right-hand hood assembly and support Disconnect all other radiator hoses.
with rod. Disconnect the battery (9). 14. Loosen clamps and disconnect intake hose (10)
3. Remove the vertical exhaust muffler (where from air cleaner (2).
installed). 15. Disconnect hoses from the air conditioning
4. Remove the left and right hood assemblies by condenser (where installed).
removing the retaining bolts. 16. Insert wooden wedges between the axle support
5. Remove the air pre-cleaner to facilitate removing (6) and the front axle to prevent movement.
the front hood assembly. 17. Remove the retaining bolts and radiator shell (3)
6. Raise the front hood assembly (1), and support from support.
with rod. 18. Remove the retaining bolt and separate the drag
7. Remove the radiator grill assembly (4). link from the steering arm (where installed).
8. Disconnect the electrical connections to the 19. Remove the hydraulic steering piping on the
horn, headlamps, and air conditioning thermo- left-hand side of the engine. Cap and plug all
stat (where installed). exposed openings to prevent contamination.
Remove and retain brackets for piping.
9. Disconnect clips retaining the front wiring
harness to the front section of the tractor. 20. Remove the drive shaft guard assembly (where
installed).
10. Drain the radiator coolant. Refer to section 10,
Chapter 2 “Cooling System”. 21. Remove the drive shaft-to-axle drive flange
retaining bolts, and remove drive shaft (where
11. Remove the engine fan shroud (14). installed).
10-23
10-24
22. Position the Splitting Tool No. 201387 under the
tractor.
23. Remove the buckle-up bolts and separate the
engine from the front axle.
NOTE: If needed, remove the front axle rear pin and
raise the engine a sufficient distance to facilitate
removal of the front axle.
20026054
6
Reconnecting the engine to the front axle
assembly
Reconnecting the engine to the front axle assembly
follows the separation procedures in reverse with the
1. When aligning the front axle assembly with the

engine, ensure the correct positioning of all
components to prevent damage from bending,
pinching or crushing.
2. Tighten the buckle-up bolts to a torque of
240-298 N⋅m (177-220 ft.-lb.).
3. Check for proper installation of all washers,
spacers, brackets and clamps.
4. Service the air conditioning system as needed
(where installed).
5. Replenish the cooling system. Refer to Section
10, Chapter 2 “Cooling System”.
6. Check all cooling system hoses for leaks.
7. Replenish and bleed air from hydraulic system as
needed.
8. Check the hydraulic oil cooler hoses for leaks.
9. Check that the horn, headlamps and air
conditioning thermostat function properly (where
installed).
10. Check the steering system for proper operation.
10-25
DISASSEMBLY AND OVERHAUL

Dismantle the engine following conventional tech-
niques, or by referring to the following removal
procedure. Refer to the Engine Specifications
section.
NOTE: Replace gaskets, seals, and O-rings when

reassembling components and/or the engine.
7
Right Hand View of Engine
CYLINDER HEAD, VALVES, AND RELATED

PARTS
Removal
1. Disconnect battery and swing battery tray away
from engine.
2. Remove vertical exhaust muffler (where
installed) and the exhaust extension pipe.
3. Remove left and right hood assemblies.
4. Remove air pre-cleaner. Raise and secure the
front hood assembly.
5. Remove engine side panels and guards.
6. Drain coolant from the radiator and engine block.
Refer to Section 10, Chapter 2 “Cooling System”.
7. Shut off heater hose taps. Disconnect and plug
heater hoses.
8. Remove radiator top hose. Cap and plug all
openings to prevent contamination.
9. Remove air cleaner-to-intake manifold tube.
10. Shut off fuel valve at bottom of fuel tank.
11. Disconnect low-pressure fuel pipes and remove
inlet manifold. Cap and plug openings
12. Disconnect and remove fuel pipes to the fuel
injector pump. Cap and plug all openings.
13. Disconnect ‘thermostart’ fuel pipe on the intake
manifold. Cap and plug all openings.
14. Disconnect and remove the ventilation tube on
the rocker cover.
15. Loosen the belt tension and remove the
alternator.
16. Disconnect tacho-drive on the engine front
cover. (where installed)
17. Disconnect all loom connections on engine
harness and secure clear of the engine.
10-26
18. Remove turbocharger assembly, Figure 8. Refer
to Section 10, Chapter 5 “Turbocharger
Overhaul”. Cap and plug all openings.
8
Turbocharger Assembly
1. Turbo Housing
2. Oil Feed/Return Tubes
3. Exhaust Manifold
4. Inlet Manifold
5. Inlet Hoses/Tubes
19. Remove water pump. Refer to Section 10,

Chapter 2 “Cooling System”. Cap and plug all
openings.
20. Remove water pump connector from the engine
cylinder head.
9
Water Pump Assembly
1. Pump Body
2. Pulley Assembly
3. Thermostat
4. Gasket
5. Thermostat Housing
6. Temperature Sender
10-27
21. Remove exhaust manifold (2) and gasket.
22. Remove inlet manifold (1) and gasket
10
Manifold Assembly
1. Inlet Manifold
2. Exhaust Manifold
23. Clean area surrounding the fuel injectors.

24. Remove injection pump-to-fuel injector, and leak
off piping.
25. Remove fuel injectors.
26. Remove rocker cover and gasket.
11
Injector Removal
1. Fuel Injector
2. Mounting Bolts
3. Copper Washer
4. Cork Washer
27. Rotate push rods with the valve closed and check
for bent rods.
12
Push Rod Installation
10-28
ROCKER SHAFT
Disassembly
NOTE: Leave bolts in rocker shaft supports during
removal to retain the support on the shaft.
1. Remove the cylinder head bolts (3), which pass
through the rocker shaft supports (2), Figure 13.
2. Loosen the rocker shaft retaining bolts (cylinder
head bolts) evenly, and alternately. Remove the
rocker shaft assembly.
3. Remove push rods in turn. Place rods in a
numbered rack to maintain the same position for
re-assembly.
4. Remove remaining cylinder head bolts working
inwards and alternately from the cylinder head
end to the center.
13
Rocker Shaft Assembly
1. Spring
2. Shaft Support
3. Retaining Bolt
4. Rocker Arm
5. Shaft
6. Spacer
CYLINDER HEAD
Disassembly
1. Remove the retainer locks (2), springs (3), seals
and rotators with a valve spring compressor (1).
Place parts in a numbered rack, Figure 14.
14
Valve Removal
1. Valve Spring Compressor
2. Retainer Locks
3. Valve Springs
10-29
2. Remove carbon deposits and clean around the
cylinder heads.
15
Valve Assemblies
Intake Valve Exhaust Valve
1. Valve Spring Lock 6. Valve
2. Spring Rotator 7. Spring
3. Seal 8. Seal
4. Spring 9. Spring Rotator
5. Valve 10. Spring Rotator
11. Valve Spring Lock
10-30
Inspection and Repair
NOTE: All cylinder heads produced from January
2000 (engine serial #902291) incorporate new
positive type valve stem seals, part #87801992
(supercedes 87840154). Replace all valve stem
seals when evidence of smoke at start up or oil in the
exhaust exists. Installation of the new type valve
stem seals in a cylinder head produced before
January 2000, requires machining off the valve stem
seat.
1. Leaking and/or discolored cylinder head core
plugs require changing. Remove all old sealant
from the cylinder head before installing new
plugs. Apply sealant G (see Specifications
Table), to the new plug mating faces, and drive
the new plugs into location, Figure 16.
Core plugs required:
4 CYL - four off in the top; one off in the rear of the
cylinder head; three off in the intake face.
6 CYL - six off in the top; one off in the rear of the
cylinder head; five off in the intake face.
16
Core Plug Installation
2. Scrape all gasket surfaces clean. Wash cylinder

head and valve guide bores in a suitable solvent.
NOTE: Before cleaning, remove injector washers.
3. Inspect cylinder head for nicks and burrs on

mating face. Remove with a suitable abrasive
and clean faces after repair.
4. Check cylinder head for flatness in all directions
using a straight edge and feeler gauge. Disparity
should not exceed 0.03 mm (0.001 in.) in any
25.4 mm (1 in.) area, or 0.127 mm (0.005 in.)
overall, Figure 17.
5. Perform the following check for a resurfaced 17
cylinder head. Place the cylinder head (without Cylinder Head Flatness
the gasket) on the cylinder block, and install bolts 1. Straight Edge
hand tight. Ensue all bolt faces seat. 2. Feeler Gauge
6. Install rocker shaft supports with long bolts.

Using a feeler gauge, check clearance between
underside of bolt heads and cylinder head or
rocker shaft support.
7. A bolt that bottoms out allows the insertion of a
0.25 mm (0.10 in.) feeler gauge under the bolt
head. To correct, increase the cylinder block
thread using a 9/16--13 UNC--2A thread tap.
Install the bolts in the holes originally checked in.
10-31
VALVE INSERTS
Cylinder Head Counter Bore
Insert Oversize Exhaust Valve Insert Intake Valve Insert

0.25 mm (0.010 in.) 44.17-44.20 mm (1.739-1.740 in.) 50.01-50.04 mm (1.969-1.970 in.)
0.50 mm (0.020 in.) 44.42-44.45 mm (1.749-1.750 in.) 50.27-50.29 mm (1.979-1.980 in.)
0.76 mm (0.030 in.) 44.68-44.70 mm (1.759-1.760 in.) 50.52-50.55 mm (1.989-1.990 in.)
NOTE: To maintain compression, coordinate

refacing the valve seat with refacing of the valve.
1. Examine the valve seat inserts and reface if

pitted. Replace loose or damaged inserts.
2. To install a new valve insert, the cylinder head
must be counter bored, as described in the above
chart. Chill new inserts in Dry Ice before
installing.
Valve Seat Specifications, Figure 18.
• Valve Seat Angle:

Intake 30.0°--30.30°
18
Exhaust 45.0°--45.30° Valve Seat Dimensions
1. Valve Seat Angle
• Valve Seat Width: 2. Valve Seat Width
Intake 1.9--2.5 mm (0.075--0.098 in.) 3. Valve Head Face to Cylinder Head Depth
Exhaust 1.8--2.3 mm (0.071--0.091 in.)
• Valve Head Face to Cylinder Head Face Depth:

Intake 0.86--1.32 mm (0.034--0.052 in.)
Exhaust 1.2--1.6 mm (0.047--0.063 in.)
NOTE: On occasion, oversized valve inserts with a

diameter of 0.25 mm (0.010 in.) and 0.5 mm (0.020
in.), are installed during manufacture. Cylinder
Heads with oversize inserts are stamped SO10/OS,
SO2O/OS, on the exhaust manifold side in line with
the valve seat concerned.
3. Check the width of the valve seat inserts, and

reface by grinding to dimensions as needed.
Figure 18.
10-32
4. Use a Dial Indicator to measure the concentricity
of the valve seats. In addition, measure valve
seat to valve guide bore. Total indicator reading
should not exceed 0.051 mm (0.002 in.), Figure
19.
19
Valve Seat Concentricity
1. Dial Indicator
2. Measuring Probe
5. Use a seat cutter to correct any seat eccentricity,

or clean up of pits and grooves. Ensure after
rework that seat width is within specified limits,
Figure 18.
6. Rotate a new or refaced valve in the seat using
engineering blue. Ensure all the blue is
transferred to the valve head protrusion. If any
blue remains below or around the seat, raise or
lower the seat accordingly, Figure 20 in the
following manner:
• Exhaust Valve - Raise by using 60 degree
grinding wheel on surface of seat bottom,
lower by using 30 degree grinding wheel on
surface of seat top. 20
Raising and Lowering of Valve Seats
1. Lowering the Valve Seat
2. Raising the Valve Seat
• Intake Valve - Raise by using 45 degree

grinding wheel on surface of seat bottom,
lower by using 15 degree grinding wheel on
surface of seat top.
21
Critical Valve Points
1. Valve Land Edge
2. Valve Head
3. Valve Face Angle
4. Valce Face
5. Valve Stem
6. Valve Tip
10-33
VALVE GUIDES
1. Use a telescopic gauge and a micrometer, to
measure the valve guide bore clearance. Check
for a maximum clearance of 0.023-0.069 mm
(0.0009-0.0027 in.) on the intake valve stem; and
0.048-0.094 mm (0.0019-0.0037 in.) on the
exhaust valve stem, Figure 22.
NOTE: Production cylinder heads may have one or
more machined, oversize valve guide bores, or
valves installed 0.38 mm (0.015 in.). Such cylinder
heads have 15 or VO15OS stamped on the cylinder
head, exhaust manifold side, adjacent to the valve
concerned.
22
Measuring the Valve Guide Bore
2. Ream out the valve stem guide as per the
1. Telescopic Gauge
following reamer and pilot combinations: When
2. Valve Guide Bore
going from a standard valve stem to an oversize,
always use reamers in sequence.
0.076 mm (0.003 in.) oversize reamer and
standard diameter pilot.
0.38 mm (0.015 in.) oversize reamer, and 0.076
mm (0.003 in.) oversize pilot.
0.76 mm (0.030 in.) oversize reamer, and 0.38
mm (0.015 in.) oversize pilot.
NEW VALVE GUIDE STEM SEALS

Introduced in May 2000, a new positive retention 1
garter-spring type valve stem seal (1), part number
87801992, replaced the umbrella type seal on
engine serial no. 902291 and above. Engine
production began preparing for the new seal in 1999,
with the machining of the valve guide outside
diameter.
During engine repair, install the new seals in place of

the umbrella seals on engines where machined valve
guides already exist, or use Tool No. CNH297669 to
machine the valve guides on engines produced 50012282
before 1999.
23
10-34
New Valve Guide Stem Seal – Installation
1. Follow all steps for cylinder head disassembly as
described in this manual.
2. Lubricate the valve guide bores with penetrating
oil (1).
1
20016642
24
3. Adjust the valve stem, cutting tool (1) to allow
113.5 mm (4.47 in.) of guide to protrude from the 1
inner cutting edge to the tip of the guide.
4. Place the cylinder head on a clean flat piece of
steel approximately the size of the cylinder head.
Position the cylinder squarely onto the bed of a
drill press and adjust to allow the valve stem
cutting guide to enter the valve guide bore.
Securely clamp the cylinder head to the drill bed.
20016643
25
5. Select a drill speed of 180-200 RPM.
6. Start the drill and slowly lower the cutting tool into
the valve guide bore (1).
1
20016645
26
10-35
7. Continue cutting until the tool bottoms on the
steel plate below the cylinder head. The cutting
tool will only cut the required amount to allow 1
installation of the valve seal.
8. Wash the cylinder head (1) to remove any debris.
20016646
27
9. Remove any sharp edges from the end of the
valve stems (1) and the keeper retaining areas, 1
as they could cut and damage the new seals,
when passing the valve stems through the seals.
10. Install the valves in the head, ensuring to wrap 2
the valve stem end and keeper area with a layer
of thin film plastic or thin tape. This prevents
damage to the valve stem seal during
installation. Carefully install the valve stem seals
(2) and remove the protective material. Re-
assemble the cylinder head following proce-
dures described in this manual.
20016647
28
VALVE SPRINGS
1. Check the square of the valve spring on a flat
surface. The distance from the top of the springs
edge to a flat vertical edge positioned next to it,
should not exceed 1.52 mm (0.060 in.) as shown
in Figure 29.
29
Valve Spring Squareness
1. Measuring Spring Squareness
10-36
2. Check both the free length, and the loaded length
of the valve springs as follows:
Free length 60.7 mm (2.39 in.)
Installed length 47-49.6 mm (1.86-1.95 in.)
Loaded length 48.26 mm (1.9 in.) using a weight
of 28-31 kg (61-68 lbs.)
Loaded length 35.69 mm (1.4 in.) using a weight
of 61-69 kg (135-153 lbs.)
3. Ensure the valve spring retainer locks are in good

condition, and replace if worn or damaged.
ROCKER SHAFT
Inspection
1. Check the internal and external diameters of the
rocker shaft for signs of wear or damage.
Thoroughly clean reused rocker shaft in solvent,
making sure all oil passages are clear before
reassembling.
2. Inspect rocker arm adjusting screws (1),
adjusting screw ball-ends, and push rods (2) for
wear, distortion, nicks and any other visible
damage, Figure 30. Replace defective parts as
needed.
3. Inspect the inside diameter of the rocker arm for
damage or wear. If any of these characteristics
are not to specification replace with new parts.
30
NOTE: Do not attempt to straighten bent push rods,
replace with new.
1. Rocker Arm Adjusting Screw
2. Push Rod
Assembly and Installation

1. Position the shaft identification groove (6)
forward and upward to ensure oil grooves and
holes face downward.
2. Assemble rocker shaft support (5) with long bolts
(1), springs (4), and spacers (3) as illustrated in
Figure 31.
31
1. Bolts
2. Rocker Arm
3. Spacer
4. Spring
5. Rocker Arm Shaft Support
6. Groove at Front of Shaft
10-37
CYLINDER HEAD
Assembly
1. Insert valves into original guide bores. Lap with
a suitable paste. Remove all traces of paste after
lapping.
2. Lubricate all components with clean engine oil
when reassembling. Use a spring compressor to
reassemble the valves, valve springs, retainers,
rotators, and keepers. Install new seals.
3. Insert each push rod into its original position,
ensuring to seat each ball end in its cam follower,
Figure 31.
Installation 4 Cylinder
Installation of the cylinder head assembly and
components follows the removal procedures in
reverse with the following requirements:
1. Install new cylinder head, intake and exhaust

manifold gaskets.
6 Cylinder
NOTE: Ensure correct installation of exhaust
manifold gasket to suit profile of exhaust ports.
2. Tighten the cylinder head bolts in sequence

progressively in three stages, Figure 32.
Stage l 156 N⋅m (115 ft.-lb.)
32
Stage 2 190 N⋅m (140 ft.-lb.) Cylinder Head Bolt Tightening Sequence
Stage 3 217 N⋅m (160 ft.-lb.)
NOTE: Lubricate bolts before assembling. Torque
bolts to specification with the engine cold.
3. Adjust valve lash setting with each piston in turn
at Top Dead Center with rockers free to move, 1
Figure 33.
Intake Valve Lash 0.36-0.46 mm
(0.014-0.018 in.)
Exhaust Valve Lash 0.43-0.53 mm
(0.017-0.021 in.)
NOTE: Set valve lash only when the engine is cold.
33
Setting Valve Lash
1. Adjuster Screw
2. Rocker Arm
3. Valve Stem
4. Feeler Gauge
10-38
4. Install the fuel injectors (1), with new washers (3),
and cork washers (4), Torque mounting bolts (2)
to 23 N⋅m (17 ft.-lb.).
5. Install the injector fuel and leak off pipes with new
washers. Tighten banjo bolts to a torque of 11
N⋅m (8 ft.-lb.).
NOTE: Hold the leak off plastic tubing securing when
tightening to prevent pipes from pivoting.
6. Install exhaust manifold bolts and tighten to a

torque of 38 N⋅m (28 ft.-lb.).
7. Install intake manifold bolts and tighten to a
torque of 35 N⋅m (26 ft.-lb.). 34
Injector Removal
1. Fuel Injector
2. Mounting Bolts
3. Copper Washer
4. Cork Washer
ENGINE FRONT COVER AND TIMING

GEAR
Removal
NOTE: Removing the front cover and servicing the
timing gear requires separation of the tractor. Refer
to Section 10, Chapter 1 “Separating the tractor”.
1. Remove the tensioner and fan belt.

2. Remove the crankshaft pulley bolt and washer.
3. Use Puller (3) Tool No. FNH09539 and Shaft
Protector (1) Tool No. FNH09212 to remove
crankshaft pulley (4), spacer and O-ring. 35
Crankshaft Pulley Removal
4. Disconnect the forward engine mounted hydrau- 1. Shaft Protector
lic pump tubes (where installed). Cap and plug all 2. Bolt
openings to prevent contamination. 3. Puller
5. Drain the engine oil and remove the oil pan. 4. Crankshaft Pulley
6. Remove the retaining bolts and the front cover

with gasket.
36
Timing Gear Cover Removal
1. Timing Cover Gasket
2. Timing Cover
3. Fuel Pump Timing Gear Cover
4. Tachometer Drive Elbow (where installed)
10-39
NOTE: Do not remove the crankshaft timing gear (2),
Figure 37. The gear is heat shrunk on to the
crankshaft and aligned to the crankshaft No. 1 pin to
0.10 mm (0.004 in.). A damaged gear will require a
new crankshaft.
37
Timing Gears
1. Camshaft Gear
2. Crankshaft Gear
3. Camshaft Idler Gear
4. Fuel Injection Pump Drive Gear
7. Use a dial indicator or feeler gauge (1), Figure 38

to measure the backlash between each set of
gears, before removing the timing gears.
8. Rotate the gears and check the backlash at four
equal points on the gears. Replace if the
backlash exceeds the following specifications,
Figure 31:
Backlash to 0.025-0.23 mm
crankshaft gear (0.001-0.009 in.)
camshaft gear (0.001-0.015 in.)
fuel injection pump gear (0.001-0.012 in.) 38
Timing Gear Backlash
1. Feeler Gauge
TIMING GEAR
Removal
1. Use a lever (1) to pry the camshaft gear (3) away
from thrust plate (4). Using a dial indicator or
feeler gauge (2), to check the clearance for
0.076-0.35 mm (0.002-0.014 in.). Install a new
camshaft thrust plate if not within specifications.
See Figure 39.
2. Remove the retaining bolt, camshaft idler gear,
and adapter from the block. Remove the
retaining bolt and camshaft gear.
3. Remove retaining nut and washer from the fuel
injection pump gear, and use a puller to remove 39
the gear from the shaft. Camshaft End Play Measurement
1. Lever
2. Feeler Gauge
3. Camshaft Gear
4. Thrust Plate
10-40
Inspection
1. Wash the gears using a suitable solvent, and
examine gear teeth for wear, burrs, or scratches.
Remove minor marks with a fine abrasive.
Thoroughly clean gears before reassembling.
2. Inspect bushings for damage, and ensure the
camshaft idler gear adapter is free from
obstruction. Check camshaft key and key-way
for damage. Repair or replace as necessary.
Installation
1. Position piston no one at Top Dead Center. Install
the spacer, key, and camshaft gear (1). Torque to
69 N⋅m (51 ft.-lb.), Figure 40.
2. Install the camshaft idler gear (3) to the block,
align timing marks, and torque to 237 N⋅m (175
ft.-lb.), Figure 40.
40
Alignment of Timing Gears
1. Camshaft Gear
2. Crankshaft Gear
3. Camshaft Idler Gear
4. Injection Pump Drive Gear
3. With piston No. 1 at Top Dead Center, assemble

fuel injection pump and new seal. Align mark on
pump flange to the 00 timing mark on the front
plate. Torque to 24 N⋅m (18 ft.-lb.). Install pump
gear with timing marks aligned to idler. Torque to
75-81 N⋅m (55-60 ft.-lbs.), Figure 41.
41
DPS Pump Gear to Camshaft Drive Gear
1. Pump Drive Gear
2. Camshaft Idler
3. Timing Mark
10-41
NOTE: Refer to Section 10, Chapter 3 “Fuel System”
for injection pump timing.
4. Lubricate and install a new seal into the rear of

the cover, using Tool No. T87T-6019-A.
5. Position a new gasket on cover plate.
42
Front Cover Oil Seal Installation
1. Front Cover
2. T87T--6019A
6. Align dowel pins and install cover. Tighten bolts

as follows:
• Torque size 18 UNC – 5/16 in. bolts to 18-24
N⋅m (13-18 ft.-lb.).
• Torque size 16 UNC 3/8 in. bolts to 34-41 N⋅m
(25-30 ft.-lb.).
7. Lubricate the crankshaft and install a new O-ring.
Slide the pulley spacer over the key. Push the
pulley onto the crankshaft completely. Tighten
the retaining bolt to a torque of 284 N⋅m (210
ft.-lb.).
8. Apply a suitable sealant (refer to the specifica-
tions table) to the front and rear housing joints. 43
9. Install a new gasket on the oil pan. Tighten bolts Timing Cover Bolt Torque Sequence
to a torque of 38 N⋅m (28 ft.-lb.).
10. If no other repair required, reconnect the engine
to the front axle assembly. Refer to Section 10,
Chapter 1 “Reconnecting the engine to the front
axle assembly”.
11. Replenish fluid levels.
10-42
OIL PAN
Removal
WARNING
Due to the weight of the oil pan it is
recommended that a hydraulic jack is used to
support and lower the oil pan to the ground.
1. Drain engine oil through oil pan plug and remove

oil level indicator.
2. Remove oil pan bolts including those through
transmission, front support, and lower to ground.

1. Clean gasket material from sump face and clean
sump in a suitable solvent. Inspect sump for
cracks, damaged threads, or damaged sump face.
Installation
1. Installation is the reverse of removal with the
2. Ensure block face is clean and free of gasket
material. Install a new gasket to the front cover
and oil pan. Apply sealer to the front plate, and
rear oil seal return joints.
3. Position the oil pan and install a bolt at each
corner finger tight to hold in position. Install
remaining bolts and torque to 38 N⋅m (28 lb.-ft.).
4. Install oil pan plug and tighten to a torque of 41
N⋅m (30 lb.-ft.)
5. Replenish oil and check pan for leakage.
CONNECTING RODS, BEARINGS,

PISTONS, AND RINGS
Removal
NOTE: The connecting rods and pistons are
removable with the engine installed, once the
cylinder head and oil pan sump are removed. Step 1
is critical when reusing old pistons, to prevent ring
land damage.
1. With the cylinder head removed, clean off any

ridge from the top of the cylinder bores using a
ridge remover.
2. With the piston at the bottom of the stroke remove
the end cap bolts, cap (2), and liner (1). Push the
piston assembly out through the top of the block,
and remove the liner from the connecting rod,
Figure 44. 44
Connecting Rod end Cap Removal
1. Bearing Liner
2. End Cap
10-43
3. Turn the crankshaft and repeat the process for
the remaining pistons. 1
NOTE: Match bearing caps and liners to each
respective connecting rod.
4. Remove snap rings (1) with an expander tool (2),

from each side of the piston, Figure 45 and
remove piston pin (3), Figure 46.
45
Piston Ring Removal
5. Ensure each piston and rod remain matched for

reassembling into the cylinder block, Figure 46.
46
Piston Assembly Disassembled
1. Piston
2. Pin Retainers
3. Piston Pin
4. Connecting Rod
5. Bearing Liners
6. Bearing Cap
7. Retaining Bolts
8. Piston Rings
10-44
Inspection and Repair • Connecting Rod Bushing Internal Diameter
1. Clean the piston and connecting rod assemblies (small end)
in a suitable solvent. Inspect for damage to ring Naturally Aspirated -- 38.113 - 38.120 mm
lands, skirts, or pin bosses. (1.5005 - 1.5008 in.)
2. Check connecting rod components for damage, Turbocharged -- 41.288 - 41.295 mm (1.6255
and place in an alignment fixture (where - 1.6258 in.)
available) to check for distortion. Ensure that any
distortion found is within specification as follows: CONNECTING ROD BUSHINGS
Maximum twist - 0.30 mm (0.012 in.) Repair
Maximum bend - 0.10 mm (0.004 in.)
1. If necessary, replace connecting rod bushing.
3. Check piston pin bushing for damage or wear in Use Tool No. FNH00053, Figure 47 to press out
the following manner: defective bushing, and press in new bushing.
Measure the outside diameter of the piston pin, Remove sharp edges and burrs upon comple-
and inside diameter of the connecting rod tion.
bushing to: NOTE: When installation a new bushing on the
• Piston Pin Outside Diameter smaller end of the connecting rod, position the slot in
Naturally Aspirated -- 38.095 - 38.100 mm the bushing at a right angle to the center line of the
(1.4998 - 1.5000 in.) connecting rod.
Turbocharged -- 41.270 - 41.275 mm (1.6248
- 1.6250 in.) NOTE: Change connecting rods as a matched set.
47
Connecting Rod Bushing Installation
1. Washer 8. Connecting Rod Facing Up
2. Collar 9. Remover Insert 1
3. Installation Insert 1 10. Remover Insert 2
4. Bushing 11. Remover Insert 3
5. Installation Insert 2 12. Connecting Rod Location
6. Pins 13. Washer
7. Fixture 14. Location Plate
10-45
2. When special tooling is not available for the
removal or installation of the connecting rod
bushing, install a standard bushing in the
following manner, Figure 48:
• Manufacture a press bar from suitable bar
stock with the end face angled enough to suit
the connecting rod bushing side face. Place
the connecting rod securely in a bench press.
Position the tool (1) on the bushing (2), and
gently drive the bushing from its position.
Manufacture a guide to assist in aligning the
bar stock during this operation.
NOTE: When installing a new bushing on the smaller
end of the connecting rod, position the slot in the 48
bushing at a right angle to the center line of the Connecting Rod Bushing Fitment
connecting rod. 1. Press Tool
2. Bushing
• Press fit a new bushing using suitable bar 3. Machined Side
stock with an end face machined flat. Use a 4. Bushing Slot Alignment
guide as described and gently drive new
bushing into the connecting rod.
• Grind the side faces of the new bushing to
match the side faces of the connecting rod
after installation. Remove all sharp edges
and loose metal shavings from the connect-
ing rod before reassembling on the engine.
3. After installing a new bushing, drill a 4.6 mm
(0.181 in.) hole through the top of the connecting
rod and drill through the existing oil hole, Figure
49.
4. Use an expanding reamer to obtain correct
bushing to piston pin clearance of 0.013-0.025
mm (0.005-0.0010 in.). Remove burrs and metal
shavings before installing on engine.
49
Drilling of Connecting Rod
1. Connecting Rod
2. Drill
10-46
CYLINDER BLOCK
Overhaul
Cylinder block plugs and senders on 4-6 cylinder
engines must be replaced if leaking or rusty. Before
installing new plugs, remove all old sealant off the
block. Install new plugs with a suitable sealant, and
torque as shown in Figures 50, 51.
NOTE: Assemble new parts, with mating faces and

threads coated in sealant, as listed below (refer to
Engine Specifications section):
50
Item Torque Sealant

Plug (1) 8-14 N⋅m (6-10 ft.-lbs.) use sealant C
Switch (2) 24-34 N⋅m (18-25 ft.-lbs.) use sealant E
Plug (3) 68-95 N⋅m (50-70 ft.-lbs.) use sealant F
Plug (4) drive in to block
Plug (5) 24-34 N⋅m (18-25 ft.-lbs.) use sealant E
10-47
51

Plugs (6) drive into block use sealant G
Plug (4) 54-81 N⋅m (40-60 ft.-lbs.)
Plug (5) drive into block use sealant G
Oil Jets (3) replace if damaged - apply engine oil during installation “DO NOT USE SEALANT”
10-48
CYLINDER BORE
1. Check the cylinder bore for scuffing and grooves
around the ring travel area. Check for
irregularities by running a finger over the surface.
Cylinder Bore to Piston Clearance
1. Check the piston-to-bore clearance in the 1
following manner, Figure 52:
• Measure the cylinder bore diameter point A
at 82.6 mm (3.25 in.) from the top of the block
(1).
• Measure the diameter of the piston at right
angles to the piston-pin (2) point B at 97.28
mm (3.83 in.) from the top of the piston.
• Subtract the piston diameter from the bore 2
diameter; the resultant figure must be:
Naturally Aspirated - 0.140-0.165 mm
(0.0055 - 0.0065 in.)
Turbocharged Engines - 0.165-0.190 mm 52
(0.0065 - 0.0075 in.) Piston to Bore Clearance
A. Bore Measurement Point
• Recheck with a new piston if clearance is
greater. When the results exceed limits, B. Piston Pin
measure the remaining cylinder bores and
pistons to establish the greatest clearance.
Based on this figure, re-bore to the next
oversize piston, or sleeve the block and fit
new standard pistons. When the clearance is
less, hone the bore to obtain desired
clearance.
Specifications
Cylinder bore taper:
Max repair limit -0.025 mm (0.001 in.)
Max wear limit -0.127 mm (0.005 in.)
Cylinder bore out-of-round:
Max repair limit -0.03 mm (0.0015 in.)
Max wear limit -0.127 mm (0.005 in.)
Cylinder bore diameter:
110.017-110.08 mm (4.4007-4.4032 in.)
1. Hone the bores if only minor imperfections exist,
bores are within specification, and piston-to-bore
clearance does not exceed 0.165 mm (0.0065
in.) for naturally aspirated or 0.190 mm (0.0075
in.) for turbocharged engines before installing
new piston rings,
10-49
2. Bore or hone cylinder bores not within
specifications, to fit the next oversize piston.
Determine finished bore size by measuring the
piston diameter at right angles to the piston pin,
and adding the appropriate piston-to-bore
clearance.
3. Oversize pistons
0.10 mm (0.004 in.)
0.51 mm (0.020 in.)
2.0 mm (0.040 in.)
4. Bores to take 0.10 mm (0.004 in.) oversize

pistons need only be honed using a rigid hone
with a grit size of 150-220. Clean thoroughly after
boring and honing.
5. Sleeving of the cylinder bores becomes
expedient when oil consumption is high due to
porosity, when replacing sleeves installed in
service, and when the cylinder bore is damaged
beyond re-boring limits.
NOTE: Use only standard pistons when recondition-
ing engines equipped with sleeves.
SLEEVES
Boring and Honing
1. Measure the outside diameter (1) of the sleeve in
several places, and average the dimension.
Counter bore the cylinder block (see step 2)
using the average dimension to obtain a press fit
between bore and sleeve. Interference of sleeve
to the cylinder bore is 0.025-0.076 mm
(0.001-0.003 in.), Figure 53.
53
Cylinder Block Sleeving
10-50
2. Counter bore the cylinder block to a depth of
204.7 mm (8.06 in.) from the block face. Surface
finish of the bore must not exceed 80 microns.
Leave a step at the bottom of the bore a minimum
of 9.7-10.2 mm (0.380-0.400 in.) to allow for run
out of chamfers.
3. Bore the sleeve through to a diameter of
114.3-116.0 mm (4.454-4.456 in.).
4. Clean the cylinder bores and thoroughly dry.
5. Grease the sleeve and press the sleeve home to
the lip in the bore. The top of the sleeve should
protrude through the top of the block 0.127-1.0
mm (0.005-0.040 in.).
6. Bore the sleeve to 110.00-111.72 mm
(4.3985-4.400 in.).
7. Skim the block face and top of sleeves to achieve
the specified flatness of 0.08 mm (0.003 in.), in
any 152 mm (6 in.) area, and 0.03 mm (0.001 in.),
in any 25.4 mm (1 in.) area. Maintain a chamfer
of 45 x 0.5 mm (0.020 in.) in the internal diameter
at the top of the sleeve, to prevent piston damage
on re-assembly.
8. Break the sharp edge at the bottom of the sleeve
before honing.
9. Hone the cylinder bore to:
Grade A 111.777-111.798 mm
(4.4007-4.4015 in.)
Grade B 111.798-111.818 mm
(4.4015-4.4023 in.)
NOTE: Surface finish must average 20 to 30
Microns, with a cross hatch of 35° -55°.
10. Maximum taper is 0.025 mm (0.001 in.) to bottom

of the bore, and maximum oval is 0.038 mm
(0.0015).
10-51
Assembly
NOTE: When replacing pistons, use the same type
piston as the one removed, with the same
identification letters and numbers, as embossed on
the underside of the old piston.
1. With the piston at Top Dead Center, use a dial

indicator (1) to record the piston-to-block height,
Figure 54. Compare measurement with the
following specifications:
Naturally Aspirated 0.28-0.58 mm

(0.011-0.023 in.)
Turbocharged 0-0.3 mm
(00.00-0.012 in.) 54
Piston to Cylinder Block Height
2. Check the cylinder bore-to-piston clearance
using the procedure previously described in this
chapter.
NOTE: Always install new pistons when the cylinder
bore-to-piston clearance exceeds specification.
• Recheck with a new piston if clearance is

greater. When the results exceed limits,
measure the remaining cylinder bores and
pistons to establish the greatest clearance.
Based on this figure, re-bore to the next
oversize piston, or sleeve the block and fit
new standard pistons. If the clearance is
less, hone the bore to obtain the desired
clearance. Follow the procedures previously
described.
10-52
3. Lubricate all of the components with engine oil
and assemble the connecting rod, and piston (1),
with the letter or grade mark on the piston aligned
to the pip on the connecting rod (2). Install the
piston pin and retainers, Figure 55.
55
Piston Connecting-Rod Alignment
1. Piston
2. Piston Rod
4. Check the piston ring (2) gap width, using a feeler

gauge (1), Figure 56, in a vertical position at the
top, middle, and bottom of the bore to:
Top compression ring 0.38-0.84 mm
(0.015-0.033 in.)
2nd compression ring 0.66-1.12 mm
(0.026-0.044 in.)
Oil control ring 0.38-0.84 mm
(0.015-0.033 in.)
56
Piston Ring Gap
1. Feeler Gauge
2. Ring
5. Ensure to use the correct expander (1) to remove

or install piston rings (2), Figure 57.
57
Piston Ring Installation
1. Piston Ring Expander
2. Piston Ring
10-53
6. Use a feeler gauge (2) to check the gap between
a new piston ring (1) and groove, Figure 58.
Top compression ring 0.112-0.155 mm
(0.0044-0.0061 in.)
2nd compression ring 0.099-0.142 mm
(0.0039-0.0056 in.)
Oil control ring 0.061-0.104 mm
(0.0024-0.0041 in.)
58
Piston Ring Side Clearance
1. Piston Ring
2. Feeler Gauge
3. Piston
7. Install the piston rings as shown in Figure 59, 150 grit stone in a 35 to 55 degree cross hatch
however, note the following: pattern. Do not hone more than enough to rough up
the polish on the cylinder bores. After honing ensure
NOTE: Before installing new pistons and rings into a
all parts are clean, and lightly oil the bores.
used cylinder bore, remove the high polish
(de-glaze) from the cylinder walls with a suitable
honing tool, preferably a Flex-Hone, as previously 8. Install top and second compression rings with the
described. Hone and install new rings and pistons word top towards the top of the piston. Stagger
when oil consumption is excessive and the engine the ring gaps a minimum of 40° from each other
has run a minimum of 300-400 hours. If the original on the diameter, and with no gap on the thrust
cross hatch pattern is evident in the cylinder bore side of the piston.
area, do not hone. If honing is required, hone with a
59
Piston Ring Assembly
Naturally Aspirated Turbocharged
1. 1st Compression Ring 1. 1st Compression Ring
2. 2nd Compression Ring 2. 2nd Compression Ring
3. Oil Control Ring 3. Oil Control Ring
10-54
9. New piston rings have been released that
provide improved ring-to-cylinder wall seating,
and more efficient wiping of oil from the cylinder
walls.
New piston ring set description:
Naturally Aspirated Engines

Ring No. 1 (top ring): This is a chrome-plated ring
with a chamfer on one internal corner (2). The ring
must be installed with the internal chamfer towards
the top of the piston (1), Figure 60.
There is an identification circle and the initials RN on

one side of the ring, which face the top of the piston.
Ring No. 2 (middle ring): This is a ‘Napier’ ductile iron

ring (3) having a taper face with a step. Install ring
with the step towards the bottom of the piston, Figure
60. 60
There is an identification circle and the initials RN on 1. Naturally Aspirated Engine Piston
one side of the ring, which face towards the top of the 2. Top Compression Ring
piston. 3. 2nd Compression Ring
4. Oil Control Ring
Oil Control Ring (lower ring): This is a chrome-plated
ring with increased conformability. It is a symmetrical
ring, and may be installed either side up (4), Figure
60.
The ring gaps must be staggered 120 degrees apart

with no gaps on the thrust side of the piston.
10-55
Turbocharged Engines
Ring No. 1 (top ring): This is a ‘Keystone’ type
tapered ring (2), with a chamfer on one internal
corner. Install the ring with the internal chamfer
towards the top of the piston (1), Figure 61.

one side of the ring, which face towards the top of the
piston.
Ring No. 2 (middle ring): This is a ‘Napier’ ductile iron

ring (3) having a taper face with a step. Install the ring
with the step towards the bottom of the piston, Figure
61.
61
one side of the ring, which face towards the top of the 1. Turbocharged Engine
piston. 2. Top Compression Ring
3. 2nd Compression Ring
Oil Control Ring (lower ring): This is a chrome-plated 4. Oil Control Ring
ring (4) with increased conformability. It is a
symmetrical ring, and may be installed either side up,
Figure 61.
The ring gaps must be staggered 120 degrees apart

with no gaps on the thrust side of the piston.
Before installing the new rings on the pistons, install

the top and mid rings in the cylinder, and measure the
end gaps in the bore they are installed in.
Gap clearances for both Naturally Aspirated and

Turbocharged engine pistons should be:
Ring No. 1 – 0.29-0.53 mm (.011-.021 in.)
Ring No 2 – 0.49-0.63 mm (.019-.025 in.)
Oil Control Ring – 0.42-0.76 mm (.017-.030 in.)
10-56
Piston Assembly into Block
1. Select the correct bearing liners, refer to the
following crankshaft section, and install in the rod
and cap. Ensure the liner tang locates in the slots
of the rod and cap.
2. Turn the crankshaft to position No 1, crank pin at
the bottom of the stroke, and lubricate all parts
with new engine oil. Using a ring compressor (2),
and a soft drive (1), slide pistons into bores,
ensuring grade letter on pistons is toward the
front of the engine, Figure 62.
62
Piston and Connecting Rod Installation
1. Soft Drive
2. Ring Compressor
3. Ensure the connecting rod bearing liner seats on

the crank pin with the bearing cap installed to the
connecting rod as a matched assembly. Install
new bolts lubricated with oil, and torque to 149
N⋅m (110 ft.-lb.).
4. Use a feeler gauge (1) to check connecting
rod-to-crankshaft for side clearance of 0.13-0.33
mm (0.005-0.013 in.) as shown in Figure 63.
63
Connecting Rod Bearing Side Clearance
1. Feeler Gauges
BALANCER, MAIN BEARINGS, FLYWHEEL,

AND CRANKSHAFT
NOTE: Installation of replaceable bearing liners in
production ensures correct crankshaft journal-to-
bearing clearance. It is possible to overhaul the main
bearings with the engine in the tractor, however, the
crankshaft can only be serviced after removal from
the tractor.
To remove the flywheel, split the engine from the front

transmission, or remove engine from the tractor.
Refer to Section 10, Chapter 1 “Separating the
Tractor”.
10-57
BALANCER
Removal and Disassembly
1. Remove the oil pan to expose the balancer, and
using a dial indicator gauge (1), check backlash
between crankshaft gear and balancer drive
gear (2), Figure 64. Position the dial plunger to
the face of one of the drive gear teeth, and then
rock the gear to measure backlash. Take
readings at 90_ intervals around the drive gear to 2
0.05-0.30 mm (0.002-0.012 in.). Install new
balancer gear if out of specification. 1
64
Balancer Gear Backlash
1. Dial Indicator
2. Backlash Check at Gears
2. Extract the roll pins (1) securing the shafts (6) to

the housing (2) and disassemble driven gears
(4). Retain washers (3, 5) for reassembly.
65
Balancer Gears
1. Roll Pin 4. Driven Gears
2. Housing 5. Thrust Washers
3. Thrust Washers 6. Shafts
Inspection and Repair Assembly

1. Measure the outside diameter of the shafts and 1. Position balancer gears and thrust washers in
the inside diameter of the gear bushings, and the housing, with timing marks aligned, and
compare to clearance of 0.005-0.020 mm facing the roll pin side of the balancer. Install
(0.002-0.008 in.). Replace shaft and/or gear shafts from the opposite side and secure with roll
assembly if exceeded. pins.
2. Examine shafts and balancer gear teeth for wear 2. Using a feeler gauge measure end-float of
and damage, and replace as necessary. Ensure assembled gears to the specification of
lubrication holes in the shafts are free from 0.20-0.51 mm (0.008-0.020 in.).
obstruction upon re-assembly. 3. Position a dial indicator gauge to the tooth of one
For crankshaft balancer gear repair and assembly, gear, and hold the other firmly. Rocking the free
refer to the crankshaft section of this chapter. gear measure backlash at 90° intervals around
the gears to 0.05-0.25 mm (0.002-0.010 in.).
10-58
Installation
1. Clean all the mating surfaces and install a new
seal (1) around the lubrication passage, Figure
66.
66
Balancer Gear Assembly
1. O-ring
2. Rotate crankshaft until timing mark (1) on

crankshaft gear aligns with timing mark on
balancer drive gear, Figure 67. Position balancer
on dowels install the bolts and torque to 1.08-1 20
N⋅m (80-90 lb.-ft.).
3. Recheck the gear backlash between crankshaft
and balancer gear as previously described.
Reinstall the oil pan if removal is not required for
other maintenance. Refer to “Oil Pan” section of
this chapter. 1
2
67
Timing of Balancer to Crankshaft
1. Gear Alignment Marks
2. Attaching Bolts
10-59
MAIN BEARING
Removal
1. Remove the oil pan and balancer, to gain access
to the crankshaft. When repairing the journal,
remove the main bearing cap, and install only
one set at a time. Leave the remainder securely
in place.
NOTE: If needed, fabricate a liner removal tool if
from a 25.4 mm (1 in x 1/8 in.) split pin. Flatten and
bend the head to conform to angle of 01/passage in
the crankshaft as shown in Figure 68.
2. Install the bearing liner removal tool Figure 68, in
the crankshaft journal oil passage. Turn the
crankshaft counter clockwise until the tool forces
the bearing out of the cylinder block.
68
Bearing Liner Removal Tool

Thoroughly clean bearing liners, journals, and caps
in a suitble solvent. Inspect for wear, scores, burrs,
and other damage. Replace as necessary.
Installation
1. Coat all parts in new engine oil before assembly.
Position the bearing cap with locking tang
towards the camshaft side of the engine and
install the bolts. Torque bolts evenly to 190-203
N⋅m (140-150 ft.-lb.).
2. Align bearing when installing a new thrust
bearing liner. See crankshaft procedures.
10-60
FLYWHEEL
Removal
1. To gain access to the flywheel, separate the
engine at the front transmission. Refer to Section
10, Chapter 1 “Separating the Tractor”.
2. Before removing the flywheel (2), rotate wheel
with a dial indicator (1) attached and check that
total indicator reading measures 0.127 mm
(0.005 in.), Figure 69. Check crankshaft to
flywheel seating if not within specifications.
69
Flywheel Runout
1. Dial Indicator
2. Flywheel

1. Inspect the flywheel ring gear for damage. If
necessary, replace damaged ring following steps
below:
• Cut old ring gear free from the flywheel.
• Clean the mating surfaces of the new ring
gear and flywheel.
• Use temperature-indicating crayons to mark
the side face of the ring gear in six equal
places. Mark with a 204°C (400°F) crayon at
a point 0.5 in (13 mm) below the root of the
teeth, and mark with a 212°C (450°F) crayon
at a point just below root of the teeth.
• Use an oxyacetylene torch with a tip size of
No. 2 maximum, and direct the flame against
the internal face of the gear.
• Quickly place the hot gear on the flywheel,
with flat face against the shoulder on the
flywheel. The gear-to-flywheel run out should
be checked using a dial indicator and should
not exceed a Total Indicator Reading of 0.63
mm (0.025 in.)
Installation
1. Clean the crankshaft rear flange and mating
surfaces and install the flywheel. Torque the bolts
to 197 N⋅m (145 ft.-lb.).
10-61
REAR COVER PLATE

Removal
1. To gain access to the engine oil pump, camshaft
gear, or end of camshaft, remove the oil pan as
previously described, then remove the rear
cover, Figure 70 in the following manner:
• Split tractor. Refer to Section 10, Chapter 1
“Separating the Tractor”.
• With rear of engine exposed, loosen and
remove the twelve retaining bolts (1). Gently
pry oft the cover plate (2).
• Clean off all sealer, remove crankshaft oil
seal, and check for damage or distortion 70
around the sealing faces. Rear Cover Plate Removal
1. Retaining Bolts
2. Cover Plate
Installation
1. Apply a liberal coating of new engine oil on a new
oil seal, and position the rear seal over the end
of the crankshaft. Attach special Tool No. FNH
01301 on the end of the crankshaft using the
three mounting bolts. Tighten evenly and
squarely until the seal is fully seated, Figure 71.
71
Rear Crankshaft Oil Seal Isntallation
1. Rear Oil Seal
2. Tool No. FNH 01301
10-62
2. Ensure rear of block face is clean and free of old

sealer. Install a new gasket and apply a suitable
sealant to faces (1), Figure 72. With the plate in
the recess, install and torque the twelve bolts (2)
in sequence as illustrated in Figure 72 to 16-23
N⋅m (144-204 in.-lb.).
3. Ensure edges of the retainer and seal assembly
are even with edges of the block (3) within 0.08
mm (0.003 in.), Figure 72. If not to specification,
loosen and realign retainer in the recess and
repeat the installation procedure.
72
Rear Cover Plate
1. Sealer Application
2. Retaining Bolts
3. Plate Alignment
4. With new crankshaft seal (1) installed, place a

dial indicator (2) on the end of the crankshaft, and
ensure seal run out is within 0.51 mm (0.020 in.)
Total Indicator Reading, Figure 73.
73
Measuring Crankshaft Seal Runout
1. Crankshaft Seal
2. Dial Indicator
10-63
OIL PUMP
Removal
1. Separate the engine from the front transmission.
Refer to Section 10, Chapter 1 “Separating the
Tractor”.
2. Remove the flywheel, back plate, oil pan and oil
pump tube.
3. Before removing the oil pump, check backlash
(1) of pump gear-to-camshaft gear. Compare
measurement to 0.40-0.56 mm (0.016-0.022 in.)
and replace gears if measurement exceeds
specifications.
74
4. Remove the camshaft gear to expose oil pump. Engine Oil Pump
5. Remove mounting bolts and detach the oil pump 1. Gear Backlash Measurement
from the block, Figure 74. 2. Pump to Block Mounting Bolts
Disassembly
Loosen and remove three pump face-plate to body
mounting bolts for the 4 cylinder engine, and four
bolts for the 6 cylinder engine. Disassemble the
pump and discard the O-rings, Figure 75.
75
Oil Pump Disassembly
1. Retaining Bolt
2. Retaining Bolt 6 Cylinder
3. O-ring Intake Port
4. O-ring Outlet Port

1. Wash all parts in a suitable solvent. Inspect
inside of pump plate and body for excessive wear
and damage. Proceed with the following checks
when finding no discrepancies.
2. Invert pump plate/rotor assembly and place
outer rotor (2) over inner rotor (1). Place a
straight edge (3) across the top of both and insert
a feeler gauge (4) between straight edge and
inner rotor. Check specification to 0.025-0.089
mm (0.001-0.0035 in.), Figure 76.
76
Measuring Oil Pump Rotor
1. Inner Rotor
2. Outer Rotor
3. Straight Edge
4. Feeler Gauge
10-64
3. Place outer rotor (1) in pump body (2). Use a
feeler gauge (3) to check for clearance between
the rotor and body. Replace pump if clearance
exceeds a maximum of 0.55 mm (0.022 in.),
Figure 77.
NOTE: Reduced pressure from a worn pump will
result in reduced engine life.
77
Measuring Outer Rotor to Pump Body
1. Outer Rotor
2. Pump Body
3. Feeler Gauge
Installation
1. Clean parts in a suitable solvent, and coat in new
engine oil. Place outer rotor in pump body and
ensure free rotation. Insert inner rotor and pump
plate assembly into the body and ensure that
shaft is fully seated into bushing.
2. Assemble the front plate to the body using 3 or 4
bolts, and torque to 23-28 N⋅m (204-252 in.-lb.).
NOTE: After tightening, check drive gear rotates
freely by hand for five revolutions. If not, disassemble
and repeat installation procedures.
3. Install a new O-ring to the output tube. Lubricate

78
and insert the pump into the block. Torque bolts
Assembly of Oil Pump
to 23-28 N⋅m (204-252 in.-lb.), Figure 78.
1. Output Tube O-ring
2. Retaining Bolts
3. Oil Pump
10-65
4. Install a new O-ring on suction port. Lubricate
and insert pump intake tube/screen assembly (2)
into oil pump (1) through bottom of engine. Install
new gasket (4) and tighten retaining bolts (3) to
a torque of 27-34 N⋅m (240-300 in.-lb.), Figure
79.
NOTE: It is not necessary to remove plug (5), Figure
79. Installation of the plug occurred during
manufacturing to facilitate machining, and remains in
position throughout engine life.
79
Oil Pump Intake Tube
1. Oil Pump
2. Pump Intake Tube
3. Retaining Bolts
4. Gasket
5. Plug
OIL FILTER SUPPORT ASSEMBLY
Procedure for turbocharged 4-cylinder engine
Removal
1. Unscrew and discard the old oil filter (1). Remove
the oil connections. Cap and plug all openings to
prevent contamination.
2. Remove the retaining bolts (2) and filter support
assembly from the block. Discard O-rings (3),
Figure 80.
80
Oil Filter Assembly 4 Cylinder
1. Oil Filter
2. Filter Housing Support Bolts
3. O-rings
3. Remove the plug (1), spring (2), pressure relief

valve (3), and O-ring (4) Figure 81.

1. Clean all components in a suitable solvent. Allow
parts to dry.
2. Check the pressure relief valve spring free-
length and compare to 52.8 mm (2.08 in.). Check
the compressed length using a weight of 15.6 kgs
(34.3 lbs.) and compare to 37 mm (1.46 in.).
Replace spring if not within specification.
81
Oil Filter Relief Valve
1. Relief Valve Plug
2. Spring
3. Valve
4. O-ring
10-66
3. Inspect all parts for damage or wear and replace
as necessary. An improperly functioning filter
assembly will cause premature engine wear due
to contaminated oil bypassing the filter and
returning to the fuel system.
Installation
1. Lubricate the pressure relief valve and spring,
then insert into the filter housing. Check that
parts move freely.
2. Install a new O-ring on the plug (1) Figure 81 and
install on filter assembly. Tighten the plug to a
3. Install filter support assembly with new O-rings
and tighten retaining bolts to a torque of 42 N⋅m
(31 ft.-lb.).
4. Screw on a new filter element hand tight
5. Install fuel pipes and tighten connections.
6. Check filter assembly and connections for
leakage.
Procedure for Naturally Aspirated 6-cylinder
Engine
Removal
1. Unscrew and discard the old oil filter (1). Remove
the oil connections. Cap and plug all openings to
2. Remove the retaining bolts (2) and filter support
assembly from the block. Discard O-rings (3),
Figure 82.
82
Oil Filter Assembly 4 Cylinder
1. Oil Filter
2. Filter Housing Support Bolts
3. O-rings
10-67
3. Remove and retain the blank-off plate (1), Figure
83, at the oil return-to-engine block port.

parts to dry.
2. Inspect all parts for damage or wear and replace
as necessary. An improperly functioning filter
assembly will cause premature engine wear due
to contaminated oil bypassing the filter and
returning to the fuel system.
Installation 83
1. Install a new O-ring on the connector (4) Figure Oil Filter Relief Valve
83 and install on filter assembly. 1. Relief Valve Plug
2. Spring
2. Install filter support assembly with new O-rings
3. Valve
and blank-off plate. Tighten retaining bolts to a
4. O-ring
3. Screw on a new filter element hand tight
4. Install fuel pipes and tighten connections.
5. Check filter assembly and connections for
leakage.
CRANKSHAFT
Removal
1. Remove the engine from the tractor and place on
engine stand.
2. Remove the following components following the
procedures described in Section 10, Chapter 1:
Flywheel
Crankshaft Pulley
Rear Cover
Front Cover
Oil Pan
Oil Pump Tube
Balancer Assembly
Connecting Rod Caps
3. Rotate the engine on the stand to put engine
bottom face up.
4. Support the crankshaft with hoist.
5. Remove main bearing caps and liners.
6. Remove the crankshaft from the cylinder block.
NOTE: Undersized crankshaft main or crank pin
journals of 0.25 mm (0.010 in.) may be installed in
current engine models. A stamp of 010 MUS and/or
010PUS on one of the crankshaft counterbalance
weights identifies this condition.
1. Clean crankshaft in a suitable solvent. Allow
shaft to dry.
2. Inspect crankshaft timing gear teeth for wear or
damage and replace if necessary.
10-68
3. Measure diameter of each crankshaft journal in
four places (A, B, C, D) Figure 84. The following
determinations can be made:
Measurement A compared with B indicates
vertical taper
Measurement C compared with D indicates
horizontal taper
Measurement A & B compared with C & D
indicates journal out-of-round
84
Measuring Crankshaft Journal
4. If the journal exceeds limits (refer to Engine

Specifications section), refinish journal to the
next undersize bearing.
5. Examine the rear oil seal journal for score marks.
Correct minor imperfections with fine emery
cloth. Severe damage will require replacing the
crankshaft.
BALANCER GEAR
Installation
NOTE: Replaceable gears are not available in all
markets. Consult your dealer for the latest
information. Install a new crankshaft if new gears are
not available.
1. Inspect the balancer gear for wear or damage to

the teeth and replace if necessary.
2. Use a suitable tool to split the gear and remove
from crankshaft. Remove residue and/or burrs
from gear journal.
3. Support the crankshaft in a vertical position nose
down.
4. Heat a new ring gear until reaching a
temperature of 193.3-215.6°C (380-420°F) as
evident in the gear turning blue.
5. Install heated ring gear over crankshaft journals
to mating surface.
6. Align gear tooth to the crankshaft timing mark
within 0.76 mm (0.030 in). Push gear on
completely.
10-69
7. Completely seat gear to the shoulder. Check that
run-out has a Total Indicator Reading of 0.25 mm
(0.010 in.) with a dial indicator, Figure 85.
85
Crankshaft Balancer Gear
1. Balancer Gear
2. Gear Location
3. Dial Indicator
TIMING GEAR
Installation
NOTE: Replaceable gears are not available in all
markets, consult your Dealer for the latest
information. Install a new crankshaft if new gears are
not available.
Inspect the timing gear for wear or damage to the

gear teeth. If damaged or worn replace with a new
gear in the following manner:
1. Heat the gear sufficiently until obtaining free

movement and removal of the gear from the
crankshaft.
2. Place a new gear into Alignment Tool (3) No.
1
FNH00881 and align the gear by the indexing pin
(1). Set the crankshaft locating-pin (2) to 4 or 6
cylinder position before heating, Figure 86.
3
2
86
Crankshaft Gear Installation
1. Gear Indexing Pin
2. 4/6 Cylinder Position Crankshaft Locating Pin
3. Alignment Tool No. FNH00881
10-70
3. Heat the new gear and the tool to 193°-216°C
(380°-420°F). Once heated place the alignment
tool onto the crankshaft key-way and push fully
home.
IMPORTANT: The gear/tool assembly must remain
in position until cooled to ambient temperature.
Moving the gear while hot may dislodge or disrupt
engine timing.
CRANKSHAFT
Assembly
1. Check the crankshaft bearing clearance using a 1
plastigauge (1) as follows:
2. Position a piece of correct size plastigauge 2
across the full width of the bearing cap (2),
approximately 6.35 mm (0.25 in.) off center,
Figure 87.
3. Install cap and tighten bolts to 149 N⋅m (110
ft.-lb.).
4. Remove the cap and use the scale to check the
width of the flattened plastigauge, Figure 87. 87
Checking Bearing Clearance
5. Widest point of gauge establishes the minimum

clearance.
6. Narrowest point of gauge establishes maximum
clearance. The taper equals the difference
between the two readings.
NOTE: Normally main bearing journals wear evenly
and will not be out-of-round, but if a liner which is to
specification is installed in an out-of round journal,
ensure liner suits maximum diameter of journal.
7. When combinations of liners do not produce

specified clearance, refinish crankshaft and
install undersize bearings. See “Engine Specifi-
cations” for bearings available.
IMPORTANT: Engines contain assembled liners of
different materials, however, always use the same
materials on the same journal.
8. Position the bearing liners and caps in the block

and coat with oil. For a refinished crankshaft,
install correct undersize bearing liners.
9. Ensure the bearing surfaces are clean, and that
bearing liner tangs align with slots in the block
and cap.
10-71
10. Align the timing mark on the crankshaft gear with
that of the camshaft idler gear, and install the
crankshaft. Install a thrust bearing cap (1) with
flange type bearing liner (2) first, and install
remaining bearing caps to original locations,
Figure 88.
88
Thrust Bearing Installation
1. Thrust Bearing Cap
2. Liner
11. Tighten all bearing caps (except thrust bearing

cap, leave finger tight) to a torque of 197 N⋅m
(145 ft.-lb.).
12. Pry the crankshaft forward against thrust surface
of bearing. Hold crankshaft forward and pry
bearing cap rearwards taking care not to pry
against flange of bearing liner. This will align thrust
surfaces of both halves of bearing. Keep forward
pressure on crankshaft and tighten bearing cap
bolts to a torque of 197 N⋅m (145 ft.-lb.).
13. Check crankshaft end-play with a dial indicator (1)
gauge. Pry crankshaft towards front of engine and
set dial indicator to zero. Pry crankshaft towards
rear of engine and note reading on dial. Install a
new crankshaft bearing liner if end-play exceeds
0.10-0.20 mm (0.004-0.008 in.), Figure 89.
89
Measuring Crankshaft End Play
1. Dial Indicator
14. If the end-play is less than specification, check

thrust bearing for burrs, scratches, or dirt.
Realign thrust bearing.
15. Install rear crankshaft oil seal as previously
described in rear plate removal.
NOTE: To ensure proper seating, assemble the seal
with the rear plate. Do not pre-install seal into
retainer.
10-72
CAMSHAFT
Removal
NOTE: Maintenance on the camshaft bearings and
tappets requires the removal of the engine from the
tractor.
1. Remove the engine front cover and cylinder head

using procedures described in Section 10,
Chapter 1.
2. Check camshaft end-play (see timing gear
procedures) and remove gear. Install a new
thrust plate before reassembling.
3. After removal of the flywheel and rear cover,
remove the camshaft oil pump drive gear.
4. If camshaft bearings need replacing, then invert
engine on the stand and remove the oil pan.
5. Remove camshaft from the rear of the engine.
NOTE: Camshafts on 4-cylinder engines consist of
three sets of bearing shells, and 6-cylinder engine
camshafts contain five sets.
6. Lift out the tappets (1), Figure 90 and place in a

numbered rack for reassembling.
90
Camshaft Tappet Assembly
1. Tappets

1. Inspect the camshaft journals and lobes for
damage, pitting, or heat discoloration. If any of
these conditions exist, install a new camshaft.
2. Inspect the oil pump drive gear on camshaft for
broken or worn teeth, and mating gear on oil
pump. If any wear or damage exists, replace
gears.
3. Check each tappet for wear or damage, and
tappet bore diameter for 25.15-25.17 mm
(0.9900-0.9910 in.), Figure 90. Replace tappet if
not within specifications.
4. Measure the diameter and out-of-round condi-
tion of bearing journals to 60.693-60.719 mm
(2.389-2.390 in.). Replace camshaft if not within
specifications.
10-73
CAMSHAFT BEARINGS
1. Inspect the camshaft bearings for wear or
damage. Measure the clearance between the
internal diameter of bearing and outside
diameter of respective journal to 0.025-0.076
mm (0.001-0.003 in.).
2. If required, remove and replace bearings using
Drive Set Tool No. FNH01255, Figure 91.
3. To remove, position tool (3) against bearing (1)
and drive bearing from bore.
4. To install new bearing: Align oil holes (2) of new
bearing with holes in block and drive bearing into
bore using tools described in step 2. 91
Camshaft Bearing Removal and Installation
NOTE: A positive alignment check must be made 1. Camshaft Bearing
with crankshaft removed, to facilitate a 4.6 mm 2. Oil Hole
(0.018 in.) rod inserted down the oil passage from the
3. Tool No. FNH01255
crankshaft main bearing. Correctly position liner by
passing end of rod through oil hole in liner.
Installation
1. Apply petroleum jelly to each tappet foot, and
coat tappet body with oil. Install tappets into
original bores.
2. Oil camshaft journals and apply petroleum jelly to
the cam lobes. Install camshaft on engine.
3. Install new spacer and key-way on end of
camshaft.
4. Install camshaft gear, and align the camshaft
gear timing mark. Recheck end-play.
5. Apply a suitable sealant to sealing flange of front
cover plate when reassembling.
10-74
INTAKE AND EXHAUST MANIFOLDS
DESCRIPTION AND OPERATION

The intake and exhaust manifolds mount on opposite
sides of the cylinder head. This configuration
maintains balanced heat distribution within the
cylinder head, and ensures minimum heat transfer to
the intake manifold.
A one-piece, cross flow, cast aluminum, plenum
chamber type intake manifold, attached to the right
side of the engine block, Figure 92, directs air from
the air cleaner into the cylinder head via tubing. A
threaded hole at the rear of the intake manifold
allows for the installation of a thermostart for cold
starting operations.
NOTE: On tractors without the thermostart installed,

a plug prevents the ingestion of dirt and other debris
into the cylinder bores. Ensure the tightness of the
plug at all times.
NOTE: Air cleaner tube connections must be tight at

92
all times to prevent dirt and other debris from entering
the cylinder bores.
A one-piece, cast iron exhaust manifold attached to
the left side of the engine block, Figure 93, channels
spent exhaust fumes into the muffler via tubing.
When installed, the turbocharger mounts the
exhaust manifold. When installed, the turbocharger
mounts to the exhaust manifold.
93
10-75
INTAKE MANIFOLD -- OVERHAUL
Removal
1. Raise right side hood assembly.
2. Disconnect the battery.
3. Remove battery hinged tray, bracket and battery
from tractor.
4. Disconnect fuel system water separator pipes.
Cap and plug openings to prevent contamina-
tion.
5. Remove injector fuel pipes. Cap and plug all
6. Remove wires at the thermostart (where
installed).
7. Remove fuel pipe at the thermostart (where
installed).
8. Remove vacuum pipe at bottom of intake
manifold (where installed).
9. Remove the fuel control linkage bracket.
10. Remove intake tube and clamps.
11. Remove the retaining bolts and remove intake
manifold from the tractor. Discard sealing
gaskets and retaining bolt O-rings.
Inspection
1. Clean the components in a suitable solvent.
Allow parts to dry. Use light grit sandpaper to
remove all traces of old gasket on mating face.
2. Inspect manifold for cracks or obstructions,
3. Inspect joint mating face for imperfections, which
may allow air leakage.
4. Replace manifold if damaged.
10-76
Installation
Installation of the intake manifold follows the removal 1
procedures in reverse with the following require- 2
ments:
1. Replace sealing gasket (1), Figure 94 and

retaining bolt O-rings.
2. Tighten intake manifold retaining bolts to a
torque of 35 N⋅m (310 in.-lb.).
3. Replenish fuel and purge air from fuel system.
94
EXHAUST MANIFOLD -- OVERHAUL
Removal
2. Remove the vertical exhaust muffler (where
installed).
3. Remove the left hood assembly.
4. Remove the retaining bolts and disconnect the
exhaust tube at the manifold. When installed,
remove the turbocharger.
5. Remove the retaining bolts and remove the
exhaust manifold from the tractor. Discard
sealing gasket.
Inspection
1. Clean all components in a suitable solvent. Use
a wire brush to remove carbon deposits. Use light
grit sandpaper to remove all traces of old gasket
on mating face.
2. Inspect manifold for cracks or obstructions,
3. Inspect joint mating face for imperfections, which
may allow air leakage.
4. Replace manifold if damaged.
Installation
Installation of the exhaust manifold follows the
removal procedures in reverse with the following
requirements:
1. Replace sealing gasket (2), Figure 94.

2. Tighten exhaust manifold retaining bolts to a
10-77
TESTING
COMPRESSION TEST PROCEDURE If compression has increased over the original

reading, there is leakage past the rings.
1. Ensure battery performance meets specifica-
tions. During a compression test, if the pressure fails to
2. Warm up the engine by operating for a minimum climb steadily and remains the same during the first
of 30 minutes, at 1200 rev/min. two successive strokes, but climbs higher on the
succeeding strokes, or fails to climb during the entire
3. Stop the engine and remove the fuel injector and test, suspect a sticking valve.
seat washer from no. 1 cylinder.
4. Clean the injector bore, and crank the engine to ENGINE BREAK-IN
blow out any loose carbon particles. (LOW HP APPLICATION)
5. Install an engine compression test gauge into the NOTE: Cylinder walls and piston rings are designed
injector bore, using a new seat washer and the with optimum hardness for long engine life. A light
injector mounting bolts. load during the break-in period, however, may cause
6. Connect the gauge and hose to the adapter. a cylinder wall condition that allows oil to creep due
to failure of the rings to seat. Therefore, perform the
7. Crank the engine. Measure at 200 rev/min. with following procedures if anticipating a “light load”
throttle closed and fuel shut-off solenoid break-in period.
de-energized. Minimum compression must be at
least 290 psi with no more than 50 psi variation
1. Fill engine with recommended break-in engine
between cylinders.
oil.
8. Observe the gauge reading and repeat the
2. Break in engine by operating vehicle on a PTO
compression test for each cylinder.
dynamometer for 5 hours using the following
COMPRESSION TEST READINGS schedule:
1. All cylinder compressions should be uniformly NOTE: To run the engine at 1200 rpm with 20% load,
within 50 psi of each other. means that when performing this test with a tractor
rated at 80 hp; start by placing a load equivalent to 16
2. A reading of more than the 50 psi below the other hp (20% of 80 hp) on the dynamometer, and run it at
cylinders indicates leakage at the cylinder head 1200 rpm for 30 minutes. Similar sequences run at
gasket, piston rings or valves. 40%, 60%, 80% etc., loads. To test 25 minutes at
3. A reading of more than 50 psi above the other 1600 rpm with full throttle means to run the engine at
cylinders indicates excessive carbon deposits on full throttle, and then apply sufficient load on the
the piston and cylinder head. dynamometer to bring the engine speed down to
1600 rpm.
4. Even compression in two adjacent cylinders
indicates a cylinder head gasket leak. Check this 1) 30 minutes at 1200 rpm with 20% load
gasket before condemning the rings or valves.
2) 30 minutes at 1400 rpm with 40% load
COMPRESSION TEST CONCLUSION
3) 30 minutes at 1600 rpm with 60% load
To determine whether the rings or the valves are at
fault, squirt the equivalent of a tablespoon of heavy 4) 30 minutes at 1800 rpm with 80% load
oil into the combustion chamber. Crank the engine to
distribute the oil and repeat the compression test. 5) 30 minutes at 2000 rpm with 90% load
The oil will temporarily seal any leakage past the 6) 30 minutes at 2070 rpm with 100% load and
rings. Obtaining approximately the same reading full throttle
indicates that the rings are performing satisfactorily
and that leakage from the valves is occurring.
10-78
7) 05 minutes at 1200 rpm with no load ENGINE BREAK-IN
(OTHER THAN LOW HP APPLICATION)
8) 25 minutes at 1600 rpm with 100% load and
full throttle 1. Fill engine with recommended break-in engine
oil.
9) 05 minutes at 1400 rpm with no load
2. Break-in engine by operating vehicle on a PTO
10) 25 minutes at 2000 rpm with 100% load and dynamometer for 2 hours and 40 min using the
full throttle following schedule::
TIME LOAD
15 min 0
12) 25 minutes at 1800 rpm with 100% load and 30 min 10%
full throttle 30 min 25%
30 min 50%
13) 05 minutes at 1600 rpm with no load 30 min 75%
10 min 100%
14) 25 minutes at 2000 rpm with 100% load and 05 min 0
full throttle 10 min 100%
NOTE: For units that can not be conveniently run on 3. Check for leaks. Recheck valve lash and reset to
a dynamometer such as Skid Steer, Loaders and minimum lash.
Backhoes: operate units as follows:
4. Operate the vehicle under normal working
1) 05 minutes at 1200 rpm with no load conditions, until recording a total of 50 hours on
the rebuilt engine. Then drain and discard engine
2) 25 minutes at 1200 rpm with 100% load and oil and filter.
full throttle
5. Install new oil filter. Replenish and check oil level
3) 05 minutes at 1200 rpm with no load dipstick. Do not overfill the engine by using the
“FULL” mark on the dipstick. Most engines will
4) 25 minutes at 1200 rpm with 100% load and not burn oil when the level is at the low operating
full throttle range, but will burn oil if continually filled to the
5) 05 minutes at 1400 rpm with no load maximum level.

full throttle

full throttle
3. Check for leaks. Recheck valve lash and reset to

minimum lash.
4. Operate the vehicle in normal working conditions
until recording 50 hours on the rebuilt engine.
Drain and discard engine oil and filter.
5. Install new oil filter, replenish with recommended
oil and recheck level at dipstick. Do not overfill
the engine by using the “FULL” mark on the
dipstick. Most engines will not burn oil with the
level at the low operating range, but will burn oil
if continually filled to he maximum level.
10-79
10-80
SECTION 10 - ENGINE
Chapter 2 - Engine Cooling System
CONTENTS

Cooling System Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10-1

The cooling system ensures correct engine
temperature and performance during vehicle opera-
tion by providing a continuous flow of cooled water
around the cylinder block. It is a recirculating by-pass
type system consisting of full-length water jackets for
each cylinder.
A single ‘V’ type belt from the crankshaft pulley drives

the water pump, which mounts to the front of the
engine. The pump draws coolant from the bottom
tank of the radiator and directs the coolant to the
cylinder block. The coolant then flows through cored
passages to cool the cylinder walls.
Passages in the cylinder head gasket allow coolant
to flow from the cylinder block to the cylinder head.
In addition, cored passages guide coolant to the fuel
injector nozzles.
Coolant passes a thermostat before reentering the

water pump. The thermostat detects temperature
changes and adjusts the flow of coolant accordingly.
To provide a faster warm-up, a by-pass allows the
coolant to re-circulate from the cylinder head to the
block with the thermostat closed. When the engine
reaches normal operating temperature, the thermo-
stat opens and allows cooled water to circulate
through the radiator and back into the block.
1
NOTE: A faulty thermostat will cause the engine to Recirculating Coolant Bypass
operate at temperatures too hot or cold, which will A. Thermostat Closed Bypass in Operation
result in impaired engine performance or damage. B. Thermostat Open Bypass Closed
Coolant within the radiator passes through exposed

cores, as an engine driven fan forces air across the
cores to cool the water.
10-2
COOLING SYSTEM OVERHAUL
Draining the Coolant 2

NOTE: Discharge the coolant into a suitable
container and dispose of in accordance with local
regulations
1. Remove the drain plug (1) on the left-hand side

of the engine block at the rear of the oil filter (2),
Figure 2.
2
Engine Block Drain Plug (left hand side)
2. Open the drain cock (1), Figure 3 at the bottom

of the radiator tank, left side. Discharge the
coolant into a suitable container and dispose of
in accordance with local regulations.
20032155
3
Engine Block Drain Plug (left hand side)
10-3
RADIATOR
Removal
1. Remove the pre-cleaner (where installed).
installed).
3. Remove the left and right hood assembly.
Remove the front hood.
4. Remove the side guards protecting the pulleys,
fan and radiator.
5. Remove the headlamp wires (where installed)
and remove the radiator protective grille.
6. Remove the air cleaner tube by loosing clamps,
7. Disconnect wires at the horn.
8. Remove the air cleaner body clamp, air cleaner,
bracket, support bar, and horn.
9. Remove the hydraulic oil cooler hoses. Cap and
plug all exposed openings to prevent contamina-
tion.
10. Remove the ‘eye’ bolts, spacers, and brackets to
the hydraulic oil cooler. Remove the cooler.
11. Drain the coolant from the radiator. Remove the
radiator cap to speed up draining process.
12. Remove the tube, plastic radiator overflow tank
and bracket.
13. Remove the retaining bolts at the base of the
radiator shell.
14. Remove the retaining bolts connecting the
radiator shell to upper support.
15. Pull the radiator shell forward and remove from
tractor.
16. Loosen the clamps and remove the upper and
lower radiator hoses.
17. Disconnect the engine oil cooler tubes from
bottom radiator tank.
18. Remove the fan shroud retaining screws.
19. Remove the radiator base retaining nuts and
washers and lift the radiator clear of the tractor.
20. Remove the fan shroud.
10-4
Disassemble
1. Disassemble the radiator overflow tank (1),
1
radiator and tubes (2) and fan with shroud (3),
Figure 6.

1. Clean all components and allow parts to dry.
2. Inspect radiator fins for damage or obstruction.
3. Inspect all tubing, O-rings and seals for
deterioration and leakage.
4. Inspect all brackets and supports for cracks and
corrosion.
2
Assembly
Assembly of the radiator and associated compo-
nents follows the disassembly procedures with the
1. Replace all O-rings and seals before assembly.

2. Check all connections, clamps, and fittings for
tightness.
Installation
Installation of the radiator follows the removal
procedures in reverse with the following require-
ments:
1. Replenish the coolant using the recommended

grade and quantity.
2. Operate the engine and check for leakage in the
radiator and tubes. 3
10-5
THERMOSTAT
Removal
1. Drain the cooling system below the level of the
coolant outlet connection.
2. Remove the coolant outlet connection retaining
bolts and slide the connection with the hose
attached to one side.
3. Remove the thermostat and gasket.
5
Coolant Outlet and Thermostat Removal
1. Cylinder Head
2. Gasket
3. Thermostat
4. Coolant Outlet Connection

1. Place the thermostat in a container of water and
heat the water. If the thermostat valve does not
open at 79-83°C (174-181°F) or near the
specified temperature, or fails to close, install a
new thermostat.
Installation
Installation of the thermostat follows the removal
procedure in reverse with the following require-
ments:
1. Coat a new coolant outlet connection gasket with

sealer and position on the cylinder head, or
manifold, before installing the thermostat.
2. Coat the edge of the thermostat with grease, and
install with the heat element located in the
cylinder head.
3. Tighten the thermostat housing retaining bolts to
a torque of 24 N⋅m (216 in.-lb.).
10-6
WATER PUMP
Removal
1. Drain the cooling system - refer to this chapter.
2. Remove the radiator - refer to this chapter.
3. Remove the alternator drive belt.
4. Remove the water tube.
5. Remove the four bolts that pass through the
water pump into the block. Remove the pump.
Disassembly
1. Remove the attaching bolts and remove the fan
from the pump pulley.
2. Use Puller Tool No. FNH09539 and a sleeve
slightly smaller than the pulley shaft to remove
the pump pulley, Figure 8.
6
Water Pump Pulley Removal
1. Pulley
2. Puller Tool No. FNH09539
3. Sleeve
4. Pump Covers
3. Remove the retaining bolts, and separate the

pump covers. Discard the gasket.
4. Use a sleeve with a diameter slightly smaller than
the bearing shaft, to press the shaft and bearing
assembly out of the impeller and pump housing,
Figure 9.
5. Use a suitable sleeve to press the seal assembly
out of the impeller side of the pump housing.
Discard the seal assembly.
7
Water Pump Shaft and Bearing Assembly Removal
1. Sleeve
2. Shaft and Bearing Assembly
3. Impeller
4. Support
5. Front Housing
6. Press
10-7
1. Inspect the impeller (5) for worn or damaged
vanes, and the seal (3) on the rear cover (4),
Figure 10. Replace impeller if required.
8
Water Pump Components
1. Pulley
2. Front Cover
3. Seal Assembly
4. Rear Cover
5. Impeller
6. Bearing Shaft Assembly
2. Inspect the bearing shaft (2), Figure 11, for

scoring or other damage.
3. Check both parts of the pump housing for cracks
or signs of leakage. Replace any defective parts.
9
Water Pump Shaft and Bearing Assembly Installation
1. Sleeve
2. Shaft and Bearing Assembly
3. Front Cover
4. Press
10-8
Assembly
1. To accomplish this step, use a sleeve that can
pass over the shaft and rest on the outside
diameter of the bearing. Press the bearing and
shaft assembly into the housing until the bearing
is flush with the face of the housing. Use a
straight edge to check the final position.
2. Turn the pump housing over and position in a
press with the seal bore facing upward.
3. Coat the outer diameter of the seal flange with a
thin application of thread sealer, and position the
seal assembly over the shaft in the center bore
of the housing.
4. Place Seal Installer Tool No. FNH04672 over the
shaft, and onto the seal assembly. Press the seal
into the bore until the flange seats flush with the
top of the housign, as shown in Figure 12.
10
Water Pump Seal Assembly Installed
1. Press
2. Seal
3. Spring
4. Seal Retainer
5. Seal Installer FNH04672
6. Front Cover
10-9
5. Support the shaft on a block of wood and use a
suitable pipe and press (4) to install the impeller
(1) onto the shaft (3), flush with the rear face of
the front cover (2). Check for proper seating and
flatness with a straight edge.
11
Water Pump Impeller Installation
1. Impeller
2. Front Cover
3. Bearing Shaft
4. Press
6. Support the shaft on a block of wood, and press

the pulley onto the shaft until obtaining a
dimension of 63 mm (2.48 in.) from the rear face
of the front cover, to the center of the pulley
groove. See Figure 14.
7. Install a new gasket, and assemble the front and
rear halves of the pump.
8. Install the fan on the pulley and tighten the bolts
to a torque of 65 N⋅m (48 ft.-lb.).
12
Water Pump Pulley Installation
A. 2.48 in. (63 mm)
1. Sleeve
2. Front Cover
3. Pulley
4. Press
Installation
Installation of the water pump follows the removal
ments:
1. Install a new pump gasket.
2. Adjust the alternator drive belt tension. Refer to
Section 10, Chapter 1.
3. Fill the cooling system, and run the engine to
check for leaks after installing all components.
10-10
SECTION 10 - ENGINE
Chapter 3 - Air Cleaning System
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10-1
SPECIFICATIONS
TORQUE VALUES
Description N⋅ m In.-lb.
Air Cleaner Tube Clamps 2.0 18 in.-lb.
Air Cleaner Retaining Bolts 23 204 in.-lb.
FAULT FINDING
Problem Possible Cause Remedy

Air Cleaner Warning Light illuminates Air Cleaner Filter Elements Clean or replace elements
clogged
Air Cleaner Warning Light illuminates after Vacuum Switch faulty Replace switch
filter service

The air cleaning system consists of a pre-cleaner
(where installed) and a dry type air cleaner assembly.
The air cleaning system removes impurities from the
air, while allowing a sufficient volume of air to enter
the engine, and ensure complete combustion of the
fuel.
Air enters a pre-cleaner (where installed) mounted
on top of the front hood. The air circulates inside the
pre-cleaner and throws the heavier dirt particles to
the outside of the container. The particles then fall to
the bottom of the chafe collector. This action prevents
the larger particles from entering the air cleaner
assembly. The standard pre-cleaner contains a lid (2)
secured by a wing nut (1), and either a glass or plastic
chafe collector (3), and tubing, Figure 1.
1
Pre-Cleaner Assembly
1. Wing Nut
2. Lid
3. Chafe Collector
10-2
From the pre-cleaner, air travels through tubing to the
air cleaner assembly, (3), which mounts under the 1
front hood, forward of the radiator. The air cleaner
assembly consists of an outer and inner filter element
and either a metal or plastic casing. The right-hand 3
end on both type casings removes for access to the
filter elements. The filter elements and end-cap on
metal type casings lock in place with wing nuts. Air
cleaners with plastic casings contain push-on filter
elements with rubber seals that hold the elements in
place. Locking clips secure the end-cap to the plastic
type casing
2
Circulating air enters the air cleaner assembly and
throws the larger particles against the casing. A 2
rubber valve allows for removal of the collected Air Cleaner
particles. The lighter particles collect at the outer filter 1. Hood Stay
element and stay suspended until cleaned out during 2. Hood Stay Support Bracket
servicing. The inner filter, located inside the outer 3. Air Cleaner
filter, prevents dust from passing through to the
engine, and provides filtration if the outer filter fails.
A restricted cleaner switch mounted in the outlet tube

of the air cleaner assembly detects an increase of
vacuum caused by a blocked filter element. The
switch activates a warning light on the instrument
panel. When the restricted cleaner light illuminates
during engine operation, stop the engine as soon as
possible and investigate the cause. Improper airflow
will cause poor engine performance, and the
ingestion of dirt and other particles into the engine
may lead to catastrophic engine failure
Overhaul
NOTE: Removal of the complete air cleaner
assembly from the tractor requires the removal of the
front hood.
Removal
1. Remove the pre-cleaner (where installed).
2. Raise the front hood and secure with hood stay
(1) and bracket (2), Figure 2.
IMPORTANT: Do not disturb or remove the inner
filter element unless necessary, as the rubber seal
must provide a positive sealing action to prevent
debris from entering the engine.
3. To service an air cleaner with a plastic type

casing, disconnect locking clips and remove
end-cap. Extract the outer filter element by hand.
Only remove the inner filter element if necessary.
10-3
To service an air cleaner with a metal casing,
unscrew wing nut (3) and remove end cap.
Extract the outer filter element (1) by hand. Only
remove the inner filter element if necessary.
3
Removal of Outer Element
To remove the inner filter element (1) in metal

casing cleaners, remove the locknut and extract
by hand, Figure 4.
4. Remove the clamps securing the intake tube to
the air cleaner and remove tube.
5. Remove the retaining bolts and remove air
cleaner assembly.
4
Removal of Inner Element

1. Wash the air cleaner casing. Allow casing to dry.
2. Inspect all parts for damage and replace as
necessary.
3. Knock loose particles from the outer filter
element by tapping both ends on a soft surface.
Do not damage filter. Particles such as dust
present on the inside of the outer filter element
necessitate replacing the element.
10-4
WARNING
Wear a face shield and eye protection when
using compressed air to clean a filter element.
4. If desired, use compressed air with a maximum

pressure of 2.1 bar (30 psi) to clean the filter
element. Insert the air nozzle inside the element
and blow the debris from the inside, through the
element and out. Blow debris off the outside of
the element by holding the nozzle a minimum of
150 mm (6 in.) from the element, Figure 5.
IMPORTANT: Never use oil, petrol or solvent to
clean a filter element. Only use water warm enough 5
to touch.
Cleaning Element with Compressed Air
5. Seal the small hole at the end of the filter element

with tape and place the element open end up in
a deep container. Add a non-suds producing
detergent such as automatic dishwashing soap
to the inside of the element. Add warm water until
level rises to the top open end of the element.
Allow the element to soak for a minimum of 15
minutes, Figure 6.
IMPORTANT: Do not allow the filter element to soak
in water and detergent longer than 24 hours or
damage to element will occur.
6
Washing the Element
6. After soaking, gently agitate the element as

shown in Figure 7, but do not allow dirty cleaning
solution to enter, into the inside portion of the
element.
7. Rinse the element in clean cold water. Use a
hose to trickle water from the outside to the inside
of the element, until water comes through clear.
Do not use water under pressure.
8. Remove the tape and shake excess water from
the element. Allow the element to dry naturally,
which will take approximately 24-48 hours.
7
Agitating the Element
10-5
IMPORTANT: Do not attempt to dry the filter element Reassembly
with compressed air. The element must be 1. Clean the inside of the air cleaner casing with a
thoroughly dry before installation to prevent rupture damp, lint-free cloth and reinstall the inner and
during operation. outer element. Ensure that the rubber sealing
rings on the ends are secure and undamaged.
9. Install a new filter element and save the cleaned
element for the next service interval. This step is 2. Refitting of the filter body to the vehicle, is the
critical in preventing the installation of a filter reverse procedure to disassembly.
element that is not completely dry.
10. When the element completely dries, inspect the Installation
paper pleats by passing a light through the Installing the air cleaner assembly follows the
element, and observing for an even unob- removal procedures in reverse with the following
structed pattern of light. Discard element if requirements:
necessary.
11. Clean the inner filter element using compressed 1. When installing the filter elements, ensure the
air only. Follow the procedure described for the rubber sealing rings are completely seated and
secure.
INNER ELEMENT 2. Tighten the air cleaner assembly retaining bolts
to a torque of 23 N⋅m (204 in.-lb.).
1. The inner element should not be disturbed
unless damaged, or contaminated by dirt 3. Tighten the air cleaner tube clamps to a torque of
through failure of the outer element. To clean the 2.0 N⋅m (18 in.-lb.).
inner element, follow the procedure for cleaning
the outer element, using compressed air only.
2. If the inner element is okay leave assembled in
the cleaner body, and change only annually, or
every 1200 hours whichever occurs first.
10-6
SECTION 10 - ENGINE
Chapter 4 - Fuel System
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fuel Injection Pump – Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maximum No-load Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DPS Fuel Injection Pump -- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DPS Fuel Injection Pump Timing (Non-Emissionized Engine) . . . . . . . . . . . . . . . . . . . . . . . 20
DPS Fuel Injection Pump -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DP 200 Series Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DP200 Series Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DP200 Series Fuel Injection Pump Shaft Lock Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Alternative Method for Removing the DP200 Series Fuel
Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Alternative Method for Installing the DP200 Series Fuel
Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Fuel Injector Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Electric Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Main Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Auxiliary Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10-1
SPECIFICATIONS
Description Unit 5610 S 6610 S 7610 S 7010 8010

Main Fuel Tank Capacity
p y liters 80 80 80 80 80
gal 21.1 21.1 21.1 21.1 21.1
Auxiliary
y Fuel Tank Capacity
p y liters 50 50 50 50 50
gal 13.2 13.2 13.2 13.2 13.2
TORQUE VALUES
Thermostart Plug 37 N⋅m 327 in.-lb.
Thermostart Union 10 N⋅m 89 in.-lb.
Thermostart Connector-to-Fuel Injection Pump 11 N⋅m 97 in.-lb.
Thermostart Pipe-to-Connector 10 N⋅m 89 in.-lb.
Fuel Filter Retaining Bolts 30 N⋅m 266 in.-lb.
Fuel Leak-Off Pipe-to-Injector Line 24 N⋅m 212 in.-lb.
Fuel Injector Nozzle Retaining Nut 48 N⋅m 35 ft.-lb.
Fuel Injector Retaining Bolts 22 N⋅m 195 in.-lb.
Fuel Injector Leak-Off Pipe Banjo Bolts 12 N⋅m 106 in.-lb.
Fuel Pipe Gland Nuts 32 N⋅m 283 in.-lb.
Fuel Tank Drain valve 07 N⋅m 62 in.-lb.
Fuel Injection Pump-to-Front Plate Retaining Bolts 24 N⋅m 212 in.-lb.
Fuel Pump Gear Retaining Nut 77 N⋅m 57 ft.-lb.
Fuel Separator retaining Bolts 30 N⋅m 266 in.-lb.
SPECIAL TOOLS
Tool Tool Number Other Tool Number
Kit, Fuel Injection Pump Timing FNH08126 380000081
Socket, Nozzle FNH08126 Nuday 8126
Adapter, Nozzle FNH08124 Nuday 8124
Fuel Injection Pump 5610S 6610S 7610S 7010 8010
8920A360W/361W X
8920A421W X
8920A431W X
8921A481W X X
10-2
FAULT FINDING
DIESEL ENGINES
IMPORTANT: Whenever making a repair, the reason for the cause of the problem must be investigated and
corrected to avoid repeat failures.
The following tables list problems and their possible causes with recommended corrective action.
Fuel not reaching injection pump 1. Restricted fuel filters 1. Check and flush the fuel
filters clean.
2. Air in system 2. Bleed the fuel filters.
3. Fuel leakage 3. Check the fuel lines and
connectors for damage.
Fuel reaching nozzles but engine 1. Low cranking speed 1. Check the cranking speed
will not start
2. Incorrect throttle 2. Check the throttle control
adjustment rod travel
3. Incorrect pump timing 3. Check the pump timing
4. Fuel leakage 4. Check the fuel lines and
connectors for leakage
5. Faulty injectors 5. See injector
troubleshooting
6. Low compression 6. Check the engine
compression
Engine hard to start 1. Low cranking speed 1. Check the cranking speed
3. Restricted fuel filters 3. Replace filters
4. Contaminated fuel 4. Check for water in the fuel
compression
6. Air in system 6. Check for air leaks on the
suction side of the system
Engine starts and stops 1. Fuel starvation 1. Check and flush clean
restricted fuel lines or fuel
filters
3. Restricted air intake 3. Check for restrictions in the
air intake
4. Engine overheating 4. Check cooling system
10-3
Erratic engine operation (surge, 1. Fuel leakage 1. Check the injector lines and
misfiring, poor governor connectors for leakage
regulation)
2. Fuel starvation 2. Check and flush clean
restricted fuel lines or
filters
5. Air in system 5. Bleed the fuel system
6. Faulty or sticking injector 6. See injector
nozzles troubleshooting
7. Incorrect engine timing 7. Check for faulty engine
valves
Engine emits black smoke 1. Restricted air intake 1. Check for restricted air
intake
2. Engine overheating 2. Check cooling system
3. Incorrect timing 3. Check the pump timing
4. Faulty injectors 4. See injector
troubleshooting
compression
6. Incorrect engine timing 6. Check the engine valves
Engine does not develop full 1. Incorrect throttle 1. Check for insufficient
power or speed adjustment throttle control movement
2. Incorrect maximum no-load 2. Check maximum no-load
speed speed adjustment
3. Fuel starvation 3. Check and flush clean
restricted fuel lines and
filters
5. Incorrect timing 5. Check pump timing
6. Low compression 6. Check engine compression
7. Incorrect engine timing 7. Check for improper valve
adjustment or faulty valves
10-4
Low pressure at pump outlet 1. Low or no fuel in tank 1. Refill tank

2. Blocked filter in lift pump 2. Clean filter
3. Actuating Shaft Worn 3. Replace Shaft
4. Pump Worn 4. Replace Pump
Air in the fuel from pump outlet 1. Blocked fuel tank breather 1. Clear blockage
2. Loose fuel connections 2. Check and tighten
3. Fuel Pump Diaphragm 3. Replace Pump
Perforated
4. Fuel pump body seam 4. Replace Pump
Leaking
5. Pump Worn 5. Replace Pump
Engine emits black smoke 1. Faulty injectors 1. Overhaul or replace injectors

Nozzle does not “buzz” while 1. Dirty or sticking needle valve 1. Clean or replace needle valve
injecting and nozzle holder
2. Valve seat leakage 2. Clean or replace valve and
nozzle assembly
3. Damaged nozzle retaining nut 3. Replace retaining nut
Nozzle leak back 1. Worn needle valve 1. Replace needle valve and
nozzle holder
2. Dirty nozzle and/or holder 2. Clean or replace nozzle and
holder
3. Loose nozzle retaining nut 3. Tighten nut
Nozzle opening pressure 1. Adjusting nut loose 1. Tighten nut
incorrect
2. Damaged nozzle or seized 2. Replace needle valve and
needle valve nozzle holder
3. Blocked nozzle holes 3. Clean nozzle
4. Incorrect shims fitted 4. Adjust shim pack
Nozzle seat leakage 1. Dirty nozzle and/or nozzle 1. Clean or replace nozzle and
holder nozzle holder
2. Sticking needle valve 2. Clean or replace needle valve
and nozzle holder
Incorrect spray pattern 1. Dirty nozzle and/or nozzle 1. Clean or replace nozzle and
holder nozzle holder
2. Restricted nozzle holes 2. Clean or replace nozzle and
nozzle holder
3. Damaged needle valve or 3. Replace needle valve and
nozzle nozzle holder
10-5

FUEL SYSTEM
The primary components in the diesel fuel system
include a fuel tank, lift pump, filter assembly,
water/sediment separator, fuel injection pump, fuel
injectors and inter-connecting fuel lines. An air
cleaner removes dirt and contaminants from the air
intake.
Fuel Flow
Non-Emissionized Engine
The fuel tank gravity feeds the water/sediment
separator, as the hand primed lift pump draws the
fuel from the separator into the filter assembly. A
vacuum created by the transfer pump, which forms
an integral part of the fuel injection pump, draws the
fuel from the lift pump and filter assembly to the inlet
port of the fuel injection pump.
The fuel injection pump delivers fuel at high pressure

to each injector, while using extra fuel from the
transfer pump for cooling and lubrication. The fuel
used for cooling and lubrication circulates to the fuel
tank, via a fitting on the injection pump governor-con-
trol housing and injector leak-off line. Excess fuel
leaking past the needle valves of the injectors also
returns to the fuel tank through the leak-off line.
Emissionized Engine
The fuel flow within the emissionized engine differs
in that an electric lift pump feeds fuel to the fuel
injection pump.
10-6
FUEL SYSTEM
1
Non-Emissionized Engine Fuel System
1. Injectors 6. Fuel Filter

2. Water/Sediment Separator 7. Hand Primer
3. DPS Fuel Pump 8. Throttle Control Cables
4. Electric Fuel Shut Off Solenoid (where installed) 9. Fuel Shut Off Tap
5. Injector High Pressure Feed Pipes 10. Cold Weather Thermostart
10-7
Fuel Flow Shut-Off
All Engines
Fuel injection pumps provide an electrical means to
shut-off fuel flow with a ’fuel shut-off’ solenoid, or a
mechanical means (where installed) with a ‘pull to
stop’ lever.
The key-start ignition switch, located on the rear

hood assembly, operates the electric fuel shut-off
solenoid (2), Figure 2. With the ignition switch in the
OFF position, a spring-loaded plunger in the solenoid
prevents fuel from entering the injection pump
through the main feed port. In the ON position, an
internal coil energizes the magnetized plunger, 2
drawing the plunger up into the body of the solenoid, Injection Pump Fuel Shut Off
allowing fuel back into the injection pump. 1. Fuel Shut Off Lever (where installed)
2. Fuel Shut Off Solenoid
A cable operated from the rear hood assembly,
controls the mechanical ‘pull to stop’ lever (1), Figure
3, on the fuel injection pump (where installed).
Pulling the cable outward causes the lever to stop
fuel flow within the injection pump, and the engine
ceases operation from a lack of fuel.
10-8
FUEL SYSTEM COMPONENTS

The non-emissionized engine fuel system consists of
the following components:
• Main Fuel Tank
• Auxiliary Fuel Tank (where installed)
• Fuel Tank Senders
• Fuel Quantity Gauge
• Fuel Shut-off Relay
• Fuel Shut-off Solenoid
• DPS Fuel Injection Pump
• Hand Primed Lift Pump
• Fuel Filter Assembly
• Fuel/Water Separator
• Fuel Control Hand Throttle
• Fuel Control Foot Pedal
• Thermostart Plug
• Fuel Injectors
• Fuel Hoses and Tubes
The emissionized engine fuel system consists of the

following components:
• Main Fuel Tank
• Auxiliary Fuel Tank (where installed)
• Fuel Tank Senders
• Fuel Quantity Gauge
• Fuel Shut-off Solenoid
• DP 200 Series Fuel Injection Pump
• Fuel Injection Pump Harness
• Electric Lift Pump
• Fuel Filter Assembly
• Auxiliary Fuel Filter Assembly
• Fuel/Water Separator
• Fuel/Water Separator Warning Switch
• Fuel/Water Separator Warning Light
• Fuel/Water Separator Harness
• Fuel Control Hand Throttle
• Fuel Control Foot Pedal
• Thermostart Plug
• Cold Advance Thermostatic Switch
• Cold Advance Wax Plug
• Fuel Injectors
• Fuel Hoses and Tubes
10-9
Main Fuel Tank
The main fuel tank (1) located behind the engine
back plate within the rear hood assembly, functions 1
as the fuel system reservoir. A filler neck allows 2
servicing of the tank and a cap prevents the entry of
dirt and other contaminants. The tank contains a vent
for releasing excessive pressure returning from the
fuel injection system. A shut-off valve (2) at the
bottom of the tank prevents fuel flow to the injection
pump when closed, as well as providing an outlet for
draining the tank, Figure 3.
3
Main Fuel Tank
Auxiliary Fuel Tank

The auxiliary fuel tank (1), Figure 4, increases the
quantity of fuel the tractor carries (where installed).
The auxiliary tank mounts under the platform on the
left-hand side, and receives fuel from the main fuel
tank during servicing.
4
Auxiliary Fuel Tank
Fuel/Water Separator
The fuel/water separator mounts on the forward
right-hand side of the engine. The assembly consists
of a cast head, which bolts to the engine and a glass
collecting bowl (5). A bleed screw (1), fuel shut-off
valve (2) and body retaining screws (3) facilitate
maintenance on the assembly.
Fuel enters the separator and flows down into the

glass bowl through the cast head. Once in the bowl
the fuel flows around the edges of the internal
separator cone. Larger, heavier particles of dirt and
water separate from the fuel and sink to the bottom
of the collecting bowl. A drain tap (4) allows for the
removal of water from the bowl when necessary, 5
Figure 5. Sediment and Water Separator
1. Bleed Screw
2. Fuel Shut Off Tap
3. Body Retainer Screws
4. Drain Tap
5. Glass Bowl
10-10
Electric Lift Pump (Emissionized engine)
The electric lift pump (1) mounts on top of the fuel
filter (4) on the right-hand side of the engine. With the
key-start ignition switch in Position 3, the lift pump
draws fuel from the fuel tanks by way of the fuel/water
separator (2) and filter assembly. From the lift pump,
fuel flows to the fuel injection pump, Figure 6.
6
Hand Primed Lift Pump (Non-emissionized
engine)
The hand primed lift pump (1) mounts on top of the
fuel filter (4) on the right-hand side of the engine. This
type of lift pump requires a hand priming of the fuel
system before attempting to start the engine. Hand
priming the lift pump draws fuel from the fuel tanks by
way of the fuel/water separator and filter assembly.
From the lift pump, fuel flows to the fuel injection
pump, Figure 7.
7
Fuel Filter and Lift Pump Assembly
1. Lift Pump
2. Bleed Screw
3. Filter Retainer
4. Fuel Filter Body
Auxiliary Fuel Filter Assembly (Emissionized

engines)
The auxiliary fuel filter assembly (1), located on the
right-hand side of the engine below the fuel injection
pump, provides additional protection from contami-
nants in the fuel. A fuel/water warning switch (2)
mounted on the filter bowl will illuminate the
fuel/water warning light on the instrument panel
when the fuel contains water, Figure 8.
40025677
10-11
Thermostart Plug
The Thermostart system aids the engine in cold
starting conditions. The system consists of a plug (1)
installed in the intake manifold (2), Figure 9, fuel
lines, and an electric circuit within the starting
system. The Thermostart plug receives gravity fed
fuel.
40025682
9
Moving the key-start ignition switch to Position four
energizes the heater coil (2) and the igniter coil (1)
within the Thermostart plug. The heater coil opens an
internal check valve (3), in the plug, allowing fuel to
reach the igniter coil. The igniter coil in the manifold
ignites the fuel, which heats passing air in the engine
intake before entering the combustion chamber.
Releasing the key-start ignition switch de-energizes
the heater coil, causing the check valve to close,
cutting off the fuel supply to the igniter coil, Figure 10.
IMPORTANT: Operating the Thermostart plug

longer than 30 seconds will cause damage to the
plug.
10
Thermostart Assembly
1. Ignitor Coil
2. Heater Coil
3. Ball Check Valve
10-12
Thermostatic Switch and Wax Plug
(Emissionized engine)
The thermostatic switch (1), Figure 11, located on the
thermostat housing at the front of the engine,
increases the cold advance performance of the
emissionized engine.
40025673
11
During engine start-up, the cylinders remain slightly
cool until the engine warms up to normal operating
temperature. During which time, the engine timing
advances slightly to reduce white smoke and
emissions. The cold advance thermostatic switch
detects when the engine reaches the desired
temperature and completes a circuit to a wax plug (1)
on the fuel injection pump, Figure 12. The wax plug
brings the engine back to normal advance.
40025681
12
10-13
DPS Fuel Injection Pump (Non-emissionized
engine)
The non-emissionized engine fuel system incorpo-
rates the DPS distributor type fuel injection pump as
shown in Figure 13. The camshaft drives the
flange-mounted pump via an idler gear on the front
right-hand side of the engine. A double lip seal
prevents engine oil from entering the pump and fuel
from entering the engine lubrication system.
The DPS fuel injection pump consists of a distributing

rotor within a hydraulic head, driven by the pump
drive shaft, and a fuel transfer pump connected to the
rotor. Pressurized fuel lubricates all moving parts
during operation of the pump. 13
DP 200 Series Fuel Injection Pump

The emissionized engine fuel system incorporates
the DP 200 series fuel injection pump as shown in
Figure 14. The sealed DP 200 series pump requires
only minimal service. The fuel shut-off solenoid (1) is
replaceable.
IMPORTANT: A faulty DP 200 series fuel injection

pump requires specialized equipment, and service
by an authorized specialist. Unauthorized repair of
this type of pump on an emissionized engine will
invalidate any existing warranty and may cause the
tractor to break local emission standards and
regulations. 14
10-14
INJECTORS
The fuel injectors (1) mounted in the cylinder head
supply fuel in the form of a spray pattern into the
cylinder bores. The controlled amounts of fuel
ensure optimum engine performance throughout the
operating range.
NOTE: Emissionized and non emissionized injectors

have different characteristics and are not inter-
changeable.
15
FUEL INJECTION PUMP – ADJUSTMENTS
Priming (Pressurizing) the Fuel System
1. Ensure the fuel tank contains a sufficient amount
of fuel.
2. Check all connections for tightness. Ensure the
filter bleed screw (2) is closed.
3. Operate the lift pump hand primer (1) on the filter
head to pump fuel into the filter assembly (4).
Continue to pump the hand primer until feeling
resistance, which indicates a primed system.
16
4. With the throttle in the ‘no-load’ speed position,
operate the starting motor and attempt to start
the engine. If unsuccessful, re-prime the fuel
system and attempt to start the engine again.
IMPORTANT: Do not crank the starting motor
continuously for more than 60 seconds, as doing so
may cause starting motor failure.
NOTE: Prime the fuel system after disconnecting or

replacing fuel system components to expel air in the
system
Emissionized Engine
1. Ensure the fuel tank contains a sufficient amount
of fuel.
2. Check all connections for tightness.
3. With the throttle in the ‘no-load’ speed position,
operate the key-start ignition switch to activate
the electric fuel pump (1). The fuel system will be
primed approximately 1 minute after start-up. A
good indication of a primed fuel system will be a
difference in the audible sound of the system
compared to initial start-up.
NOTE: Prime the fuel system after disconnecting or
replacing fuel system components to expel air in the 17
system
10-15
FUEL INJECTION PUMP IDLE SPEED

ADJUSTMENT
All Engines
1
NOTE: The fuel control pedal and hand throttle
linkages connect behind the steering motor cover on
the right-hand side, and share common linkage to the
fuel injection pump. Therefore, after performing the
fuel injection pump idle speed adjustment, operate
both the foot pedal and the hand throttle to verify
correct operation.
1. Run the engine until reaching the recommended

engine operating temperature.
2. Remove the cotter and clevis pins to the fuel 20012252
control linkage where the short and long rods
attach near the fuel injection pump (1), Figure 18. 18
3. Loosen the locknut and adjust the idle speed stop
screw (1), Figure 19, until obtaining an idle speed
of 700--800 rpm. Tighten the locknut.
4. Reconnect the throttle linkage with cotter and
clevis pins.
5. Recheck idle speed and readjust as required.
6. Ensure that no excessive free-play exists within
the throttle linkage due to worn components. To
determine if free-play exists, move the throttle 1
controls through the foot pedal, and then the
hand throttle. The input to the fuel injection pump
should be immediate as evident in the engine
rpm lowering or increasing. 19
10-16
FUEL INJECTION PUMP MAXIMUM

NO-LOAD SPEED ADJUSTMENT
All Engines
NOTE: The fuel control pedal and hand throttle link-

ages connect behind the steering motor cover on the
right-hand side, and share common linkage to the
fuel injection pump. Therefore, after performing the
fuel injection pump idle speed adjustment, operate
both the foot pedal and the hand throttle to verify cor-
rect operation.
1. Run the engine until reaching the recommended
engine operating temperature.
2. Remove the cotter and clevis pins to the fuel
control linkage where the short and long rods
attach near the fuel injection pump (1), Figure 18.
3. Loosen the maximum no-load speed stop screw
(1), Figure 20.
4. Set the throttle linkage to the maximum no-load
speed as shown in Table 1. Adjust screw as
needed to obtain specification.
TABLE 1
5610S 6610S 76103 7010 8010 1

Maximum 2375 2375 2375 2250 2250
No-load rpm rpm rpm rpm rpm
Speed
5. Tighten the locknut to a torque of 7--9 N⋅m (60--84 20

in.-lb.) and secure with locking sleeve and
sealing wire.
6. Reconnect the throttle linkage with cotter and
clevis pins.
7. Recheck maximum no-load speed and readjust
as required.
8. Ensure that no excessive free-play exists within
the throttle linkage due to worn components. To
determine if free-play exists, move the throttle
controls through the foot pedal, and then the
hand throttle. The input to the fuel injection pump
should be immediate as evident in the engine
rpm lowering or increasing.
10-17
FUEL INJECTION PUMP – REMOVAL DPS Fuel injection Pump (Non-emissionized

engine)
A. Remove the engine timing cover from the
All Engines
front of the engine, forward of the fuel
IMPORTANT: A DP 200 series fuel injection pump injection pump. For models with a mechani-
requires specialized equipment, and service by an cal tachometer type instrument panel, it will
authorized specialist. Unauthorized repair of this be necessary to remove the tachometer
type of pump on an emissionized engine will cable from the front of the timing gear cover
invalidate any existing warranty and may cause the before removing.
tractor to break local emission standards and
regulations. B. Remove the pump timing gear bolt.
1. Disconnect the battery negative (ground) cable. C. Remove the timing gear using a suitable
puller.
2. Clean fuel injection pump and surrounding areas
to before removing from the engine to prevent D. Remove the fuel injection pump retaining
contamination. bolts and remove pump from engine.
3. Disconnect all fuel tubing from the pump. Cap
and plug opening to prevent contamination.
4. Remove the fuel shut-off solenoid connector.
5. Disconnect the throttle control linkage at the fuel
injection pump.
6. Remove the pulley guard on the right--hand side
of the engine (where installed)
7. Remove the fan drive belt.
8. Remove the idler pulley. Refer to Section 10,
Chapter 1.
9. Proceed with Step 9 depending on configuration:
10-18
DP 200 Series Fuel injection Pump
A. Remove the engine timing cover from the
front of the engine, forward of the fuel
injection pump. For models with a mechani-
cal tachometer type instrument panel, it will 1
be necessary to remove the tachometer
cable from the front of the timing gear cover
before removing.
IMPORTANT: Carry out Step B only if reinstalling the

same fuel injection pump without servicing. 2
B. Rotate the engine until obtaining approxi-
mately 40° bottom top dead center compres- 21
sion stroke. Loosen the pump timing gear
bolt, but DO NOT REMOVE GEAR. Rotate
the engine to 28° bottom top dead center
compression stroke and tighten the pump tag
securing bolt to a torque of 13 N⋅m (115
in.--lb.). Position (1) shows the unlocked tag,
and position (2) shows the locked tag, Figure
21.
C. Remove the pump timing gear bolt.
D. Remove the timing gear using a suitable

puller.
E. Remove the fuel injection pump retaining

bolts and remove pump from engine.
10-19
DPS INJECTION PUMP TIMING
(NON-EMISSIONIZED ENGINE)
Timing of the DPS fuel injection pump-to-engine
requires the alignment of the scribed line on the
pump flange to the zero degree mark on the rear of
the engine front plate, as shown in Figure 22.
However, it is also a requirement to establish internal
timing of the DPS type pump while off the tractor to
achieve the correct specifications.
When not internally timing the DPS fuel injection

pump, note the setting of the pump, relative to the
zero degree mark on the rear of the engine front
plate. Mark the plate with a center punch to align with
the scribed line of the pump flange. This mark will 22
facilitate installing an original, new, or reconditioned
pump.
Timing gauge, splined shaft and slotted

arm
Timing gauge, adaptor for D.P.S. fuel

injection pump
D.P.S. Fuel injection pump timing mark,

checking fixture
23
Engine Injection Pump Static Engine

Model Outlet
(Cyl./cu.cm) Timing (Internal) Timing
5610S 4/4400 X 262 10

6610S 4/4400 X 263 10
7610S 4/5000 T X 264 10
7010/8010 6/6600 Z 276 10
10-20
DPS FUEL INJECTION PUMP ENGINE TIMING
MARKS
1. Rotate the engine to approximately 30d Before
Top Dead Center with No.1 cylinder on the
compression stroke, check this at the flywheel
(1).
2. Remove the fuel injection pump from the engine.
APB10008
24
3. Position the tapered splined adaptor (PD 67--2)
(2) into the fuel pump timing gear (1).
25
4. Set the timing gauge arm on tool (MS 67--B) to
the ‘specified’ internal pump timing degrees
marking indicated in Table 1. Then position the
timing tool into the splined Adaptor (PD 67--2),
locating the slotted arm against the timing cover.
5. Rotate the engine slowly until the static engine
timing mark on the flywheel is aligned on the
compression stroke No. 1. i.e 10° .
The timing gauge arm slot indicates the correct
timing position for alignment (of the fuel injection
pump timing mark) when the pump is reas-
sembled. Highlight this point on the engine front
plate.
26
10-21
DPS FUEL INJECTION PUMP

INSTALLATION
1. Install fuel injection pump to front engine plate
with a new o-ring on the pump mounting flange.
2. Install the three injection pump to engine front
plate mounting bolts.
If the pump has not been internally timed, align
the scribed line on the pump flange with the
center punch reference mark previously made
on the rear of the engine front plate.
Tighten the mounting bolts to a torque of 40 N⋅m
(29 ft-lb.).
3. Install the pump drive gear, aligning the gear with

the woodruff key on the pump drive shaft. Also
ensure that the drive gear timing mark aligns with
the gear timing mark.
4. Install the lock washer and retaining nut to the
pump drive shaft and tighten the gear nut to a
torque of 75--81 N⋅m (55--60 ft-lb.)
5. Position a new inspection cover gasket and
install the inspection cover to the engine front
cover. Tighten the retaining bolts.
6. Connect the fuel lines to the injection pump and
tighten.
7. Reconnect the throttle and fuel shutoff controls to
the injection pump.
8. Prime the system using the hand primer lift
pump. Start the tractor and adjust the engine idle
and maximum no-load speeds, see “Adjust-
ments for the DPS Distributor Type Fuel Injection
Pump” in this section.
10-22
Solenoid Shut-off Valve
Removal
Refer to Figure 27.
It is possible to remove the fuel injection pump

solenoid shut-off valve and replace as necessary.
1. Disconnect the battery negative (ground) cable

if not already done.
2. Remove the electrical connectors from the
solenoid shut-off valve terminals.
3. Unscrew the solenoid and remove from the fuel
injection pump complete with the O-ring, piston 27
and spring. Discard the O-ring. Solenoid Shut-Off Valve Components
1. Solenoid Valve
4. Plug the fuel injection pump opening to prevent 2. Rubber O-ring
contamination. 3. Piston
4. Spring
Installation
Installation of the fuel injection pump solenoid
shut-off valve follows the removal procedures in
NOTE: Replace the fuel injection pump solenoid

shut-off valve as a complete, matched assembly.
1. Install a new O-ring on the solenoid valve.

2. Tighten the solenoid shut-off valve into the fuel
injection pump to a torque of 28 N⋅m (248 ft-lb.).
10-23
DP 200 SERIES FUEL INJECTION PUMP

(EMISSIONIZED ENGINE)
Description
The Delphi DP 200 series fuel injection pumps carry
over many of the features from the prior DPS series
pumps, plus have new features to improve
performance and meet emissions standards. For
example:
• The pumps incorporate features to prevent

unauthorized adjustment of the pump-to-engine
timing.
• The fuel injection pump drive shaft is no longer
keyed to the pump drive gear on the engine like
the DPS pumps were. The fuel injection pump
shaft is taper fit to the fuel injection pump drive
gear.
• The pump housing no longer has the elongated
mounting holes or plain round holes.
The new mounting and drive design makes it

necessary to precisely time the fuel injection pump
and the engine, before installing the pump.
An alternate procedure is used for removing and

installing the Delphi DP 200 series fuel injection
pump on engines where the flywheel timing marks
are NOT accessible, or the flywheel does NOT have
timing marks.
NOTE: Because emissionized engines have very

tight fuel injection timing tolerances, you must follow
the procedures in this manual as accurately as
possible. If you do not, the fuel injection system will
be mistimed. The engine will function poorly, and will
not be EPA compliant.
10-24
SPECIAL TOOLS (ALL ENGINES)

To time the engine and lock time the pump, use Fuel
Injection Timing Kit Tool No. 380000081 which
includes:
• Degree Wheel Tool No. 380000410 (1),
Figure 28
1
28
• Pump to Degree Wheel Adapter 380000409 (1),
Figure 29
• Fuel Injection Pump Drive Gear Puller, Figure 30
29
30
Fuel Injection Pump Drive Gear Puller
1. Bolt 5/16 -- UNF x 2 in (51mm), With integral washer (3 3. Holes 0.375 in (9.5mm) dia on 2.2 in (56.87mm) dia
Bolts required) equally spaced material of 0.394 in (10mm) Plate
2. Bolt 3/4 x 16 -- UNC x 2 in (51mm) HRLC P&O Steel.
10-25
The degree wheel and pump-to-degree wheel
adapter are also available as a kit, NH01384, Figure
31. All items shown are part of kit NH01384.
However, you do not need the splined shaft (1), and
DPS timing gauge (2), to lock time the DP200 Series
pumps.
To perform the alternate timing procedure on engines 1

without the engine flywheel timing marks, or the
flywheel timing marks are inaccessible, you will
need: 2
• Fuel Injection Pump Drive Gear Puller 20012272

• Piston Position Tool, Figure 32
31
PISTON POSITION TOOL
50015706
PN: 280929
PN: 9635082
50015706/50016637
32
10-26
• Woodruff Key, Part #72769
• Timing Pointer, 4 Cylinder, Figure 33
4 CYLINDER TIMING POINTER
50015705
50016639
33
10-27
DP200 SERIES FUEL INJECTION PUMP

Removal
NOTE: The direction of engine rotation, clockwise

and counterclockwise, is as viewed from the flywheel
end of the engine.
The fuel injection pump, Figure 34, must be removed
for timing. This process involves setting the engine to
a specified basic timing position, locking the fuel
injection pump drive shaft into position, and
removing the pump.
1. Disconnect the battery negative (ground)

terminal.
2. Clean all dirt from the injection pump and
surrounding areas.
3. Shut off the fuel supply.
34
4. Disconnect the throttle linkage (1), Figure 35, the
fuel shut-off solenoid wire, 2; and the wax motor 1
2
wire, 3. The wax motor is the cold start device.
5. Disconnect all fuel lines from the pump and cap
all openings to prevent contamination.
6. Remove the fan shields, if equipped, located to
the front of the fuel injection pump.
7. Loosen the fan belt tension.
20012252 3
35
8. Remove the engine timing cover (1), Figure 36.
20012261
36
10-28
9. Loosen the cap screw retaining the engine
flywheel inspection cover, and swing the cover
(1), out of the way. The timing marks (2), are
located on the flywheel. There is an arrow
marked above the inspection opening (3),
3
1
Figure 37.
APB10008
2
37
10. Install a socket on the crankshaft pulley retaining
screw (1), Figure 38, and rotate the engine
counterclockwise until the No. 1 piston is 1
approximately 30 degrees Before Top Dead
Center (BTDC) on the compression stroke.
20012255
38
11. If the flywheel indicates that the No. 1 piston is 30
degrees BTDC, and the pump mounting bolts (1),
Figure 39, are accessible through the pump drive
gear (2), the engine is on the compression
stroke. If you can’t see the bolts, rotate the
engine 360 degrees. The pump mounting bolts
should now be accessible through the pump
drive gear. 2
19983010
39
10-29
12. With the No. 1 piston approximately 30 degrees
BTDC on the compression stroke, continue to
rotate the engine counterclockwise until the PUMP TIMING DEGREE CHART
flywheel is exactly at the basic timing as shown
on the “Pump Timing Degree Chart,” Figure 40. Cylinder Basic Pump Lock
13. To ensure accuracy, look straight in at the Timing Degree
stationary marker above the timing opening (1),
Figure 41, and align it with the basic timing mark 4 N/A 29 Degrees BTDC 29 Degrees
on the flywheel.
4 T/C 28 Degrees BTDC 29 Degrees
6 28 Degrees BTDC 40 Degrees
40
14. If the basic timing mark is passed by, back the
flywheel up several degrees to clear backlash out
of the drive gear train. Again attempt to set the
timing exactly at the basic timing mark. Accuracy
in this step is critical. 1
APB10008
41
15. Remove the pump timing gear retaining nut (1),
Figure 42, and washer (2), but do not break the
gear free from the shaft .
19983010
42
10-30
16. Lock the fuel injection pump by loosening the
locking bolt, moving the locking tab to the locked
position, and torquing the locking screw to 13
N⋅m (120 in.-lb.). Figure 43 shows the locking
tab. Callout 1 shows the unlocked position;
callout 2 is the locked position. 1
43
17. Install the puller (1), Figure 44, and break the fuel
injection pump drive gear away from the tapered
pump shaft.
1
NOTE: The gear will remain inside the front cover.
20012257
44
18. Remove the puller, then remove the pump
retaining screws (1), by accessing them through 1
the slots in the pump drive gear (2), Figure 45.
19983009
45
19. Remove the pump and cap all openings so dirt
cannot enter.
10-31
DP200 SERIES FUEL INJECTION PUMP

SHAFT LOCK TIMING
If the engine static timing was set and the pump was
locked before removal, the fuel injection pump
should be properly lock timed. You can use the
procedure that follows to:
• Verify the pump lock timing on a pump that’s
been lock timed and removed from the engine.
• Verify pump timing on a pump that has been
returned from an authorized Delphi distributor, or
received from parts.
• Lock time a pump that has been removed without
being lock timed.
To lock time the fuel injection pump or verify lock

timing:
1. Install the woodruff key, part number 72769 (1),
Figure 46, onto the pump drive shaft. The pump
is driven by the fit of the tapered drive gear to the
tapered drive shaft on the pump. The key shown
is for lock timing the pump only. Do not attempt 1
to install the pump with the key installed.
2. Install the pump to degree wheel adapter
(NH01342) (1), Figure 47, over the shaft in
alignment with the key. Also install the washer
(part number 83918488), 2; and nut (part number
83918492) (3), Figure 25. Hold the adapter
(NH01342) and tighten the nut to 13 N⋅m (10
ft.-lb.). You can use the washer and nut that
retained the pump drive gear to the pump on the 46
engine.
3. Install the collar (4), Figure 25, over the pump.
4
1
2
19983002
47
10-32
4. Set the degree wheel tool (NH01341) (1), Figure
48, at the pump lock degrees shown in the 3
“Pump Timing Degree Chart,” in Figure 18 in the 2
previous section, before the tool is installed on
the pump. Make sure the marker (2), Figure 26, 1
is secured firmly to the degree wheel tool with the
thumb screw, 3.
48
5. Install the degree wheel (1), over the master
spline on the degree wheel adapter, Figure 49.
Do not rotate the pump drive shaft. It should stay
locked at this point.
1
19983005
49
10-33
6. Make sure the slotted marker arm on the degree
wheel (1), Figure 50, aligns with the scribe mark
on the pump, 2.
19983006
50
7. If the slot on the degree wheel does not align with
the scribe mark on the pump, unlock the pump by
loosening the shaft locking bolt (1), Figure 51,
and rotate the degree wheel until the slotted
marker on the degree wheel aligns with the
scribe mark on the pump.
8. Lock the pump by moving the locking tab to the
locked position and torquing the locking screw to
13 N⋅m (10 ft.-lb.).
9. Remove the degree wheel, nut, washer, gear,
key, and guide from the pump.
19983007
1
IMPORTANT: Always remember to remove the key
from the pump. 51
NOTE: If the pump was at a Delphi distributor for any

internal repair or calibration other than just lock
timing, the original reference scribe mark should
have been ground off and a new one made. The
accuracy of the above procedure is based on the
scribe mark on the pump housing being correct.
10-34
INSTALLATION
The following procedure is for installing a fuel
injection pump if the engine flywheel timing marks
are accessible and the pump was removed using the
standard removal procedure.
IMPORTANT: Clean the fuel injection pump drive

shaft taper of all residual oil and dirt as well as the
taper in the fuel injection pump drive gear. Use a
non-residual solvent. This is to prevent possible drive
gear slip when in operation.
1. Ensure the engine is at the proper basic timing

according to the “Pump Timing Degree Chart,”
shown earlier in Figure 43. Install the pump on
the engine using new o-rings, 14437585, on
each bolt before inserting the bolts through the
mounting holes. Failure to use new o-rings on the
mounting bolts may allow engine lubricant to leak
out. Torque the hardware to 20 -- 24 N⋅m (15 -- 18
ft.-lb.).
2. Place the washer and start the nut on the fuel
injection pump drive shaft. Initially tighten the
pump drive gear retaining nut to 20 N⋅m (15
ft.-lb.).
3. Loosen the pump lock screw, move the tab to the
unlocked position (1), Figure 52, and torque the
screw to 13 N⋅m (10 ft.-lb.).
52
4. Full tighten the pump drive gear retaining nut (1),
Figure 53, to 75 -- 81 N⋅m (55 -- 60 ft.-lb.).
5. Connect all fuel lines to the fuel injection pump.
Torque the high pressure gland nuts at the
injection pump to 33 N⋅m (24 ft.-lbs.).
19983010
53
10-35
6. Connect the throttle cable (1), Figure 54, fuel
shut-off solenoid wire, 2; and wax motor wire, 3. 1
2
7. Install the engine timing cover and torque the
hardware to 22 N⋅m (16 ft.-lb.).
20012252 3
54
8. Slip the fan belt back on. Make sure it is routed
properly over the pulleys and fits correctly in the
pulley grooves.
9. Install the fan shields, if equipped, and any other
parts removed to gain access during the
procedure.
10. Swing the flywheel timing inspection cover back
into place and tighten the screw.
11. Connect the battery negative cable.
12. Before starting the engine, turn the key on to
allow the electric fuel pump to run. The lift pump
should lug down when it pressurizes the system.
If the pump does not fill the system with fuel
within 1 -- 2 minutes, shut the key off. On some
units, it may be difficult to prime the system if the
fuel level is low or the fuel was bled out of the
electric lift pump suction line. Fill the fuel tank
first. If the unit still does not prime, some other
method may be required to initially get the fuel to
the lift pump.
10-36
ALTERNATIVE METHOD FOR REMOVING

THE DP200 SERIES FUEL INJECTION PUMP
This procedure is for engines where the engine
flywheel timing marks are NOT accessible or the
flywheel does not have timing marks.
NOTE: The direction of engine rotation, clockwise

and counterclockwise, is as viewed from the flywheel
end of the engine.
The fuel injection pump must be removed for timing.

This process involves setting the engine to a
specified basic timing position, locking the fuel
injection pump drive shaft into position, and
removing the pump.
1. Disconnect the battery negative (ground)
terminal (1), Figure 55.
2. Clean all dirt from the fuel injection pump and
surrounding areas. 1
3. Remove the crankcase ventilation tube.
4. Disconnect all fuel lines from the pump and cap
all openings to prevent dirt from entering.
3171-08
55
5. Disconnect the throttle linkage (1), Figure 56, the
fuel shut-off solenoid wire (2), and the wax motor 1
2
wire, 3. The wax motor is the cold start device.
6. Remove the accessory drive belt. On 4-cylinder
engines, install a wrench on the tensioner pulley
attaching bolt to remove tension from the belt. On
3-cylinder engines, loosen the alternator mount-
ing bolts and move the alternator towards the
engine to remove tension from the belt.
20012252 3
56
10-37
7. On 4-cylinder engines, remove the idler pulley
(1), Figure 57.
1
20012253
57
8. Remove fuel injector bleed off line bolts (1),
Figure 58, from the Number 1 and Number 2 fuel
injectors. Discard the two washers on each banjo 1
bolt.
1
NOTE: In steps 11 -- 25, we will determine the Top
Dead Center (TDC) position of the Number 1 piston,
as well as the engine basic timing position. We will
use the timing pointers listed earlier in the “Special
Tools” section as a reference point and we will mark
the flywheel pulley at the TDC and the basic timing
positions.
58
9. Remove the Number 1 fuel injector’s fuel supply
line and mounting bolts and remove the fuel
injector (1), Figure 59. Discard the cork dust
washer (2), and copper sealing washer, 3. They
will be replaced later.
3 1 2
20012259
59
10-38
10. Install the piston position tool (1), Figure 60, with
the probe 11.0 cm below the base, but DO NOT
1
install the bolts to retain the tool. See Figure 6 for
dimensions of the piston position tool.
20012260
60
11. Remove the fuel injection pump cover (1),
Figure 61.
20012261
61
12. Turn the engine counterclockwise until the piston
position tool rises up (1), Figure 62, indicating the 1
piston is close to Top Dead Center (TDC).
20012277
62
10-39
13. If you can see the pump mounting bolts (1),
Figure 63, through the holes in the pump drive 1
gear (2), the engine is coming up on Top Dead
Center, compression stroke. If you cannot see
the bolts, rotate the engine approximately 360 1
degrees until the tool starts to rise again and the
pump mounting bolts are visible through the drive
gear. 2
14. Rotate the engine clockwise slightly to allow the
piston position tool to drop back down so that the
base of the tool is flat against the top of the head. 1
19983010
63
15. Install two 5/16-18 x 1 inch capscrews (PN
9635884) in the piston position tool, Figure 64,
and torque to 22 N⋅m (17 ft.-lb.).
16. Slowly rotate the engine counterclockwise until
the piston contacts the tool.
20012263
64
17. Install the pointer using the pump cover bolts
holes. Figure 65 shows the 4-cylinder pointer.
20012278
65
10-40
18. Install a 6-inch long piece of tape on the
crankshaft pulley, starting 1 inch counterclock-
wise from the pointer and extending it clockwise,
Figure 66.
20012264
66
19. Mark the tape next to the pointer with the piston
against the piston position tool, Figure 67.
20012265
67
20. Rotate the engine clockwise slowly almost one
turn until the piston again contacts the tool and
mark the tape next to the pointer, Figure 68. The
center of these two points is Top Dead Center
(TDC).
20012266
68
10-41
21. Measure the distance between the two points
using a mechanic’s ruler. Divide the distance by
two and measure this distance from either mark
toward the center. Mark the tape at this point,
Figure 69.
For example:
Distance between the two points where the
piston hit the piston position tool = 41.0 mm (1.61
in) TDC
41.0 mm (1.61 in) divided by 2= 20.5 mm (0.81

in)
So, you would measure 20.5 mm (0.81 in) from 20012267
one of the points toward the center and mark the
tape. This is TDC. 69
22. Mark the TDC point on the flywheel pulley with a

punch, Figure 70.
TDC
20012268
70
10-42
23. Find the specified distance from TDC to the basic
timing mark on the flywheel pulley from the
“Pump Timing Degree Chart” below. Measure
that distance counterclockwise from the TDC
mark on the pulley, Figure 76. Mark the tape at
this point. This is the engine basic timing before TDC
TDC. Use a punch to mark the pulley, Figure 71.

Basic
Timing
Mark
20012269
71
PUMP TIMING DEGREE CHART - ALTERNATE TIMING METHOD
Distance from TDC to Basic Timing

Cylinder Basic Timing Mark on Flywheel Pulley Pump Lock Degree
4 N/A 29 Degrees BTDC 48.9mm +/--0.1mm 29 Degrees
(1.93 +/-- 0.004 in)
24. Remove the piston position tool, install the

injector with a new cork dust gasket (part number
81806277) and a new copper sealing washer
(part number 81873921), and torque the bolts to
22 N⋅m (17 ft.-lb.).
25. Install the fuel bleed off line with a new sealing
washer (part number 81867564) above and
below each fitting, and torque the bolts to 13 N⋅m
(10 ft.-lb.). Tighten the supply tube to the fuel
injector to 32 N⋅m (23 ft.-lbs.).
26. Rotate the engine counterclockwise until the
pointer aligns with the basic timing mark. 20012270
Remove the top bolt from the pointer and swing
it out of the way. 72
27. Remove the pump drive gear nut (1), Figure 73,
and the washer, 2. Make sure the engine does
not rotate. If in doubt, install the pointer and make
sure the pointer aligns with the basic timing mark.
19983010
73
10-43
28. Lock the fuel injection pump by loosening the
locking bolt, Figure 74, moving the locking tab to
the locked position, and torquing the locking
screw to 13 N⋅m (10 ft.-lb.). Callout 1 shows the
unlocked position; callout 2 is the locked position.
1
74
29. Install the puller (1), Figure 75, and break the fuel
injection pump gear away from the tapered pump
shaft.
1
NOTE: The gear will remain inside the front cover.
20012257
75
30. Remove the pump retaining screws (1),
Figure 76, by accessing them through the slots 1
in the pump drive gear, 2.
31. Remove the pump and cap all openings so dirt
cannot enter.
19983009
76
10-44
ALTERNATIVE METHOD FOR INSTALLING

THE DP200 SERIES FUEL INJECTION PUMP
Use this installation procedure if the flywheel timing
marks were not accessible and you used the
alternate method of removing the fuel injection
pump.
NOTE: Remember, the direction of engine rotation,

clockwise and counterclockwise, is as viewed from
the flywheel end of the engine.
1. Install the pointer and ensure the engine is at the

correct basic engine timing mark previously
punched on the crankshaft pulley.
2. Remove the pointer and install the pump on the
engine using new O rings, 14437585, on each
bolt before inserting the bolts through the
mounting holes. Failure to use new o-rings on the
mounting bolts may allow engine lubricant to leak
out. Torque the hardware to 20 -- 24 N⋅m (15 -- 18
ft.-lb.).
3. Place the washer and start the nut on the fuel
injection pump drive shaft. Initially tighten the
pump drive gear retaining nut to 20 N⋅m (15 ft lb).
4. Loosen the pump lock screw, move the tab to the
unlocked position (1), Figure 77, and torque the
screw to 13 N⋅m (10 ft.-lb.).
77
5. Fully tighten the pump drive gear retaining nut
(1), Figure 78, to 75 -- 81 N⋅m (55 -- 60 ft.-lb.).
6. Connect all fuel lines from the injection pump.
Torque the high pressure gland nuts at the
injection pump to 33 N⋅m (24 ft.-lbs.).
19983010
78
10-45
7. Connect the throttle cable (1), Figure 79, fuel
shut-off solenoid wire (2) and wax motor wire (3). 1
2
8. Install the engine timing cover and torque the
hardware to 22 N⋅m (16 ft.-lb.).
9. Slip the fan belt back on. Make sure it is routed
properly over the pulleys and fits correctly in the
pulley grooves.
10. Install the crankcase ventilation tube.
11. Connect the negative battery cable.
12. Before starting the engine, turn the key on to
allow the electric fuel pump to run. The lift pump 20012252 3
should lug down when it pressurizes the system. 79
If the pump does not fill the system with fuel
within 1 -- 2 minutes, shut the key off. On some
units, it may be difficult to prime the system if the
fuel level is low or the fuel was bled out of the
electric lift pump suction line. Fill the fuel tank
first. If the unit still does not prime, some other
method may be required to initially get the fuel to
the lift pump.
NOTE: After you complete this alternate procedure,

the crankshaft pulley will be marked for the basic
engine timing when the pointer made for this tractor
is used. If the fuel injection pump needs to be
removed again, the original pointer and marks on the
crankshaft pulley can be used to time the engine. For
this reason, it is suggested that the pointer made for
this unit be installed on the pump inspection cover
and left with the unit, Figure 80.
The Dealer-Certified Technician Test follows.

You can review this section by answering questions
23 -- 25. 20012271
80
10-46
FUEL INJECTORS
The fuel injectors apply fully atomized fuel to each
cylinder, creating a condition which fuel burns
efficiently and with a minimum of smoke.
Each fuel injector consists of a nozzle assembly,

needle valve, injector body, and regulating spring.
The fuel injection pump delivers fuel to the injector

inlet port. Fuel flows through a drilling in the injector
body to the needle valve seat. The pressurized fuel
from the injection pump lifts the needle valve off the
seat against the spring force. The fuel atomizes
when forced through the five holes in the nozzle tip.
A loss of fuel pressure from the fuel injection pump
allows the spring force to reseat the needle valve.
To lubricate the fuel injectors, a small amount of fuel

passes between the needle valve and nozzle body.
The excess fuel rises to the top of the injector and
returns to the fuel tank via the injector leak-off line.
OVERHAUL
2
Removal
1. Raise and support the hood assembly
3
3. Clean the area around the fuel injectors to
4. Remove the fuel pipes (1) at the injectors from
the injection pump. Cap and plug all openings to 1
prevent contamination, Figure 81.
5. Remove the banjo bolts (2) and discard the two
copper washers with each bolt. Remove the 81
leak-off piping (3), Figure 81.
6. Remove the two retaining bolts (3) from each
injector and remove injectors from the cylinder
head. Discard the cork dust washer (1) and
cooper-sealing washer (2), Figure 82.
NOTE: The cooper sealing washer may need 1
extraction from the cylinder bore.
3
7. Cover the cylinder head injector openings to
82
10-47
FUEL INJECTOR TESTING

WARNING
The spray from a fuel injector test set will pierce
skin with fatal results. Always point the spray
from an injector away from self and by-standers.
WARNING
Fuel spray is flammable. Ensure no open flames
exist in the testing area, and do not generate
excessive vapor.
NOTE: During the Nozzle Opening Pressure and

Spray Pattern tests, collect the spray in a container
partially filled with rags to absorb the spray (1),
Figure 83.
1. Fill the tester with calibrating type fuel oil and

leave the filler cap slightly loose to prevent the 1
forming of a vacuum during testing.
TA6010115
83
2. Prime the tester until emitting fuel oil from the
testing line. 2
3. Connect the injector to be tested (1), Figure 84. 1
4. Screw in the right-hand knob on the tester to
prevent a blocked injector nozzle from damaging
the gauge.
5. Pump the tester to check nozzle. If nozzle opens
begin testing. If nozzle is blocked or jammed,
disassemble the injector.
Nozzle Opening Pressure Setting

Slowly pump the injector tester and observe the APB10004
pressure at which the needle valve lifts, and fuel 84
emits from the nozzle tip. The opening pressure must
be 240 bar (3481 psi) for non-emissionized, and 290
bar (4206 psi) for emissionized engines. Adjust the
nozzle opening pressure setting by rotating the
adjuster on top of the injector (2) clockwise or
counterclockwise, Figure 84.
Spray Pattern Test

Pump the tester rapidly and observe the spray
pattern from the holes in the nozzle. Ensure an
atomized spray, free from distortion and irregular
streaks of fuel, emits from the nozzle. The tester will
not provide a suitable test for atomization under
working conditions; however, it is a reliable indication
of how well the nozzle works.
10-48
Nozzle Seat Leakage Test
Wipe the nozzle tip dry and apply pressure of 230 bar 1
(3336 psi). The nozzle tip and bottom face must
remain essentially dry with no accumulation or drips
of fuel. Replace the nozzle assembly when leakage
occurs. A slight dampness will not necessitate
replacing the nozzle assembly. Use blotter paper to
check fuel accumulation on the nozzle tip (1),
Figure 85.
Nozzle Back Leakage Test

Apply 230 bar (3336 psi) of pressure to the injector,
then release the tester handle. Measure the time
taken for pressure to fall from 148 bar to 99 bar 85
(2147-1435 psi). If the time taken is less than 6
seconds, replace the nozzle. If the time taken s
greater than 45 seconds, suspect carbon on the
valve or blocked back leak drillings.
NOTE: Reinstall the injectors on the engine after all

tests end successfully.
Disassembly
1. Place the injector in a suitable holding fixture with
the nozzle upward. Do not clamp the injector
body in a vise or damage will result. Use a ratchet
(1) and Socket Tool No. FNH08126 to loosen the 1
nozzle retaining nut.
2
NOTE: Socket in Figure 86 is shown cut-away to
display injector tip.
86
10-49
2. Remove the nozzle retaining nut, nozzle body
(1), needle valve (2) and the adapter plate.
1
87
3. Remove the injector body (1), from the holding
fixture. Invert and remove the regulating spring
seat (2), spring (3) and adjustment shims.
NOTE: Place injector components in clean fuel until 1
installing to prevent corrosion.
2
3
88
10-50
INSPECTION AND REPAIR

1. Clean the injector body by soaking in a carbon
solvent and brushing with a brass wire brush.
Inspect the body for damaged threads and
pressure face, making sure the holes in the
injector nozzle are thoroughly clean with no signs
of corrosion or pitting.
2. Clean the spring and spring seat using a brass
wire brush and check for scoring, pitting or
corrosion.
3. Clean the dowel adaptor plate using a brass wire

brush. Inspect the plate for loose or bent dowels,
damaged pressure face or corrosion.
4. Clean the needle valve and body by soaking in a
carbon solvent and brushing with a brass wire
brush. Using a suitable Nozzle Cleaning Kit,
clean the nozzle as follows:
NOTE: Discard the needle valve if damaged or
evidence of overheating exists (valve will be blue in
color). Replace needle valve and needle body
assembly as a matched set.
89
5. Clean the nozzle spray holes with a cleaning wire
protruding 1.5 mm (0.06 in.) from a pin vise (1).
Insert the wire into each hole, pushing and
rotating gently to clear holes, Figure 90.
90
10-51
6. Clean the needle valve seat using a valve seat
scraper (1) by rotating and pushing the tool onto 1
the valve seating.
7. Clean the fuel port using a fuel port scraper.
Insert the scraper into the port, press hard
against the side of the cavity and rotate to clear
all carbon deposits from this area.
91
8. Use a Reverse Flush Nozzle Adaptor, Tool No.
FNH08124 (1), on the injector tester and reverse
flush the nozzle to remove the carbon loosened
during cleaning. 1
9. After flushing the nozzle, polish the valve seat by
placing a very small amount of tallow on the end
of a polishing stick and rotate in the nozzle.
92
10. Clean the top of the needle valve using a needle
valve scraper (1).
11. Clean the nozzle retaining nut threads with a
brass wire brush. Remove carbon deposits and
inspect threads for damage.
1
APB10013
93
10-52
Assembly
1. Rinse all injector parts in clean fuel oil and 4
assemble injectors wet. 3
2. Pass the regulating spring (1) and spring seat (2)
into the injector body (3). Place the injector body
into a suitable holding fixture. 5
3. Assemble the needle valve (4) into the nozzle
body and position the dowel adapter plate onto
the nozzle body. Insert this assembly into the
retaining nut (5)
2 1
94
4. Assemble the dowel adapter plate (1) and nozzle
retaining nut assembly onto the injector body.
Tighten the retaining nut to a torque of 48 N⋅m (35
ft.-lb.).
5. Perform fuel injector testing procedures.
95
Installation
Installation of the fuel injectors follows the removal
ments:
1. Install the injectors into the cylinder head with

new cork dust washers and cooper sealing
washers.
2. Install the injector retaining bolts and tighten to a
3. Connect the leak-off pipes using new washers
and tighten the banjo bolts to a torque of 12 N⋅m
(106 in.-lb.).
4. Connect fuel lines from injection pump to fuel
injectors and tighten pipe nuts at both ends to a
5. Replenish fuel system as needed and purge
system of air.
10-53
ELECTRIC LIFT PUMP
Removal
NOTE: Tractors with fuel systems incorporating the
DP 200 series fuel injection pump include the electric
lift pump.

2. Disconnect the wiring from the lift pump (1),
Figure 96.
3. Unscrew the filter head assembly connection
and remove lift pump.
96
Installation
Installation of the electric lift pump assembly follows
the removal procedures in reverse with the following
requirements:
1. Replace the O-rings (1), Figure 97.
97
10-54
MAIN FUEL TANK 1
Removal
installed).
3. Remove left and right hood assembly.
4. Remove all attaching components as necessary
2
to remove the rear hood assembly. Remove rear
hood.
5. Disconnect wiring harness(s) on top of the main
fuel tank. 98
6. Drain main fuel tank into a suitable container by Main Fuel Tank
opening the valve at the bottom of the tank. (2),
Figure 98.
7. Remove fuel lines at the top of the main fuel tank
and at the drain valve. Cap and plug all openings
to prevent contamination of the fuel system.
8. Disconnect fuel tank sender electrical connector.
9. Remove side mounting bolts, top center support
bracket bolts and the bottom support bolt, which
secure the main fuel tank to the tractor. Remove
the guard at the base of the steering column to
ease removal of the bottom support bolt.
10. Retain all attaching hardware to facilitate
installation. Remove fuel tank.
Inspection
1. Inspect the main fuel tank for cracks. Replace if
defective.
Installation
Installation of the main fuel tank follows the removal
ments:
1. Tighten the fuel tank drain valve to 7 N⋅m (62

in.-lb.).
2. Ensure tightness of all fuel pipe connections.
3. Replenish fuel. Purge air from fuel system.
4. Check fuel tank and piping for leakage.
10-55
AUXILIARY FUEL TANK

The auxiliary fuel tank varies in design depending on
model. The procedures to follow describe removal of
a standard tank.
Removal
2. Drain fuel from the auxiliary tank into a suitable
container by opening the auxiliary tank drain
valve.
3. Disconnect auxiliary tank outlet fuel pipe. Cap
and plug exposed openings to prevent contami-
nation.
4. If necessary, remove the left platform. Removal
of the left platform provides access to the forward
strap outer retaining bolt.
5. Remove forward strap by removing retaining
bolts. 2
6. Support auxiliary fuel tank (1) before removing
the rear support bracket. Remove the rear
support bracket (3), Figure 99.
7. Remove fuel tank.
1
NOTE: The auxiliary fuel tank rear support bracket
lower bolt (1) to rear axle may be a left-handed
thread. In this situation, ensure to loosen the bolt in
a clockwise direction, Figure 99.
3
8. Support the fuel tank and remove.
99
Auxiliary Fuel Tank Support Bracket
1. Support Bracket Bolt (left handed thread)
Inspection
1. Inspect the auxiliary fuel tank for cracks. Replace
if defective.
Installation
The installation of the auxiliary fuel tank follows the
requirements:
1. Tighten the auxiliary fuel tank drain valve to 7 N⋅m

(62 in.-lb.).
2. Ensure tightness of all fuel pipe connections.
Refer to Engine Specifications.
3. Replenish fuel. Purge air from fuel system.
4. Check auxiliary fuel tank and piping for leakage.
10-56
SECTION 10 - ENGINE
Chapter 5 - Turbocharger
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10-1
TURBOCHARGER SPECIFICATIONS
Description
Bearing Journal Radial Maximum Clearance 0.056-0.127 mm 0.002-0.005 in
Thrust Bearing Axial Maximum Clearance 0.025-0.084 mm 0.0010-0.0033 in
SPECIFICATIONS
Turbocharger Torque Values

Turbine Housing/Locking Plate Bolts 20-25 N⋅m 177-221 in.-lb.
Turbocharger-to-Manifold Bolts 41-47 N⋅m 30-35 ft.-lb.
Oil Intake Pipe Banjo Bolt 54-81 N⋅m 40-60 ft.-lb.
Oil Intake-to-Oil Filter Connector 18-20 N⋅m 159-177 in.-lb.
Oil Intake Pipe Connector-to-Oil Filter 54-81 N⋅m 40-60 ft.-lb.
Oil Return Pipe-to-Turbocharger Bolts 20-25 N⋅m 177-221 in.-lb.
Oil return Pipe –to-Block Connector 54-81 N⋅m 40-60 ft.-lb.
Oil Return Pipe Connector-to-Block 27 N⋅m 239 in.-lb.
Intake /Exhaust Hose Clamps 2-3 N⋅m 18-27 in.-lb.
10-2
TURBOCHARGER
Description and Operation

Mounted on the exhaust manifold, the turbocharger
consists of gas turbine and air compressor wheels on
opposite ends of a common shaft.
The exhaust turbine, a centripetal radial inflow

designed mechanism, incorporates a cast turbine
wheel, wheel shroud, and a housing, which encloses
the wheel and directs the flow of gas through the
turbine.
The air intake compressor, a centrifugal radial

outflow designed mechanism, incorporates a cast
compressor wheel, back-plate assembly, and a
housing, which encloses the wheel and directs the air
flow through the compressor.
The center housing supports the compressor and

turbine wheel shaft, within a pair of identical
bearings. Passages drilled in the center housing
direct oil, supplied by the engine from the inlet port,
to the oil grooves machined in the bearing bores. The
oil grooves align with holes in the bearings.
Piston rings, installed at each end of the shaft

between the bearing and adjacent wheel, prevent
lubricating oil from entering the turbine and
compressor area.
During operation of the turbocharged engine,
exhaust gas from the exhaust manifold flows into the A
turbine (C). The exhaust gas pressure and heat
energy extracted causes the turbine wheel to rotate,
which causes the compressor wheel to rotate.
The turbine housing directs cooled and expanded D B

exhaust gas leaving the turbine wheel to the engine
exhaust system (D), where it expels to the
atmosphere.
Rotation of the compressor wheel draws ambient air

(B) from the air cleaner into the compressor housing, APB10501 C
where the air compresses and flows to the engine
intake manifold (A). 1
A. To intake manifold
B. From air cleaner
C. From exhaust manifold
D. To exhaust muffler
10-3
The increased volume and density of the air
delivered to the engine cylinders permit a corre- 4
sponding increase in the volume of fuel that can be
introduced into the cylinders, while maintaining the
air/fuel ratio required for proper combustion. Since
engine power output is a function of the volume of
fuel burned, the increase in the volume of fuel 5
introduced as a result of turbocharger operation
results in an increase in engine power output. 3 2
2
1. From air cleaner
2. Compressed air flow
3. Engine cylinder
4. Exhaust gas flow
5. Turbine
TURBOCHARGER FAULT FINDING fact would not be evident after removing the
It is important when troubleshooting a suspected turbocharger from the engine.
turbocharger malfunction, to keep in mind that a
turbocharger cannot compensate for incorrect Furthermore, failure to take appropriate steps to
engine operating temperatures; deficiencies of the ensure correct installation, such as repairing or
engine air intake, fuel, or exhaust systems; or for replacing defective clamps or ducting, could cause
damaged engine components such as valves, the replacement unit to fail in a similar manner.
pistons, rings, liners, etc. Replacing a good
turbocharger with another will not correct engine The following chart contains information pertaining to
deficiencies. probable failure modes of turbocharged engines,
possible causes for such failures, and the
Consequently, systematic troubleshooting of a maintenance action required remedying each
suspected turbocharger failure is essential for two possible cause. It is not represented that this
very important reasons. First, it must be determined information is all--inclusive. On the contrary, consider
what, if anything, is wrong with the turbocharger so this information primarily as representative of the
that it can be repaired. Second, it must be methods or techniques employed, in troubleshooting
determined what action will prevent a reoccurrence a turbocharged engine malfunction.
of the failure.
In general, perform the troubleshooting procedures
In many cases, the evidence required to determine with the least effort, and in the least amount of time,
the cause of a malfunction is destroyed in the first. Perform no removal or disassembly procedures
process of removing the turbocharger from the until visual inspections and sensory tests (sight and
engine. If a turbocharger failed as a result of a faulty feel) with the turbocharger installed have been
installation (such as loose duct connections that performed. The possible causes and procedure are
permitted ingestion of dirt by the compressor), this generally arranged in the order of ease of
accomplishment.
10-4
FAULT FINDING
PROBLEMS POSSIBLE CAUSES
1. Engine lacks power or emits black Dirty air cleaner
smoke
Loose compressor-to-intake manifold connections
Leak at engine intake at turbocharger mounting flange
Turbo rotating assembly binding
Air cleaner-to-turbocharger duct restricted
Compressor-to-intake manifold duct restricted
Engine exhaust system restricted
Engine malfunction (rings, pistons, valves and associated
parts).
2. Engine exhaust emits blue smoke Dirty air cleaner
Loose compressor-to-intake manifold connections
Leak at engine intake manifold
Plugged engine oil filter
Restricted duct between air cleaner and turbocharger
compressor
Seal leak at compressor end of turbocharger
Engine malfunction (rings, pistons, valves and associated
parts)
3. Excessive engine oil consumption Wrong type or viscosity of engine lubricating oil
Seal leaks at compressor end of turbocharger (indicated by
oil in housing or on wheel)
Oil in engine exhaust manifold (caused by malfunction of
rings, pistons, valves and associated parts).
4. Noisy turbocharger Dirty air cleaner
Foreign material or object in compressor-to-intake manifold
duct
Foreign object in engine exhaust system
Carbon buildup in turbine housing
Turbocharger rotating assembly binding or dragging
5. Turbocharger rotating assembly Damaged compressor wheel
binding or dragging
Damaged turbine wheel
Compressor or turbine wheel rubbing on housing due to
worn bearings, shaft journals or bearing bores
Excessive dirt buildup in compressor (housing or wheel)
Excessive carbon buildup behind turbine wheel (overhaul
turbine)
10-5
PROBLEM POSSIBLE CAUSES

6. Seal leaks at compressor end of Dirty air cleaner
turbocharger
Restricted duct between air cleaner and turbocharger
Loose compressor-to-intake manifold dust connections
Leak at engine intake manifold
Restricted turbocharger oil drain line
Plugged engine crankcase breather
Worn or damaged compressor wheel (worn bearings, bores
or journals)
Excessive piston blow-by or high internal crankcase
pressure
7. Seal leaks at turbine end of Excessive pre-oiling

turbocharger
Plugged engine crankcase breather
Restricted turbocharger oil drain line
Worn turbocharger bearings, bearing, bores, or journals.
8. Worn turbocharger bearings, bores Inadequate pre-oiling following turbocharger installation or
or journals engine lube servicing
Contaminated or improper grade of engine oil used in
engine
Insufficient oil supplied to turbocharger due to “oil lag”
Restricted turbocharger oil feed line
Plugged engine oil filter
Insufficient lube oil supplied to turbocharger due to engine
oil pump malfunction
10-6
OVERHAUL
Removal
installed).
3. Remove the left side hood assembly.
4. Remove the exhaust muffler-to-turbocharger
clamp (5), bracket and tube.
5. Disconnect the air cleaner-to-turbocharger
clamp (1) and tube. Disconnect the intake
manifold-to-turbocharger clamp and tube. 3
6. Disconnect and remove the oil intake pipe (6),
and the oil return pipe (3). Cap and plug all
turbocharger (1) from the exhaust manifold (3).
Discard the sealing gasket (2), Figure 4. 1
Disassembly
1. Clean the turbocharger in a suitable solvent
before disassembly. Allow part to dry.
2
2. To facilitate re-assembly, mark the compressor
housing, turbine housing and center housing.
3
10-7
3. Remove compressor housing ‘C’ clip from center
housing intake side (1).
NOTE: Exercise care when removing the compres-
sor housing to avoid damaging the compressor
wheel blades. If needed, tap the turbine housing with
a soft faced hammer.
5
4. Loosen and remove bolts from the turbine
housing exhaust side, and lockplates (1).
6
Cleaning
Before cleaning, inspect all parts for burning,
rubbing, or impact damage that may not be evident
after cleaning. Clean all parts in a non caustic
solution, using a soft bristle brush, a plastic blade
scraper, and dry compressed air to remove residue.
DO NOT -- Use abrasive cleaning methods which

might damage or destroy machined surfaces.
DO NOT -- Immerse CHRA in solvent.
DO NOT -- Blow under compressor wheel with
compressed air.
DO NOT -- Permit wheel/shaft assembly to spin when
blowing off solvent and residue.
10-8
Inspection
1. Inspect the compressor housing as follows:
• Check for wheel rubbing damage in the
contour area. Remove minor imperfections
with 80 grit silicon carbide abrasive cloth.
• Inspect snap ring grooves for wear, damage

or corrosion.
• Check for dents, burrs or distortion between

the compressor housing and the center
housing/rotating assembly, which may pre-
vent proper sealing.
Replace compressor housing if defective.
2. Inspect the turbine housing as follows:

• Check for wheel rubbing damage in the
contour area. Remove minor imperfections
with 60 grit silicon carbide abrasive cloth.
• Inspect snap ring grooves for wear, damage

or corrosion.
• Check for dents, burrs or distortion between

the turbine housing and the center housing/
rotating assembly, which may prevent proper
sealing.
NOTE: Disassembly of the compressor/rotating

assembly will negate the precise balancing per-
formed at the factory, and necessitate replacing the
assembly.
10-9
Center Shaft Radial Check
Check the bearing journal radial clearance when
discovering compressor or turbine wheel rubbing, or
when noticing a high pitched sound during operation,
as follows:
1. Remove turbocharger from the tractor

2. Attach a dial indicator with a suitable probe to the
center housing. The indicator plunger must
extend through the oil outlet port and contact the
shaft of the turbine wheel assembly.
3. Manually apply an equal amount of pressure
simultaneously to the compressor and turbine
wheels to move the shaft away as far as possible 7
from the dial indicator probe.
4. Set the dial indicator to zero.
wheels to move the shaft toward the dial indicator
probe as much as possible. Record the reading
on the indicator.
NOTE: To achieve the most accurate measurement
possible, roll the wheels slightly in both directions
while applying pressure.

wheels, to move the shaft away from the plunger
again. Note that the indicator pointer returns
exactly to zero.
7. Repeat steps 2 through 5 several times to ensure
recording the correct measurement of maximum
radial clearance, as indicated by shaft move-
ment.
8. Replace the center housing/rotating assembly if
maximum clearance not within 0.056-0.127 mm
(0.002-0.005 in.).
10-10
Thrust Bearing Axial Clearance Check
Check the thrust bearing axial clearance as follows:
1. Remove the turbocharger from the tractor.

2. Place a dial indicator (1) with the probe on the
compressor end of the shaft assembly.
3. Manually move the compressor/turbine wheel
assembly as far from the plunger as possible.
4. Set the dial indicator to zero.
assembly toward the plunger as much as
possible. Record the shaft movement as shown
on the indicator dial. 8

assembly as far away from the plunger as
possible. Note that the indicator plunger returns
to zero.
7. Repeat steps 2 through 5 several times to ensure
recording the correct measurement of maximum
axial clearance, as indicated by shaft movement.
8. Replace the center housing/rotating assembly if
maximum clearance not within 0.025-0.084 mm
(0.0010-0.0033 in.).
Assembly
NOTE: When replacing parts during overhaul,
transfer scribe marks made during disassembly from
the old part to the new part.
1. Replace the following components when over-

hauling the turbocharger:
• Compressor Housing Snap Ring
• Compressor Housing O-ring
• Turbine Housing retainer Plates
• Turbine Housing retaining Bolts
2. Replace the following components only if faulty:

• Center Housing/Rotating Assembly
• Compressor Housing
• Turbine Housing
3. Transfer alignment scribe marks on old snap
rings, made during disassembly, to new snap
rings. Coat rings in clean engine oil.
4. Install new snap ring on the compressor end of
the center housing/rotating assembly, with the
beveled side facing the turbine end.
10-11
5. Install O-ring (1) on center housing flange
(compressor end). Place compressor housing
into position. Do not damage compressor
blades.
6. Rotate the compressor housing to line up with
scribe marks made during disassembly.
7. Install the snap ring (lug first) into the compressor
housing groove. Face the beveled side toward
the turbine end and align with scribe marks made
during disassembly. Ensure snap ring fits
completely into groove.
9
8. Position the turbine housing discharge side
down, on a flat level surface. Place the turbine
wheel end of the shaft into the housing. Do not
damage the turbine blades. Align with scribe
marks.
10
9. Position the locking plates. Coat the retaining

bolts (1) in a suitable anti-seize compound and
install. Tighten the bolts to a torque of 20-25 N⋅m
(177-221 in.-lb.).
11
10-12
Installation
Installation of the turbocharger follows the removal
ments:
1. Fill the turbocharger center housing with clean oil

and rotate the main shaft to lubricate the
bearings.
2. Install a new sealing gasket and position
turbocharger on exhaust manifold. Tighten
retaining bolts to a torque of 41-47 N⋅m (30-35
ft.-lb.).
3. Install washers and connect the oil intake tube
banjo bolt. Tighten banjo bolt to a torque of 54-81
N⋅m (40-60 ft.-lb.).
4. If necessary, install the oil intake tube connector-
to oil filter head. Tighten connector to a torque of
54-81 N⋅m (40-60 ft.-lb.).
5. Connect oil intake tube pipe to the oil filter head
connector and tighten to a torque of 18-20 N⋅m
(159-177 in.-lb.).
6. Place a suitable container below the oil return
port.
7. Disconnect the electrical solenoid at the fuel
injection pump.
8. Crank the engine until oil flows from the return
port. After obtaining oil flow, stop the engine and
reconnect the electrical solenoid at the fuel
injection pump.
9. Install new gasket and connect the oil return pipe
to the turbocharger connector 20-25 N⋅m
(177-221 in.-lb.).
10. If necessary, tighten return pipe-to-block fitting to
a torque of 27 N⋅m (239 in.-lb.).
11. Connect oil return pipe to the block fitting and
tighten to a torque of 54-81 N⋅m (40-60 ft.-lb.).
12. Connect the air inlet and outlet tubes. Tighten
clamps to a torque of 2-3 N⋅m (18-27 in.-lb.).
13. Check engine oil level and replenish as needed.
14. Idle engine and check all tubes, pipes and seals
for leakage.
15. Operate the engine at rated speed and listen to
turbocharger for signs of metal contact. If
noticed, stop engine immediately and recheck
turbocharger.
NOTE: The turbocharger rotating assembly will
coast freely to a stop upon engine shut-down, as long
as the engine ran at normal operating temperature.
If after stopping the engine, the rotating assembly
jerks to a stop, immediately investigate and correct.
10-13
Testing 8. Internal inspection of the center housing can be
1. With engine stopped, check duct clamping accomplished by removing the oil drain line and
devices for tightness. looking through the oil drain opening. When a
sludged or coked condition exists, a heavy
2. With engine running at idle speed, lightly spray sludge buildup will be seen on the shaft between
duct connections with starting fluid. Leaks at the bearing journals and in the center housing
connections will be indicated by an increase in from the oil drain opening back of the turbine end.
engine speed due to the starting fluid being
drawn into the compressor and pumped into the 9. Thorough cleaning of the air induction system is
engine combustion chambers. essential following compressor wheel damage
due to foreign object impact. In many cases,
3. With engine running at idle speed, check duct metal pieces from the wheel become imbedded
connections for leaks by applying lightweight oil in the air cleaner element. If the element is not
or soap suds to areas of possible leakage and changed in such cases, these metal pieces can
looking for bubbles. Exhaust gas leakage be drawn into the replacement turbocharger and
between the cylinder head, exhaust manifold cause it to fail in the same manner as the original
and the turbocharger inlet will also create a noise unit.
level change.
10. With the air inlet and exhaust gas ducting
4. With engine running at idle speed, check for removed from the turbocharger, examine both
unusual noise and vibration. If either condition is the compressor and turbine wheels for blade
noted, shut down the engine immediately to damage. Examine the outer blade tip edges for
protect the turbocharger and engine from further evidence of rubbing on adjacent housing
damage. With the engine stopped, check the surfaces.
turbocharger shaft steel assembly for damage.
NOTE: A light is required for examining the turbine
5. With engine running, a change in the noise level wheel blade tips, which are positioned inside the
to a higher pitch can indicate air leakage between turbine housing. The surfaces requiring inspection
the air cleaner and the engine, or a gas leak can be viewed from the outlet end of the turbine
between the engine block and the turbocharger housing.
inlet.
6. Exhaust gas leakage may be indicated by heat Rotate the rotating assembly by hand and feel for
discoloration in the area of the leak. smooth turning, dragging or binding. Push the
rotating assembly sideways while rotating to feel for
7. With the engine running, noise level cycling from wheel rub. If there is any indication of rubbing,
one level to another can indicate a plugged air perform the bearing clearance inspection proce-
cleaner, a restriction in the air cleaner- dures outlined in this manual under Preventive
to-compressor duct, or a heavy buildup of dirt in Maintenance. If the rotating assembly rotates freely
the compressor housing or on the compressor and there is not evidence of binding or rubbing, it can
wheel. be assumed that the turbocharger is serviceable.
10-14
SECTION 18 -- CLUTCH -- CHAPTER 1
SECTION 18 - CLUTCH
Chapter 1 - Single Clutches
CONTENTS

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Single Clutch Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
18-1

A larger, higher capacity clutch is now being
equipped on 10 ‘S’ series tractors. This 356 mm (14
in) clutch will deliver longer service life, including
work requiring frequent engagement and disengage-
ment. The following lists the major differences:
1. It is simple and efficient.
2. The clutching and de-clutching characteristics
assure a comfortable, low-force pedal feel.
3. Better absorption of torsion vibrations and
increased torque reserve capacity.
4. An extended clutch service life expectancy of
5000 hours during normal operation.
5. An increase in permitted wear reserves of the
clutch compared to previous clutches, which use
fingers and helical springs.
6. NO MAINTENANCE is required to the clutch 20025024
assembly during the service life, due to a simple 1
diaphragm design.
For models under 100 HP, the new clutch is equipped
with a 6 pad organic disc. Models over 100 HP, and
all tractors with dual power, are equipped with a 7 pad
”Cerametalic” disc and damper, Figure 1.
Advantages of ”Cerametalic” disks:
1. The disc material is a “Cerapad” that has an

excellent thermal stability, which is to say it will
not disintegrate, even at temperatures as high as
800_C (1472_F), and the friction coefficient stays
stable.
2. The flex-mounted disc pads help prevent chatter
or vibration under any clutch operation.
3. An increase in the total clutch friction area
provides greater capacity, and lower operating
temperatures.
4. The torsion damper is designed specifically for
tractor applications and has 3 phases of action,
as listed below:
The first phase helps prevent transmission gear
noise chatter when not under load.
The second and third phases cushion the sudden
changes in torque, when manual clutching under
load, or when dual power shifting.
NOTE: A conversion kit which includes all the
required parts to retrofit tractors from an original 330
mm (13 in) clutch to a 356 mm (14 in) clutch is
available, by Part No. (86106321).
18-2
Older ‘S’ series tractors are equipped with either a
dry Organic, or “Cerametalic” 330 mm (13 in) 3 1
diameter clutch.
The single plate, clutch disc Figure 2, incorporates

friction linings (1), on each side and a splined-hub
(2), which is located on the forward end of the
transmission input shaft. The disc is installed
between the flywheel, a pressure plate, and the
cover assembly that is attached to the flywheel.
NOTE: The 10 ‘S’ series tractor incorporates a 2

conventional type of clutch with four release levers. 10024888
2
Clutch Disc
1. Friction Lining
2. Splined Hub
3. Torsion Damper Springs
The following table lists parts required for the

assembly of the 356 mm (14 in) clutch into the tractor,
as well as deleted parts.
356 mm (14 in) Diaphragm Clutch 330 mm (13 in) Clutch 330 mm (13 in) Diaphragm Clutch
QTY PART NO DESCRIPTION QTY PART NO DESCRIPTION QTY PART NO DESCRIPTION
1 82983562 Flywheel 1 81871636 Flywheel 1 81871636 Flywheel
1 82983564 Disc Assembly 1 82981612 Disc Assembly 1 82981612 Disc Assembly
1 82983565 Clutch Assembly 1 82983113 Clutch Assembly 1 82983113 Clutch Assembly
1 82983566 Cover Assembly 1 82983360 Cover Assembly 1 82011590 Cover Assembly
9 10571779 Lock Washer 8 83907387 Lock Washer 8 83907387 Lock Washer
9 82880843 Bolt 8 81821205 Bolt 8 81821205 Bolt
3 82983577 Dowel 1 81800704 Dowel 1 81800704 Dowel
1 81800705 Dowel 1 81800705 Dowel
1 82983581 Shaft and Lever 1 82981151 Shaft and Lever 1 82983581 Shaft and Lever
Assembly Assembly Assembly
18-3
3
Clutch Assembly
1. Clutch Release Hub 4. Pressure Plate Assembly
2. Release Hub Bearing 5. Clutch Disc
3. Clutch Housing Assembly 6. Flywheel
OPERATION levers. This draws the pressure plate away from the
With the clutch engaged, the spring loaded pressure clutch disc, releasing the disc from contact with the
plates force the clutch disc into contact with the flywheel. Thus, the frictional drive disconnects from
engine flywheel. the transmission, allowing gear changing to occur.
Frictional contact between the disc linings, the After releasing the clutch pedal, a spring returns the
pressure plate, and the surfaces of the flywheel, pedal to the free position. In addition, the release
transmits drive from the flywheel to the shaft of the bearing moves away from the release levers of the
transmission via the clutch disc. pressure plate assembly.
A rod connects the clutch pedal to a lever, and The main springs of the pressure plate assembly
release shaft assembly. then reassert pressure on the pressure plate, moving
it towards the clutch disc, and into contact with
Depression of the clutch pedal moves the release the flywheel. This reestablishes drive to the
shaft and fork, in turn moving the release bearing transmission.
forward, which depresses the pressure plate release
18-4
ADJUSTMENTS
Pedal free travel is the only adjustment required for
single clutches. Free travel is the amount of pedal
movement from the fully released position to the
point when first encountering resistance.
Clutch Pedal Free Play Adjustment

The clutch free travel should be:
28-41 mm (1.1-1.6 in) at the clutch pedal.

If adjustment is required:
1. Loosen the lock nut (1); remove the split pin (4)
and clevis pin (3), from the connecting rod clevis
(2), Figure 4.
2. Turn the clevis to adjust the length of the control
rod, until obtaining correct specification for pedal
free travel.
3. Secure the clevis pin, with a new split pin, and
tighten the lock nut.
4
OVERHAUL
Procedure for Installing 356 mm (14 in) Clutch
IMPORTANT: Verification of the flywheel / clutch-to-
bell housing clearance is essential. Rework of the
bell housing is required, Figure 5.
10025030
5
Dimensions for reworking the bell housing as shown
in Figure 6:
• Diameter ‘A’ Reference - 99.999-100.024 mm

(3.9370-3.9379 in). B
A
• Machining Diameter ‘B’ - 400.0-401.0 mm
(15.75-15.79 in).
• Length ‘C’ – 124.0-128.0 mm (4.88-5.04 in).
10025031
C
18-5
Dimensions for altering tractor steps without an
auxiliary tank installed, Figure 7: B A
• Dimension ‘A’ – 97.54 mm (3.84 in)
C
• Dimension ‘B’ – 13.00 mm (0.51 in)
• Dimension ‘C’ – 44.50 mm (1.75 in)
10025032
7
For tractor steps with an auxiliary tank installed, cut
the floorboard 25 mm (1 in) further rearward (1),
Figure 8.
1
10025033
8
Follow the procedure outlined in the following steps
when installing a 356 mm (14 in) clutch:
1. Install the flywheel to the engine hub adapter.

Torque bolts 170-224 N⋅m (125-165 ft.-lbs.),
Figure 9.
10025034
18-6
2. Center the clutch disc on the flywheel with a
spline-guide, and mount the clutch pressure
plate assembly to the flywheel, and torque bolts
to 24-30 N⋅m (18-22 ft.-lbs.), Figure 10.
10025035
10
3. Install the clutch bearing fork on the shaft and
lever assembly within the transmission bell
housing. Torque the bolt head to 41-48 N⋅m
(30-35 ft.-lbs.), Figure 11.
4. Buckle up transmission to engine. Refer to
Section 10 Engines.
10025036
11
5. Adjust clutch (1) free play, measuring 19.05 mm
– 44.45 mm (3/4-1 3/4 in) at floorboard, Figure
12. 1
6. Check free play after first 50 hours and, every
150 hours thereafter, to assure optimum
operational conditions and long service life.
IMPORTANT: Do not operate the tractor with the
throw-out bearing loaded (No free play or with clutch
pedal partially depressed).
10025037
12
18-7
Disassembly 2. On the 330 mm (13 in) clutch assembly, punch
NOTE: Special Tool Kit No. FNH 02142 (Universal ferrules clear of the drive strap, bolt heads and
clutch Fixture) replaces Tool Kit No. SW12B, remove bolts with a socket through holes in the
however procedures for using both tool kits follow. cover.
3. On the cover assembly, remove the release lever
Using Tool No. SW12B Figure 13 thrust plate retaining springs and withdraw the
1. Clean the pressure plate and cover assembly plate.
thoroughly, then attach the assembly centrally on 4. Pry the staked portion of the release lever,
the base plate with Tool No. SW12B/8 or eyebolt nut from the slot of each eyebolt.
SW12B/10 (Disc Spacers) between the pressure Remove the nuts.
plate and the base of the tool.
5. Gradually loosen the bolts retaining the pressure
NOTE: Use Tool No. SW12B/10 (Disc Spacers) for plate cover, to the base plate of the tool, to
the 330 mm (13 in) clutch. release all spring pressure, then remove the
bolts and the pressure plate cover.
NOTE: Use Bolt Tool No. SW12B/25 for the 330 mm
(13 in) clutch. Loosen the bolts evenly and diagonally 6. Remove the coil springs from the pressure plate.
across the clutch to prevent distortion of the cover
assembly.
22 3
21
20
19
4
18
17 8 6
16 7
12
15
11 9
14
13 10
5
10024893
13
Clutch Pressure Plate Assembly Overhaul and Adjustment -- Tool No. SW12B
1. Base Plate -- SW12B/15 12. Bolt -- SW12B/24
2. Bridge Spider -- SW12B/14 13. Center Spacer -- SW12B/5
3. Actuator Assembly -- SW12B/28 14. Pillar Spacer -- SW12B/1
4. Actuator Cam Platform Extension -- SW12B/20 15. Center Spacer -- SW12B/4
5. Riser Spacers -- jSW12B/9 16. Center Spacer -- SW12B/7
6. Washer -- SW12B/26 17. Center Spacer -- SW12B/3
7. Bolt -- SW12B/23 18. Center Spacer -- SW12B/2
8. Washers -- SW12B/27 19. Center Spacer -- SW12B/6
9. Disc Spacers -- SW12B/8 20. Gauge Finger Body -- SW12B/11
10. Disc Spacers -- SW12B/10 21. Gauge Finger -- SW12B/13
11. Bolt -- SW12B/25 22. Locknut -- SW12B/12
18-8
7. Hold the inner ends of the release levers
upwards, against the eyebolts, and move the 4
struts until removal of the eyebolts and release
levers from the pressure plate is possible, Figure 1
14.
8. Withdraw the eyebolts from the release levers
and remove the pivot pins.
9. Remove the spindle nut; thrust washer, bridge,
and adapter plate, then separate the clutch cover
2
from the pressure plate.
10. Remove the clutch pressure release springs 3
from the pressure plate, then remove the release 10024889
lever struts, eyebolts, and levers by applying 14
pressure to the bolts. Remove the eyebolts and,
Release Lever Removal
the pivot pins.
1. Eyebolt
2. Pressure Plate
3. Strut
4. Release Lever
18-9
Assembly Using Tool No. SW12B Assembly of the single clutch is the reverse of the
NOTE: Before assembling, coat the following disassembly procedure, observing the following
components with silicon base grease. requirements for 330 mm (13 in):
• The plain end of the eyebolts. 1. Insert new locking ferrules, and drive the bolts
• The eyebolt nut seats in the cover. into the drive straps. Tighten to the specified
• The overall length of the release lever pivot pins. torque. Ensuring correct location of the ferrules
• The contact edges of the release lever struts. in the straps and pressure plate. Punch the
ferrules to lock the bolt heads in position.
• The tips of the release levers on installation of the
release lever thrust plate.
20025022
15
Adjusting Clutch Pressure Plate Release levers Using Tool No. SW12B
1. Locknut -- SW12B/12 7. Base Plate -- SW12B/15
2. Gauge Finger -- SW12B/13 8. Pressure Plate
3. Gauge Finger Body -- SW12B/11 9. Eyebolt Nut
4. Center Spacer -- SW12B/4 10. Release Lever
5. Bridge Spider -- SW12B/14 11. Pillar Spacer -- SW12B/1
6. Disc Spacer -- SW12B/10
SINGLE CLUTCH SETTING PROCEDURE

1. Attach Tool No. SW12B/20 (Actuator Cam 4 1
Platform Extension) to the threaded pillar of Tool
No. SW12B/28 (Actuator Assembly) with the 2
flange of the extension facing downwards. Screw
the actuator into the base of Tool No. SW12B/14
(Bridge Spider), until the flange of the extension
contacts the clutch release levers, Figure 16.
2. Operate the handle of the actuator to depress the
clutch release levers. Repeat several times to
settle the clutch mechanism. Then remove the 3
actuator, and extension. 10024890
NOTE: Do not install spacers, part number 16

C5NN7N596B, when replacing pressure plate, part Settling Clutch Mechanism
number D8NN7563A with pressure plate, part 1. Actuator Cam Platform Extension Tool No. SW12B/20
number 82983360. The 30% increase in lift travel on 2. Clutch Assembly
the latter pressure plate eliminates the need for 3. Base Plate -- Tool No. SW12B/15
spacers.
4. Actuator -- Tool No. SW12B/28
18-10
3. Attach Tool No. SW12B/1 (Pillar Spacer) to the
base of Tool No. SW12B/14 (Bridge Spider), and
position the appropriate Center Spacer over the
pillar.
4. Place Tool No. SWB/11 (Gauge Finger Body)
over the Pillar Spacer and install Tool No.
SW12B/13 (Gauge Finger) and secure with Tool
No. SWB/12 (Locknut).
5. Rotate the Gauge Finger over each release
lever. Adjust the eyebolt nuts until each release
lever touches the Gauge Finger. Remove the
Pillar Spacer and Finger Gauge, Figure 17.
6. Lock the eyebolt nuts of the clutch by staking the
cylindrical portion of the nut into the slot in the
eyebolt.
7. On the 330 mm (13 in) clutch, install the release
lever thrust plate and retaining springs.
8. Remove the pressure plate cover-to-base plate
retaining bolts and lift the pressure plate and 20025023
cover assembly from the base plate. The
pressure plate and cover assembly are now 17
ready for installation on the engine. Universal Clutch Fixture -- Consists of
1. FNH01267 -- Release Lever Gauge
Assembly Using Tool No. FNH 02142 Figure 15 2. FNH01268 -- Spring Compressor Bridge
Assembly of the single clutch is the reverse of the 3. FNH01269 -- Gauge Spacer 0.200″
disassembly procedures. In addition, observe the 4. FNH01270 -- Gauge Spacer 0.255″
following requirements. 5. FNH01271 -- Gauge Spacer 0.492″
6. FNH01272 -- Gauge Spacer 0.575″
1. Rotate the assembly on the fixture base until the FNH01273 -- Gauge Spacer 0.792″ (Not Shown)
bolt holes in the clutch cover align with the mating FNH01274 -- Gauge Spacer 0.982″ (Not Shown)
holes in the fixture base; then drop the clutch FNH01275 -- Gauge Spacer 0.550″ (Not Shown)
cover-to-flywheel bolts into place. Use the bolts 7. FNH02143 -- Gauge Spacer Assembly
as guides during this stage of the assembly, and (3 included in kit)
do not tighten. 8. FNH01279 -- Gauge Pin
9. FNH01280 -- Spindle Nut
NOTE: Do not install spacers, part number 10. FNH01281 -- Thrust Washer
C5NN7N596B, when replacing pressure plate, part
11. FNH01282 -- Guide Pin (3 included in kit)
number D8NN7563A with pressure plate, part
12. FNH01283 -- Fixture Base
number 82983360. The 30% increase in lift travel on
13. FNH01284 -- Risser Block (3 included in kit)
the latter pressure plate eliminates the need for
14. FNH00450 -- Fixture Spindle
spacers.
15. FNH01286 -- Long Cap Screw
2. On the ‘S’ Series tractors with 330 mm (13 in) 16. FNH01287 -- Short Cap Screw
clutch, it will be necessary to install one Shim 17. FNH01288 -- Shim Spacer (3 included in kit)
Spacer Tool No. FNH01288, on the clutch cover, 18. FNH01289 -- Adapter Plate
at each clutch cover-to-flywheel bolt, before 19. FNH01294 -- Nut for Bottom Side of Spindle
setting bolts into position, Figure 17.
3. On the ‘S’ Series tractors with 330 mm (13 in)
clutch, install the drive strap locking ferrules and
ferrule bolts but do not tighten.
4. Tighten the clutch cover-to-flywheel bolts equally
and in diagonal sequence. On all the 10 ‘S’ series
tractors with the 330 mm (13 in) clutch tighten the
drive strap locking ferrule bolts to the specified
torque.
18-11
SINGLE CLUTCH SETTING PROCEDURE

1. Remove the spindle nut, the thrust washer, and 8
the bridge. Install Gauge Spacer and, the
Release Lever Gauge Tool No. FNH01267,
Install the Gauge Spacer with the identification
7
number facing upward.
2. Install the release lever, eyebolt nuts. Rotate the 1
Release Lever Gauge over each lever and adjust 6
eyebolt nut until gauge lightly contacts lever.
Attach release lever plate to the release levers, when
adjusting the 330 mm (13 in) clutch. The gauge
should just touch all the way around the release lever
plate, Figure 18. 2
3. After adjustment of the levers is complete, stake

the cylindrical portion of each eyebolt nut into the 5 3
slot of each eyebolt.
4. Remove the Release Lever Gauge and the 4
Gauge Spacer. Reinstall the adapter plate,
bridge, thrust washer, and the spindle nut. 10024891
Tighten the spindle nut finger tight, and remove
18
the clutch cover-to-flywheel bolts.
Adjusting Release Levers on a 13 in. (330 mm)
Remove the clutch from the fixture by removing the Clutch Using Tool No. SW510
spindle nut, the thrust washer, the bridge, and the 1. Anti-rattle Spring
adapter plate. The clutch is now ready for installation 2. Release Lever Eyebolt Nut
on the flywheel. 3. Identification Marks
4. Shim Spacers
5. Drive Strap Locking Ferrule Bolt
6. Retaining Spring
7. Release Lever Plate
8. Release Lever Gauge Tool No. SW510--2
18-12

NOTE: The diaphragm type clutch has no
serviceable components. A new assembly will be
required if there is discovery of any faults during
inspection.
Friction Disc
Inspect the clutch disc to ensure the linings are not
loose, cracked, worn or contaminated with oil. Check
for secure rivets. If signs of overheating from clutch
slipping or excessive wear are evident, replace the
disc.
IMPORTANT: Investigate the source of any oil or

grease on the facings and repair before installing a
new disc.
Pressure Plate
Inspect the diaphragm fingers for equal height on the
pressure plate assembly. Check the face of the
pressure plate for cracks, scoring or distortion.
Check for discoloration due to excessive heat. Check
for smooth operation. Discard the plate if discovering
any of the above discrepancies.
Release Bearing
Check that bearing hub moves freely over the
transmission hub carrier. Ensure the bearing rotates
smoothly, and check the face of the bearing for
damage or wear. Examine the clutch release fork for
cracks, bends, and end alignment. Replace any
damaged parts.
Clutch Pedal
Inspect the clutch pedal for cracks, and excessive
free-play between the bushings and pedal shaft.
Replace any damaged parts.
Clutch Release Cross-Shaft

Inspect the clutch release cross-shaft and transmis-
sion housing bushings. The shaft should rotate
smoothly without any free-play. Replace any
damaged parts.
18-13
INSTALLATION 3. Locate the clutch assembly on the flywheel and

install the spacers (where applicable) between
IMPORTANT: When installing a new pressure plate the flywheel and the clutch cover. Install the bolts
or cover assembly, remove the protective film off the and washers and tighten to the specified torque,
friction face with white spirit.
4. Remove the locator tool from the clutch disc.
1. Lightly lubricate the hub splines of the 5. Reconnect the engine to the front transmission
transmission-input shaft with the specified assembly.
grease.
6. To ensure total release of the clutch when the
2. Position the clutch disc on the flywheel with the pedal is fully depressed, check pedal free play
marked face and damper springs towards the and pedal travel. Adjust as necessary.
flywheel.
Use Tool Kit No. FNH02142 to centralize the disc.
TORQUE 27-- 37 LB-FT
TORQUE SEE APPROPRIATE 82886182
[BEFORE ASSEMBLY LUBRICATE

LD HUB AND LUGS]
(MUST BE ASSEMBLED WITH

BOLT HEAD TOWARDS FRONT
OF VEHICLE)
[BEFORE ASSEMBLY
LUBRICATE DISC SPLINES]
[BEFORE ASSEMBLY LUBRICATE

SHAFT O.D. & TRANSCASE
BUSHING I.D. (BOTH ENDS)]
[APPLY APPROPRIATE GREASE

(BOTH ENDS). TORQUE 69-- 103
LB-IN]
10024891
19
18-14
SECTION 18 - CLUTCH
Chapter 2 - Servicing Clutch Associated Parts
CONTENTS

Specifications and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clutch Pedal Free-play (Travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Clutch Pilot Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clutch Release Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Clutch Release Shaft Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clutch Pedal Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
18-1
SPECIFICATIONS AND SPECIAL TOOLS
CLUTCH TYPE 5610S 5610S 6610S 6610S 7610S 7010 8010

DUAL DUAL
POWER POWER
LUK-356 mm (14 in) 314654M 369551M 262801M 850341M 802651M
Diaphragm Cerametalic THRU THRU THRU THRU pres- THRU
present present present ent present
LUK-356 mm (14 in) 314654M 369551M
Diaphragm Organic THRU THRU
present present
LUK-330 mm (13 in) BETWEEN BETWEEN BETWEEN Up to BETWEEN
Diaphragm Cerametalic 314350M & 368801M & 262386M & 850341M 802559M &
314354M 369551M 262801M 802651M
LUK-330 mm (13 in) BETWEEN BETWEEN
Diaphragm Organic 314350M & 368801M &
314354M 369551M
AP or SACHS-330 mm
(13 in) Cerametalic
AP or SACHS-330 mm BETWEEN BETWEEN BETWEEN BETWEEN

(13 in) Organic 312865M & 365072M & 260317M & 802064M &
314350M 368801M 262386M 802559M
TORQUE VALUES
HARDWARE
Flywheel-to-Engine Hub Adapter Bolts 170-224 N⋅m 125-165 ft.-lbs.
Clutch Pressure Plate-to-Flywheel Bolts 24-30 N⋅m 18-22 ft.-lbs.
Clutch Release Bearing Fork-to-Shaft Bolt 41-53 N⋅m 30-39 ft.-lbs.
Clutch Pedal Connecting Rod Turnbuckle Locknut 34 N⋅m 25 ft.-lbs.
Clutch Cover to Flywheel Bolts –Single Clutch 31-39 N⋅m 23-29 ft.-lbs.
Clutch Pedal Pivot Bolt 176 –217 N⋅m 130-160 ft.-lbs.
Pressure Plate Drive Strap Locking Ferrule Bolts 27-34 N⋅m 20-25 ft.-lbs.
Flywheel to Crankshaft Bolts 136-149 N⋅m 100-110 ft.-lbs.
PTO Drive Plate Bolts 129 N⋅m 95 ft.-lbs.
CLUTCH PEDAL FREE-PLAY (TRAVEL)
356 mm (14 in) Clutch 19.05-44.45 mm 3/4-1-3/4 in

330 mm (13 in) Clutch 28-41 mm 1.1-1.6 in
18-2
SPECIAL TOOLS
DESCRIPTION NEW NUDAY TOOL

HOLLAND
Step Plate-Set of 11 FNH 09210 9210
Set Plate-Set of 6 FNH 09211 9211
Driver Set-16 Drivers 3/8″ - 1 3/8″ Dia. FNH 09514 9514
Jaws, Special Bearing Cup Pulling FNH 09564 9564
Hammer, Slide FNH 09567 9567
Attachment, Bearing Pulling FNH 09190 9190
Puller, Pilot Bearing FNH 09527 9527
Puller, Grip-O-Matic FNH 09198 9198
Aligning Arbor FNH 01262 1262
Aligning Arbor for ”Cerametallic” Clutches FNH 01263 1263
Universal Clutch Fixture FNH 02142 2142
Clutch Adapter Kit FNH 02145 2145
Gauge Spacer, 0.300″ FNH 01277 1277
18-3
CLUTCH PILOT BEARING

DESCRIPTION
Installed within the flywheel, at the rear end of the
engine crankshaft, and located in the PTO drive
plate, is a pre-lubricated ball bearing assembly,
which supports the front end of the transmission-in-
put shaft.
NOTE: When overhauling or installing the bearing,
pack the area to the front of the bearing within the
flywheel with a suitable high melting point grease.
OVERHAUL
Removal
1. Remove the clutch. See Chapter 1.
2. Use the Slide Hammer (2), Tool No. FNH 09567,
and Bearing Cup Puller (1), Tool No. FNH 09564,
to remove the PTO drive plate bearing (3), Figure
1.
1
Installation
1. Lightly tap the bearing into the rear end of the
crankshaft or PTO drive plate, with the shield
side facing outwards. Use a suitable Step Plate
(1), Tool No. FNH09210 or FNH09211, to install
the bearing (3), Figure 2 into the flywheel (2).
Reinstall the pilot bearing retainer and flywheel,
and tighten the securing bolts to the correct
torque.
2. Install the clutch. See Chapter 1.
18-4
CLUTCH RELEASE BEARING

1
DESCRIPTION 4
Standard agricultural tractors incorporate a pre-lubri-
cated clutch release bearing. The optional heavy-
duty clutch assembly features an external greaser,
mounted on the front end of the transmission
housing, connected to the release-bearing hub by a
flexible tube.
10024892 2
3
OVERHAUL
Removal
1. Separate the engine and front axle from the front
transmission.
2. Disconnect the front end of the clutch control rod
by removing the split pin and clevis pin. For
models with an external greaser, disconnect the
flexible tube from the release-bearing hub.
3. Remove the retaining bolt (3), securing the clutch
release shaft fork (2), to the shaft (4), Figure 3.
4. Support the fork and release bearing hub
assembly, and extract the release shaft. 4
NOTE: Remove the left-hand steps to facilitate
removal of the release shaft, on models with a cab.
5. Remove the fork, and withdraw the release

bearing assembly (1), Figure 3.
IMPORTANT: Do not attempt to remove the bearing
from the hub on models with an external greaser.
Perform servicing as a complete assembly.
6. For models without an external greaser, use

Bearing Puller Attachment (3), Tool No. FNH
09190 and the “Grip-O-Matic” Puller (1), Tool No.
FNH 09198, and a suitable Step Plate (4), to
separate the release bearing from the hub (2),
Figure 4.
18-5
Installation
Installation of the clutch release bearing follows the
removal procedure in reverse, with the following
requirements:
• Lubricate the hub bore, with a high-temperature
grease.
• Tighten the release shaft fork pinch bolt to the
specified torque.
• Check that release bearing operates correctly
when the clutch pedal is depressed.
• Check the clutch pedal free-play as described in
Chapter 1, and adjust as necessary.
CLUTCH RELEASE SHAFT BUSHINGS

Removal
1. Remove the clutch release shaft as previously
described in this Chapter.
2. Drive the bushings out of the front transmission
housing, using Driver Set Tool No. FNH 09514.
Installation
1. Install the new bushings, chamfered ends first,
into the transmission housing, using Driver Set
Tool No. FNH 09514. Ensure the bushings are
flush with the outside edge of the hole.
2. Reinstall the clutch release shaft as previously
CLUTCH PEDAL BUSHINGS
1
1. Remove the left-hand platform and support 5 6
bracket.
2. Remove the split pin and clevis pin and
disconnect the clutch release rod from the clutch
pedal.
3. Remove the clutch pedal pivot bolt.
NOTE: The pivot bolt has a left-hand thread.
4. Remove the assist spring and rear bracket.

Remove the pedal assembly.
4
2
5. Use Driver Set Tool No. FNH 09514 to drive out
the two bushings from the clutch pedal hub. 3
10024912
5
Clutch Linkage -- 5610, 6610, 7610
Less Straddle Mount Cab
1. Clutch Pedal Assist Spring
2. Pedal Spring Rear Bracket
3. Pivot Bolt
4. Clutch Release Rod
5. Clutch Pedal
6. Left-hand Platform
18-6
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1
Chapter 1 - 8 x 2 Transmission
CONTENTS

Specifications, Tightening Torques and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
8x2 Non-synchromesh Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tractor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Ground Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transmission - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Introduction to Transmission Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gear Shift Levers and Covers - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Start Inhibitor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Transmission Front End - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
21-1
SPECIFICATIONS, TIGHTENING TORQUES AND SPECIAL TOOLS
8X2 NON-SYNCHROMESH TRANSMISSION

Item Reduction 5610S 6610S 7610S 7010 8010
Gearbox
Output Shaft without
End-Float
Output Shaft without 0.076 mm (0.003 in.)
End-Float Shims 0.127 mm (0.005 in.)
Available 0.305 mm (0.012 in.)
Output Shaft with 58-98 N (13-22 lb)
Pre-Load
Output Shaft with 0.10 mm (0.004 in.)
Pre-Load Shims 0.15 mm (0.006 in.)
Available 0.50 mm (0.019 in.)
Input Shaft 1.1-2.3 N⋅m
Bearing Pre- 10-20 in.-lb.
Load Torque
Input Shaft 0.078 mm (0.003 in.)
Bearing Pre- 0.127 mm (0.005 in.)
Load Shims 0.305 mm (0.012 in.)
Oil Capacity Rear Axle*
(single-speed) 62.0 liters
PTO-Rear Axle (16.3 gal)
Oil Capacity Rear Axle*
(two-speed) 66.0 liters
PTO-Rear Axle (17.5 gal)
NOTE: On the 7010 and 8010 models with front

wheel drive, increase the rear axle oil quantity by 1.2
liters (1.3 quarts).
TORQUE VALUES
Clutch Release Bearing Hub Support Bolts 67 49
Clutch Release Fork Bolt 47 35
Front Support Plate Bolts 44 32
Gear Shift Cover Assembly Bolts 56 41
Gear Shift Fork Retaining Screws 31 23
Oil Baffle/Shift Lever Stop Plates 22 16
Output Shaft Retainer Bolts 44 32
Rear Support Plate Retaining Bolts 44 32
Reverse Idler Shaft Retaining Bolt 23 17
Start Inhibitor Switch 40 30
21-2
SPECIAL TOOLS
DESCRIPTION NEW HOLLAND GLOBEL PART
NUMBERS
Hammer, Slide FNH09567
Step Plates (set of 11) FNH09210
Puller, Grip-O-Matic FNH09196
Puller, Push (includes legs and pads) FNH09506
Attachment, Bearing Puller FNH09190
Legs, Push Puller 16 1/2″ (pr) FNH09521
Shaft Protectiors (set of 6) FNH09212 380000564
Transmission/Rear Axle Oil Specification Ambra Multi-G (NH 410 B)
Ground Speed Charts

The charts on the two following pages show the Rear tire size Conversion factor
ground speeds in MPH and km/h. The charts are
for tractors fitted with Dual Power and creeper 13.6 - 36 0.960
gears. If the tractor does not have either of these 13.6 - 38 0.993
features, then ignor the lines on the chart that are
preceded by ‘C’ or ‘Power’. The road speeds in the 16.9 - 30 0.933
charts relate to tractors with 16.9 - 34 rear tires. If 16.9 - 38 1.067
the rear tires of the tractor differ, then multiply
each of the ground speeds shown in the printed 18.4 - 26 0.899
charts by the following conversion factors: 18.4 - 30 0.966
18.4 - 34 1.033
18.4 - 38 1.101
20.8 - 38 1.148
21-3
TRACTOR SPECIFICATIONS
REAR TIRE PRESSURES AND PERMISSIBLE LOADS
(Radial tires -- including front tires on four wheel drive tractors)
Inflation Pressure -- (bar)

Load
L d 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.6
Index
Load Capacity per Tire -- kg
107 680 725 770 815 860 910 955 1000 1050 975
109 720 765 815 860 910 960 1005 1055 1100 1030
114 830 885 940 --990 1050 1100 1155 1210 1260 1180
116 885 940 995 1055 1115 1170 1225 1280 1340 1250
119 965 1020 1090 1145 1210 1270 1335 1390 1455 --1360
121 1020 1080 1150 1220 1285 1355 1420 1485 1555 1450
122 1045 1120 1185 1265 1330 1400 1465 1535 1605 1500
123 1070 1145 1220 1295 1365 1430 1515 1585 1660 1550
124 1105 1180 1260 1335 1410 1490 1565 1640 1715 1600
126 1170 1250 1335 1415 1495 1580 1660 1740 1820 1700
127 1200 1285 1370 1450 1535 1620 1710 1780 1875 1750
128 1230 1320 1410 1495 1580 1670 1755 1840 1926 1800
134 1445 1550 1655 1760 1855 1965 2065 2165 2270 2120
135 1510 1615 1720 1825 1920 2030 2130 2230 2335 2180
136 1550 1660 1765 1875 1875 2080 2185 2290 2395 2240
137 1605 1710 1820 1925 2035 2140 2245 2350 2460 2300
139 1715 1825 1935 2050 2155 2270 2380 2495 2600 2430
141 1820 1935 2055 2170 2290 2410 2520 2640 2760 2575
142 1875 1990 2115 2230 2355 2480 2595 2710 2836 2650
144 1980 2110 2240 2360 2490 2615 2745 2975 3000 2800
146 2085 2225 2370 2510 2650 2790 2930 3070 3210 3000
153 2525 2700 2875 3045 3215 3390 3565 3755 3905: 3650
155 2675 2865 3045 3225 3415 3595 3780 3960 4150 3875
157 2835 3035 3235 3430 3630 3825 4020 4260 4415 4125
159 3000 3210 3420 3635 3845 4060 4260 4475 4685 4375
166 3695 3945 4190 4435 4685 4935 5180 5425 5675 5300
The above table is for guidance only. For exact information regarding inflation pressures and loads for your
particular tires, consult your authorized New Holland dealer.
GROUND SPEEDS
A decal similar to that shown in this figure is affixed
to the instrument console, immediately below the
instrument panel.
The decal illustrates the gear shift pattern and the

approximate ground speed in all forward and reverse
ratios at three alternative engine speeds. The
example shown is for a tractor having a rated engine
speed of 2100 rev/min.
The right hand side of the decal represents the range

and main shift lever positions. To the left will be seen
a number of white rectangles, representing the
ground speeds available in each of the gear ratios. 1
Ground Speed Decal
1. Gearshift Lever Positions
2. Ground Speeds
3. Tire Size
4. Engine Speed Range
21-4
The left-hand edge of each rectangle represents an Each table shows the ground speed at five different
engine speed of 1500 rev/min., the right-hand edge engine speeds in each gear ratio (forward and
2100 rev/min. Each rectangle has a black dot reverse) and are accurate to two decimal places.
representing 1900 engine rev/min (the engine speed
at which the standard PTO speed of 540 rev/min. is The tables are for tractors fitted with the optional Dual
obtained). Power. If your tractor does not have this feature then
you should ignore the line in the table preceded by
Example the word ‘Power’.
To find the approximate ground speed at 2100 Reduction gearboxes (creeper gears) with ratios of
engine rev/min. in 4th gear, follow the dot on the 4th 5.7:1 and 10:1 are available as dealer installed
gear rectangle, down to the MPH line or up to the accessories in certain world markets.
KPH line. In the example shown, the ground speed
indicated is approximately 4.7 MPH or 7.5 KPH. If your tractor has a reduction gearbox then it will be
necessary to divide the ground speeds in the table
Ground speed is affected by the size of the rear tires appropriate to your tractor by the reduction ratio of
fitted to the tractor. Ground speed tables for each the creeper gearbox.
available rear tire size are provided below and on the
following pages.
GROUND SPEEDS -- with 16.9 - 30 Rear Tires

Engine speed (rev/mm) Engine speed (rev/mm)
Gear Dual 1500 1700 1900 2100 2200 1500 1700 1900 2100 2200
Power
Ground Speed in Miles per Hour Ground Speed in Kilometers per Hour
I--L Power 0.87 1.00 1.12 1.23 1.29 1.42 1.61 1.79 1.98 2.08
2--L Power 1.10 1.25 1.39 1.54 1.62 1.77 2.00 2.24 2.47 2.59
I--L Direct 1.14 1.29 1.44 1.59 1.66 1.82 2.07 2.31 2.56 2.68
2--L Direct 1.42 1.61 1.79 1.98 2.08 2.27 2.57 2.87 3.18 3.33
3--L Power 1.94 2.19 2.44 2.70 2.84 3.10 3.52 3.93 4.34 4.55
3--L Direct 2.48 2.81 3.15 3.48 3.64 3.99 4.52 5.05 5.59 5.85
4--L Power 2.63 2.99 3.33 3.68 3.86 4.24 4.80 5.36 5.93 6.21
1--H Power 3.17 3.60 4.02 4.44 4.66 5.10 5.79 6.46 7.14 7.48
4--L Direct 3.38 3.83 4.28 4.73 4.96 5.44 6.16 6.88 7.61 7.97
2--H Power 3.94 4.46 4.98 5.50 5.77 6.33 7.17 8.01 8.86 9.28
1--H Direct 4.08 4.61 5.16 5.70 5.97 6.55 7.42 8.29 9.17 9.60
2--H Direct 5.04 5.72 6.40 7.06 7.40 8.12 9.20 10.28 11.36 11.90
3--H Power 6.89 7.81 8.73 9.66 10.12 11.09 12.57 14.04 15.53 16.27
3--H Direct 8.84 10.02 11.20 12.38 12.97 14.22 16.11 18.00 19.90 20.85
4--H Power 9.41 10.66 11.92 13.1 13.79 15.12 17.14 19.15 21.17 22.17
4--H Direct 12.03 13.63 15.23 16.1 17.67 19.34 21.91 24.49 27.07 28.35
R--L Power 1.26 1.44 1.61 1.77 1.85 2.03 2.30 2.57 2.85 2.98
R--L Direct 1.62 1.34 2.06 2.27 2.39 2.62 2.97 3.32 3.66 3.84
R--H Power 4.52 5.7--7 5.72 6.32 6.62 7.27 8.23 9.20 10.17 10.66
R--H Direct 6.91 6.58 7.36 8.13 8.52 9.35 10.59 11.83 13.08 13.70
L = Low H = High R = Reverse
21-5
GROUND SPEEDS -- with 13.6 - 38 or 16.9 - 34 Tires (these tires have the same rolling radius)
Gear Dual 1500 1700 1900 2100 2200 1500 1700 1900 2100 2200
Power Ground Speed in Miles per Hour Ground Speed in Kilometers per Hour
1--L Power 0.93 1.06 1.19 1.31 1.37 1.51 1.71 1.91 2.11 2.21
2--L Power 1.17 1.33 1.48 1.64 1.72 1.88 2.13 2.38 2.63 2.76
I--L Direct 1.21 1.37 1.53 1.69 1.77 1.94 2.20 2.46 2.72 2.85
2--L Direct 1.51 1.71 1.91 2.11 2.21 2.42 2.74 3.06 3.39 3.55
3--L Power 2.06 2.33 2.60 2.88 3.02 3.30 3.74 4.18 4.62 4.84
3--L Direct 2.64 2.99 3.35 3.70 3.88 4.25 4.81 5.38 5.95 6.23
4--L Power 2.80 3.18 3.55 3.92 4.11 4.51 5.11 5.71 6.31 6.61
1--H Power 3.38 3.83 4.28 4.73 4.96 5.43 6.16 6.88 7.60 7.96
4L Direct 3.60 4.08 4.56 5.04 5.28 5.79 6.56 7.33 8.10 8.49
2--H Power 4.19 4.75 5.30 5.86 6.14 6.74 7.63 8.53 9.43 9.88
1--H Direct 4.34 4.91 5.49 6.07 6.36 6.97 7.90 8.83 9.76 10.22
2--H Direct 5.37 6.09 6.81 7.52 7.88 8.64 9.79 10.94 12.09 12.67
3--H Power 7.34 8.32 9.30 10.28 10.77 11.81 13.38 14.95 16.53 17.32
3--H Direct 9.41 10.67 11.92 13.18 13.81 15.14 17.15 19.17 21.19 22.20
4--H Power 10.02 11.35 12.69 14.02 14.69 16.10 18.25 20.39 22.54 23.61
4--H Direct 12.81 14.51 16.22 17.93 18.78 0.59 23.33 26.08 28.82 30.19
R--L Power 1.34 1.53 1.71 1.88 1.97 2.16 2.45 2.74 3.03 3.17
R--L Direct 1.73 1.96 2.19 2.42 2.54 2.79 3.16 3.53 3.90 4.09
R--H Power 4.81 5.45 6.09 6.73 7.05 7.74 8.76 9.79 10.83 11.35
R--H Direct 6.19 7.01 7.84 8.66 9.07 9.95 11.27 12.60 13.93 14.59

Gear Dual 1500 1700 1900 2100 2200 1500 1700 1900 2100 2200
1--L Power 1.07 1.39 1.28. 1.41 1.47 1.62 1.84 2.05 2.27 2.37
2--L Power 1.26 1.43 1.59 1.76 1.85 2.02 2.29 2.56 2.83 2.97
1--L Direct 1.30 1.47 1.64 1.82 1.90 2.08 2.36 2.64 2.92 3.06
2--L Direct 1.62 1.84 2.05 2.27 2.37 2.60 2.94 3.29 3.64 3.81
3--L Power 2.21 2.50 2.79 3.09 3.25 3.55 4.02 4.49 4.96 5.20
3--L Direct 2.84 3.21 3.60 3.98 4.17 4.57 5.17 5.78 6.39 6.69
4--L Power 3.01 3.42 3.81 4.21 4.42 4.85 5.49 6.13 6.78 7.10
1~H Power 3.63 4.12 4.60 5.08 5.33 5.83 6.62 7.39 8.17 8.55
4--L Direct 3.87 4.38 4.90 5.42 5.67 6.22 7.05 7.88 8.70 9.12
2--H Power 4.50 5.10 5.69 6.30 6.60 7.24 8.20 9.16 10.13 10.61
1--H Direct 4.66 5.27 5.90 6.52 6.83 7.49 8.49 9.49 10.49 10.98
2--H Direct 5.77 6.54 7.32 8.08 8.47 9.28 10.52 11.75 12.99 13.61
3--H Power 7.89 8.94 9.99 11.04 11.57 12.69 14.38 16.06 17.76 18.61
3--H Direct 10.11 11.46 1281 14.16 14.84 16.27 18.43 20.60 22.77 23.85
4--H Power 10.77 12.19 13.63 15.06 15.78 17.30 19.61 21.91 24.22 25.37
4--H Direct 13.76 1559 17.43 19.26 20.18 22.12 25.06 28.02 30.96 32.43
R--L Power 1.44 1.64 1.84 2.02 2.12 2.32 263 2.94 3.26 3.41
R--L Direct 1.86 2.11 2.35 2.60 2.73 3.00 3.40 3.79 4.19 4.19
R--H Power 5.17 5.86 6.54 7.21 7.57 8.32 9.41 10.52 11.64 12.19
R--H Direct 6.65 7.53 8.42 9.30 9.74 10.69 12.11 13.54 14.97 15.67
21-6
GROUND SPEEDS -- with 13.6 - 38 or 16.9 - 34 Tires (these tires have the same rolling radius)
Gear Dual 1500 1700 1900 2100 2200 1500 1700 1900 2100 2200
I--L Power 0.91 1.03 1.16 1.28 1.33 1 47 1.66 1 86 2.05 2.15
2--L Power 1.14 1.29 1.44 1.60 1.67 1.83 2.07 2.33 2.56 2.69
1--L Direct 1.18 1.33 1.49 1.64 1.72 1.89 2.14 2.39 2.65 2.77
2--L Direct 1.47 1.66 1.86 2.05 2.15 2.36 2.67 2.98 3.30 3.45
3--L Power 2.00 2.27 2.53 2.80 2.94 3.21 3.64 4.07 4.50 4.71
3--L Direct 2.57 2.91 3.26 3.60 3.78 4.14 4.68 5.24 5.79 6.06
4--L Power 2.72 3.09 3.45 3.81 4.00 4.39 4.97 5.56 6.14 6.43
1--H Power 3.29 3.73 4.16 4.60 4.83 5.28 5.99 6.69 7.40 7.74
4--L Direct 3.50 3.97 4.44 4.90 5.14 5.63 6.38 7.13 7.88 8.26
2--H Power 4.08 4.62 5.16 5.70 5.97 6.56 7.42 8.30 9.18 9.61
1--H Direct 4.22 4.78 5.34 5.91 6.19 6.78 7.69 8.59 9.50 9.94
2--H Direct 5.23 5.93 6.63 7.32 7.67 8.41 9.53 10.64 11.76 12.33
3--H Power 7.14 8.10 9.05 10.00 10.48 11.49 13.02 14.55 16.08 16.85
3--El Direct 9.16 10.38 11.60 12.82 13.44 14.73 16.69 18.65 20.62 21.60
4--H Power 9.75 11.04 12.35 1364 14.29 15.67 17.76 19.84 21.93 22.97
4--H Direct 12.46 14.12 15.78 17.45 18.27 20.03 22.70 25.38 28.04 29.37
R--L Power 1.30 1.49 1.66 1.83 1.92 2.10 2.38 2.67 2.95 3.08
R--L Direct 1.68 1.91 2.13 2.36 2.47 2.72 3.08 3.44 3.80 3.98
R--H Power 4.68 5.30 5.93 6.55 6.86 7.53 8.52 9.53 10.54 11.04
R--H Direct 6.02 6.82 7.63 8.43 8.83 9.68 10.97 12.26 13.55 14.20

Gear Dual Engine speed (rev/mm) Engine speed (rev/ruin)
Power 1500 1701 1900 2100 2200 1500 1700 1900 2100 2200
Ground Speed in Miles per Hour Ground Speed in Kilometers per Hour
I--L Power 0.97 1.10 1.24 1.36 1.43 1.57 1.78 1.99 2.20 2.30
2--L Power 1.22 1.38 1.54 1.71 1.79 1.96 2.22 2.48 2.74 2.87
1--L Direct 1.26 1.43 1.59 1.76 1.84 2.02 2.29 2.56 2.83 2.97
2--L Direct 1.57 1.78 1.99 2.20 2.30 2.52 2.85 3.18 3.53 3.69
3--L Power 2.14 2.43 2.71 3.00 3.14 3.43 3.89 4.35 4.81 5.04
3--L Direct 2.75 3.11 3.49 3.85 4.04 4.42 5.01 5.60 6.19 6.48
4--L Power 2.91 3.31 3.69 4.08 4.28 4.69 5.32 5.94 6.57 6.89
1--H Power 3.52 3.99 4.45 4.92 5.16 5.65 6.41 7.16 7.91 8.28
4--L Direct 3.75 4.25 4.75 5.24 5.49 6.03 6.83 7.63 8.43 8.83
2--H Power 4.36 4.94 5.52 6.10 6.39 7.01 7.94 8.88 9.81 10.28
1--H Direct 4.52 5.11 5.71 6.32 6.62 7.25 8.22 9.19 10.16 10.63
2--H Direct 5.59 6.34 7.09 7.83 8.20 8.99 10--19 11.38 12.58 13.18
3--H Power 7.64 8.66 9.68 10.70 11.21 12.29 13.92 15.56 1720 18.02
3--H Direct 9.79 11.10 12.40 13.71 14.37 15.75 17.85 19.95 22.05 23.10
4--H Power 10.43 11.81 13.20 14.59 15.29 16.75 18.99 21.22 23.45 24--57
4--H Direct 13.33 15.10 16.88 18.66 19.54 21.43 24.28 27.14 29.99 31.41
R--L Power 1.39 1.59 1.79 1.96 2.05 2.25 2.55 2.85 3.15 3.30
R--L Direct 1.80 2.04 2.28 2.52 2.64 2.90 3.29 3.67 4.06 4.26
R.H Power 5.01 5.67 6.34 7.00 7.34 8.05 9.12 10.19 11.27 11.81
R--H Direct 6.44 7.29 8.16 9.01 9.44 10.35 11.73 13.11 14.50 15.18
21-7
TRANSMISSION - DESCRIPTION AND

OPERATION 1--5 2--6 4--8 C
A non-synchromesh transmission with a constant
mesh design, provides eight forward, and two L
reverse speeds through two manually operated
levers. The main gear lever selects any one of four
forward, or one reverse speed, and a second shorter N
lever selects an overall high or low ratio.
A neutral start switch Incorporated in the transmis- 3--7 R1--R2 H

sion, prevents the starter motor from operating when
the secondary (range) lever is not in the neutral
OM286 MT
position.
The gears are all in constant mesh and gear 2

connections are made by sliding couplings. The Gear Shift Lever Positions
transmission main shaft is located in the top drive line (With Optional Creeper Gears)
L = Low Range
and the main countershaft and output shaft are N = Neutral
located in the bottom drive line. The transmission is C = Creeper gears
available with Independent single or two speed PTO, H = High Range
not shiftable. Refer to the “POWER TAKE-OFF” R = Reverse
-Section for further details of the PTO drive line.
The transmission features straight cut type gears on

all gears. Roller bearings are used throughout the
transmission, except on the output shaft assembly
where taper roller bearings are used. Shims between
the output shaft end cover and bearing retainer
provide the method of controlling output shaft end
float.
The low-pressure hydraulic system provides a

proportionate amount of oil for pressure lubrication of
the front transmission. The oil cooler located at the
front of the tractor cools the hydraulic oil, then directs
the oil to the front transmission through external
tubing.
The main countershaft and output shaft are hollow,

and consist of cross drilling, which allows passage of
the hydraulic oil from the cooler, to lubricate and cool
the transmission gears.
Returning hydraulic oil from the front transmission

flows to the rear axle, and then back to the hydraulic
system. Therefore, a common oil reservoir between
the front transmission, rear axle, and hydraulic
system exists.
A Dual Power option which consists of a planetary

gear set installed directly between the clutch and
input shaft of the standard transmission is available.
The planetary gear set provides either a direct drive
or an underdrive in each gear ratio of the standard
transmission. Refer to 8 ¢ 2 Dual Power Section 21
Chapter 4.
21-8
21-9
INTRODUCTION TO TRANSMISSION GEAR SHIFT LEVERS AND COVER -

OVERHAUL OVERHAUL
To assist in overhauling the transmission, note the Removal
following on component accessibility:
1. If the tractor is equipped with a cab, lift up the
Components Accessible With Transmission floor mats and remove the floor panel in order to
Installed: gain access to the shift cover.
• Gear Shift Levers 2. Place the gear shift levers in the neutral position.
• Gear Shift Cover Assembly 3. Disconnect the Battery negative (ground) cable.
4. Disconnect the neutral start switch wires from the
• Neutral Start Switch harness connection.
Components Accessible With Engine Removed 5. Remove the gearshift cover retaining bolts and
Only: partially lift the space cover from the transmis-
All items above, plus the following: sion casing. With the cover raised, disconnect
the neutral start switch wires from the switch and
• Clutch Assembly remove the shift cover assembly from the
transmission.
• Clutch Release Shaft Fork and Bearing
Disassembly
Assembly
1. Remove the oil baffle plate retaining bolts from
• Main Input Shaft the underside of the shift cover and remove the
plate and washers.
• Front Upper and Lower Shaft Front Bearings
2. Unscrew and remove the gear shift lever knobs.
• Front End Oil Seal
3. Use a hacksaw to partially cut the lever retaining
Components Accessible With Transmission snap rings. If possible place the gear shift lever
Removed: into the jaws of a vice as close to the snap ring as
possible. Then using a chisel, finally break off the
All items above, plus the following:
rings. During this operation ensure the retaining
• Rear Cover Assembly rings are not dangerously ejected from the
grooves on the levers. Slowly release the vice
• PTO Drive Shaft and remove the springs, ball retainers and
levers.
• Selector Rails, Forks, Detent Components and
Interlocks NOTE: It is not necessary to remove the lever
locating pins in the cover assembly as the levers are
• Output Shaft Assembly slotted.
• Range Cluster Gear
• Front Upper Shaft Components Inspection

1. Wash the shift cover and shift lever assemblies
• Front Lower Shaft Components in a suitable solvent and dry with a clean, lint free
cloth or compressed air.
• Reverse Idler Components
2. Inspect the shift cover for cracks or other
damage. Replace the cover when necessary.
3. Inspect the shift lever ball seats and ends for
wear, and the lever locating pins in the cover.
Replace the pins if worn or damaged. New pins
should be pressed into the cover.
4. Inspect the lever retaining springs for cracks or
distortion, and inspect the retaining snap ring
grooves on the levers.
5. Inspect the neutral start switch wiring harness for
damage. Replace the harness if necessary.
21-10
4
Top Cover Assembly
1. Neutral Start Switch Wiring Harness 13. Washer
2. Shift Cover Bolt 14. Washer
3. Washer 15. Range (High/Low) Lever
4. Cover 16. Main Gear Lever
5. Gasket 17. Pin, Start inhibitor switch
6. Pin 18. Dowel
7. Spring 19. Lever Locating Pins
8. Ball 20. Retainer
9. Spring 21. Lever Spring
10. Pin 22. Seal
11. Baffle Plate Retaining Bolt -- 3 off 23. Snap Ring
12. Baffle Plate 24. Gear Lever Knob
Assembly Installation
Assembly of the gear shift levers and cover follows Installation of the gear shift levers and cover follows
the disassembly procedures in reverse with the the removal procedures in reverse with the following
following requirements: requirements:
1. Place the two oil baffle washers on the underside 1. Apply a suitable grease to a new gasket (to hold
of the shift cover, then install the oil baffle plate in place) and position gasket on shift cover
with the retaining bolts. assembly. Install the cover using removal
procedures in reverse with the following
2. Assemble the ball retainers and springs.
requirements.
Compress the springs and install new retaining
snap rings. 2. Ensure the start inhibit actuator housing is
aligned with the locating pin in the shift cover.
3. Reassemble the two oil baffle washers to the
underside of the shift cover, the oil baffle plate 3. Tighten the cover retaining bolts to a torque of 56
and the retaining bolts. N⋅m (41 ft.-lb.).
21-11
NEUTRAL START SWITCH

Removal
1. Remove the shift cover as previously described.
2. Unscrew the neutral start switch (1) from the
housing, Figure 5.
Insection
1. Inspect the neutral start switch for wear or
damage. Replace as necessary.
5
Assembly and Installation
Assembly and installation of the neutral start switch
follows the removal procedures in reverse, with the
1. Test the switch operation by connecting a test

bulb in series with the switch terminals and a
battery. Move the switch actuator housing along
the high/low shift rail and away from the center
line of the actuating dowel. The test bulb should
only light when the actuator housing is centerd
over the actuating dowel.
NOTE: Do not move the actuator housing more than
6 mm (0.25 in.) from the actuating dowel center line 6
or the dowel may come out of the shift rail.
TRANSMISSION FRONT END - OVERHAUL

Removal
1. Separate the engine from the transmission, see
“SEPARATING THE TRACTOR” Section 10.
2. Remove the gear shift levers and cover as
previously described in this Chapter.
Disassembly
1. Remove the clutch release fork retaining bolt (3),
Figure 7 and withdraw the clutch release shaft (4)
from the casing. Remove the clutch release fork
(2) from the transmission. Slide the clutch
7
release bearing and hub (1) from the clutch
release hub support.
21-12
2. Transmissions With Dual Power: Disassemble
the Dual Power unit as described in 8 ¢ 2 Dual
Power Section. Remove the Dual Power housing
retaining bolts and lift the housing from the
transmission casing. Take care not to lose the
anti-spin washer located between the transmis-
sion main shaft front gear and front bearing, if the
bearing comes away with the dual power
housing.
8
Transmissions Less Dual Power: Disconnect the
low pressure lubrication lines from the clutch
release bearing hub support and the front
support plate. Remove the hub support (1),
Figure 8. Remove the snap ring (1) retaining the
main drive input shaft (2) to the transmission
main shaft, Figure 9 and withdraw the input shaft.
9
3. Remove the front support plate retaining bolts
(2), Figure 10 and withdraw the plate (1) from the
housing. If necessary, drive the plate from the
housing using a suitable drift inserted into the
main transmission compartment.
10
1. Inspect the clutch release components for wear,
see “CLUTCHES” - Section 18.
2. Transmission Without Dual Power: Inspect the
main shaft front oil seal located in the clutch
release bearing hub support, and if necessary,
use Slide Hammer, Tool No. FNH09567, to
remove the seal. Use a Step Plate, Tool No.
FNH09210 and sleeve of suitable diameter to
install a new seal, with the sealing lip facing
rearwards. Lubricate the sealing lip with a
suitable grease before installing.
21-13
3. Inspect the main drive input shaft and retaining
snap ring and replace if worn or damaged.
4. Inspect the main countershaft front bearing and
replace if worn or damaged. Use Puller Tool No.
FNH09196 (2) and Shaft Protector Tool No.
FNH09212 or 380000564 (3) to remove bearing
(1) from the shaft, Figure 11.
Use a sleeve of 32mm (1.25 in) internal diameter
and 41mm (1.62 in) external diameter to install a
new bearing onto the countershaft.
11
Assembly
1. Install the front support plate to the transmission
case using a new gasket. If necessary, lift the
main shaft and main countershaft to align the
countershaft front bearing. Install the retaining
bolts and tighten to 44 N⋅m (32 ft.-lb.).
Transmissions With Dual Power: Re-assemble
the Dual Power components as detailed in the 8
¢ 2 Dual Power Section.
NOTE: If the front bearing (3) came off with the Dual
Power Housing during the removal procedure,
ensure that the anti-spin washer (2) is properly
reinstalled and secured in place between the
transmission main shaft front gear (1) and bearing
Figure 12. If the bearing has remained on the main
shaft during disassembly, coat the outer edge of the
bearing with a suitable adhesive, such as New
Holland Stud and Bearing Lock, Part No. 82995772
before reassembling, to prevent the bearing from
rotating in the Dual Power Housing.
12
Transmissions Without Dual Power: Install the
main drive input shaft into the forward end of the
transmission main shaft and secure with the
snap ring. Place studs in two of the five bolt holes
to ensure correct alignment of the clutch release
hub on assembly. This will prevent damage to the
release hub oil seal. Position a new gasket on the
front support plate and slide the clutch release
hub support over the studs. Drive the support into
position with the drain hole downwards. Remove
the studs, install the retaining bolts and tighten to
67 N⋅m (49 ft.-lb.).
2. Install the clutch release bearing and hub
assembly onto the hub support.
3. Insert the release fork fingers into the slots in the
hub and install the release shaft through the
casing and release fork. Install the fork retaining
bolt and tighten to 47 N⋅m (35 ft.-lb.).
21-14
TRANSMISSION -- OVERHAUL
Disassembly
1. Remove the clutch operating mechanism, clutch
release hub support, Dual Power transmission
(when installed), front support plate and main
drive input shaft assembly as previously
2. Remove the shift levers and cover assembly as
previously outlined in this Chapter, together with
the neutral start switch from the high/low shift rail.
3. Remove the snap ring (4), the thrust washer (3)
and the hydraulic pump idler gear (2), located on
the output shaft retainer, Figure 13. 13
4. Remove the rear support plate retaining bolts (1),

Figure 12 and using a soft faced mallet drive the
forward end of the PTO drive shaft rearwards.
This will separate the rear support plate (1) from
the transmission casing. If necessary, lever the
rear support plate from the casing and remove
the plate with the PTO drive shaft (4), Figure 14.
5. Remove the snap ring (2) retaining the PTO drive
shaft rear bearing (5) and drive the shaft and
bearing out of the support plate.
6. Remove the bolts securing the output shaft
retainer to the rear support plate and remove the
retainer (3) Figure 13 and shims from the rear
support plate. 14
7. Partially remove the secondary countershaft

assembly (1) until the front bearing is out of the
location. Lift the secondary countershaft to allow
the output shaft assembly (2) to be removed from
the rear compartment, Figure 15, followed by
removal of the secondary countershaft.
15
21-15
8. Remove the high/low sliding coupling (1) from
the rear of the main countershaft, Figure 16.
16
Gear Shift Mechanism
1. Remove the four detent plungers (1) and springs
(2). The detent balls (3) located below the springs
should be collected with shift rail removal, Figure
17.
17
2. Unscrew the neutral start switch (5) from the
housing. Loosen the locknut and remove the bolt
locking the high/low range fork (6) to the shaft.
Remove the range lever connector (4) from the
shaft and slide the rail out from the rear of the
gearbox, Figure 18. Place a clean cloth beneath
the neutral start switch actuator housing. Take
care to ensure the ball, spring and actuating
dowel are collected from the housing and rail. Lift
the high/low shift fork from the rear compartment.
3. Unscrew the locknut and retaining screw from
the 1st-5th/3rd-7th shift fork (3) at the front of the
shift rail, Figure 18. Drive the rail forward from the
transmission casing, pushing the sealing plug
out with the end of the rail. Remove the shift 18
connector and fork.
4. Unscrew the locknut and retaining screws from
the 4th-8th shift fork (8) and connector (1) and
push the shift rail rearwards from the transmis-
sion case, Figure 18. Remove the fork and the
connector.
5. Unscrew the locknut and retaining screw from
the Reverse/2nd-6th shift arm (2) and connector
and slide the top rail out rearwards, Figure 18. Lift
the shift arm and the connector from the
transmission case.
21-16
6. Remove the locknut and screw (1) retaining the
Reverse/2nd-6th shift fork to the lower shift rail
(4), Figure 19 and push out the rail rearwards.
Remove the shift fork from the transmission
casing.
7. Remove the interlock plungers from the cross
bore in the transmission case. If necessary,
remove the bore plug situated on the left-hand
side of the case to facilitate removal of the
plungers.
Reverse Idler Assembly

1. Bend down the locktab and remove the bolt (3)
retaining the reverse idler shaft to the transmis- 19
sion case, Figure 19.
2. Drive the shaft out forwards and lift out the
reverse idler gear (2).
Mainshaft Assembly
1. Position a Step Plate, Tool No. FNH09210, in the
bore at the rear of the main shaft.
2. Drive the shaft forwards, using a suitable drift,
from the transmission case and remove the
4th-8th coupling gear.
Main Countershaft Assembly
1. If not previously removed, use Puller Tool No.
FNH09196 and Step Plate Tool No. FNH09210,
to remove the main countershaft, front bearing.
Remove the snap ring (4) located behind the
bearing, and remove thrust washer (2), Figure
20.
2. Slide the main countershaft (3) rearwards, and
remove the gears (1), couplings, and thrust
washer. Store components in the order of
removal to aid in reassembling.
NOTE: The inner and outer sections of the sliding
couplings are matched during manufacture and
should not be separated. 20
21-17

Rear End Components
1. Inspect the PTO drive shaft and bearing
assembly. If the bearing is worn or damaged, use
Puller, Tool No. FNH09516, Pulling Attachment,
Tool No. FNH09190 and Shaft Protector, Tool No.
FNH09212 or 380000564, to remove. Use a
convenient length of sleeve 37 mm (1.44 in.)
internal diameter and 44 mm (1.75 in.) external
diameter to install a new bearing.
2. Inspect the output shaft retainer and rear bearing
cup for wear or damage. If necessary, remove
the cup from the retainer using a suitable punch.
Use Step Plate, Tool No. FNH09210 and a
suitable punch to install the new bearing cup.
3. Inspect the output shaft assembly for wear or
damage. If necessary, use Puller, Tool No.
FNH09198 (1), Puller Adaptor, Tool No.
FNH09190 (2) and Shaft Protector, Tool No.
FNH09212 or 380000564 (4), to remove the front
pilot bearing cone and roller assembly (3), Figure
21.
21
4. Use Puller, Tool No. FNH09516 (1) and Shaft
Protector, Tool No. FNH09212 or 380000564 (4),
to remove the gear (2), rear bearing (3), and
thrust washer in one operation, Figure 22.
5. Inspect the output gear bushing for wear, and
replace the gear and bushing assembly if
necessary.
22
21-18
6. Install the steel thrust washer by aligning the flats
of the washer with the flats of the shaft. Position
the rear bearing on the output shaft, Figure 32,
component ‘E’. Use Puller Tool No. FNH09516
(1), Pulling Attachment Tool No. FNH09526 (3),
and Shaft Protector Tool No.FNH09212 or
380000564 (5), to assemble. Use a suitable
sleeve with a 40 mm (1.6 in.) internal diameter,
and 50 mm (2 in.) external diameter (2), to pull
the bearing (4) into position, Figure 23.
23
7. Inspect the secondary countershaft assembly for
wear or damage. If necessary, use Puller, Tool
No. FNH09516, Pulling Attachment, Tool No.
FNH09526 and Step Plate, Tool No. FNH09210,
to remove the rear bearing. 5
8. If necessary, remove the secondary countershaft
front bearing (2), using 2 steel rods (4) 4.6 mm
(.18 in.) diameter and 51 mm (2 in.) long. Insert 4
rods through the two holes in the driving gear.
Use Puller Tool No. FNH09516 (1), Pulling
Attachment Tool No. FNH09190 (3), and Step
Plate Tool No. FNH09210 (5), to push the bearing
from the countershaft, Figure 24
9. Use Puller, Tool No. FNH09516, Pulling 24
Attachment, Tool No. FNH09190 and Step Plate,
Tool No. FNH09210, to install both front and rear
bearings.
Main Shaft Components
1. Inspect the main shaft assembly, the front and
rear bearings and PTO drive shaft oil seal located
inside the forward end of the shaft.
2. If necessary, use Puller Tool No. FNH09516 (1),
Pulling Attachment Tool No. FNH09190 (2), and
Step Plate Tool No. FNH09210 (4) to remove the
main shaft front and rear bearing (3). When
removing the front bearing, in addition to the
special tools listed above, use 2 steel rods 4.6
mm (.18 in.) diameter and 51 mm (2 in.) long,
inserted through the two holes in the driving gear.
3. Use Puller, Tool No. FNH09516, Pulling
Attachment, Tool No. FNH09526 and Step Plate, 25
Tool No. FNH09210 to install a new rear bearing.
A new front bearing should be installed using the
above tools together with a sleeve 64 mm (2.5
in.) internal diameter and 76 mm (3.0 in.) external
diameter of convenient length.
21-19
NOTE: Whenever removing or installing the main
shaft, front bearing ensure the anti-spin washer is in
good condition before assembling.
4. Inspect the PTO drive shaft oil seal located within

the main shaft and remove if worn or damaged.
Install a new seal, after lightly greasing the
sealing lip, with the sealing lip facing rearwards.
Use a Step Plate, Tool No. FNH09210 and sleeve
of convenient size to drive the seal into location.
Main Countershaft Components
1. Inspect the main countershaft assembly and if
necessary, use Puller, Tool No. FNH09506 (1),
Puller Legs, Tool No. FNH09521 (6), Ratchet,
Tool No. FNH09162 (2), Pulling Attachment, Tool
No. FNH09526 (3) and Shaft Protector, Tool No.
FNH09212 or 380000564 (5), to pull the rear
bearing (4) from the countershaft, Figure 26.
26
2. Inspect the output shaft pilot bearing cup located
in the end of the main countershaft (1) for
excessive wear. If necessary, remove the
bearing cup using a suitable punch (2) inserted
through the two holes in the gear (3), Figure 27.
3. Use a suitable Step Plate, Tool No. FNH09210
and Puller, Tool No. FNH09516, to install a new
output shaft pilot bearing cup into the rear of the
main countershaft.
27
4. Use Puller, Tool No. FNH09516 (1), Pulling
Attachment, Tool No. FNH09526 (3), Step Plate,
Tool No. FNH09210 (5) and a sleeve 51 mm
(2.00 in.) internal diameter and 82 mm (3.21 in.)
external diameter of convenient length (4), to
install a new rear bearing (2) onto the main
countershaft, Figure 28.
28
21-20
5. Inspect all gears which mount on the main
countershaft for damage and wear. With the
gears on the countershaft, check the bushings
for free play. Inspect the reverse idler gear and
bushing assembly and replace if necessary.
6. Inspect the main countershaft rear bearing cup
(1) situated in the transmission case and if
damaged or worn, use Slide Hammer, Tool No.
FNH09567 (2), to remove, Figure 29. Install a
new cup using a suitable drift.
7. Inspect the countershaft front bearing for wear
and damage. If necessary, install a new bearing.
8. Inspect all components with internal splines, 29
external splines, or gear teeth, and if worn or
damaged, replace on reassembly.
9. Inspect the lubrication drillings for obstructions.
21-21
Gear Shift Mechanism c. Phosphor-bronze thrust washer.
1. Inspect the gear shift forks, rails, arms and d. Reverse gear (dog-teeth rearward).
connectors for wear or distortion. Inspect the
detent on the shift rails and replace the shift rail e. Phosphor-bronze thrust washer.
if the detents are worn.
f. 1st-5th gear (dog-teeth forward).
Transmission Case g. 3rd-7th/1st-5th Sliding coupling and

1. Wash out the transmission case with a suitable connector.
solvent to remove all particles of metal and dirt.
h. 3rd-7th gear (dog-teeth rearward).
Dry with a clean, lint free cloth or compressed air.
2. Inspect the case for cracks or other damage. i. Thrust washer
Replace if necessary.
j. Snap ring.
Assembly
k. Front bearing.
NOTE: Refer to Figure 33 during transmission
reassembly unless otherwise stated. 2. Support the main countershaft during reas-
sembly and ensure the rear bearing seats
squarely in the bearing outer track.
Main Countershaft Assembly
1. Pass the main countershaft through the rear 3. Position the high/low sliding coupling on the rear
compartment and assemble the gears in the of the main countershaft.
following sequence:
Main Shaft Assembly
a. 2nd-6th gear (dog-teeth forward).
1. Ensure correct positioning of the snap ring
NOTE: The connectors mentioned in step 1(b) have retaining the main shaft rear bearing in the
a chamfer on one side of the inside diameter. This transmission casing.
chamfer must face the rear of the transmission to 2. Install the 4th-8th coupling gear on the rear of the
allow the connector to seat correctly on the main main shaft with the shift fork groove to the front.
countershaft splines. The sliding coupling and
connector are matched during manufacture and 3. Position the main shaft assembly in the
should be installed with the etched marks aligned. transmission casing.
4. Drive the main shaft assembly rearwards to seat
b. Reverse/2nd-6th sliding coupling and con-
the rear bearing in the location within the casing.
nector.
21-22
Reverse Idler Assembly
1. Position the reverse idler gear (1) between the
supporting lugs, Figure 30, with the extended
hub of the gear towards the front of the
transmission.
2. Install the reverse idler shaft from the rear
compartment with the retaining bolt hole
forwards. Install the retaining bolt (2) and locktab,
and tighten the bolt to 23 N⋅m (17 ft.-lb.) and bend
up the locktab.
30
Gear Shift Mechanism
Refer to Figure 31.
1. Install the Reverse/2nd-6th shift fork (4) onto the

appropriate sliding coupling on the main
countershaft and install the lower shift rail (5)
from the rear compartment with the fork retaining
hole to the rear of the shift rail, Figure 31. Install
the fork retaining screw and lock nut then tighten
the screw to 31 N⋅m (23 ft.-lb. ). Secure with the
lock nut.
31
2. Insert the two interlock plungers into the bore
from the left-hand side of the transmission case
and install the plug. Position each plunger
between the three shift rail bores.
3. Position the 4th-8th shift fork (10) on the sliding
coupling. Install the shift rail (1) from the rear, with
the oil relief groove rearwards and pass through
the bore in the shift fork. Install the retaining
screw and locknut and tighten to 31 N⋅m (23
ft.-lb.).
NOTE: When installing the remaining top shift rails,
ensure the rails already installed are in the neutral
position so the interlock plungers do not prevent the
rail from entering the front support bore.
4. Position the lower end of the Reverse/2nd-6th

shift arm (6) into the locating hole in the
Reverse/2nd-6th shift fork (4). Pass the
Reverse/2nd-6th top shift rail (9) in from the rear
with the oil relief groove rearwards. With the shift
rail correctly located in the shift arm, install the
retaining screw and locknut then tighten to 31
N⋅m (23 ft.-lb.).
21-23
5. Position the 1st-5th/3rd-7th shift fork (3) in the
sliding coupling located at the front of the main
countershaft. Install the 1st-5th/3rd-7th shift rail
(2) from the front of the transmission. Insert the
rail in the shift fork and secure with the retaining
screw. Install the shift connector to the rear of the
rail and secure with the retaining screw. Tighten
the retaining screws and lock nuts to 31 N⋅m (23
ft.-lb.). Install the sealing plug at the front of the
rail.
6. Position the high/low shift fork (7) in the groove
of the high/low sliding coupling located on the
output shaft. Install the high/low shift rail (8) in the
shift fork. Secure the shift fork with the retaining
screw and tighten the screw and lock nut to 31
N⋅m (23 ft.-lb.).
NOTE: The shorter plunger is located in the vertical
bore above the high/low shift rail.
7. Install the four shift rail detent balls, springs and
plungers. Ensure the balls and plungers slide
freely in the bores.
Rear End Components
1. Ensure the snap ring located immediately in front
of the secondary countershaft front bearing is in
position in the transmission casing bore.
2. Hold the secondary countershaft assembly in
position at the top of the rear compartment, while
installing the output shaft assembly. Align the
secondary countershaft and drive forward until
the front bearing seats against the locating snap
ring in the transmission case.
3. Position the rear support plate without the output
shaft retainer assembly, on the transmission rear
face. Drive the plate into position on the dowels,
then install the retaining bolts Tighten bolts to a
torque of 44 N⋅m (32 ft.-lbs.).
4. Install the PTO drive shaft and rear bearing
through the rear of the transmission. Use a
soft-faced mallet to drive the shaft and bearing
into position. Secure the rear bearing with a snap
ring.
5. Install shims between the rear support plate and
output shaft, bearing retainer, to obtain the
specified end-play in the output shaft, taper roller
bearings. Use the following procedure:
a. Install shims to obtain a thickness of 1.6 mm
(0.06 in.), and install the output shaft bearing
retainer assembly on the rear support plate.
b. Install the four retaining bolts and tighten to
a torque of 44 N⋅m (32 ft.-lbs.).
21-24
c. Position the plunger of a dial indicator gauge
(3) against the end face of the output shaft
(2), Figure 32. Lever the shaft in and out and
note the end-play reading. If no end-play is
registered, add additional shims to produce
a gauge reading.
d. Remove the indicator gauge and the four

retainer bolts. Withdraw the retainer (1) and
shims.
e. Remove shims to obtain an end float

between 0.038 mm (0.0015 in.) and 0.086
mm (0.0034 in.)
32
NOTE: Shims are available in thicknesses of 0.076
mm, 0.127 mm and 0.305 mm (0.003 in., 0.005 in.
and 0.012 in.).
f. After obtaining the correct end-play, install

the bearing retainer (with the oil slot to the
top), shims, and bolts. Tighten bolts to a
torque of 43 N⋅m (32 ft.-lbs.). Recheck end
play.
g. Install the hydraulic pump idler gear, thrust

washer, and snap ring.
Assemble the front-end components following the

procedures outlined in “Transmission Front End -
Overhaul”.
Assemble the shift levers, cover, and neutral start

switch following the procedures outlined in “Gear
Shift Levers and Cover - Overhaul”.
Installation
1. Connect the transmission to the engine and rear
axle, see “SEPARATING THE TRACTOR”
Section 10.
2. Refill the transmission/rear axle with the correct
grade and quantity of oil.
21-25
Key to Figure 33
Transmission Components
A -- Input Shaft Assembly D -- Main Countershaft

1. Clutch Release Bearing Hub Support 1. Main Countershaft Front Bearing
2. ‘O’ Ring Seal 2. Snap Ring
3. Input Shaft Seal 3. Washer
4. Input Shaft Retaining Clip 4. 3rd -- 7th Gear
5. Seal 5. Coupling Matched With Connector, item 6
6. Input Shaft 6. Connector Matched With Coupling, item 5
7. Seal 7. 1st -- 5th Gear
8. Washer
9. Reverse Gear
10. Washer
11. Coupling Matched With Connector, Item 12
12. Connector Matched With Coupling, Item 11
13. 2nd -- 6th Gear
B -- Top Shaft (Mainshaft)
14. Bearing Outer Cup
1. Input Cluster Gear Front Bearing 15. Taper Bearing
2. Anti--Spin Washer -- With Dual Power Only 16. Countershaft
3. Input Cluster Gear 17. Bearing Outer Cup
4. Input Cluster Gear Rear Bearing
5. Casing Snap Ring
6. 4th --8th Connector Gear
E -- Output Shaft Assembly
1. Taper Bearing
2. Lube Oil Transfer Tube
3. High/Low range Coupling
4. Output Shaft
C -- Secondary Countershaft (Range 5. Low Range Gear
Cluster) 6. Thrust Washer
7. Taper Bearing
1. Casing Snap Ring
2. Secondary Countershaft Front Bearing
3. Secondary Countershaft Gear Cluster
4. Secondary Countershaft Rear Bearing F -- End Cover Assembly
1. Snap Ring
2. Snap Ring
3. PTO Shaft Bearing
4. Snap Ring
5. PTO Shaft
6. Bearing Outer Cup
7. End Cover
8. Shims
9. Output Shaft Retainer
21-26
33
21-27
21-28
Chapter 2 - 16 x 4 Dual Command (Dual Power) Transmission
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dual Command Transmission - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Planetary Gear Set Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
21-1
SPECIFICATIONS
Planetary Gear Set Free Play 0.004-0.020 in

(0.10-0.51 mm)
Planetary Gear Set Free Play 0.013 in. (0.33 mm)
Shims Available 0.032 in. (0.81 mm)
Planetary Cover to Housing 0.046-0.060 in.
Shimming Gap (1.17-1.52 mm)
Planetary Gear Set Free Play Average Planetary cover Shim Thickness to
Shimming Chart to Housing Gap be added
0.001-0.013 in. (0.025-0.33 mm) 0.045 in. (1.14 mm)

0.014-0.026 in. (0.36-0.66 mm) 0.032 in. (0.81 mm)
0.027-0.032 in. (0.69-0.81 mm) 0.026 in. (0.66 mm)
0.033-0.045 in. (0.84-1.14 mm) 0.013 in. (0.33 mm)
0.046-0.060 in. (1.17-1.52 mm) None
Dual Command System at 2100 rev/min
Pressure (Low Pressure 15.2-18 bar (220-261 psi)
Hydraulic Circuit Test)
Tarnsmission Lubrication at 1000 rev/min
Pressure Test 5.3-8.5 bar (73-123 psi)
TORQUE VALUES
Control Valve Solenoid Nut 5.4 4
Control Valve Spool Plug 38 28
Control Valve Body Retaining Bolts 44 32
Planetary Housing Retaining Bolts 105 77
Planetary Cover Retaining Bolts 47 35
Lubrication Tube Connector 18 13
Pressure Line Control Tube Connector 13 9
SPECIAL TOOLS
Description New Holland
Step Plates (set of 11) FNH09210
Puller, Gnp-O-Matic FNH09516
Legs, Push Puller 16 1/2” (pr) FNH09521
PTO Clutch Compressor FNH01312
Jaws, Special Bearing Cup Puller (pr) FNH09564
Attachment, Bearing Cup Puller FNH09507
Bearing Gauge, End-Play FNH01303
Planetary Shaft Puller FNH04721
Pressure Gauge, 600 psi FNH06653
Adapter FNH00705
Adapter FNH09507
Test Hose FNH09507
21-2
FAULT FINDING
The following table lists problems and their possible causes with recommended remedial action.
PROBLEM POSSIBLE CAUSE REMEDY
Dual Command system 1. Direct drive clutch snap ring 1. Replace snap ring
pressure below specification displaced
in normal drive only
2. Damaged or leaking control 2. Replace gasket
valve body gasket
3. Leaking sealing rings on direct 3. Replace sealing rings and/or

drive clutch housing hub or Dual Command housing
worn Dual Command housing
4. Leaking inner or outer seals on 4. Replace seals

direct drive clutch piston
5. Broken or cracked direct drive 5. Replace piston or housing

clutch piston or housing
Dual Command system 1. Damaged or leaking control 1. Replace gasket

pressure below specification valve body gasket
in power drive only
2. Leaking inner or outer seals on 2. Replace seals
under drive clutch piston
3. Broken or cracked underdrive 3. Replace piston
clutch piston
Dual Command system 1. Fault in low pressure hydraulic 1. Refer to Hydraulic Systems,
pressure below specification circuit Pressure Testing, Section 35.
in both normal drive and
power drive
Dual Command system 1. Fault in low pressure hydraulic 1. Refer to Hydraulic Systems,
pressure above specification circuit Pressure Testing, Section 35.
in both normal drive and
power drive
No power to rear wheels when 1. Low Dual Command system 1. Refer to first problem
normal drive engaged (power pressure in direct drive clutch
drive operative) circuit
2. Scorred, burred or binding 2. Replace piston

direct drive clutch piston
3. Control valve spool jammed in 3. Check control valve spool
underdrive position
4. Worn or defective direct drive 4. Replace clutch plates

clutch plates
5. Direct drive clutch pressure 5. Install snap ring correctly or

plate snap ring out of groove or replace
broken
21-3
No power to rear wheels when 1. Scorred, burred or binding 1. Replace piston

power drive engaged (normal underdrive clutch piston
drive operative)
2. Control valve spool jammed in 2. Check control valve spool

direct drive position
3. Worn or defective underdrive 3. Replace clutch plates

clutch plates
No power to rear wheels when 1. Low Dual Command system 1. Check system pressure
Dual Command is engaged in pressure
normal drive or power drive
2. Defective planetary gear set 2. Check components and

ring gear, planetary carrier, sun replace as necessary
gear, shaft or main shaft splines
3. Main transmission or rear axle 3. Check and overhaul as

problem necessary
4. Clutch problem 4. Overhaul clutch
Engine stalls or lugs when 1. Scorred, burred or binding 1. Replace piston

shifting from power drive to underdrive clutch piston
normal drive
2. Broken or defective underdrive 2. Replace springs

clutch piston return springs
3. Warped or defective underdrive 3. Replace clutch plates

clutch plates
Engine stalls or lugs when 1. Scorred, burred or binding 1. Replace piston

shifting from normal drive to direct drive clutch piston
power drive
2. Broken or defective direct drive 2. Replace springs

clutch piston return springs
3. Warped or defective direct 3. Replace clutch plates

drive clutch plates
Lubrication pressure below 1. Weak or broken cooler/lubrica- 1. Overhaul cooler/lubrication

specification tion valve spring, or valve stuck valve
open
2. Blocked or restricted oil cooler 2. Replace oil cooler
Lubrication pressure above 1. Incorrect cooler/lubrication 1. Overhaul cooler/lubrication

specification valve spring or valve stuck valve
closed
21-4
DUAL COMMAND TRANSMISSION -

The Dual Command transmission consists of a
planetary gear set installed directly between the
clutch and the input shaft of the transmission.
The planetary gear set incorporates two hydraulic
operated clutches, which lock an element (s) of the
planetary gear system together, to produce either
direct drive or power under-drive. Power under-drive
lowers the speed and increases torque.
Normal Direct Drive
With reference to Figure 1.
Locking any two members of a planetary gear

system together results in a direct drive with no
change in speed or direction of rotation.
Compressing the direct drive clutch plates locks the

sun gear (3) to the planetary carrier (2) which is the
output member of the system. Applying power to the
ring gear (1) results in normal direct drive.
1
Power Underdrive
Compressing the underdrive clutch plate, locks the

sun gear (4) to the planetary housing. Applying
power to the ring gear (1) forces the pinions (2) to
rotate on their own axis and ‘walk’ around the sun
gear, taking the planetary carrier (3) with them. The
planetary turns in the same direction as the ring gear
but at a lower speed with a resultant increase in
torque. This condition produces a power underdrive.
2
A two position control valve operates the dual
command feature (1), Figure 3. Located on the side
of the planetary gear set housing, the valve directs oil
from the steering section of the tandem hydraulic
system pumps, to engage either the direct drive or
the underdrive clutch assembly. The low pressure
regulating and lubrication circuit relief valve housed
within the PTO valve assembly, regulates the oil
pressure.
Ground speeds in normal direct drive remain 1
unchanged from the previous 8-speed transmission.
21-5
Oil Flow to the Direct Drive Clutch
With the Dual Command control switch (1) Figure 4,

located on the instrument panel is in the normal
(direct drive) position, electric current flows to the 1
control valve solenoid, and energizes the solenoid
coil.
The energized solenoid coil closes the pilot valve,

preventing hydraulic oil at Port ‘A’ from acting on the
top of the control valve spool.
10025026
The hydraulic oil flows through the center of the
control valve and applies pressure to the bottom of 4
the spool, forcing the spool upward. Hydraulic oil
from Port ‘A’ is then directed between the lands of the
spool, to the gallery drilled in the planetary housing,
which connects with the gap between the second
and third sealing rings on the direct drive clutch hub.
A drilled passage in the direct drive clutch hub allows

the hydraulic oil to act behind the direct drive clutch
piston. The pressure acts on the piston, which
compresses the piston spring, locking the direct drive
clutch plates together, engaging the direct drive
clutch.
Hydraulic oil from the rear of the under-drive clutch

piston returns to sump via the control valve and
planetary housing.
21-6
R5--4--03 TI
5
Oil Flow to Direct Drive Clutch
Reservoir and
Pressure Oil Lubrication Oil Exhaust Oil
1. Pilot Valve 8. Hub Support Plate 14. Pinion

2. Control Valve Spool 9. Direct Drive Clutch Plates 15. Planetary Carrier
3. Sealing Rings 10. Direct Drive Clutch Piston 16. Planetary Housing
4. Transmission Input Shaft Return Spring 17. Underdrive Clutch Plate
5. Direct Drive Clutch Piston 11. Sun Gear 18. Underdrive Clutch Piston
6. Transmission Countershaft 12. Centre Shaft Return Springs
7. Direct Drive Clutch Housing 13. Ring Gear and Input Shaft 19. Underdrive Clutch Piston
21-7
R5--4--04 TI
6
Oil Flow to Underdrive Clutch
Reservoir and
Pressure Oil Lubrication Oil Exhaust Oil
1. Pilot Valve 8. Hub Support Plate 14. Pinion

2. Control Valve Spool 9. Direct Drive Clutch Plates 15. Planetary Carrier
3. Sealing Rings 10. Direct Drive Clutch Piston 16. Planetary Housing
4. Transmission Input Shaft Return Spring 17. Underdrive Clutch Plate
5. Direct Drive Clutch Piston 11. Sun Gear 18. Underdrive Clutch Piston
6. Transmission Countershaft 12. Centre Shaft Return Springs
7. Direct Drive Clutch Housing 13. Ring Gear and Input Shaft 19. Underdrive Clutch Piston
21-8
Engaging the direct drive clutch locks the planetary The carrier, being the output member of the system,
carrier to the sun gear, which is splined to the direct turns in the same direction but at a slower speed than
drive clutch housing. When any two members of the the ring gear, thereby producing an underdrive with
planetary assembly lock together, a direct drive a resultant decrease in speed and increase in torque.
results with no change in speed or direction of
rotation. Therefore, as the planetary carrier and the Lubrication Oil Flow
sun gear lock together, power input at the ring gear Lubrication oil is supplied by the low pressure
passes directly to the planetary carrier, which is hydraulic system. This oil is directed via tubing
splined via a connecting shaft to the input shaft of the through a transmission oil cooler, before entering a
transmission. passage in the control valve body shown schemati-
cally at ‘B’ in Figure 5 and Figure 6.
Oil Flow to the Underdrive Clutch
With reference to Figure 6: The oil passes through a drilled passage in the
planetary housing between the first and second
When the Dual Command control switch is in the sealing rings on the direct drive clutch hub and
power (under-drive) position, the electrical connec- through a drilled passage in line with the direct drive
tion to the control valve solenoid is broken, which clutch plates. The oil flows around the clutch plates
de-energizes the solenoid coil. and through the planetary assembly. As the
members of the planetary assembly rotate, oil is
The de-energized solenoid coil opens the pilot valve, thrown off to lubricate the bearings and other
allowing hydraulic oil at Port ‘A’ to act on both the components in the housing. Oil in the bottom of the
upper and lower surfaces of the control valve spool. housing is directed through a tube connecting the
The area on the upper surface of the spool is greater housing with the main countershaft bearing in the
than the area of the lower surface. The difference in hub support plate.
pressure forces the spool down, directing hydraulic
oil from Port ‘A’ to a drilled passage in the planetary Excess oil in the housing flows directly into the
housing to the under-drive clutch piston. transmission case to lubricate the transmission
gears and bearings. Oil entering the hub support
The pressure acts on the piston, which compresses plate flows into the center passage of the
the piston spring, locking the under-drive clutch countershaft and lubricates the bearings and gears
plates together, engaging the under-drive clutch. through cross drillings in the shaft. As the
components on the countershaft and output shaft
Hydraulic oil from the rear of the direct drive clutch revolve, oil is carried to the input shaft and range
piston returns to sump via the control valve and cluster gear to lubricate the upper gears and
planetary housing. bearings in the transmission case. Excess oil in the
countershaft flows directly into the transmission
Engaging the underdrive clutch locks the direct drive casing through a slot in the front support plate.
clutch housing to the planetary housing. As the sun
gear is splined to the inner hub of the direct drive Oil collected in the transmission case is allowed to
clutch assembly, it is also locked to the planetary flow into the rear axle center housing, with which it
housing. Applying power to the ring gear and holding forms a common oil reservoir, through passages in
the sun gear, causes the pinions of the planetary the transmission output shaft retainer.
carrier to rotate on their own axis and ‘walk’ around
the sun gear taking the carrier with them.
21-9
PLANETARY GEAR SET -- OVERHAUL

Removal
1. Drain the oil from the transmission and rear axle
1
center housings.
2. Disconnect the wiring harness from the wire
assembly at the plug connector located above
the transmission bell-housing. It is not necessary
to take the wire assembly out of the transmission
plug.
3. Pull the large rubber plug free from the 2
transmission bell-housing and disconnect the 10024910
lubrication (2) and pressure (1) control lines from
the control valve body, Figure 7. 7
4. Unplug the wire assembly (1) from the Dual

Command solenoid Figure 8.
5. Remove the bolts securing the valve body (2) to 1
the planetary housing and remove the valve 2
body.
6. Remove the gasket from the valve body.
10024911
8
7. Remove the pressure line connector and
lubrication line connector from the valve body
and remove the O-ring seals from the
connectors.
8. Separate the engine from the transmission as
described in “SEPARATING THE TRACTOR”
Section 10.
9. Disconnect the rod between the clutch pedal and
the clutch release cross-shaft lever by removing
the clevis pin at the lever end.
10. Remove the clutch release fork retaining pin (5),
Figure 9, support the fork (4) and remove the
clutch release cross-shaft (6).
11. Remove the fork and clutch release bearing
assembly (3).
12. Remove the bolts (1) from the planetary cover
(2).
13. Remove the cover from the planetary housing.
14. Remove the gasket from the cover.
21-10
15. Remove the ring gear and shaft assembly, Figure 16. Remove the planetary carrier, shaft, sun gear
10, from the housing. and direct drive clutch assembly as a complete
unit.
10
Planetary Gear Set Components -- Exploded View
1. Cover 8. Underdrive Clutch Assembly
2. Thrust Washer 9. Planetary Carrier
3. Sun Gear 10. Pilot Bearing
4. Direct Drive Clutch 11. Ring Gear and Shaft Assembly
5. Shaft 12. Shim
6. Thrust Washer 13. Ring Gear Bearing
7. Planetary Housing
NOTE: If removal of the ring gear includes the Dual

Command reduction gear set and direct drive clutch
unit (1) from the transmission due to the shaft (2)
being a tight fit in the ring gear bearing. In these
cases the shaft may be extracted from the ring gear
bearing by means of a Slide Hammer, Tool No.
FNH09567 (3) and the Planetary Shaft Puller Tool
No. FNH04721 (4) placed over the rear of the shaft,
Figure 11.
11
17. If necessary, remove the pilot bearing from the
shaft using Puller, Tool No. FNH09198, Pulling
Attachment, Tool No. FNH09190 and Step Plate,
Tool No. FNH09210/4.
18. Remove the shaft and separate the planetary
carrier from the direct drive clutch assembly.
19. Remove the sun gear from the inner splines of
the direct drive clutch assembly.
20. Remove the bolts (2) securing the planetary
housing (1) to the transmission case, Figure 12.
12
21-11
21. Remove the planetary housing from the case.
NOTE: Take care not to lose the anti-spin washer
located between the transmission main shaft front
gear and front bearing, if the bearing comes away
with the Dual Command housing.
22. Remove and discard the gasket on the rear hub

of the planetary housing.
23. Remove the O-ring between the planetary
housing and the transmision front plate.
13
Direct Drive Clutch Assembly -- Exploded View
1. Steel Plates 7. Piston Return Spring
2. Pressure Plate 8. Sealing Rings
3. Snap Ring 9. Direct Drive Clutch Housing
4. Friction Plates 10. Piston Seals
5. Snap Ring 11. Piston
6. Spring Retainer
DISASSEMBLY
Direct Drive Clutch
1. Remove the sealing rings (8), Figure 13, from the
rear hub of the direct drive clutch housing (9).
2. Depress the piston return spring and remove the
snap ring (3) from the inner hub using Clutch
Compressor, Tool No. FNH01312 (4) and either
Puller, Tool No. FNH09516 or a press ram (1),
Figure 14.
3. Release the pressure and ensure the spring
retainer (2) does not enter the snap ring groove.
4. Remove the spring retainer and spring. 14
21-12
5. Remove the clutch pressure plate snap ring (2),
as shown in Figure 15.
NOTE: When removing the clutch plates, note the
order of removal to facilitate installation.
6. Remove the pressure plate, the friction and steel

plates from the clutch housing (1).
WARNING
To prevent the piston from causing injury during
removal, place the direct drive clutch housing
face down on a bench. When using an air nozzle
to aid in removal, the piston rapidly expels.
15
7. Place an air hose nozzle in the hole between the
middle and rear sealing ring grooves in the clutch
housing hub and blow out the piston.
8. Remove the piston inner and outer seals.
WARNING
To prevent injury when removing the large snap
ring from the internal surface of the planetary
housing, manufacture four restraining clamps as
shown in Figure 16, and equally space around
the planetary housing rim. Use the planetary
housing bolts to retain the clamps, Figure 17.
16
Underdrive Clutch
1. Remove the large snap ring (1) from the inner
surface of the planetary housing (2), Figure 17.
17
21-13
2. After removing the snap ring (3) Figure 18,
gradually release the restraining clamps.
IMPORTANT: Note the order of the clutch plates
when removing.
3. Remove the spring retainer (4), pressure plate

(2) and friction plate (5), figure 18
4. Remove the piston return springs (1), locating
dowel pins (11) and rear plate (6), Figure 18.
IMPORTANT: Position the planetary housing (9) so
that the underdrive piston will not cause injury when
expelled.
18
5. Place an air hose nozzle in the pressure supply Underdrive Clutch Assembly -- Exploded View
port of the control valve housing and carefully 1. Piston Return Springs
blow out the underdrive piston (10). 2. Pressure Plate
6. Remove the inner and outer seals from the piston 3. Snap Ring
(7), Figure 18. 4. Spring Retainer
5. Friction Plate
6. Rear Plate
7. Piston Seals
8. Control Valve Body
9. Planetary Housing
10. Piston
11. Dowel Pins
Control Valve Assembly

1. Remove the plug (2) located in the control valve

body (3) at the opposite end of the solenoid (1).
2. Remove the solenoid and pilot valve assenbly.
3. Remove the control valve spool (4).
19
1. Clean all parts in a suitable solvent and dry
thoroughly with a dry, lint-free cloth or
compressed air.
2. Examine the lubrication inlet tube, the pressure
inlet tube, and the lubrication oil tube for damage
or distortion. Discard any defective tubes.
3. Examine the control valve solenoid cable for
damage or loose connections.
21-14
4. Inspect the clutch release hub (2) and bearing (4)
for excessive wear or damage. If necessary,
remove the bearing from the hub with Pulling
Attachment, Tool No.FNH09190 (3), Step Plate,
Tool No. FNH09210 (5) and either a press or
Puller, Tool No. FNH09198 (1), see Figure 20.
Press a new bearing onto the hub ensuring the
thrust face of the bearing faces away from the
shoulder on the hub.
5. Pack the recess in the bearing hub bore with a
high melting point grease.
6. Inspect the clutch release fork for cracks or
excessive wear and replace as necessary.
20
7. Inspect the cross-shaft and lever for distortion or
excessive wear and install a new assembly, if
damage is evident. Inspect the shaft bushings for
excessive wear and replace if found to be
defective. Drive the bushings into the housing
until flush with the outside edges of the
cross-shaft locating bores.
8. Inspect the planetary cover for damage or
distortion. Check the face of the cover and the
mating surface for nicks or burrs and remove any
imperfections with an abrasive stone.
9. Inspect the planetary carrier and gears,
planetary shaft, pilot bearing and thrust washer
for damage or wear. Install new parts as
necessary.
10. Inspect the sun gear for excessive wear or
damaged teeth.
11. Inspect the sealing rings from the rear hub of the
direct drive clutch assembly for damage,
distortion or cracks.
When installing new seals, insert the seals in a 60
mm (2.38 in.) internal diameter test bore for a
period of 10 minutes prior to assembly. This
procedure ensures the seals obtain the correct
amount of pre-tension to avoid damage on
assembly. Install the new seals using a suitable
grease to hold the seals in position during
reassembly and ensure the seals do not protrude
above the lands of the direct drive housing.
12. Inspect the bore in the hub of the planetary
housing where the direct drive sealing rings
locate. Replace the planetary housing when
detecting excessive wear or damage
21-15
13. Inspect the direct drive clutch housing both
externally for cracks or damage and internally for
wear and piston scuffing. Inspect the housing
external splines for cracked, broken or missing
teeth.
14. Inspect the direct drive clutch piston, friction
plates, steel plates, pressure plate and snap ring
and install new piston seals.
15. Inspect the direct drive clutch piston return
spring, spring retainer and snap ring for damage.
16. Inspect the thrust washer for damage or
distortion.
17. Inspect the planetary housing for cracks or
damage. Inspect the underdrive clutch piston,
locating dowel pins, springs, rear plate, friction
plate, pressure plate, spring retainer and snap
ring and install new piston seals. Discard and
replace any cracked, damaged or badly worn
parts.
18. Inspect the transmission input shaft front bearing
(4) in the hub of the planetary housing (3). If
necessary, use Puller, Tool No. FNH09507 (2)
and Slide Hammer, Tool No. FNH09567 (1) to
remove the bearing, Figure 21. Press in a new
bearing.
19. Inspect the ring gear and shaft assembly for 21
damage or wear. Inspect the shaft splines for
damage. If necessary, install a new ring gear and
shaft assembly.
IMPORTANT: The shim located behind the ring gear
bearing governs the planetary gear set end-play. If
any of the major components of the planetary gear
set are changed, refer to ‘Planetary Gear Set
Shimming Procedure’ in this Chapter, to determine
the correct size shim to be installed.
20. Inspect the ring gear bearing (2) for wear or
damage. If necessary, remove the bearing with 6
Puller, Tool No. FNH09506 (6), Puller Legs, Tool
No. FNH09521 (5), Pulling Attachment, Tool No.
FNH09526 (4) and Step Plate, Tool No.
FNH09210/4 (1), as shown in Figure 22. Take
care not to damage the shim located behind the
bearing. Ensure to place the shim against the
step on the ring gear shaft (3) and then press the
new bearing onto the shaft, using a convenient
length sleeve of 82.6 mm (3.25 in.) internal
diameter and 95.3 mm (3.75 in.) external
diameter.
22
21-16
21. Inspect the valve spool bore in the valve body for 3. Install the planetary carrier and thrust washer
damage or wear. onto the sun gear and ensure the splines of the
planetary carrier engage with all of the direct
22. Inspect the valve spool lands for scratches, wear
drive clutch friction plates.
or other damage. Remove minor burrs or
scratches with a fine abrasive material. Clean 4. Hold the components tightly together and install
and dry thoroughly prior to reassembly. the planetary shaft from the rear. Tap the shaft,
if necessary, to ensure full engagement.
23. Inspect the solenoid for cracks or damage. if any
doubt exists as to the serviceability of this 5. Press the pilot bearing onto the shaft using a
component, replace with a new solenoid sleeve of 41.2 mm (1.62 in.) internal diameter
assembly. and 47.8 mm (1.88 in.) external diameter.
6. Position the planetary housing (with underdrive
Assembly clutch installed) on a bench.
Assembly of the direct drive clutch, the underdrive
NOTE: Support the planetary housing on blocks so
clutch and control valve follows the disassembly
that the rear of the planetary shaft does not contact
procedure in reverse, with the following require-
workbench, when installing the direct drive clutch
ments:
and planetary gear set.
1. Apply a proprietary thread sealant on the pilot
7. Place the thrust washer in the housing with the
valve assembly threads and tighten the nut to a
tab up and towards the rear of the transmission.
torque of 5.4 N⋅m (4 ft.-lb.)
8. Install the direct drive clutch and planetary gear
2. Ensure the gap of the underdrive clutch retaining
set assembly in the housing. Ensure the
snap ring is placed in line with the lubrication port
assembly is fully seated in the housing.
of the Dual Command Housing.
9. Install the ring gear and shaft assembly (without
PLANETARY GEAR SET SHIMMING the ring gear bearing or shim) in the housing.
PROCEDURE Place the Ring Gauge, Tool No. FNH01303, on
IMPORTANT: Perform the planetary gear set the step of the ring gear shaft.
shimming procedure after installing a new cover, 10. Position the cover on the planetary housing
bearing, ring gear, planetary carrier, sun gear, direct without the gasket.
drive clutch or planetary housing.
IMPORTANT: Ensure proper seating of all compo-
A shim located between the bearing and the step on nents in the housing.
the ring gear shaft, effects free play between
planetary housing components. 11. Measure the distance between the face of the
cover and the face of the housing at three
The free play must be between 0.10-0.51 mm conveniently spaced intervals. Average the three
(0.004-0.020 in.). For free play available shims, see measurements.
Specifications. If the average measurement falls between 1.17-1.52
mm (0.046-0.060 in.) the free play is within the
Determine the shim required to give the specified required limits and no shims are necessary. If the
free play as follows: average measurement is less than the range stated,
determine the shim thickness required by referring to
1. Install the sun gear in the inner splines of the the relevant chart listed in Specifications.
direct drive clutch assembly.
2. Place the thrust washer in the planetary carrier
and align the splines.
21-17
12. Remove the cover and the ring gear and shaft
assembly from the planetary housing. Remove
the ring gauge and place the appropriate shim(s)
on the step of the ring gear shaft. Press the
bearing onto the ring gear using a convenient
length sleeve of 82.6 mm (3.25 in.) internal
diameter and 95.3 mm (3.75 in.) external
diameter.
13. Remove the components from the planetary
housing and retain in order for final installation.
Installation
NOTE: When installing a new cover, bearing, ring
gear, planetary carrier, sun gear, direct drive clutch or
planetary housing, refer to ‘Planetary Gear Set
Shimming Procedure’ in this Chapter, before
installing the planetary components in the transmis-
sion case.
Installation of the planetary gear set and control

valve follows the removal procedures in reverse, with
the following requirements:
1. The cover easily seats in the housing with

components installed correctly. Do not force the
cover. Difficulty installing the cover indicates
improper assembly.
2. Install new O-ring seals on the lubrication oil
transfer tube.
3. Coat all tube joints with a proprietary sealing
compound.
4. Install new O-ring seals on the control valve
pressure line and lubrication line connections.
21-18
PRESSURE TESTING
For the following tests ensure the tractor hydraulic oil
is at operating temperature, the transmission and
hydraulic system are in neutral, and the power
take-off is disengaged.
Dual Command System Pressure Test
(Low Pressure Hydraulic Circuit Test)
1. Remove the pressure switch (1) for the low
pressure hydraulic circuit, Figure 23.
23
2. Install a 0-400 psi (0-30 bar) pressure gauge,
FT.8616 (1), Figure 24 with adaptor FT8503 or
FNH 00705 (2) and test hoses, part Nos
83936707 and 83926717 (3).
3. Set the engine speed to 2100 rev/min. and
observe the pressure reading. A reading of
220-261 psi (15.2 -18 bar) should be recorded.
24
21-19
Transmission Lubrication Pressure Test
1. Operate the tractor and set the engine speed to
1000 rev/min. Stop the engine but do not
re-adjust the throttle.
2. Using a test hose (4), part number, E1NN-
F493-AA with adaptor FT.8503-8 and a suitable
7/16 in. JIC adaptor (3), which must be a tight fit
inside the oil cooler inlet hose (1), connect the
400 psi pressure gauge, FT.8616 (5), to the
cooler inlet hose, Figure 25, using a suitable
hose clamp (2) to secure.
3. Using an assistant to start the engine, observe
the reading on the pressure gauge. Do Not run
the tractor longer than is necessary to observe 25
the pressure gauge reading.
The pressure recorded should be 73-123 psi (5.3-8.5
bar), depending on engine speed. 73-123 psi
(5.0-8.5 bar) is the minimum operating pressure of
the lubrication circuit relief valve located in the PTO
valve and clutch assembly.
21-20
Chapter 3 - Reduction Gearbox Assembly
CONTENTS

Specifications, Tightening Torqes, and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Reduction Gearbox - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Reduction Gearbox Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
21-1
SPECIFICATIONS, TIGHTENING TORQES, AND SPECIAL TOOLS
SPECIFICATIONS
Reduction Ratio 5.7:1
Output Shaft End Float with 0.0015-0.0034 in

Reduction Gearbox (0.038-0.086 mm)
Output Shaft Torque Pre-Load with Pull required to turn the output shaft with string
Reduction Gearbox wound around output shaft splines
9.5-16 lb. (1.0-1.8 N)
Output Shaft Pre-Load Shims 0.004 in. (0.10 mm)

Available for Reduction Gearbox 0.006 in. (0.15 mm)
0.020 in. (0.50 mm)
TIGHTENING TORQUES
Components ft.-lb. N⋅ m
Rear Support Plate Retaining Bolts 32 44
Output shaft Retainer Socket Head Screws 23 31
SPECIAL TOOLS
Description New Holland
Step Plates FNH09210
Internal/External Puller FNH09507
Slide Hammer FNH09567
21-2
REDUCTION GEARBOX -- engagement between the coupling and any
DESCRIPTION AND OPERATION component of the reduction gear set exists. Thus the
coupling and output shaft are not driven.
The reduction gearbox is available as an option on
the 8x2 transmission, provides an extra reduction The transmission low range is selected by sliding the
ratio below the standard low range. An epicyclic gear gear shift rail rearwards to the detent position
set mounted on the transmission output shaft adjacent to neutral. The movement of the rail,
provides this reduction. through the selector fork, causes the coupling to
engage the reduction gear set carrier. Power
When installed on the 8x2 non-synchromesh
transmits from the secondary countershaft, via the
transmission, the gearbox provides an additional
carrier and coupling to the output shaft. The carrier
creep range of four forward, and one reverse speed,
consists of the same number of gear teeth on the
which increases the total number of ratios available
outside diameter as the output shaft gear utilized on
to twelve forward and three reverse. On 16x4
standard transmission. Therefore, the ground
transmissions with dual command installed, an
speeds obtained in the low range are identical to
additional eight forward and two reverse speeds are
those of a standard transmission.
provided, increasing the total ratios available to
twenty-four forward and six reverse. The creep range is selected by sliding the gear shift
rail and fork further rearward to the final detent
The epicyclic gear set consists of:
position. The coupling is moved by the selector fork
• An outer ring gear positioned in relation to the inside the carrier assembly to engage the
transmission housing. intermediate ring gear. Power transmits from the
secondary countershaft to the coupling via the
• Planetary gears mounted on the carrier, with the planetary gear set.
rear gear teeth engaging the outer ring gear.
The planetary gear set is designed so that the carrier
• A carrier with teeth formed on the outside is driven and causes the planetary gears to rotate
diameter to act as the output shaft gear. with the rear teeth engaged in the stationary ring
gear. The forward teeth of the planetary gears
• An intermediate ring gear, which engages the engage and drive the intermediate ring gear at
front teeth of the planetary gears. reduced speed. The coupling engages the intermedi-
• A coupling, which drives the output shaft and ate ring gear, therefore, drives the output shaft at a
engages the carrier or intermediate ring gear. reduced speed to obtain the required creep range.
The selector fork and gearshift rail allows movement

of the coupling. In the neutral position, no
21-3
1
Reduction Gearbox
1. Roller Bearing 11. Support Plate
2. Thrust Washer 12. Intermediate Ring Gear
3. Needle Roller Bearing 13. Planetary Gear
4. Spacer 14. Carrier
5. Taper Roller Bearing 15. Coupling
6. Output Shaft Retainer 16. Output Shaft
7. Roller 17. Needle Roller Bearing
8. Socket Head Screw 18. Thrust Washer
9. Shim(s) 19. Selector Fork
10. Outer Ring Gear 20. Gear Shift Rail
21-4
REDUCTION GEARBOX OVERHAUL

Removal
1. Drain the oil from the transmission.
2. Separate the rear axle from the transmission,
see “SEPARATING THE TRACTOR” Section
10.
3. Remove the gear shift cover as described in
Section 21.
4. Remove the snap ring, thrust washer and
hydraulic pump idler gear, located on the output
shaft retainer.
5. Remove the rear support plate retaining bolts (2) 2
and lever the support plate (1) away from the
transmission, Figure 2.
6. Remove the rear support plate (2) and the PTO
shaft (1) as an assembly, Figure 3.
3
7. Extract the secondary countershaft assembly (1)
enough to free up the bearing from it’s location.
Lift up on the secondary countershaft and
remove the output shaft and reduction gear set
(2), Figure 4.
8. Remove the secondary countershaft.
9. Remove the high/low/creep coupling from the
rear of the transmission, or the output shaft, as
required.
21-5
Disassembly
1. Remove the output shaft retainer (1) from the
rear support plate (2), Figure 5.
2. Remove the outer ring gear (3) from the rear
support plate.
5
3. Remove the output shaft (2) from the reduction
gear set assembly (1). If necessary, use a soft 3 1
faced hammer to drive the output shaft forwards
out of the assembly, Figure 6. Ensure the
intermediate ring gear (3) remains inside the
reduction gear set.
NOTE: Removal of the output shaft will push the
bearing off the rear of the output shaft.
6
4. Remove the thrust washer (3) and needle roller
bearing from the output shaft (or intermediate
ring gear (4) should these components remain
inside the gear set assembly).
5. Lay the epicyclic gear set on the bench with the
intermediate ring gear upward. Remove the
intermediate ring gear (4), Figure 7.
6. Remove the thrust washer, needle roller bearing,
spacer and second needle roller bearing from the
carrier.
7. Remove the planetary gears (2) from the carrier
(1). Take care to retain the bearing rollers, Figure
7. 7
21-6
1. Inspect the output shaft retainer and rear bearing
cup for wear or damage. If necessary, use Pulling
Attachment, Tool No. FNH09507 and Slide
Hammer, Tool No. FNH09567 to remove the cup
from the retainer. Use a suitable Step Plate, Tool
No. FNH09210 to install a new bearing cup.
2. Inspect the rear support plate for wear or damage
and replace if necessary.
3. Inspect the output shaft and pilot bearing.
Replace worn or damaged components.
4. Inspect the secondary countershaft and PTO
drive shaft bearings located in the rear support
plate. Replace any unserviceable bearing with a
suitable Step Plate, Tool No. FNH09210.
5. Inspect all needle roller bearings and thrust
washers. Replace any unserviceable items.
6. Inspect the planetary gear set carrier, ring gears
and planetary gears and replace any worn or
damaged components on reassembly. However,
if several components are worn, the complete
reduction gear set should be replaced.
7. Inspect the coupling and gear shift mechanism.
Replace any unserviceable components.
Assembly
Assembly follows the disassembly procedures in
reverse with the following requirements.
1. Use high quality grease to position the thirteen 5

mm diameter rollers (3) and eleven 9 mm
diameter rollers (1) around the planetary gears
(2), Figure 8.
21-7
2. Install the planetary gears (3) and rollers (4) in
the carrier (1), which rest inside the outer ring
gear (2). During installation, turn each gear until
the master tooth (marked with a punched dot)
points towards the center of the carrier.
9
Planetary Gear to Carrier Relationship
NOTE: If gear identification marks for the master
tooth do not exist, use a rod laid between the gears
to establish which pair of teeth on the rear gear, align
with a pair on the front gear, then proceed as follows:
10
1. With reference to Figure 11 and viewed from the
front, four pairs of gear teeth are in alignment.
Identify the right-hand tooth of any aligned pair
on the 12 teeth gear as the master tooth.
11
Identification of Master Tooth on 5.7:1
Reduction Ratio Planetary Gear
1. 16 Teeth Gear
2. 12 Teeth Gear
3. Master Tooth on 12 Teeth Gear
4. Rod Used to Establish Alignment of Gear Teeth
21-8
2. Install the smaller diameter thrust washer (2),
chamfered side up, on the carrier hub before
installing the intermediate ring gear (1) into the
carrier to fully engage with the planetary gears,
Figure 12.
3. Place the gear coupling, groove to the front, on
the output shaft.
12
4. Position the larger diameter washer (1) on the
output shaft (2) with the chamfered side facing
the coupling (3) Figure 13.
5. Lubricate the needle roller bearings with high
quality grease and install the narrow needle roller
bearing in the intermediate ring gear. Install the
two wide needle roller bearings, with the spacer
between them, in the carrier.
6. Hold the previously assembled output shaft
vertically and install the carrier assembly on the
output shaft.
13
NOTE: With the carrier installed, the output shaft will
protrude above the carrier rear thrust face.
7. Push the output shaft rear bearing against the

output shaft shoulder (1).
8. Use feeler gauges (2) to check the clearances
between the bearing (3) and the carrier. The gap
should be 0.3-0.8 mm (0.012-0.032 in.), Figure
14.
14
21-9
Installation
1. Install the assembled carrier and output shaft unit
in the transmission. Ensure the coupling
engages the selector fork.
2. Remove the outer ring gear from the reduction
gear set assembly.
3. Install the rear cover plate on the transmission.
4. Install the support plate retaining bolts and
tighten to a torque of 47 N⋅m (35 ft.-lb.).
5. Install the outer ring gear into the rear cover.
6. Replace the shims, and bolt the output shaft
retainer to the support plate to support the ring
gear. Tighten the socket head screws to a torque
value of 31 N⋅m (23 ft.-lb.).
7. Using a pull scale and string wound around the
output shaft, check the output shaft torque
pre-load. With the transmission in neutral, the
pull scale should read between 1.0-1.8 N (9.5-16
lb.). Add or subtract shims from between the
output shaft retainer to obtain the correct
pre-load
Alternatively, if a pull scale is not available, add
or subtract shims to obtain an output shaft end
float of between 0.038-0.086 mm
(0.0015-0.0034 in.).
8. Install the hydraulic pump, idler gear, and thrust
washer, and retain with the snap ring.
9. Replace the gear shift cover.
10. Reconnect the transmission and rear axle as-
semblies, see “SEPARATING THE TRACTOR”
Section 10.
11. Fill the transmission with the correct grade and
quantity of oil.
21-10
SECTION 23 -- FRONT AXLE TRANSFER BOX -- CHAPTER 1
SECTION 23 - FRONT AXLE TRANSFER BOX
Chapter 1 - Front Axle Transfer Box
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
23-1
SPECIFICATIONS
CLEARANCES AND TOLERANCES
Item
Clutch Spring Free Length 48.0 mm 1.89 in
Output Shaft Bearings Rolling Resistance 1.5-3.5 kgs 3.3-7.7 lb
Idler Gear Bearing Rolling Resistance 0.4-1.0 kgs 0.90-2.2 lb
Output Shaft End-Float 0.025-0.075 mm 0.001-0.003 in
SHIM THICKNESS AVAILABLE

Item
Output
p Shaft Bearings
g 0.1 mm 0.004 in
and
d Idler
Idl Gear
G Bearing
B i 0.25 mm 0.010 in
0.3 mm 0.012 in
0.5 mm 0.020 in
Shaft End-Float 1.00-2.25 mm 0.04-0.089 in
(in increments of 0.05 mm) (in increments of 0.002 in.)
OIL CAPACITY
Lubricated by Rear Axle Oil
Transfer Box Increases Rear Axle Oil Level by 1.3 liters 1.4 qt
SPECIAL TOOLS
Tool New Holland / Other Globel Part No.
Attachment, Bearing Pulling FNH09190
Shaft Protectors, (Set of 6) FNH09212 380000564
Gauge, Shim FTC307979
TORQUE VALUES
Component
Rear Bearing End-Plate Retaining Bolts 40 N⋅m 30 ft.-lbs.
Front Bearing End-Plate Retaining Bolts 40 N⋅m 30 ft.-lbs.
Idler Gear Retaining Bolt 80 N⋅m 59 ft.-lbs.
Transfer Box Retaining Bolts 80 N⋅m 59 ft.-lbs.
Drive Shaft-to Drive Flange Attaching Bolts 57 N⋅m 42 ft.-lbs.
23-2
DESCRIPTION AND OPERATION pressure from the power-take off and dual power
The transfer box assembly connects main transmis- circuits activates the dog clutch.
sion output to the front drive axle, through a
A helical gear mounted on the pinion shaft of the rear
universally jointed drive shaft. The transfer box
axle, transmits drive through a mating helical idler
mounts under the rear axle, center housing, and the
gear, carried in two taper roller bearings in the
drive shaft passes along the central axis of the
transfer box, to a third gear on the lower shaft. The
tractor.
number of teeth on the lower output gear determines
All transfer box assemblies are identical in the gear ratio of the transfer box assembly, Figure 1.
construction with the exception of the internal gear
Two taper roller bearings support the lower shaft,
ratio. Different ratios are required for the various
which has a sliding dog type clutch meshed on the
types of front and rear tire sizes. A stamped ratio on
center portion. The drive gear carries a mating dog
the forward face of the housing below the output
type clutch that is free to rotate on the shaft when not
shaft, identifies which transfer box is installed.
engaged with the sliding component. The clutch
The transfer box assembly features a simple dog engages by four radically positioned springs and
type clutch to engage the front axle. Hydraulic releases by hydraulic pressure controlled from the
electrical switch on the instrument panel.
1
Transfer Box Assembly -- Cutaway View
1. Sliding Clutch 7. Sealing Rings
2. Coil Springs (4 off) 8. External Oil Tube
3. Output Shaft 9. Double Check Valve
4. Solenoid Valve 10. Oil Transfer Tube
5. Electrical Feed Connection 11. Driven Gear
6. Hydraulic Oil Connection 12. Idler Gear
23-3
An electro-solenoid operated valve directs hydraulic gear to rotate on the shaft, and disconnects drive to
pressure from the power take-off and dual power the front axle.
circuits via tubing that connects to the rear of the
transfer box. When electric current activates the A broken electrical circuit deactivates the solenoid,
solenoid, hydraulic pressure flows through the which causes hydraulic pressure to collapse within
transfer tube to the center bore of the lower shaft. the feed lines and chamber ‘A’. The radically
positioned springs then force the sliding clutch
Hydraulic pressure enters a double check valve element towards the driven gear. As the sliding clutch
positioned in the center bore, and lifts an inner check moves, discharging oil slides the whole check valve
ball off the seat, allowing hydraulic pressure to pass rearwards, and the inner ball seats, preventing oil
through the check valve, and reach chamber ‘A’, from passing through the valve center. The moving
Figure 2. valve exposes a large exhaust path through drilled
passages in the shaft and the gear, to the rear axle
Chamber ‘A’, sealed by two rings, expands and reservoir. This permits rapid engagement of the
moves the sliding clutch element against the clutch. A small amount of oil also exhausts from the
radically positioned springs, and out of engagement solenoid to allow the check valve to move.
with the teeth on the driven gear. This action frees the
2
Clutch Operation -- Schematic View (Inset showing clutch engagement)
1. Driven Gear 5. Spring Keeper Plate
2. Oil Transfer Tube (inlet) 6. Sliding Clutch
3. Check Valve (ball unseated) 7. Oil Exhaust Route
4. Return Springs (4 off) 8. Check Valve (ball seated, valve moved rearwards)
23-4
OVERHAUL
Removal
1. Park the tractor on a hard level surface. Set the
parking brake and chock the wheels.
2. Remove the drive shaft guard.
3. Disconnect the drive shaft from the axle input
flange coupling. Slide the rear coupling from the
transfer box assembly output shaft and remove
the drive shaft.
4. Remove the rear axle/transmission drain plug
from the transfer box casing and allow the oil to
drain into a suitable container, Figure 3. 3
Transfer Box Installed Beneath Rear Axle
1. Retaining Bolts (13 off)
2. Drain Plug
3. Solenoid Valve Cover
4. Feed Wire Protection Tube
5. Hydraulic Feed Pipe
5. Remove the solenoid cover plate on the

right-hand side of the transfer box assembly, and
disconnect the wire and protective tube, Figure
4.
6. Disconnect the hydraulic oil tubing from the
casing.
7. Support the transfer box with a suitable jack.
Remove the retaining bolts and lower the transfer
box assembly from the tractor.
4
Solenoid Cover Removed and Electrical
Connections
1. Coil Feed
2. Solenoid Assy
3. Earth Connection
4. Supply Wire
5. Electrical Protection Tube
6. Hydraulic Feed Pipe
23-5
Disassembly
1. Remove the external oil tube linking the solenoid
port to the transfer box end plate. Remove the
solenoid coil-retaining nut and slide the coil from
the core. Unscrew the core and valve assembly
from the recess, Figure 5.
5
Solenoid Valve/Core Removed from Casing
1. Valve/Core
2. Earth Wire
3. Coil Retaining Nut
4. Coil and Feed Wire
2. Unscrew the socket head bolt securing the idler

gear and bearing assembly, Figure 6. If
necessary, apply heat to the thread-locking
compound on the nut to aid in removal.
6
Idle Gear Shaft Retainer
1. Shaft
2. Socket Head Bolt
3. Idler Gear
4. Shouldered Anchor Nut
3. Drive out the central shaft or arbor. Mark the front

of the idler gear to aid reinstallation. Remove the
gear and bearing assemblies, keeping the
bearings, spacers and shims together to
facilitate reinstallation, Figure 7.
7
Removing Idler Gear
1. Idler Gear
2. Shaft
3. Bearing Assembly
23-6
4. Remove the output shaft end plate retaining bolts
and remove plate. Collect and identify the shims
positioned between the plate and the bearing
outer track, Figure 8.
8
Removing Output Shaft End Plate/
Seal Carrier and Shims
1. Shims
2. Output Shaft
3. End Plate/Seal Carrier
4. O-ring Seal
5. Remove the rear end plate retaining bolts and

remove plate, Figure 9. Remove the oil transfer
tube from the shaft.
6. Gently drive the shaft forward and backward to
remove the bearing outer tracks.
9
Removing Output Shaft Rear End Plate
1. End Plate
2. Bearing Assembly
3. Oil Transfer Tube
4. O-ring Seal
23-7
7. Lever the clutch spring keeper against the
springs, Figure 10. To release the load, remove
the snap ring.
8. Remove the four clutch springs.
10
Levering Clutch Spring Keeper Plate
Against Clutch Springs
1. Levers (Pry Bars)
2. Snap Ring
3. Keeper Plate
4. Clutch Spring (4 off)
5. Suitable Sockets
9. Position two suitable lengths of steel rod or

tubing between the driven gear and the front of
the casing, for passing the shaft through the drive
gear. Remove the bearing, Figure 11.
10. Ease the shaft forward as far as the clutch will
permit and lift out the driven gear and thrust
washer.
11
Removing Output Shaft Rear Bearing
1. Adaptor
2. Bearing
3. Driven Gear
4. Output Shaft
5. Support Rods
23-8
11. Remove the output shaft front bearing using
Puller Tool No. FNH09516, Attachment Tool No.
FNH09190, and Shaft Protector Tool No.
380000564 or FNH09212, Figure 12.
12. Remove the clutch snap ring, by passing it along
the shaft, over the short spline area.
12
Removing Output Shaft Front Bearing
1. Shaft Protector 380000564 or FNH09212
2. Puller FNH09516
3. Bearing
4. Attachment FNH09190
5. Output Shaft
13. Ease the shaft rearward and draw the clutch

forward, to expose the clutch rear-sealing ring,
Figure 13. Remove ring.
13
Clutch Sealing Rings on Output Shaft
1. Rear Sealing Ring
2. Clutch Body
3. Front Sealing Ring
4. Output Shaft
23-9
14. Ease the shaft rearwards from the transfer box,
through the clutch and out the rear-bearing bore,
Figure 14. Lift out the clutch and spring keeper.
14
Output Shaft Moved Rearward from
Transfer Box Case
1. Clutch Body
2. Spring Keeper
3. Output Shaft
15. Remove the check valve from the center bore of

the shaft, Figure 15.
NOTE: Applying air pressure to the cross drilling
between the clutch sealing rings will aid in removal of
the check valve.
15
Check Valve Removed from Inner Bore of
Output Shaft
1. Output Shaft
2. Check Valve
3. Central Bore
23-10
16
Transfer Box Assembly -- Exploded View
1. Bolt 17. Shim
2. Shim 18. Front End Plate
3. Spacer 19. Felt/Lip Seal
4. Idler Gear 20. O-ring
5. Rear End Plate 21. Bearing
6. Oil Transfer Tube 22. Spring (4 off)
7. O-ring 23. Solenoid Cover
8. Bearing 24. Solenoid/Valve
9. Thrust Washer 25. Casing
10. Check Valve 26. Oil Tube
11. Driven Gear 27. Retainer
12. Output Shaft 28. Shim
13. Sealing Rings 29. Bearing
14. Sliding Clutch 30. Shim
15. Spring Keeper 31. Bearing
16. Snap Ring 32. Shaft
23-11
1. Remove the O-ring seals from the shaft end
plates, Figure 17, and the remaining sealing ring
on the center of the shaft.
17
Output Shaft End Plates
1. O-ring Seal -- Front Plate
2. O-ring Seal -- Rear Plate
2. Remove the felt seal from the output shaft, front

end plate and discard, Figure 18. Do not install a
new seal at this stage.
3. Clean all components with a suitable solvent.
Allow parts to dry.
4. Remove the transfer box hydraulic feed pipe
from the tractor and clean the filter/screen inside
the adapter.
18
Output Shaft Front End Plate
1. End Plate
2. Felt/Lip Seal
5. Inspect the valve core O-ring and back-up seals.

Replace as necessary, Figure 19.
19
Solenoid Valve Core
1. O-rings
2. Back-up Rings
3. O-rings
4. Valve Core
23-12
6. Inspect the idler gear bearings for wear or
damage. If necessary, replace bearings as a
matched set. Slide the inner tracks from the gear,
Figure 20.
7. Inspect the idler gear and lower gear teeth for
wear or damage, and if discovered, inspect the
drive gear on the rear axle pinion.
20
Idler Gear Bearing Inner Tracks
1. Idler Gear
2. Separating Shoulder
3. Inner Track (2 off)
8. Inspect the clutch ”dog teeth” on both the sliding

clutch component and the driven gear for wear or
damage. If discovered, replace as a matched set,
Figure 21.
9. Inspect the clutch springs for deformity and
cracks. Check that spring free-length measures
48.0 mm (1.89 in.).
10. Inspect the spline of the clutch and shaft for wear
or damage.
11. Inspect the lower shaft bearing assemblies for
wear or damage.
12. Inspect the output shaft to drive shaft spline for
wear or damage. 21
Clutch Dog Teeth
1. Clutch Dog Teeth
2. Driven Gear Dog Teeth
Assembly
1. Install new O-ring seals on the two end plates
and a new clutch sealing ring on the shaft at the
small diameter. Do not install the larger sealing
ring until positioning the shaft inside the casing.
2. Coat the check valve with grease, and install the
valve in the shaft with the spring facing forward
and the ball to the rear, Figure 22. The grease will
hold the valve in place during assembly.
22
Check Valve Installation in Output Shaft
1. Output Shaft
2. Check Valve
3. Identification Section
23-13
3. Thoroughly lubricate the inside of the clutch.
Position the clutch in the casing with the spring
keeper plate.
4. Pass the shaft through the rear bore, the clutch,
and the keeper plate. Install the larger
diameter-sealing ring, and then lubricate both
the large and small sealing rings, Figure 23.
5. Completely install the clutch on the shaft in the
closed position.
6. Move the shaft completely forward, and install
the driven gear and thrust washer on the shaft.
23
Output Shaft Entered in Casing
1. Rear Sealing Ring
2. Clutch Body
3. Front Sealing Ring
4. Output Shaft
7. Support the output shaft and press the rear

bearing on using a suitable spacer, Figure 24.
8. Install the snap ring on the output shaft adjacent
to the keeper plate.
9. Drive the front bearing on the output shaft using
a suitable sleeve on the inner track.
24
Pressing Rear Bearing onto Output Shaft
1. Adaptor
2. Bearing
3. Driven Gear
4. Output Shaft
23-14
10. Install the four clutch springs. Compress the
keeper plate and springs to facilitate installing the
snap ring. Completely seat the snap ring in the
groove, Figure 25.
25
Levering Clutch Spring Keeper Against Clutch Springs
1. Levers (Pry Bars)
2. Snap Ring
3. Keeper Plate
4. Clutch Springs (4 off)
5. Suitable Sockets
11. Ensure the check valve is in position inside the

shaft. Install the bearing outer track and the
bearing end-plate with the oil transfer tube,
Figure 26. Tighten the bolts to a torque of 40 N⋅m
(30 ft.-lbs.).
12. Install the front bearing outer track and front
bearing retainer, without the felt seal and shims.
26
Installing Output Shaft Rear End Plate
1. End Plate
2. Bearing Assembly
3. Oil transfer Tube
4. O-ring Seal
13. Temporarily tighten the bolts.

14. Determine the degree of end float with a dial
indicator mounted against the clutch assembly,
by moving the shaft forward and backward,
Figure 27.
15. Select shims to equal the end float result, then
add another 0.1 mm (0.004 in.) shim to the total.
27
Assessing Output Shaft End Float
23-15
16. Remove the front bearing retainer, install the
shim pack and plate then hand-tighten the
retaining bolts, Figure 28.
28
Installilng Output Shaft End Plate and Shims
1. Shims
2. Output Shaft
3. End Plate Without Lip Seal
4. O-ring Seal
17. Use a string wrapped around the output shaft and

a spring balance, to measure the rolling
resistance of the shaft within the bearings.
Progressively tighten the end-plate bolts until
reaching a torque of 40 N⋅m (30 ft.-lbs.) and
record the resistance, Figure 29.
NOTE: During the rolling resistance measurement,
keep the string from over wrapping on the shaft, and
read the spring balance only when the shaft is
rotating, and not at the very beginning of rotation.
18. Add shims to increase the rolling resistance or

subtract shims to decrease, until obtaining the
specified figure of 1.5-3.5 kgs (3.3-7.7 lb) with the 29
bolts tightened to 40 N⋅m (30 ft.-lbs.). Measuring Rolling Resistance of Output
19. Remove the front bearing plate to install a new Shaft Bearings
felt seal. Squarely seat the seal and install the 1. String
bearing plate without damaging the seal. Tighten 2. Spring Balance
the bolts to the torque specified in step 18.
20. Assemble the solenoid valve and transfer tube
following the disassembly procedures in reverse.
21. Calculate the taper roller bearing pre-load,
before reassembling the idler gear, by measuring
the rolling resistance, using Shim Gauge Tool
No. FTC307979 as follows:
a. Slide the bearing outer tracks into the idler
gear and assemble the inner bearings with
the spacer and a 0.3 mm (0.012 in.) shim
between them.
23-16
b. Mount this assembly on the special tool and
tighten the tool bolt to a torque of 68 N⋅m (50
ft.-lbs.), Figure 30.
30
Idler Gear and Bearing Assembly Mounted
on Special Tool
1. Idler Gear
2. Special Tool FT 3169 (307979)
3. Spacer
4. Shim
c. Lock the tool stock in a vise. Wrap string

around the gear and use a spring balance to
measure the rolling resistance of the
bearings, Figure 31.
NOTE: During the rolling resistance measurement,
keep the string from over wrapping on the gear, and
read the spring balance only when the shaft is
rotating, and not at the very beginning of rotation.
31
Measuring Rolling Resistance of Idler Gear Bearings
1. Special Tool FT 3169 (307979)
2. String
3. Spring Balance
23-17
d. Increase the shim value placed between the
bearings to reduce rolling resistance, or
decrease the shim value to increase the
resistance. Adjust shims until obtaining the
specified rolling resistance of 0.4-1.0 kgs
(0.90-2.2 lb).
e. Measure the distance across the bearing
inner races as shown in Figure 32, using a
deep throat micrometer and record as
measurement ‘A’
32
Measuring Distance Across Idler Gear
Bearing Inner Races
1. Bearing Inner Races
2. Micrometer
3. Shim and Spacer
4. Tool No. FT3169 (307979)
f. Measure the distance across the casing idler

gear mounting lugs with an internal vernier
caliper, Figure 33, and record as measure-
ment ‘B’.
g. Subtract measurement ‘A’ from measure-
ment ‘B’ and make a shim pack equal to this
result. Divide the resultant value by two and
place this value of shims on each side of the
bearing assemblies.
NOTE: It is not necessary for the shims to be of equal
value on each side of the bearings, as long as the
sum of the shims equals the required amount.
33
Measuring Width of Idler Gear Mounting Lugs in
Transfer Box Casing
Example:
Measurement ‘A’ = 3.75 mm

Measurement ‘B’ = 3.95 mm
Then B - A = C
3.95 mm - 3.75 mm = 0.2 mm

(0.16 in. - 0.15 in. = 0.01 in.)
Divide total by two:
0.2 mm ÷ 2 = .1 mm
(0.01 in. ÷ 2 = 0.005 in.)
Place .1 mm (0.005 in.) thick shim on each side

of bearing assemblies.
23-18
22. Remove the idler gear from the special tool.
Lightly lubricate and assemble the gear,
bearings and shims to the transfer box casing as
shown in Figure 34. Apply thread-locking
compound and tighten retaining bolt to a torque
of 80 N⋅m (59 ft.-lbs.).
34
Idler Gear Installed in Transfer Box Casing --
Sectioned View
1. Idler Gear
2. Shim
3. Center Shaft
4. Shim
5. Spacer
6. Casing
7. Shim
Installation
Installation of the transfer box assembly follows the
removal procedures in reverse.
NOTE: Use the specified gasket between the

transfer box and rear axle housing. Any variation in
thickness or material could result in gear noise, rapid
wear, or other discrepancies.
1. Tighten the transfer box assembly retaining bolts

to a torque of 80 N⋅m (59 ft.-lbs.). Apply suitable
thread-locking compound to the drive shaft-to-
axle drive flange coupling bolts and tighten to a
2. Fill the rear axle with recommended type and
quantity of oil.
23-19
23-20
SECTION 25 -- FRONT AXLE--FOUR WHEEL DRIVE -- CHAPTER 1
SECTION 25 - FRONT AXLE--FOUR WHEEL DRIVE
Chapter 1 - Four Wheel Drive
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hub and Planetary Reduction Gear Assembly - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Axle Shafts - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Steering Swivel Pin Bearings - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Steering Cylinder and Track Rods – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Front Axle – Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Differential Crown Wheel and Pinion Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . 31
Drive Shaft - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
25-1
SPECIFICATIONS
Item Specification
Front Wheel Toe-In 0-6.0 mm 0-0.24 in
Front Wheel Toe-Out 0-13 mm 0-0.5 in
Hub bushings 20 mm 0.79 in
24 mm 0.95 in
Axle Hub Bearings Rolling Resistance 3.0-4.8 kgs 6.6-10.5 lb
Differential Bearing Rolling Resistance 2-6 kgs 4.4-13.2 lb
Pinion Bearings Turning Torque 14.3-20.4 kgs-cm 12-18 lb-in
Swivel Bearing Turning Torque 8-11 N⋅m 6-8 ft.-lbs.
Swivel Pin Bearing Pre-Load 0.20-0.40 mm 0.008-0.016 in
Crown Wheel to Pinion Gear Backlash 0.15-0.25 mm 0.006-0.010 in
Limited Slip
p Differential Clutch Pack Clearance 0.1-0.2 mm 0.004-0.008 in
New Plate Size 1.6 mm 0.084 in
Maximum Wear 0.15 mm 0.006 in
Thrust Plates under Side Gears New Plate Size 2.8 mm 0.11 in
Maximum Wear 0.1 mm 0.004 in
Axle Shaft End Float 0.2-0.5 mm 0.008-0.020 in

Item
Axle End-Float Thrust Washers 1.5 mm 0.060 in
2.0 mm 0.079 in
2.5 mm 0.098 in
Swivel Bearing
g Shims 0.6 mm 0.024 in
0.8 mm 0.031 in
1.0 mm 0.039 in
1.2 mm 0.047 in
1.4 mm 0.055 in
1.6 mm 0.063 in
1.8 mm 0.071 in
2.0 mm 0.079 in
Differential Clutch Pack Shims 2.8 mm 0.110 in
2.9 mm 0.114 in
3.0 mm 0.118 in
3.1 mm 0.122 in
3.2 mm 0.126 in
3.3 mm 0.130 in
Differential Bearing Resistance Shims 0.6-1.8 mm 0.024-0.071
(in increments of 0.1 mm) (in increments of 0.004 in.)
25-2
OIL CAPACITY
Axle Differential 6 liters 6.3 qt
Front Hub – Four Wheel Drive – Each 1.0 liters 1.1 qt
SPECIAL TOOLS
Tool New Holland Other Reference Number
Pinion Setting Gauge FNH04775
Attachment, Bearing Cup Puller FNH09507
Puller, Bearing FNH09527
Installer, Oil Seal FTC307971
Installer, Bushing FTC307974
Installer, Bushing FTC307975
Wrench, Bearing Retaining Nut FTC307978
TORQUE VALUES
Component
Ring Gear and Carrier Assembly Retaining Bolts 95 N⋅m 70 ft.-lbs.
Planetary Carrier Assembly Cover Shouldered Studs 70 N⋅m 52 ft.-lbs.
Planetary Carrier Assembly 8 mm Socket Screws 80 N⋅m 59 ft.-lbs.
Upper and Lower Swivel Pin Retaining Bolts 120 N⋅m 89 ft.-lbs.
Track Control Rod End-to-Steering Arm Retaining Bolts 120 N⋅m 89 ft.-lbs.
Differential Assembly Bearing Adjuster Locking Plate Bolts 13 N⋅m 10 ft.-lbs.
Differential Assembly Support Casing Retaining Bolts 169 N⋅m 125 ft.-lbs.
Drive Shaft-to Drive Flange Attaching Bolts 57 N⋅m 42 ft.-lbs.
Steering Cylinder Ball Joints 300 N⋅m 221 ft.-lbs.
Steering Cylinder End-Plate Retaining Bolts 120 N⋅m 89 ft.-lbs.
Crown Wheel Retaining Bolts 230 N⋅m 170 ft.-lbs.
25-3

An identification plate attached to the right-hand rear
side of the axle casing carries the axle type, a
stamped serial number, total gear ratio, reference
number, oil capacity/type, and grease type. Use this
information when servicing parts.
The pivoting center of the axle allows articulation

when traveling rough ground. The input shaft, or
drive pinion, passes through the hollow center of the
rear articulation bushing. This arrangement keeps
the drive shaft, connecting the front axle with the
transfer case assembly, in a straight plain, through all
degrees of articulation.
Axle shafts consist of double, universal joint

assemblies, which allow constant running.
Three epicyclic planet gears, in the hub and

planetary gear assembly, accomplish final reduction.
The hub and planetary gear assemblies attach to the
axle center casing by swivels, which use both cone
and cup type bearings.
The axle features a differential assembly in a

removable casing, attached to the axle center
casing. The differential assembly is equipped with a
standard self-applied, limited slip system.
25-4
1
Front Axle -- Cutaway View
1. Drive Shaft Input Coupling 9. Front Articulation Trunnion Mounting
2. Steering Cylinder Rod 10. Crown Wheel
3. Track Rod End Assembly 11. Planetary Reduction Gear
4. Hub and Planetary Reduction Gear Assembly 12. Center Casing Breather
5. Axle Shaft Double Universal Joint Assembly 13. Removable Differential Assembly Carrier
6. Swivel Casing 14. Steering Cylinder
7. Swivel Pin Assembly 15. Rear Articulation Trunnion Mounting
8. Axle Center Casing
25-5
The multi-plate clutch on each side of the differential
side gears provides limited slip action. As traction is
lost on one front wheel, the torque reaction on the
differential exerts an axial outward force through the
side gears to pressurize the clutch plates. The outer
plates lock to the differential casing and the inner
plates to the side gears. As the force increases,
relative movement between the friction surfaces
becomes difficult and locks the side gears to the
casing, effectively locking the differential. As soon as
the slip tendency is overcome, the torque reaction
collapses and the system automatically unlocks.
A double acting piston controls the steering cylinder
rod as it extends through each side of the steering
cylinder, outward to the ball mounted track rods,
which connect the steering cylinder rod to each hub
assembly. The steering cylinder attaches to the
differential assembly carrier and is removable.
The hub and planetary reduction gear assembly, axle
shafts, steering swivels, steering cylinder, and track
control rods do not require removal of the axle from
the tractor to service and overhaul.
ADJUSTMENT
Front Wheel Toe-in – Four Wheel Drive
WARNING
This series of tractor contains lights, which meet
lighting requirements when operating or travel-
ing on public highways. If adjustment to the
wheel track length is beyond the initial factory
setting, it may require repositioning of the lights,
to comply with legal requirements. Additionally,
the tractor width should never exceed the
maximum length permitted by law.
The procedures for adjustment of the front wheel

toe-in on four wheel drive models is identical to that
of two wheel drive models in Chapter 1, Section 25
120, except for the following:
1. Adjust both track control rods in equal

increments to obtain the correct toe-in, (See
Specifications).
Front Wheel Track Adjustment – Four Wheel

Drive
Front wheel drive tractors have fixed axle assem-
blies. However, the track width is adjustable by
changing the wheel rim relative to the center disc, the
rim and/or disc relative to the axle hub, or by
interchanging both front wheels, Figure 2.
20025065
2
25-6
HUB AND PLANETARY REDUCTION GEAR

ASSEMBLY - OVERHAUL
Removal
1. Position the tractor on a hard level surface, apply
parking brake and chock the rear wheels.
2. Disconnect the battery negative (ground) cable.
3. Jack up the front axle and securely support the
front of the tractor.
4. Remove the front wheel(s).
5. Turn the wheel hub to position filler/drain plug at
the lowest point and drain the oil.
6. Remove the two 8 mm socket screws (3) and the
two shouldered wheel studs (2), Figure 3 that
secure the planetary carrier to the hub assembly.
7. Tap the planetary carrier with a soft mallet. Pry
the carrier from the hub using the slots provided.
3
Planetary Carrier Retainers
1. Socket Screws
2. Shouldered Wheel Nuts
8. Remove the planetary carrier, Figure 4, being

careful of the thrust pad located on the center of
the carrier.
4
Removing Planetary Carrier from
Hub Assembly
25-7
9. Remove the sun gear retaining snap ring and
remove gear, spacer and thrust washer from axle
shaft, Figure 5.
5
Removing Sun Gear Components
1. Thrust Washer
2. Spacer
3. Sun Gear
4. Snap Ring
10. Remove the ring gear and carrier retaining bolts,

Figure 6.
6
Ring Gear and Carrier Retaining Bolts
1. Axle Shaft
2. Ring Gear and Carrier
3. Retaining Bolts
11. Install four of the retaining bolts into the threaded

jacking holes in the ring gear. Tighten the bolts
evenly to draw off the ring gear and carrier.
Figure 6 and Figure 7.
7
Using Jack Bolts to Remove Ring Gear
and Carrier Assembly
1. Jack Bolts
25-8
12. Remove hub assembly, and if necessary tap the
hub using a soft mallet on the rear face, Figure 8.
8
Removing Hub Assembly
13. Carefully pry off inner bearing from the swivel

casing, Figure 9.
14. Remove the oil seal from the inner side of the
hub.
9
Levering Off Hub Inner Bearing
25-9
Disassembly
NOTE: When disassembling planetary carrier
assembly, keep all parts for each shaft together to
facilitate reassembling.
Inspect for oil leakage between the shaft cover and

carrier. If no leakage is found, it is not necessary to
remove the cover.
1. Remove the planetary carrier outer cover

screws. Remove cover.
2. Drive out the pins that secure each shaft to the
planetary carrier, Figure 10.
3. Push shafts outward and collect thrust washers,
planetary gears, and bearing rollers
10
Removing Shaft Roll Pins
1. Shaft
2. Housing
3. Planet Gear
4. Roll Pin
25-10
11
Planetary Carrier
1. Thrust Washer 9. Cover Plate
2. Planet Gear 10. Retaining Screw
3. Needle Roller Bearings 11. Shaft O ring Seal
4. Thrust Pad 12. Shaft
5. Locating Dowel 13. Roll Pin
6. Shouldered Wheel Stud 14. Carrier Housing
7. Carrier to Hub Screw 15. Thrust Washer
8. Drain/Filler Plug

parts to dry.
2. Inspect the hub main bearings. Inspect the outer
tracks in the hub housing and replace if
necessary, by using a drift punch to remove and
pressing the new outer tracks in until fully seated.
3. Inspect the planetary gear bearings, rollers and
shafts, and replace as complete sets if found to
be worn or damaged. A worn roller will
undoubtedly signify wear to the bearing path
inside the planetary gear and to the shafts.
4. Remove the retaining rings and separate the ring 12
gear and carrier. Inspect the ring gear teeth and Ring Gear and Carrier
retaining rings for wear or damage, Figure 12. 1. Retaining Ring
2. Retaining Ring
3. Carrier
4. Ring Gear
25-11
5. Inspect the ring gear carrier to swivel fixed
bushings.
NOTE: Two bushing sizes exist on each hub. Seven
bushings have a diameter of 20 mm (0.79 in.) and
one bushing has a diameter of 24 mm (0.95 in.). The
larger bushing serves as a master locator, and
ensures the correct installation of the carrier, Figure
13.
6. Inspect the eight, hub bushings for damage

caused by fretting, particularly if noticed that the
bolts were below torque during disassembly.
7. Inspect the sun gear, planetary gear, thrust
washers, spacers, and the thrust pad for wear 13
and damage. Replace any defective compo- Ring Gear and Carrier Retention -- Section View
nents. 1. Axle Shaft
2. Swivel Casing
3. Hub
4. Carrier
5. Locating Bushing (7 x 20 mm + 1 x 8 mm)
6. Carrier Retaining Bolt
8. Replace the planetary gear shaft O-ring seals.

9. Inspect the swivel assembly oil seal journal for
damage, Figure 14. To replace, cut off the journal
and thoroughly clean the swivel assembly
surfaces. Press on a new journal using a
continuing bead of suitable fixture agent to the
mating surface. This is critical in preventing oil
leakage.
14
Hub Oil Seal Wear Journal
1. Swivel Casing
2. Wear Journal
25-12
10. If necessary, fabricate a special tool as shown in
Figure 15 to facilitate pressing the journal against
the mating surface.
11. Inspect the planetary shaft cover, carrier, and
hub mating surfaces for minor nicks or burrs. Use
an abrasive stone to remove.
15
Oil Seal Journal Installation Tool
A. 90 mm (3.543 in.)
B. 140 mm (5.512 in.)
C. 155.2 mm (6.110 in.)
D. 175 mm (7.0 in.)
E. 18.5 mm (0.728 in.)
Material: Mild Steel
Assembly
Assembly of the planetary carrier follows the
disassembly procedures in reverse, observing the
following:
1. Ensure thirty bearing rollers are in each planetary

gear.
2. Use new roll pins to secure the shafts to the
housing.
3. Apply sealant to the chamfered heads of the
three cover attaching bolts.
Installation
1. Install the hub inner bearing onto the swivel
assembly. Install a new oil seal into the hub, and
ensure proper seating.
2. Lubricate the oil seal journal area with suitable
grease.
3. Assemble the hub to the swivel assembly.
4. Support the hub and slide in the outer bearing.
Maintain the hub in position while installing the
ring gear and carrier.
25-13
NOTE: The hub bearings, hub housing, and the
swivel stub, are machined to fine limits, eliminating
the need for bearing pre-load or rolling resistance
adjustments.
5. Assemble the ring gear and carrier with the

retaining rings.
6. Bolt the ring gear and carrier to the swivel
assembly, Ensure the correct position of the
larger bushing, Figure 16.
7. Tighten the bolts evenly to a torque of 95 N⋅m (70
ft.-lbs.).
16
Tightening Ring Gear and Carrier Assembly
Retaining Bolts
1. Axle Shaft
2. Ring Gear and Carrier
3. Retaining Bolts
8. Install the thrust washer, spacer, sun gear and a

new snap ring, Figure 17.
9. Coat the mating surfaces of the planetary carrier
and the hub with a suitable sealant.
17
Installing Sun Gear Components
1. Thrust Washer
2. Spacer
3. Sun Gear
4. Snap Ring
10. Install the thrust pad in the center of the carrier

assembly and position the carrier on hub. Install
the two 8 mm socket screws and tighten to a
11. Install the two shouldered wheel studs and
tighten to a torque of 70 N⋅m (52 ft.-lbs.), Figure
18.
12. Install the drain plug and replenish hub with oil.
18
Installing Planetary Carrier Retainers
1. Socket Screws
2. Shouldered Studs
25-14
AXLE SHAFTS - OVERHAUL

Removal
1. Remove the planetary carrier assembly, sun
gear, spacer and thrust washer as previously
described.
2. Position a suitable sling around the hub and
swivel casing, Figure 19.
3. Disconnect the track rod end from the steering
control arm.
19
Hub and Swivel Assembly Supported by Sling
4. Remove the upper and lower swivel pin retaining

bolts, Figure 20, and carefully lever the swivel
pins and shims from the casing, noting the
position of the shims. Identify the top and bottom
pin and shims to aid in reassembling.
20
Upper Swivel Pin and Retaining Bolts
1. Swivel Pin
2. Retaining Bolts
3. Lever Slot
4. Greaser
5. Carefully ease the hub and swivel assembly from

the axle casing Figure 21. Ensure not to pull the
axle shaft from the axle casing. Support the outer
end of the axle shaft as it passes through the seal
when the hub and swivel casing is moved away
from the axle casing.
21
Removing Swivel Casing and Hub Assembly
25-15
6. Carefully pull the axle shaft from the axle casing,
while guiding it through the outer oil seal, Figure
22.
22
Removing Axle Shaft from Axle Casing

Allow parts to dry.
2. Inspect the universal joints for wear to the plated
metal in the inner and outer yokes, and inspect
the axle shaft spline for fretting and wear.
3. Inspect the bearing and seal journal areas for
wear or damage.
4. Disassemble the universal joints and inspect for
wear or damage. If damage is present, consider
replacing the complete axle shaft.
5. Remove the axle shaft oil seals from the axle
casing, Figure 23. 23
Removing Axle Shaft Oil Seal from Axle Casing
1. Slide Hammer
2. Oil Seal
6. Remove the swivel casing assembly oil seal

Figure 24.
24
Removing Oil Seal from Swivel Casing
1. Swivel Casing
2. Oil Seal
3. Slide Hammer
25-16
7. Inspect the axle shaft bushings in the swivel
casing and in the axle casing. Replace worn or
damaged bearings using Attachment Tool No.
FNH09507 and Hammer Tool No. FNH09567,
Figure 25.
NOTE: An internally positioned spring ring prevents
the moving of the axle shaft bushing in the swivel
casing. Do not damage this ring during removal.
25
Removing Axle Shaft Bushing from Axle Casing
1. Bushing
2. Tool No. FHN09507
3. Tool No. FNH09567
8. Remove and replace worn or damaged bushing

in the swivel casing using Installer Tool No.
FTC307974, Figure 26.
9. Remove and replace worn or damaged bushing
in the axle casing using Installer Tool No.
FTC307975. Fully seat bushings.
10. Install new oil seals in the swivel and axle
casings. Position seals squarely.
26
Installing Axle Shaft Bushing in Swivel Casing
1. Bushing Installer Special Tool
2. Driver Handle No. 550
25-17
Installation
NOTE: When reassembling the axle shafts, ensure
each bearing cup is correctly installed, with no
interference of bearing rollers, and positively seat
snap rings into grooves.
1. Lubricate the bushing and oil seal in the axle

casing and swivel casing using suitable grease.
2. Pass the axle shaft through the axle casing
bushing and install in the differential side gear.
Ensure not to damage the oil seal.
3. Pass the swivel casing over the axle shaft and
onto the axle casing. Ensure not to damage the
oil seal.
4. Install the swivel pins and shims in exactly the
same location where removed.
5. Tighten the swivel pin retaining bolts to a torque
of 120 N⋅m (89 ft.-lbs.).
6. Install the sun gear thrust washer spacer and sun
gear.
7. Installation of the planetary gear carrier to the
hub assembly follows the removal procedures in
reverse.
8. Fill the hub assembly with oil. Check the
differential oil, and grease the swivel bearings.
25-18
STEERING SWIVEL PIN BEARINGS -

OVERHAUL
Removal
1. Position the unit on a hard level surface and raise
the front wheel. Securely support the unit in this
position and remove the front wheel.
2. Remove the planetary gear carrier assembly,
sun gear, spacer, and thrust washer, as
previously described.
3. Disconnect the steering track control rod end
from the steering arm.
4. Support the hub and planetary carrier assembly
using a crane and sling, Figure 27.
27
Hub and Swivel Assembly Supported by Sling
5. Remove the upper and lower swivel pin retaining

bolts, Figure 28, and lever the swivel pins from
the casing. Note the position of the shims and
identify the top and bottom pins, Figure 29.
28
Upper Swivel Pin and Retaining Bolts
1. Swivel Pin
2. Retaining Bolts
3. Lever Slot
4. Greaser
29
Removing Upper Swivel Pin
1. Swivel Pin
2. Shim
25-19
6. Carefully ease the hub and swivel assembly from
the axle casing, Figure 30. Ensure not to pull the
axle shaft from the axle casing. Support the outer
end of the axle shaft as it passes through the seal
when the hub and swivel casing is moved away
from the axle casing.
30
Removing Swivel Casing and Hub Assembly
Disassembly
1. Remove the upper and lower swivel pin grease
seals, Figure 31.
31
Removing Swivel Pin Grease Seal
2. Remove the swivel pin bearing outer cup using

Attachment Tool No. FNH09507 and Hammer
Tool No. FNH09567, Figure 32.
NOTE: It may be necessary to heat the axle casing
or apply a bead of weld to the inner surface of the
bearing, to cause the bearing to contract for ease of
removal.
32
Removing Swivel Pin Bearing Outer Cup
1. Slide Hammer
2. Outer Cup
25-20
3. Drive off the cone half of the swivel bearing for
each pin using a suitable drift, Figure 33.
Inspection
1. Clean all components with a suitable solvent,
including the axle casing ends. Allow parts to dry.
2. Inspect the oil seal in the swivel casing and
replace if worn or damaged.
3. Inspect the greasers for blockage
33
Removing Swivel Pin Bearing Cone
Assembly
1. Install new outer bearing cups on the axle casing
ends using a suitable driver, Figure 34.
NOTE: It may be necessary to heat the axle casing
and chill the bearing to aid installation.
1
34
Installing Swivel Pin Bearing Outer Cup
1. Suitable Driver Tool
2. Bearing Cup
2. Install new oil seals adjacent to each bearing

cup, Figure 35.
35
Installing Swivel Pin Grease Seal
25-21
3. Press and seat new cones halves onto the swivel
pins, Figure 36.
36
Pressing Swivel Pin Bearing Cone Onto Pin
1. Spacer Block
2. Bearing Cone
3. Swivel Pin
Installation
1. Reposition the hub and swivel casing on the axle
shaft and install on the axle casing. Ensure not to
damage the seal by the axle shaft passing
through the swivel casing. Ensure not to damage
the upper and lower swivel pin seals.
NOTE: The swivel pin bearings are pre-loaded by
0.20–0.40 mm (0.008-0.016 in.). Adjust the pre-load
after installing a new bearing, or a new swivel casing.
Set the pre-load at the upper limit for new bearings
and at the lower limit for resetting old bearings.
2. Install the lower swivel pin assembly with a 1.0

mm (0.040 in.) shim positioned under the head of
the pin, Figure 37.
3. Install the upper swivel pin assembly without
shims.
4. Tighten the upper and lower swivel pins to a
37
Lower Swivel Pin and Shim Installation
1. Swivel Pin
2. Shim (1 mm)
25-22
5. Record swivel pin bearing clearance by
mounting a dial gauge with the stylus on the top
of the upper swivel pin, and the body clamped to
the axle casing, Figure 38.
6. Set the gauge to zero and move the swivel casing
upwards. Record the amount of free-play
generated by the 1.0 mm (0.040 in.) shim.
7. Add the specified pre-load to the recorded
measurement and subtract the total from 1.00
mm (0.040 in.) shim already in position. The end
total is the resultant thickness of shim needed to
obtain the specified pre-load. Divide this
resultant shim size by two, for two shim packs of
equal size for the lower and upper swivel pins. 38
Dial Gauge Mounted to Record Swivel Pin
Bearing Clearance
Example:
Recorded movement ‘A’ = 0.20 mm (0.008 in.)
Specified pre-load ‘B’ = 0.40 mm (0.016 in.)
Shim in place ‘C’ = 1.0 mm (0.040 in.)
Calculation C - (A + B)
= 1.0 mm – [0.20 mm + 0.40 mm]

= 1.0 mm - 0.60 mm
= 0.40 mm
Or
= 0.040 in. – [0.008 in. + 0.016 in]

= 0.040 in. - 0.024 in.
= 0.016 in.
Then,
0.40 mm ÷ 2 = 0.20 mm (shim value per swivel pin.)
Or
0.016 in. ÷ 2 = 0.008 in. (shim value per swivel pin.)
8. Remove the swivel pins and the original 1.00 mm

(0.40 in.) shims and install the calculated shim
value to each swivel pin.
9. Grease the swivel pins with suitable grease.
10. Install the planetary gear carrier thrust washer,
spacer, and sun gear. Fill the hub with oil, (See
Specification).
11. Connect the track control rod end to the steering
arm and tighten bolt to a torque of 120 N⋅m ((89
ft.-lbs.).
25-23
STEERING CYLINDER AND TRACK RODS

– OVERHAUL
Removal
NOTE: Remove the steering cylinder if the
differential support casing requires removal. It is not
necessary to remove the steering cylinder for
steering cylinder seal leakage.
1. Position the tractor on a hard level surface.

2. Loosen the cylinder end plate, and the cylinder to
differential casing retaining bolts, by two turns,
Figure 39.
3. Turn the steering wheel to the left and unseat the
end cap and cylinder from the differential casing.
NOTE: There will be a slight loss of oil from the end
cap.
4. Apply parking brake and chock rear wheels.

Raise the left wheel and block the axle securely.
Remove left wheel.
39
Steering Cylinder End Plate/Retaining Bolts
1. Retaining Bolts
2. End Plate
3. Cylinder Rod
4. Hydraulic Hose
5. Disconnect the left and right-hand track control

rod ends from the steering arms, Figure 40.
40
Steering Track Rod End
1. Track rod
2. Steering Arm
25-24
6. Unscrew the track control rods from the steering
cylinder ball joints and unscrew the ball joints
from the steering cylinder, Figure 41.
NOTE: A high torque value on the connections will
require support and proper tooling to loosen.
41
Disconnecting Track Rod and Ball Joint from
Cylinder Rod
1. Ball Joint
2. Track Rod
3. Track Rod Clamp
4. Cylinder Rod
7. Disconnect the hydraulic hoses and remove

fitting from right side of cylinder.
8. Remove the four mounting bolts and steering
cylinder from the differential carrier, Figure 42.
Cap all open hose connections to prevent
contamination.
42
Removing Steering Cylinder from
Differential Carrier Mounting
1. Hydraulic Hose
Disassembly
1. Remove the piston and rod assembly (2) from the
steering cylinder barrel (1), Figure 43.
2. Slide the cylinder end plate off from the left side
of the barrel.
43
Removing Cylinder Rod and Piston Assembly
from Cylinder Barrel
1. Cylinder Barrel
2. Piston and Rod Assembly
25-25
3. Remove the wear rings, piston seals, O-rings,
end plate seal and wiper seals from the cylinder,
Figure 44.
44
Steering Cylinder Exploded View
1. Wear Ring 7. Wiper Seal
2. Wiper Seal 8. End Plate O-Ring Seal
3. Oil Seal 9. Wear Ring
4. Cylinder Barrel 10. Piston Seal
5. End Plate 11. Piston Seal Expander (O-Ring)
6. Oil Seal 12. Cylinder Rod and Piston
Inspection
parts to dry.
2. Inspect the piston and rod assembly for damage.
Remove minor nicks and abrasions using an
abrasive stone.
3. Inspect the inside of the cylinder barrel for
damage.
NOTE: Replace the complete steering cylinder
assembly after discovering damage to the piston and
rod assembly, or the cylinder barrel.
4. Inspect the track control rod ends, and the
cylinder rod ball joint for looseness. Replace the
ball joint if worn or damaged.
25-26
Assembly
1. Install new seals in the cylinder end plate and
right-hand side cylinder end.
2. Install new seals and wear rings on the piston,
and a new O-ring on the end plate.
3. Lubricate all seals and the piston assembly with
clean hydraulic oil and reinstall into the cylinder
barrel.
NOTE: Allow the center seal with the O-ring on the
piston and rod assembly, to contract naturally before
installing into cylinder barrel.
Installation
1. Installation of the steering cylinder follows the
requirements:
2. Tighten the steering cylinder ball joints to a
torque of 300 N⋅m (221 ft.-lbs.), and torque the
cylinder end plate retaining bolts to 120 N⋅m (89
ft.-lbs.).
3. Position hydraulic connections and hoses to
prevent interference with other components,
through all degrees of front axle steering.
4. Fill the steering reservoir with the correct oil, (See
Specifications).
5. Adjust and set the front wheel toe-in using the
procedures in Section 44.
45
Toe-in Adjustment
1. Rear Measurement
2. Measurement Height-Hub Height
3. Front Measurement
25-27
FRONT AXLE – REMOVAL AND

INSTALLATION
Removal
NOTE: If the unit is equipped with a front weight kit
or ballast, or a front mounted implement, consider
removing these components first.
1. Position the tractor on a hard level surface. Apply

the parking brake and chock the rear wheels.
2. Remove the drive shaft guard retaining bolts and
remove guard.
3. Remove the drive shaft to axle drive flange
retaining bolts, Figure 46.
4. Slide the shaft from the transfer box output shaft
and remove.
5. Raise the front of the tractor until both wheels 46
clear the ground and securely block the tractor Drive Shaft to Axle Coupling
below the junction of the engine to front 1. Axle Drive Flange
transmission. 2. Drive Shaft to Drive Flange Attaching Bolts
3. Drive Shaft
6. Remove the front wheels.
7. Disconnect the hydraulic hose connections from
the steering cylinder.
NOTE: Consider delaying the disconnection of
hoses until partially lowering the axle from the front
support, to improve access.
8. Position suitable jacks or lifting equipment to

support the weight of the axle. Before removing
the front and rear support pillars, ensure the
stability of the axle.
25-28
9. Loosen the front and rear support retaining bolts
Figures 47 and 48, evenly and gradually lower
the jacks or lifting equipment. Check that the axle
is stable and secure.
47
Front Support Pillar Retaining Bolts
1. Retaining Bolts
10. Remove the front and rear support retaining

bolts, and lower the axle to the ground.
Disconnect the steering hoses if not discon-
nected previously, as the axle is lowered.
48
Rear Support Pillar Retaining Bolts
1. Support Pillar
2. Retaining Bolts
3. Flange Coupling

Allow parts to dry.
2. Inspect the bushings on the front and rear
trunnions of the axle and differential casings for
wear or damage, Figure 49.
49
Front and Rear Support Pillar Bushings
1. Rear Support Bushing
2. O-ring Seal
3. Rear Trunnion Bushing
4. Front Support Bushing
5. Front Trunnion Bushing
25-29
3. Remove the O-ring seal from the bushing inside
the rear support, Figure 50. Clean all mating
surfaces of the bushing and rear support.
4. Install the front, and rear supports onto the
trunnions, and assess the degree of wear by
rocking the supports from side to side. Replace
bearings in pairs if wear or damage is excessive.
NOTE: Fore and aft movement of the axle before
removal signifies worn bushing thrust faces.
5. Removal of the bushings in the supports requires

the removal of the locating bolt and greaser
assembly. Use a press to remove the rear
support bushing. Cutting may be required to 50
remove the front support bushing. Install new Rear Support Pillar Bushing and O-Ring Seal
bushings with the grease holes aligned with the 1. O-ring Seal
drilling in the support and replace the locating 2. Bushing
bolt and greaser assembly. 3. Bushing Locator and Greaser
4. Support Pillar
6. Remove the axle drive flange as described in this
5. Locators
section.
7. Remove the trunnion bushings, cutting length-
wise to ease removal. Install new bushings in
trunnions.
8. Reinstall the axle drive flange as described in this
section.
Installation
Installation of the axle follows the removal
procedures in reverse.
1. Apply thread locking compound to the axle input

coupling flange to drive shaft retaining bolts and
tighten to a torque of 57 N⋅m (42 ft.-lbs.).
2. Tighten the support pillar bolts to a torque of 370
N⋅m (273 ft.-lbs.).
3. Fill the steering reservoir with oil.
4. Cycle the steering from lock to lock to purge air
from the circuit. Recheck reservoir level.
5. Check and adjust front wheel toe-in as described
in this section.
25-30
DIFFERENTIAL CROWN WHEEL AND

PINION ASSEMBLY – OVERHAUL
Removal
1. Remove the axle assembly as described in this
section.
2. Remove the swivel casings, and axle shafts, as
described in this section.
3. Remove the steering cylinder assembly as
described in this section.
4. Drain the oil from the differential housing.
5. Position the axle housing so that the differential
support casing is upwards. Remove the
differential support to axle retaining bolts, Figure
51. Remove the support.
51
Differential Support Casing Retaining Bolts
Disassembly
1. Remove the drive flange retaining snap ring and
remove the flange from the pinion shaft, Figure
52.
52
Removing Drive Flange
1. Input Shaft
2. Drive Flange
3. Snap Ring
25-31
2. Remove the O-ring seal from the inner face of the
drive flange and the spacer positioned in front of
the pinion/bearing retaining nut, Figure 53.
3. Position a piece of hard wood in mesh with the
crown wheel and pinion to effectively lock the two
gears to facilitate removal of the pinion and
bearing retaining nut.
4. Remove the retaining nut and washer using
Wrench Tool No. FTC307978.
53
Drive Flange O-Ring Seal
1. Spacer/Washer
2. O-ring Seal
3. Drive Flange
4. Snap Ring
5. Remove the differential unit bearing adjuster ring

lock nut locking plates, Figure 54.
54
Differential Unit Bearing Adjuster Locking Plates
1. Locking Plates
6. Mark the bearing adjuster ring nuts relative to the

respective bores and the position of each within
the bores. This will aid when assembling new
components that effect bearing pre-load. Mark
each end cap to the casing to prevent
interchanging during assembly, Figure 55.
55
Marking Bearing Caps Relative to Casing
25-32
7. Remove the bearing cap retaining nuts. Remove
caps and adjuster nuts. Lift out the differential.
crown wheel assembly from the support casing.
Collect the bearing outer tracks and identify them
to the respective sides, Figure 56.
56
Removing Differential and Crown Wheel Assembly
8. Remove the crown wheel retaining bolts, Figure

58, and separate the crown wheel from the
differential housing
57
Crown Wheel Retaining Bolts
1. Retaining Bolt
2. Crown Wheel
3. Differential
9. Turn the housing over and allow the differential

gear shift-locking pin to fall out. Slide the shaft
from the differential housing, Figure 58.
58
Differential Gear Shaft Locking Pin
1. Shaft
2. Pin
25-33
10. Manipulate the two differential gears to the
opening in the housing and remove the gears
and the thrust washers, Figure 59.
59
Removing Differential Gears
1. Thrust Washer
2. Gear
3. Side Gear
11. Remove the side gears and the limited slip,

differential lock clutch components. Keep the
clutch plates in order and place them on the
side-gear mounts for subsequent inspection and
assembly, Figure 60.
60
Removing Differential Side Gear and Clutch Pack
1. Side Gear
2. Clutch Pack
12. Push out the drive pinion from the differential

support casing, and collect the collapsible
spacer and outer bearing inner race, Figure 61.
61
Drive Pinion Removed from Differential Support Casing
1. Pinion and Bearing
2. Support Casing
3. Washer
4. Retaining Nut
5. Outer Bearing Inner Race
6. Collapsible Spacer
25-34
parts to dry.
2. Remove all traces of sealant from the differential
support casing mounting face, and mating
surfaces of the axle casing.
3. Remove all traces of locking compound from the
crown wheel retaining bolts, and locating dowels.
4. Inspect the crown wheel and pinion teeth for
wear or damage. Replace both gears as a
matched set if necessary.
5. Inspect the differential side bearings. If neces-
sary, pull off the inner race using Puller Tool No.
FNH09516, and Attachment Tool No.
FNH09190, Figure 62.
62
Removing Differential Side Bearing
1. Puller FNH09516
2. Shaft Protector
3. Pulling Attachment FNH09190
4. Bearing Inner Race
6. Inspect the pinion bearings for wear or damage.

If necessary, remove the inner bearing, inner
race using Puller Tool No. FNH09516, and
Attachment Tool No. FNH09190, Figure 63.
Drive out the outer tracks from the differential
support casing.
NOTE: Retain the shim positioned between the
pinion inner bearing and the head of the pinion.
7. Inspect the differential gears, thrust washers and

shaft for wear or damage, and replace as
necessary.
8. Inspect the side gears and the spline within each
gear for wear or damage, and replace as 63
necessary. Removing Pinion Inner Bearing Race
1. Puller FNH09516
2. Shaft Protector
3. Pinion
4. Pulling Attachment FNH09190
5. Bearing Inner Race
25-35
9. Inspect the bushings in the differential housing
for wear. If necessary pull bushings out using
Puller Tool No. FNH09527, Figure 64. Press in
new bushings.
64
Removing Differential Housing Bushing
1. Puller FNH09527
2. Bushing
10. Inspect the limited slip, differential clutch packs,

Figure 65. The plates should be perfectly flat.
Inspect the internal spline area and the outer lugs
on the interfacing plates, and the internal wearing
plates for maximum wear of 0.15 mm (0.006 in.).
New plates measure 1.6 mm (0.084 in.) thick.
Inspect the thrust plate under the head of each
side-gear for maximum wear of 0.1 mm (0.004
in.). New thrust plates measure 2.8 mm (0.112
in.) thick.
65
Side Gears and Clutch Packs
1. Side Gears
2. Interfacing Drive Plate
3. Internally Splined Driven Friction Plate
4. Inner Thrust Plate
11. Inspect the condition of the axle casing, the

differential support casing, and the differential
gear housing.
12. Remove the input drive flange oil seal from the
differential support casing, Figures 66 and 67.
66
Input Drive Flange Oil Seal
1. Oil Seal
25-36
Assembly assembly, or pinion bearings, or when changing
1. Recalculate the thickness of the shim placed the differential support casing. If all these
behind the head of the drive pinion on the pinion components are reusable, then use the original
shaft, when replacing the crown wheel and pinion calculated shim value.
67
Differential, Crown Wheel and Pinion Assembly -- Exploded View
1. Bushing 17. Pinion
2. Adjusting Ring 18. Crown Wheel
3. Shaft Lock Pin 19. Adjuster Ring
4. Differential Gear 20. Locking Plate
5. Thrust Washer 21. Bearing
6. Oil Seal 22. Bushing
7. Coupling Flange 23. Thrust Washer
8. Snap Ring 24. Differential Gear
9. O-ring 25. Differential Housing
10. Spacer 26. Shaft
11. Nut 27. Clutch Pack
12. Keyed Washer 28. Side Gears
13. Bearing 29. Clutch Pack
14. Collapsible Spacer 30. Bearing
15. Bearing 31. Locking Plate
16. Shim
25-37
2. Calculate the shim thickness as follows:
• Install the pinion bearings in the differential
support casing as shown in Figure 68. Lightly
clamp the bearings using Pinion Setting
Gauge, Tool No. FNH04775. Install tool with
the cut-away side upward. Tighten the clamp
enough to lightly, hand turn the bearing
cones. Do not over tighten.
• Install the differential support casing, side
bearing caps (not the bearing tracks) and
tighten the retaining nuts to a torque of 169
N⋅m (125 ft.-lbs.)
68
Pinion Bearings Clamped in Casing
1. Pinion Setting Gauge FNH04775
2. Pinion Bearing Assemblies
• Measure the side bearing bore using an

internal micrometer or vernier caliper and
record measurement as dimension ‘A’,
Figure 69.
69
Measuring Diameter of Differential Housing
Bearing Bores
25-38
• Place the circular bar from Tool No.
FNH04775 across the two bearing bores in
the support casing, Figure 70 and use a
depth gauge to measure and record as
dimension ‘B’.
• Use the recorded measurements and the
formula below to determine the required
thickness of shim needed:
C = B – 25.0 mm (0.98 in.) [Diameter of bar] + 1/2 A
The difference between calculation ‘C’ and the

dimension etched on the head of the pinion results in
the actual shim thickness.
70
Example:
Measuring Dimension ‘B’
C = 104.1 mm – 25 mm +1/2 (90 mm) = 124.1 mm 1. Depth Gauge
Etched on the pinion is 121.0 mm 2. Bar Gauge - FNH04775
3. Pinion Shaft Bearings
124.1 mm – 121.0 mm = 3.1 mm (shim thickness) 4. Pinion Setting Gauge - FNH04775
5. Differential Support Casing
Select the calculated shim thickness from the
range available, (See Specifications). Install on
the pinion shaft with the chamfer adjacent to the
pinion gear.
3. Press the inner bearing onto the pinion shaft until
completely seated, Figure 71.
IMPORTANT: Use a new collapsible spacer on the
pinion shaft. DO NOT use the old part.
4. Assemble the pinion bearing and spacer

assembly into the differential support casing and
install the outer bearing and retaining nut.
Eliminate bearing free-play by tightening the nut,
using Wrench, Tool No. FTC 307978.
71
Pressing Inner Bearing onto Pinion
1. Press
2. Protector
3. Pinion
4. Shim
5. Inner Bearing Race
25-39
5. Wrap string evenly around the exposed pinion
input spline, and use a pull scale to measure the
force required to rotate the pinion shaft within the
bearings, Figure 72. Read the scale during
rotation, not when the rotation starts.
6. Progressively tighten the retaining nut until
obtaining a force of 14.3-20.4 kgs-cm (12-18
lb-in.) It may be necessary to temporarily reinstall
the differential and crown wheel, to preset
rotation of the pinion during tightening of the
bearing retaining nut.
72
Checking Pinion Shaft Bearing Rolling Resistance
1. Spring Balance
2. String
3. Differential Housing
4. Pinion Shaft
7. After obtaining the specified scale reading, lock

the retaining nut to the shaft by placing the
retaining nut locking sleeve in the machined slot
of the pinion shaft.
8. Assemble the differential side-gears and limited
slip, clutch components. Position the gears in the
housing with the inner thrust plate adjacent to the
side-gear. The inner thrust plate wear face must
be adjacent to the interfacing drive plate with
external lugs, followed by a driven friction plate
with an internal spline. Each side-gear should be
equipped with one inner thrust plate, five
interfacing drive plates (external lugs), and four
driven friction plates (internal spline), Figure 73. 73
Side Gears and Clutch Packs
1. Side Gears
2. Interfacing Drive Plate
3. Internally Splined Driven Friction Plate
4. Inner Thrust Plate
25-40
9. Position the differential gears and the thrust
washers in the housing and assemble the shaft.
Slide the shaft into position, aligning the locking
bore with the matching bore in the housing.
Install the shaft-locking pin, Figure 74.
10. Install the crown wheel with the locating dowel in
place. Coat the threads of the retaining bolts with
a suitable locking compound and tighten to a
74
Installing Differential Gear Shaft Locking Pin
11. Press and completely seat the two side bearings

onto the housing.
12. Place the assembled differential housing into the
support casing. Position the bearing outer tracks,
support casing bearing caps and bearing
adjuster rings, Figure 75. Ensure the correct
positioning of the centering bushings, the crown
wheel, and pinion. The crown wheel must be to
the left of the pinion when viewed from the input
side.
13. Tighten the bearing cap retaining nuts just
enough to support the caps, while adjusting the
adjuster rings to remove all free-play. First
tighten the crown wheel, side-locking ring to 75
move the crown wheel against the pinion, and Installing Differential Housing Side Bearing
then tighten the other adjuster until it becomes Outer Track Adjuster Ring and Cap
difficult to move. Do not force the adjuster. 1. Crown Wheel
2. Centering Bushing
3. Adjuster Ring
4. Bearing
5. Bearing Outer Track
6. Cap
25-41
NOTE: Serious damage to the gear set will occur if
the bearing cap retaining nuts are over tightened,
forcing the crown wheel against the pinion.
14. Measure the backlash between the crown and

pinion with a dial indicator. Place the stylus 90_
to the crown wheel teeth, Figure 76.
15. Use the adjuster rings to obtain a desired
backlash of 0.15-0.25 mm (0.006-0.010 in.).
Adjust the rings in equal amounts, moving the
crown wheel to and from the pinion. During this
procedure, gently tap each bearing cap with a
soft mallet, to ensure bearings remain correctly
seated. Repeat procedure in two equally spaced 76
positions around the crown wheel. Measuring Crown Wheel to Pinion Back Lash
16. Adjust the pre-load on the differential side 1. Dial Indicator
bearings using the following method: 2. Crown Wheel
3. Adjuster Ring
• Determine the resistance of the pinion 4. Pry Bars
bearings as described in steps five and six if
not previously done, and record as measure-
ment ‘D’.
• With the crown wheel in mesh with the pinion,
and the correct backlash set, use a string and
pull scale to measure the resistance required
to rotate the pinion and crown wheel/differen-
tial assembly, and record as measurement
‘E’.
• Subtract the original pinion bearing resist-
ance measurement ‘D’ from the new
measurement ‘E’ taken from the pinion and
crown wheel/differential assembly, resist-
ance and record as measurement ‘F’.
Example:
9.1 kgs (20 lb) = ‘D’
12.25 kgs (27 lb) = ‘E’
12.25 kgs – 9.1 kgs = 3.15 kgs (7 lb) = ‘F’
• Tighten each differential side bearing

adjuster in equal amounts (to preserve the
backlash adjustment), until obtaining resist-
ance within the lower band of 2-6 kgs
(4.4-13.2 lb).
17. Tighten the differential assembly bearing adjust-
er locking plate bolts to a torque of 13 N⋅m (10
ft.-lbs.).
18. Recheck the backlash and install adjuster ring
locking tabs. Tighten the adjuster rings to align
the locking tab with the slot.
25-42
19. Recheck the bearing resistance.
20. Install a new drive flange oil seal in the pinion
shaft bore using Installer FTC307971, Figure 77.
Install the spacer O-ring seal and input flange on
the pinion shaft. Lubricate the sealing surface on
the flange with axle oil. Install a new snap ring to
secure the input flange on the shaft.
77
Installing Drive Flange Oil Seal
1. Tool No. FT3161 (307971)
2. Oil Seal
3. Pinion Shaft Bore
4. Driver Handle
Installation
1. Apply suitable sealant to the differential support
casing and axle casing mating surfaces.
NOTE: Thoroughly clean the differential support
casing and axle casing mating surfaces before
applying sealant.
2. Assemble the differential support casing to the

axle housing and evenly tighten the retaining
bolts to a torque of 169 N⋅m (125 ft.-lbs.).
3. Assemble the swivel hub and drive shafts to the
axle as described in this section.
4. Install the axle on the tractor as described in this
section.
5. Fill the axle differential and the wheel hubs with
the correct grade and quantity of oil, (See
Specifications).
25-43
DRIVE SHAFT - OVERHAUL

Removal
1. Position the tractor on a hard level surface. Apply
the parking brake and chock the wheels.
2. Remove the drive shaft guard.
3. Before disassembling, inspect the universal and
sliding joints for wear. Additionally, inspect the
tubular sections of the drive shaft for buckling or
damage.
4. Remove the drive shaft coupling-to-front axle
drive flange retaining bolts and disconnect the
coupling, Figure 78. 78
5. Slide the shaft off the transfer box, output shaft. Drive Shaft Front Universal Joint
1. Coupling
2. Yoke
3. Spider
4. Greaser
Inspection
1. Thoroughly clean the area around the universal
joints and inspect for wear or damage. The
discovery of worn yokes on both universals may
require replacement of the drive shaft.
2. Thoroughly clean the sliding joint and inspect the
spline for wear and fretting.
Installation
Installation of the drive shaft and guard assembly
follows the removal procedures in reverse, with the
following requirements.
1. Apply a suitable thread-locking compound to the

axle input coupling flange-to-drive shaft retaining
bolts.
25-44
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
Chapter 1 - Rear Axle
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rear Axle Shaft Bearing Pre-load Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Differential Bearing Pre-load Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Maximum Permissible Rear Axle Loading with Ballast and Mounted Equipment . . . . . . . . . 4
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Final Reduction Gear Assembly (Planetary Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Separating the Tractor Between the Front Transmission and the Rear Axle . . . . . . . . . . . . . 9
Rear Axle Shaft Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Planetary Gear Assembly and Axle Housing – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Differential and Differential Lock Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Differential Lock Control Linkage – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Drive Pinion Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Rear Axle Assembly Final Reduction Drop Trumpet (Drop Box) -- Component
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
27-1
SPECIFICATIONS
REAR AXLE SHAFT BEARING PRE-LOAD SPACERS
RESULTANT SPACER TO BE INSTALLED
FIGURE
1.24-1.32 mm (0.049-0.052 in) 1.14 mm (0.045 in)
1.35-1.42 mm (0.053-0.056 in) 1.24 mm (0.049 in)
1.45-1.52 mm (0.057-0.060 in) 1.35 mm (0.053 in)
1.55-1.63 mm (0.061-0.064 in) 1.45 mm (0.057 in)
1.65-1.73 mm (0.065-0.068 in) 1.55 mm (0.061 in)
1.75-1.83 mm (0.069-0.072 in) 1.65 mm (0.065 in)
1.85-1.93 mm (0.073-0.076 in) 1.75 mm (0.069 in)
1.96-2.03 mm (0.077-0.080 in) 1.85 mm (0.073 in)
2.06-2.13 mm (0.081-0.084 in) 1.96 mm (0.077 in)
2.16-2.24 mm (0.085-0.088 in) 2.06 mm (0.081 in)
2.26-2.34 mm (0.089-0.092 in) 2.16 mm (0.085 in)
DIFFERENTIAL BEARING PRE-LOAD SPACERS

MEASURED SHIM TO BE INSTALLED
GAP
0.61-0.74 mm (0.024-0.029 in) 0.97-1.02 mm (0.038-0.040 in)
0.76-0.87 mm (0.030-0.034 in) 1.12-1.17 mm (0.044-0.046 in)
0.91-1.04 mm (0.036-0.041 in) 1.27-1.32 mm (0.050-0.052 in)
1.07-1.19 mm (0.042-0.047 in) 1.42-1.47 mm (0.056-0.058 in)
1.22-1.35 mm (0.048-0.053 in) 1.58-1.63 mm (0.062-0.064 in)
1.37-1.50 mm (0.054-0.059 in) 1.73-1.78 mm (0.068-0.070 in)
1.52-1.63 mm (0.060-0.064 in) 1.88-1.93 mm (0.074-0.076 in)
1.65-1.78 mm (0.065-0.070 in) 2.03-2.08 mm (0.080-0.082 in)

Item
Rear Axle Shaft Rolling Torque 11.6 28.2 N⋅m
11.6-28.2 Nm 8.56 20.8 ft.-lbs.
8.56-20.8 ft. lbs.
End-Float 0.025-0.076 mm 0.001-0.003 in
Drive Pinion Bearing Pre-Load (Pull Scale) 5.9-10.5 kg 13-23.2 lb
Differential Bearing Rolling Torque (Pull Scale) 7.0-30 kg 15-66 lb
27-2
TORQUE VALUES
Hardware N⋅ m Ft.-Lbs.
Rear Disc to Hub Nuts (Manual Adjust Wheels) 390 N⋅m 288 ft.-lbs.
Rear Disc to Rim Nuts (Manual Adjust Wheels) 240 N⋅m 177 ft.-lbs.
Buckle-Up Bolts 240-298 N⋅m 177-220 ft.-lbs.
Differential Case Retaining Bolts 92-125 N⋅m 68-92 ft.-lbs.
Drive Pinion Bearing Retainer Bolts 136-170 N⋅m 100-125 ft.-lbs.
Planetary Gear Retaining Bolt 339-542 N⋅m 250-400 ft.-lbs.
Axle Shaft Housing Retaining Bolts 176-258 N⋅m 130-190 ft.-lbs.
Axle Shaft Retaining Bolts 339-542 N⋅m 250-400 ft.-lbs.
Differential Ring Gear Retaining Nuts 115 N⋅m 85 ft.-lbs.
Differential Lock Fork Pivot Shaft Retaining Bolts 57-76 N⋅m 42-56 ft.-lbs.
Differential Lock Hanger Retaining Bolts 57-76 N⋅m 42-56 ft.-lbs.
Inner Brake Housing Retaining Bolts 88-121 N⋅m 65-89 ft.-lbs.
Ring Gear Thrust Block 37-50 N⋅m 27-37 ft.-lbs.
OIL CAPACITY
Quantity Single Speed P.T.O. Two-Speed P.T.O.
Liters 62.0 66.0
Gallons 16.5 17.5
NOTE: With front wheel drive, increase the rear axle oil fill by 1.2 Liters (1.3 quarts).
27-3
SPECIAL TOOLS
Tool New Holland Part Other Reference Global Part
Numbers Numbers Numbers
Kit, Splitting MS 2700
Bridge FNH01503
Block, Gauge FNH01504
Spacer FNH01505
Remover/Installer, Planetary Ring Gear FNH02123
Gauge, Differential Bearing Pre-Load FNH02141
Remover, Rear Axle Collar FNH02184
Step Plate (Set of 11) FNH09210
Step Plate, (Set of 6) FNH09211
Shaft Protectors (Set of 6) FNH09212 380000564
Driver Set FNH09514
Legs, Push Puller 16 1/2″ (pr) FNH09521
Slave Ring CT9056
Taper Base 370
MAXIMUM PERMISSIBLE REAR AXLE LOADING WITH BALLAST AND MOUNTED

EQUIPMENT
Model Kg Lb
5610S, 6610S 4990 11,001
7610S, 7010, 8010 5445 12,004
NOTE: Measure maximum permissible rear axle loading with only the rear wheels on the scale inclusive of ballast
and mounted equipment in the raised position.
27-4
FAULT FINDING
1. Rear Axle Noisy 1. Lack of oil 1. Top up as required
2. Incorrect oil specification 2. Drain and refill with oil of

correct specification
3. Worn axle bearings 3. Disassemble and inspect

bearings
2. No Drive 1. Axle shaft housing 1. Operate the differential lock.

If the tractor drives, this
(NOTE: Refer also to ‘Clutch indicates a failure within an
Systems’ fault finding. axle shaft housing assembly.
2. Differential Unit 2. If the tractor does not drive
the fault may lie in the
differential unit. Ensure the
Clutch and transmission
systems are not at fault.
3. Differential Lock not 1. External linkage damaged or 1. Replace/repair as required

engaging (mechanically broken
engaged)
2. Internal linkage, cross shaft 2. Remove the HPL top cover

rod, fork or pivot shaft and inspect
damaged/broken
3. Damaged or broken teeth on 3. Remove differential and

differential lock adaptor or inspect differential lock
coupling assembly
4. Differential Lock not 1. Spring broken between 1. Remove differential and

disengaging (mechanically adaptor and coupling replace spring
engaged)
2. Teeth of adaptor or coupling 2. Remove differential and
damaged/burred replace damaged parts
27-5
DESCRIPTION AND OPERATION • Independent Power Take-Off Components

Engine and gearbox drive transmits to the rear • Transmission Handbrake
wheels via the rear axle assembly, which attaches to
the rear of the front transmission. Housed within the The drive coupling transmits drive from the
rear axle assembly are the following components: transmission output shaft to the spiral bevel pinion.
The pinion meshes with the differential ring gear, and
is located between two preloaded, opposing, tapered
• Main Drive Pinion and Differential Ring Gear
bearings in front of the rear axle housing.
• Differential Assembly
• Differential Lock Assembly Taper roller bearings mounted in the axle shaft
• Rear Wheel Brake Assembly housings, support the ring gear riveted to the
differential case assembly.
• Final Reduction Gears
• Axle Half Shafts
1
Rear Axle Assembly
1. Outer Brake Housing 13. Planet Gears
2. Axle Housing Outer Bearing 14. Axle Housing Inner Bearing
3. Axle Shaft 15. Sun Gear
4. Axle Shaft Oil Seal 16. Differential Lock Fork
5. Planet Gear Carrier
17. Drive Pinion
6. Axle Housing
18. Drive Pinion Locknut
7. Brake Torque Pin
19. Rear Axle Center Casing
8. Differential Assembly
9. I.P.T.O Drive and Driven Gears 20. Pinion Bearing Retainer
10. I.P.T.O Rear Shaft 21. Differential Ring Gear
11. Differential Lock Assembly 22. Thrust Block
12. Rear Wheel Brake Assembly 23. Inner Brake Housing
27-6
NOTE: Replace the rivets with bolts and nuts when
removing the ring gear from the differential case 1 2
assembly.
A thrust block on the heavy-duty axle prevents the

ring gear from flexing due to pre-loading from the
drive pinion.
The casting of the block ensures an adequate

quantity of lubricating oil flows to the drive pinion
bearings.
The axle shaft housings operate with higher oil levels 3

than the center housing. The left-hand axle housing
(1) and the right-hand axle housing (2) both have 2
restrictions (3) to maintain the increased levels, Left and Right Hand Axle Housings
Figure 2. 1. Left Hand Axle Housing
2. Right Hand Axle Housing
3. Restriction
The differential case assembly forms two halves

bolted together to enclose the differential spider and
side gears.
The drive from the pinion transmits via the ring gear
and differential case assembly to the arms of the
spider. Pinion gears mounted on the spider are in
constant mesh with the side gears.
The brake assemblies mount on the spline end of the

intermediate shafts, which spline into the side gears.
The outer end of each intermediate gear forms the

sun gear of an epicyclic final reduction gear set,
mounted within the axle housings.
A reduction gear set transmits drive to the wheels

from the intermediate shaft to the axle shaft.
The planetary gear carrier mounts to the inner spline

of the axle outer shaft. Tapered roller bearings
installed in each axle housing support the axle
shafts.
Hydraulic system oil lubricates the rear axle

components. The partially immersed differential ring
gear assembly splash feeds oil to the bearings and
bushings.
Differential Lock Assembly
The differential lock assembly installed on the
left-hand side of the crown wheel, overcomes tractor
wheel slippage, by connecting one of the side gears
to the differential case assembly. This action locks
the differential assembly together, which provides
direct drive to both wheels.
27-7
The differential lock assembly consists of a sliding
coupling (3) connected to the spline of the side gear,
an adapter (2) positioned between the coupling and
left-hand differential case (1), and a spring (4)
positioned between the coupling and adapter. In
addition, there is a fork and lever assembly (not
shown), Figure 3.
The spring ensures engagement of the coupling to

the adapter only when required, and the disengage-
ment of the adapter dog-teeth with the differential
case.
The fork and lever assembly connects to a foot pedal

through spring controlled linkage. Depressing the foot 3
pedal causes the fork to force the coupling dog-teeth
to mesh with the adapter, locking the side gear to the
differential case. There is no requirement to depress
the foot pedal after the differential lock engages.
The mechanically operated differential lock automat-
ically disengages when spring pressure overcomes
the side forces acting on the coupling teeth, which
occurs when there is equal torque to both wheels.
FINAL REDUCTION GEAR ASSEMBLY

(PLANETARY GEAR)
The rear axle housing incorporates an epicyclic
reduction gear assembly to increase the torque
transmitted to the rear wheels. The outer end of the
intermediate shaft acts as a planetary sun gear for
three planet gears installed within a carrier. The
carrier mounts to the spline of the rear axle shaft.
The planet gears mesh with a ring gear mounted in
the axle housing. The revolving intermediate shaft
forces the planet gears to revolve around the inside
of the ring gear, causing the planet gear carrier to
rotate at a reduced speed and transmit increased
torque to the rear axle and wheels.
OPERATIONS OR REPAIRS PERFORMED
WITH THE LEFT-HAND HALF AXLE
REMOVED:
• Differential Fork Overhaul
• Sun Gear Assembly Overhaul
• Half Shaft Assembly Overhaul
• Left-hand Brake Plate Overhaul
OPERATIONS OR REPAIRS PERFORMED
WITH THE RIGHT-HAND HALF AXLE
REMOVED
• Differential Lock Assembly Overhaul
• Sun Gear Assembly Overhaul
• Half Shaft Assembly Overhaul
• Crown Wheel and Pinion Assembly Overhaul
• Right-hand Brake Plate Overhaul
27-8
SEPARATING THE TRACTOR BETWEEN THE
FRONT TRANSMISSION AND THE REAR AXLE
2. Drain the oil from the rear axle center casing.
3. Remove the right-hand steering gear cover.
4. Disconnect the rear harness from the multi-con-
nector.
5. Remove the clips retaining the harness to the
front transmission and to the platforms.
6. Disconnect the oil cooler pipes at the axle
housing.
7. Disconnect the brake pedal return springs from
the platform.
left-hand and right-hand platforms.
disconnect the clutch control rod from the clutch
release arm.
10. Install the tractor Splitting Kit Tool No. MS 2700,
which consists of a Support Trolley (1), Support 2 1
Stand (2) and Rail (3), Figure 4. 10024894 3
4
11. Remove the buckle up bolts and separate the
rear axle assembly (3) from the front transmis-
sion (1), Figure 5. 1
10024895
5
Reconnecting the Front Transmission to the
Rear Axle Assembly
Reconnection of the front transmission to the rear
axle assembly follows the disconnect procedures in
12. Ensure the hydraulic pump drive gear meshes
with the pump driven gear.
13. Tighten the buckle-up bolts to a torque of
240-298 N⋅m (177-220 ft.-lbs.).
27-9
REAR AXLE SHAFT ASSEMBLY – 5. Remove the fenders and roll over protection
OVERHAUL devices, then remove the rear wheels. Reinstall
nuts onto studs to prevent damage to the stud
Removal threads during overhaul.
1. Chock the front wheels to prevent movement. 6. Support the rear of the cab (where installed) or
Release the hand brake. platform and move away from the half shaft to be
2. Drain the oil from the rear axle center casing. removed.
3. Disconnect hydraulic lift rods, automatic pick-up 7. Support the axle shaft housing on a suitable
hitch tie rods, hand-brake cables and foot-brake trolley jack. Remove the retaining bolts and then
linkage. separate the axle housing from the tractor.
4. Safely raise and support the rear of the tractor.
5 6 7 8 9
10
1
4
2
3
10024896
6
1. Axle Shaft 6. Axle Shaft Lock
2. Axle Housing 7. Axle Shaft Retaining Bolt
3. Planet Ring Gear 8. Washer
4. Brake Assembly 9. Spacer
5. Sun Gear 10. Planet Gear Carrier Assembly
27-10
Disassembly
1. Remove the large o-ring located in the inner end
of the axle housing.
NOTE: If removing the right-hand housing, remove
the differential assembly to prevent damage during
axle overhaul.
2. Remove the inner brake retaining bolts.

3. Remove the inner brake housing, brake linkage,
friction disks, and actuating disc assembly, using
the procedures outlined in Section 33 “Brakes”.
4. Lift the intermediate shaft and sun gear out of the
axle, and remove the outer brake housing.
5. Remove the axle shaft locking bolt and tab.
NOTE: It may be necessary to heat the locking tab to
melt the sealant applied during production.
WARNING
Do not remove or replace the planetary gear
assembly without the specified tools, or without
positioning the specified tools correctly, as this
may result in personal injury.
6. Remove the planet gear and carrier assembly (2)

from the axle housing using Puller (1) Tool No.
FNH09507, Figure 7. Collect the shim and
washer from underneath the carrier assembly.
27-11
7. Separate the seal retainer in the outer end of the

axle housing.
8. Remove the axle shaft and inner bearings from
the housing. Use a special fabricated tool for
pressed fit bearings as shown in Figures 8 and 9.
9. Repeat steps for opposite axle housing.
17.0 in
15.5 in
4.0 in
7.75 in
8.5 in
5/ in
8
1.0 in -- 12 UNF
11.0 in
3/ in
4
8
Axle Shaft Removal Tool
27-12
parts to dry.
2. Inspect all components for damage or excessive
wear, and replace parts as necessary.
3. If the axle shaft outer cone and roller assembly

(3) requires removal, use Puller (4) Tool No.
FNH09506, Legs (1) Tool No. FNH09521,
Attachment (2) Tool No. FNH09526, and Shaft
Protector Tool No. FNH09212, Figure 10.
4. Install the shaft seal following the cone and roller
bearing assembly using a suitable sleeve and
press.
10
5. If necessary, use a Slide Hammer Tool
No.FNH09567 (1) to remove the bearing cup (3)
from the outer end of the axle housing (2), Figure
11. To replace the cup, use a suitable step plate
and a mallet. Ensure to seat cup completely in
the housing.
11
Assembly
Re-assembly of the rear axle shaft assembly follows
the disassembly procedures in reverse with the
1. Assemble the inner brake housing, brake

linkage, friction disks, and actuating disc
assembly, using the procedures outlined in
Section 33 “Brakes”.
27-13
Installation
Installation of the axle shaft assembly follows the
requirements:
1. Apply a suitable wheel bearing grease to the

shaft seal, and the cone and roller assembly
2. Perform the following adjustments before
installing the axle shaft housing completely,
using the procedures described in this chapter:
A. Adjust the axle Shaft Bearing Pre-Load
B. If replacing any of the following components,
perform a Differential Bearing Pre-Load:
• Planetary Ring Gear
• Outer Brake Housing
• Inner Brake Housing
• Rear Axle Center Casing
• Right-Hand Axle Housing
3. Tighten all hardware to the correct torque values
as listed in Section 27 “Specifications”
4. Refill the rear axle center casing with the correct
type and quantity of oil. Refer to Section 27
“Specifications”.
5. If necessary, adjust the mechanical linkage to the
foot brake and handbrake (where installed).
PLANETARY GEAR ASSEMBLY AND AXLE

HOUSING – OVERHAUL
Removal
1. Remove the axle housing. Refer to Section 27
“Rear Axle Shaft Assembly – Overhaul”.
2. Remove the planetary gear assembly. Refer to
Section 27 “Rear Axle Shaft Assembly –
Overhaul”.
Disassembly
1. Remove the retaining ring securing the planet
gear shafts (1), Figure 12.
2. Place the carrier assembly on a press. Remove
the cone and roller assembly (5), and the planet
gear shafts (3), using a Step Plate (1) Tool No.
FNH09211, and three sockets (2), Attachment
(4) Tool No. FNH09526, Taper Base (6) Tool No.
370 and Slave Ring (7) Tool No. CT9056, Figure
12.
12
27-14
3. Remove the gears (3), thrust washers (2 & 5) and
spacers from the carrier (7). Retain the rollers (4)
located between the planet gear shafts (8) and
the gears for reassembling, Figure 13.
4. Use Slide Hammer Tool No. FNH09567 and
Puller Tool No. FNH09507 to remove the bearing
cup installed in the axle housing.
13
Planet Gear Carrier Assembly
1. Retaining Ring
2. Thrust Washer
3. Planet Gear
4. Rollers
5. Thrust Washers
6. Cone and Roller Assembly
(S Model Only)
7. Carrier
8. Planet Gear Shaft

parts to dry.
2. Inspect all components for damage and
excessive wear. Replace all defective parts.
3. If the planetary ring gear (1) requires replace-
ment, perform the following procedure, Figure
14:
A. Insert Special Tool (2) SW6 behind the ring
gear (1) and adjust the moveable plates to
desired location. Tighten the locknuts (4),
Figure 14. If needed, manufacture a special
plate for use with tool SW6 as shown in
Figure 15.
14
27-15
B. Position the axle housing under a hydraulic
press with the ball end of the housing
downward. Insert a bar between the Special
Tool No. SW6 and the press ram. Press the
ring gear out.
C. Install a new ring gear with the bell end of the
axle housing up. Press the ring gear in, until
completely seated and no gap exist between
bottom of the gear and the housing shoulder.
10.0 in
3.0 in 3.0 in
0.5 in
0.5 in 60° 60° 45°
4.0 in 2.5 in
4 x 0.5 in B.S.W. R 5.0 in.
15
Ring Gear Removal Adaptor Plate
27-16
Assembly
Assembly of the planetary gear assembly follows the
disassembly procedures in reverse with the following
requirements:
1. Install an equal number of rollers either side of

the spacer within the gear bores.
2. Use grease to hold rollers in position while
installing the shafts (1), through the planet gears
(2). Position the shafts with the flat portion of the
shaft heads away from the center of the carrier,
for proper installation of the retaining ring (3),
Figure 16.
16
Installation
Install the planetary gear and axle housing
assemblies using the procedures described in
Section 27 “Rear Axle Shaft Assembly – Overhaul”
with the following requirement:
1. Tighten all hardware to the correct torque values

as specified in Section 27 100 “Specifications”.
DIFFERENTIAL AND DIFFERENTIAL LOCK

ASSEMBLY – OVERHAUL
Removal
1. Chock the front wheels to prevent movement.
Release the hand brake.
2. Drain the oil from the rear axle center casing.
3. Disconnect hydraulic lift rods, automatic pick-up
hitch tie rods, hand-brake cables and foot-brake
linkage.
4. Safely raise and support the tractor to
accommodate removal of the right-hand wheel
and axle shaft housing assembly.
5. Remove the fender and roll over protection
devices, then remove the right-hand rear wheel.
Reinstall nuts onto studs to prevent damage to
the stud threads during overhaul.
6. Support the right-hand axle shaft housing on a
suitable trolley jack. Remove the retaining bolts
and then separate the axle housing from the
tractor.
7. Remove the differential assembly.
27-17
Disassembly
1. Remove the differential lock ring (9) from the end
of the side gear. Remove the stop washer (10),
coupling (8), spring (11) and adapter (12), Figure
17.
2. Identify the two halves of the differential case to
facilitate assembling.
17
Differential Assembly
1. Cone and Roller Assembly 9. Retaining Ring
2. Ring Gear and Housing Assembly 10. Washer
3. Side Gear 11. Spring
4. Pinion Gear Assembly 12. Adaptor
5. Side Gear 13. Retaining Bolt
6. Differential Case 14. Thrust Washer
7. Cone and Roller Assembly 15. Thrust Washer
8. Coupling 16. Thrust Washer
27-18
3. Remove the cone and roller assembly (3) from
the smaller half of case, using Puller (1) Tool No.
FNH09516, Attachment (2) Tool No. FNH09526 1
and Step Plate (4) Tool No. FNH09210 and 4
FNH09211, Figure 18.
4. Remove the differential case retaining bolts (13),
Figure 17.
5. Separate the differential case (6), Figure 17.
6. Remove the thrust washer (14), first side gear 3
(5), spider and pinion assembly (4), second side 2
gear (3) and thrust washer (15), Figure 17.
10024897
7. Remove the cone and roller assembly (1) on the
ring gear half (2), using Puller Tool No. 18
FNH09516, Attachment Tool No. FNH09526 and
Step Plate Tool No. FNH09210, Figure 17.
8. Separate the pinion gears from the spider
assembly.
parts to dry.
2. Inspect all parts for damage and excessive wear.
Replace any defective component.
3. If replacing a differential ring gear, drill out the
rivets and replace with bolts and nuts. Tighten
the bolts to a torque of 115 N⋅m (85 ft.-lbs.).
NOTE: When replacing the ring gear, install a new
matching drive pinion assembly. Refer to section 27
“Drive Pinion Assembly - Overhaul”
27-19
Assembly
Re-assembly of the differential and differential lock
follows the disassembly procedure in reverse with
1. Coat all bearings with suitable grease before

installing.
2. To correctly install retaining ring (part number
81803542) after installing the pilot bearing on the
pinion shaft, place the ring into the groove, and
use pliers to form the ring in the groove.
3. Tighten the differential case retaining bolts to
torque of 92-125 N⋅m (68-92 ft.-lbs.).
Installation
Installation of the differential and differential lock
follows the removal procedures in reverse with the
1. Check the differential bearing pre-load. Refer to

Section 27 180 “Adjustments”.
DIFFERENTIAL LOCK CONTROL LINKAGE

– OVERHAUL
Removal
1. Remove the retaining bolts and the hanger and 3 2
pedal assembly (1) from the center housing,
Figure 19.
2. Remove the control rod and sleeve assembly
from the center housing.
3. Remove the control rod oil seal if previously
leaking or damaged.
4. If the operating fork requires replacement,
remove the left-hand axle housing, see Section
27 “Rear Axle Shaft Assembly – Overhaul”.
5. Remove the retaining bolts, fork pivot shaft (2),
and fork (3) as an assembly, Figure 19. 1
6. Remove the retaining ring and washer. Slide the
19
pivot shaft out of the fork.
Differential Lock Pedal Assembly
1. Pedal
2. Shaft
3. Fork
27-20
parts to dry.
2. Inspect all components for excessive wear and
damage. Replace all defective parts.
3. If the hanger and pedal assembly bushings
require replacement, perform the following
procedure:
A. Remove the pin from the hanger and pedal
assembly.
B. Separate the hanger and the pedal.
C. Use Driver Set Tool No. FNH09514 to
remove and install new bushings.
D. Position hanger with pedal and install pin.
Installation
Installation of the differential lock control linkage
1. Tighten the differential lock fork pivots retaining

bolts to a torque of 57--76 N⋅m (42--56 ft.-lbs.).
2. If removed, ensure to follow all installation
procedures when reinstalling the rear axle
housing assemblies as described in Section 27
“Rear Axle Shaft Assembly – Overhaul”.
3. Refill the rear axle casing with the correct grade
and quantity of oil.
27-21
DRIVE PINION ASSEMBLY – OVERHAUL

Removal
1. Release the handbrake.
2. Separate the tractor following the procedures
described in Section 27 “Separating the Tractor
between the Front Transmission and the Rear
Axle”.
3. Remove the PTO clutch assembly, see Section
31 “Power Take-Off”.
4. Remove the transmission handbrake assembly
(where installed). Refer to Section 33 “Braking
System”.
NOTE: If installed, remove the transmission
handbrake shield for the pinion drive gear, before
removing the pinion assembly.
5. Remove the differential and differential lock

assembly. Refer to Section 27 “Differential and
Differential Lock Assembly – Overhaul”.
6. Remove the drive pinion retaining bolts,
washers, and drive pinion assembly (1) from the
housing (3). Two threaded holes are provided in
the pinion bearing retainer (2) for jacking bolts
(4), to facilitate removal, Figure 20.
20
27-22
Disassembly
With reference to Figure 21:
NOTE: There is either a staked nut or double nut with

a locking tab washer arrangement securing the
pinion shaft to the bearing retainer.
1. Remove the pinion nut (6), spacer (7), Inspection and Repair
handbrake gear and shims (where installed), or 1. Clean all components in a suitable solvent. Allow
the washer, Figure 21. parts to dry.
2. Use a soft mallet to knock the front end of the 2. Inspect all components for excessive wear and
pinion shaft assembly from the bearing retainer damage. Replace all defective parts.
and remove the cone and roller assembly (5),
Figure 21. 3. If necessary, remove the bearing cups from the
retainer using Slide Hammer Tool No.
3. Remove the retaining ring (3) from the pinion FNH09567 and Puller Tool No. FNH09507. To
gear (1) and pull the pinion bearing (2) from the install new bearing cups, use a press and Step
shaft, Figure 21, using Puller Tool No. FNH09198 Plate Tool No. FNH09210.
and Attachment Tool No. FNH09190.
4. To install the rear bearing on the pinion shaft, use
4. Remove the bearing (4) from the shaft using Puller Tool No. FNH09516 and Attachment Tool
Puller Tool No. FNH09516, and Attachment Tool No. FNH09190 and a suitable sleeve.
No. FNH09190.
7 8
1
5 4
MTG27021 3
21
Drive Pinion Assembly
1. Pinion Shaft 5. Cone and Roller Assembly
2. Pinion Bearing 6. Pinion Nut
3. Retaining Ring 7. Spacer
4. Cone and Roller Assembly 8. Pinion Assembly Housing
27-23
Assembly
NOTE: Installation of a new pinion shaft requires the
installation of a new matching differential gear. Refer
to Section 27 “Differential and Differential Lock
Assembly – Overhaul”.
Re-assembly of the drive pinion follows the

requirements:
1. Check the pinion bearing pre-load. Refer to

Section 27 “Adjustments”.
Installation
Installation of the drive pinion assembly follows the
requirement:
1. Tighten the bearing retainer support bolts to a

27-24
ADJUSTMENTS
Rear Axle Shaft Bearing Pre-Load
1. Install the axle shaft into the axle shaft housing.
2. Install the inner bearing cone and roller assembly
onto the shaft. Using a suitable sized tube, tap
the bearing onto the shaft. DO NOT completely
seat the bearing into the bearing cone.
3. Install a 2.16 mm (0.085 in) spacer (1), Figure 22,
onto the axle shaft and install the planetary gear
carrier into the housing.
4. Install the carrier retaining bolt and tighten to a
22
5. Set a dial indicator (3) as shown in Figure 23.
Zero the gauge and measure the end-float by
lifting the axle casing (1).
6. Subtract the measured end-float from the size of
the spacer installed and record.
23
27-25
Table 1:
RESULTANT SPACER TO BE
FIGURE INSTALLED
1.24--1.32 mm 1.14 mm
(0.049--0.052 in) (0.045 in)
1.35--1.42 mm 1.24 mm
(0.053--0.056 in) (0.049 in)
1.45--1.52 mm 1.35 mm
(0.057--0.060 in) (0.053 in)
1.55--1.63 mm 1.45 mm
(0.061--0.064 in) (0.057 in)
1.65--1.73 mm 1.55 mm
(0.065--0.068 in) (0.061 in)
1.75--1.83 mm 1.65 mm
(0.069--0.072 in) (0.065 in)
1.85--1.93 mm 1.75 mm
(0.073--0.076 in) (0.069 in)
1.96--2.03 mm 1.85 mm
(0.077--0.080 in) (0.073 in)
2.06--2.13 mm 1.96 mm
(0.081--0.084 in) (0.077 in)
2.16--2.24 mm 2.06 mm
(0.085--0.088 in) (0.081 in)
2.26--2.34 mm 2.16 mm
(0.089--0.092 in) (0.085 in)
7. Determine the correct size of spacer required by

comparing the recorded measurement with
Table 1.
Example:
Spacer Installed 2.16 mm

Reading Obtained 0.66 mm
Resultant Figure 1.50 mm
Spacer Installed 0.085 in

Reading Obtained 0.026 in
Resultant Figure 0.059 in
Therefore, the required spacer is 1.35 mm (0.053 in).
8. Remove the axle shaft retaining bolt and remove

the planet gear carrier assembly, lock washer
and large 2.16 mm (0.085 in) spacer.
9. Install the new selected spacer, washer and
planet gear carrier assembly. Tighten the
retaining bolt to a torque 339-542 mm (250-400
ft.-lbs.).
27-26
10. After shimming is complete, measure the axle
shaft rolling torque. Fabricate a plate (1) to slide
over the wheel studs (3) as shown in Figure 24,
with a bolt head or nut welded in the center. Using
a suitable torque wrench (2), check the rolling
torque to 11.6-28.2 N⋅m (8.6-20.8 ft.-lbs.). If
necessary, add shims to reduce the rolling torque
or subtract the shims to increase.
11. Repeat steps for opposite rear axle shaft.
24
Differential Bearing Pre-Load
Adjust the bearing pre-load by adding or subtracting
shims between the differential bearing cup, and the
inner brake housing. Make this adjustment to the
bearing in the right-hand axle shaft housing.
1. Install the inner brake disc without the

intermediate shaft, brake discs, and brake
actuator assembly into the axle shaft housing.
2. Remove the differential bearing cup and shim
from the inner brake housing.
3. Place the Gauge Block Tool No. 1504 from Kit
Tool No. 2141 into the vacant bearing location.
25
4. Install the Bridge Tool No. 1503 from Kit Tool No.
2141 across the inner brake housing flange.
Install the Spacer Tool No. 1505 from Kit Tool No.
2141 between the flange and the special tool.
5. Use a feeler gauge to measure the gap between
the underside of the Bridge and the top side of the
Gauge Block, Figure 25.
27-27
Table 2:
GAP SHIM TO BE
MEASURED INSTALLED
0.61--0.74 mm 0.97--1.02 mm
(0.024--0.029 in) (0.038--0.040 in)
0.76--0.87 mm 1.12--1.17 mm
(0.030--0.035 in) (0.044--0.046 in)
0.91--1.04 mm 1.27--1.32 mm
(0.036--0.041 in) (0.050--0.052 in)
1.07--1.19 mm 1.42--1.47 mm
(0.042--0.047 in) (0.056--0.058 in)
1.22--1.35 mm 1.58--1.63 mm
(0.048--0.053 in) (0.062--0.064 in)
1.37--1.50 mm 1.73--1.78 mm
(0.054--0.059 in) (0.068--0.070 in)
1.50--1.63 mm 1.88--1.93 mm
(0.060--0.065) (0.074--0.076 in)
1.65--1.78 mm 2.03--2.08 mm
(0.066--0.071) (0.080--0.082 in)
6. From Table 2 determine the initial size of shim to

be used.
7. Remove the Bridge and Gauge Block. Install the
selected shim and bearing.
8. After correctly shimming the bearing, check the
rolling torque of the differential assembly using
the following procedure:
A. Remove the left-hand axle shaft housing if
not already removed.
B. Remove the pinion and bearing retainer
assembly.
27-28
C. Remove the differential lock spring, and slide
the differential lock coupling into the engage
position (1), Figure 26.
D. With the differential assembly installed, and
the right-hand inner brake housing flange
bolted to the axle center casing, install the
intermediate shaft into the differential
assembly.
E. Wrap a length of string around the
intermediate shaft (2) and attach a Pull Scale
(3). Measure the rolling torque after the shaft
is moving. Do not measure when the shaft
initially begins to turn. Check for a rolling
torque of 7.0-30 kg (15-66 lb) on the Pull 26
Scale, Figure 26.
F. If necessary, add shims to increase the
rolling torque or subtract shims to decrease,
until obtaining the specified torque.
G. Assemble the rear axle shaft assemblies.
Refer to Section 27 “Rear Axle Shaft
Assembly – Overhaul”.
Drive Pinion Bearing Pre-Load
1. Lubricate the pinion bearings.
2. Install the pinion (3) and retainer assembly (4) in
a vice, Figure 27
3. Install the stake nut (or adjusting nut), a new lock
washer, and locknut.
4. Attach a Pull Scale, Figure 28.
27
5. Check bearing pre-load 5.9-10.5 kg (13-23.2
ft.-lbs.).
6. Adjust until obtaining the correct pre-load.
Tighten the locknut and bend tabs on lock
washer (where installed). Recheck pre-load.
28
27-29
REAR AXLE ASSEMBLY FINAL 10. Remove the output shaft inner bearing (33) and
REDUCTION DROP TRUMPET (DROP BOX) spacer (34).
-- COMPONENT OVERHAUL NOTE: Do not let the output shaft gear drop while
removing the shaft from the drop box.
Removal
11. Pull the output shaft (41), outward while grasping
Refer to Figure 29. the output shaft gear (3).
1. Park the tractor on a hard, level surface. Set the 12. Remove the output shaft seal (38).
parking brake and chock the front wheels. 13. Remove the retaining bolts (40) with washers
2. Jack the right or left-hand rear axle assembly as (39) to facilitate removing the bearing retainer
necessary. (37). Remove the retainer, bearing (36) and
spacer (35).
3. Remove the cover retaining bolt (44) with washer
(43) and remove cover. (42). 14. Remove the pinion cover retaining bolts (17) and
washers (16). Remove pinion cover (15).
4. Remove wheel assembly.
15. Remove the outer snap ring (14), spacer (13),
5. Remove the oil level plug (1C) and washer (1B) inner snap ring (12) and bearing (11).
to facilitate oil drainage.
16. Remove the pinion shaft assembly (10).
6. Remove oil plug (47) and drain drop box oil into
a suitable container. 17. Remove the pinion shaft inner bearing (9); snap
ring (8) and seal (7).
7. Remove the retaining bolts (49) with washers
(48) to the output shaft gear cover (46). Remove 18. Remove the idler shaft retaining bolt (28) with
cover and gasket (45). washer (27), retainer (26) and discard O-ring
(25).
8. Remove retaining bolts (29) with washers (30) to
facilitate removing the output shaft inner cover 19. Remove the snap ring (22) and pull out the idler
(31). Remove cover. shaft assembly (24), while removing outer
bearing (23), idler gear (21), inner spacer (20),
9. Use Wrench Tool No. FNH00002 to remove the bearing (19) and spacer (18) from inside the drop
output shaft retaining nut (32). box.
NOTE: For instructions on manufacturing the special Removal of the rear axle shaft requires the removal
Wrench Tool No. FNH00002, see Figure 31. of the rear axle outer assemblies. Refer to “Rear Axle
Shaft Assembly-Overhaul” in Section 27.
27-30
29
27-31
Installation
Refer to Figure 30. 7. Tighten the idler gear retaining bolt (22) to a
Installation of the final reduction drop box compo- 8. Tighten the output shaft inner cover bolt (10) to
nents follows the removal procedures in reverse with a torque of 24 N⋅m (18 ft.-lbs.).
9. Tighten the output gear cover retaining bolts (1)
1. Replace output shaft gear cover gasket (5) to a torque of 24 N⋅m (18 ft.-lbs.).
before installing cover (2). 10. Tighten the pinion drive cover retaining bolt (21)
2. Apply a bead of liquid gasket FP--119 to all cover to a torque of 24 N⋅m (18 ft.-lbs.).
mating surfaces except the output shaft gear The oil in the center housing of the rear axle remains
cover, which contains a solid gasket. separate from the final reduction drop trumpet (drop
box) axle.
3. Replace the O-ring (25), Figure 29, on the idler
shaft assembly.
Important: Use oil specification ESN--M2C86--B or
4. Ensure the pinion inner seal (15), seats correctly ESN--M2C159--B when servicing the rear axle final
into the drop box to prevent oil leakage from the reduction drop trumpet assemblies.
rear axle to the drop box. The seal must sit 132
mm (5.1 in) from the mating surface where the 11. Unscrew the oil level plug (1C), Figure 29. Add oil
pinion cover rests, inward. See reference (A), to the drop box until the level reaches the height
Figure 30. of the oil level plug. The drop box assembly
5. Tighten the output shaft bearing and seal retainer requires 4.5 liters (9.5 pints) of oil. Drain
bolts (25) to a torque of 51 N⋅m (38 ft.-lbs.). excessive oil by removing the oil drain plug (47),
Figure 29 and allowing the oil to pour into a
6. Tighten the output shaft retaining nut (6), using suitable container.
Wrench Tool No. FNH00002, to a torque of
583--733 N⋅m (430--540 ft.-lbs.). 12. Recheck the oil level and install the oil level plug.
TABLE 1 Refer to Figure 30

ITEM DESCRIPTION ITEM DESCRIPTION
1 Output Gear Cover M8 x 1.25 x 30 Retaining Bolts 15 Pinion Inner Seal
2 Output Shaft Gear Cover 16 Pinion Inner Bearing and Snap Ring
3 Output Shaft Gear 17 Pinion Shaft Assembly
4 Output Gear Cover Oil Drain Plug 18 Pinion Outer Bearing and Snap Ring
5 Output Shaft Gear Cover Gasket 19 Pinion Shaft Assembly Cover
6 Output Shaft M70 Retaining Nut 20 Pinion Outer Spacer and Snap Ring
7 Output Shaft Assembly Inner Cover 21 Pinion Shaft Cover M8 x 1.25 x 30 Retaining Bolts
8 Output Shaft Assembly 22 Idler Gear M8 x 1.5 x 20 Retaining Bolt
9 Output Shaft Bearing and Spacer 23 Idler Gear O--ring and Retainer
10 Output Shaft Inner Cover M8 x 25 Retaining Bolts 24 Output Shaft Outer Spacer and Bearing
11 Idler Gear Inner Spacers x2 and Bearing 25 Output Shaft Bearing Retainer M10 x 1.5 x 30 Bolts
12 Idler Shaft 26 Output Shaft Bearing Retainer and Outer Seal
13 Idler Gear 27 Output Shaft to Wheel Rim Bolts
14 Idler Gear Outer Retaining Ring and Bearing A 132 mm (5.1 in)
27-32
18
16
15 17
20
19
21
22
12 23
24 25
11
10 13 14
9
8
7
27
6
5 26
1
2
4
3
20032151
30
27-33
If necessary, fabricate Wrench Tool No. FNH00002
31
27-34
SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1
Chapter 1 - Power Take-Off Systems
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PTO -- Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mechanically Operated P.T.O. Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
P.T.O. Clutch Oil Flow – Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
P.T.O. Clutch Oil Flow - Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
P.T.O. Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Regulating Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cooling and Lubrication Circuit Relief Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
P.T.O. Clutch – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
P.T.O. Shafts and Gears – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Single Speed Shafts and Gears - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Two-speed Shafts and Gears – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
16x4 Dual Command (Power) Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
31-1
SPECIFICATIONS
ITEM
6-Spline Shaft Rotates 540 rev/min at 1900 Engine rev/min
21-Spline Shaft Rotates 1000 rev/min at 2050 Engine rev/min (7010 & 8010
at 2060 erpm)
Pressure Regulating Valve Maintains Oil Pressure of 11.0-12.4 bar (160-180 psi) at
850 Engine rev/min
Relief Valve Maximum Pressure of 3.1-4.5 bar (45-65 psi)
Output Shaft End-Play 0.076-0.127 mm 0.003-0.005 in
Upper Shaft End-Play 0.025-0.737 mm 0.001-0.029 in
Output Shaft Turning Torque 0-7 N⋅m 0-62 in.-lb.
Hydraulic Oil Operating Temperature 57-63_ C 134-146_ F

Location
Pressure Regulating Valve 1.20 mm 0.050 in
Relief Valve 1.20 mm 0.050 in
Drive Gear End-Play 0.025 mm 0.001 in
0.076 mm 0.003 in
0.127 mm 0.005 in
0.305 mm 0.012 in
0.508 mm 0.020 in
Output Shaft Bearing 0.051 mm 0.002 in
0.076 mm 0.003 in
0.254 mm 0.010 in
Upper Shaft – (two shims required) 0.254 mm 0.010 in
TORQUE VALUES
Component
Brake Band Adjuster Screw Initial Torque 1-1.2 N⋅m 9-11 in.-lb.
Brake Band Adjuster Screw Final Torque back off adjuster screw 2-1/2 turns
Pressure Regulating Valve Locator Pin (Front) 27-35 N⋅m 239-310 in.-lb.
Pressure Regulating Valve Locator Pin (Rear) Initial Torque 1 N⋅ m 9 in.-lb.
Pressure Regulating Valve Locator Pin (Rear) – Back Off 1/4 Turn 21-27 N⋅m 186-239 in.-lb.
then Final Torque
Output Shaft Bearing Retainer Bolts 190-230 N⋅m 140-170 ft.-lbs.
Upper Shaft Rear Bearing Retainer Bolts 68 N⋅m 50 ft.-lbs.
Clutch Support Bolts 19-23 N⋅m 14-17 ft.-lbs.
Sump Cover Retaining Bolts 37-50 mm 27-37 ft.-lbs.
31-2
SPECIAL TOOLS
Tool New Holland Other Reference Number
Gauge, Pressure 400 lb FNH00074
Adapter, Test FNH01221A
Compressor, Spring FNH01312
Adapter, Hydraulic Test Fitting FNH04646
Driver Set FNH09514
Gauge, Pressure FT4096
Adapter, Test FT4100-2
Tube, Test FT4100-1
31-3
DESCRIPTION AND OPERATION actuator holds the clutch housing stationary upon
The power take-off (PTO) enables the transfer of disengagement.
engine power directly to mounted or trailed The two-speed PTO features a double set of helical
equipment through a shaft at the rear of the tractor. reduction gears running in constant mesh and the
The output shaft speed is restricted to 540-rev/min installation of either of two interchangeable output
for equipment designed for use with the 6-spline shafts. Drive from the PTO rear shaft transmits via
shaft, and 1000-rev/min for equipment designed for the 540 or 1000-rev/min gear to the output shaft.
the alternate 21-spline shaft. The 540-rev/min gear engages the 6-spline output
The PTO input shaft passes through the transmis- shaft when installed. The output shaft will rotate at
sion upper shafts, and attaches to both the engine 540-rev/min with the engine speed set to 1900-rev/
flywheel and the PTO clutch hub with spline ends. min.
The speed of the output shaft is independent of the The 1000-rev/min gear engages the 21-spline output
transmission or tractor ground speed, but directly shaft when installed. The output shaft will rotate at
related to the speed of the engine. 1000-rev/min with the engine speed set to
2050-rev/min for 5610S, 6610S, and 7610S series
During engagement of the PTO, a hydraulically and 2060-rev/min for 7010 and 8010 series tractors.
operated piston clamps the friction and steel drive
plates together, thereby transmitting drive from the The PTO output shaft will rotate by hand to facilitate
flywheel to the PTO output shaft. A valve assembly attachment of equipment.
located in the left-hand side of the rear axle housing Whether or not the tractor is in motion, it is possible
controls hydraulic oil to the clutch piston. The control to engage, operate and disengage the PTO system.
valve spool features a hydraulic feathering capability, The clutch for single speed or two-speed PTO
which allows for the smooth engagement of the PTO systems operates mechanically.
clutch. A brake band applied by a small hydraulic
1
PTO Schematic (Single Speed Shown)
1. PTO Output Shaft Cap 7. PTO Input Shaft
2. PTO Output Shaft 8. Hydraulic Pump Drive Gear
3. Driven Gear 9. PTO Clutch Assembly
4. Oil Supply Pipe 10. Brake Band
5. PTO Valve Assembly 11. PTO Rear Shaft
6. Hydraulic Pump Idler Gear 12. Drive Gear
31-4
MECHANICALLY OPERATED P.T.O.

CLUTCH
IMPORTANT: Never operate the tractor with the PTO
output shaft removed. The shaft supports the driven
gears and acts as a bearing. Operation without the
shaft installed may cause severe damage.
A selector lever located on the left-hand side of the

driver’s seat provides for mechanical operation of the
PTO clutch, and control valve. Operating the selector
lever moves linkage to the control valve spool to the
‘engage’ or ‘disengage’ position.
P.T.O. CLUTCH OIL FLOW – DISENGAGED

With reference to Figure 2:
With the engine operating, the rear steering pump

supplies hydraulic oil to the inlet port of the PTO
control valve.
The pressure regulating valve housed within the PTO

assembly maintains the oil pressure at 11.0-12.4 bar
(160-180 psi) and acts as a relief valve. The oil
pressure is limited to a maximum of 4.5 bar (65 psi)
at 1250-engine rev/min.
Under normal operation, the valve assumes a closed

position.
With the selector lever in the ‘disengage’ position, the

control valve spool moves completely to the left and
held in place by a detent. Low-pressure circuit oil
entering the valve flows past the control valve spool
to operate the brake piston. As the piston is applied
the brake band tightens and prevents the output
shaft from turning.
When the engine stops running, the pressure

regulating valve closes, and a groove in the control
valve spool land allows oil applied to the brake piston
to return, releasing the brake.
31-5
2
Oil Flow -- Clutch Disengaged
Pressure Oil Cooler / Lubrication Oil Exhaust Oil
1. Clutch Housing 7. Transfer Port to Oil Cooler 13. Clutch Piston Return Spring
2. Sealing Rings 8. Orifice 14. Clutch Hub
3. Clutch Support 9. Control Valve Spool 15. Clutch Plates
4. Orifice 10. Detent Ball and Spring 16. Brake Band
5. Cooler / Lubrication Circuit 11. Brake Piston 17. Clutch Piston
Relief Valve 12. Brake Piston Return Spring
6. Pressure Regulating Valve
31-6
P.T.O. CLUTCH OIL FLOW - ENGAGED

With reference to Figure 3 and Figure 4:
The control valve spool comprises of two parts

connected by a link and spring, which enables
feathering engagement of the clutch.
When the selector lever initially starts moving to the

‘engage’ position, the control valve spool landed
portion moves to the right, blocking the supply of oil
from the pump. At the same time, oil pressure can
exhaust from both the clutch piston and brake
cylinder, resulting in a ‘brake-off’ and ‘clutch-off’
situation.
3
P.T.O. Clutch Engagement
1. Pressure Sensing Drilling ‘A’ Brake Applied -- Clutch Off

2. Pressure Regulating Valve ‘B’ Brake Off -- Clutch Off
3. Orifice ‘C’ Brake Off -- Clutch Feathering
4. Valve Spool Connecting Link and Spring ‘D’ Brake Off -- Clutch Engaged
5. Detent Ball and Spring
31-7
As the selector lever continues to move toward the
‘engage’ position, the spool moves further right and
uncovers the supply oil orifice to the clutch. This
allows controlled oil flow around the spool through a
drilling and clutch support to the piston. As oil
pressure forces the piston against resistance of the
clutch return spring, the oil pressure increases in the
system.
The landed portion of the spool has a small central

drilling to the right-hand end. Supply oil pressure
flows through the drilling and acts on the spool end.
Oil pressure builds and forces the spool to the left,
compressing the spring located between the two
halves of the spool, and restricts oil flow from the
supply port. This restriction of oil flow ensures a
feathering of clutch engagement in relation to the
movement of the selector lever.
With the selector lever completely in the ‘engage’

position, a detent holds the control valve spool in the
far right position. Pressurized oil then acts on the
clutch piston, compressing the clutch return spring,
forcing the clutch plates together, which engages the
clutch. Further feathering is no longer possible and
clutch engagement receives maximum pressure.
An orifice (8), Figure 4 will restrict oil flow to the

clutch, and prevent subsequent shock loading, if
rapid movement of the selector lever to the ‘engage’
position occurs.
The brake piston return spring forces oil to exhaust

from the brake cylinder, across the valve spool to the
brake dump port, ensuring release of the brake band.
The pressure regulating valve maintains oil pressure

acting on the clutch piston, during clutch engage-
ment under all conditions. Excess exhaust oil flows
in the same manner as in clutch disengagement, to
the lubrication and cooling circuits.
31-8
4
Oil Flow -- Clutch Engaged
1. Clutch Housing 7. Transfer Port to Oil Cooler 13. Clutch Piston Return Spring
2. Sealing Rings 8. Orifice 14. Clutch Hub
3. Clutch Support 9. Control Valve Spool 15. Clutch Plates
4. Orifice 10. Detent Ball and Spring 16. Brake Band
5. Cooler / Lubrication Circuit 11. Brake Piston 17. Clutch Piston
Relief Valve 12. Brake Piston Return Spring
31-9
P.T.O. PRESSURE TEST

Conduct the following control valve pressure test
when the PTO clutch fails to operate, or after the
clutch and control valve have been overhauled.
NOTE: Perform the following control valve pressure

test only when the Dual Power and PTO section of
the hydraulic pump produces the specified hydraulic
flow and pressure.
PRESSURE REGULATING VALVE TEST

1
1. Operate the tractor until reaching the hydraulic oil
specified operating temperature of 57-63_C 4
(134-146_F). Shut down the engine.
2. Disconnect the dual power and front wheel drive
tubes, or the pressure test plug from the
hydraulic pump (1), Figure 5.
3
3. Connect Adapter (4) Tool No. FNH01221 and 2
Tube (2) Tool No. FNH01552 with Pressure
Gauge (3) Tool No. FNH00074 to the pressure
test location, Figure 5.
10024898
4. Start the tractor engine and move the PTO
control to the ‘disengage’ position. With the 5
engine at 850-rev/min, observe the pressure Pressure Regulating Valve Pressure Test
gauge reading. Move the selector lever to the 1. Hydraulic Pump
‘engage’ position and recheck gauge reading. 2. Tube Tool No. FNH01552
3. Pressure Gauge FNH00074
5. The pressure reading on the gauge should be
4. Adaptor Tool No. FNH04657
11.0-12.4 bar (160-180 psi) with the selector
lever in the ‘disengage’ position. If BELOW
specification, remove the PTO control valve and
increase the pressure regulating valve shim-
ming. See specifications for shims available. In
addition, check the brake piston seal for damage.
6. If the pressure reading is BELOW specifications
with the selector lever moved to the ‘engage’
position, then remove the clutch. Check the
clutch housing-to-sealing rings and the clutch
piston for wear and damage.
7. If pressures observed are HIGHER than
specifications remove the clutch and control
valve and check for restrictions. In addition,
check for a sticking pressure regulating valve.
8. Repair or replace any components found
defective.
9. Remove all special tools and reconnect dual
power and front wheel drive tubes, or reinstall
test plug in hydraulic pump.
31-10
COOLING AND LUBRICATION CIRCUIT

RELIEF VALVE TEST 1
1. Remove the cooler tube banjo bolt and separate
the tube from the bolt. Ensure that the plastic 2
transfer tube stays installed in the control valve.
2. Connect Pressure Gauge (1) Tool No. FT 4096
and Adapter (2) Tool No. 4646 onto a suitable 3
Auxiliary Services Control Valve Hose (3). Install
the banjo bolt (4) through the fitting on the hose
and into the rear axle port, Figure 6. 4
3. Start the tractor engine and run at 1250-rev/min.
10024899
Observe the pressure gauge reading.
4. If the pressure observed is not 3.1-4.5 bar (45-65 6
psi), then remove the control valve and increase Cooler/Lubrication Circuit Relief Valve Pressure Test
or decrease the number of washers located in the 1. Pressure Gauge tool No. FT.4096 or 7284
cooling/lubrication circuit, relief valve. 2. Adaptor Tool No. FT.4096-1 or 4646
3. Auxiliary Services Control Valve Hose
5. Remove the pressure gauge adapter and hose. 4. Banjo Bolt
Reconnect the cooling tube and banjo bolt.
Ensure the correct installation of the plastic
transfer tube in the PTO control valve.
P.T.O. CLUTCH – OVERHAUL

Removal 2
On tractors without load monitor:
1. Remove the hydraulic top cover to expose The

PTO clutch assembly (1) and control valve (2),
Figure 7.
2. Remove the PTO rear shaft, bearing, and
bearing retainer as a complete assembly.
7
3. Release the clip (4) securing the intake tube (3)
to the control valve, Figure 7. Remove the tube.
4. Remove the plastic transfer tube from the oil
cooler feed port.
5. Remove the oil cooler tube banjo bolt (1), and the
rear locating pin and locknut (2), and the front
locating pin (3), Figure 8.
6. Slide the clutch and valve assembly rearwards,
and disengage linkage to the control valve spool.
31-11
7. Remove the clutch (1) and control valve
assembly (2), Figure 9.
9
PTO Clutch and Valve Assembly
1. PTO Clutch Housing
2. Valve Assembly
Disassembly
1. Remove the clutch housing hub (2) and thrust
washer (3) from clutch housing (1), Figure 10.
10
PTO Hub and Clutch Assembly
1. Clutch
2. Hub
3. Thrust Washer
2. Slide clutch from clutch support. Remove snap

ring (4) and disassemble clutch pack from
housing (1). The clutch pack includes the
feathering spring (2), five internal spline friction
plates (3), a pressure plate (5) and five external
spline steel plates (6), Figure 11.
IMPORTANT: Note the order of removal for the
clutch plates.
11
Clutch Housing and Drive Plates
1. Clutch Housing
2. Feathering Spring
3. Internally Splined Friction Plates (5 off)
4. Snap Ring
5. Pressure Plate
6. Externally Splined Steel Plates (5 off)
31-12
3. Use Spring Compressor Tool No. 1312 and
Puller Tool No. FNH09516, to remove piston (1)
2
and return spring (2), Figure 12.
NOTE: Apply compressed air to the port between the
front and center sealing ring grooves in the clutch
housing hub to expel the piston from the housing if
needed.
4. Remove the O ring and seal from the piston.
12
Clutch and Valve Assembly
1. Piston
2. Return Spring
5. Disassemble clutch brake band assembly (1),

Figure 13.
1
6. Separate clutch support (2) from valve body (3),
Figure 13.
13
PTO Control Valve and Brake Band
1. Brake Band
2. Clutch Support
3. Valve Body
31-13
7. With reference to Figure 14, disassemble clutch
control valve and brake components.
14
PTO Clutch Control Valve and Brake Components
1. Split Pin 8. Guide
2. Spring 9. Plug (chamfer facing spring)
3. Control Valve Spool 10. Snap Ring
4. Control Valve Body 11. Cooler/Lubrication Circuit Relief Valve
5. Brake/Piston 12. Pressure Regulating Valve
6. Return Spring 13. Detent Ball and Spring
7. Snap Ring
31-14
Allow parts to dry.
2. Inspect the cast iron sealing rings (1) on the
clutch housing, Figure 15. Replace if worn or
damaged.
3. Inspect the clutch housing externally for cracks
or damage, and internally for wear and piston
scuffing.
4. Inspect the clutch piston for scoring or burrs and
install a new O-ring and seal.
5. Inspect the clutch hub spline and gear for wear
and damage.
15
Assembly
Assembly of the power take-off clutch follows the
requirement:
1. Use new O-rings and seals, Figure 14.

2. Install the pressure regulating valve with the “V”
groove land positioned away from the valve
spring.
31-15
3. If the brake band requires replacement, soak the
band in rear axle oil for at least 3 minutes before
installation.
4. Adjust the brake band as follows:
• Loosen the locknut (1), Figure 16.
• Screw in adjuster (2) to tighten the band until
reaching a torque of 1-1.2 N⋅m (9-11 in.-lb.),
Figure 16.
• Loosen adjuster screw by 2 ½ turns and
tighten locknut.
• To check brake band concentricity after
adjustment, hold the PTO clutch and brake
as shown in Figure 16, with the control valve 16
housing at the 3 o’clock position. The control
valve housing should fall to the 6 o’clock
position under it’s own weight.
• Lightly bend band to shape if required and
repeat adjustment procedure.
Installation
Installation of the power take-off clutch follows the
requirements:
1. Use the following procedure when tightening the

locating pins and locknuts:
• Install the front pin first and tighten to a torque
of 27-35 N⋅m (239-310 in.-lb.), Figure 8
• Install the rear pin and tighten to a torque of
1 N⋅m (9 in.-lb.). Loosen rear pin by 1/4 turn
and tighten to a torque of 21-27 N⋅m (186-239
in.-lb.), Figure 8.
• Ensure clutch is free to rotate.
2. Test the pressure regulating valve as outlined in
this Section to ensure the proper seating of the
sealing rings on the clutch.
31-16
P.T.O. SHAFTS AND GEARS – OVERHAUL

SINGLE SPEED SHAFTS AND GEARS -
OVERHAUL
Removal
1. Drain oil from rear axle/transmission.
2. Remove the split pins and clevis pins. Remove
the hydraulic lift rocker.
3. Unscrew and remove the output shaft cap.
4. Remove retaining bolts and then remove the
upper shaft with the bearing and retainer as an
assembly.
5. Remove the right-hand rear axle assembly.
6. Remove the output shaft gear retaining nut
split-pin, retaining nut, and washer.
7. Remove the output shaft retaining bolts, output
shaft, bearing retainer, and shims.
Disassembly
4 1
1. Separate the bearing retainer from the upper
shaft and bearing assembly.
2. Use Puller (1) Tool No. FNH09198 and
Attachment (2) Tool No. FNH09190 to remove
the bearing (4) from the upper shaft (3), Figure
17.
3
2
10024900
17
31-17
4
3
2
10024901
18
3. Remove the drive gear attached to the spline
shaft.
4. Remove the output shaft (1) from the bearing
retainer (2), Figure 18.
5. Remove the bearing cone and roller assembly 1
from the output shaft driven gear (3) & (4), and 4
remove from center housing, Figure 18.
6. Use Puller (1) Tool No. FNH09516 and
Attachment (2) Tool No. FNH09526 to remove
outer bearing cone and roller assembly (4) from
2
3
the output shaft (3), Figure 19.
10024902
Inspection and Repair 19

Allow parts to dry.
2. Inspect gears for wear, cracks, and chipped teeth.
3. Inspect bearing assemblies for wear or discolor-
ation due to overheating.
4. Inspect the oil seal and bearing cup in the output
shaft bearing retainer. If necessary, remove the
cup and oil seal using Hammer Tool No.
FNH09567 and Puller Tool No. FNH09507.
Install new oil seal in the retainer before replacing
the bearing cup.
5. Inspect the upper shaft rear bushing in the center
housing for wear and replace if necessary. Use
Bushing Kit Tool No. FNH09514 to extract and
reinstall a new bushing. Liberally coat the new
bushing with oil before installing on the shaft.
6. Inspect the output shaft bearing cup in the center
housing for scouring or excessive wear. If
necessary, replace cup using Puller Tool No.
FNH09507 and Hammer Tool No. FNH09567
with Step Plate Tool No. FNH09210.
31-18
Assembly
Assembly of the PTO single speed shaft and gears
follows the disassembly procedures in reverse.
Installation
Installation of the PTO single speed shaft and gears
1. Install the output shaft bearing retainer (3)
without the shims and tighten the four retaining
bolts (2) finger tight. Rotate the shaft (4) by hand 4
to correctly seat the bearings, Figure 20.
Retighten the bolts finger tight.
1
2. Measure the gap between the bearing retainer
(3) and the center housing with a feeler gauge
(1), Figure 19, at various points to ensure the
housing is parallel with the center housing. 2
3. To ensure correct end-play, select a combination
of shims equal in thickness to the measured gap
plus 0.127 mm (0.005 in). Remove the output 3
10024903
shaft bearing retainer and reinstall with shims.
Tighten the retainer bolts to a torque of 190-230 20
N⋅m (140-170 ft.-lbs.) and check that shaft turns
by hand. Use a dial indicator gauge to check
output shaft end-play to 0.076-0.127 mm
(0.003-0.005 in). After obtaining the correct
end-play, apply a suitable sealing compound to
the four retaining bolts and torque to 190-230
N⋅m (140-170 ft.-lbs.).
4. Check output shaft turning torque for a
measurement of 0-7 N⋅m (0-62 in.-lb.)
31-19
TWO-SPEED SHAFTS AND GEARS –

1
OVERHAUL
Removal
1. Remove the rear axle center housing drain plug
(3), Figure 21, and drain oil into a suitable
container.
2. Remove the output shaft cap and retaining ring.
3. Remove the output shaft. 2
4. Remove the retaining bolts and output shaft
bearing retainer. 3
10024904
21
5. Remove the upper shaft rear bearing retainer
bolts and retainer (1), Figure 22. 1
6. Remove the PTO drive gear assembly (2),
Figure 22 and the upper shaft.
NOTE: Retain shims located between the drive gear
assembly and the ring on the upper shaft. The front
bearing cup remains in the housing.
7. Remove the sump cover bolts, and gasket.

2
CAUTION
The PTO driven gears will drop to the bottom of 10024905
the housing when removing the output shaft
sleeve, bearing, seal and thrust washer. 22
8. Hold the PTO output shaft driven gears in

position, remove the output shaft sleeve,
bearing, seal, and thrust washer.
31-20
23
Two Speed PTO Upper Shaft Components
1. Bearing Retainer 6. Snap Ring
2. Shims (drive gear end float) 7. Snap Ring
3. Drive Gear Assembly 8. Bearing
4. Shims (rear shaft end float) 9. Bearing
5. Upper Shaft
31-21
9. Remove the two driven gears through the bottom
of the center housing and retain four thrust
washers and the needle thrust bearing.
24
Two Speed Non Shiftable PTO Output Shaft and Driven Gears
1. Output Shaft Retaining Ring 9. Thrust Washer (thin)
2. Output Shaft Cap 10. Thrust Washer (thick)
3. Output Shaft Bearing Retainer 11. Output Shaft Front Bearing
4. Gasket 12. Needle Thrust Bearing
5. Output Shaft Sleeve Oil Seal 13. 1000 rev/min Driven Gear
6. Output Shaft Sleeve 14. Output Shaft Rear Bearing
7. Thrust Washers 15. Snap Ring
8. 540 rev/min Drive Gear 16. PTO Output Shaft
31-22
Disassembly
1. Remove the output shaft sleeve oil seal located 1
in the output shaft bearing retainer and the O ring
seal from the sleeve.
2. Remove the output shaft rear bearing retaining
ring (1), and remove the bearing (2) from the
sleeve (3), Figure 25.
3. Use Puller Tool No. FNH09507 and Hammer
FNH09567 to remove the output shaft front
needle bearing from the housing. 3
10024906
2
25
4. Remove the drive gear bearings (4) from the
drive gear assembly (3) using Puller (1) Tool No. 1
FNH09198, Attachment (2) Tool No. FNH09190
and Step Plate (5) Tool No. FNH09210, Figure
26. 5
5. Remove the drive gear front bearing cup from the
housing and the rear bearing cup from the
bearing retainer using Puller Tool No. FNH09507 2
and Hammer Tool No. FNH09567. Identify the
shims and spacer, located between the rear
bearing cup and bearing retainer.
4 3
10024907
26
Allow parts to dry.
2. Inspect the upper shaft spline for cracks,
excessive wear and distortion.
3. Inspect gears for chipped teeth and wear.
4. Inspect the bearings for wear and discoloration
due to overheating.
5. Inspect the output shaft, sleeve, seal, rear
bearing retainer, thrust needle bearing and thrust
washers for obvious damage or excessive wear.
6. Replace all unserviceable parts.
31-23
Assembly NOTE: Do not install the upper shaft at this time.
Assembly follows the disassembly procedure in
reverse with the following requirements: • Remove the rear bearing retainer from the
housing and remove the cup from the
1. Use sleeves of a suitable diameter, or step plates retainer. Install approximately 2.0 mm (0.080
to install the bearings in the housing. in) of shim thickness behind the rear bearing
cup to create a gap between the retainer and
2. Replace the seal in the output shaft rear bearing
center housing.
retainer and the O-ring seal located in the output
shaft sleeve. • Install the bearing retainer without the O-ring
seal with the word ‘TOP’ upwards, and
3. Install the output shaft rear bearing on the sleeve tighten the bolts sufficiently enough to seat
with retaining ring. bearings.
4. Press on the drive gear assembly bearings onto • Measure the gap with a feeler gauge
the drive gear assembly. between the housing and the bearing
retainer at several places, to determine the
average gap.
Installation
Installation of two-speed PTO shafts and gears • Calculate shim thickness required:
Example:
Shim Thickness
1. Install a thrust washer between the two driven
gears and the rear driven gear (1000-rev/min) Installed 2.03 mm (0.080 in.)
and the sleeve. Average Gap 0.36 mm (0.014 in.)
2. Install the needle thrust bearing and washers (subtract) 1.67 mm (0.066 in.)
between the front driven gear (540-rev/min) and End-Float 0.10 mm (0.004 in.)
the housing. (subtract) 1.57 mm (0.062 in.)
3. Install the rear bearing retainer with the word
‘TOP’ upwards. Shim Thickness
Required 1.57 mm (0.062 in.)
4. Perform the following adjustment If replacement
of the upper shaft, drive gear assembly, drive • Install the required shim pack into the
gear assembly bearings, drive gear rear bearing retainer behind bearing cup. Install a new
retainer or rear axle center housing has O-ring seal.
occurred:
• Install the upper shaft with front and rear
NOTE: If reassembling all original components, then retaining rings, but without shims. Reinstall
install original shims. the rear bearing retainer with the word ‘TOP’
upwards, and tighten the bolts to a torque of
• Install the drive gear and bearing assembly 68 N⋅m (50 ft.-lbs.).
into the center housing and ensure correct
seating of the front bearing.
31-24
• Shim the upper PTO shaft as follows:
-- Push the shaft rearwards until the rear
ring on the shaft contacts the drive gears.
-- Use a feeler gauge (1) to measure the
end-play between the shoulder ring (3)
on the front of the shaft (2) and the rear
of the PTO clutch housing (4), Figure 27.
-- If necessary, add shims to obtain an
upper shaft end-play measurement of
0.025-0.737 mm (0.001-0.029 in). Add-
ing shims requires the removal of the
rear bearing retainer, drive gear assem-
bly and upper shaft.
-- Install the correct amount of shims on the 27
PTO shaft and reassemble. Recheck
upper shaft end-play.
5. The drive gear assembly should rotate freely by
hand with no radial or axial movement of the
gear. If there is radial or axial movement, recheck
the shimming procedure. If the gear does not
easily rotate, remove the PTO upper shaft and
reinstall the drive gear and bearing retainer, or
check for proper installation of the clutch and
clutch brake. If the gear will not rotate, recheck
the shimming procedure.
6. Install the driven gears using the following
procedure:
• Insert the 1000-rev/min driven gear through
the opening in the bottom of the housing and
hold rearwards. Support the gear and insert
the 540-rev/min driven gear to engage with
the spigot on the front of the 1000-rev/min
gear.
• Push both gears forward as an assembly, to
engage the 540-rev/min spigot with the
recess in the front bearing housing. Support
the gears.
• Install the rear bearing and sleeve.
7. Loosen the PTO valve locating pins to enable the
upper shaft spline to engage with the clutch.
8. Adjust the PTO clutch locating pins and locknut.
9. If experiencing difficulty installing the two-speed
6-spline output shaft, use a screwdriver fitted in
one of the slots to turn the shaft sleeve, and align
the spline in the sleeve with those of the shaft.
10. Check that the turning torque of the PTO shaft
reads 0-7 N⋅m (0-62 in.-lb.).
31-25
16X4 DUAL COMMAND (POWER) TRANSMISSION

SPECIFICATIONS
Dual Command System Pressure at 2100 rev/min
(Low Pressure Hydraulic Circuit Test) 15.2-18 bar
(220-261 psi)
Transmission Lubrication Pressure Test at 1000 rev/min
5.3-8.5 bar
(73-123 psi)
TORQUE VALUES
Description N⋅ m Ft.-Lbs.
Control Valve Solenoid Nut 5.4 4
Control Valve Spool Plug 38 28
Control Valve Body Retaining Bolts 44 32
Planetary Housing Retaining Bolts 105 77
Planetary Cover Retaining Bolts 47 35
Lubrication Tube Connector 18 13
Pressure Line Control Tube Connector 13 9
SPECIAL TOOLS
DESCRIPTION VL CHURCHILL NEW HOLLAND
Hammer, Slide MS 284 NH 9567
Step Plates (set of 11) 630S NH 9210
Puller, Grip-O-Matic medium 1002 NH 9198
Puller, Grip-O-Matic large 1003 NH 9516
Puller, Push (includes legs and pads) 938 NH 9506
Attachment, Bearing Puller small 951 NH 9190
Attachment, Bearing Puller large 952 NH 9526
Legs, Push Puller 16-1/2″ (pr) 930B NH 9521
PTO Clutch Compressor N-775 NH 1312
Jaws, Special Bearing Cup Puller (pr) FT 943 NH 9564
Attachment, Bearing Cup Puller 943 NH 9507
Bearing Gauge, End-Play FT 5000 NH 1303
Planetary Shaft Puller FT 5004 NH 4721
Pressure Gauge, 600 psi FT 8616 NH 06653
Adapter FT 8503 NH 00705
Adapter FT 8503-8
Test Hose E1NN-F493-AA
31-26
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
SECTION 33 - BRAKING SYSTEM
Chapter 1 - Braking System
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disc Brake Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Parking Brake Assembly – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake Pedal and Linkage – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
33-1
SPECIFICATIONS
SPECIAL TOOLS
Tool New Holland Other Reference
Driver, Set FNH09514 818
Puller, Bearing FNH09527 954-C
FAULT FINDING
Problem Possible Causes Remedy
Excessive Pedal Travel brakes require adjustment adjust linkage
Unequal Braking brakes require adjustment adjust linkage
component defective replace defective component
TORQUE VALUES
Component N⋅ m Ft.-Lbs.
Left Foot Pedal-to-Cross Shaft Pinch Bolt 57-76 42-56
Left Cross Shaft-to-Lever Pinch Bolt 57-76 42-56
Actuating Rod Locknuts 54-74 40-55
33-2

The standard braking system consists of two
mechanically operated brake assemblies installed in
the left and right rear axle housings. Brake pedals
transmit input to the brake assemblies via
mechanical linkage. A T-handle and ratchet
assembly locks the pedals for parking and
emergency stopping.
4
8
7
6
3
1 5
20024908
1
Brake Assembly
1. Brake Disc 6. Ball
2. Intermediate Disc 7. Spring
3. Actuating Disc 8. Actuating Links
4. Inner Brake Housing 9. Brake Actuating Rod
5. Outer Brake Housing
Rear Brake Assemblies The left brake pedal connects to the left actuating rod
The brake assembly contains brake discs (1) with an by way of a cross-shaft and lever. The right brake
internal spline, intermediate discs (2), and a two-disc pedal connects to the right actuating rod via an
actuating assembly (3). In addition, the brake attachment on the shaft of the right pedal assembly.
assembly splits to an inner (4) and outer (5) housing,
Figure 1. When the bake pedals are depressed, rotation of the
actuating assembly discs relative to one another
The actuating assembly discs incorporate ramp cause the steel balls to ride up the disc ramps, forcing
pockets in which steel balls (6) ride during the braking the actuating discs apart.
process. Springs (7) hold the actuating discs
together, and two links (8) connect the actuating rod Upon moving apart, the actuating discs force the
(9) to the actuating assembly, Figure 1. brake discs against the brake housing, providing a
braking action on the intermediate shaft.
33-3
Foot Brake Assembly
The left and right foot brake pedal assemblies (1),
Figure 2 operate independently, to aid turning the 1
tractor in confined spaces, or together for normal
stopping. A sliding pin on the underside of the brake
pedal assemblies locks both pedals together.
During field operation, the brake pedal assemblies

may be unlocked. Due to the close proximity of the
pedals to one another, it is still possible to apply both
brakes together when required.
The left brake pedal incorporates teeth for 20025027

engagement with the parking brake ratchet mecha-
nism. 2
Two springs return the brake pedals to the unapplied

position (upward) when foot pressure is released.
WARNING
For your safety, always lock the brake pedal
assemblies together when traveling at transport
speeds, or if operating the tractor with a trailer
installed.
Parking Brake
The parking brake consists of a T-handle (1), Figure
3, rod assembly, and a ratchet mechanism located on
the right-hand side of the transmission, forward of the
operator’s seat.
During application of the parking brake, the ratchet

mechanism locks the foot brake pedals in the applied
position. This results after locking the left and right
pedal assemblies together with the sliding pin,
pulling the T-handle up and rotating 1/4 turn, and
depressing the foot pedals until the teeth of the
ratchet mechanism engage the pedal assemblies. 20025028
Disengaging the T-handle unlocks the foot brake
pedals. 3
IMPORTANT: Never use the parking brake to stop a

moving tractor, except in an emergency. After such
an event, inspect all transmission and parking brake
components for damage. Ensure to release the
parking brake before moving the vehicle.
33-4
DISC BRAKE ASSEMBLY – OVERHAUL

Removal
1. Remove the rear axle shaft housing. Refer to
Section 27 “Rear Axle”.
2. Remove the inner brake retaining bolts.
Disassembly
disconnect the brake control rod from the
actuating links.
2. Remove the bolts retaining the links to the
actuating discs.
3. Unclip and remove four actuating disc retaining
springs, and separate the discs.
4. Remove and retain the six steel balls for
reassembling.

parts to dry.
2. Inspect components for wear or damage and
replace parts as necessary.
Assembly
Re-assembly of the disc brake assembly follows the
disassembly procedures in reverse.
Installation
Installation of the disc brake assembly follows the
33-5
PARKING BRAKE ASSEMBLY – 5. If needed, remove two retaining bolts and

OVERHAUL remove the rod assembly bracket (4).
Removal
1. Chock the front and rear wheels.
2. Release the parking brake. parts to dry.
3. Remove the split pin (1) from the lower end of the 2. Inspect cable for kinks, tightness, frayed wires
rod assembly (2). and the rod assembly for bending and damage.
4. Remove T-handle (3) and rod assembly (2) from Replace parts as necessary.
tractor. 3. Inspect the ratchet teeth of the left foot brake
pedal and replace if worn.
3
4 15
9
20 2
17 18 16 1
19
12 18
17 14 5
7
16 6
13
11 8
10
20024909
33-6
Installation
BRAKE PEDAL AND LINKAGE –
OVERHAUL
Reference Figure 4.
Removal
1. Chock the front and rear wheels and release the
parking brake if not previously done.
2. Disconnect the two return springs (5), from the
pedals located under the right-hand platform.
3. Remove the split pin (6) and clevis pin (7)
securing the right-hand actuating rod (8) to the
right-hand pedal assembly shaft (9).
4. Remove the retaining ring (10) and washer (11)
securing the right-hand pedal to the brake
cross-shaft (12).
5. Remove the right-hand pedal assembly and
retain the bushing (13) for reinstallation.
6. Remove the pinch bolt (14), which clamps the
left-hand pedal (15) assembly to the cross-shaft.
7. Slide the left-hand pedal assembly from the
cross-shaft, and retain the special key (16),
washer (17) and seal (18) for reinstallation.
8. If required, remove the cross-shaft using the
following procedure:
• Drain the oil from the rear axle center casing.
• Remove all brake pedal components if not
previously removed, from the cross-shaft on
the right-hand side of the rear axle casing.
• On the left-hand side of the rear axle casing,
remove the cotter pin and clevis pin, which
secure the cross-shaft lever (19) to the
actuating rod.
• Hold the cross-shaft lever and slide the shaft
out of the rear axle center casing from the
left-hand side.
Allow parts to dry.
2. Inspect all components for wear or damage.
Replace parts as necessary.
3. With the brake cross-shaft removed, inspect the
cross-shaft bushings (20), Figure 4, installed in
the rear axle casing, for excessive wear or
damage. Replace as necessary using Puller Tool
No. FNH09527 to remove bushings and Driver
Set Tool No FNH09514 to install bushings.
4. Replace the brake cross-shaft oil seals. Press
new oil seals into the rear axle center casing with
the steel side of the seal facing outwards.
33-7
Installation
Installation of the brake pedals and linkage follows
requirements:
1. Ensure there are no burrs on the brake

cross-shaft and install into rear axle center
casing.
2. Refill the rear axle with oil, see Section 27.
3. Use a suitable grease on the ends of the rods and
clevis pins
Foot Brake Adjustment

WARNING
Be aware of local regulations concerning the
braking system. Regularly maintain the brakes to
ensure compliance with the law and to ensure
safe operation of the tractor.
With the brake pedals locked together and applied,

the tractor should stop in a straight line. To correct
this discrepancy, adjust the brake actuating rods
using the following procedure:
1. Chock the front and rear wheels.

2. Release the parking brake.
3. Unlock the brake pedals.
4. Loosen the locknut (1) on the right-hand
actuating rod, and turn the adjusting nut (2),
Figure 5, until free-play at the right brake pedal
is 38 mm (1.5 in).
5. Repeat for the left-hand pedal assembly.
6. Lock the brake pedals together and road test to
ensure the brakes are balanced, and that the
tractor stops in a straight line. Any further
adjustment required to balance the brakes
should be performed on the right-hand brake.
5
Footbrake Adjustment (right-hand side shown)
1. Locknut
2. Adjuster Nut
33-8
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
Chapter 1 - Hydraulic Circuits
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Component -- General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
35-1
SPECIFICATIONS
CONTROL VALVE SIZES
Color mm In.
Orange 15.029-15.034 0.5917-0.5919
Green 15.034-15.039 0.5919-0.5921
Yellow 15.039-15.044 0.5921-0.5923
Blue 15.044-15.052 0.5923-.05926
White 15.052-15.057 0.5926-0.5928
CONTROL VALVE BUSHING SIZES
Color mm In.
Green/White 25.400-25.405 1.0000-1.0002
Orange 25.405-25.410 1.0002-1.0004
Green 25.410-25.415 1.0004-1.0006
Yellow 25.415-25.420 1.0006-1.0008
Blue 25.420-25.425 1.0008-1.0010
White 25.425-25.430 1.0010-1.0012
Blue/White 25.430-25.435 1.0012-1.0014
35-2
LIFT CYLINDER RETAINING BOLT SIZES
1 BOLT 76 mm 3.0 in
2 BOLT 64 mm 2.5 in
3 BOLT 57 mm 2.2 in
4 BOLT 76 mm 3.0 in
1
LIFT CYLINDER PISTON SIZES
A 105 mm 4.13 in
B 134 mm 5.28 in
C 3.0 mm 0.12 in
D 40 mm 1.58 in
E 155 mm 6.10 in
35-3
SPECIAL TOOLS
Description New Holland Other Reference

Set, Tool Hydraulic Lift Control Valve FNH00014
Hose, Testing FNH00093 0093
Wrench, Spanner Coupler FNH00095
Adapter, Pressure Test FNH00705 0705
Fitting, Hydraulic Test FNH00835 0835
Gauge, Setting, Hydraulic Lift Control FNH01261 1261
Installer, Pump Inlet Seat FNH01305 1305
Installer, Needle Bearing FNH01326 1326
Remover, Needle Bearing FNH01327 1327
Fitting, Hydraulic FNH01393 1393
Valve, Needle FNH01394 1394
Gauge, Pressure 0-345 bar (0-5000 psi) FNH02028 2028
Installer/Remover, Control Valve Bushing FNH02191 2191
Meter, Flow 50 GPM 0-200 litrs/min at 5000 psi FNH02755 2755
Fitting, Hydraulic ‘T’ FNH04649 4649
Fitting, Hydraulic Test FNH04653 4653
Gauge, Load Monitor FNH04656 4656
Locator, Hydraulic Lift Cross-Shaft Bearing FNH06209 6209
Adapter, Hydraulic Pressure Test FNH06211 6211
Gauge, Pressure 0-41 bar (0-600 psi) FNH06653 6653
Attachment, Bearing Puller FNH09190 9190
Plate, Step (Set of 11) FNH09210 9210
Attachment, Bearing Cup FNH09507 9507
Puller, ‘Grip-O-Matic’ FNH09516 9516
Hammer, Slide FNH09567 9567
Adapter, Control Valve Bushing FNH10090 10090
Adjuster, Hydraulic Valve FNH10419
35-4
Description
Hydraulic Oil Operating Temperature 57-63_ C 135-146_ F
Hydraulic Oil Maximum Operating Temperature 77_ C 170_ F
High Pressure Circuit Maximum Operating Pressure 183 bar 2650 psi
Detent Regulating Valve Opens 148-162 bar 2150-2350 psi
Steering Motor Relief Valve Opening Pressure 2WD 138-145 bar 2000-2100 psi
with Engine speed at 1200 rpm
Steering Motor Relief Valve Opening Pressure 4WD 166-172 bar 2400-2500 psi
Steering Circuit Maximum Pressure 2WD 145 bar 2100 psi
Steering Circuit Maximum Pressure 4WD 172 bar 2500 psi
Oil Cooler Maximum Leak Detection Pressure 1.7 bar 25 psi
Lubrication Circuit Operating Pressure 5.0-8.5 bar 73-123 psi
Low Pressure Circuit Operating Pressure 15.2-17.9 bar 220-260 psi
Priority Valve (Hydraulic Top Cover) 5-5.9 bar 70-85 psi
Unload Valve (Priority Valve Pack) 4.1-21 bar 60-300 psi
Unload Valve Spring Length (Priority Valve Pack) 4.8 cm 1.9 in
Flow Control Valve Spring Length (Priority Valve Pack) 7.3 cm 2.9 in
Auxiliary Circuit Check Valve Spring Length (Combining 5.5 cm 2.2 in
Valve)
Lift Cylinder Piston Diameter 105 mm 4.13
Lift Cylinder Relief Valve 197-210 bar 2850-3050 psi
Lift Cylinder Safety Valve Opening Pressure 197-203 bar 2850-2950 psi
Hydraulic Lift Control Lever Pull Check 45-71 N 20-30 lb
Lubrication Circuit Relief Valve Operating Pressure 5.0-8.5 bar 73-123 psi
Auxiliary Pump Remote Circuit Relief Valve 186-190 bar 2700-2750 psi
Drop Poppet Valve Opening Pressure .7-.8 bar 10-12 psi
Main Pump Flow Rate (New Pump) 35 litrs/min 9.3 gal/min
minimum of 166 bar (2400 psi) at 2100 Engine rpm
Main Pump Flow Rate (Used Pump) 32 litrs/min 8.4 gal/min
Main Pump Relief Valve Operating Pressure 176-183 bar 2550-2650 psi
Steering Pump Flow Rate (New Pump) 35 litrs/min 9.3 gal/min
at 2100 Engine rpm
Steering Pump Flow Rate (Used Pump) 31 litrs/min 8.2 gal/min
at 2100 Engine rpm
Engine Mounted Fixed Displacement Auxiliary Pump 30 litrs/min 8 gal/min
(New Pump)
Engine Mounted Fixed Displacement Auxiliary Pump 23 litrs/min 6 gal/min
(Used Pump)
35-5
TORQUE VALUES
Description N⋅ m Ft.-lb./In.-lb.
Hydraulic Lift Pump Drive Gear Nut 50-56 N⋅m 37-41 ft.-lb.
Hydraulic Lift Pump Front End-Cover Mounting Bolts 50-62 N⋅m 37-46 ft.-lb.
Transmission Mounted Pump Retaining Bolts 57-76 N⋅m 42-56 ft.-lb.
Hydraulic Lift Pump Pressure Relief Valve 60-68 N⋅m 44-50 ft.-lb.
Engine Mounted Pump End-Cover Retaining Bolts 61-68 N⋅m 45-50 ft.-lb.
Engine Mounted Pump Drive Gear 40-45 N⋅m 30-33 ft.-lb.
Engine Mounted Pump Retaining Bolts 57-76 N⋅m 42-56 ft.-lb.
Engine Mounted Pump Inlet Tube Retaining Bolts 15-20 N⋅m 133-177 in.-lb.
Hydraulic Lift Cylinder-to Lift Cover Retaining Bolts 224-271 N⋅m 165-200 ft.-lb.
Hydraulic Lift Cylinder Safety Valve 102-122 N⋅m 75-90 ft.-lb.
Hydraulic Lift Cover Assembly-to-Rear Axle Casing 136-170 N⋅m 100-125 ft.-lb.
Hydraulic Lift Arm Retaining Nuts 27-41 N⋅m 240-360 in.-lb.
Hydraulic Lift Filler Plug 50 N⋅m 37 ft.-lb.
Control Valve Turnbuckle Locknut 14 N⋅m 124 in.-lb.
Control Valve Front and Rear Plate Retaining Bolts 43 N⋅m 32 ft.-lb.
Control Rod Turnbuckle Lock Nut 34 N⋅m 301 in.-lb.
Quadrant Assembly-to-Lift Cover Bolts 68 N⋅m 50 ft.-lb.
Selector Lever Adjuster Rod Locknut 12 N⋅m 106 in.-lb.
Lift Lever Adjuster Rod Locknut 12 N⋅m 106 in.-lb.
Draft Control Nut Set Screw 30 N⋅m 266 in.-lb.
Position Control Adjusting Screw Locknut 24 N⋅m 212 in.-lb.
Yoke Retaining Nut Set-Screw 27-34 N⋅m 240-300 in.-lb.
Priority Valve Pack-to-Lift Cover Retaining Bolts 57-76 N⋅m 42-56 ft.-lb.
Unload Valve Front Plug 23-48 N⋅m 204-420 in.-lb.
Flow Control Valve Rear Plug 27 N⋅m 240 in.-lb.
Detent Shaft Pivot Coupling 7 N⋅ m 60 in.-lb.
Detent Housing Retaining Screws 7 N⋅ m 60 in.-lb.
Priority Check Valve 7 N⋅ m 60 in.-lb.
Remote Coupler Sleeve 81 N⋅m 60 ft.-lb.
Remote Valve-to-Mounting Bracket 27-35 N⋅m 240-312 in.-lb.
Remote Valve Centering Spring Retaining Bolt 9 N⋅ m 80 in.-lb.
Remote Valve Housing-to Coupler Bolts 15-20 N⋅m 133-177 in.-lb.
35-6
FAULT FINDING
IMPORTANT: To avoid repeat failures, investigate
and correct the cause of the defect when making
repairs to the hydraulic system.
Problem Probable Cause Correction

Failure to lift implement Pressure relief valve opening too Check relief valve setting
soon
Flow control valve malfunction Check flow setting
Overhaul or replace valve if defective
Control valve malfunction Check for sticking valve or bent spool
Mechanical malfunction Check for seized cross-shaft, bent levers,
and all linkage for smooth operation and
proper lubrication. Replace defective
parts
Lift cylinder malfunction Check for seized piston, worn cylinder, in-
correct safety valve setting or leakage.
Overhaul or replace defective parts
Hydraulic Pump Perform pressure test of pump
Check filter for clogging
Overhaul or replace defective pump
Rear axle oil level incorrect Check and replenish as necessary
Priorityy valve p
pack Check valve pack for leakage
Overhaul or replace defective valve pack
Slow lift or failure to lift under Pressure relief valve opening too Check relief valve setting
load soon
Implement too heavy Lighten load
Blocked oil galleries Remove obstruction
Control valve malfunction Check for sticking valve or bent spool
Hydraulic pump Perform pump pressure test
Check filter for clogging
Overhaul or replace pump
Lift and No drop
p Draft Control malfunction Check main spring adjustment
Control valve stuck in lift position Overhaul or replace control valve
Lift drops
p with control lever in Unload valve sticks Overhaul or replace valve
l
lower or neutrall when
h engine
i Combining valve sticks Overhaul or replace valve
stopped
Control valve sticks Overhaul or replace valve
Implement
p lifts but drops
p with Lift cylinder
y malfunction Check piston seals
controll lever
l in
i neutrall or raise
i Check cylinder for wear or cracking
position
Overhaul or replace cylinder
Safety valve malfunction Check setting of valve
35-7
FAULT FINDING (continued)
Problem Probable Cause Correction

Remote valve slow operation Flow control valve incorrect Adjust flow control knob to desired setting
setting
System pressure low Check system components
Detent regulating valve incorrect Adjust detent regulating valve
setting
Remote valve malfunction Pressure check remote valve
Low oil level Replenish oil in rear axle center casing
Initial hesitation when resum- Check valve worn or spring Overhaul or replace check valve
i a remote cycle
ing l Check valve spring distorted Overhaul or replace check valve
Hydraulic
y system
y relief valve Centering spring damaged Replace faulty components
opens at end
d off remote cycle
l Detent regulating valve set too Adjust setting of valve
high
Remote valve spool returns to Detent regulating valve set too low Adjust setting of valve
neutral before cylinder reach-
es end of stroke Remote control valve spool worn Overhaul or replace remote valve
35-8

The hydraulic system provides oil flow at regulated
pressures for the operation and lubrication of various
circuits within the tractor, as well as providing
accurate and sensitive control of implements over a
wide range of operating conditions.
The standard hydraulic system consists of a top link

sensing and three-point linkage system, a single or
tandem (gear type) main pump, an engine mounted
auxiliary pump (optional with the tandem pump
installed), lift cylinder assembly, and optional remote
valve(s). The rear axle center casing functions as the
hydraulic system reservoir.
A lift control valve, and priority valve pack containing

several valves, function together to direct the
hydraulic oil as needed. A pressure regulator, and
various relief-valves and check valves protect the
circuits and components from overload conditions,
encountered during normal and arduous operation,
as well as prevent back-flow of oil.
The hydraulic system includes two major circuits:
• The High Pressure Circuit
• The Low Pressure, Steering and Lubrication

Circuit
For models with older configurations, i.e. manufac-

tured before 1999; the steering circuit remained
completely independent and separate of the
low-pressure and lubrication circuit. Thus, three
major circuits existed.
35-9
High-Pressure Circuit The front pump within the (tandem gear) main pump
Refer to Figure 3. assembly circulates pressurized hydraulic oil to the
priority valve pack. A relief valve installed in the pump
Operating with a maximum pressure of 183 bar
protects the circuit from overload, with an operating
(2650 psi), the high-pressure circuit supplies oil for
pressure of 176-183 bar (2550-2650 psi).
control of the hydraulic lift assembly, remote control
valve(s), and auxiliary equipment (where installed). The oil supply from the auxiliary pump flows to the
priority valve pack via external tubing, while the
With two or more remote valves installed on the
supply from the main pump flows to the priority valve
tractor, it is necessary to supplement the (tandem
pack through internal galleries within the hydraulic
gear) type transmission mounted pump output, with
top cover.
an engine mounted (auxiliary) pump.
3
Hydraulic Circuit for Tractor with Fixed Displacement Tandem Gear Type Pump, Engine Mounted Single
Gear Type Pump, and Top Link Sensing Hydraulic Lift Assembly
1. Position Control Link 13. Exhaust Valve

2. Selector Link 14. Lift Cylinder Safety Valve
3. Draft Control Mainspring 15. Auxiliary Pump Intake Filter
4. Yoke 16. Engine Mounted Auxiliary Hydraulic Pump
5. Selector Rod and Roller Assembly (where installed)
6. Actuating Link 17. Check Valve
7. Pressure Relief Valve 18. Combining (Sequencing) Valve
8. Steering Pump 19. Flow Control Valve
9. Hydraulic Lift Pump 20. Priority Valve Pack
10. Pump Intake Filter 21. Unload Valve
11. Lift Piston 22. Check Valve
12. Control Valve 23. Lift Arms
35-10
Low-Pressure, Steering and Lubrication Circuit The rear pump within the (tandem gear) main pump
The low-pressure hydraulic circuit performs two assembly circulates pressurized hydraulic oil
major functions. To supply pressurized hydraulic oil through tubing to the steering motor, hydraulic PTO
for the operation of the steering system, 4WD clutch, clutch control valve, and to the Dual Power clutch
hydraulic PTO clutch, PTO brake, and Dual Power control valve (where installed) within the transmis-
assembly (where installed). Secondly, to supply sion housing.
lubricating oil to the hydraulic PTO clutch, Dual
Power assembly (where installed) and the transmis- With a (single gear) main pump assembly, the engine
sion. Before entering the transmission, lubricating oil mounted pump supplies pressurized oil to the
passes through an oil cooler mounted in front of the steering system
radiator.
A pressure regulating valve in the hydraulic PTO
Designed with an open center, the low-pressure and clutch assembly controls oil flow to the lubricating
lubrication circuit provides a constant flow of and cooling circuit. In addition, excessive oil in the
hydraulic oil throughout the system for as long as the lubrication circuit discharges to sump through an
engine continues to run. adjacent relief valve. The relief valve protects the
circuit from overloading with a minimum operating
pressure of 5.0 bar (73 psi).
A B C
4
Pressure Regulating Valve and Relief Valve -- High Pressure Circuit Operation
1. Pressure Regulating Valve A. Low Pressure Circuit Outlet

2. Low-Pressure Relief Valve B. High Pressure Circuit Outlet
C. Low Pressure Circuit Sensing Gallery
D. Supply Oil from Pump
System Pressure Low Pressure Return Oil
35-11
5
Low-Pressure, Steering, and Lubrication Circuit with (tandem gear) Transmission Mounted Pump
(Sheet 1 of 2)
35-12
6
Low-Pressure, Steering, and Lubrication Circuit with (tandem gear) Transmission Mounted Pump
(Sheet 2 of 2)
35-13
Refer to Figures 5 and 6.
A = High Pressure Oil 183 bar (2650 psi) 1. Transmission Mounted Tandem Gear Pump
B = Steering Pressure up to 2. Transmission 8 x 2
2WD -- 145 bar (2100 psi) 3. 4WD Clutch
4WD -- 172 bar (2500 psi)
C = Low Pressure Oil 15.2 -- 17.9 bar (220 -- 260 psi) 5. Lubrication Relief Valve
D = Lubrication Oil 5.0 -- 8.5 bar (73 -- 123 psi) 6. PTO Control Valve -- Engaged
E = Suction / Return to Sump 7. PTO Clutch Assembly -- Engaged
Configurations with Independent Steering The steering wheel, when turned, rotates a shaft
Circuit within the steering column and bracket assembly. A
A power steering pump and reservoir assembly steel sleeve couples the shaft to the steering motor
mounts to the left-hand side of the engine. The input shaft. The steering motor reacts by directing
engine timing gears drive the power steering pump hydraulic oil under pressure from the power steering
at crankshaft speed. Two spur type gears, riding pump to the double-acting unbalanced steering
within specially designed bearing blocks, produce oil cylinder (2WD), or the double-acting, balanced
flow for the operation of the power steering. The steering cylinder (4WD), to drive the front wheels.
self-contained reservoir provides a holding tank for
the hydraulic oil required by the steering system. The steering motor contains a metering unit to
regulate the volume of oil to the steering cylinder,
A steering circuit oil cooler, attaches to the front of the proportional to the angular movement of the steering
engine on the left side. It provides cooling provisions wheel. This controls the rate of turn. A check valve
for circulating oil, before the oil returns to the steering functions in combination with the metering unit to
system reservoir. allow manual operation of the steering system in the
absence of pressurized oil from the pump.
A pressure relief valve installed in the power steering
pump protects the steering system from excessive On 2WD models, the steering motor incorporates
pressure. In some steering system configurations, suction valves, which prevent cavitation in the
the steering motor contains an integral relief valve, in steering cylinder when oil transfers from a small area
which case, the power steering pump will not contain to a larger area, with the steering motor in neutral.
a relief valve.
Passages in the spool and sleeve allow oil from the
A flow regulator installed in the power steering pump, opposite side of the steering cylinder to flow back
controls oil flow for consistent steering performance through the oil cooler, to the reservoir, by way of the
through all engine speeds. steering motor housing.
Independent Steering Circuit Oil Flow

The power steering pump directs pressurized oil to
the steering motor via a resonance damper filter. The
filter reduces noise from the system and absorbs
pressure surges from the pump.
35-14
A B C
7
Pressure Regulating Valve and Low Pressure Relief Valve
(Low and High Pressure Circuit Operation)
1. Pressure Regulating Valve A. Low Pressure Circuit Outlet

2. Low-Pressure Relief Valve B. High Pressure Circuit Outlet
C. Low Pressure Circuit Sensing Gallery
D. Supply Oil from Pump
System Pressure Low Pressure Return Oil
35-15
High-Pressure Hydraulic Circuit Oil Flow With the control valve in the neutral position, the
Refer to Figure 8. following function occurs:
Refer to Figure 9.
The rear axle center casing functions as a reservoir,
and supplies oil to the hydraulic circuits. Hydraulic oil • The trapped hydraulic oil within the lift cylinder
drawn by the pump assembly enters the pump inlet holds the cylinder in the desired position.
port, and passes through a micron filter assembly.
• Pressurized oil enters the combining valve,
The lift (main) pump discharges pressurized oil located in the priority valve pack on top of the
through the outlet port, where the oil circulates to the hydraulic lift cover. The combining valve either
hydraulic lift assembly control valve. The control returns the oil to the reservoir, or directs it to the
valve directs the hydraulic oil depending upon the remote valve(s), depending on demand.
position of the spool as described in the following:
Hydraulic circuits without remote valves installed, do
not require a combining valve.
8
Hydraulic Circuit for Tractor with Fixed Displacement Tandem Gear Type Pump
and Top Link Sensing Hydraulic Lift Assembly
1. Position Control Link 13. Exhaust Valve
2. Selector Link 14. Lift Cylinder Safety Valve
3. Draft Control Mainspring 15. Auxiliary Pump Intake Filter
4. Yoke 16. Engine Mounted Auxiliary Hydraulic Pump
5. Selector Rod and Roller Assembly
17. Check Valve
6. Actuating Link
18. Combining (Sequencing) Valve
7. Pressure Relief Valve
19. Flow Control Valve
8. Steering Pump
9. Transmission Mounted Hydraulic Pump 20. Priority Valve Pack
10. Pump Intake Filter 21. Unload Valve
11. Lift Piston 22. Check Valve
12. Control Valve 23. Lift Arms
35-16
With the control valve in the neutral position, the
following oil flow occurs:
Refer to Figure 9.
• Pump pressure enters the lift cover at Gallery E,
where the control valve prevents the oil from
entering Galleries C & D.
• Pressurized oil flows up Gallery E to the flow

control valve and unload valve.
• The unload valve opens to return at the left side

via Gallery C, and the control valve center.
• Oil pressure applied to the center face of the

spool in the unload valve holds the spool to the
left.
• With the unload valve held to the left, oil in Gallery

D, and in the spring-loaded end of the flow control
valve, returns to sump through Gallery G, by way
of a small internal drilling in the unload valve.
• Oil pressure in Gallery E now acts on the

right-hand face of the flow control valve via an
internal drilling, and moves the valve full left,
which allows the oil to flow from gallery E to
Gallery F.
• With the remote valve(s) in neutral, the load

sensing, line pressure vents to sump through the
remote valve(s). Pressurized oil in Gallery F acts
on the right-hand side of the combining valve,
and moves the valve to the left, which ports oil
from Gallery F to return through Gallery G.
• The oil in the lift cylinder remains trapped in

galleries A and B by the control valve land, and
the check valve.
35-17
9
Control Valve Oil Flow in Neutral
(Tractors with Fixed Displacement Hydraulic Pump)
Main Pump Auxiliary Exhaust Oil Trapped Oil

Pressure Oil Pump Oil
1. To Remote Valves 5. From Main Pump 10. To Reservoir

2. Combining Valve 6. Control Valve 11. Remote Valve Pilot Line
(Sequencing) Valve 7. Exhaust Valve (Load Sense Line)
3. Unload Valve 8. To Lift Cylinder 12. From Auxiliary Pump
4. Flow Control Valve 9. Check Valve
GALLERY A, To Lift Cylinder and Auxiliary Services GALLERY H, Auxiliary Pump Supply
Valve (where fitted)
GALLERY E, Main Pump Supply GALLERY G, Return to Sump
35-18
With the control valve in the lowering position,
the following functions occur:
• Pressurized oil enters the combining valve,
located in the priority valve pack on top of the
hydraulic lift cover. The combining valve either
returns the oil to the reservoir, or directs it to the
remote valve(s), depending on demand.
• Hydraulic oil within the lift cylinder returns to

sump through the control valve and exhaust
valve.
With the control valve in the lowering position,

the following oil flow occurs:
Refer to Figure 10.
• Pump pressure enters the lift cover at Gallery E,

where the control valve prevents the oil from
entering Galleries C and D.
• Pressurized oil flows up Gallery E to the flow

control valve and unload valve.
• The unload valve opens to sump on the left side

via Gallery C, and the control valve center.
• Oil pressure applied to the center face of the

spool forces the spool to the left.
• With the unload valve held to the left, oil in Gallery

D, and in the spring-loaded end of the flow control
valve, returns to sump through Gallery G, by way
of a small internal drilling.
• Oil pressure in Gallery E acts on the right-hand

face of the flow control valve via an internal
drilling, which moves the valve full left, allowing
the oil to flow from gallery E to Gallery F.
• In both the neutral and lowering positions, a lack

of demand from the remote valve(s) will cause
the combining valve to discharge hydraulic oil
back to sump.
• As the control valve moves to the right from

neutral to the lowering position, lift cylinder oil
flows out of Galleries A and B, through the control
valve, and on to sump through the exhaust valve.
• Excess oil flow from the lift cylinder through the

exhaust valve forces the valve down against the
spring, which reduces the exhaust port aperture.
NOTE: The reduced exhaust port aperture conse-

quently controls the lowering of the lift arms
irrespective of the loading on the lift linkage.
35-19
R8--333
10
Control Valve Oil Flow in Lowering Position
Main Pump Auxiliary Exhaust Oil Trapped Oil


35-20
With the control valve engaged in the ‘slow’
raising position, the following functions occur:
When raising the hydraulic lift, two conditions occur,
referenced as ‘slow’ and ‘fast’ raises. The number of
open ports in the control valve that direct pressurized
oil to the lift cylinder determines the speed of the lift.
Moving the lift control lever to the point where the

hydraulic lift starts to raise, engages ‘slow’ lift
and the following functions occur:
• Pressurized oil flows to the lift cylinder or
combining valve.
• The position of the control valve determines the

position of the flow control valve, giving priority to
lift cylinder demand, and diverting the surplus oil
to the combining valve.
• The combining valve either returns the surplus oil

to the reservoir, or directs it to the remote
valve(s), depending on demand.
With the control valve engaged in the ‘slow’

raising position, the following oil flow occurs:
Refer to Figure 11.
• The initial movement of the lift control lever shifts

the control valve from the neutral to the ‘slow’
raise position. This allows pressurized oil from
Gallery E to flow to Gallery C through a drilled
passage in the control valve, and the left-hand
end of the unload valve.
• The combination of spring pressure in the unload

valve, and oil pressure in Gallery C, shifts the
unload valve spool full right, connecting Galleries
E and D through a large cross drilling.
• The channel drilled in the unload valve restricts

the hydraulic oil flow to 7.6 litrs/min (2 gal/min),
which induces a smooth initial lift. The reduced
pressure acts on the left-hand face of the flow
control valve spool, and moves it to the right. The
initial oil flow from the flow control valve enters
Galleries A and B through a check valve.
• Further movement of the control valve to the left,

uncovers a series of ports connecting Gallery E
with Gallery D. Oil flow increases into Gallery D,
which speeds up the lift cylinder movement. The
flow control valve moves further to the right,
reducing oil flow from gallery E to Gallery F.
35-21
11
Control Valve Oil Flow in Slow Raising Position
Main Pump Reduced Pump Auxiliary

Pump Oil Exhaust Oil
Pressure Oil Pressure Oil

35-22
With the control valve engaged in the ‘fast’
raising position, the following functions occur:
• The flow control valve gives full priority to the lift
cylinder.
• At this point, operation of the remote valve(s)

would only be possible with an additional
auxiliary engine mounted pump installed.
With the control valve engaged in the ‘fast’

raising position, the following oil flow occurs:
Refer to Figure 12.
• The full rear movement of the lift control lever

shifts the control valve pass the ‘slow’ raise
position to the ‘fast’ raise position. All the ports in
the control valve bushing uncover, allowing
increased pump oil flow from Gallery E to Gallery
D.
• The combination of spring pressure in the unload

valve, and oil pressure in Gallery C, shifts the
unload valve spool full right, connecting Galleries
E and D through a large cross drilling.
• Oil flows from Gallery E to Gallery D with less

restriction and the pressure on both sides of the
flow control valve equalizes. The flow control
vale spring moves the spool to the full right
position, closing off Gallery E from Gallery F.
• All pressurized oil from the pump diverts to the lift

cylinder through Gallery A, giving the lift cylinder
priority over the remote valve(s).
• The size of the ports in the flow control valve

bushing limit the oil flow to the lift cylinder to a
maximum of 31 litrs/min (8 gals/min)
• The completely closed off Gallery F allows the

combining valve to move to the right, preventing
oil flow to sump through Gallery G, unless there
is an auxiliary engine mounted pump installed.
35-23
12
Control Valve Oil Flow in Fast Raising Position
Main Pump Auxiliary Exhaust Oil


35-24
Fixed Displacement Engine Mounted
(Single Gear) Pump - Oil Flow
Refer to Figure 13.
The optional auxiliary engine mounted pump

supplements pressurized oil to the remote valve(s)
circuit.
• A pilot (load sensing) signal applied to the left end

of the combining valve moves the valve to the
right. This blocks the connections of Gallery F to
G and Gallery H to G progressively, depending
on the hydraulic requirements of the remote
valve(s).
• Pressurized oil from the auxiliary pump enters

the priority valve pack and forces open the
remote valve feed check-valve open to combine
with oil flow from the main pump in Gallery F.
• With the remote valve(s) circuit in neutral, the

load sensing line vents, and pump oil pressure in
Gallery F moves the combining valve to the left,
opening pump oil flow to return through Gallery
G.
• The relief valve within the combining valve vents

oil to return through Gallery G, if pressure
exceeds 186-190 bar (2700-2750 psi) in the load
sensing line, or if there is an overload in the
remote circuit. The change in pressure across
the combining valve moves the spool to the left,
allowing excess oil flow from both pumps in
Galleries F and H to be exhausted to return
through Gallery G.
35-25
13
Control Valve Oil Flow in Fast Raising Position
(Tractors with Fixed Displacement Engine Mounted Hydraulic Pump)
Main Pump Auxiliary Exhaust Oil


35-26
Low Pressure, Steering and Lubrication Circuit
Oil Flow
The rear pump (steering) within the transmission
mounted tandem pump assembly, provides pressur-
ized hydraulic oil to the low-pressure, steering and
lubrication circuit.
• A relief valve incorporated within the steering

motor, controls the maximum oil pressure
supplied to the steering circuit during steering
operation. The relief valve operates at 145 bar
(2100 psi) on 2 wheel drive tractors, and 172 bar
(2500 psi) on all other models.
• The flow of oil leaving the steering motor returns

to the steering pump body, then is redistributed
to the hydraulic PTO clutch control valve
assembly through the rear axle center casing,
and external tubing.
• Oil also flows to the dual power clutch control

valve (where installed) located in the front
transmission housing.
• After full actuation of the dual power clutch

(where installed) and hydraulic PTO clutch,
system pressure rises until the pressure
regulating valve, located within the hydraulic
PTO clutch control valve assembly, opens to
release oil into the lubrication circuit.
• The majority of hydraulic oil in the lubrication

circuit passes through external tubing to an oil
cooler mounted in front of the radiator.
• A proportion of hydraulic oil exhausts through the

hydraulic PTO clutch assembly to lubricate the
clutch plates.
• A relief valve adjacent to the pressure regulating

valve in the hydraulic PTO clutch control valve
assembly protects the lubrication circuit against
excessive pressures, by discharging surplus oil
directly to sump.
• Cooled oil from the oil cooler flows to the front

transmission, and through the dual power
housing (where installed) to the center passages
of the transmission countershaft and output
shafts. Radial drillings in the shafts facilitate
pressure lubrication of the bearings and gears.
• The lubrication oil exhausts to the common front

and rear transmission reservoirs.
35-27
Hydraulic System Control
Two distinct systems are incorporated:
• Draft Control
• Position Control
The control system selected depends on the type of

implement in use and the operating conditions.
A position control lever and a draft control lever

operating in a quadrant on the right-hand side of the
operator’s seat, provide control of the hydraulic lift
system.
14
Hydraulic Control Selector Lever
The Draft Control lever (1), Figure 14, operates in a
slotted bracket with formed notches to prevent
accidental movement of the lever. The lever clears
the notches for moving, when eased to the left.
A decal adjacent to the Draft Control lever clearly

identifies the Draft and Position Control settings.
With the Draft Control lever in the forward notch (3),

the hydraulic system operates Draft Control in
maximum sensitivity. This is the most sensitive
setting and variations in soil density cause the
hydraulic system to respond with relatively large
corrections. Moving the Draft Control lever progres-
sively away from the forward most notch, decreases
draft control sensitivity. The rearmost notch (2)
positions the system in Position Control, Figure 14.
IMPORTANT: Always set the draft control lever to the

rearmost notch, when not operating the Draft
Control, such as when attaching equipment,
transporting equipment, or with no equipment
attached.
Hydraulic Lift Control Lever

The hydraulic lift control lever (5), raises or lowers the
three-point linkage and implement to the required
height or working depth. Pushing the lift control lever
forward lowers the implement. Pulling the lift control
lever to the rear raises the implement.
An adjustable stop (4), Figure 14, provides a means

of returning the lift control lever to the selected setting
during use. The stop can be by-passed by easing the
lever to the right until clear.
35-28
Principles of Draft Control the top link against the tractor. The draft force will
The Draft Control system manages the working alter according to the depth of work and soil type.
depth of soil engaging implements to maintain an
even pull on the tractor, and to reduce wheel When draft forces increase beyond selection, the
slippage. compressive force on the top link (3) pushes the yoke
(2) further into the hydraulic lift cover, and the
When lowering a soil-engaging implement, e.g. a hydraulic system raises the implement until restoring
plow, into the ground, the draft forces (A) applied to the desired amount of draft. When draft forces
the implement tend to make the plow pivot at the decrease below selection, the compressive force on
point where it attaches to the lower links (B). Without the top link reduces, and the yoke moves out from the
the top link, the plow would tip up (C). Due to the top top cover, and the hydraulic system responds by
link resistance, the plow stays level in the ground. lowering the implement until restoring the desired
This demonstrates compressive force (1) acting on amount of draft.
15
The Principal of Draft Forces Applied Through the Hydraulic Linkage
1. Compression Force A. Draft Forces
2. Draft Control Yoke B. Lower Link Pivot Point
3. Top Link C. Tipping Force
35-29
Top Link Sensing and Three-Point Linkage
Draft forces applied to an implement, transmit
mechanically from a rocker (1) and control yoke (2),
to the Draft Control mechanism, via the top link (3) of
the three-point linkage. The hydraulic system
responds by raising or lowering the implement, to
restore and maintain uniform draft loading.
16
Draft Control – Lowering control valve spool rearward into the lowering
The draft control lever (10) connects to the control position.
arm (9) by a clevis link. As the control lever moves
downward, the arm rises and aligns the control rod The lowering action stops, when the implement draft
and roller assembly (5). The control rod and roller compresses the draft control main spring (2) in a
assembly attaches to the far end of the lever arm. forward direction enough to cause the main spring
The top pivot point of the control link (4) connects to plunger to move the control link forward. This action
the draft control main spring plunger (1). causes the control rod to pivot the actuating lever
about the top attaching point. The actuating lever
Downward movement of the lift control lever (11) overcomes the rearward pressure of the control
moves the actuating lever (14) forward. The valve spring and moves the control valve spool
actuating lever pivots about the control rod connector forward into the neutral position.
(8) and allows the control valve spring (7) to move the
10
12 13 14 1
11
3
9
8 7 6 5 4
17
Draft Control -- Lowering into Work (Less Cab)
35-30
Draft Control – Raising main spring eases. The control valve spring moves
An increase in draft to the implement transmits the control valve spool rearward, back into the
through the yoke (1) to compress the draft control neutral position.
main spring (2), moving the draft control main spring
plunger (3) in a forward direction. The control rod and A further decrease in draft reduces the draft control
roller assembly (4) connected to the plunger by the main spring compression and the pressure on the
control link (5), pivots about the actuating lever (6). actuating lever. The control valve spring extends and
The actuating lever overcomes the pressure of the moves the control valve spool, rearward into the
control valve spring (7), and moves the control valve lowering position. As the implement runs deeper, the
spool forward, into the raise position. As the draft increases and the control valve spool returns to
implement lifts, the draft forces acting on the yoke the neutral position.
reduce, and the compression of the draft control
6 3
4 5
18
35-31
Draft Control – Transport Position During Position control, the control rod and roller
Pulling the draft control lever (9) to the top of the assembly (1) aligns with the lower end of the control
quadrant selects the transport position. The top of link (2). With the control rod and roller in this position,
the actuating lever (4) pivots rearwards about the any variations in draft loading applied to the yoke (3)
control rod connector, which allows the control valve through the top link and three-point linkage system
spring (5) to move the control valve spool forward, will not alter the control rod and roller. Consequently,
into the raise position. the actuating lever (4) and control valve (5) remain
unchanged unless movement of the draft control
To limit the height of the implement, the piston skirt lever (9) occurs.
contacts a stop pin attached to the actuating lever,
when reaching the full raised position. The control Moving of the lift control lever (6) pivots the control
valve spool moves rearward into the neutral position, rod and repositions the control valve spool, to raise
stopping further movement of the lift piston. The stop and lower the implement as required.
pin functions in both Draft and Position control.
As the lift arms move, the position control link (7)
rides the position control cam (8), moving the control
Principles of Position Control rod and actuating lever. With the lift arms in the
The system of Position control enables the working desired position, the actuating lever returns the
depth or height of an implement, relative to the control valve to neutral, which stops further
tractor, to be pre-set and maintained. movement of the lift arms. Therefore, a direct
relationship exists between the height of the lift arms
and the position of the draft control lever.
19
Position Control Linkage Operation
1. Control Rod and Roller Assembly 5. Control Valve/Spring Assembly

2. Selector Link 6. Control Lever
3. Yoke 7. Position Control Link Roller
4. Actuating Lever 8. Position control Cam
9. Draft control lever
35-32
HYDRAULIC COMPONENT Flow Control Valve

The flow control valve, located in the priority valve
GENERAL DESCRIPTION pack, controls oil flow to the lift control valve, by
sensing pressure variations. The flow control valve
Fixed Displacement Transmission Mounted also diverts surplus oil to the combining valve.
(Tandem Gear) Type Pump
The fixed displacement, transmission mounted
(tandem gear) type pump, located on the right-hand Unload Valve
side of the rear axle center casing, consists of a front The unload valve, located in the priority valve pack,
(lift) pump and a rear (steering) pump. The pump responds to flow control valve movement, and
assembly directs pressurized oil through internal operates in two positions. In the raised position, the
galleries within the hydraulic top cover, to the valve allows oil to flow to the lift cylinder. In the neutral
high-pressure circuit, and through external tubing to or lowering position, the valve directs oil to the
the low-pressure, steering and lubrication circuit. reservoir (rear axle center casing).
The pump receives drive via an idler gear from the

Power Take-off (PTO) clutch hub. See Section 35, Combining Valve
Chapter 2 for more detail. The combining valve regulates the flow of oil to the
remote valve circuit, and combines the flow of oil from
the main and auxiliary pumps as required.
Fixed Displacement Engine Mounted
(Single Gear) Type Pump The combining valve performs the following
The fixed displacement, engine mounted (single functions:
gear) type pump, located on the left-hand side of the
engine, functions differently depending on the type of • Directs main hydraulic and auxiliary pump oil flow
pump installed on the transmission. On tractors fitted to remote circuits on demand, and returns oil flow
with a (tandem gear) type main pump, the engine to sump when no demand exists.
mounted (auxiliary) pump supplies pressurized oil to • Directs oil flow to sump if pump output exceeds
the priority valve pack to supplement the remote remote circuit demand.
valve(s) circuit. On tractors fitted with a (single gear)
type main pump, the engine mounted (steering • Protects the remote circuits and auxiliary pump
pump) supplies pressurized oil to the steering circuit from excessive pressure.
system. A drive gear at the rear of the camshaft
drives the pump. See Section 35, Chapter 2 for more
detail. Hydraulic Lift Control Valve
The hydraulic lift control valve, mounted under the
top lift cover, controls the lift cylinder. The control
Hydraulic Top Cover valve ports pressurized oil to the lift cylinder for ‘slow’
The hydraulic top cover provides a base for mounting or ‘fast’ raising, or directs oil back to sump for the
the priority valve pack, brackets for the hydraulic lift ‘neutral’ and ‘lowering’ positions. The lift control
control lever, draft control lever, and quadrant. In valve receives mechanical input from the lift control
addition, the cover houses the top link sensing and lever through internal linkage.
draft control linkage system, hydraulic lift control
linkage, lifting cylinder and arms, internal galleries,
and covers the hydraulic reservoir (rear axle center Hydraulic Lift Cylinder
casing). The lift cylinder operates the lift arms to raise, lower
and transport an implement. The lift cylinder
assembly consists of a control valve, piston, exhaust
Priority Valve Pack valve, safety valve, drop poppet valve, and a
The priority valve pack, located on top of the restrictor valve.
hydraulic lift cover contains a set of valves, which
establishes pump oil priority, and controls the flow of
oil to the lift cylinder, auxiliary equipment and remote
valves.
35-33
Lift Cylinder Exhaust Valve Pressure Relief Valves
The spring-loaded exhaust valve, located in the lift The pressure relief valve, located in the main pump,
cylinder, restricts the flow of exhaust oil from the lift limits maximum pressure in the high-pressure
cylinder, thereby maintaining the rate of drop for hydraulic system, and prevents pump overload.
controlled lowering.
A pressure relief valve located in the combining valve
protects the remote circuits and auxiliary pump.
Lift Cylinder Safety Valve
The spring-loaded lift cylinder safety valve, located in A relief valve installed in the steering motor protects
the lift cylinder wall, protects the lift cylinder circuit the steering circuit from excessive pressure.
from overloading, such as, when transporting
implements over rough ground. The safety valve
requires no servicing. Hydraulic Oil Filters
A full flow micron filter assembly screws on the
transmission mounted main pump housing.
Priority Valves
A smaller micron filter screws onto the auxiliary
Installed in the lines between each individual remote
engine mounted pump.
valve, priority valves enable the remote valve with
the highest operating pressure complete control of oil
flow from the pump.
Pressure Regulating Valve
The pressure regulating valve housed within the
Power Take-Off (PTO) assembly maintains low-pres-
Check Valves
sure circuit oil at 15.2-17.9 bar (220-260 psi). The
The priority valve pack contains two check valves:
valve controls oil pressure acting on the hydraulic
A check valve, installed in the auxiliary pump, supply PTO clutch piston during clutch engagement, and the
port, prevents back feed from the main pump to the clutch brake, and supplies the lubrication and cooling
auxiliary pump. circuit with oil. When the engine stops running, the
pressure regulating valve closes.
A second check valve, installed in the base of the
priority valve pack, prevents oil flow from the lift
cylinder to the flow control valve, during lift cylinder
lowering, neutral, or shock loading conditions.
Other check valves, installed in the lines between two

or more remote valves, prevent oil back flow between
the valves.
A double-spool remote valve contains a check valve

within the valve housing.
35-34
Chapter 2 - Hydraulic Pumps
CONTENTS

Fixed Displacement Transmission Mounted (Tandem Gear) Type Pump . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fixed Displacement Engine Mounted (Single Gear) Type Pump . . . . . . . . . . . . . . . . . . . . . . 11
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
35-1
FIXED DISPLACEMENT TRANSMISSION MOUNTED (TANDEM GEAR) TYPE PUMP
DESCRIPTION AND OPERATION hub via an idler gear (7). The lift pump supplies oil to
The fixed displacement (tandem gear) type pump the high-pressure circuit, to operate the hydraulic lift
mounts on the right-hand side of the rear axle center and remote control valve(s).
casing. The pump housing contains two separate
The rear pump (3), with narrower gears, referred to
gear type pumps:
as the steering pump, provides oil to the
The front pump (5), referred to as the hydraulic lift low-pressure, steering, and lubrication circuits.
pump, receives drive from the hydraulic PTO clutch
1
Cross Section of Transmission Mounted Fixed Displacement Gear Type Pump
1. Outlet Port to Hydraulic Lift 6. Hydraulic Lift Pump Outlet Port
2. Steering Pump Drive Gear 7. Pump Assembly Drive Gear (idler gear)
3. Steering Pump Driven Gear 8. Hydraulic Lift Pump Drive Gear
4. Outlet Port to PTO 9. Drive Link
5. Hydraulic Lift Pump Driven Gear 10. Pump Inlet Port (Both Pumps)
35-2
Both pumps share a common full flow, intake filter
mounted on the pump.
The hydraulic PTO clutch hub transmits drive to the

hydraulic lift pump via an idler gear, and a drive link
(1) transmits drive from the lift pump to the steering
pump, Figure 2.
The gears in both pumps continuously revolve at the

same speed as long as the engine runs. Aluminum
bearing blocks incorporating steel bushings provide
support for the gears.
35-3
Oil Flow
The fixed displacement (tandem gear) type pump
assembly receives oil from the rear axle center
casing reservoir through an intake tube attached to
the pump inlet port.
When the engine runs, the hydraulic PTO idler gear
drives the pump and draws oil through the inlet port
and intake filter into the spaces between the gear
teeth in each pumping unit (B). As the gears rotate
(1), trapped oil between the gear teeth and pump
body flows to the pump outlet ports and discharges
into the hydraulic circuits (A).
A relief valve operating at 176-183 bar (2550-2650

psi) protects the lift pump from excessive pressure.
The valve allows excess oil to return directly to sump
whenever an overload condition occurs. There is no
requirement to remove the pump from the tractor to
replace the relief valve. However, it is not an
adjustable valve, and will require removal if not within
specifications.
Low-pressure oil expelled from the pump mounting

face flows through the wall of the rear axle center
casing, and through tubing to the hydraulic PTO 3
clutch control valve assembly. From the hydraulic
PTO control valve, oil flows to the oil cooler, before
providing pressure lubrication to the transmission
and dual power clutches (where installed).
A relief valve within the steering motor provides

protection for the steering system.
OVERHAUL
Removal
1. Drain oil from the rear axle center casing.
2. Disconnect brake pedal return springs.
3. Remove the right-hand platform.
4. Disconnect the brake actuating rods from the
levers. Refer to Section 33 “Braking Systems”.
5. Disconnect the Dual Power pressure feed tube
(16x4 transmissions) from the hydraulic pump.
6. Remove the brake pedal linkage. Refer to
Section 33 “Braking Systems”.
7. Disconnect all hydraulic connections at the
pump. Cap and plug all exposed openings to
8. Remove the pump retaining bolts and remove
the pump.
35-4
Disassembly
NOTE: When disassembling the pump, lay compo-
nents out in the order of removal to facilitate
re-assembly.
Refer to Figure 4.
1. Remove the pressure relief valve with O-rings

and back-up ring from the pump. The relief valve
is not adjustable and therefore requires
replacement if not operating within specifica-
tions.
2. Remove the transfer tube and O-ring.
3. Unfold tabs and remove the input drive gear nut
(3) and locking washer (4) at the front (lift) pump.
Then remove the input drive gear (2) and key (5)
from the drive link (1). 6
NOTE: Use a soft mallet to loosen the drive gear from
the tapered drive shaft if necessary.
4. Remove the six end-cover retaining bolts and

washers (6), Figure 4.
5
3 4
4
5. Ease the cover (1) forward to clear the locating
dowels (3) and then tilt the cover to clear transfer
tube (2). Lift cover off pump, Figure 5.
35-5
6. At the front pump, remove the drive shaft and
driven gear (16) as an assembly, and collect the
bearing blocks (3), (14). Identify components to
facilitate assembly, Figure 6.
7. Observe the positioning of the seals (12), (13), to
facilitate re-assembly, Figure 6.
CAUTION
An internal snap ring secures the drive shaft to
the driven gear assembly. Damage to the snap
ring or drive shaft is likely to occur if
disassembly is attempted.
6
Hydraulic Lift Pump (Front Pump) -- Exploded View
1. Pump Housing 9. Locking Washer

2. Steering Pump 10. Drive Gear
3. Bearing Block 11. Oil Seal
4. Driven Gear 12. Nylon Back--Up Ring
5. Transfer Tube 13. Seal
6. End Cover 14. Bearing Block
7. Bolts (4 Long, 2 Short) 15. Woodruff Key
8. Nut 16. Drive Shaft and Gear Assembly
35-6
8. Remove the rear (steering) pump assembly (1),
Figure 7, from the pump housing.
9. Remove the gears and bearing blocks.
10. Remove the sandwich plate (7), Figure 7.
11. Identify the positioning of all components
including the nylon back-up rings and seals to
facilitate re-assembly.
7
Steering Pump (Rear Pump) -- Exploded View
1. Pump Body 9. Nylon Back--Up Ring

2. Seal 10. Pump Housing
3. Nylon Backing Strip 11. Seal
4. Bearing Block 12. Nylon Backing Strip
5. Driven Gear 13. Bearing Block
6. Seal 14. Transfer Tube and Snap Ring
7. Sandwich Plate 15. Drive Gear
8. Seal
35-7
parts to dry.
2. Inspect bushings and bearing blocks for wear or
damage. Check for blocked lubrication scrolls in
the bushings. Replace the gears and bearing
blocks as a matched set if required. DO NOT
service separately.
3. Inspect pump gears for wear or damage,
particularly the bearing journals, gear teeth and
side facings.
4. To ensure maximum pump efficiency, the width of
each pair of pump gears must be within 0.005
mm (0.0002 in) of one another, and the journals
within 0.013 mm (0.0005 in).
5. Remove light scoring marks on the gear facing
areas using a sheet of ‘O’ grade wet or dry
abrasive paper and lubrication on a true flat
surface. Polish the area repaired using light
pressure in a rotating motion. Polished journals
will achieve free movement in the body.
6. Inspect the gear track, embedded during the
manufacturing process for the gear teeth, on the
suction side of the pump. The track depth must
not exceed 0.10 mm (0.004 in), or continue
beyond the suction half of the gear aperture.
Replace the pump when gear tracks do not fall
within specification.
7. Burrs found at the edge of the gear track should
be removed with ‘O’ grade emery paper.
8. Inspect the pump cover for damage or cracks,
particularly adjacent to the inlet and outlet ports,
filter connection and pump face. Check internal
passages for blockage.
9. Any component found unserviceable should
necessitate replacing the pump assembly. If in an
emergency, worn components are replaced
individually, note the following points:
• The installation of new bearings will re-center
the gears and prevent the tips of the gear
teeth from bottoming, if continuing to use a
pump body where the track is out of
specifications. Thereby resulting in pump
inefficiency.
• Under working conditions, hydraulic pres-
sure within the pump loads the gears towards
the inlet side of the pump body. Continued
use of worn bearing and gear journals
causes the gears to shift, thus deepening the
gear track in the pump body.
35-8
Assembly
Assembly of the fixed displacement transmission
mounted (tandem gear) type pump follows the
requirements:
1. When replacing the pump dowels, install new

dowels with 2.54 mm (0.10 in) protruding from
the pump housing.
2. Replace all O-rings and seals.
3. Install washers (1) and (5) and O-ring seals (2)
and (4) on the transfer tube (3), Figure 8.
4. Coat all seals and O-rings with petroleum jelly.
5. Lubricate all parts with clean hydraulic oil.
6. Assemble original gears with original bearings
exactly as removed. This step is critical in
maintaining pump efficiency.
8
7. The bearing block (4) in the steering pump body
(2), contains a radius edge (4). Install the radius
edge’ at the bottom of the steering pump body
bore (3), Figure 9.
NOTE: Only one of the two bearing blocks installed
in the steering pump contains a corner radius edge.
Installation of the sharp edged radius block in this
position will prevent correct assembly and cause
damage to the pump.
8. Pack the cavity behind the lips of the front-end

cover input drive shaft seal with high melting
point grease.
9
Bearing Block Installation
1. Relieved Edge
2. Steering Pump Body
3. Radiused Edge
4. Radiused Edge
35-9
9. The end-cover bolts have different lengths.
Ensure to install the correct bolts in the locations
exactly as removed, Figure 10, and tighten to a
torque of 50-62 N⋅m (37-46 ft.-lb.).
10. Install the pressure relief valve and tighten to a
torque of 60-68 N⋅m (44-50 ft.-lb.).
11. Install the input drive gear nut and tighten to a
torque of 50-56 N⋅m (37-41 ft.-lb.). Bend the
washer locking-tab against the pump drive, gear
nut.
12. Keep all ports and lines capped and plugged until
installation of hydraulic connections to prevent
entry of foreign objects and contaminants. 10
End Cover Bolt Location
A. Bolt M10 x 100 mm with Ground Shank
B. Bolt M10 x 100 mm with Dull Black Shank
C. Bolt M10 x 115 mm with Ground Shank
D. Bolt M10 x 115 mm with Dull Black Shank
Installation
The installation of the transmission mounted fixed
displacement (tandem gear) type pump follows the
requirements.
1. To prevent internal and external leakage, and

improve pump efficiency, perform the following
when installing new O-rings and seals:
• Lubricate with clean hydraulic fluid
• Do not allow connections to pinch, or O-rings

to roll and twist when installing.
• Ensure proper positioning.
• Completely seat into grooves.
2. Before installing, fill pump suction port with clean

hydraulic oil and hand rotate the gears.
3. Tighten the pump-to-transmission retaining bolts
to a torque of 57-76 N⋅m (42-56 ft.-lb.).
4. Tighten all hydraulic connections and fittings.
5. Replenish the rear axle center casing oil. Refer
to Section 27 “Mechanical Rear Wheel Drive”.
6. Perform a pressure test of the pump. Refer to
Section 35, Chapter 5 “Adjustments and
Testing”.
7. Operate the brake pedals after assembling, and
check for binding and proper operation. Refer to
Section 33 “Braking System”.
35-10
FIXED DISPLACEMENT ENGINE MOUNTED (SINGLE GEAR) TYPE PUMP

The fixed displacement, engine mounted (single gear)
type pump, located on the left-hand side of the engine,
functions differently depending on the type of pump
installed on the transmission. On tractors fitted with a
(tandem gear) type main pump, the engine mounted
(auxiliary) pump supplies pressurized oil to the priority
valve pack to supplement the remote valve(s) circuit.
On tractors fitted with a (single gear) type main pump,
the engine mounted (steering pump) supplies
pressurized oil to the steering system. A drive gear at
the rear of the camshaft drives the pump.
The pump contains one set of spur type gears
supported by aluminum bearings and steel bushings.
The gears constantly rotate as the engine runs.
A replaceable micron filter screwed onto a threaded

adapter in the pump cover cleans the oil before
entering the pump.
Oil Flow
On entering the pump (B), hydraulic oil fills the spaces
between the teeth of the revolving gears (1). As the
gears continue to rotate, oil trapped between the gear
teeth and pump body flows to the pump outlet port (A)
and discharges into the auxiliary or steering circuit,
Figure 11.
The fixed displacement engine mounted pump

contains a screw-on type filter bowl. After passing
through the filter element and up the center of the 11
membrane, the oil moves rearward, exiting near
upper section.
35-11
OVERHAUL
Removal
1. Thoroughly clean the pump area before removal.
2. Disconnect the hydraulic connections from the
pump. Cap and plug all openings to prevent
contamination.
3. Disconnect the engine crankcase breather
assembly tube and clamp (where installed) from
the pump housing
4. Remove the pump retaining bolts, lock washers,
and then lift the pump from the engine.
12 13
7 11
10
8 9
6
1
2 4
3 5
14
15
20026042
12
35-12
Disassembly
Refer to Figure 12.
1. Mark the external gear housing (7), pump body

(12) and cover (not shown) to facilitate relocating
parts upon installation exactly as removed,
Figure 12.
2. Unscrew and remove the micron filter assembly
from the pump base (13).
3. Remove the retaining ring (1) and large dished
plug (2) from the external gear housing (7).
4. Release the lock washer (4) and remove the
locknut (3), key (5) and external gear (6). Tap the
end of the drive gear shaft to release the drive
gear from the tapered shaft if necessary.
NOTE: Ensure not to damage the threads on the end
of the pump drive shaft, and do not allow the shaft key
to damage the shaft seal.
5. Remove the pump cover retaining bolts (14).

NOTE: If necessary, remove the hydraulic fittings
installed in the pump body to facilitate removal of the
pump cover retaining bolts.
6. Use a soft mallet to separate the external drive

gear housing (7), pump body (12), and pump
base (13).
7. Remove the driven gear (10), drive shaft (15),
bearing block (9), bearing block (11) and seals.
Identify orientation of the components to
facilitate re--assembling.
8. Remove the retaining clip (1) from the end of the
idler gear shaft and remove it from the housing
(2), Figure 13. 1
9. Remove the plug from the end of the idler gear
shaft by giving the housing a sharp tap on a
wooden block.
NOTE: Compressed air administered to the bleed
hole located on the pump--to--engine mounting face
will facilitate removal of the plug.
2
10. Remove the idler gear shaft, idler gear and two
washers. 20026043
13
35-13
parts to dry.
2. Inspect bearing block and bushing for wear and
the bushings. If necessary, replace block
together with gears and do not service
separately.
3. Inspect pump gears for wear or damage. In
particular, inspect the bearing journals, gear
teeth and side facings.
20026044
14
35-14
each pair of pump gears must be within 0.005 A A
mm (0.0002 in) of one another (B), and the
journals within 0.013 mm (0.0005 in) (A),
Figure 15.
5. Remove light scoring marks on the bearing face
area using a sheet of ‘O’ grade emery paper
lubricated with paraffin on a true flat surface. B
Polish the area repaired using light pressure in a
rotating motion. Polished journals will achieve
free movement in the body.
6. Inspect the pump body for a light track cut by the 20026045
gear teeth on the suction side of the pump body.
Using an internal micrometer measure the body 15
at the bearing location, and at the track position
to determine depth. The track should not exceed
0.10 mm (0.004 in) depth, or continue beyond the
suction half of the gear aperture. Replace the
pump when gear tracks do not fall within
specification
9. Inspect the external gear and housing for wear,
damage, cracks, and the idler gear for free
rotation on the shaft.
10. Any component found unserviceable should
necessitate replacing the pump assembly. If in an
emergency, worn components are replaced
individually, note the following points:
11. The installation of new bearings will re-center the
gears and prevent the tips of the gear teeth from
bottoming, if continuing to use a pump body
where the track is out of specifications. Thereby
resulting in pump inefficiency.
12. Under working conditions, hydraulic pressure
within the pump loads the gears towards the inlet
side of the pump body. Continued use of worn
bearing and gear journals causes the gears to
shift, thus deepening the gear track in the pump
body.
35-15
Assembly Installation
Assembly of the fixed displacement engine mounted Installation of the fixed displacement engine
(single gear) pump follows the disassembly mounted (single gear) type pump follows the removal
procedures in reverse with the following require- procedures in reverse with the following require-
ments: ments:
1. Replace all seals and O-rings. 1. Before installing, fill pump suction port with clean
2. Coat all seals with petroleum jelly, and ensure
correct positioning. 2. Insert a new O-ring on the pump.
3. Lubricate all parts with recommended hydraulic 3. Tighten the pump-to-engine retaining bolts to a
oil. torque of 57-76 N⋅m (42-56 ft.-lb.)
4. Assemble original gears with original bearings 4. Tighten the inlet tube retaining bolts to a torque
exactly as removed. This step is critical to of 15-20 N⋅m (133-177 in.-lb.).
maintain pump efficiency.
5. Tighten the outlet tube retaining screws to a
5. Install the bearing block with the recess against torque of 7-10 N⋅m (62-89 in.-lb.)
the gear faces, and the relieved radius edge
6. Install the engine crankcase breather assembly
toward the pump outlet.
tube, and clamp (where installed) on the pump
6. Assemble the bearings with the ‘Y’-shaped housing.
recesses adjacent to the gear faces and the
7. Check the pump pressure output. Refer to
relieved radii facing the outlet side of the body.
Section 35, Chapter 5 “Adjustments and
7. Pack the cavity behind the lips of the front-end Testing”.
point grease.
8. Install the idler gear shaft plug with the slotted
face towards the shaft.
9. Install the pump end-cover retaining bolts and
10. Install the external drive gear with locking tab,
washer and nut. Tighten nut to a torque of 40-45
N⋅m (30-33 ft.-lb.). Ensure to bend the washer
locking-tab against the external drive gear nut.
installation, to prevent entry of foreign objects
and contaminants.
35-16
Chapter 3 - Remote Control Circuit
CONTENTS

Remote Valve Circuit Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remote Control Valve -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Remote Control Valve Coupler -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
35-1

A remote valve circuit installed on the tractor consists
of a remote control valve(s) (5), remote valve supply
line (1), load sensing line (2), auxiliary pump supply
line (if necessary) (3), priority valve pack (4), and a
remote valve return line (6).
The hydraulic lift cylinder receives priority over the

remote valve(s) for oil supply, with surplus oil directed
through the combining valve in the priority valve pack
to the remote valve(s).
A circuit with two or more remote valves requires a

check valve installed at the ‘T’ fitting in the pilot (load
sensing) line for each valve. 1
The rate of flow through the remote valve, controlled

by a restrictor, varies the speed of operation for
attached implements.
The remote valve couplers remain spring-loaded to

the closed position when disconnected from auxiliary
equipment.
35-2
Figure 2 shows the principle components of the
double spool, remote valve assembly, which will
assist in identifying the parts detailed in the oil flow
description that follows.
A single-spool remote valve contains the same

individual components as a double spool less the
second spool.
REMOTE VALVE CIRCUIT OIL FLOW
Neutral Position
Refer to Figure 3.
• A centering spring holds the control valve spool

in neutral with the center land blocking pump
supply Gallery B.
• The control valve spool also isolates Galleries G

and H from pump supply Gallery B, and oil return
Galleries E and F. This traps the hydraulic oil in
both ends of the lift cylinder.
• Galleries C and D connect with the return oil

Galleries E and F, allowing pressure in the load
sensing lines to return to sump.
• The combining valve moves to the left,

compressing the spring, and diverts oil flow from
the pumps, back to the reservoir through the
priority valve pack.
35-3
24
25
26
28 27
2
Double Spool Remote Control Valve
1. Valve Body 15. Detent Regulating Valve Spring

2. Spool 16. Spacer
3. Flow Restrictor 17. Detent Regulating Valve
4. Load Check Valve 18. Detent Housing
5. Flow Restrictor End Plug 19. Shuttle Check Valve
6. Flow Restrictor Control Shaft 20. Flow Control Spring
7. Flow Restrictor Control Knob 21. Flow Control Spool
8. Detent Plunger 22. Priority Check Valve Ball (double spool only)
9. Spool Centering Spring 23. Priority Check Valve Retainer
10. Locknut 24. Spiral Retaining Clip
11. Detent Piston Spring 25. Seals
12. Detent Piston 26. Detent Cap Retaining Ring
13. Detent Valve Spring Adjuster 27. End Cap
14. Detent Balls 28. Seals
35-4
3
Single Remote Control Valve Operation--Neutral
Pump Pressure Oil Exhaust Oil Trapped Oil
1. Flow Control Restrictor 9. Centering Spring 17. Return to Sump*

2. Load Check Valve 10. External Cylinder 18. Auxiliary Pump Supply*
3. Check Valve Spring 11. Valve Body 19. Hydraulic Priority Valve Assembly*
4. Flow Control Knob 12. Control Valve Spool 20. Supply to Remote Valve
5. Detent Regulating Valve 13. Shuttle Check Valve 21. Combining (Sequencing) Valve*
6. Detent Spool 14. Load Sense Line (Pilot Line) 22. Main Pump Supply via Combining
7. Detent Plunger and Spring 15. Flow Control Spring Valve*
8. Detent Balls 16. Flow Control Spool
* Tractors with Fixed Displacement Hydraulic Pump Only
For Tractors Fitted with Variable Displacement CCLS Hydraulic Pump
A = CCLS Pump Supply B = CCLS Pump Load Sensing Line
35-5
Raise Position
Refer to Figure 4.
• With the remote control valve lever in the raise

position, the control valve spool moves forward
and the spring-loaded detent balls engage the
rear grooves in the detent plunger.
• Pump supply Gallery B connects to Galleries G

and D while Galleries H and C connect to return
through Gallery E.
• When initially moving the remote control valve

lever, the pressure in Gallery D equalizes with the
cylinder pressure, or the hydraulic back-pres-
sure, whichever is greater.
• The pressurized oil in Gallery D flows to the

shuttle check valve and through an internal
drilling to the detent regulating valve, flow control
valve spool, and the pilot line (load sensing).
• The pilot line (load sensing) pressure from

Gallery D acts on the end of the combining valve
spool, moving the spool to the right. The return
Gallery in the priority valve pack closes and the
main hydraulic and auxiliary pump pressure oil
flows to the remote control valve inlet port A.
• Pump pressurized oil flows from Gallery A to

Gallery B through the flow control valve spool,
flow control restrictor, and the load check valve.
• The flow control restrictor setting (manually

pre-set with the flow control knob) determines the
volume of oil entering Gallery B and flowing to
Gallery G.
• Exhaust oil from the cylinder Gallery H returns to

the reservoir through Gallery E.
• When the cylinder fully extends, pump supply

pressure increases until the detent regulating
valve opens. Pump pressurized oil moves the
detent spool against the detent spring and
releases the clamping effort on the detent balls at
the end of the control valve spool. The centering
spring now moves the spool back to the neutral
position.
35-6
4
Single Remote Control Valve Operation--Raising
Pump Pressure Oil Exhaust Oil
1. Flow Control Restrictor 9. Centering Spring 17. Return to Sump

2. Load Check Valve 10. External Cylinder 18. Auxiliary Pump Supply
3. Check Valve Spring 11. Valve Body 19. Hydraulic Priority Valve
4. Flow Control Knob 12. Control Valve Spool Assembly
5. Detent Regulating Valve 13. Shuttle Check Valve 20. Supply to Remote Valve
6. Detent Spool 14. Load Sense Line (Pilot Line) 21. Combining (Sequencing) Valve
7. Detent Plunger and Spring 15. Flow Control Spring 22. Main Pump Supply via
8. Detent Balls 16. Flow Control Spool Combining Valve
35-7
Lowering Position
Refer to Figure 5.
• Moving the remote control valve lever to the

lowering position forces the control valve spool
rearwards, allowing the spring loaded detent
balls to engage the front groove in the detent
plunger.
• Gallery B connects to Galleries H and C, and

Gallery G connects to Galleries D and F. This
action reverses the connection to-and-from the
cylinder. Pressurized oil retracts the remote
cylinder in the same manner as described in the
raising sequence.
• The shuttle check valve enables the pilot line to

sense pressure in Gallery C, and directs the flow
of oil to operate the detent regulating valve and
flow control valve spool.
• The flow control restrictor rotates, reducing the

slotted area in which oil flows into Gallery B and
to the control valve and restricting oil flow to
Gallery B. The degree of restriction, causes
supply pressure to increase compared to pilot
line pressure.
• Pressure from the pump supply line, acts on the

right hand end of the combining valve, and the
spool moves against the spring, diverting surplus
oil to sump.
35-8
5
Single Remote Control Valve Operation--Lowering with Slow Flow Control Setting
Pump Pressure Oil Reduced Oil Flow Exhaust Oil

35-9
Cylinder Overload
Refer to Figure 6.
Under normal operating conditions, a detent

regulating-valve protects the remote circuit from
excessive pressure, by returning the control valve
spool to neutral when high pressure arises, or the
cylinder reaches the end of the stroke. If the operator
overrides the detent, protection of the circuit occurs
through the following:
• Excessive cylinder pressure in the pilot line from

Gallery H opens the integral combining valve
relief valve, reducing the pressure acting on the
left-hand end of the valve.
• The combining valve spool moves left and directs

oil flow from the pumps to return, limiting
maximum remote pressure to 192 bar (2750 psi).
35-10
6
Single Remote Control Valve Operation--External Cylinder Overload
Pump Pressure Oil Reduced Oil Flow Exhaust Oil

35-11
Double Remote Valve Oil Flow
Refer to Figure 7.
• Operation of two or more remote valves

simultaneously, is possible irrespective of
cylinder load.
• When two spools operate a light load and heavy

load circuit simultaneously, the oil flowing from
the control valve attempts to flow to the light load
circuit The flow control spool maintains pre-set
flow to the light load circuit.
• The shuttle ball in the load sense line pushes

firmly toward the low pressure circuit, isolating
the line from the remote valve operating under
the lighter load condition.
• Hydraulic oil from pump supply Gallery B flows to

the left side of the flow control valve spool
through the shuttle check valve. Oil flows through
radial holes in the spool at Gallery A to Gallery B.
• When pressure differs greatly between two

operating remote circuits, an excessive amount
of oil flows from the pump supply Gallery B
through the flow control valve, via the restrictor,
to the remote circuit operating at the lower
pressure. This additional flow results in in-
creased pressure generated on the right-hand
end of the flow control spool.
• The flow control spool moves to the left and

compresses the spring, progressively covering
the radial holes in the spool. This restricts oil from
Gallery A to the load check valve, and eliminates
excessive oil flow to the light load circuit, while
maintaining supply line pressure from the heavy
load circuit.
35-12
7
Double Remote Control Valve Operation
Pump Controlled Reduced Exhaust Oil
Pressure Oil Oil Flow Oil Flow

35-13
Oil Flow in Float
Refer to Figure 8.
• The float position allows operation of single

acting cylinders when lowering under light load
conditions.
• With the remote control lever full forward to the

‘float’ position, the control valve spool moves
rearward past the lowering position to allow
engagement of the detent balls with the float
detent plunger groove.
• The control valve spool requires manual

movement to neutral by the operator, as the
shuttle check valve generates no pressure to
release the detent mechanism.
• Galleries E, F, G and H connect to return,

allowing the cylinder to ‘float’ and assume any
position.
• Galleries C and D also connect to Galleries E and

F, allowing only low back pressure on either side
of the shuttle check valve. There is no pressure
in the pilot line, and the pump output returns to
the reservoir through the combining valve.
35-14
8
Single Remote Control Valve Operation--Float
Pump Pressure Oil Exhaust Oil Trapped Oil

35-15
Remote Valve Coupler Oil Flow
Refer to Figure 9.
• The couplers remain spring-loaded to the closed

position when disconnected from auxiliary
equipment.
• With equipment connected and the remote valve

pressurized, oil forces the hose connection
check valve off the seat, while the spring-loaded
probe remains in contact with the face of the
check valve.
• Pressurized oil forces the locking sleeve within

the coupler rearward, applying the locking balls
against the end of the probe, preventing the
probe from moving rearward.
• The probe locks in the forward position, which

holds the connector check valve fully open, even
under low-pressure conditions.
35-16
9
Remote Valve Coupler Operation
A Coupler Disconnected (Not Pressurized) 1. Coupler Assembly

B Coupler Connected (Pressurized) 2. Auxiliary Equipment Hose Connector
3. Hose Connector Check Valve
4. Probe
5. Locking Sleeve
6. Locking Balls
35-17
Remote Valve Control Levers
Two levers operate the remote control valves at the
rear of the tractor. Located at the right-hand side of
3
the operator’s seat, the outer lever (1) controls the
outer valve, and the inner lever (2) controls the inner
valve within the remote housing, Figure 10.
The remote control valve levers operate in four

positions:
• Pull lever back from the neutral position to extend

the cylinder.
• Push the lever forward past neutral to retract the

cylinder. 10
• Push the lever full forward past the retract
position to select the float position.
• Align lever with the symbol on the decal for

neutral.
Symbols on a decal (3), Figure 10, affixed adjacent

to the control levers, identify the extend, neutral,
retract and float positions
In the float position, the cylinder extends and retracts

freely, allowing implements to follow the ground
contour. In addition,
A detent-regulating valve locks the remote control

lever in either the extended or retracted position, and
allows the control lever to spring to the neutral
position when the cylinder reaches the end of the
stroke. Manual positioning of the control lever to
neutral is possible. In the ‘float’ position, the lever will
not return to neutral automatically.
35-18
Remote Valves
Each remote control valve incorporates a flow control
valve and a pair of couplers. The couplers lock and
are self-sealing, but will allow the remote cylinder
hoses to pull free, if the implement becomes
disconnected.
An ‘extended cylinder’ symbol molded into the rubber

dust cap identifies the upper (lift) coupler (2),
Figure 11.
A ‘retracted cylinder’ symbol identifies the lower

(drop) coupler (3), Figure 11.
11
Remote Cylinders NOTE: When topping off the rear axle oil level to the
full mark on the dipstick to accommodate remote
WARNING cylinder implements, a maximum of 59 liters (15.5
Before connecting or disconnecting hydraulic gal) should not be exceeded. Alternatively, installa-
hoses or the remote cylinders, lower the tion of remote control cylinders with a total oil
implement, stop the engine and relieve the capacity of up to 18 liters requires no additional oil
pressure in the circuit by moving the remote provided the tractor operates on level ground.
control levers full forward to the ‘float’ position
and back to neutral. Never work under, or allow To connect a remote cylinder, insert the feed or return
anyone near raised equipment, as it will drop hose through the slit in the appropriate dust cap.
when relieving system pressure. Check hose for correct seating with the coupler, and
for sufficient slack in the hose to allow the
tractor/equipment to turn in either direction.
WARNING
Never work under implements raised by a After connecting a remote cylinder to a remote valve,
hydraulic device, as a sudden loss of pressure, run the engine and toggle the control levers to the
inadvertent control selection, or a ruptured hose ‘float’ position and back to neutral to equalize
may cause the implement to drop, even with the pressure between the valve, hose and coupler.
engine shut down.
Pushing the hose into the coupler and quickly pulling
the hose back will pop it free from the coupler.
IMPORTANT: Before connecting remote cylinder
hoses, stop the engine. Thoroughly, clean the The flow control valve meters the flow of oil to the
connections to prevent oil contamination. Remote remote cylinder and thus controls the rate of
cylinders operate with oil drawn from the tractor response of the cylinder. Turning the flow control
hydraulic system. Therefore, always check and knob counterclockwise increases the rate of flow,
replenish the hydraulic system oil after connecting, and turning the knob clockwise decreases the rate of
and after cycling remote cylinder equipment. flow (4), Figure 11.
Operating the tractor with a low oil level, or with
broken down, or contaminated oil could result in Detent adjusting screws (1) on the remote valves
failure of the rear axle, transmission or hydraulic allow adjusting of the detent mechanism within the
systems. valve, thereby effecting the neutral position,
Figure 11.
35-19
Double-Acting Cylinders
Refer to Figure 12. 4 1
Installation of a double-acting cylinder requires a
feed hose (1) connection from the remote upper
coupler (4) to the piston-end of the cylinder, and a
return hose (2) from the lower coupler (3) to the
rod-end of the cylinder.
Positioning the control lever rearwards to the ‘raise’

position extends a double-acting cylinder.
Positioning the control lever forward to the ‘lower’ 3 2

position retracts a double-acting cylinder.
12
Further movement of the control levers forward
selects ‘float’ which allows the cylinder to extend or
retract freely. This feature assists with equipment
such as scraper blades and loaders.
Single-Actuating Cylinders
Refer to Figure 13.
1
Connect the hose (1) from a single-actuating cylinder
to the upper coupler (2) on the remote control valve.
Positioning the control lever rearward to the ‘raise’

position extends a single-acting cylinder.
Manually return the lever to the neutral position to

stop the cylinder before full extension or allow the
valve to return to neutral automatically when the
cylinder reaches the end of the stroke. 2
Positioning the control lever to the full forward ‘float’ 13
position retracts a single-acting cylinder.
IMPORTANT: Select the ‘float’ position to lower a

single-acting cylinder. The ‘lower’ position operates
the double-acting cylinders.
Continuous Flow Hydraulic Equipment
Connect continuous flow type equipment, e.g. 4 1
hydraulic motors, with the feed hose (2) connected to
the lower coupler (3), and the return hose (1)
connected to the upper coupler (4), of the same
valve.
2
With the remote control lever moved toward the
forward ‘float ‘ position, the motor slows to a halt and
becomes stationary. The motor begins operating
again with the control lever moved out of the ‘float’
position.
3
14
35-20
Observe the following safety precautions: hydraulic oil temperature must not exceed 77_ C
(170_ F).
1. Do not open any by-pass valves in the equipment 5. If high temperature persists under normal
or motor. Use the control valve to control the rate operating conditions, install an oil cooler in the
of flow or speed of the motor. motor return circuit.
2. Do not hold the remote control valve lever to
operate equipment. If the detent will not hold the Operating Several Remote Valves
lever, adjust the detent screw and check the Simultaneously or Remote Valves with
equipment for proper adjustment. Hydraulic Lift Simultaneously
NOTE: Holding the remote control valve lever after When operating two or more remote valves
the cylinder reaches the end of the stroke, causes the simultaneously, or remote valve(s) with the hydraulic
relief valve to open. Extended periods of oil flow lift simultaneously, adjust the remote valve(s) to a
through the relief valve results in a rising of oil partial flow rate. This prevents a full flow circuit from
temperature. receiving excessive oil from circuits with less
pressure.
3. To assure optimum hydraulic cooling and
prevent overheating, operate continuous flow
equipment at the highest flow setting and lowest Bleeding Air from Remote Cylinders
engine speed that produces the required It is necessary to bleed trapped air from a new
equipment performance and speed. cylinder, or from a cylinder that remained ‘out of
service’ for a period of time, or after disconnecting
4. Use a temperature gauge if possible, installed in and reconnecting hoses. After connecting hoses to
the remote circuit when operating hydraulic the remote control valve couplers, position the
motors for continuous operation. If over-heating cylinder requiring bleeding with the hoses upward.
occurs, stop the hydraulic motor and allow Extend and retract the cylinder at least seven times
cooling. Position the flow control setting to using the control lever.
maximum with engine speed at a minimum,
appropriate to equipment performance. The Check the rear axle oil level before and after remote
recommended operating temperature of 57-63_ cylinder operation.
C (134-146_ F) should be obtained. The
35-21
REMOTE CONTROL VALVE - OVERHAUL
Removal
1. Disconnect the control linkage (2), and hydraulic
connections (1, 3 and 4).
15
Disassembly
1. Separate the control valve (1) from the coupler
assembly (2).
16
2. Remove the end cap (3) and O-ring (4).
3. Remove the flow control spool (1) and spring (2)
from rear of housing.
17
35-22
4. Remove the flow control knob (2). Push the
restrictor end-plug (3) as far as possible into
housing and remove retaining clip (1).
NOTE: The plug only pushes into the housing by
approximately 1 mm (0.040 in), which is sufficient to
allow removal of the retaining clip.
18
5. Remove the flow control restrictor and compo-
nents as shown in Figure 19. Discard O-rings
and seals.
19
Flow Control Restrictor
1. Spiral Circlip 7. Load Check Valve

2. Knob 8. Flow Restrictor
3. O-ring 9. Restrictor End Plug
4. Back--up Ring 10. O-ring
5. Shaft 11. Back-up Ring
6. Spring
35-23
6. Remove fixing screws (4) and pull detent
assembly (1) from the end of the flow control
spool (3) and discard O-ring (2).
20
7. Using a suitable press, push in end-cap (2)
sufficiently into detent housing (12) to accommo-
date removal of snap ring (3). Press and release
the end-cap to allow spring within the detent
housing to eject end-cap.
21
Detent Mechanism
1. Lock Nut 10. Detent Balls

2. End Cap 11. Washer
3. Snap Ring 12. Detent Housing
4. Spring 13. Valve
5. Detent Spool 14. O-ring
6. Back-up Ring 15. Back-up Ring
7. O-ring 16. Rod
8. O-ring 17. Spring
9. Back-up Ring 18. Adjusting Screw
35-24
8. Disassemble detent assembly and detent
regulating valve components as shown in
Figure 22.
NOTE: Ensure to collect all nine detent balls (10),
Figure 22.
22
Detent Mechanism
1. Lock Nut 10. Detent Balls

2. End Cap 11. Washer
3. Snap Ring 12. Detent Housing
4. Spring 13. Valve
5. Detent Spool 14. O-ring
6. Back-up Ring 15. Back-up Ring
7. O-ring 16. Rod
8. O-ring 17. Spring
9. Back-up Ring 18. Adjusting Screw
35-25
9. Compress the centering spring (5) and remove
detent plunger (3) from shaft (2), Figure 23.
10. To prevent damage to the housing from the
exposed end of the main spool (7), remove the
spool from the opposite end of the housing.
Retain washer (4). Remove retainer (1) and (6).
23
Centering Spring Assembly
1. Retainer 5. Spring
2. Shaft 6. Retainer
3. Detent Plunger 7. Main Spool
4. Washer
11. Remove the retaining clip and shuttle check

valve (1). Remove and discard O-rings and
back-up rings (2, 3 and 5). Use a suitable tool (4)
to assist removing the valve, Figure 24.
24
35-26
12. Remove the priority check valve (2), ball (1) and
discard O-rings (3), Figure 25.
25
Inspection
parts to dry.
2. Inspect all components for obvious damage,
excessive wear or distorted spools and valves.
Replace defective components.
35-27
NOTE: The main spool, flow control spool and restrictor match the valve body and are not available separately.
24
25
26
28
27
26
Double Spool Remote Control Valve
1. Valve Body 15. Detent Regulating Valve Spring

2. Spool 16. Spacer
3. Flow Restrictor 17. Detent Regulating Valve
4. Load Check Valve 18. Detent Housing
5. Flow Restrictor End Plug 19. Shuttle Check Valve
6. Flow Restrictor Control Shaft 20. Flow Control Spring
7. Flow Restrictor Control Knob 21. Flow Control Spool
8. Detent Plunger 22. Priority Check Valve Ball (double spool only)
9. Spool Centering Spring 23. Priority Check Valve Retainer
10. Locknut 24. Spiral Retaining Clip
11. Detent Piston Spring 25. Seals
12. Detent Piston 26. Detent Cap Retaining Ring
13. Detent Valve Spring Adjuster 27. End Cap
14. Detent Balls 28. Seals
35-28
Assembly
Assembly of the remote valve(s) follows the
disassembly procedures in reverse, with the
1. Replace all O-rings and back-up rings.

2. Reassemble using Figure 27 for guidance of
component location.
3. Install housing O-rings as follows:
• Position O-ring (1) into the detent valve
channel in the housing.
27
• Install the spool (2) from the opposite end of
the housing with O-ring (1) as shown in
Figure 28.
4. Apply thread Lock to the threads of the detent
shaft.
5. Assemble centering spring, and screw shaft onto
main spool. Tighten to a maximum torque of 7
N⋅m (60 in.-lb.).
6. Reconnect the control valve to the coupler
assembly with the O-ring seal between the
coupler and valve. Tighten to a torque of 15-20
N⋅m (133-177 in.-lb.).
28
Installation 3. Replenish hydraulic oil and check level in the rear

Installation of the remote valve(s) follows the axle casing.
4. Operate the remote valve(s) and check valve and
requirements:
connections for leakage.
1. Install the remote control valve on the tractor and 5. Purge air from hydraulic oil following the
tighten retaining bolts to a torque of 27-*35 N⋅m procedures in “Bleed Air From Remote Cylinder”
(240-312 in.-lb.). in this Chapter.
2. Reconnect the hydraulic connections and control
linkage.
35-29
REMOTE CONTROL VALVE COUPLER -

OVERHAUL
It is not necessary to remove the remote control valve
assembly from the tractor to overhaul the couplers.
Disassembly
1. Using a suitable spanner wrench, or Tool No.
FNH00095, or a prefabricated tool as shown in
Figure 29, unscrew coupling as follows:
• Fabricate the tool using a 30 mm socket (1)
welded inside of a sleeve (2), with three 6 mm
screws 120_ around the circumference of the
29
sleeve.
Tool for Removing Coupler
• Place the three locking screws into the round 1. 30 mm Socket (welded inside item 2
holes on the outer diameter of the coupler. 2. Sleeve
Use a standard wrench to unscrew the
3. Hardened Locking Screw (3 off) made from 6 mm
coupler. Bolts
35-30
2. Disassemble the coupling as shown in Fig-
ure 30.
30
Remote Valve Coupler
1. O-ring 12. Retaining Ring

2. Adaptor 13. Coupler Housing
3. Sleeve Assembly 14. Locking Body
4. Front Sealing Ring 15. Back-up Ring
5. O-ring 16. O-ring
6. Probe Assembly 17. Spring
7. Spring 18. Locking Sleeve
8. Washer 19. Retaining Ring
9. O-ring 20. Back-up Ring
10. Back-up Ring 21. O-ring
11. Locking Balls
35-31
3. Remove and discard O-rings (3) and slipper
seals (2) from inside the coupler housing (1),
Figure 31.
31
Inspection
parts to dry.
2. Inspect all components for wear or damage.
Replace parts as necessary.
Assembly
Assemble the coupler using the disassembly
ments:
1. Lubricate new O-ring seals with clean hydraulic

fluid and insert into the coupler housing grooves.
2. Shape the slipper seals (1) as in Figure 32 and
insert inside of O-ring seals.
3. Lightly oil the coupler and install into housing.
NOTE: The coupler engages and slightly expands
the slipper seal upon insertion.
32
4. Tighten the sleeve to a torque of 81 N⋅m (60
ft.-lb.).
5. Perform a pressure test of remote valve(s). Refer
to Chapter 5 “Adjustments and Testing”.
35-32
CONTENTS

Oil Cooler -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Pressure Regulating Valve -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Lift Cover -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Priority Valve Pack -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic Lift Cylinder Assembly -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
35-1
OIL COOLER – OVERHAUL PRESSURE REGULATING VALVE -

OVERHAUL
Removal
1. Remove the air pre-cleaner, release the latches, Removal
raise and support the front hood panel. 1. Refer to Section 31 “Power Take-Off” for removal
2. Gently tap the radiator grill upwards and remove of the hydraulic PTO and control valve assembly.
from tractor.
3. Unscrew the retaining bolt and remove horn. Inspection
4. Remove the clamps and disconnect the parts to dry.
hydraulic oil connections to the oil cooler
assembly. Cap and plug all exposed connections 2. Inspect the spool and locating bores for wear,
to prevent contamination. burrs, or scratches. Remove minor burrs or
scratches using a fine abrasive.
5. Remove retaining ‘eye’ bolts and brackets.
Remove oil cooler. 3. Inspect the valve spring for damage.
4. Inspect oil passages for blockage.
Inspection 5. Check that the spool moves freely within the
1. Wash the external areas of the oil cooler bore.
assembly to remove dirt and foreign matter.
Thoroughly clean the fin area. 6. Replace all O-rings and seals.
2. Inspect the fins for damage. Straighten any bent

fins. Installation
Refer to Section 31 “Power Take-Off” for assembly of
3. Inspect hoses and connections for damage and the hydraulic PTO assembly.
replace parts as necessary.
1. Perform pressure test of the low-pressure and
Installation lubrication circuits. Refer to Section 35 “Adjust-
Installation of the oil cooler assembly follows the ments and Testing”.
requirements:
1. Check the hydraulic oil level and replenish as

necessary.
2. Operate the tractor and check the oil cooler
assembly for leaks.
35-2
35-3
35-4
Refer to Figures 1 and 2.
A = High Pressure Oil 183 bar (2650 psi) 1. Transmission Mounted Tandem Gear Pump
B = Steering Pressure up to 2. Transmission 8 x 2
2WD -- 145 bar (2100 psi) 3. 4WD Clutch
4WD -- 172 bar (2500 psi)
C = Low Pressure Oil 15.2 -- 17.9 bar (220 -- 260 psi) 5. Lubrication Relief Valve
D = Lubrication Oil 5.0 -- 8.5 bar (73 -- 123 psi) 6. PTO Control Valve -- Engaged
E = Suction / Return to Sump 7. PTO Clutch Assembly -- Engaged
35-5
HYDRAULIC LIFT COVER - OVERHAUL
Removal
1. Place lift arms in the lowest position.
2. Remove the cotter pin and clevis pin from both lift
arms. Remove left and right-hand lift rods.
3. Remove the top link and disconnect the lift
linkage.
4. Remove the clips and clevis pin securing the
draft control main spring yoke to the rocker and
swing the rocker away from the yoke.
5. Disconnect the control levers from the remote
valve(s) by removing cotter pins.
6. Disconnect and remove the remote valve(s),
support bracket and tubing.
7. Remove the oil cooler feed tube in front of the
hydraulic lift cover.
1
8. Disconnect the remote feed (2), pilot line (3) and
auxiliary feed (4) tubing from the priority valve 4
pack (1). Plug and cap all exposed ports and
connections.
9. Remove the retaining bolt and support bracket
for the rear transmission dipstick.
2
10. Remove seat retaining bolts and seat assembly.
3
NOTE: If overhauling or removing the lift cylinder
loosen the lift cylinder retaining bolts before 20026046
removing the lift cover. Do not remove the lift cylinder
bolts completely. 3
11. Clean the lift cover before removing to prevent

contamination.
12. Remove the retaining bolts, and lift the cover
clear of the rear axle center casing. Support the
cover with the internal linkage facing upward. DO
NOT let the assembly rest on any of the controls.
35-6
Disassembly
4
NOTE: Except for the removal of the selector arm,
which requires removal of the lift cylinder control rod,
removal of the internal linkage to the hydraulic lift 1
cover will not require removal of the lift cylinder, cross
shaft or lift arms.
1. Remove the cotter pin, clevis pin (1) and the

turnbuckle (4) of the control valve (3). Separate
from the actuating lever (2), Figure 4. 3
2. Remove the lift cylinder control rod to facilitate
removal of the selector arm. 20026047
2
4
3. Remove split pin, washers, and selector arm (4)
from the control rod and roller assembly, link (2), 6
Figure 5. 5
4. Remove the retaining clip and actuating lever (5), 1
Figure 5, from the position control lever shaft.
5. Slide the actuating lever (5) and control rod and
roller assembly (3) off the support pins. Remove
the retaining clip and separate the lever from the
control rod, Figure 5.
6. Disconnect the selector arm tension spring.
20026048 4 3 2
35-7
1
10
8
2
7
5 3
4
20026049
6
7. Remove the retaining clip and position control NOTE: To facilitate removal of the selector link and
link (10) from the intermediate link (3), Figure 6. intermediate link assemblies, turn the draft control
plunger.
8. Remove the retaining clip and selector link (2)
from the draft control linkage, Figure 6.
11. Remove the retaining nut and eccentric shaft (1),
9. Remove the draft control plunger centralizing Figure 6.
bolt and selector link tension spring bracket.
12. Remove the position control link (10) with spacer,
10. Remove clips and intermediate link (3) from the Figure 6.
selector link (2), Figure 6.
35-8
Refer to Figure 7.
8
WARNING 1
Beware of internal spring pressure when 7
removing the hydraulic lift control lever,
retaining nut and washer.
13. Remove the lift position control lever retaining

nut (6) and washer (4). 2
14. Remove the control lever (8) and friction disc (3).
15. Remove quadrant retaining bolts (2) and rotate 6
the quadrant assembly (7) to disengage the draft
control lever (1).
16. Remove the lift position control lever shaft, spring 3
and washers from the top cover.
17. Knock out the two pins retaining the selector 4
lever handle to the selector arm shaft and
remove the handle. 5
20026050
18. Remove the lift arms by bending the lock tabs
back, and removing the retaining bolts. 7
19. Remove dust seals from cross-shaft bores.

20. Support the ram arm and drive the cross-shaft
out with a soft hammer. Remove the ram arm and
bushings from the shaft.
21. Remove the remaining two bushings on the
opposite side of the cover.
22. If required, remove the draft control mainspring
by unscrewing the yoke, loosening the set-screw
and removing the large hexagonal nut.
23. Remove the lift cover breather cap.

parts to dry.
2. Inspect all linkage for excessive wear, corrosion,
distortion, burrs or other visible damage.
Remove minor burrs with a fine abrasive.
Replace any defective components
3. Check all linkage for freedom of movement and
smooth operation.
4. Inspect springs for breaks and deformity.
35-9
Assembly 14. Align the spline on the ram arm, and lift arms with
Assembly of the lift cover and components follows the corresponding spline on the cross-shaft.
the disassembly procedures in reverse with the
15. Install washers, locking tabs and bolts to both
ends of the cross-shaft. Tighten one bolt to a
torque of 27-41 N⋅m (240-360 in.-lb.) and secure
1. Replace all O-rings, gaskets and seals. lock tab. Tighten the opposite bolt until lift arms
2. Replace the draft control plunger yoke dust seal. fall slowly under own weight. Secure the lock tab.
3. Tighten the yoke retaining nut set-screw to a NOTE: Do not over tighten lift arm retaining bolts, as
torque of 27-34 N⋅m (240-300 in.-lb.). damage to the cross shaft seals will occur.
4. Lubricate the connecting rod, selector linkage,
16. After assembling, check for a pull of 45-71 N
hydraulic lift cross-shaft bushings, draft control
(20-30 lb) at the lift control lever handle, through
spring and plunger.
an arc of 100-125 mm (4-5 in) around the
5. Push the inner end of the lift control lever shaft quadrant periphery as measured from the
outward to compress the internal spring, for bottom stop. If necessary, adjust the lift position
engagement of the control lever on the flats at the control lever retaining-nut.
outer end of the shaft.
17. Check adjustments of the draft control main
6. Tighten the quadrant assembly-to-lift cover spring and hydraulic control linkage setting.
retaining bolts to a torque of 68 N⋅m (50 ft.-lb.). Refer to Section 35 Chapter 5 “Adjustments and
Testing”.
7. Tighten the lift control lever to a torque of 12 N⋅m
(106 in.-lb.). 18. before installing the hydraulic top cover, apply a
thin bead of a suitable gasket sealer to both sides
8. Centralize the control rod roller on the selector
of the cover gasket. The bead must continue
link.
around the entire face of the gasket to a
9. Tighten the control rod turnbuckle to a torque of thickness of 1 mm (1/32 in).
34 N⋅m (301 in.-lb.).
19. Install lift cover assembly retaining bolts and
10. Tighten the selector lever adjustable rod to a tighten to a torque of 136-170 N⋅m (100-125
torque of 12 N⋅m (106 in.-lb.). ft.-lb.).
11. Tighten the Position Control adjusting screw NOTE: Ensure to install various external brackets to
locknut to a torque of 24 N⋅m (212 in.-lb.). top cover retaining bolts exactly as removed, before
applying torque
12. Tighten the draft control nut set screw to a torque
of 30 N⋅m (266 in.-lb.).
20. Manually raise lift arms (engine not running) and
13. Tighten the control valve turnbuckle locknut to a check that arms fall slowly under weight.
torque of 14 N⋅m (124 in.-lb.). Recheck torque applied to lift arm retaining bolts
when arms fail to perform as specified.
35-10
PRIORITY VALVE PACK – OVERHAUL

Removal
1. Lower the hydraulic lift arms completely. 5
1
2. Disconnect the remote feed (2), pilot line (3) and
auxiliary feed (4) tubing from the priority valve 4
pack (1). Plug and cap all exposed ports and
connections.
3. Remove the retaining bolts (5) and remove
priority valve pack, Figure 8.
2
3
20026046
Disassembly
8
WARNING
Be aware of internal spring pressures when
disassembling valves.
NOTE: Identify the various components, component

locations, and order of removal to facilitate
re-assembling the valves.
NOTE: Remove and discard O-rings in the

counter-bore of the oil passages.
Lift Circuit Check Valve

1. Remove plug.
2. Remove the O-ring (6) cage (5), spacer (4),
spring (3), ball (2), O-ring and seat (1) from the
housing (7).
35-11
Flow Control Valve
5 12
1. Remove the plug (1) from the priority valve pack
(14). Discard the O-ring. 4
1
2. Remove the spring (4).
3. Remove the spool (5). 11
Unload Valve 3
8
1. Remove the plug (3) from the priority valve pack
(14). Discard O-ring.
7 2 9 10
6
3. Remove the spool (8).
Combining Valve 10
1. Remove the auxiliary pump fitting (where
installed) or the plug (6) (less pump fitting).
Discard the O-ring.
3. Remove the spool (10).
NOTE: The internal relief valve (2), Figure 10,
installed within the combining valve, protects the
auxiliary pump circuit from excessive pressure. It
requires no adjustment.
Auxiliary Pump Circuit Check Valve
1. Remove stop, ball (12) and spring (13).
NOTE: The auxiliary pump circuit check-valve and
the combining valve function together.
Priority Valve Pack Restrictor
1. Unscrew and remove restrictor (11). Discard the
O-ring.
Inspection
parts to dry.
2. Inspect the valve bores, plugs and caps for
damage or burrs. Remove minor burrs or
scratches with a fine abrasive. Any heavy scoring
of the bores necessitates replacement of the
priority valve pack.
3. Inspect the valve springs for wear, damage or
deformity.
4. Inspect oil passages and ports for obstructions.
5. Check that spools move freely within the valves.
7. Inspect all linkage for excessive wear, corrosion,
distortion, burrs or other visible damage.
Remove minor burrs with a fine abrasive.
Replace any defective components.
8. Check all linkage for freedom of movement and
smooth operation.
35-12
Assembly
IMPORTANT: Install spools into valves using gentle
pressure and rotation. Excessive force will damage
the valves
1. Coat all O-rings with petroleum jelly. Check that
O-rings seat properly (where installed).
Lift Circuit Check Valve

1. Install the O-ring and seat (1), ball (2), spring (3),
spacer (4), cage (5), and O-ring (6) into the
housing (7).
2. Install plug.
11
Flow Control Valve
1. Slide the spool into the flow control valve with the
‘four land’ section headfirst.
2. Insert the spring in the valve front.
3. Screw in the rear plug by one thread.
4. Install the front hexagon cap completely and
tighten.
5. Install the rear plug completely and tighten to a
Unload Valve
1. Insert the unload valve spool with the small end
headfirst.
2. Insert the spring into the valve front.
3. Install the front plug and tighten to a torque of
23-48 N⋅m (204-420 in.-lb.).
Combining Valve
1. Insert the combining valve spool with the relief
valve headfirst.
2. Insert the spring into the valve front.
3. Install the end cap and tighten to a torque of 27
N⋅m (240 in.-lb.).
Check Valve (auxiliary pump circuit)

1. Insert the ball, then the spring, and wire stop into
the rear of the check valve.
2. Install the plug and tighten.
35-13
Installation cylinder. Screw on the Special Nut also included
Installation of the priority valve pack follows the with Tool No. FNH02191 to the rear of the guide
removal procedures in reverse with the following until the taper on the nut fits squarely in the rear
requirements: end of the bushing.
9. Steadily turn the tool handles to withdraw the
1. Tighten the priority valve pack to lift cover bushing.
retaining bolts to a torque of 57-76 N⋅m (42-56
ft.-lb.). 10. Alternatively, use Bushing Installer/Removal
Tool No. FNH02191 to remove the control valve
2. Perform operational check of the hydraulic bushing.
system.
11. Use a soft metal rod to force out the lift piston.
3. Check valves and connections for leaks.
4. Replenish hydraulic oil in rear axle casing. Inspection and Repair
HYDRAULIC LIFT CYLINDER ASSEMBLY – 1. Clean all components in a suitable solvent. Allow
OVERHAUL parts to dry.
2. Inspect the top surface of the cylinder and the
Removal mating face on the lift cover, for burrs and scores.
1. Remove the lever and remove turnbuckle. 3. Inspect the valves, bores, and plugs for damage
or burrs. Remove minor burrs or scratches with
2. Remove the retaining bolts securing the lift
a fine abrasive. Any heavy scoring of the bores
cylinder assembly to the lift cover. Move the lift
necessitates replacement of the lift cylinder
arms to the raised position and remove the
assembly.
cylinder by lifting off the dowels.
4. Inspect the valve springs for wear or damage.
Disassembly 5. Inspect oil passages and ports for obstructions.
Refer to Figure 12.
6. Check that spools move freely within the valves.
Ensure the spring loaded pin moves freely within
1. Remove the lift cylinder safety valve. Discard the the control valve spool. Inspect pin for damage.
seal.
2. Discard all the O-rings installed in the counter-
bores of the oil passages.
Assembly
3. Remove the retaining bolt, and the control valve
1. Select a control valve bushing with the same
rear cover, spring and valve.
color marking as the one adjacent to the control
4. Compress the control valve spring to slide the valve bore. Refer to section 35 “Specifications”.
valve face off the plate.
2. Use Bushing Installer/Removal Tool No.
NOTE: The control valve spool incorporates a FNH02191 with Adapter Tool No. FNH10090
spring-loaded pin, which requires no adjustment. (where needed) to install a new bushing in the lift
cylinder
5. Remove the drop restrictor valve. Discard the
3. Lubricate the bushing and steadily turn the
O-ring. Remove the oil baffle. Remove the
handles to pull the bushing into the bore until the
retaining ring and extract the spring and spacer.
front face of the bushing contacts the inner face
6. Remove the retaining bolts and control valve of the guide.
front plate. Discard O-ring.
4. Draw the bushing through the bore to protrude
7. Remove the drop poppet valve and spring. 2.0 mm (0.08 in) beyond the front face of the lift
cylinder. Remove the special nut and tool.
8. Attach the short threaded end of the guide
included in the Bushing Installer/Removal Tool 5. Alternatively, use the Bushing Installer/Removal
No. FNH02191 and pass through the control Tool No. FNH02191 to install the control valve
valve bushing from the front end of the lift bushing.
35-14
6. If replacing the control valve spool, select the 12. Install a new O-ring, and screw the drop restrictor
largest spool that will rotate 360_ for the full valve assembly into the cylinder.
length of the bushing, smoothly, and with no
13. Install the lift cylinder safety valve and tighten to
binding. Use only light lubrication and insert
a torque of 102-122 N⋅m (75-90 ft.-lb.).
spool at both ends when checking. Refer to
Section 35 “Specifications” for valve spool sizes. NOTE: Install the O-ring near the closed end and the
backup seal near the open end of the piston.
NOTE: Color coding serves only as a guide for
Lubricate the O-ring and seal before installing.
matching the correct spool with the correct bushing.
It may be necessary to lap a slightly oversized spool
with metal polish to fit the bushing.
Installation
7. Install the control valve spring onto the control 1. Install new O-rings in the counter bores of the lift
valve spool. Compress the spring long enough to cylinder oil passages.
position the spool within the rear cover plate. 2. Check ring dowels for correct installation.
8. Lubricate the parts with clean hydraulic oil and 3. Insert the forward end of the lift piston connecting
insert the spool into the bushing. Tighten the rear rod into the piston and position the lift cylinder on
cover retaining-bolt to a torque of 43 N⋅m (32 the dowels.
ft.-lb.).
4. Install the lift cylinder to lift cover retaining bolts
9. Insert the drop poppet valve, tapered end first, and tighten to a torque of 224-271 N⋅m (165-200
into the bore and install the spring. ft.-lb.).
10. Install the front cover plate while ensuring the 5. Install the turnbuckle assembly and connect the
drop poppet valve spring seats correctly. Tighten rear end to the actuating lever. Install clevis pin
the retaining bolts to 43 N⋅m (32 ft.-lb.). and cotter pin.
11. Insert the spacer, spring and drop restrictor valve 6. Perform the Draft and Position Control adjust-
into the housing. Attach the retaining ring and oil ments. Refer to Section 35 “Adjustments and
baffle. Testing”.
35-15
12
Hydraulic Lift Cylinder -- Exploded View
1. Piston 9. Seal
2. O-rings 10. Control Valve Bush
3. Ring Dowels 11. Diffuser
4. Ball 12. O-ring
5. Spring 13. Exhaust Valve
6. Plug 14. ASC Valve Spool
7. O-ring 15. Control Valve
8. Safety Valve
35-16
Chapter 5 - Adjustments and Testing
CONTENTS

Draft Control Main Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Draft Control Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Position Control Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remote Control Valve External Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
35-1
DRAFT CONTROL MAIN SPRING

ADJUSTMENT 1
NOTE: Check the draft control main spring before
performing all other Draft or Position Control
adjustments.
1. Lower the lift arms completely.

2. Place the selector lever in Position Control (1)
3. Place the lift control lever at the bottom of the
quadrant (2), Figure 1.
1
Refer to Figure 2.
4
4. Unscrew the yoke (1) to remove pre-load on the
main spring (2).
5. Loosen the set-screw (3), and turn the retainer 3
nut (4) counterclockwise to create free-play in the
5
main spring, then turn clockwise until eliminating
all free-play.
6. Tighten the retainer nut set screw to a torque of
27-34 N⋅m (240-300 in.-lb.).
1 2
7. Screw the yoke onto the plunger (5) until
eliminating all free-play, and align the hole in the
yoke horizontally. 2
DRAFT CONTROL LINKAGE ADJUSTMENT
NOTE: Check adjustments for the Draft Control
linkage before adjusting the linkage in the Position
Control system.
1. Complete the Draft Control main spring
adjustment.
Refer to Figure 3.
2. Align the upper edge of the lift control lever (1)

with the draft control setting notch on the
quadrant (7).
3. Place the draft control lever in the seventh draft
detent on the quadrant (9).
4. Loosen the draft control quadrant retaining bolts (5) .
35-2
Refer to Figure 4.
5. Move the quadrant until the bottom of the control

rod roller (1) measures 49.5 mm (1.95 in) above 4
the lift cover surface. Use Set Gauge Tool No. 1
FNH01261 to check the dimension (3). After
obtaining desired measurement, tighten the
retaining bolts to a torque of 68 N⋅ ⋅m (50 ft.-lb.).
6. Remove the control valve front plate by removing

retaining bolts.
NOTE: Do not let the drop poppet valve and spring 3
drop from the lift cylinder housing.
2
7. Loosen the locknut and adjust the turnbuckle
until the spring-loaded pin at the front of the
control valve projects 4.83 mm (0.19 in) beyond
the control valve bushing. Use Set Gauge Tool
No. FNH01261 to check the dimension. After
obtaining the desired measurement, tighten the 20026051
turnbuckle To a torque of 14 N⋅m (124 in.-lb.).
4
POSITION CONTROL LINKAGE

ADJUSTMENT
1. Lower the lift arms completely.
2. Align the upper edge of the lift control lever with
the Position Control setting notch on the
quadrant.
3. Place the draft control lever in the Position
Control detent on the quadrant.
4. Check the position of the control rod and roller
assembly, from the top cover mounting face
using Gauge Tool No. FT 8527. The control rod
roller must fall within 1 mm of the gauge
dimension, which is 0.76 mm (0.03 in) below the
lift cover surface. Tighten the locknut.
5. Replace the control valve front plate, 43 N⋅m (34
ft.-lb.).
6. Loosen the locknut and rotate the eccentric shaft
until the spring-loaded pin at the front of the
control valve projects 4.83 mm (0/19 in beyond
the control valve bushing. Tighten the locknut.
Replace the control valve front plate and tighten the
retaining bolts.
35-3
REMOTE CONTROL VALVE EXTERNAL PRESSURE TESTING

LINKAGE ADJUSTMENT The following test procedures confirm the efficiency
NOTE: It is not a requirement to remove the hydraulic and output of the fixed displacement transmission
lift cover for adjustment of the remote valve external mounted (tandem gear) and auxiliary engine
linkage. mounted pumps. The pressure and flow values listed
throughout this chapter, represent the minimum
values acceptable before overhaul becomes neces-
1. Place the remote control valves in the neutral
sary. The values include adjustments for system
position. The distance from the center of the rod
back-pressure.
end hole to the valve body for neutral must be
38.1 mm (1.5 in). If the hydraulic lift, remote valve(s), hydraulic PTO,
2. Remove the trunnion lock nut at the inner end of steering or other hydraulic component does not
the actuating rod. operate correctly after verifying pump efficiency,
refer to the appropriate section which describes the
3. Remove the split pin and washer. Separate the fault finding, overhaul and testing of these
trunnion from the actuator. components.
4. Turn the trunnion to adjust the actuating rod-end
until the control valve handle assumes a vertical
position within 2_. Check after reconnecting
trunnion, and with the valve spool still in the
neutral position.
5. Install the washer and split pin. Tighten the
trunnion locknut.
35-4
Main Hydraulic Pump Flow and Pressure Test
1. Remove plug (1) from the pump outlet port,
Figure 5.
2. Install adapter into the pump outlet port.
Adapter
• Adapter Part No. 81862770
• O-ring Part No. 83999938
3. Attach Test Hose Tool No. FNH00093 and Flow

Meter Tool No. FNH02755 to the pump outlet port 5
and the adapter.
4. Connect a Test Hose Tool No. FNH00093 from
the flow meter return to a remote valve raise port.
5. Move remote valve control lever to the ‘float’
position.
6. Open the load valve on the flow meter
completely.
7. Start engine and set speed to 2100 rev/min.
8. Gradually close the load valve until obtaining a
pressure reading of 137 bar (2000 psi) on the
flow meter gauge.
9. Run the tractor until the hydraulic oil reaches a
normal operating temperature of 57-63_ C
(135-146_ F). Do not allow oil to exceed a
maximum temperature of 77_ C (170_ F).
10. Continue to close the load valve on the flow
meter until the relief valve begins to crack and
pressure no longer increases, as observed on
the flow meter gauge. The pressure must be
176-183 bar (2550-2650) psi, and remain
constant within 10% of the specified pressure
until the relief fully opens, and pressure reduces
to zero. Do not allow oil to exceed the maximum
pressure as damage to the pump may occur.
Remove and replace the pump relief valve if not
within specifications and recheck system.
11. If the relief valve operates correctly, open the
load valve on the flow meter until obtaining a
pressure of 166 bar (2400 psi), and record the
pump flow.
12. The minimum flow rate on a new pump must be
35 liters/min (9.3 gal/min), and on a used pump
31 liters/min (8.4 gal/min). Overhaul the pump if
not within specifications and recheck.
35-5
Alternate Main Hydraulic Pump Pressure Test
If necessary, connect Pressure Gauge (0-5000 psi)
Tool No. FNH02028 in place of the flow meter to
check the maximum pump pressure.
Alternatively, in the absence of an auxiliary engine

mounted pump, connect the pressure gauge directly
into a remote valve. Operation of the remote valve
will accurately display pump pressure.
Steering Pump Flow Test
1. Disconnect the steering pump feed (1) and return
(2) tubes, Figure 6.
35-6
2. Connect Flow Meter FNH02755. Refer to
Figure 7.
NOTE: The flow meter must be capable of
withstanding back-pressure of 21 bar (300 psi).
NOTE: If using hoses of a different size with the flow

meter, use an adapter with a female thread size of
13/16 in – 16 ORFS for installation into the pump inlet
and outlet ports
3. Open flow meter load valve completely.

IMPORTANT: Damage to the steering pump will
occur if the flow meter load valve remains closed.
7
Installation of Flowmeter for
4. Start engine and set engine speed to 2100
Steering Pump Flow Test
rev/min.
1. Flowmeter Load Valve
5. Gradually close the load valve until obtaining a 2. Return Hose from Flowmeter
pressure of 137 bar (2000 psi) on the flow meter 3. Adaptors 4FT.859
pressure gauge. DO NOT increase the pump 4. Inlet Hose to Flowmeter
pressure beyond this value.
6. Observe the pump flow. Overhaul the steering
pump for values less then 31 liters/min (8.2
gal/min).
Low Pressure, Lubrication and Cooling Circuit

Test
Following the steering pump check, perform a
pressure test on the lubrication and cooling circuit.
Low Pressure Circuit Test

1. Connect 0-41 bar (0-600 psi) Pressure Gauge
Tool No. FNH06653 at the pump low-pressure
circuit fitting.
2. Start the tractor and set engine speed to 2100.
rev/min
3. Observe pressure reading on gauge and
compare to 15.2-17.9 bar (220-260 psi).
35-7
Lubrication and Cooling Circuit Test
1. Operate the tractor and set engine speed to 1000
rev/min. Stop the engine but do not readjust the
throttle.
Refer to Figure 8.
1 2
2. Connect 0-41 bar (0-600 psi) Pressure Gauge
Tool No. FNH06653 (1), to the oil cooler inlet
hose (2). Use Test Hose No. FNH00093 (3), Test
Fitting Tool No. FNH0835 (4) (assembled from
FNH06946 and FNH00705), and a suitable 7/16
in. adapter to connect the test hose to the inlet
hose.
3. With an assistant, start the engine and observe 3
the pressure gauge reading. Do not run the
engine longer than necessary to observe the 4
pressure gauge reading.
4. The pressure observed (depending on engine 8
speed) should be at the minimum operating Lubrication Circuit Relief Valve Check
pressure of the lubricating circuit relief valve,
1. Oil Cooler Inlet Hose
which is 5.0-8.5 bar (73-123 psi)
2. Hose Clamp
3. Suitable 7/16 in JIC Adaptor to Connect Test Hose to
Auxiliary Engine Mounted Pump Flow Test Inlet Hose
1. Remove the pressure relief valve (1) from the 4. Test Hose 83936707
auxiliary engine mounted pump 5. Pressure Gauge FT.8616 or FNH 06653
2. Install Plug Part No. 83900652 and Seal Part No.

81800812 in place of relief valve. This will return
oil from the lift pump to sump.
35-8
3. Connect Flow Meter FNH02754 and inlet hose
(1) to the right-hand inner remote control valve 2
(2) lift coupler, and the return hose (3) to the outer
lift coupler.
4. Set the remote valve flow control knob to
minimum flow.
5. Completely open the flow meter load valve (4). 1
3
6. Start the engine and set engine speed to 2100
rev/min.
7. Move the remote valve control lever to the ‘float’ 4
position, which controls oil flow from the flow
meter to the remote valve.
9
8. Move the remote valve control lever to the extend
position, which controls oil flow from the remote
valve to the flow meter.
9. Check that the flow meter registers oil flow in both
directions. Set remote control valve flow knobs to
maximum flow.
10. Adjust the load valve on the flow meter until
obtaining a pressure reading of 137 bar (2000
psi) on the gauge, and record the flow.
11. Oil flow readings of less than 23 liters/min (6
gal/min) necessitate overhauling the pump.
12. Gradually close, the load valve on the flow meter
until the reading on the pressure gauge no longer
increases. This value must be in the range of
176-200 bar (2550-2900 psi), which falls within
the operating range of the relief valve in the
combining valve. Overhaul the priority valve
pack if not within specifications.
13. Shut down the engine and remove plug from
pump. Reinstall the pump relief valve.
14. Check hydraulic oil for proper servicing.
35-9
Remote Valve Pressure Test allow the hydraulic oil to reach an operating
Perform a pressure test of the remote valve after temperature of 57-63 _C (135-146 _F).
servicing.
9. Continue to close the flow meter load valve, while
observing a steady rise in pressure, until the
1. Install the inlet hose of a suitable flow meter into detent regulating valve opens, at which point the
the lift coupler of the valve to be tested. needle on the flow meter gauge fluctuates, and
2. Set the flow control knob to maximum flow. the remote control lever returns to neutral.
3. Install the flow meter return hose into the lift 10. The gauge reading immediately preceding
coupler of another valve on the tractor. needle fluctuation must be within 148-162 bar
(2150-2350 psi) which is the pressure when the
4. Open load valve on flow meter completely. detent regulating valve must open.
5. Ensure all connections are tight. Start tractor and 11. For readings not within specifications, adjust the
set engine speed to 1700 rev/min. ‘return to neutral’ pressure as follows:
6. Position the remote control lever of the valve with • Loosen the detent regulating valve locknut.
the flow meter RETURN hose connected to the
full forward “float” position. • Turn the adjusting screw to change pressure.
One-half turn of the adjusting screw changes
7. Position the remote control lever of the valve the pressure approximately 31 bar (450 psi).
tested rearwards, to the ‘extend’ position.
8. Gradually close the flow meter load valve until
obtaining a pressure of 137 bar (2000 psi), and
35-10
SECTION 41 -- STEERING SYSTEM -- CHAPTER 1
Chapter 1 - Hydrostatic Steering System
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
41-1
SPECIFICATIONS
Description
Front Wheel Toe-in 0-6.0 mm 0-0.24 in
Front Wheel Toe-out 0-13 mm 0-0.5 in
Power Steering Pump Gear Track maximum wear limit 0.064 mm 0.0025 in
Power Steering Pump Relief Valve 73-79 bar 1050-1150 psi
Steering Motor Relief Valve Opening Pressure (2WD) 138-145 bar 2000-2100 psi
Steering Motor Relief Valve Opening Pressure (4WD) 166-172 bar 2400-2500 psi
Steering Circuit Maximum Pressure (2WD) 145 bar 2100 psi
Steering Circuit Maximum Pressure (4WD) 172 bar 2500 psi
Transmission Mounted Steering Pump Flow Rate 36 litrs/min 9.6 gal/min
(New Pump)
at 2100 Engine rpm
Transmission Mounted Steering Pump Flow Rate 31 litrs/min 8.2 gal/min
(Used Pump)
at 2100 Engine rpm
41-2
TORQUE VALUES
Description N⋅m Ft.-Lb. (in.-lb.)

Steering Motor Upper Cover Bolts 27 20 (239 in.-lb.)
Steering Motor End-Cover Bolts 23 17 (204 in.-lb.)
Steering Motor-to-Mounting Bracket Bolts 24 18 (212 in.-lb.)
Steering Motor Hose Connections 20 15 (180 in.-lb.)
Steering Motor Relief Valve Plug 24 18 (212 in.-lb.)
Steering Cylinder Ball Joint Clamp 43 32
Steering Hose-to-Rigid Tubing Gland Connections 34 25 (301 in.-lb.)
Steering Cylinder End-Plate Bolts 120 89
Steering Cylinder-to-Anchor Adjusting Clamp 110 81
Steering Cylinder-to-Track Rod Adjusting Clamp 14 10 (124 in.-lb.)
Steering Cylinder Ball Joint Nuts 300 221
Steering Cylinder Gland and Tube-to-Cylinder 271 200
Power Steering Pump Flow Control Valve Plug 22 16 (195 in.-lb.)
Power Steering Pump Reservoir Casing Bolt 16 12 (142 in.-lb.)
Power Steering Pump Front Cover Bolts 31 23 (274 in.-lb.)
Power Steering Pump Drive Gear Retaining Nut 42 31
Power Steering Pump Body Through Bolts 35 26 (312 in.-lb.)
Power Steering Pump Relief Valve Plug 24 18 (212 in.-lb.)
Power Steering Pump Check Valve Plug 17 13 (156 in.-lb.)
Steering Wheel-to-Steering Shaft Retaining Nut 55 41
Steering Column-to-Steering Motor Coupling Bolts 31 23 (274 in.-lb.)
Steering Motor Bracket-to-Column Bracket Bolts 45 33 (398 in.-lb.)
Steering Column Support Bracket-to-Transmission Housing Bolts 150 111
UNBALANCED STEERING CYLINDER BIAS VALVE
Description Part Number

Valve 82983361 12 bar 174 psi
Elbow 82983407 90_
Tube Assembly 82983405 Steel
41-3
SPECIAL TOOLS
Tool Description New Holland Global Part Number

Part Number
Installer, Seal CNH294056
Attachment, Bearing FNH09190
Puller
‘T’ Fitting FNH00838
Reducer FNH00724
Hose Assembly FNH07099
Gauge, 0-5000 psi FNH02028 380000566
Adapter FNH01408
Adapter FNH00119
Test Kit CNH292870
Adapter CNH293874
Adapter CNH291318
SHIM THICKNESS
Description
Power Steering Pump Relief Valve 0.254 mm 0.010 in
0.381 mm 0.015 in
Power Steering Rocker Shaft End-Float 1.270 mm 0.050 in
1.524 mm 0.060 in
1.778 mm 0.070 in
2.032 mm 0.080 in
Power Steering Valve Housing-to-Bearing Housing 0.102 mm 0.004 in
0.127 mm 0.005 in
0.254 mm 0.010 in
0.635 mm 0.025 in
Steering Motor Upper Cover 0.064 mm 0.0025 in
0.127 mm 0.005 in
0.254 mm 0.010 in
0.762 mm 0.030 in
41-4
FAULT FINDING
IMPORTANT: To avoid repeat failures, investigate and correct the cause of the defect when making repairs to
the electrical system.
STEERING SYSTEM
Problem Probable Cause Remedy

No steering available, or excessive effort Oil level incorrect Replenish oil with the correct
q
required to steer grade and quantity
Air in system Tighten loose connections.
Bleed air from system
Relief valve malfunctioning Test relief valve and overhaul
or replace if necessary
Steering pump malfunctioning Test pump and overhaul if
required
Steering cylinder leaking Tighten connections or
overhaul cylinder
Steering column shaft Repair or replace
damaged
Control valve spool sticking or Repair or replace
worn
Metering unit malfunctioning Repair or replace
Steering wanders Linkage or ball joint excessive Check for correct torque,
play Repair or replace defective
components
Steering cylinder leaking Tighten connections or
overhaul cylinder
worn
Control valve return springs Replace springs
worn
Tire pressures not equal Service both tires to correct
pressure
Toe-in out of adjustment Adjust toe-in
Torsion bar worn (2WD) Repair or replace
Valve shimming incorrect Check for correct amount of
shims and modify accordingly
Front wheels surge when steering Steering cylinder leaking Tighten connections or
overhaul cylinder
worn
Control valve return springs Replace springs
worn
High steering system noise Wrong filter installed on steer- Verify steering pump filter
ing pump, causing cavitation contains correct part number,
and vibration in piping to and that it is correctly installed
steering motor (Refer to ASIST 3572)
Oil level incorrect Replenish oil with the correct
grade and quantity
Air in system Tighten loose connections.
Bleed air from system
Oil contains water Replace oil
41-5

The steering system controls the direction of the front
wheel assemblies with pressurized hydraulic oil.
There is no mechanical linkage connecting the steer-
ing column to the wheels, thereby making the steer-
ing system hydrostatic.
Tractors with Self-Contained Power Steering

Systems:
Refer to Figure 1.
Steering system components include:
• Power Steering Pump (1)

• Oil Reservoir (2)
• Pressure Relief Valve (3)
• Oil Cooler (4)
• Steering Wheel and Column (5)
• Steering Motor (6)
• Steering Cylinder (7)
• Hoses and Piping (8)
41-6
The power steering pump and reservoir assembly
(1), Figure 2, mounts to the left-hand side of the en-
gine. The engine timing gears drive the power steer-
ing pump at crankshaft speed. Two spur type gears,
riding within specially designed bearing blocks, pro-
duce oil flow for the operation of the power steering.
The self-contained reservoir provides a holding tank
for the hydraulic oil required by the steering system.
Other components installed on the pump include the

low-pressure inlet tube (2), pressurized outlet tube
(3) and the reservoir breather (4), Figure 2.
An oil cooler mounted to the front of the engine on the

left side, cools circulating oil, before the oil returns to
the steering system reservoir.
20030988
2
A pressure relief valve installed in the power steering
pump protects the steering system from excessive
pressure. In some steering system configurations,
the steering motor contains an integral relief valve, in
which case, the power steering pump will not contain
a relief valve.
A flow regulator (1), Figure 3, installed in the power

steering pump, controls oil flow for consistent steer-
ing performance through all engine speeds.
The power steering pump directs pressurized oil to

the steering motor via a resonance damper filter. The
filter reduces noise from the system and absorbs
1
pressure surges from the pump.
The steering motor housed within the steering col-

umn and bracket assembly, bolts to the forward aper-
ture at the top of the transmission housing. The lower
end of the motor protrudes into the transmission. A R-8-494
steel plate and polyurethane insert provides a seal 3
between the steering column bracket and transmis-
sion aperture.
41-7
The steering wheel, when turned, rotates a shaft The steering cylinder on 2WD tractors is a double
within the steering column and bracket assembly. A acting, unbalanced type, which connects to the front
steel sleeve couples the shaft to the steering motor axle beam on one end, and either the right-hand side
input shaft. The steering motor reacts by directing hy- of the tie bar, or left-hand wheel spindle, depending
draulic oil under pressure from the power steering on configuration. The combination of an unbalanced
pump to the double-acting unbalanced steering cyl- steering cylinder (piston end area greater than rod-
inder (2WD), or the double-acting, balanced steering end area) with a reactionary steering valve, creates
cylinder (4WD), to drive the front wheels. The steer- a biased system. This disparity may cause the front
ing column adjusts to vary the angle of tilt. wheels to drift left, whether the tractor is moving or
stationary.
The steering motor contains a metering unit to regu-
late the volume of oil to the steering cylinder, propor- A bias valve introduced into production in 2001, was
tional to the angular movement of the steering wheel. added in-line of the unbalanced steering cylinder
This controls the rate of turn. A check valve functions rod-end, to counteract the force of the larger piston
in combination with the metering unit to allow manual area at the cylinder end. This action creates a bal-
operation of the steering system in the absence of anced cylinder under a majority of operating condi-
pressurized oil from the pump. tions.
On 2WD models, the steering motor also incorpo- The steering cylinder on 4WD tractors is a double-
rates suction valves, which prevent cavitation in the acting balanced type. The cylinder housing mounts
steering cylinder when oil transfers from a small area to the backside of the front axle, in the center, with the
to a larger area, with the steering motor in neutral. cylinder ball joints connecting to the left and right
front wheel swivel assemblies.
41-8
R--10--625
4
1. Drive Shaft Input Coupling 9. Front Articulation Trunnion Mounting
2. Steering Cylinder Rod 10. Crown Wheel
3. Track Rod End Assembly 11. Planetary Reduction Gear
4. Hub and Planetary Reduction Gear Assembly 12. Centre Casing Breather
5. Axle Shaft Double Universal Joint Assembly 13. Removable Differential Assembly Carrier
6. Swivel Casing 14. Steering Cylinder
7. Swivel Pin Assembly 15. Rear Articulation Trunnion Mounting
8. Axle Centre Casing
41-9
OIL FLOW through another passage within the spool and sleeve
The power steering pump draws oil from the self-con- until reaching the steering cylinder.
tained reservoir assembly, pressurizes the oil, then
directs the oil to the steering motor.
opposite side of the steering cylinder to flow back
When holding the steering wheel still, springs in the through the oil cooler, to the reservoir, by way of the
steering motor maintain the spool and sleeve in the steering motor housing.
neutral position, stopping the flow of oil to the steer-
Manual steering provides a means of controlling the
ing cylinder. Trapped oil within the cylinder transfers
tractor when a loss of oil pressure occurs. When turn-
between the left and right sides of the cylinder as the
ing the steering wheel for a right-hand turn, the me-
wheels react to the ground, providing feedback to the
tering unit forces oil into the power steering cylinder.
operator.
On the suction side of the metering unit, return oil
Turning the steering wheel causes movement of the flows from the steering cylinder through the check
control valve spool within the sleeve to form a series valve to feed the metering unit. The same action oc-
of passages. When turned right, oil flows through the curs for left-hand turns.
sleeve along a groove in the spool and into the steer-
Returning oil flow from the steering motor enters the
ing motor housing to the metering unit. The drive
oil cooler, then flows back to the reservoir assembly.
shaft rotates the metering unit, directing the oil
10
9
7
8
3 2
4
20030991 6
5
Power Assisted Steering Pump Components

1. Reservoir 6. Drive Gear
2. Pressure Relief Valve Assembly 7. Pump Body--Front
3. Pump Body--Rear 8. Sealing Rings
4. Bearing Blocks 9. Pump Gears
5. Pump Body 10. Filter Element
41-10
Tractors with Steering System Incorporating This controls the rate of turn. A check valve functions
Transmission Mounted Pump: in combination with the metering unit to allow manual
Steering system components include: operation of the steering system in the absence of
pressurized oil from the pump. The pressure relief
• Transmission Mounted Steering Pump valve, an integral part of the steering motor, protects
• Pressure Relief Valve the system from over-pressurization.
• Steering Wheel and Column The steering cylinder on 2WD tractors is a double
• Steering Motor acting, unbalanced type, which connects to the front
• Steering Cylinder axle beam on one end, and either the right-hand side
of the tie bar, or left-hand wheel spindle, depending
• Hoses and Piping
on configuration. The combination of an unbalanced
steering cylinder (piston end area greater than rod-
The PTO idler gear drives the transmission mounted end area) with a reactionary steering valve, creates
steering pump. Unlike the self-contained steering a biased system. This disparity causes the front
system, the transmission mounted pump receives oil wheels to drift left, whether the tractor is moving or
from the rear axle casing, which is a common reser- stationary.
voir for the hydraulic system.
A bias valve introduced into production in 2001, was
The steering wheel, when turned, rotates a spline added in-line of the unbalanced steering cylinder
shaft within the steering motor. The steering motor rod-end, to counteract the force of the larger piston
reacts by directing hydraulic oil under pressure from area at the cylinder end. This action creates a bal-
the transmission-mounted pump to the double-act- anced cylinder under a majority of operating condi-
ing unbalanced steering cylinder (2WD), or the tions.
double-acting, balanced steering cylinder (4WD), to
drive the front wheels. The steering column adjusts The steering cylinder on 4WD tractors is a double-
to vary the angle of tilt. acting balanced type. The cylinder housing mounts
to the backside of the front axle, in the center, with the
The steering motor contains a metering unit to regu- cylinder ball joints connecting to the left and right
late the volume of oil to the steering cylinder, propor- front wheel swivel assemblies.
tional to the angular movement of the steering wheel.
41-11
OIL FLOW through another passage within the spool and sleeve
The steering pump within the transmission mounted until reaching the steering cylinder.
tandem pump assembly; draws oil from the rear axle
center casing, pressurizes the oil, and then directs
opposite side of the steering cylinder to flow back to
the oil to the steering circuit.
return by way of the steering motor housing
When holding the steering wheel still, springs in the
Manual steering provides a means of controlling the
steering motor maintain the spool and sleeve in the
tractor when a loss of oil pressure occurs. When turn-
neutral position, stopping the flow of oil to the steer-
ing the steering wheel for a right-hand turn, the me-
ing cylinder. Trapped oil within the cylinder transfers
tering unit forces oil into the power steering cylinder.
between the left and right sides of the cylinder as the
On the suction side of the metering unit, return oil
wheels react to the ground, providing feedback to the
flows from the steering cylinder through the check
operator.
valve to feed the metering unit. The same action oc-
Turning the steering wheel causes movement of the curs for left-hand turns.
control valve spool within the sleeve to form a series
Returning oil flow from the steering motor reenters
of passages. When turned right, oil flows through the
the steering pump body. The pump redistributes the
sleeve along a groove in the spool and into the steer-
oil through the rear axle center casing to the cooling
ing motor housing to the metering unit. The drive
and lubrication circuit.
shaft rotates the metering unit, directing the oil
41-12
CONTENTS

Steering Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Steering Cylinder – Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Steering Cylinder – Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Flow Control Valve -- Power Steering Pump (Where Installed) . . . . . . . . . . . . . . . . . . . . . . 23
Transmission Mounted Tandem Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine Mounted Power Steering Pump (Where Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Steering System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
41-1
STEERING MOTOR
Removal
1. Disconnect battery negative (ground) cable.
2. Remove steering motor cover.
3. Before removing, identify and mark the position
of each steering hose and motor connection (1),
Figure 1, to facilitate re-assembly.
IMPORTANT: Failure to identify the correct position
of the hydraulic connectors on the steering motor
may lead to improper installation. The steering sys-
tem rapidly over heats with hydraulic connector part
number 390584S2 installed in the pressure ‘IN’ port
vice steering cylinder port.
4. Remove the four steering hoses from steering

motor. Cap and plug openings to prevent con-
tamination.
5. Remove the bolt securing the steering column 1
coupler to the steering motor.
6. Remove the steering motor from the left-hand
side of the steering column support-bracket.
41-2
2
1. Drive Pin 14. Check Valve Retainer
2. Control Valve Sleeve 15. Check Valve Ball
3. Centering Springs 16. Pressure Relief Valve Assembly
4. End Plate Retaining Bolts / Washers 17. Seal
5. End-Plate 18. Steering Motor Housing
6. O-Ring 19. Back-up Ring
7. Metering Unit Stator 20. Suction Valve Balls
8. O-Ring 21. Suction Valves
9. Rotor Plug 22. O-Ring
10. Metering Unit Rotor 23. Spring Retainer and Bearing Assembly
11. Distributor Plate 24. Thrust Washer
12. O-Ring 25. Control Valve Spool
13. Drive Link
41-3
Disassembly
1. Secure the steering motor in a holding fixture with
the end-plate upward.
2. Remove the seven end-plate retaining bolts.
Note the position of the pin bolt (1) to facilitate re-
installation, Figure 3.
NOTE: The position of the pin bolt must remain the
same on re-assembly.
3
Refer to Figure 4.
3. Remove the end-plate (1).

4. Remove the O-ring (2) and discard.
5. Remove the rotor plug (4) from the metering unit
(3).
4
Refer to Figure 5.
6. Remove the metering unit (3).

8. Remove the distributor (2).
41-4
10. Mark the alignment of the metering unit stator (1)
and the metering unit rotor (2), Figure 6.
11. Disassemble metering unit.
6
12. Remove the drive link (1) from the steering motor
housing (2), Figure 7.
13. Remove the distributor plate.
7
Refer to Figure 8.
14. Remove the two suction valves (1) and balls (2).
15. Unscrew the check valve retainer (3).
41-5
16. Remove the check valve retainer (1) and ball (2),
Figure 9. 1
2
60--41--005 TI
9
17. Remove the pressure relief valve assembly (1),
Figure 10.
1
60--41--006 TI
10
18. Push out the control valve and outer sleeve (2)
from the steering motor body (1), Figure 11.
NOTE: When removing the control valve and outer
sleeve, position the drive-pin horizontally to prevent
the pin from slipping into the internal gallery.
11
41-6
19. Remove the thrust washer, spring retainer, and
bearing assembly (1) from the control valve, Fig- 1
ure 12.
60--41--009 TI
12
20. Note the arrangement of the centering-springs
(1) before removing, Figure 13. 2
60--41--010 TI
13
21. Use a suitable guide (2) to push out centering
springs (1) from control valve, Figure 14.
22. Remove the drive-pin (2), Figure 13.
23. Remove the control valve spool from the outer
sleeve.
24. Discard O-rings.
20030989
14
41-7
Inspection
1. Clean all components in a suitable oil-based sol-
vent. Allow parts to dry.
2. Inspect sleeves for scratches, burrs and nicks.
Remove minor imperfections with a fine abra-
sive. Replace components if defective.
Assembly
NOTE: Replace all O-rings and seals when re-
assembling.
Refer to Figure 15.
1. Insert the control valve spool (4) into outer sleeve

(2) and align slots (3).
2. Install the drive-pin (1).
15
3. Insert centering spring (2) into control valve (1)
slot as shown in Figure 16.
16
4. Install the thrust washer, spring retainer and
bearing assembly (1), Figure 17. 1
NOTE: Position the inner bearing race with chamfer
side facing the control valve spool.
60--41--009 TI
17
41-8
5. Apply a light coating of clean hydraulic oil to the
outer sleeve.
6. Insert the outer sleeve (2) into the steering motor
housing (1), Figure 18.
18
7. Coat O-ring and back-up rings with clean hydrau-
lic fluid and position on Seal Installer Tool No.
CNH294056 (1), Figure 19.
60--41--013 TI
19
8. Position Seal Installer Tool (1) into the sleeve (2)
and push down using a twisting action, Figure 20. 1
9. Completely seat the seal.
2
10. Remove seal installer tool.
11. Install control valve and spool.
NOTE: Position the control valve with the drive-pin
horizontal, to facilitate installation into the steering
motor housing.
60--41--014 TI
20
41-9
12. Install the pressure relief valve (1) with, spring,
retainer, and valve head, Figure 21.
1
60--41--006 TI
21
Refer to Figure 22.
13. Install the check valve, ball (2) and retainer (1) 3
into steering motor housing.
NOTE: Screw the check valve retainer down into the 4 1
motor body just below the surface.
14. Install the suction valves (3) and balls (4) into 2
steering motor housing.
60--41--005 TI
22
15. Position a new O-ring (3) and install distributor
plate (1) onto steering motor housing (2), Figure
23.
23
41-10
Refer to Figure 24.
16. Before installing the drive link, align the control

valve drive pin (2), perpendicular (3) with the
front face of the motor housing (1).
17. Install the drive link (4) into the steering motor
housing. Ensure the drive link engages the drive-
pin correctly.
24
18. Assemble the metering unit stator and rotor (2),
using the guide mark (1) from ‘Disassembly Step
10, Figure 25.
20030990
25
Refer to Figure 26.
19. Install new O-rings (1) if not previously done.

20. Install the assembled metering unit (3) to the dis-
tributor plate (2).
26
41-11
Refer to Figure 27.
21. Install the rotor plug (4) into the metering unit (3).
22. Install a new O-ring (2).
23. Position the end-plate (1).
27
Refer to Figure 28.
24. Install the seven retaining bolts into the end-

plate. Ensure to install the pin bolt in the original
location of removal (1).
25. Tighten the retaining bolts to an initial torque of
11 N⋅m (97 in.-lb.).
26. Tighten the retaining bolts to a final torque of 29
N⋅m (257 in.-lb.).
28
27. Install the four hose connectors (1), Figure 29,
into the steering motor housing. Tighten connec- 1
tors to a torque of 83 N⋅m (61 ft.-lb.).
NOTE: Install the hydraulic connectors on the steer- 1
ing motor exactly as removed. The steering system
rapidly over heats with hydraulic connector part num-
ber 390584S2 installed in the pressure ‘IN’ port vice
steering cylinder port.
Installation
1. Install the steering motor into the left-hand side 60--41--007 TI
of the steering column support-bracket. 29
2. Tighten the retaining bolts to a torque of 31 N⋅m
(274 in.-lb.).
3. Attach the hoses to the connectors on the steer-
ing motor. Tighten gland nuts to a torque of 20
N⋅m (180 in.-lb.).
4. Install the steering motor cover.
5. Connect the battery negative (ground) cable.
6. Replenish oil and purge air from hydraulic sys-
tem. Refer to Section 35 “Hydraulic Systems”.
7. Check steering system for proper operation.
41-12
STEERING CYLINDER – TWO WHEEL DRIVE
R-8-493
30
Steering Cylinder Assembly

1. Clamp 9. Ball Joint
2. Ball Joint 10. Clamp
3. Wiper Seal 11. Wiper Seal
4. Gland Seal 12. Piston
5. Bearing Bush 13. Piston Seal Pack
6. Bearing Bush 14. Gland-to-Cylinder Seals
7. Gland Seal 15. Gland and Tube Assembly
8. Piston Rod
Removal
1. Park the tractor on a hard level surface with the
front wheels straight ahead.
NOTE: Observe the position and location of the
steering hoses and connectors to facilitate re-as-
sembly.
2. Disconnect the cylinder hoses. Cap and plug

3. Remove the retaining nuts (3) and separate ball
joints (1) from the right-hand tie rod (2), and the
axle, Figure 31.
31
41-13
Disassembly
1. Drain the cylinder of oil.
2. Remove the steering hose connector at the pis-
ton end. Remove the bias valve (2) and the 90_
elbow (1) at the cylinder rod-end (3), Figure 32,
(where installed).
3. Cap and plug openings to prevent contamination.
32
4. Loosen the clamp bolts (1) and remove ball joint
assemblies (2), Figure 33.
IMPORTANT: When using a holding fixture such as
a vice, do not clamp directly around the cylinder bar-
rel, as damage to the cylinder will occur.
33
41-14
5. Using a suitable spanner wrench (2) as shown in
Figure 34, unscrew the extension tube (1) and
gland assembly.
6. Remove the gland and piston rod assembly from
the cylinder.
7. Remove and discard O-rings and seals.
Inspection
1. Wash all components in a suitable solvent. Allow
parts to dry.
34
2. Inspect all parts for obvious damage and wear.
Replace defective components.
3. Inspect ball joints for looseness.
Assembly
1. Install new O-ring (3), piston seal (4) and wear
ring (1) onto piston (2), Figure 35.
35
41-15
36
Steering Cylinder Assembly
1. Piston and Rod Assembly 9. Seal Kit items*
2. Cylinder 10. Nut
3. Extension Tube 11. Track rod end
4. Track Rod End 12. Clamp Bolt
5. Dust Washer * Seal Kit Consists of:--
6. Clamp Bolt Rod Seals and Bushing
7. Clamp Piston Seals
8. Nut Gland Seals
41-16
2. Install new rod seals (3) in gland (1). Ensure the
sealing lip faces towards oil pressure. Install new
back-up rings (5), O-rings (4) and rod wipers (2),
Figure 37.
37
3. Lubricate seals and slide gland assembly (2)
onto piston/rod (1), Figure 38.
38
4. Insert the piston/rod (1) and gland assembly (3)
into the cylinder barrel (2), Figure 39.
5. Screw gland into barrel and seat completely.
39
41-17
6. Install the steering hose connector at the steering
cylinder piston end. Install the 90_ elbow (1) and
the bias valve (2) at the cylinder rod-end (3), Fig-
ure 40 (where installed).
40
Installation
Installation of the steering cylinder follows the remov-
al procedures in reverse with the following require-
ments:
1. Screw anchor and ball joint into extension tube

completely, then unscrew ball joint a fraction of a
turn to correctly position connectors as shown in
Figure 41.
2. Tighten the ball joint clamps to a torque of 43 N⋅m
(32 ft.-lb.).
3. Compress the cylinder rod until piston bottoms in
the cylinder.
41
Refer to Figure 42.
4. Install cylinder anchor-end ball joint (1) to the

track rod.
5. Tighten the ball joint nut to a torque of 120 N⋅m
(89 ft.-lb.).
6. Position the wheels to the full right-hand turn
position as shown in Figure 42.
7. Starting with the steering cylinder rod fully re-
tracted, extend the cylinder rod out by 4.0-10.0
mm (.16-0.4 in).
42
41-18
8. Adjust cylinder rod-end ball joint, until aligned
with lug on track rod, and then install ball joint nut.
9. Tighten ball joint nut to a torque of 173 N⋅m (130
ft.-lb.).
10. Position wheels straight ahead and adjust track
rod until obtaining a toe-out of 0-13 mm (0-0.5 in),
measured on the wheel rim at hub height. Use A
minus B as shown in Figure 43. Also see Section
25 “Front Axle”
11. Ensure the spindle stops contact axle-housing
stops on full left and right turns.
12. Connect steering hoses.
43
13. Replenish hydraulic oil level.
14. Check cylinder and hoses for leakage, and purge
air from the hydraulic system by running the en-
gine, and operating the steering system.
STEERING CYLINDER – FOUR WHEEL

DRIVE
Removal
1. Position the tractor on a level surface with the
wheels straight ahead.
2. Loosen the retaining bolts (1) two turns, which
secure the cylinder end-plate (2), and cylinder (3)
to differential casing, Figure 44.
3. Turn the steering wheel to the left and unseat the
end cap and cylinder from the differential casing. R-10-530
44
Steering Cylinder End Plate/Retaining Bolts
1. Retaining Bolts
2. End Plate
3. Cylinder Rod
4. Hydraulic Hose
NOTE: There will be a slight loss of oil from the end

cap.
4. Remove the track rod and retaining bolt (1) from

the left and right-hand steering arm (2), Figure
45.
R-10-571
45
Steering Track Rod End
1. Track Rod
2. Steering Arm
41-19
Refer to Figure 46.
5. Remove the clamp bolt (3), from the left and right-
hand track-rod (2).
6. Unscrew the track-rod, from the left and right-
hand ball joint (1).
7. Unscrew the left and right-hand ball joint from the
steering cylinder (4).
R-10-570
46
Disconnecting Track Rod and Ball Joint from
Cylinder Rod
1. Ball Joint
2. Track Rod
3. Track Rod Clamp
4. Cylinder Rod
8. Disconnect the hydraulic hoses. Cap and plug

9. Remove fitting from right side of cylinder.
10. Remove steering cylinder retaining bolts and re-
move the steering cylinder from the differential
carrier, Figure 47.
R-10-531
47
Removing Steering Cylinder from Differential
Carrier Mounting
1. Hydraulic Hose
Disassembly
1. Remove the cylinder rod (4) with end-plate (3),
and piston assembly (2) from the cylinder barrel
(1), Figure 48.
2. Slide the end-plate off from the left side of the
cylinder.
R-10-580
48
Removing Cylinder Rod and Piston Assembly
from Cylinder Barrel
1. Barrel 3. End Plate
2. Piston (part of rod) 4. Rod
41-20
Refer to Figure 49.
3. Remove the wear rings.

4. Remove the piston seal.
5. Remove the O-rings.
6. Remove the wiper seals.
R-10-581
49
Steering Cylinder Exploded View
1. Wear Ring 7. Wiper Seal
2. Wiper Seal 8. End Plate O-ring Seal
3. Oil Seal 9. Wear Ring
4. Cylinder Barrel 10. Piston Seal
5. End Plate 11. Piston Seal Expander (O-ring)
6. Oil Seal 12. Cylinder Rod and Piston
Inspection
1. Clean all components in suitable oil based sol-
vent. Allow parts to dry.
2. Inspect the rod, and piston assembly, for wear,
corrosion or distortion. Remove minor nicks and
abrasions using an abrasive stone.
3. Inspect the inside of the cylinder barrel for chaf-
fing.
When finding the rod and piston assembly, or the cyl-
inder barrel defective beyond service, replace the
complete steering cylinder.
4. Inspect both track rods, and both cylinder ball

joints for wear or looseness. Replace parts if
found defective.
41-21
Assembly
Refer to Figure 49.
1. Install new wiper and oil seals in the cylinder end

plate.
2. Install new wiper and oil seals in the cylinder bar-
rel.
3. Install a new wear ring on the piston.
4. Install a new wear ring, piston seal and O-ring on
cylinder rod.
5. Lubricate all seals and the piston assembly with
clean hydraulic oil.
6. Install piston assembly into the cylinder barrel.
NOTE: Allow the center seal with the O-ring on the
piston and rod assembly to contract naturally before
installing into cylinder barrel.
Installation
Installation of the steering cylinder follows the remov-
al procedures in reverse with the following require-
ments:
1. Tighten the steering cylinder ball joints to a

2. Tighten the cylinder end-plate retaining bolts to
a torque of 120 N⋅m (89 ft.-lb.).
3. Position hydraulic connections and hoses to pre-
vent interference with other components,
through all degrees of front axle steering.
4. Check the level of the hydraulic oil and replenish
as necessary with the correct grade and quantity.
5. Cycle the steering system and check for leaks,
correct operation.
6. Check for contact of the wheel swivels to the
steering stops at full left and full right movement.
If adjustment of stops is required, follow the pro-
cedures for “Steering Stops-adjustment” de-
scribed in this chapter.
41-22
Steering Stops - Adjustment
Refer to Figure 50.
Each front wheel swivel contains two steering stops

(2), which contact machined areas (3) on the front
axle. Adjustment of the stops is as follows:
1. Loosen the locknut (1) of the steering stop requir-

ing adjustment.
2. Turn the stop bolt counter-clockwise to reduce
the steering angle of the wheels, or clockwise to
increase the steering angle.
OM16
3. After adjustment, check that the minimum clear-
ance between the tires, and any part of the tractor 50
on full left or full right movement, is 20 mm (0.75 Steering Stop
in). 1. Locknut
2. Stop Bolt
4. With wheels full left, check that the left-hand rear
3. Boss
steering stop makes contact with the front axle,
at the same time the right-hand front steering
stop makes contact with the front axle.
5. Tighten the stop bolt locknut to a torque of 150
N⋅m (110 ft.-lb.).
6. If necessary, check front wheel toe-in using the
procedures described in Section 25 “Front Axle”.
FLOW CONTROL VALVE - POWER STEERING

PUMP (Where Installed)
The power steering pump incorporates a flow control
valve within the pump body.
Removal
Refer to Figure 51.
1. Remove steering pump reservoir retaining bolt.

2. Remove the reservoir casing from the pump
body (1). R-8-494
3. Remove flow control valve plug (2), and discard
O-ring (3). 51
4. Remove flow control valve spool (4), and spring

(5).
41-23
Inspection
1. Inspect the flow control valve spool for nicks,
burrs, distortion, or corrosion. Replace spool if
defective.
Installation
1. Install flow control valve and spring into the pump
body.
2. Install new O-ring seals around the upper plug.
3. Install flow control valve plug and tighten to a
4. Install the steering pump reservoir casing and re-
taining bolt. Tighten bolt to a torque of 16 N⋅m
(142 in.-lb.).
TRANSMISSION MOUNTED TANDEM PUMP
2
Removal
1. Remove the right-hand rear wheel assembly.
2. Remove the rear axle drain plug and drain the hy-
draulic oil.
3. Disconnect the brake actuating rods from the lev-
ers. Refer to Section 33 “Braking Systems”.
4. Remove the brake pedal assemblies. Refer to
Section 33 “Braking Systems”. 1
52
Fixed Displacement Gear Type Pump Installation
1. Return from Steering Motor
2. To Steering Motor
5. Disconnect all hydraulic connections at the

pump. Cap and plug all exposed openings to pre-
vent contamination.
6. Remove the pump retaining bolts and lift pump
off transmission housing.
Disassembly
1. Unfold tabs and remove the input drive gear nut 6
(5) and locking washer (4) at the front (lift) pump.
Then remove the input drive gear (2) and key (3) 3
from the drive shaft (1), Figure 53. 5
4
NOTE: Use a soft mallet to loosen the drive gear from
the tapered drive shaft if necessary.
2. Remove the six end-cover retaining bolts (6) and 53
washers.
41-24
3. Ease the end-cover (1) forward to clear the locat-
ing dowels (3), then tilt the cover to clear transfer
tube (2), Figure 54. Lift cover off pump.
CAUTION
Do not attempt to disassemble the internal snap
ring, which secures the drive shaft to the driven
gear assembly. Damage to the snap ring or drive
shaft is likely to occur.
54
Refer to Figure 55.
4. At the front pump, remove the drive shaft and

driven gear as an assembly, and collect the bear-
ing blocks. Identify components to facilitate as-
sembly.
5. Observe the positioning of the seals to facilitate
re-assembly.
55
Hydraulic Lift Pump (Front Pump) -- Exploded View
1. Pump Housing 9. Locking Washer
2. Steering Pump 10. Drive Gear
3. Bearing Block 11. Oil Seal
4. Driven Gear 12. Nylon Back--Up Ring
5. Transfer Tube 13. Seal
6. End Cover 14. Bearing Block
7. Bolts (4 Long, 2 Short) 15. Woodruff Key
8. Nut 16. Drive Shaft and Gear Assembly
41-25
Refer to Figure 56.
6. Remove the rear (steering) pump assembly from

the pump housing.
7. Remove the gears and bearing blocks.
8. Remove the connector shaft and sandwich plate.
9. Identify the positioning of all components includ-
ing the nylon back-up rings and seals to facilitate
re-assembly.
56
Steering Pump (Rear Pump) -- Exploded View
1. Pump Body 9. Nylon Back--Up Ring
2. Seal 10. Pump Housing
3. Nylon Backing Strip 11. Seal
4. Bearing Block 12. Nylon Backing Strip
5. Driven Gear 13. Bearing Block
6. Seal 14. Transfer Tube and Snap Ring
7. Sandwich Plate 15. Drive Gear
8. Seal
41-26
parts to dry.
2. Inspect bushings and bearing blocks for wear or
the bushings. Replace the gears and bearing
blocks as a matched set if required. DO NOT ser-
vice separately.
3. Inspect pump gears for wear or damage, particu-
larly the bearing journals, gear teeth and side fac-
ings.
each pair of pump gears must be within 0.005
mm (0.0002 in) of one another, and the journals
within 0.013 mm (0.0005 in).
5. Remove light scoring marks on the gear facing
areas using a sheet of ‘O’ grade wet or dry abra-
sive paper and lubrication on a true flat surface.
Polish the area repaired using light pressure in a
rotating motion. Polished journals will achieve
free movement in the body.
6. Inspect the gear track, embedded during the
manufacturing process for the gear teeth, on the
suction side of the pump. The track depth must
not exceed 0.10 mm (0.004 in), or continue be-
yond the suction half of the gear aperture. Re-
place the pump when gear tracks do not fall with-
in specification.
9. Any component found unserviceable should ne-
cessitate replacing the pump assembly. If in an
emergency, worn components are replaced indi-
vidually, note the following points:
• The installation of new bearings will re-center
the gears and prevent the tips of the gear
teeth from bottoming, if continuing to use a
pump body where the track is out of specifi-
cations. Thereby resulting in pump inefficien-
cy.
• Under working conditions, hydraulic pres-
sure within the pump loads the gears towards
the inlet side of the pump body. Continued
use of worn bearing and gear journals
causes the gears to shift, thus deepening the
gear track in the pump body.
41-27
Assembly
Assembly of the fixed displacement transmission
mounted (tandem gear) type pump follows the re-
moval procedures in reverse with the following re-
quirements:
1. When replacing the pump dowels, install new

dowels with 2.54 mm (0.10 in) protruding from
the pump housing.
3. Install washers (1) and (5) and O-ring seals (2)
and (4) on the transfer tube (3), Figure 57.
4. Coat all seals and O-rings with petroleum jelly.
6. Assemble original gears with original bearings
exactly as removed. This step is critical in main-
taining pump efficiency.
57
7. The bearing block (4) in the steering pump (2)
contains an edge with a radius (1). Install the
bearing block with the radius edge to the bottom
of the steering pump bore (3), Figure 58.
NOTE: Only one of the two bearing blocks installed
in the steering pump contains a corner edge with a
radius. Incorrect installation of the sharp edged ra-
dius block (13), Figure 56, will damage the pump.
8. Pack the cavity behind the lips of the front-end

point grease.
58
Bearing Block Installation
41-28
9. The end-cover bolts have different lengths. En-
sure to install the correct bolts in the locations ex-
actly as removed, Figure 59, and tighten to a
torque of 50-62 N⋅m (37-46 ft.-lb.).
10. If removed, install the pressure relief valve and
11. Install the input drive gear nut and tighten to a
torque of 50-56 N⋅m (37-41 ft.-lb.). Bend the
washer locking-tab against the pump drive, gear
nut.
installation of hydraulic connections to prevent
entry of foreign objects and contaminants. 59
End Cover Bolt Location
A. Bolt M10 x 100 mm with Ground Shank
B. Bolt M10 x 100 mm with Dull Black Shank
C. Bolt M10 x 115 mm with Ground Shank
D. Bolt M10 x 115 mm with Dull Black Shank
Installation
The installation of the transmission mounted fixed
displacement (tandem gear) type pump follows the
removal procedures in reverse with the following re-
quirements.
1. To prevent internal and external leakage, and im-

prove pump efficiency, perform the following
when installing new O-rings and seals:
• Lubricate with clean hydraulic fluid.
• Do not allow connections to pinch, or O-rings
to roll and twist when installing.
• Ensure proper positioning.
• Completely seat into grooves.
2. Before installing, fill pump suction port with clean
3. Tighten the pump-to-transmission retaining bolts
to a torque of 57-76 N⋅m (42-56 ft.-lb.)
4. Tighten all hydraulic connections and fittings.
5. Replenish the rear axle center casing oil. Refer
to Section 27 “Mechanical Rear Wheel Drive”.
6. Perform a pressure test of the pump. Refer to
Section 35, Chapter 5 “Adjustments and Test-
ing”.
7. Operate the brake pedals after assembling, and
check for binding and proper operation. Refer to
Section 33 “Braking System”.
41-29
ENGINE MOUNTED POWER STEERING

PUMP (WHERE INSTALLED)
Removal
1. Remove engine pulley side guards (where
installed).
2. Disconnect the steering hoses from the pump in-
let (1) and outlet (2) ports, and drain hydraulic oil
into a suitable container, Figure 60. Cap and plug
all openings to prevent contamination.
3. Remove the retaining bolts securing the steering IR-7-1-03
pump to the timing gear casing. Remove the
pump and drain the remaining oil from the pump 60
casing.
Disassembly
1. Remove the reservoir retaining bolt and ring.
Then lift off reservoir casing. Retain the spring,
washer and retainer for re-assembly.
2. Discard the large O-ring seal and filter element.
3. Loosen tab on drive gear retaining nut lock-
washer.
4. Remove the drive gear nut.
5. Use Puller Tool No. FNH09198 and Attachment
Tool No. FNH09190 to remove the drive gear
1
from the tapered drive gear shaft.
6. Remove drive gear shaft key, ring and seals.
7. Remove pressure relief valve from the pump
body (where installed). Retain the shims, pin,
and valve seat and spring for re-assembly. Dis-
card all seals and O-rings.
8. Remove the retaining bolts, which secure the
rear cover to the pump body and front flange. Dis- 3
card the inner and outer seals.
20030992 2
9. Note the position of the two bearing blocks (1)
and pump gears (2), and then remove from steer- 61
ing pump body (3), Figure 61. Pump Gears and Blocks Removed
1. Bearing Blocks
10. Remove the snap ring securing the drive shaft oil
2. Pump Gears
seal to the front flange. Remove oil seal.
3. Pump Body
41-30
parts to dry.
Refer to Figure 62.
4
2. The gear track on the inner wall of the pump body
must be free from scoring and burrs. The gear 1
track wear must not exceed 0.064 mm (0.0025
in) depth.
3. Inspect each pump gear (1) & (3) for pitting. Re-
placement of the steering pump gears will require
replacement of the entire pump assembly.
4. Inspect each bearing block (2) & (4) for signs of
scoring. Remove light scoring by lapping on a 3
surface plate using fine emery paper. Replace 20030993 2
excessively worn bearing blocks.
62
Assembly
Assembly of the power steering pump follows the
requirements:
1. Lightly coat all parts in clean hydraulic oil.

2. Replace all seals and O-rings.
3. Install the bearing blocks and drive gears exactly
as removed.
4. Tighten the front and rear retaining bolts evenly
to a torque of 21 N⋅m (186 in.-lb.).
5. Install a new lock-washer under pump drive gear
retaining nut.
6. Install drive shaft nut. Tighten to a torque of 78
N⋅m (58 ft.-lb.).
7. Pour a small quantity of hydraulic oil into steering
pump for lubrication.
8. Check drive-gear for freedom of movement by
turning gear by hand.
9. Install a new oil filter element.
41-31
Installation
The installation of the power steering pump follows
requirements:
1. Replenish the power steering reservoir as need-

ed. To fill the reservoir, remove the cap on the
reservoir casing. The oil capacity of the steering
system is 2.1 litrs (4.4 pt).
2. Perform power steering pump pressure check.
Refer to “Testing” section as described in this
chapter.
3. Operate the steering system through several
complete cycles to verify correct operation, to
purge air from the system, and to check connec-
tions for leakage
4. Recheck the oil level and replenish as necessary.
STEERING SYSTEM TESTING
Steering System Incorporating the Engine

Mounted Power Steering Pump Testing
1. Disconnect engine-mounted power steering
pump to steering motor pressure tube.
2. Insert ‘T’ Fitting Tool No. FNH00838.
3. Insert Reducer Tool No. FNH00724
4. Attach Hose Tool No. FNH07099.
5. Connect the Pressure Gauge Tool No.
FNH02028 to the reducer.
6. Check all connections for tightness.
7. Start the engine.
8. Turn the steering wheel in one direction until
wheel swivel contacts axle stop (lockout posi-
tion). Hold the wheels against the stop and ob-
serve the gauge reading.
9. Compare the gauge reading with the pressure
relief valve setting of 3.4-3.5 bar (111-113 psi).
10. To adjust the steering system lockout-pressure,
remove the pressure relief valve, and add or sub-
tract shims.
41-32
11. After obtaining the correct lockout-pressure, re-
move the test equipment.
12. Recheck oil level.
4
13. Operate the steering system through several 1
complete cycles to verify correct operation, and
to purge air from the system.
14. Check connections for evidence of leaking.
Engine-Mounted Power Steering Pump Testing

Refer to Figure 63.
20030994 3 2
1. Disconnect the engine-mounted steering pump
pressure hose at the output elbow fitting (4). 63
Pump Pressure Test Installation
2. Attach Adapter Tool No. FNH01408 (3). 1. Pressure Gauge, Tool No. FT.8503A or 2028
3. Attach Adapter Tool No. FT8526 (2). 2. Adaptor, Tool No. FT.8526
3. Adaptor, Tool No. FT.8503-5 or 1408
4. Output Elbow
4. Connect the Pressure Gauge Tool No.

FNH02028 (1) to the pump output elbow.
5. Start the engine. Observe the gauge reading and
compare with the pressure relief valve setting of
3.4-3.5 bar (111-113 psi).
WARNING
Operate the engine just long enough to obtain an
accurate reading on the pressure gauge. Pro-
longed operation of the engine with test equip-
ment attached will cause damage to the steering
system from overheating.
6. To adjust the engine-mounted steering pump 64

pressure, remove the pressure relief valve, and Pressure Relief Valve
add or subtract shims. Refer to Figure 64. 1. Shims
2. Spring
NOTE: Increase the shim thickness by 0.25 mm
3. Valve
(0.01 in) to increase the pressure relief valve setting
4. Valve Seat
by 6.9 bar (100 psi).
7. After obtaining the proper pump pressure, rein-

stall the relief valve.
8. Remove test equipment.
9. Check the level of oil in the reservoir.
41-33
Steering System Testing
1. Start the engine and set engine speed to 1000
rev/min.
2. Turn the steering wheel quickly from stop to stop.
The reaction of the front wheels should be imme-
diate.
3. About the time the front wheels contact the axle
stops, the steering motor relief valve opens, and
engine speed reduces to approximately 970 rev/
min.
Steering Motor Pressure Relief Valve Testing

1. Disconnect the left-hand turn feed hose at the
steering cylinder.
2. Install a 0-5000 Pressure Gauge Tool No. FNH
02028, with Adapter Tool No. FNH00119, and a
locally procured 7/16 JIC male X 9/16 JIC male
adapter, Figure 65, to the cylinder feed hose.
3. Using Hydraulic Test Kit No. 292870, install
Adapters 293874 and 291318 into the banjo fit-
ting of the steering cylinder.
4. Start engine and set engine speed to 1450 rev/
min.
5. Turn the steering wheel counterclockwise, using
22 N (5 lb) of pull and observe reading on gauge.
6. Observe cylinder feed line gauge and compare
reading to the pressure relief valve setting:
2WD 153-163 bar (2220-2370 psi)
4WD 180-191 bar (2620-2770 psi)
Adjust the steering motor pressure relief valve when

necessary, to obtain specified pressures.
7. Check oil level and replenish as necessary.

41-34
Steering Motor Pressure Relief Valve
Adjustment
Refer to Figure 65.
1. Disconnect the steering motor from the steering

column bracket. Refer to the “Steering Motor”
overhaul section of this chapter.
2. Connect suitable test hoses to the pressure and
return tubes of the steering motor as shown in
Figure 65.
3. Using a ‘T’ fitting, connect a 0-5000 psi gauge to
the pressure line of the steering motor.
4. Using a ‘T’ fitting, connect a 0-500 psi gauge to
the return line of the steering motor.
5. Check all test connections for tightness.
6. Start the engine and idle 1450-1500 rev/min. run
the engine until the transmission oil reaches the
recommended operating temperature of 68°C
(155°F).
7. Turn the steering wheel clockwise or counter-
clockwise until contacting stop. Compare read-
ing on Gauge A to 162 bar (2350 psi) on 2WD, or
190 bar (2750 psi) on 4WD.
8. Compare the reading on gauge B to 17 bar (250
psi).
9. To establish differential pressure, subtract the
measurement of gauge B from the measurement
of gauge A and compare to 145 bar (2100 psi) on
2WD, and 190 bar (2500 psi) on 4 WD.
10. If the pressure readings do not fall within specifi-
cations, turn the pressure relief valve adjuster
(13) using an 8 mm hexagon key. Half of a turn
on the adjuster equates to approximately 13.8
bar (200 psi).
11. After obtaining desired pressure setting, remove
test equipment.
12. Check oil level and replenish as necessary.
41-35
1
13
2
12
3
9 B 10
T
11
8 7 A 6
65
Steering Motor Relief Valve Adjustment
1. Plug 8. Size 8 ORS Swivel Running Tee
2. Steering Shaft 9. Size 10 ORS Swivel Running Tee
3. Relief Valve 10. Pressure Gauge 0--500lbf.in2
4. Fabricated Steering Motor Output Hose 11. Size 6 ORS Blanking Cap
5. Tractor Tubes to Steering Cylinder 12. Spring
6. Fabricated Hose for Pump Supply to Steering Motor 13. Adjuster
7. Pressure Gauge 0--5000lbf.in2
41-36
SECTION 44 -- FRONT AXLE--TWO WHEEL DRIVE -- CHAPTER 1
SECTION 44 - FRONT AXLE--TWO WHEEL DRIVE
Chapter 1 - Two Wheel Drive
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Front Axle Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front Wheel Spindle - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Center Steering Arm - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front Axle - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
44-1
SPECIFICATIONS
Item
Front Wheel Toe-In 0-6.0 mm 0-0.24 in.
Front Wheel Toe-Out 0-13 mm 0-0.5 in.
FRONT AXLE TRACK ADJUSTMENT

Model Adjustable Width Clearance
5610S 1422-2032 mm (56-80 in.) 457 mm (18 in.)
6610S 1422-2032 mm (56-80 in.) 457 mm (18 in.)
7610S 1422-2032 mm (56-80 in.) 457 mm (18 in.)
7010 Low Profile 1524-2032 mm (60-80 in.) 254 mm (10 in.)
8010 Low Profile 1524-2032 mm (60-80 in.) 254 mm (10 in.)
8010 High Profile 1829-2134 mm (72-84 in.) 635 mm (25 in.)
SPECIAL TOOLS
Tool New Holland Globel Part No.
Shaft Protectors, (Set of 6) FNH09514 380000564
Driver Set FNH09514
Driver Set FNH09515
TORQUE VALUES
Component
Track Control Rod Locator Bolts 25 N⋅m 18 ft.-lbs.
Front Wheel Axle Track Bolts 210 N⋅m 155 ft.-lbs.
Spindle Arm-to-Wheel Spindle Bolts 165 N⋅m 122 ft.-lbs.
Track Control Rod End-to-Steering Arm Retaining Bolts 120 N⋅m 89 ft.-lbs.
Wheel Hub Retaining Nut Initial Torque 27-40 N⋅m 20-30 ft.-lbs.
Wheel Hub Retaining Nut Final Torque 61-74 N⋅m 45-55 ft.-lbs.
44-2
DESCRIPTION AND OPERATION The offset centerline of the wheel spindles creates a
The front axle assembly consists of a hollow, center trailing effect of the front wheels, which eliminates a
axle beam with a telescopic section at each end, that need for a castor angle.
is centrally mounted to the front support assembly by The keyed upper portion of each wheel spindle
two support pins, Figure 1. allows for installation of a spindle arm.
Each telescopic end of the center axle beam Two track control rods consist of a hollow tube and
incorporates an outer axle assembly. Machined extendable telescoping rod ends.
holes in the outer axle assemblies match the center
axle beam for varying the front wheel axle track Two taper roller bearings support the wheel hub on
length. The left-hand and right-hand outer axle the wheel spindle. A nut on the spindle retains the
assemblies consist of a beam and welded tube, outer cone and roller assembly, and provides for
which accept the wheel spindles. adjustment of the bearing pre-load. A grease nipple
located in the wheel hub assembly allows for regular
The wheel spindles mount to the left-hand and greasing of the wheel bearing.
right-hand outer axle assemblies with bushings. A
thrust bearing on the lower end of each wheel spindle A drag link operates a steering gear arm on the front
supports the axle assemblies during vertical thrust. support assembly, and two track control rods connect
the steering gear arm to the left and right hand
spindle arms.
1
Front Axle Assembly (Power Steering shown)
1. Track Rod Assembly 5. Front Support Assembly
2. Steering Cylinder 6. Axle Assembly Right Hand
3. Axle Assembly (left hand) 7. Axle Beam
4. Front Axle Pivot Assembly
44-3
ADJUSTMENTS
4 1
Front Wheel Toe-in/Toe-out Adjustment
Front wheel toe-in / toe-out adjustment is accom-
plished by setting the length of the right-hand track
control rod. The correct toe-in setting is set in
production. The spindle arms and outer axle
assemblies are marked to identify the correct
position of the front wheels, with the steering in the
straight-ahead position, Figure 2.
2
10024883
3
2
Front Wheel Toe-in Adjustment
If the toe-in alignment marks on the spindle arms and
outer axle assemblies are not visible, or installation 1
of replacement parts occurred, use the following
procedure to determine the toe-in setting:
1. On flat, level ground, slowly drive the tractor in a 2

straight line for at least 3 m (10 ft). Stop the tractor
and ensure the front wheels remain in the
straight-ahead position.
2. Mark the inboard rim of both front wheels toward
the front, at center of wheel hub.
24666
3. Measure the distance between the two marks
and note as dimension ‘A’, Figure 3. 3
4. Maintain the straight-ahead position, and move

the tractor forward so the wheels rotate 180_ and
the marks on dimension ‘A’ face the rear.
5. Measure the distance between the two marks
and note as dimension ‘B’.
NOTE: If dimension A is larger then B, the toe-out is
A minus B. If dimension B is larger than A, the toe-in
is B minus A.
6. To ensure accurate results, repeat procedure

three times with three different marks equally
spaced around each wheel rim, and take the
average dimension for toe-in / toe-out. This
method minimizes inaccuracy due to wheel rim
run-out.
7. Check front wheel toe-in at 0-6.0 mm (0-0.24 in.),
i.e. the measurement taken at the front of the
rims should be the same as the rear or be smaller
by up to 6 mm (0,24 in.). Proceed with steps 8
through 12 if not within specification.
8. Set the front wheels in the straight-ahead
position.
44-4
9. Remove the right-hand track control rod clamp
bolt (3), and loosen the locating bolt (1), Figure
4.
4
Track Rod -- Hydrostatic Steering
(left-hand side illustrated)
1. Locating Bolt
2. Threaded Section
3. Clamp Bolt
Toe-In Adjustment without Alignment Marks

Turn the threaded portion of the track control rod,
until obtaining the desired toe-in. Check after
reinstallation of clamp bolt. After obtaining correct
toe-in adjustment, establish new alignment marks on
the spindle arms and outer axle assemblies.
Toe-In Adjustment with Alignment Marks

Turn the threaded portion of the track control rod,
until the desired marks align on both spindle arms
and the outer axle assemblies, Figure 4. Check
marks after reinstalling the clamp bolt.
1. Install the track control rod clamp and locator

bolts. Tighten to 25 N⋅m (18 ft.-lbs.).
2. Recheck toe in.
Front Wheel Track Adjustment

WARNING
The 10 ’S’ series tractor contains lights, which
meet lighting requirements for operating or
traveling on public highways; Adjustment to the
wheel track length beyond the initial factory
setting, may require repositioning of the lights to
comply with legal requirements. Additionally, the
tractor width should never exceed the maximum
length permitted by law.
1. To extend the front wheel track, apply the

handbrake and place blocks at the front and rear
wheels. Jack up the front axle and place on axle
stands.
2. To permit adjustment of the axle track,
disconnect the track control rods.
44-5
3. Remove the outer axle assembly retaining bolts,
and move the telescopic sections of the axle
assemblies as shown in Figure 5, until obtaining
the desired position. Reinstall the outer axle
assembly bolts. Adjust both ends of the track
control rod equally, when varying the front wheel
center track length.
4. Tighten the front wheel axle track retaining bolts
to a torque of 210 N⋅m (155 ft.-lbs.). Recheck all
torque settings after 50 hours of operation.
5. Position the front wheels straight ahead to align
toe-in marks on both the spindle arms and outer 20025064
axle assemblies.
5
6. Align the track control rod locator clamps with the
nearest notches. Install bolts and tighten to 25
N⋅m (18 ft.-lbs.).
NOTE: Check for an equal number of notches
exposed at either end of the track control rod.
Front Wheel Toe-out Adjustment
After resetting the front wheel track length, the front
wheel toe-out may require adjustment. For correct
operation, the front wheels should be parallel or toe
out slightly.
Measure the distance between the wheel rims, at the

front of the wheels, at the center of the wheel hub.
Rotate both front wheels 180_ and check the
measurements again, this time at the rear of the
wheels. This will eliminate wheel rim run-out errors.
The correct toe-out setting is 0-13 mm (0-0.5 in.), i.e.
the measurement taken at the front of the rims should
be the same as the rear or greater by up to13 mm (0.5
in.)
Should it be necessary to adjust the front wheel

toe-out, proceed as follows:
Remove the locator bolt (1) figure 6, from the

left-hand end of the track control rod. Loosen the
clamp bolt (3), and turn the threaded section (2) in or
out until the toe out is correct with locator bolt
reinserted. Tighten to 25 N⋅m (18 ft.-lbs.).
44-6
FRONT WHEEL SPINDLE - OVERHAUL

Disassembly
NOTE: For overhaul of the wheel bearings only,
follow steps 1-8. For overhaul of the spindle bearings
only, proceed from step 9
1. With the tractor on firm level ground, apply the

handbrake and chock the rear wheels. Loosen
the front wheel retaining nut 1/4 turn.
2. Use a suitable jack or hoist to raise the front
wheels off the ground.
3. Remove the wheel retaining nuts and remove
wheel assemblies. 1
4. Unscrew the hub grease-retaining cap.
5. Remove the cotter pin installed in the castellated 2
nut. Remove nut and washer, Figure 6.
6. Remove the hub assembly, and the outer cone
and roller assembly from the front wheel spindle.
3
10024884
6
7. Remove the inner cone and roller assembly from
the wheel spindle. Remove the grease retainer.
8. Remove the nut and bolt retaining the spindle 1
arm.
9. Remove the spindle arm from the spindle. If the
spindle arm is tight, use Puller Tool No. 1002 or 4
9198, Attachment Tool No. 951 or 9190 and Shaft
Protector Tool No. 625-A or 9212 to aid in
removal, Figure 7.
2
3
10024885
44-7
10. Remove the spindle key and dust seal, Figure 8
11. Remove the wheel spindle and thrust bearing
from the axle. 1
10024886
8
Allow parts to dry. Lightly lubricate the machined
surfaces.
2. Inspect the roller bearing cones, rollers, and cups
for signs of excessive wear or damage. Replace
any damaged parts as necessary.
3. Inspect the spindle bushings in the axle housings
for wear or scoring. If replacement is necessary,
remove the axle outer section from the tractor,
using Driver Set Tool No. 818 or 9514, and T-818
or 9515. Take care not to damage the axle outer
section bores.
NOTE: Check for proper seating of cups against the
shoulders in the wheel hub.
4. Inspect the spindle thrust bearing for correct

operation and replace if necessary.
5. Inspect the wheel spindle bearing surfaces for
scoring or excessive wear.
44-8
Assembly
1. Pack the thrust bearing with a suitable grease,
and install on the wheel spindle with the shroud
facing upwards as indicated by the manufactur- 1
er’s reference stamp on the bearing, Figure 9.
2. Install the wheel spindle into the outer axle
assembly, and check for smooth rotation in the
bushings.
3. Install a new wheel spindle dust seal with the
2
groove in the outer boundary of the seal nearest
the base.
10024887
4. Install the key in the wheel spindle, and then
install the spindle arm. Ensure the alignment of 9
the bolt hole in the arm with the recess in the
spindle. Install the bolt, lock-washer and nut.
Tighten to a torque of 165 N⋅m (122 ft.-lbs.).
5. Install the wheel hub grease retainer.
6. Install the front wheel inner bearing cone and
roller assembly on the spindle.
7. Pack the wheel hub and bearings with suitable
grease. Install the wheel hub.
8. Install the front wheel outer bearing cone and
roller assembly on the spindle.
9. Install the hub retainer washer with the tab in the
spindle key-way. Install the wheel hub, retaining
nut.
10. Tighten the wheel hub retaining nut to an initial
11. Rotate the hub clockwise 3 to 6 revolutions.
12. Tighten the hub retaining torque to a final torque
of 61-74 N⋅m (45-55 ft.-lbs.).
13. Back off the retaining nut by two flats, and then
retighten to the nearest position to allow insertion
of a new cotter pin.
14. Install the wheel and tire assembly on the hub
and install nuts.
15. Remove the jack or hoist, and the wheel chocks.
44-9
CENTER STEERING ARM - OVERHAUL

Removal
1. Remove the radiator as outlined in Section 10
Chapter 1.
2. Remove the track control rod lock nuts and
disconnect the two control rods from the center
steering arm.
3. Remove the lock nut and drag link from the
center steering arm.
4. Rotate the center steering arm to gain access to
the bolt, which secures the steering arm to the
shaft, then remove the bolt.
5. Remove the grease cap and bolt.
6. Extract the center steering arm shaft.
7. Remove the center steering arm from the front
support assembly.

1. Clean all components with suitable solvent.
Allow parts to dry.
2. Inspect the center steering arm shaft bushings
for excessive wear and damage. Replace if
necessary using Driver Set Tool No.818 or 9514
and T-818 or 9515.
3. Inspect the center steering arm for cracks or
distortion and replace if necessary.
Installation
Installation follows the removal procedures in
reverse, with the following requirements in addition:
1. Pack bushings with suitable grease before

installation.
44-10
FRONT AXLE - OVERHAUL Plate Tool No. 630-S or 9210. Reinstall the
grease-retaining plug.
Disassembly
3. Inspect the front axle support assembly for
1. Use a suitable jack or hoist to support the front cracks and other damage. If necessary, replace
end of the tractor. Chock the wheels. the support assembly using the procedures
2. Remove the track rod outer retaining nuts and below:
disconnect the rods from the spindle arms. • Remove the radiator as outlined in Section
3. Remove the outer axle assembly bolts and nuts, 10.
and remove outer axle and wheel assemblies. • Disconnect the drag link from the center
4. Support the front axle beam to remove weight off steering arm
the support pins. • Support the weight of the front support
assembly, remove the retaining bolts, and
5. Straighten the locking tabs on the support pin
remove assembly.
anchors.
• Install a new front support assembly with
6. Remove the axle support pin retaining bolts and retaining bolts following the procedures
anchors. outlined in “Separating the Tractor”.
7. Use a rod in the cross-drillings to push out the NOTE: Insert a correct amount of spacers between
support pins sufficiently enough to gain access to the engine oil pan and the front axle support
the retaining bolt flange. Remove the pins. assembly to fill the gap, before installing the lower
bolts and nuts. For spacer thickness available, see
8. Remove the thrust washer, and the center axle
“Specifications”.
beam from the tractor.
4. Reinstall the radiator as outlined in Section 10.
1. Clean all components with a suitable solvent. Assembly
Allow parts to dry. Assembly follows the disassembly procedures in
2. Inspect the front support assembly pin bushings reverse, with the following requirements in addition:
for excessive where and damage. If necessary,
remove the bushing grease retaining plug with a 1. Pack bushings with suitable grease before
suitable drift and replace the bearing using Step installation.
44-11
44-12
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 1
Chapter 1 - Description, Operation and Overhaul
CONTENTS

Specifications -- Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lighting and Instrumentation Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical Components -- Description, Operation and Overhaul . . . . . . . . . . . . . . . . . . . . . . 24
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Instrument Panel Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Instrument Panel Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Instrument Panel Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Four--Wheel Drive Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Dual Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Key--Start Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Warning Flasher Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Power Take Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Neutral Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cold Advance Thermostatic Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Air Cleaner Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
55-1
Fuel/Water Separator Warning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Work Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Oil Pressure Sender Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Stop Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Main Fuel Tank Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Auxiliary Fuel Tank Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Instrument Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fender Mounted Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
External Headlamp Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Tail/Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Work Lamp Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Grille Mounted Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
55-2
SPECIFICATIONS
STARTING SYSTEM
Description
Battery
y ((wet)) Ampere capacity 107 A
Ampere rating (cold cranking) 800 CCA
Voltage 12 V
Cells 6
Ground polarity Negative
Alternator Type A127 55 A
Ground polarity Negative
Nominal voltage 12 V
Maximum alternator rev/min 15,000 rev/min
Maximum out-put at max engine speed 45 A
Rotor field winding resistance 3.2 ohm
Stator winding resistance (per phase) 2.43 ohm
Brush length (new) 17 mm (0.67 in.)
Minimum brush length 5 mm (0.20 in.)
Alternator Internal
Regulator Controlled voltage 13.6-14.4 V
Starting
g Motor Positive engagement - solenoid operated
Maximum no-load current draw at 12 V and 80 A
8000 rev/min
Minimum brush length 7 mm (0.28 in.)
Maximum commutator diameter 42.5 mm (1.67 in.)
Maximum armature shaft end-play 0.4 mm (0.016 in.)
55-3
COMPONENTS
Description
Horn Voltage 12 V
Maximum current draw 5.2 A
Oil Pressure Switch Voltage 12 V
Operating pressure 0.55-0.83 bar (8-12 psi)
Engine
g Coolant Temperature
p Voltage 12 V
S d
Sender Resistance 400 ohm at 38_ C (100_ F)
Air Cleaner Restriction Switch Voltage 12 V
Operating pressure 920-930 mbar atmospheric
pressure
Fuel Gauge
g Voltage 12 V
Resistance at Low calibration mark 250 ohm
Resistance at High calibration mark 19 ohm
Resistance at Full mark 88 ohm
Resistance at 1/2 Full mark 44 ohm
Resistance at Empty mark 1 ohm
Temperature
p Gauge
g Voltage 12 V
Temperature
p Gauge
g Voltage 12 V
Resistance at Center calibration mark 113 ohm
Auxiliaryy Fuel Pump
p Voltage 12 V
Maximum current draw at zero delivery 1.6 A
Main Fuel Tank Sender Voltage 12 V
(P N
(Part Number
b 82983007)) Resistance EMPTY 250 +/-- 4 ohm
Resistance FULL 31 +/-- 4 ohm
Main Fuel Tank Sender Voltage 12 V
(P N
(Part Number
b EE3NN9A316BA)
NN A BA) Resistance EMPTY 250 +/-- 10 ohm
Auxiliaryy Fuel Tank Sender Voltage 12 V
7010/8010
/ Resistance EMPTY 250 +/-- 4 ohm
(Part Number 82983006)
Resistance FULL 40 +/-- 3.5 ohm
Auxiliaryy Fuel Tank Sender Voltage 12 V
7010/8010
/ Resistance EMPTY 250 +/-- 10 ohm
(Part Number D8NN9A316LB)
55-4
LAMPS
Description Quantity Rating/Type
Instrument Panel Illumination Bulbs 2 12 V
Instrument Panel Warning Light Bulbs 4 12 V
Working Lamp Bulb 1 12 V 55 W - H3
Tail Lamp/Warning Flasher Bulbs 2 12 V P21/5 W
Turn Signal Bulb (where installed) 2 12 V 21W
License Plate Bulb (where installed) 2 12 V 10 W - R19/10
Headlamp Bulbs 2 12 V 60/55 W - H4
TORQUE VALUES
Description N⋅⋅M LB FT (LB. IN.)
Starting Motor Housing Bolts 114 mm (4.5 in.) 7 N⋅m 5 (60 lb. in.)
Starting Motor Housing Bolts 127 mm (5 in.) 11 N⋅m 8 (96 lb. in.)
Starting Motor-to-Fly Wheel Housing Bolts 30 N⋅m 22 (264 lb. in.)
Starting Motor Solenoid Terminal Nuts 7 N⋅m 5 (60 lb. in.)
Starting Motor Solenoid Retaining Nuts 5 N⋅m 4 (48 lb. in.)
Starting Motor–to-Engine Block Retaining Bolts 34 N⋅m 25 (300 lb. in.)
Starting Motor End-Housing Nuts 10 N⋅m 7 (84 lb. in.)
Starting Motor Drive-Lever Eccentric Pivot Pin 22 N⋅m 16 (192 lb. in.)
Starting Motor End-Housing Ground Cable 15 N⋅m 11 (132 lb. in.)
Starting Motor Ground Cable Securing Nut 7 N⋅m 5 (60 lb. in.)
Alternator Main Output Terminal 6 mm (0.24 in.) 4 N⋅m 3 (36 lb. in.)
Alternator Phase Terminal Nut 5 mm (0.20 in.) 4 N⋅m 3 (36 lb. in.)
Alternator Shaft Nut 38 N⋅m 28 (336 lb. in.)
Alternator Housing Bolts 5 N⋅m 4 (48 lb. in.)
Alternator Rear Cover Screws 3 N⋅m 2 (24 lb. in.)
Alternator Regulator Retaining Screws 5 N⋅m 4 (48 lb. in.)
Alternator Terminal Nuts 3 N⋅m 2 (24 lb. in.)
Alternator Rectifier Retaining Screws 3 N⋅m 2 (24 lb. in.)
Alternator Regulator/Brush-Box Screws 3 N⋅m 2 (24 lb. in.)
Governor Drive Gear Nut 136 N⋅m 100 lb. ft.
Governor Housing-to-Engine Front Cover Bolts 30 N⋅m 22 (264 lb. in.)
Warning Flasher Switch Retaining Nut 4 N⋅m 3 (36 lb. in.)
Horn Assembly Retaining Nut 4 N⋅m 3 (36 lb. in.)
Coolant Temperature Sender Switch 34 N⋅m 25 (300 lb. in.)
Air Cleaner Restriction Warning Switch 8 N⋅m 6 (72 lb. in.)
Oil Pressure Sender Switch 30 N⋅m 22 (264 lb. in.)
Battery Terminal Retaining Nuts 7 N⋅m 5 (60 lb. in.)
Key-Start Ignition Switch Retaining Nut 8 N⋅m 6 (72 lb. in.)
Lights Switch Retaining Nut 8 N⋅m 6 (72 lb. in.)
Fuel Tank Float Retaining Nut 3 N⋅m 2 (24 lb. in.)
Turn Signal Switch Retaining Nut 4 N⋅m 3 (36 lb. in.)
Tail/Warning Lamp Retaining Nut 10 N⋅m 7 (84 lb. in.)
Work Lamp Retaining Nut 18 N⋅m 13 (156 lb. in.)
Headlamp Retainer Securing Nut 16 N⋅m 12 (144 lb. in.)
55-5
FAULT FINDING
IMPORTANT: To avoid repeat failures, investigate
and correct the cause of the defect when making
repairs to the electrical system.
LIGHTING AND INSTRUMENTATION SYSTEMS

Several or all lights
g do not illuminate Battery discharged Recharge battery
Battery cables/terminals loose or Clean cables/terminals, tighten
defective connections, or replace defective
component
Harness connections loose Check connections for tightness
Fuse burned out Check circuit and replace fuse
Wiring defective Check circuit wiring and repair
Light switch defective Repair or replace switch
Bulbs burned out Check voltage regulator
Individual lights
g do not illuminate Bulb faulty or burned out Replace bulb
Bulb contacts defective or cor- Clean contacts or repair
roded
Fuse burned out Check circuit and replace fuse
Wires loose or broken Repair or replace wiring
Ground connection poor Clean and tighten ground connec-
tion
Lights
g burn-out repeatedly
p y Wire corroded or loose Repair or replace wiring
Bulb or mounting bracket loose Tighten bulb or bracket
Voltage regulator faulty Replace voltage regulator if neces-
sary
Warningg lights
g and g
gauges
g Key-start ignition switch faulty Replace switch
inoperative Fuse burned out Check circuit and replace fuse
Key-start ignition switch connec- Tighten connectors on back of
tors loose switch
Wiring defective Check wires and repair
Gauge
g erratic or inoperative
p Wiring defective Check wires and repair
Connectors loose Tighten connectors on back of
instrument panel
Gauge defective Replace gauge
Sender defective Replace sender
Voltage stabilizer defective Replace voltage stabilizer
Auxiliary fuel tank change-over Replace fuel change-over switch
switch defective (where installed)
55-6
STARTING SYSTEM
Engine
g will not crank and starting
g motor Battery discharged Charge battery
relay or solenoid will not engage Key-start ignition switch defective Check circuit, replace switch
Starting system relay defective Check circuit, replace relay
Neutral start switch defective Check circuit, replace switch
Starting circuit open, or high Check circuit connections and repair
resistance
Engine will not crank with starting motor Engine seized Check engine crankshaft. If binding,
relay or solenoid engaged repair defective component or check
remaining engine components.
Battery discharged Charge battery
Starting motor connections loose or Tighten connections or replace
defective
Battery connections loose or defective Tighten connections or replace
Starting motor defective Overhaul or replace starting motor
Starting motor relay or solenoid Check circuit and replace relay or
contacts burnt solenoid
Engine will not crank with starting motor Starting motor drive assembly Overhaul or replace starting motor
turning
g defective
Solenoid or pinion engagement levers Replace defective component
defective
Flywheel ring-gear defective Replace defective component
Engine
g cranks slowlyy Battery discharged Charge battery
Starting circuit operates under Check system components and replace
excessive resistance defective part
Starting motor defective Overhaul or replace starting motor
CHARGING SYSTEM
Battery
y low in charge
g or discharge
g Drive belt loose or worn Adjust tension or replace belt
Battery electrolyte low Replenish electrolyte
Connections loose causing high Tighten loose connections
resistance
Temperature sensor defective Replace sensor
Voltage regulator defective Replace voltage regulator
Alternator defective Overhaul or replace alternator
Battery
y overheats Battery defective Service battery or replace
No alternator output
p Drive belt loose, worn or broken Adjust tension or replace belt
Connections loose or broken Tighten or repair connection
Intermittent or low alternator output
p Drive belt loose, worn or broken Adjust tension or replace belt
Connections loose or broken Tighten or repair connection
55-7
ALTERNATOR
Warning light dims and/or battery Charging circuit connection faulty Repair or replace defective
low connection
Rotor slip-rings or brushes Replace slip-rings or brushes
defective
Warningg light
g extinguishes
g but Rectifier defective Repair or replace rectifier
brightens with increased speed Charging circuit connection faulty Repair or replace defective
connection
Warning
g light
g out with batteryy hot Voltage regulator defective Replace voltage regulator
Temperature sensor defective Replace temperature sensor
Warningg light
g out with batteryy Voltage regulator defective Replace voltage regulator
discharged Stator defective Replace stator
Rectifier or diodes defective Replace rectifier or diodes
Warningg light
g illuminates Drive belt loose or broken Adjust tension or replace belt
continuously Surge protection diode defective Replace surge protective diode
Isolation diodes defective Replace isolation diodes
Temperature sensor defective Replace temperature sensor
defective
Stator defective Replace stator
Rectifier or diodes defective Replace rectifier or diodes
Warningg light
g extinguished
g Bulb burned out Replace bulb
continuously Alternator connection faulty Repair connection
defective
Stator defective Replace stator
Warning
g light
g flashes intermittentlyy Alternator connection faulty Repair connections
Charging system defective Check circuit and repair
Warning light dims continuously Rotor slip-rings or brushes Replace slip-rings or brushes
defective
55-8
ENGINE WILL NOT START WITH THE TRANSMISSION IN NEUTRAL,

PTO DISENGAGED, AND THE KEY-START IGNITION SWITCH IN POSITION 5
Is the battery fully charged? NO Recharge battery

YES
Is the fully charged battery producing NO Replace defective battery

approximately 12.6 V?
YES
With the key-start ignition switch in Investigate the engine for seizing.
Position 5, is the starting motor trying to YES Repair or replace defective
crank the engine? component(s)
NO
With the key-start ignition switch in

Position 5, is there +12 V at the starting YES Is the solenoid clicking?
motor solenoid? NO YES
NO
Replace defective Suspect faulty

solenoid windings, brushes or
mechanical failure of
the starting motor
Check neutral start switch circuit for

loose, frayed or broken wires and YES Repair wire or connector
connectors. Defect found?
NO

Position 5, is there +12 V to the neutral YES Replace neutral start switch
start switch?
NO
55-9

Position 5, is the starting system relay YES Replace starting system relay
clicking?
NO

Position 5, is there +12 V to the starting YES Replace starting system relay
system relay?
NO
With the PTO switch in the closed Investigate PTO switch and harness.
(disengage) position, is there +12 V to the NO Repair or replace defective component
starting relay?
YES
With the key-start ignition switch in Check the main feed to the key-start
Position 2, do the displays on the NO ignition switch from the battery
instrument panel function?
YES
Check the key-start ignition switch wires Repair wires or connectors

YES
and connectors. Defect found?
NO
Replace key-start ignition switch
55-10
ELECTRICAL SYSTEM
PRECAUTIONARY STATEMENTS IMPORTANT: Note the routing of the wiring, position
Observe the following precautions to avoid damage of the wiring clamps, and terminal connections
to equipment, personal injury, or death. before removing components to facilitate installation.
IMPORTANT: Do not allow wiring and clamps to

WARNING come in contact with sharp edges, exhaust system
Batteries contain sulfuric acid. Avoid contact components or moving parts.
with the skin, eyes and clothing. Wear protective
clothing and face shield when working on IMPORTANT: Check conductors for exposure, and
batteries. terminal connections for correct engagement.
WARNING IMPORTANT: Check circuit current draw before

applying power to a new wire harness.
Do not make or break electrical connections,
including the battery terminals, with the engine
running. DESCRIPTION AND OPERATION
Conventional in design, the electrical system
features a 12-volt (wet) type battery, 55-amp
WARNING alternator, key-start ignition, neutral start and PTO
Do not short-circuit any charging components to safety switches. The wiring, lights, and instrumenta-
ground. tion specifications of the tractor will vary by model.
The standard lighting configuration includes:

WARNING
Disconnect the battery negative (ground) cable • Dual Beam Halogen Headlamps (front grille,
before installing or removing electrical compo- fender or side-mounted)
nents, performing maintenance on electrical • Halogen Working Lamp
components, or when using a battery charger. • Red/Amber Tail Lamps
WARNING
Supplemental lighting combinations available (not in
Observe correct polarity when installing batter- all markets), which satisfy local governmental
ies or using a single slave battery to jump-start regulations, operational requirements, and operator
the engine. Follow the instructions in the preferences, include:
operator’s manual, as well as the battery
manufacturer’s recommendations. • Utility Lamp
• Turn Indicator Lamps
WARNING • Stop Lamps
Always replace fuses with the correct type and • Implement Lamp
correct rating. • License Plate Lamps
• Position Lamps
IMPORTANT: Check terminals and connections for
continuity and tightness before operating electrical
components.
55-11
The electrical system incorporates various compo- WIRE HARNESSES
nents, which provide for the operation, regulation The wire harnesses form an electrical circuit, which
and protection of the electrical system. The standard directs power to the components of the electrical
electrical configuration will contain all, or several of system by location. The harnesses attach with
the following components: connectors, and route from the front of the tractor to
the rear, and up the fenders. Each harness removes
• Instrument Panel independently of one another to facilitate mainte-
• Four-Wheel Drive Select Switch nance. The electrical system includes all or several
• Dual Power Select Switch of the following harnesses:
• Key-Start Ignition Switch
• Grille Mounted Headlamp Harness
• Lights Switch
• Front-Main Harness
• Horn Switch
• Fuel/Water Warning Switch Harness
• Power Take Off (PTO) Switch
• Fuel Pump Harness
• Neutral Start Switch
• Rear-Main Harness
• Cold Advance Thermostatic Switch
• Rear Harness
• Thermostart Switch
• Power Take Off (PTO) Switch Harness
• Fuel/Water Separator Warning Switch
• Left Fender Harness
• Air Cleaner Restriction Switch
• Right Fender Harness
• Stop Lamp Switch
• Turn Signal Switch
• Work Lamp Switch
• Warning Flasher Switch
• Warning Flasher Unit
• Engine Oil Pressure Sender
• Engine Coolant Temperature Sender
• Main Fuel Tank Sender
• Auxiliary Fuel Tank Sender
• Starting System Relay
• Fuse Box
55-12
Grille Mounted Headlamp Harness - Description
and Location 3
The grille mounted headlamp harness (1) connects
to the front-main harness (2) to form connector C1
behind the coolant overflow tank (3), in front of the
radiator, Figure 1.
2
1
40025666
1
The harness connects to each headlamp assembly
(1), at the back of the grille, Figure 2.
1
40025667
2
Front-Main Harness - Description and Location
The front-main harness begins at two multi-connec-
tor plugs (1), located forward of the main fuel tank.
The connectors attach to the rear main-harness to
form connectors C2-A and C2-B. In addition, a
ground wire (2) connects to the rear support
assembly, Figure 3.
2
1
40025668
55-13
Connector C2-A (1) contains nine pins and
connector C2-B (2) contains four pins, Figure 4.
1
Table 1 identifies the circuits completed by the
connectors.
2
Table 1 (Emissionized Engine)
Connector Circuit
C2-A Horn
C2-A Alternator
C2-A Fuel Shut-off Relay
C2-A Coolant Temperature Warning 40025669
C2-A Ground Wire 4

C2-A Oil Pressure Warning
C2-A Air Restriction Warning
C2-A Headlamp
C2-A Headlamp
C2-B Ignition Switch-to-Starting Solenoid
C2-B Ignition Switch-to-Thermostart
C2-B Neutral Switch-to-Starting Solenoid
C2-B Tachometer
The front-main harness (1) routes downward to the

alternator regulator, and along the engine cylinder
head, where it splits at the front of the engine block
(2), Figure 5. 1
2
40025670
5
The components, which receive power from the
front-main harness, include:
• Grille Mounted Headlamp Harness (1), 2

located behind the coolant overflow tank (2),
in front of the radiator, Figure 6.
40025666
55-14
• Horn Assembly (1), located in front of the air
cleaner at the front of the engine, Figure 7.
40025671
7
• Air Cleaner Restriction Switch (1), located in
the air intake tube over the engine near the
thermostat housing, Figure 8.
40025672
8
• Engine Coolant Temperature Sender (1),
located in the thermostat housing; Figure 9
(Low profile six-cylinder shown).
40025674
55-15
• Alternator (1), located at the front, left-hand
side of the engine, Figure 10.
1
40025675
10
• Oil Pressure Sender Switch (1), located on
the left-hand side of the engine block, Figure
11.
40025676
11
• Starting Solenoid (1), located on the top of
the starting motor (2) on the right-hand side
of the engine block, Figure 12.
2
NOTE: Figure 12 illustrates the starting motor
solenoid with the protective cover removed for
illustration purposes.
NOTE: The front-main harness receives protection

from overload conditions through a fuse link
incorporated between the starting solenoid wiring, 1
and the multi-connector plug.
40025680
12
55-16
• Thermostart Element (1), located on the air
intake manifold, Figure 13.
• Battery Temperature Sensor, located on the
back of the battery tray.
40025682
13
Fuel Pump Harness - Description and Location
A change to the fuel system circuit in July 1999
included the incorporation of the fuel pump harness 2
for emissionized engines. The harness routes along
the front of the engine and down the right-hand side
of the block to direct current to the following
components:
1
• Fuel Shut-off Solenoid (1), located on the fuel
injection pump (2), on the right-hand side of
the engine block, Figure 14.
40025678
14
• Cold Advance Thermostatic Switch (1),
located in the thermostat housing, Figure 15
(high clearance 4-cylinder shown).
40025673
15
55-17
• Lift Pump (1), located on the fuel filter
assembly on the right-hand side of the 1
engine block, Figure 16.
40025679
16
• Fuel Injection Pump Wax Plug (1), located on
the right-hand side of the engine block,
Figure 17.
1
40025681
17
Fuel/Water Separator Warning Switch Harness -
Description and Location
The fuel/water separator warning switch harness
connects to the fuel/water separator (1), Figure 18,
and routes along the top of the cylinder head along
side the front-main harness. The opposite end
connects to the instrument panel cluster.
1
40025677
18
55-18
Rear-Main Harness - Description and Location
The rear-main harness begins at two multi-connec-
tors (1), Figure 19, forward of the main fuel tank.
50030974
19
The multi-connectors attach to the front-main
harness to form connector C2-A (1) and C2-B (2), 3
Figure 20. The rear-main harness routes over the top
of the main fuel tank, down the steering column, and
attaches at the opposite ends to the PTO switch to 1
form connector C3, and to the rear harness to form 2
connector C4.
The rear-main harness incorporates a fuse box (3), 4

which mounts on the rear support assembly (4),
Figure 20, to protect the electrical systems and
components from overload conditions.
40025683
20
The components connected to the rear-main
harness include:
• Fuel Shut-off Relay (1), located at the rear

support assembly, Figure 21. 1
2
• Starting System Relay (2), located at the rear
support assembly, Figure 21.
40025684
21
55-19
• Fuel Shut-off Relay Diodes (1), located inline
of the fuel shut-off relay, Figure 22.
40025684
22
• Instrument Panel (1) located on the rear
hood assembly, forward of the steering
wheel, Figure 23.
40025685
23
• Main Fuel Tank Sender (1), located on top of
the main fuel tank probe, underneath the
instrument panel, Figure 24.
1
40025686
24
55-20
• Key-Start Ignition Switch (1), located on the
rear hood assembly, on the right side of the
steering wheel, Figure 25.
• Turn Signal Switch (2), located on the rear
hood assembly, on the right side above the 2
key-start ignition switch; Figure 25 (not
shown).
1
40025687
25
• Dual Power Select Switch (1), located on the
rear hood assembly, on the left side of the
steering wheel, Figure 26.
1
40025688
26
• Four Wheel Drive Select Switch (1), located
on the rear hood assembly, on the right side
of the steering wheel, Figure 27.
1
40025689
27
55-21
• Lights Switch (1), located on the rear hood
assembly, lower left-hand side, Figure 28.
1
• Horn Switch (2), located on the rear hood
assembly, on the lower left-hand side below
the lights switch, Figure 28.
2
40025690
28
• Warning Flasher Switch (1), located on the
steering motor cover, left-hand side, Figure
29. 1
40025691
29
• Auxiliary Fuel Tank Sender located on top of
the auxiliary fuel tank probe under the
left-hand platform (1), Figure 30.
40025692
30
55-22
The rear-main harness ends at connector C3 where
it attaches to the PTO switch harness (1), and at
connector C4, where it attaches to the rear harness 1
(2), behind the steering motor cover, Figure 31. 2
40025693
31
Rear Harness (Models with fender mounted
headlamps) - Description and Location
The rear harness connects to the rear-main harness
at connector C4 (1), Figure 32, behind the steering
motor cover (2), and routes down to the left-hand
platform. The harness then routes along the
transmission, splits near the rear axle, and routes to 1
the left and right-hand fenders, directing current to
the tail/warning lights, fender mounted headlamps
and the work lamp.
2
NOTE: Figure 32 shows the steering motor cover
partially removed for the purpose of illustration. 40025694
32
Rear Harness (Models without fender mounted

headlamps) - Description and Location
The rear harness connects to the rear-main harness
at connector C4 (1) behind the steering motor cover,
and routes down and along the left-hand platform (2),
Figure 33.
NOTE: Figure 33 shows the steering motor cover 1

partially removed for the purpose of illustration.
2
40025693
33
55-23
The rear harness (1) attaches to the left-hand fender
harness (2) near the left brake control rod (3), Figure 3
34 to form connector C5, and to the right-hand fender
harness to form connector C6 (not shown) in the
same area.
2
Left Fender Harness (Models without fender 1
mounted headlamps) - Description and
Location
The left fender harness connects to the rear harness
at connector C5 and routes up the left fender to direct
current to the tail/warning lamp. A spur lead from the 40025695
left-hand tail/warning lamp directs power to the work
lamp. 34
Right Fender Harness (Models without fender

mounted headlamps) - Description and
Location
The right fender harness connects to the rear
harness at connector C6 and routes along the edge
of the lift cover and up the right fender to direct
current to the tail/warning lamp.
ELECTRICAL COMPONENTS - DESCRIPTION, OPERATION AND OVERHAUL

INSTRUMENT PANEL
The instrument panel (1), Figure 35, provides
gauges and warning lights for monitoring system
performance, operational limits and malfunctions,
which may occur when operating the tractor.
The electronic tachometer and the mechanical

tachometer type instrument panel contain the same
standard components, but differ in installation and in
appearance. The instrument panel (regardless of
type) will contain all, or most of the following
components depending on model: 1
40025696
35
Refer to Figure 36.
7 8 1
• Coolant Temperature Gauge (1)
• Oil Pressure Warning Light (2)
• Fuel/Water Separator Warning Light (3)
• Tachometer (4)
• Air Cleaner Restriction Warning Light (5)
• Alternator Charging Warning Light (6)
• Fuel Gauge (7)
• Hour Meter (8) 6 4
5 3 2
40025696
36
55-24
The instrument panel incorporates cavities for the
installation of two additional warning light bulbs (1),
Figure 37. The cavities remain plugged when not in
use.
The electronic tachometer replaced the mechanical

tachometer in production as shown in Table 2. The
electronic tachometer and instrument panel service
kit includes a wire cluster, which provides the wiring
configuration required for installation in place of the
mechanical tachometer.
1
Table 2 40025697
Tractor Model Serial Number 37

5610S 311297M and after
8010 HC 801814M and after
INSTRUMENT PANEL GAUGES

The electronic instrument cluster receives a
square-wave signal generated by one phase of the
alternator at terminal W.
2
Tachometer and Hour Meter

The tachometer (1) indicates engine revolutions per
minute on a scale of 100 rev/min units. The hour
meter (2) records the total operating time of the
tractor, which provides a guide for determining 1
service intervals, Figure 38.
50030975
38
Two PTO symbols on the tachometer scale (1),
Figure 39, indicate engine speed at which the PTO
shaft obtains 540 or 1000 rev/min for standard PTO
operation.
50030975
39
55-25
Coolant Temperature Gauge
The coolant temperature gauge (1), Figure 40,
indicates coolant temperature with the engine
operating. The needle will enter the red area on the
scale when the coolant temperature rises above the
recommended engine operating temperature. The
temperature sender in the thermostat housing
controls the needle on the gauge, which receives
power from the key-start ignition switch in Position 2.
Fuel Gauge
2 1
The fuel gauge (2), Figure 40, indicates the level of 40025696
fuel in the main and auxiliary (where installed) fuel
tanks. The needle will enter the red area of the scale 40
when the fuel level reduces to less than ¼ of a tank.
The fuel tank senders control the needle on the
gauge, which receives power from the key-start
ignition switch in Position 2.
INSTRUMENT PANEL WARNING LIGHTS

Alternator Charging System Warning Light
The alternator charging system warning light, Figure
41, will illuminate on the instrument panel if
insufficient charge from the alternator occurs during
engine operation. It is normal at first start-up for the
light to briefly illuminate, and extinguish when engine
speed increases above idle.
40025698
41
Air Cleaner Restriction Warning Light
The air cleaner restriction warning light, Figure 42,
will illuminate on the instrument panel during engine
operation, if the air cleaner restriction switch detects
an increase in vacuum in the air intake tube. This
condition indicates an obstruction in the air cleaner,
or a dirty air cleaner filter.
40025698
42
55-26
Fuel/Water Separator Warning Light
The fuel/water separator warning light, Figure 43, will
illuminate on the instrument panel during operation
of the engine if the fuel/water separator switch
detects water in the fuel system.
!
40025699
43
Oil Pressure Warning Light
The oil pressure warning light, Figure 44, will
illuminate on the instrument panel during engine
operation if the oil pressure sender detects oil
pressure below 0.83 bar (12 psi) in the main gallery.
It is normal when starting the engine, for the light to
illuminate and extinguish approximately 30 seconds
later.
40025699
44
55-27
INSTRUMENT PANEL - OVERHAUL

(Replacing the Mechanical Tachometer with the
Electronic Tachometer Instrument Panel)
Removal
1. Remove and save the two bolts securing the
mechanical tachometer adapter to the fuel
injection pump gear cover, at the front of the
engine, right-hand side.
2. Clean the area where the adapter mounted.
3. Install a new gasket. OM279B
4. Install a cap using the same bolts removed in 45

Step 1. Tighten bolts to a torque of 8.14 - 12.2 Mechanical Tachometer
N⋅m (72 - 108 lb. in.).
5. Remove and save the four screws (1) securing
the instrument panel to the rear hood assembly,
Figure 45.
6. Remove the instrument panel to expose
terminals. Retain the rubber seal around the
frame for re-installation.
NOTE: Figure 45 illustrates the mechanical
tachometer type instrument panel.
7. Identify the bulbs, wires and connectors before

removing from the instrument panel. Table 3,
which corresponds with Figures 46 through 51,
will facilitate installation.
NOTE: Identifying the wires of the instrument panel
by using wire color only is not practical, as wire colors
vary between harnesses and instrument clusters.
55-28
Table 3
Item Number Description Type Wire Color
1 Instrument Panel Illumination Bulb Light-to-Light Black
Splice Red/White
2 Coolant Temperature Gauge Connector Green
Splice Green
Connector Red
Connector Red
3 Coolant Temperature Gauge Gauge-to-Ground Black
4 Coolant Temperature Gauge Gauge-to-Sender Blue/Green
5 Oil Pressure Warning Light Temp-to-Oil Pressure Green
Lamp-to-Diode White/Brown
6 Fuel/Water Separator Warning Light Lamp Red
Red
Brown
7 Tachometer Connector White
8 Air Cleaner Restriction Warning Light Lamp-to-Diode Black/Slate
Splice Green
9 Alternator Charge Warning Lamp Lamp-to-Diode Brown/Yellow
Splice Green
10 Fuel Gauge Gauge-to-Sender Green/Black
Splice-to-Aux. Sender Green/Black

11 Fuel Gauge Splice-to-Lamp Black
Splice-to-Ground Black
Fuel Sender-to-Ground Black

Connector Black
Connector Black
12 Fuel Gauge Connector Red
13 Instrument Panel Illumination Bulb Light-to-Light Black
Splice Black
Splice Red/White
55-29
Installation
1. Route the new instrument cluster along with the 1 13
rear-main harness on top of the main fuel tank
12
and secure. 2
Install the bulbs and connect the wires listed in Table 11
3 to the new electronic tachometer and instrument 3
panel terminals shown in Figure 46 as follows:
4 10
1) Install the instrument panel illumination bulb
(1), Figure 46. 7
5 6 8 9
40025697
46
2) Connect the coolant temperature gauge
multi-connector (2), Figure 47. 2
40025700
47
3) Connect coolant temperature gauge-to-
ground connector (3), Figure 48. 3
4) Connect coolant temperature gauge-to- 4
sender connector (4), Figure 48.
5) Install the oil pressure warning light (5),
Figure 48.
6) Install the fuel/water separator warning light 5
(6), Figure 48. 6
40025701
48
55-30
NOTE: A new wire provided with the electronic
instrument cluster connects at terminal (7), Figure
49, in place of the mechanical tachometer cable, and
to terminal W at the alternator. 7
7) Connect the tachometer wire (7), Figure 49.
40025702
49
8) Install the air cleaner restriction warning light
(8), Figure 50.
9) Install the alternator charge warning light (9),
Figure 50. 8
40025703
50
Perform Step 10 when the tractor configuration
includes two fuel senders in support of the main fuel
tank, and an auxiliary tank. If auxiliary tank is not 10
installed, the resister module is not required. Save
resister module for future use, and proceed to Step 12
12.
10) Connect the fuel gauge wires (10, 11 and 12)

to the resistor module included in the service
kit, Figure 51.
11
40025704
51
55-31
11) Connect resistor module (1), Figure 52,
provided with the service kit, to the rear of the
electronic panel behind the fuel gauge. The
resistor module connects to terminals 10, 11
and 12 identified in Figure 46.
12) When not installing the resistor module,
connect fuel gauge wires 10, 11 and 12
identified in Figure 51, directly to terminals
10, 11 and 12 identified in Figure 46. 1
13) Install instrument panel illumination bulb
(13), Figure 46.
2. Check connectors for tightness, warning bulbs 40025705
for security, and wires for correct routing.
3. Place the instrument panel into the rear hood 52
assembly with the rubber seal installed around
the frame.
4. Install the retaining screws.
5. Move the key-start ignition switch to Position 2.
6. Ensure fuel level gauge, coolant temperature
gauge, and warning lights operate.
7. Move the lights switch to Position 2.
8. Ensure the instrument panel bulbs illuminate.
10. Check that the tachometer registers engine rpm.
FOUR-WHEEL DRIVE SELECT SWITCH

Operation
Pressing the green side of the rocker switch (1) 1
causes the switch to close and direct power to the
four-wheel drive (4WD) solenoid. The 4WD solenoid
will engage the front wheels. Pressing the black side 2
of the rocker switch (2) opens the switch, stopping
power to the four-wheel drive (4WD) solenoid, thus
disengaging the front wheel drive, Figure 53.
40025689
53
55-32
The green side of the switch contains a picture of a
connected tractor axle (1), and it illuminates when
selected. The black side of the switch contains a
picture of a split axle (2), Figure 54.
Removal
2. Remove the steering motor cover to gain access
to the back of the switch.
3. If greater access is required, remove the 1 2
instrument panel.
4. Remove the connector off the back of the switch.
54
5. Remove the light bulb connector.
6. Press in the retaining tab (1) on both sides of the

switch, Figure 55. Remove switch from the rear
hood assembly.
IMPORTANT: Prying the switch will break the plastic
tabs. Press the tabs in to remove. 1
Diagnostic Testing
Use a Multi-meter for the following test:
1. Select four-wheel drive by pushing in the green

side of the switch.
40025958
55
2. Check for continuity between terminal A and
terminal B, Figure 56.
40025959
56
55-33
3. Check for continuity between terminal D and
terminal E, Figure 57. Terminals D and E power D
the light bulb.
4. Disengage four-wheel drive by pushing in the E
black side of the switch.
5. Check for continuity between terminal B and
terminal C, Figure 56.
Replace switch if continuity test fails at any point.
Installation
Installation of the four-wheel drive select switch
40025960
follows the removal procedures in reverse.
57
DUAL POWER SWITCH

Operation
Pressing the orange side of the switch (1) causes the
switch to close and direct power to the dual drive 2
solenoid. Pressing the black section of the switch (2),
Figure 58, opens the switch and stops current flow to
the dual drive solenoid, which puts the transmission
1
back in direct drive.
40025688
58
The orange side of the switch contains a picture of a
tortoise (1), and it illuminates when selected. The
black side of the switch contains a picture of a hare
(2), Figure 59.
Removal
1 2
3. If greater access is required, remove the
instrument panel.
59
55-34
4. Remove the connector off the back of the switch.
5. Remove the light bulb connector.
6. Press in the retaining tab (1) on both sides of the
switch, Figure 60. Remove switch from the rear 1
hood assembly.
IMPORTANT: Prying the switch will break the plastic
tabs. Press the tabs in to remove.
40025958
60
Diagnostic Testing
1. Select dual power by pushing in the orange side C

of the switch.
B
2. Check for continuity between terminal A and
terminal B, Figure 61.
40025959
61
3. Check for continuity between terminal D and
terminal E, Figure 62. Terminals D and E power D
the light bulb.
4. Disengage dual power by pushing in the black E
side of the switch.
5. Check for continuity between terminal B and
terminal C, Figure 61.
Installation
Installation of the dual power switch follows the
40025960
62
55-35
KEY-START IGNITION SWITCH

Operation
Refer to Figure 63.
The five positions of the key-start ignition switch
include:
• Position (1) - ‘OFF’

• Position (2) - Warning Lights/Instruments
‘ON’
• Position (3) - Accessories/Lift Pump ‘ON’
• Position (4) - Thermostart ‘ON’ 20030983
• Position (5) - Starting Solenoid/Motor
‘Activate’ 63
Moving the key approximately 1/16 turn in a clockwise

direction from Position 1 (1), Figure 64, to Position 2
directs current to the instrument warning lights,
gauges, dual power select switch, four-wheel drive
select switch, and the warning flasher switch. Another 1
1/16 turn moves the switch to Position 3, which directs
current to the horn switch and warning flashers switch.
Moving the switch to Position 4 directs current to the
Thermostart (where installed) and the fuel shut-off
relay. As the key-start ignition switch moves into
Position 5, current will pass through the starting
system relay to the starting motor solenoid. The PTO
lever must be in the disengage position to close the 40025687
PTO switch, which in turn closes the starting system
relay, allowing current to the neutral start switch. In 64
addition, the secondary (range) lever must be in the
neutral position to close the neutral start switch, and
allow current from the starting system relay to the
starting motor solenoid. The key-start ignition switch
springs back to Position 3 when released from
Position 5, to disengage the starting motor. When
attempting to reactivate the starting motor after the
engine failed to start, return the key-start ignition
switch to Position 1 (OFF) before proceeding.
IMPORTANT: Operating the starting motor longer

than 60 seconds may damage the motor beyond
service.
Removal
instrument panel.
4. Remove the connectors off the back of the
switch.
5. Remove the retaining nut.
6. Remove the switch from the back of the rear
hood assembly.
55-36
Diagnostic Testing
Refer to Figure 65. C
B
1. With the key-start ignition switch in Position 1

(key is vertical), check that NO continuity exists
between terminals.
2. Move the switch to Position 2. D
3. Check that continuity exists between terminals A
and terminal D. A E
40025961
4. Move the switch to Position 3.
5. Check that continuity exists between terminals A 65
and terminal D, between terminals B and
terminal D, and between terminals A and
terminals B.
and terminal C.
9. Check that continuity exists between terminal C
and terminal E, and between terminals A and
terminal C, and between terminals A and
terminal E.
Key-Start Ignition Switch Terminal Continuity Testing
Terminals A B C D E
Positions
1
2 X X
3 X X X
4 X X
5 X X X
Installation
Installation of the key-start ignition switch follows the
requirements:
1. Tighten the key-start ignition switch retaining nut

to a torque of 8 N⋅m (72 lb. in.).
2. Check wires and connections for interference
with hand throttle linkage.
55-37
LIGHTS SWITCH
Operation 1
The lights switch (1), Figure 66, rotates clockwise for
selection of different lighting conditions. As the
switch moves from position to position, different
contacts close within the switch to direct current to
the various lamps. The standard positions are:
• Position 1 - Lights ‘OFF’

• Position 2 - Tail Lamps ‘ON’
• Position 3 - Headlamps ‘LOW’
40025962
• Position 4 - Headlamps ‘HIGH’ (1), Figure 67.
66
40025963
67
Removal
Refer to Figure 68.
2
2. Remove the steering motor cover to gain access 1
instrument panel.
4. Remove the connectors from the back of the
switch.
5. Remove retaining nut (1). 40025962
6. Push in the spring-loaded retaining pin on the 68

side of the handle and remove handle (2).
7. Push the switch through the steering motor cover
and remove the light switch assembly.
55-38
Diagnostic Testing
Refer to Figure 69.
1. Move the lights switch to Position 1. .

2. Check that NO continuity exists between the
terminals.
and terminals B.
20030984
69
Back of Lights Switch
and terminals B, between terminals A and
terminal D, and between terminals B and
terminal D.
8. Check that continuity exists between terminals A,
terminals B, and terminals C.
Terminals A B C D
Positions
1
2 X X
3 X X X
4 X X X
Installation
Installation of the lights switch follows the removal
ments:
1. Tighten the lights switch retaining nut to a torque

of 8 N⋅m (72 lb. in.).
2. Move lights switch to each position and check for
correct operation.
55-39
HORN SWITCH
Operation
Pushing the horn button (1), Figure 70, inward forces
the switch to close, completing a circuit to the horn
assembly (1), Figure 71. With the button depressed, 1
the circuit will remain complete and the horn will
continue to sound. Releasing the push button allows
the switch to open, which breaks the circuit and stops
the horn from sounding.
Removal 40025962
70
instrument panel.
4. Remove the connectors from the back of the
switch.
5. Remove the retaining nut from the back of the
switch. Collect the two washers for reinstallation.
6. Remove the horn switch. 1
Diagnostic Testing
40025964
1. Press the push button inward and hold. Check
that the contacts close, and continuity exists 71
between the terminals on the switch.
2. Release the button.
terminals on the switch.
Replace switch if continuity test fails.
Installation
Installation of the horn switch follows the removal
ments:
1. Tighten the horn switch retaining nut to a torque

of 4 N⋅m (36 lb. in.).
2. Sound the horn to ensure correct operation, by
pushing the horn button inward.
55-40
WARNING FLASHER SWITCH

Operation
The warning flasher switch closes when toggled to
the ‘ON’ position, completing a circuit, and sending
current to the flasher unit. The flasher unit causes the
red and amber tail lamps to flash repeatedly. The
warning flasher switch receives power with the
key-start switch in Position 3 ‘ACCESSORIES’.
Removal
1. Remove the battery negative (ground) cable.
2. Remove the steering motor cover (1), Figure 72.
3. Remove the terminal screws and separate the 1
rear-main harness connector (2) and the flasher 3
unit connector (3) from the terminals on back of
the switch, Figure 72.
4. Remove retaining nut (1), Figure 73. 2
5. Remove warning flasher switch from back of
steering motor cover assembly.
40025965
72
Diagnostic Testing
1. Move the warning flasher switch to the ‘ON’
position.
2. Check that continuity exists between the switch 1
terminals.
3. Move the switch to the ‘OFF’ position.
switch terminals.
Installation 40025691
Installation of the warning flasher switch follows the
removal procedures in reverse with the following 73
requirements:
1. Tighten the warning flasher switch retaining nut

to a torque of 4 N⋅m (36 lb. in.).
2. Operate the switch to ensure correct operation of
the flasher unit.
55-41
POWER TAKE OFF (PTO) SWITCH

Operation
The PTO switch (3) mounts to the rear of the PTO
lever bracket (2) as shown in Figure 74. Moving the
PTO lever (1) to the disengaged (rear) position forces
a plunger on the switch inward, closing a set of
contacts within the switch, and completing a circuit to
the starting system relay. This ensures that the
starting system relay will receive the 12 volts
required to close the relay, sending power to the
neutral start switch for engine start-up. With the PTO
lever in the engage (forward) position, the switch 20030995
opens, stopping current to the starting system relay.
The relay opens, preventing the engine from starting. 74
Moving the PTO lever to the engage position after
engine start-up will not interrupt engine operation.
The PTO switch harness attaches to the rear-main

harness (1) at connector C3 (2), Figure 75.
1
Removal
40025966
75
2. Remove the two screws (1), spacers (2) and bar
(3), which mount the PTO switch to the PTO lever
bracket, Figure 76. 1
3. Remove the switch assembly.
3
2
40025967
76
55-42
4. Pull back the rubber guard (1) from the back of
the switch (2), Figure 77.
1
5. Pull the connector (3) away from the switch,
Figure 77.
3
40025968
77
Diagnostic Testing
Refer to Figure 78.
D
C
1. Press in the PTO switch plunger and hold (PTO
disengaged position).
B
2. Check that continuity exists between terminal A
and terminal D (outward two terminals).
A
3. Release the PTO switch plunger (PTO engage
position).
40025969
78
4. Check that continuity exists between terminal B
and terminal C (inward two terminals).
NOTE: Continuity should not exist between terminal
A and terminal B, or between terminal C and terminal
D.
Installation
Installation of the PTO switch follows the removal
ments: 20030995
1. Install the PTO switch (3) on the PTO lever 79

bracket (2) forward enough to hear the switch
click into position against the lever (1), Figure 79.
Ensure the switch centers flatly against the PTO
lever with the lever in the bracket detent.
55-43
NEUTRAL START SWITCH

Operation
The neutral start switch (start inhibitor) located in the
front transmission, prevents the starting motor
solenoid from operating with the secondary range
gearshift lever (1), Figure 80, out of the neutral
1
position. The neutral start switch receives power
from the starting system relay with the PTO start
switch in the disengaged position (switch depressed)
and the key-start switch in Position 5.
40025970
80
Removal
2
2. Remove steering motor cover screws (1),
Figure 81 (one shown).
3. Pull steering motor cover out far enough to 1
access the rear-main harness to neutral start
switch connector.
4. Disconnect the rear-main harness connector
from the neutral start switch connector.
5. Slide the rubber grommet (2) and wires out from
the steering motor cover, Figure 81. 40025971
6. Remove the transmission top cover. 81

7. Remove the neutral start switch.
Diagnostic Testing
1. Position the transmission secondary range

gearshift lever in the neutral position (1),
Figure 82.
2. Check that continuity exists at the pins of the
neutral start switch connector. 1
3. Position the transmission secondary range
gearshift lever out of the neutral position.
4. Check that NO continuity exists between the pins
20030987
of the neutral start switch connector.
Replace switch if continuity test fails. 82
Installation
Installation of the neutral start switch follows the
55-44
COLD ADVANCE THERMOSTATIC SWITCH

Operation
The thermostatic switch (1), Figure 83, located on the
thermostat housing on the front of the engine,
increases the cold advance performance of the 1
emissionized engine.
40025673
83
During start-up, engine cylinders remain slightly cool
until the engine warms to normal operating tempera-
ture. During which time, the engine timing advances
slightly to reduce white smoke and emissions. The
cold-advance thermostatic switch detects when the
engine reaches the desired operating temperature and
closes, completing a circuit to the fuel injection pump
wax plug (1), Figure 84. The wax plug brings the fuel
injection pump back to normal timing.
Removal
1
1. Raise and secure the right hood assembly.
40025681
84
3. Remove the fuel pump harness connectors from
the switch terminals.
4. Unscrew the switch and remove from the
thermostat housing.
Diagnostic Testing

2. Check for zero voltage at the wax plug connector
until the engine warms up to operating temperature.
Replace the cold advance thermostatic switch if

voltage registers at the wax plug with the engine cold. 1
Installation
Installation of the engine cold advance thermostatic
switch follows the removal procedures in reverse.
AIR CLEANER RESTRICTION SWITCH

Operation
An obstructed air cleaner (1), Figure 85, or a dirty air
cleaner filter will increase the vacuum within the air
40025964
intake tube to the engine.
85
55-45
With the increase in vacuum, the air cleaner
restriction switch (1) mounted within the air intake 1
tube (2), Figure 86, closes and completes a circuit to 2
the air cleaner warning light on the instrument panel.
Removal
1. Raise and secure the right hood assembly.
3. Remove the front-main harness and fuel pump
harness connectors from the terminals on the air
cleaner restriction switch. 40025672
86
4. Place a wrench on the shaft of the switch (1),
Figure 87, which screws into the intake tube.
Turn the switch counterclockwise until free from
intake tube.
NOTE: Do not grasp the switch body by hand and
attempt to remove by twisting. This will cause
damage to the switch.
40025972
87
Diagnostic Testing

2. Check for zero voltage at the air cleaner
restriction warning light (1), Figure 88, on the
instrument panel.
Replace the air cleaner restriction warning switch
when the warning bulb illuminates on the instrument
panel with no obstruction to the air cleaner.
40025698
Installation
Installation of the air cleaner restriction switch follows 88
requirement:
1. Tighten the air cleaner restriction warning switch

to a torque of 8 N⋅m (72 lb. in).
55-46
FUEL/WATER SEPARATOR WARNING

SWITCH
Operation
Water detected in the fuel/water separator (2) will
cause the fuel/water warning switch (1), Figure 89, to
close, and complete a circuit to the fuel/water
warning light on the instrument panel. The bulb will
illuminate until the switch opens, which will stop the 2
current flow to the warning light.
1
Removal 40025677
89
2. Remove the fuel/water warning switch harness
connectors from the switch.
3. Drain the fuel from the separator in a suitable
container.
4. Unscrew the switch and remove.
Diagnostic Testing

2. Check for zero voltage at the fuel/water
separator warning light.
Replace switch when the fuel/water separator
warning bulb illuminates and it is determined that the
separator contains no water.
Installation
Installation of the fuel/water separator warning
switch follows the removal procedures in reverse.
WORK LAMP SWITCH

Operation
The work lamp switch (1), Figure 90, located
underneath the back of the work lamp, turns the lamp
on and off. Moving the switch to the ‘ON’ position, 1
closes the switch, and directs current to illuminate
the bulb. Moving the switch to the ‘OFF’ position
opens the switch, and current no longer reaches the
bulb. The work lamp switch receives power with the
lights switch in one of the ‘ON’ positions.
40025973
90
55-47
Removal
Refer to Figure 91.

2. Remove work lamp lens-cover screws.
1
3. Remove lens-cover.
4. Remove bulb connector (1) from the switch.
5. Squeeze the side clips (2). Remove work lamp
switch.
2
40025974
Diagnostic Testing
Use a Multi-meter for the following test: 91

2. Press the work lamp switch to the ‘ON’ position.
3. Check for +12 V at the bulb connector (1), Figure
91.
4. Press the work lamp switch to the ‘OFF’ position.
5. Check for zero voltage at the bulb connector.
6. Move the lights switch to Position1 ‘OFF’.
Replace switch if voltage test fails.
Installation
Installation of the work lamp switch follows the
requirement:
1. Operate the work lamp switch to ensure correct

installation.
55-48
OIL PRESSURE SENDER SWITCH

Operation
The oil pressure sender switch (1), Figure 92,
installed on the left-hand side of the engine block
closes by way of spring pressure when oil pressure
drops below 0.83 bar (12 psi). This completes the
warning circuit to ground, which illuminates the oil 1 2
pressure warning light on the instrument panel.
When oil pressure rises above the spring force at
approximately 0.55 (8 psi), the contacts within the
switch open, breaking the circuit, and the warning
light extinguishes. When starting the engine, it is 40025676
normal for the low-pressure warning light to
illuminate, and then extinguish approximately 30 92
seconds after engine oil pressure rises.
Removal
2. Remove the sender (2), Figure 92.
3. Unscrew the switch from the engine block and
remove.
Diagnostic Testing
1. Turn the engine off.

2. Move the key-start ignition switch to Position 2.
3. Check for continuity between the oil pressure
switch terminal and ground. This will indicate a
closed switch and a complete circuit. The
warning light on the instrument panel will
illuminate.
4. Start the engine and run until reaching the
recommended oil operating pressure.
5. Check that NO continuity exists between the oil
pressure switch terminal and ground. This will
indicate an open switch and a broken circuit. The
warning light will extinguish.
Replace the oil pressure sender switch if the
continuity test fails.
Installation
Installation of the oil pressure sender switch follows
requirement:
1. Tighten the switch to a torque of 30 N⋅m (22 lb. ft.).
55-49
STOP LAMP SWITCH (WHERE INSTALLED) Installation

Installation of the stop lamp switch follows the
Operation removal procedures in reverse with the following
The switch mounts on either brake pedal shank, requirement:
(depending on model). Depressing the brake pedal
forces a plunger to close contacts within the switch, 1. Apply the brakes after installing the stop lamp
and complete a circuit to the stop lamp assemblies. switch to ensure correct positioning of the switch
and operation.
With no force on the brake pedals, the pedal shank
forces a plunger away from the switch contacts, TURN SIGNAL SWITCH
causing a break in stop-lamp circuit continuity, and (WHERE INSTALLED)
the stop lamp assemblies extinguish
Operation
The toggle type switch operates the turn signals
Removal (where installed). The key-start switch must be in
1. Disconnect battery negative (ground) cable. Position 3 ‘ACCESSORIES’.
2. Disconnect the wires from the switch terminals. Removal

3. Remove the retaining nut. 1. Disconnect battery negative (ground) cable.
4. Remove the stop lamp switch. 2. Remove the rear hood panel.
3. Disconnect the turn signal switch from the rear
Diagnostic Testing main-harness.
4. Remove the three retaining screws and
1. Push in the switch plunger (brake on position) lock-washers. Remove the turn signal switch
and hold. assembly.
2. Check that continuity exists between the switch 5. Separate the switch-cover from the base and
terminals. unscrew the terminals. Note the position of the
wires to facilitate reinstallation.
3. Release the switch plunger (brake off position).
Installation
4. Check that NO continuity exists at the switch
Installation of the turn signal switch follows the
terminals.
55-50
MAIN FUEL TANK SENDER

Removal
2. Remove the instrument panel retaining screws, to
facilitate moving the instrument cluster in a position,
which allows access to the main fuel tank sender.
3. Pull the fuel sender (1) off the fuel tank probe, 1
Figure 93.
Diagnostic Testing
Main Fuel Tank Sender Part Number 82983007: 40025975
1. With the fuel tank EMPTY, check for a resistance 93
of 250 +/-- 4 ohm.
2. With the fuel tank FULL, check for a resistance
of 31 +/-- 4 ohm.
Main Fuel Tank Sender Part Number
E3NN9A316BA:
1. With the fuel tank EMPTY, check for a resistance
of 250 +/-- 10 ohm.
of 31 +/-- 2 ohm.
Installation
Installation of the main fuel tank sender follows the
AUXILIARY FUEL TANK SENDER
Removal
2. If necessary, remove the left-hand platform to
gain access.
3. Pull the auxiliary fuel tank sender off the top the
fuel tank probe.
Diagnostic Testing
Auxiliary Fuel Tank Sender Part Number 82983006:
of 250 +/-- 4 ohm.
of 40 +/-- 3.5 ohm.
Auxiliary Fuel Tank Sender Part Number
D8NN9A316LB:
of 250 +/-- 10 ohm.
of 64 +/-- 4 ohm.
Installation
Installation of the auxiliary fuel tank sender follows
the removal procedures in reverse.
55-51
INSTRUMENT PANEL LIGHTS
Operation
Moving the lights switch to Position 2 completes a
circuit to the instrument panel bulbs. Moving the
lights switch to Position 1 ‘OFF’ will break the circuit
to the instrument panel bulbs, and the lights
extinguish.
The following procedures apply to both the left and

right side bulbs.
OM279B
Removal
1. Disconnect the battery negative (ground) cable. 94
2. Remove the instrument panel retaining screws

(1), Figure 94.
3. Pull the instrument panel from the rear hood
assembly enough to gain access to the back of
the panel. Retain the rubber gasket (1) from
2
around the housing assembly, Figure 95.
1
4. Pull the bulb assembly (2) out of the bracket on
the back of the instrument panel, Figure 95.
5. Turn and pull the bulb out of the bulb assembly.
Diagnostic Testing
40025976
2. Check for +12 V at the bulb socket assembly. 95

4. Check for zero voltage at the bulb socket
assembly.
Installation
Installation of the instrument panel bulb follows the
requirement:
1. Press the rubber seal onto the instrument panel,

and ensure that the seal seats correctly against
the rear hood when reinstalling. This will prevent
moisture from entering behind the instrument
panel, and possibly contacting the wires and
connections.
55-52
HEADLAMPS
Internal headlamps mount in front of the radiator and
shine through apertures in the radiator grille. 1
External headlamps mount at the front edge of the

fender, or on the front of the radiator grille (1), Figure
96.
FENDER MOUNTED HEADLAMP

Removal
Refer to Figure 97.
40025977
1. Remove the screws and bolts securing the back 96

cover to the fender underside.
2. Remove retaining screws (1) from the front of the
headlamp. 2
3. Remove the spring-loaded adjusting screws (2).
4. Remove the headlamp assembly from the
fender.
5. Pull the connector and rubber cap from the rear
of the lamp assembly.
6. Detach the return spring and remove bulb. 1
7. To remove the complete headlamp assembly,
remove the wire harness connectors from the
40025978
back of the headlamp.
Installation 97
Installation of the fender mounted headlamp follows
the removal procedures in reverse.
Fender Mounted Headlamp Angle Adjustment

1. Loosen or tighten the spring-loaded adjusting
screws (2), Figure 97, until obtaining the desired
position of the lamp.
EXTERNAL HEADLAMP BULB

Removal
Refer to Figure 98.
1. Apply a screwdriver in the slot (2) on the

underside of the headlamp shell. Pry out the
rim/lamp assembly.
2. Pull the connector (3) from the rear of the bulb.
3. Detach the retaining spring (1).
4. Remove the bulb.
OM310
Installation
Installation of the external headlamp bulb follows the 98
55-53
TAIL/WARNING LAMP
Removal
1. Remove the retaining screws (1) from the lens
1
cover (low profile shown) Figure 99.
2. Remove lens cover.
40025979
99
3. To remove the entire bulb socket, loosen the
clamp screws (1) and pull socket out of clamp,
Figure 100.
40025980
100
4. To remove the bulb (1), Figure 101, push bulb
inward against the spring and twist, until the bulb
releases.
40025981
101
55-54
5. Depending on model configuration, proceed as
follows:
Low Profile Tractor
1
• Remove the tail/warning lamp assembly by
disconnecting the wires and removing the
retaining nut (1) Figure 102.
40025982
102
• If necessary, remove the tail/warning lamp
frame (1) by removing the mounting bolt (2),
Figure 103.
• To adjust the frame, loosen the mounting
bolt, and move the frame to the desired
position. Retighten mounting bolt.
1
2
40025983
103
High Clearance Tractor
• Remove the lens cover screws (1), Figure

104.
• Remove lens cover.
1
40025984
104
55-55
• Remove the lamp assembly by disconnect-
ing the wires and removing the retaining nut 1
(1) on the underside of the fender (2), Figure
105.
Installation
Installation of the tail/warning lamp follows the
requirement: 2
1. Tighten the tail/warning lamp retaining nut to a

torque of 10 N⋅m (84 lb. in.).
40025985
105
WORK LAMP BULB
Operation
Moving the lights switch to Position 2 completes a
circuit to the tail/warning lamps. The left-hand tail
lamp directs current to the work lamp switch through 1
a single wire lead (1). Selecting the ‘ON’ position of
the lamp switch closes the internal contacts, and
supplies power to illuminate the work lamp bulb.
Selecting ‘‘OFF’ on the work lamp switch breaks the
contact, stops current flow, and extinguishes the
bulb.
20030996
106
Removal
Refer to Figure 107. 1
1. Remove lens cover retaining screws. 3
2. Remove lens cover. 2
3. Remove lens/reflector assembly.
4. Remove bulb connector by pulling lead upward (1).
5. Squeeze retaining clips (2). Remove bulb and
socket assembly (3).
4
Installation
40025974
Installation of the working lamp bulb follows the
removal procedures in reverse. 107
Work Lamp Adjustment

To adjust the work lamp position proceed as follows:
1. Loosen retaining nut (4), Figure 107.

2. Position the lamp as desired.
3. Tighten the working lamp retaining nut to a
torque of 18 N⋅m (156 lb. in.).
4. Further adjustment of the work lamp includes
tilting the entire lens cover up or down, and left
or right.
55-56
GRILLE MOUNTED HEADLAMPS
Removal
Refer to Figure 108.
1. Remove the air pre-cleaner (1) where installed.

2. Open the right and left side front hood latches (2).
20030997
108
3. Raise the front hood assembly and secure prop
(1) to the air-cleaner bracket (2), Figure 109.
OM313
109
4. Slide the radiator grille upward to free locking
tabs (1), as shown in Figure 110.
1
OM426
110
55-57
5. Pull the connector (1) from the back of the bulb
socket, Figure 111.
1
40025986
111
6. Pull the rubber cap (1) from the rear of the lamp
assembly (2), Figure 112. 1 2
40025987
112
Refer to Figure 113.
7. Squeeze the retaining clip (1) and remove the

bulb (2) from the bulb assembly.
8. If required, remove the headlamp lens and frame
3
assembly by removing the four retaining bolts 2
(3).
1
40025988
113
55-58
Diagnostic Testing
Refer to Figure 114. C
Use a Multi-meter for the following test: A
B
1. Move the lights switch to Position 3 ‘Headlamps
LOW’.
2. Check for +12 V at terminal B.
3. Move the lights switch to Position 4 ‘Headlamps
HIGH’.
4. Check for +12 V at terminal C.
40025989
The ground terminal is A.
114
Installation
Installation of the grille mounted headlamp follows
requirement:
IMPORTANT: Do not allow fingers to contact the

halogen bulb. Use a clean cloth when changing the
bulb. Natural moisture and oils in the skin will cause
premature failure of the halogen bulb.
1. After installation, adjust the angle of the

headlamp to prevent blinding oncoming drivers.
Procedures for adjusting the grille mounted

headlamp angle
1) Turn one or more of the spring-loaded
screws (1), Figure 115, until the headlamp
obtains a beam of 100-400 mm (4 - 16 in.)
below the headlamp centerline at a distance
of 6 m (20 ft.).
OM455
115
Fuse Box and Fuses
The fuse box mounts at the top of the rear
engine-support assembly in the engine compartment,
and connects to the rear-main harness. To gain
access, the battery tray swings out of the way. A
plastic or rubber cover prevents entry of dirt in the fuse
box. The fuse box contains two rows of four fuses.
For fuse identification and protected circuits, refer to

Figure 116, and Tables 4 through 6.
ME17
116
55-59
Table 4
Emissionized Engine (with added Fuel Pump Harness after July 1999)
Includes Electronic Tachometer Instrument Cluster
Fuse No. Rating Color Circuit
1 15 A* Blue Horn
2 5A Orange Fuel Shut-off Relay
3 Not Used
4 7.5 A Brown Lights Switch
5 15 A Blue Headlamps HIGH
6 10 A Red Headlamps LOW
7 7.5 A* Brown Instruments/Gauges
8 7.5 A Brown Accessories
(Items changed in July 1999 marked with asterisk)
Table 5
Emissionized Engine and Non-Emissionized Engine with
Changes Incorporated in 1997
1 7.5 A* Brown Horn*
2 10 A Red Fuel Shut-off Relay*
3 Not Used*
4 7.5 A* Brown Lights Switch*
5 15 A* Blue Headlamps HIGH*
6 10 A Red Headlamps LOW*
7 5 A* Orange Instruments/Gauges*
8 7.5 A* Brown Accessories*
(Items changed in 1997 marked with asterisk)
Table 6
1 10 A Red Accessories
2 10 A Red Horn, Fuel Shut-off Relay
3 10 A Red Headlamps LOW
4 10 A Red Headlamps HIGH
5 10 A Red Tail Lights
6 10 A Red Instrument Panel Lights
7 15 A Blue Lights Switch
8 10 A Red Instruments/Gauges
Replacing Fuses
IMPORTANT: Do not replace blown fuse with
another of a different rating.
1. To remove fuse, firmly grasp fuse and pull directly
out. Install a new fuse by pushing the fuse evenly
into the fuse box until fully seated.
55-60
Chapter 2 - Alternator and Charging System
CONTENTS

Alternator -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Alternator -- Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Alternator -- Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
55-1

The charging system consists of a storage battery,
alternator with an internal regulator, and circuit
wiring. The alternating current (AC) produced by the
alternator provides a higher maximum output than a
direct current (DC) producing generator, and
increases the charge rate at lower engine speeds. In
addition, the alternator operates safely at high
engine speeds and requires no commutator, unlike a
DC generator.
The alternator mounts to the front of the engine on
the left-hand side, and contains the following
components:
Refer to Figure 1.
• Rotor (1)
• Stator (2)
• Rectifier Pack (3)
• Regulator/Brush Box (4)
20030998
55-2
Rotor
The engine crankshaft drives the alternator by way of
a belt-driven pulley (1) attached to the rotor shaft.
The rotor shaft rotates within a heavy-duty, sealed
roller bushing.
An integral fan (2) adjacent to the pulley draws air

through the alternator for cooling.
The rotor field coil receives current via two carbon

brushes, which bear against slip rings on the rotor 1
shaft. Current flowing through cooper wire in the rotor
2
field produces a magnetic field. The configuration of 20025990
the armature, formed into pole shoes, ensures the
concentration of the magnetic field. 2
Stator
The moving magnetic field created by the rotor and
brushes induces current into the windings of the
stator.
The stator, fabricated from laminations of thin steel

pressings wrapped by wound wires, collects and
concentrates the magnetic field. The stator windings
contain currents, which pass from one direction to
another with each complete revolution of the rotor.
This activity creates an S-phase alternating current.
Alternating current generates in a series of pulsation.

To smooth output, the rotor features six pairs of
poles. For every revolution of the rotor, the output
characteristic of each stator winding completes six
cycles.
The battery requires pure direct current (DC) for

charging, making alternating current (AC) unsuit-
able. Therefore, the stator windings connect to a
rectifier pack, which converts the AC current to DC
current.
Rectifier
The rectifier consists of six diodes (1) and a module 1 2
(2) containing field diodes. The diodes check current
flow in one direction only. Three diodes mount in a
positive plate, and three diodes in a negative plate
(3). Terminal links connect each of the three stator
output wires to a different diode on each plate.
As the rotor revolves, the diodes convert the AC

current from the stator to DC current, which
effectively charges the battery.
The three field diodes contained within the field diode 3 1

20030999
module connect to the stator output wires and supply
DC current to the rotor field winding. 3
55-3
Regulator and Brush Box
The internal regulator (1) maintains output voltage at
a safe working level. The regulated output voltage
level, preset during manufacturing, requires no
adjustment. A sealed assembly houses the regulator
components within the brush-box. The regulator,
regulator components, and brush-box require
service as a complete assembly, Figure 4.
Alternator Operation
Turning the key-start switch to the ‘ON’ position
directs a small current flow from the battery, through
the rotor field winding. A circuit establishes through
the charge indicator warning light, alternator IND
(indicator) terminal, rotor field winding, alternator
regulator and ground. The charge indicator warning
light illuminates and the rotor partially magnetizes.
When the engine starts, the partially magnetized

rotor revolves within the stator windings and
generates 3-phase AC current. A constant portion of
the current converts to DC current by the three field
diodes incorporated in the rectifier pack. The DC 1
current feeds back to supplement current flowing
through the rotor field winding. This action results in
an ever-increasing magnetic influence of the rotor
along with an associated rise in generated output
current and voltage.
20031417
During the rise in generated output voltage (reflected
at the IND terminal), the brilliance of the warning light 4
reduces. When voltage at the IND terminal equals
that of the battery side of the warning light, the lamp
extinguishes.
The rising voltage continues until reaching the

predetermined regulated voltage level.
If the drive belt fails, voltage will not build up within the
alternator, and the charge indicator warning-light
remains on to indicate failure.
ALTERNATOR - OVERHAUL
Removal
1. Disconnect battery negative (ground) cable. 1
2. Remove alternator guard (1), Figure 5 (where
installed).
20031418
55-4
3. Disconnect alternator main connector plug (2).
4. Disconnect battery temperature sensor lead (3).
5. Remove belt adjustment bolt (6).
6. Remove mounting bolt (4).
7. Remove the alternator (1).
20031419
55-5
20031420
7
Alternator Components
1. Rotor 9. Bolt 17. Rear End Bracket 25. Spacer

2. Insulator 10. Nut 18. Insulator 26. Washer
3. Washer 11. Washer 19. Stator 27. Through Bolt
4. Spring Washer 12. Regulator/Brushbox 20. Rectifier 28. Fan
5. Nut 13. Bearing 21. Insulator 29. Double Spacer
6. Suppressor (if fitted) 14. Nut 22. Nut 30. Front End Bracket
7. Washer 15. Washer 23. Washer 31. Battery Temp
8. Nut 16. Insulator 24. Pulley Sensor
Refer to Figure 7. 7. Gently tap rear face of the front-end bracket to

Disassembly separate the front-end bracket and rotor
assembly (1) from rear-end bracket, stator and
1. Remove nut (8) from the through bolt (27), rectifier assembly (20).
allowing removal of the radio interference
suppressor (6) (where installed). 8. Remove nuts, washers and insulators from the
terminals on the rear bracket.
2. Remove the nut (10) from the battery tempera-
ture sensor (31). 9. Remove the rectifier retaining screws.
3. Remove the three securing bolts and regulator/ 10. Remove stator and rectifier from the rear
brush box assembly (12). Separate the wire bracket.
connection to the regulator. 11. Unsolder stator leads from the tags on the
4. Remove remaining through bolt nuts. rectifier.
5. Tap the threaded end of the housing bolts to 12. Remove retaining nut on rotor shaft (22).
release spline at the hexagon head end. 13. Remove the components off the rotor shaft. Note
6. Mark the alternator front-end bracket (30), stator the order of removal to facilitate re-assembly.
(19), and rear-end bracket (17) to facilitate 14. Press rotor shaft out of the front-end bracket
proper alignment when re-assembling. bearing.
55-6
1. Clean all components.
2. Examine parts for wear, or excessive damage.
3. Inspect rotor poles and stator for signs of
chaffing. Chaffed areas indicate excessively
worn bearings, which will require replacement.
4. Replace entire front-end bracket and bearing
assembly for an excessively worn or defective
front-end (Drive-bearing).
5. Inspect rear-end bracket roller bearing for
excessive wear or damage.
To replace rear-end roller bearing, use the following
procedure:
1) Support rear-end bracket (2), and drive out
roller bearing (1) with a suitable size mandrel
20031421
2) Press the new bearing (2) into the housing

(1). Position the bearing 0.50-0.70 mm (.020
- .028 in) from the inner face of the bearing
boss (3), Figure 9.
20031422
55-7
Assembly
Assembly of the alternator follows the disassembly
procedures in reverse with the following requirements:
1. To avoid misalignment, install the stator
assembly in the front-end bracket, then install 1
rear-end bracket to the stator laminations.
Installation
Installation of the alternator follows the removal
ments:
1. Ensure the battery negative (ground) cable

remains disconnected from the battery while
installing the alternator.
2. Adjust the alternator drive belt tension using the
adjusting bolt (1), Figure 10, until obtaining 13-19
mm (0.50-0.75 in) deflection; with moderate
finger pressure applied to the longest run of the
belt, as shown in Figure 11. 20031423
10
ALTERNATOR - TESTING
Initial testing of the alternator does not require
removal of any charging system components from
the tractor, and includes the following:
• Alternator Plug Connection Test

• Battery Temperature Sensor Circuit Test
• Alternator Charging Current and Controlled
Voltage Test
• Alternator Charging Circuit Voltage Drop
Test
• Ground Voltage Drop Test
• Alternator Maximum Output Performance
Test
Test equipment required:
20031424
• Voltmeter (0-30 V moving coil)
• Voltmeter (0-1 V) 11
• Ammeter (0-70 A moving coil)
• 1.5 ohm, 70 A Variable Load Resister
• Jumper Lead 6.35 mm (0.25 in)
NOTE: Follow the manufacturer’s instructions when

using test equipment to ensure accuracy.
55-8
Alternator Plug Connection Test
Refer to Figure 12.
1. Turn the key-start switch to the ‘ON’ position. DO

NOT start the engine.
2. Remove the main connector plug (1) from the
alternator.
3. Connect the negative side of a Voltmeter (2) to
the alternator frame (3).
4. Connect the positive side of a Voltmeter to one of
the plug terminals.
5. Check for battery voltage.
6. No voltage indicates a continuity fault in the
external cable circuitry. Investigate the cause
and repair. 20031425
7. Repeat the procedure for each connector plug
terminal. 12
NOTE: In certain configurations, only one of the

terminals in the connector plug actually connects
with the harness.
8. Connect one end of a jumper lead to the ‘IND’

terminal on the connector plug.
9. Connect the opposite end of the jumper lead to
the alternator frame.
10. Check that the charging warning light illuminates
on the instrument panel.
11. Disconnect the jumper lead.
12. Reattach the connector plug to the alternator.
If the charging warning light fails to illuminate after
reattaching the connector plug, suspect a fault within
the regulator or rotor circuits. In addition, check the
cleanliness of the ‘IND’ terminal.
13. Investigate the cause and repair.

15. Reconnect the main connector plug.
55-9
Battery Temperature Sensor Circuit Test
Refer to Figure 13.
1. Remove the orange sensor lead (1) from the

battery temperature-sensor terminal on the
alternator. This lead protrudes from the regulator
and brush-box assembly (2).
2. Connect the positive side of a Voltmeter to the
sensor lead.
2
3. Connect the negative side of a Voltmeter to the
alternator frame. 1
40025991
13
4. Check for battery voltage.
Test fails if no voltage registers. In which case,
proceed to Step 5.
5. Disconnect the front main-harness-to-battery

sensor plug (1), Figure 14.
6. Connect a 205 ohm resister across the sensor
plug terminal. See Figure 15.
If voltage registers:
1
7. Replace sensor.
If voltage fails to register, suspect a continuity fault in
the external circuitry.
8. Investigate the cause and repair. 20031426

9. Remove test equipment. 14
10. Reconnect the sensor lead on the alternator and
the battery.
20031427
15
1. Resistor
2. Connector
3. Battery Tray
4. Sensor Plug
55-10
Alternator Charging Current and Controlled
Voltage Tests
Refer to Figure 16.
1. All electrical components must be off, including
the key-start switch.
alternator. DO NOT remove the battery tempera-
ture-sensor lead (6).
4. Connect one end of a jumper lead (1) to the ‘IND’
terminal on the alternator.
5. Connect the opposite end of a jumper lead to the
connector plug.
6. Connect the negative side of an Ammeter (5) to
the connector plug main-terminal.
7. Connect the positive side of the Ammeter (5) to
6
the alternator output-terminal.
8. Connect the negative side of a Voltmeter (3) to
the alternator frame (4).
alternator output terminal. 20031428
10. Reconnect the battery. 16

11. Turn the key-start switch to the ‘ON’ position.
12. Start the engine and increase engine speed to
2000 rev/min.
13. Observe the Ammeter and Voltmeter readings.
If the Ammeter registers a charging current, stop the
engine. Amperage indicates a faulty alternator
component. Refer to the “Alternator Component
Testing” section of this chapter.
15. Disconnect the front main-harness-to-sensor plug.
16. Connect a 205 ohm resistor across the sensor
plug terminals.
17. Restart the engine and increase engine speed to
2000 rev/min.
18. Observe the Ammeter and Voltmeter readings.
Check that the voltage registers higher than the
battery voltage, and that the voltage stabilizes at
13.6-14.4 V when the Ammeter reading falls
below 10 ohm.
If the voltage exceeds 14.4 V, suspect the alternator
regulator. If the voltage registers below 13.6 V, suspect
a faulty alternator component, or a high resistance fault
in the external connections of the charging circuit.
19. Stop the engine.
21. Disconnect the test equipment.
55-11
Alternator Charging Circuit Voltage-Drop Test
Refer to Figure 17.
1. Turn the key-start switch to the ‘OFF’ position. .

3. Disconnect the main connector plug (1) from the
alternator. DO NOT remove the temperature
sensor lead (6).
4. Connect a jumper lead (3) to the ‘IND’ terminal of
the connector plug.
the ‘IND’ terminal of the alternator.
6. Connect the negative side of a Millivoltmeter (4)
to the positive terminal of the battery.
7. Connect the positive side of the Millivoltmeter to
the connector plug main-terminal. 6
8. Connect the positive side of an Ammeter (2) to
the alternator main-output terminal.
9. Connect the negative side of the Ammeter to the
connector plug main terminal. 20031429
10. Reconnect the battery negative (ground) cable. 17

11. Connect a variable-load resister (5), adjusted for
minimum current draw (maximum resistance),
across the battery terminals.
2000 rev/min.
13. Slowly increase the current loading of the
variable-load resistor (decreasing resistance)
until the Ammeter registers 45 A.
14. Observe reading on the Millivoltmeter.
If alternator output not within specifications, and
Millivoltmeter registers above 400 mV, suspect a
high resistance fault in the external circuit.

Millivoltmeter registers below 400 mV, suspect a
faulty component within the alternator. Refer to the
“Alternator Component Testing” section of this
chapter.
15. Investigate the cause of the fault and repair.

16. Remove the test equipment.
55-12
Ground Voltage-Drop Test
Refer to Figure 18.
1. Turn the key-start switch to the ‘OFF’ position.

sensor lead (6).
4. Connect a jumper lead (3) to the ‘IND’ terminals
of the main connector plug.
6. Connect the positive side of a Millivoltmeter (4)
to the battery negative (ground) terminal.
7. Connect the negative side of a Millivoltmeter to 6
the alternator frame.
the alternator main-output terminal.
connector plug main-terminal. 20031430
10. Reconnect the battery negative (ground) cable. 18

11. Connect a variable-load resister (5), adjusted for
minimum current draw (maximum resistance),
across the battery terminals.
2000 rev/min.
13. Slowly increase the current loading of the
variable-load resistor (decreasing resistance)
until the Ammeter registers 45 A.
14. Observe reading on Millivoltmeter.
Millivoltmeter registers above 200 mV, suspect a
high resistance fault in the external circuit.

Millivoltmeter registers below 200 mV, suspect a
faulty component within the alternator. Refer to the
“Alternator Component Testing” section of this
chapter.
15. Investigate the cause of the fault and repair.

55-13
Alternator Maximum Output Performance Test
Refer to Figure 19.
1. Turn the key-start switch to the ‘OFF’ position.

sensor lead (6).
4. Connect a jumper lead (3) to the ‘IND’ terminal of
the main connector plug.
6. Connect the negative side of an Ammeter (4) to
the connector plug main terminal.
7. Connect the positive side of the Ammeter to the 6
alternator output-terminal.
8. Connect the positive side of a Voltmeter (2) to the
alternator output-terminal.
9. Connect the negative side of the Voltmeter to the
alternator frame. 20031431
10. Disconnect the front main-harness-to-sensor 19

plug.
11. Connect a 205 ohm resister (5) across the sensor
plug terminals.
12. Reconnect the battery.
13. Turn the key-start switch to the ‘ON’ position.
2000 rev/min.
15. Slowly increase the current loading of the resistor
(decreasing resistance) until the Ammeter
registers 45 A.
16. Observe the reading on the Voltmeter.
If the Voltmeter registers below 13.6 V, suspect a
faulty alternator component.
17. Stop the engine.

19. Disconnect the test equipment.
55-14
ALTERNATOR – COMPONENT TESTING

Test equipment required:
• 12 V Battery
• Test Lamp (12 V, 2.2 W)
• Test Lamp (12 V, 36 W minimum)
• 110 V Insulation Tester or 250 V Meg-ohm
Meter
Rectifier Assembly – Diode Test

Refer to Figure 20
Test each of the six diodes separately as follows:
1. Connect a 12 V battery (3) and a 2.2 W test lamp

(2) in series with one of the diode connecting pins
(1).
2. Connect a test lead to the diode connecting-pin.
3. Connect the opposite test lead to the diode plate.
4. Observe test lamp for illumination.
5. Reverse test lead connections.
If the test lamp illuminated with the test leads in both
configurations, suspect a faulty diode. Replace the
rectifier if any diode fails the test.
20031432
20
Rectifier Field-Diode Test

Refer to Figure 21.
The field diode module contains three separate

diodes.
Test each diode as follows:
1. Connect a 12 V battery (3) and a 2.2 W test lamp

(2) in series with the field-diode module.
2. Connect a test lead to the alternator ‘IND’
terminal (1).
3. Connect the opposite test lead to a field-diode
connection (4).
5. Reverse test lead connections.
If the test lamp illuminated with the test leads in both 20031433
configurations, suspect a faulty diode. Replace the
rectifier if any diode fails the test. 21
55-15
Stator-Winding Insulation Test
Refer to Figure 22.
1. Connect a 110 V insulation tester or a 250 V

Meg-ohm meter (3) to a stator output wire (2).
2. Connect the 110 V insulation tester or a 250 V
Meg-ohm meter to the stator lamination (1).
3. Follow the manufacture’s instructions for the test
equipment used. If the test produces unsatisfac-
tory results, replace the stator assembly.
20031434
22
Stator-Winding Continuity Test
Refer to Figure 23.
1. Connect any two, of the three, stator output-wires

(2) in series with a 12 V battery (3) and a 36 W test
lamp (4).
2. Observe test lamp for illumination. If the test lamp
fails to illuminate, replace the stator assembly
(1).
3. Transfer one of the test lamp leads to a third
stator output-wire.
If the test lamp fails to illuminate, replace the stator
assembly.
Rotor Slip-Ring Inspection

Perform the following slip ring inspection before
20031435
testing the rotor components.
23
1. Clean each slip ring.
2. Inspect slip rings for indications of burnt areas,
which will require refinishing. If required, use fine
glass paper to refinish until producing a highly
polished surface. Replace defective rings if
necessary.
3. Re-clean slip rings after refinishing.
55-16
Field-Winding Resistance Test
Refer to Figure 24.
1. Connect an Ohmmeter (3) between the two slip

rings (2) of the rotor (1).
2. Observe reading on Ohmmeter for 3.2 ohm.
Replace the rotor if test fails.
20031436
24
55-17
Field-Winding Insulation Test
Refer to Figure 25.
1. Connect a 110 V insulation tester or 250 V

Meg-ohm meter (3) to a slip ring (2) and rotor
pole (1).
2. Follow the manufacture’s instructions for the test
equipment used. If the test produces unsatisfac-
tory results, replace the rotor assembly.
Alternator Frequency Output Test

Check the alternator square-wave signal at terminal
‘W’ with an Electronic Signal Simulator Test Set
FNH01031A. This test set measures frequency in
hertz.
1. Table 1 lists acceptable alternator frequency

output results.
20031437
25
Table 1
Engine RPM Alternator Output Tolerance

500 102.5 Hz 480-520 RPM
1500 307.5 Hz 1480-1520 RPM
2500 512.5 Hz 2400-2500 RPM
55-18
Chapter 3 - Starting Motor and System
CONTENTS

Starting System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Starting System Circuit Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Starting Motor -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
55-1
DESCRIPTION AND OPERATION The solenoid contacts close even if the pinion and
The starting system consists of a starting motor and ring gear misalign. When misalignment occurs, the
solenoid, a relay, transmission neutral-start (inhibi- engagement spring compresses and forces the
tor) switch, PTO safety switch, key-start ignition pinion into full contact, as the starting motor begins
switch, and heavy-duty circuit wiring. to turn.
The starting motor, a four-poled, brush type motor, Power to the solenoid and starting motor stops by
incorporates an integral solenoid and positive-en- releasing the key-start ignition switch. The solenoid
gagement drive assembly. return spring, acting through the pivoting linkage
mechanism, pulls the drive-pinion out-of-mesh, and
The integral solenoid contains two windings reopens the solenoid contacts.
connected in parallel. One winding grounds through
the motor and functions as a low-resistance ‘pull in’ A clutch device incorporated in the drive-pinion
coil. The other winding grounds through the solenoid assembly prevents the armature from rotating
body and functions as a high-resistance ‘hold-in’ coil. excessively, if the drive-pinion remains in mesh with
The solenoid contains a single set of contacts and a the flywheel ring-gear after the engine starts.
two-piece plunger.
STARTING SYSTEM TESTING
Operating the key-start ignition switch in the closed
Use a high rated Battery Starter Tester, a Voltmeter
position, with the transmission in neutral, energizes
(0-20 V), and an Ammeter (0-1,000 A) for the most
the starting motor solenoid coil. The now magnetized
conclusive test result, as well as a rapid diagnosis of
coil pulls the plunger into the solenoid core. Plunger
the starting system. When using test equipment,
movement transmits via a pivoting mechanism to
follow the manufacture’s recommended procedures.
force the drive-pinion into mesh with the flywheel ring
If the test equipment recommended above is not
gear. Upon full engagement, the solenoid plunger
available, use standard equipment providing the
closes a set of contacts to allow a direct feed from the
same ratings to determine if the starting system
battery to all four field coils, thus providing full power
operates correctly.
to the starting motor.
Before testing:
One end of the ‘pull-in’ coil now connects to the
positive side of the battery through the key-start
ignition switch. The opposite end connects to 1) Check the battery for full charge.
positive through the solenoid contacts. This action 2) Check entire starting system wiring for
causes the by-passing of the ‘pull-in’ coil, allowing frayed, broken or loose wires and connec-
the ‘hold-in’ coil to keep the solenoid plunger tions.
engaged.
55-2
Starting Motor Circuit Current Draw
Refer to Figure 1.
1. Disconnect the battery (3) negative (ground)

cable.
2. Disconnect the battery positive cable from the
starting motor solenoid (4).
IMPORTANT: When testing the starting system, only
use an Ammeter, which has a maximum capacity of
1000 A or greater, or damage to the Ammeter will
occur.

the positive terminal of the battery.
starting motor solenoid input-terminal 20031438
5. Reconnect the battery negative (ground) cable to
1
the battery negative terminal.
positive terminal of the battery.
negative terminal of the battery.
8. Disconnect the wire from the shut-off solenoid

(1), Figure 2, on the fuel injection pump.
10. Observing the readings on the Voltmeter and
Ammeter. Check that voltage remains steady at
12 V and amperage remains 250-300 A.
Overhaul or replace the starting motor when: 1
• Current measures less than specification.
• Current measures greater than specifica-
tions, and all other starting system circuit
40025678
tests produce satisfactory results.
If drawn current remains within specification, but a 2
voltage drop occurs, test the starting system circuit
resistance. Refer to this chapter.
STARTING SYSTEM CIRCUIT RESISTANCE

TEST
Test for voltage drops within each individual
component as follows:
IMPORTANT: Disconnect the wire from the shut-off

solenoid on the fuel injection pump (1), Figure 2.
55-3
Battery Positive Cable
starting motor solenoid, battery terminal (1),
1
Figure 3.
3. Crank engine and observe the Voltmeter.
If voltage registers above 0.2 V, check cable
connections for looseness. Tighten connections and
recheck. Replace cable if voltage remains exces-
sive.
40025992
Battery Negative (Ground) Cable 3

engine block.
negative terminal of the battery.
4. Observe the Voltmeter.
If the Voltmeter registers above 0.2 volts, check
ground cable connections for tightness. If voltage
remains excessive, replace the negative (ground)
cable.
Starting Motor Ground Connections

starting motor frame.
engine block.
4. Observe the Voltmeter.
If the Voltmeter registers above 0.2 volts, check
ground connections between starting motor flange
and rear engine support. Replace ground connec-
tions if voltage remains excessive.
STARTING MOTOR - OVERHAUL

Removal
1. Disconnect negative (ground) cable from the
battery.
2
2. Remove the retaining nut (1) and protective
cover (2) off the solenoid assembly on the
starting motor, Figure 4.
1
3. Disconnect the positive lead at the solenoid
assembly.
4. Disconnect the coil feed-wire.
40025993
55-4
5. Remove the three starting motor retaining bolts.
6. Remove the starting motor.
1
Disassembly
1. Disconnect the field coil housing-to-solenoid
assembly braided wire (1), Figure 5.
Refer to Figure 6.
2. Remove front housing-assembly screws.

3. Remove solenoid assembly.
40025992
55-5
20031439
6
Starter Motor -- Exploded View
1. Stud and Bolt Kit 11. Housing Assembly

2. End Cap 12. Solenoid Assembly
3. Collar and Ring Assembly, Drive Thrust 13. Solenoid Hardware Kit
4. Brush End Plate Assembly 14. Lever Assembly
5. Brush Assembly 15. Brush Spring
6. Brush Assembly 16. Brush Holder Assembly
7. Field Coils and Housing Assembly 17. Washer
8. Armature 18. Nut
9. Centre Bearing Plate 19. Drive Assembly
10. Bushing
NOTE: The plunger remains in the drive engage- 9. Remove washer from the armature at the
ment lever. commutator end.
10. Compress the brush spring, bend back the spring
4. Remove the plunger from the drive engagement retaining tabs, and release the spring to remove the
lever by gripping plunger, lifting up front-end, and brush from the holder. Remove all four brushes.
releasing it from the lever.
11. Remove the carrier.
5. Remove nuts and screws, which secure the
12. Remove the motor casing from the armature and
end-cap and brush plate to the housing.
drive-end bracket.
6. Remove C-clip. 13. Remove the drive engagement lever pivot pin
7. Remove armature shaft shims. from the drive-end housing.
8. Remove the end housing. 14. Drive the thrust collar squarely off the snap ring
and remove snap ring from grooved area.
NOTE: The brush gear will remain on the Remove the drive assembly and inner-plate-re-
commutator. taining ring from the armature shaft.
15. Remove the armature and drive assembly.
55-6
1. Check brushes for minimum length of 7 mm (.28
in.).
2. The commutator face must be clean and free of
burnt spots. Use fine glass paper to remove
spots. Clean when finished.
3. If necessary, skim the commutator without
exceeding a minimum diameter of 42.5 mm (1.7
in.). After skimming, polish commutator with fine
glass paper and clean.
Brush Removal and Installation

1. Unsolder field brush leads from the field coils.
2. Unsolder ground brush leads from the brush
holders.
3. Solder new brush leads using 300 W soldering
iron and resin core solder.
4. Ensure new brushes move freely in holder.
Smooth rough edges of the brushes.
Armature Insulation Test
Refer to Figure 7.
1. Connect an Ohmmeter (1) between the armature 1

shaft (2) and commutator segments (3).
2. Observe reading on Ohmmeter.
If the Ohmmeter registers a reading, the armature
insulation test fails. 2
20031440 3
7
55-7
Field Coil Insulation Test
Refer to Figure 8. 2
1. Connect an Ohmmeter (1) between the field

winding brushes (2), in turn, and a clean,
unpainted part of the housing (3).
2. Observe reading on Ohmmeter.
If the Ohmmeter registers a reading, the field coil

insulation test fails.
Field Winding Continuity Test

1. Connect an Ohmmeter between each field-wind- 1 3
ing brush, and the main-feed terminal.
20031441
2. Check for a reading of 1 ohm.
Replace the field coil and housing assembly when 8
the field winding continuity test fails.
Drive Pinion Assembly Inspection

1. Check that the pinion rotates clockwise only. If
the pinion sticks, rotates in both directions, or if
there is damage to the pinion teeth, replace the
drive assembly.
Assembly
Assembly of the starting motor follows the
requirements:
1. Before installing the starting motor, check

armature end play. Refer to this chapter.
2. Perform the starting motor no-load test. Refer to
this chapter.
Armature End-play
1. Attach a dial indicator to the drive end-housing
flange. Locate the dial indicator pointer on the
end of the armature shaft.
2. Lever the armature full forward and zero the dial
indicator.
3. Lever the shaft full rearwards and record the
reading on the dial indicator.
4. A reading greater than 4 mm (0.015 in.) indicates
excessive wear in the armature and brush
end-plate assemblies. Replace defective com-
ponents and re-check end play.
55-8
Starting Motor No-Load Test
NOTE: To obtain the best results while performing
the starting motor no-load test, use a fully charged
battery, a battery starter tester (with a high rated
discharge), and a (carbon pile) variable load resistor.
1. Secure the starting motor in a vice.

2. Connect the battery negative (ground) cable to
the starting motor mounting flange (4).
8
3. Connect a jumper lead (6) to the battery terminal
on the starting motor solenoid.
4. Connect the opposite end of the jumper lead to 7
the switch terminal on the starting motor
solenoid. 20031442
9
negative (ground) terminal of the battery (8).
the positive terminal of the battery.
8. Connect the negative side of the Ammeter (1) to
the battery terminal on the starting motor
solenoid.
9. Hold a hand tachometer (5) on the end of the
armature shaft.
10. Adjust the carbon pile to 11.7 V to actuate the
starting motor.
11. When the armature rotates between 7600 and
8500 rev/min, compare the current to a
maximum of 160 A.
If not within specification, check for the following
discrepancies:
• Grounded field coils

• Chaffing armature
• Distorted armature shaft.
55-9
55-10
Chapter 4 - Battery, Servicing and Testing
CONTENTS

Battery -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
55-1

The electrical system features a 12-Volt, negative 1
ground, low maintenance, lead-acid type battery with
six-cell construction (1), Figure 1.
NOTE: A low maintenance battery will not lose water

from the electrolyte under normal charging condi-
tions. Conditions that will cause water loss include
prolonged charging above 14.4 volts, and from the
use of faulty charging system or boost/recovery
charging equipment.
The battery functions as a source of current for

starting the engine, lighting the tractor, and providing
instrumentation. The battery also aids in controlling
voltage in the electrical system, and furnishes
current when the electrical demands exceed the
alternator output.
20031443
Construction of the battery includes six cells with
positive and negative plates placed alternately next 1
to one another within each cell. A non-conducting,
porous envelope separates each positive plate from
the negative plate. The positive plates, welded to a
post strap, form a positive terminal, and the negative
plates, welded to a similar post strap, form a negative
terminal.
NOTE: Touching of the negative and positive plates

together will short-circuit the cell.
Composition of the positive plate includes a lead grid

with lead peroxide pasted into the grid openings, and
the negative plate contains a lead grid with spongy
lead pasted into the grid openings. The plates remain
submerged in a liquid electrolyte solution of diluted
sulfuric acid.
The battery mounts on a hinged tray (1), which
swings out for improved access. A spring-loaded
retaining latch (2), Figure 2, secures the tray
Battery Temperature Compensation

Changes in battery temperature and loading directly
affect the charging system. A circular temperature- 1
sensing pad (2), Figure 4, attaches to the bottom of
the battery tray. The battery sensor detects changes
in battery temperature, and relays the information to
the voltage regulator, which adjusts the charge rate
accordingly.
20031443 2
55-2
BATTERY - OVERHAUL
Removal
1. Unclip (1) and raise the right-hand hood panel,
Figure 3.
2. Pull up the battery tray retaining-latch or unscrew
the retaining nut (where installed). Swing the
battery and tray clear of the engine.
3. Disconnect the negative (ground) battery
terminal.
4. Disconnect the positive battery terminal. 20031444
Refer to Figure 4
5. Remove the battery-to-tray securing strap (3).

6. Disconnect the battery temperature sensing wire
(2), at the front main-harness connector.
7. Lift the battery out of the tray (1).
3
20031445
55-3
INSPECTION AND SERVICING Servicing the Battery

Battery ‘State of Charge’ WARNING
The specific gravity of the battery electrolyte indicates Batteries contain sulfuric acid, which generates
the ‘state of charge’. The specific gravity of a fully a highly explosive mixture of hydrogen and
charged battery at 25 _C (77 _F) is 1.280 minimum. oxygen gas during charging.
The approximate state of charge may also be

determined using an accurate digital Voltmeter (+/-- WARNING
0.01 V) as follows: Never use equipment that generates flames or
Less than 10.5 V battery unserviceable* sparks when controlling the electrolyte level.
Less than 11.8 V battery discharged

WARNING
Less than 12.3 V battery 1/2 charged
Do not remove the battery cover plugs without
Greater than 12.6 V battery fully charged protection for eyes and hands.
*See “Performance Test” for possible recovery of a
mildly sulfated battery. When servicing a battery, observe the following
steps.
Measure voltage of an unloaded battery only. Rest
the battery for a minimum of four hours before 1. Maintain the electrolyte to the recommended
unloading. For recently operated tractors, or a level, approximately 5 mm (0.25 in) above the
battery recently charged, turn on the headlamps for plates in a standard battery. Failure to maintain
2 minutes. a proper level of electrolyte may result in a high
concentration of acid and will damage the
When a battery discharges, sulfuric acid in the separators and impair the performance of the
electrolyte combines chemically with the plates, plates.
which lowers the specific gravity of the solution.
2. Use only distilled or de-mineralized water. Never
A battery hydrometer will determine the specific use tap water. Do not overfill
gravity of the electrolyte in a cell, while the amount of
3. Always keep the battery at least 75% charged to
unused sulfuric acid in the solution measures the
prevent the plates from becoming sulfated,
degree of change of that cell.
which causes loss of efficiency and possible
damage to plates at lower temperatures.
A battery operating in a lower temperature requires
a greater charge, and the lower the temperature, the 4. Avoid overcharging the battery. Excessive
more necessary it is that the battery be in a fully charging will create high internal heat that will
charged condition. For example, a battery with a expand and warp the plates, distort the battery
specific gravity of 1.225 at 27 _C (80 _F) will operate case, or displace the sealing compound.
the starter motor at warm ambient temperatures but Excessive charging will also cause plate grid
may not, at lower ambient temperatures due to low deterioration and produce water loss.
battery efficiency. Correct care and periodic
5. When fast charging the battery, ensure the
inspection will maintain long battery life.
battery temperature remains below 50 _C (122
Table 1 shows the effect of temperature on the _F).
efficiency of a typical battery: 6. Do not add sulfuric acid to a cell unless loss of
electrolyte occurred through spilling. Before
Table 1 replenishing, ensure the correct specific gravity
Temperature Efficiency of a Fully of the solution.
Charged Battery 7. When fully charging a battery, use only a slow
25 _C (77 _F) 100% charge rate. A high charge rate will rapidly boost
--4.5 _C (23.9 _F) 82% the battery capacity, but must be followed by a
slow charge to bring the battery to full capacity.
--24 _C (--11.2 _F) 64%
--27.5 _C (--17.5 _F) 58%
--31 _C (23.8 _F) 50%
--34.5 _C (--30.1 _F) 40%
--37.5 _C (--35.5 _F) 33%
55-4
Dry-Charged Batteries Recharging a heavily discharged battery
1. Remove the battery cell vent plugs. The recommended method of recharging a mainte-
nance free lead-acid battery includes using a
2. Fill each cell with electrolyte to the recommended constant voltage charger. Charge a heavily dis-
level with electrolyte of 1.280 specific gravity. charged battery for a period of 48 hours at 12 V with
NOTE: The electrolyte must be diluted with sulfuric acid a current limitation of 47.5 A for 107 Ah.
preferably at a temperature of 21-32 _ C (70-90_ F).
Table 2 lists recommended current levels and times
for constant current chargers:
3. Allow the battery to stand fifteen minutes after
filling. Recheck the electrolyte level and
replenish as necessary. Table 2
4. Charge the battery for 4 hours at a rate of 5-8 Battery Type Description Current Time
amps, in accordance with the battery instruc- 107 Ah Slow Charge 5A 25 hrs
tions. Allow the cells to gas freely. (800 CCA)
5. Install the battery cell vent plugs when finished. 10 A 12.5 hrs
Fast Charge* 18 A 7 hrs
Charging the Battery
Before charging a battery: *Fast charge method for emergencies only.
1. Thoroughly clean the battery casing, terminals, INSTALLATION

and cell covers with dilute ammonia or hot water.
1. Clean the battery. Check installation of cell vent
2. Check the level of the electrolyte, and replenish plugs for tightness.
if below recommended level.
2. Seat battery squarely on battery tray.
WARNING
3. Secure strap with retaining nuts
Charging a battery produces an explosive gas.
Do not expose to sparks or flame when checking 4. Install the battery temperature sensing wire.
the electrolyte level, and never connect or 5. Coat terminals with petroleum jelly (Vaseline or
disconnect the charger until turned off. equivalent). Do not use conventional lubricating
greases as electrolyte corrosion may occur.
Charging 6. Connect the positive battery terminal first, then
1. Charge the battery with a slow charger at a rate the negative terminal.
of 3-6 amps until the battery reaches full charge. 7. Check terminal connections for correct polarity
This may take up to 36 hours or longer for a and tightness. Do not over-tighten. Install dust
heavily discharged battery. A severely sulfated covers over terminals (where installed).
battery may not accept a charge at all. When the
battery has finished charging, the cells will gas 8. Swing battery tray back into place over the
freely and the specific gravity will remain constant. engine and secure with latch, or screw down the
Remove the charger after three consecutive retaining nut (where installed).
hydrometer readings, taken at hourly intervals;
indicate that specific gravity no loner rises. Battery Testing
2. When using a fast or high rate of charge, follow Test equipment required:
the manufacture’s instructions for the battery and
the charger. High rated charging raises the • Hydrometer
temperature of the electrolyte. Unless the charger • Battery Starter Tester
consists of an automatic time or temperature • Thermometer
device, the electrolyte temperature may exceed
50 _C (122 _F), which will result in violent cell • Battery Charger
gassing and/or damage to internal components.
3. Re-check the electrolyte level in each cell and
replenish as necessary.
55-5
Testing Specific Gravity Example 1
1. Take the hydrometer reading of the electrolyte Temperature below 30 _C (86 _F)
with the float in the vertical position. Electrolyte Temperature 19 _C (66 _F)
Hydrometer Reading 1.270
2. Adjust the hydrometer reading for electrolyte Subtract 11 x 0.004 0.008
temperature variations as follows: 5.5
1) Subtract four points (0.004 specific gravity) Corrected Specific Gravity 1.262
for every 5.5 _C (10 _F) below the
temperature of hydrometer calibration.
2) Add four points (0.004 specific gravity) for Example 2
every 5.5 _C (10 _F) above the temperature Temperature above 30 _C (86 _F)
of hydrometer calibration. Electrolyte Temperature 40 _C (104 _F)
Hydrometer Reading 1.220
The following examples demonstrate specific gravity Subtract 10 x 0.004 0.007
corrections using a hydrometer calibrated at 30 _C 5.5
(86 _F): Corrected Specific Gravity 1.277
Refer to Table 3 to determine the state of change:

Table 3
State of Charge Corrected Specific Corrected Specific Average Battery Voltage
Gravity at 15 _C (59 _F) Gravity at 25 _C (77 _F)
100% 0.295 1.287 12.76 V
75% 1.253 1.246 12.52 V
50% 1.217 1.210 12.30 V
25% 1.177 1.170 12.06 V
Discharged 1.137 1.130 11.84 V
NOTE: Specific gravity must not vary more than NOTE: After adding distilled water, charge the
0.025 points between cells. battery for a short period before testing with the
hydrometer to ensure an accurate reading.
A specific gravity measurement of 1.280 or more
indicates a fully charged battery in good operating NOTE: Charging a battery under static conditions will
condition. Should the corrected specific gravity cause denser electrolyte to accumulate at the bottom
measure below 1.280, charge the battery and of the cells. Periodically shake the battery to mix the
inspect charging system to determine cause of the electrolyte and improve the charge rate. This will
low charge. result in a more accurate hydrometer reading.
55-6
Battery Performance Test 3. Turn the charger timer past a ‘3 minutes’ charge
The performance test determines if the battery indication and then back to the ‘3 minutes’ mark.
contains adequate capacity to turn the engine. The
4. Set the charging rate as close as possible to 40
voltage reading obtained determines the condition of
amperes.
the battery.
5. After 3 minutes of fast charge, record the
The battery must contain the correct electrolyte level Voltmeter reading.
and an open circuit voltage of 12.5 V before testing. A reading over 15.5 V signifies a sulfated or worn
battery. Replace the battery.
CAUTION
Recovery of a mildly sulfated battery is possible by
Do not leave the high discharge load on the
using a multiple battery type charger, with an
battery for more than 15 seconds.
open-circuit, upper voltage limit of 50 volts. The high
resistance of a sulfated battery will require a high
1. Set the current control switch on the battery voltage setting to overcome the sulfated plates.
starter tester to the ‘OFF’ position. Initially, no charge acceptance will be visible. After a
2. Set the voltage selector switch equal to, or few minutes of inactivity, a small charge will become
slightly higher than the rated battery voltage. apparent, followed by a rapid increase in the charge
rate. The charge rate must not exceed 14 amperes,
3. Connect the positive cable of the tester to the or an electrolyte temperature of 50 _C (122 _F).
positive terminal of the battery. When the ampere rate stabilizes, reset the volts until
4. Connect the negative cable of the tester to the the charge rate steadies at 5 amperes. Continue at
negative terminal of the battery. this rate until the electrolyte specific gravity stops
rising at approximately 1.275-1.280 at 20 C (68 _F),
5. Turn the current control switch until the Ammeter which may take up to 48 hours of charging. Stand the
reads half the CCA rating of the battery. Record battery for 24 hours and then conduct the “Capacity
the voltage reading. Test” as described in this chapter.
A reading of 9.6 V or greater after 15 seconds
signifies that the battery will provide an acceptable With a reading below 15.5 V test the specific gravity
output, as well as readily accept a normal charge. of each cell and recharge the battery to the following
scale:
A reading below 9.6 V signifies a battery
unsatisfactory for service. Use the “Test Charging” Table 4
procedures described in this chapter for a battery
that fails the capacity test. Specific Slow Charge Fast Charge
Gravity Only Up To
Test Charging 1.150 or less 60 minutes

Use the test charging procedure for batteries that fail 1.151-1.175 45 minutes
the capacity test. 1.176-1.200 30 minutes
1.201-1.225 15 minutes
1. Connect the positive lead of the battery starter
tester (with high rate discharge) to the positive
terminal of the battery. NOTE: When determining the cause of battery
2. Connect the negative lead of the battery starter problems, check the fan belt tension and charging
tester to the negative terminal of the battery. system.
55-7
Common Causes of Battery Failure –11 _C (26.6 _F and 12.2 _F). Excessively high boost
• Internal open or short circuit charging and gassing will cause separation of active
materials from the grids. Separation destroys the
• Loss of electrolyte
chemical function of the battery.
• Separation of active materials from grids
• Accumulation of sulfate crystals too large to Crystal growth occurs whenever batteries stand
disperse discharged. High temperatures and extended
• Failure of inter-cell components discharge periods increase this condition. At room
temperature after one week, the battery may not
• Separators punctured by excessive crystal recover while on the vehicle. Recharge will require a
growth, causing short circuit higher constant voltage. After three weeks, the
• Excessive over-charging battery will suffer permanent degradation, and the
• Electrolyte freezing procedures for charging a heavily discharged battery
will be required.
A fully charged battery will not freeze until –65 _C When cranking the engine, if the battery starts to
(--85 _F). A 50% charged battery freezes between fade, stop cranking and allow the battery to stand for
–17 _C and –27 _C (1.4 _F and --16.6 _F). Fully two minutes to recover. The recovery time required
discharged electrolyte freezes between –3 _C and increases as the temperature decreases.
55-8
Chapter 5 - Electrical System Diagrams
CONTENTS

Legend 1 -- Non-Emissionized Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table 1 -- Non-Emissionized Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Legend 2 -- Emissionized Engine Less Fuel/Water Separator Circuit . . . . . . . . . . . . . . . . . . . 3
Table 2 -- Emissionized Engine Less Fuel/Water Separator Circuit . . . . . . . . . . . . . . . . . . . . . 4
Legend 3 -- Emissionized Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 3 -- Emissionized Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 4 -- Electrical Diagram Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
55-1
LEGEND 1
Item Number Description
C1 Connector, Grille Mounted Headlamp Harness-to-Front Main Harness
C2-A Connector, Front Main Harness-to-Rear Main Harness
C2-B Connector, Front Main Harness-to-Rear Main Harness
C3 Connector, Rear Main Harness-to-Power Take Off Switch Harness
C4 Connector, Rear Main Harness-to-Rear Harness
C5 Connector, Rear Harness-to-Left Fender Harness
C6 Connector, Rear Harness-to-Right Fender Harness
1 Fuel Shut Off Relay
2 Tail/Warning Lamp Right Side
3 Tail/Warning Lamp Left Side
4 Work Lamp
5 Warning Flasher Unit
6 Warning Flasher Switch
7 Four Wheel Drive Select Switch
8 Four Wheel Drive Solenoid
9 Power Take Off (PTO) Switch
10 Starting Circuit Relay
11 Grille Mounted Headlamp Left Side
12 Grille Mounted Headlamp Right Side
13 Horn Assembly
14 Coolant Temperature Sender Switch
15 Oil Pressure Sender Switch
16 Battery Sensor
17 Alternator
18 Dual Power Control Solenoid
19 Starting Motor
20 Thermostart Plug
21 Air Cleaner Restriction Switch
22 Fuel Shut Off Solenoid
23 Starting Motor Solenoid
24 Fuse Link
25 Fuse Link
26 Battery
27 Dual Power Select Switch
28 Neutral Start Switch
29 Fuel Pump
30 Coolant Temperature Gauge
31 Key-Start Ignition Switch
32 Lights Switch
33 Horn Switch
34 Air Cleaner Restriction Warning Light
35 Oil Pressure Warning Light
36 Alternator Charge Warning Light
37 Instrument Panel Lights
38 Main Fuel Tank Sender
39 Auxiliary Fuel Tank Sender
40 Fuse Box
41 Fuel Level Gauge
55-2
TABLE 1
Wire Color Symbol
BLACK B
GREEN G
LIGHT GREEN LG
BROWN N
PINK K
RED R
SLATE S
BLUE U
WHITE W
YELLOW Y
GREY Z
PURPLE P
LEGEND 2
(EMISSIONIZED ENGINE LESS FUEL/WATER SEPARATOR CIRCUIT)
4 Work Lamp
13 Horn Assembly
16 Battery Sensor
17 Alternator
19 Starting Motor
20 Thermostart Plug
24 Fuse Link
55-3
LEGEND 2 (CONTINUED)
25 Fuse Link
26 Battery
29 Fuel Pump
32 Lights Switch
33 Horn Switch
40 Fuse Box
41 Fuel Level Gauge
42 Work Lamp Switch
43 Wax Plug
44 Thermostatic Switch
45 Fender Mounted Headlamp Right Side
46 Fender Mounted Headlamp Left Side
47 Auxiliary Fuel Pump (Lift Pump)
TABLE 2
Wire Color Symbol
BLACK B
GREEN G
LIGHT GREEN LG
BROWN N
PINK K
RED R
SLATE S
BLUE U
WHITE W
YELLOW Y
GREY Z
PURPLE P
55-4
LEGEND 3
4 Work Lamp
13 Horn Assembly
16 Battery Sensor
17 Alternator
19 Starting Motor
20 Thermostart Plug
24 Fuse Link
25 Fuse Link
26 Battery
29 Fuel Pump
32 Lights Switch
33 Horn Switch
40 Fuse Box
41 Fuel Level Gauge
42 Work Lamp Switch
43 Wax Plug
44 Thermostatic Switch
45 Fender Mounted Headlamp Right Side
46 Fender Mounted Headlamp Left Side
47 Auxiliary Fuel Pump (Lift Pump)
48 Fuel/Water Separator Warning Switch
49 Fuel/Water Separator Warning Light
50 Tachometer
55-5
TABLE 3
Wire Color Symbol
BLACK B
GREEN G
LIGHT GREEN LG
BROWN N
PINK K
RED R
SLATE S
BLUE U
WHITE W
YELLOW Y
GREY Z
PURPLE P
55-6
TABLE 4
ELECTRICAL DIAGRAM SYMBOLS
Symbol Description Symbol Description
BATTERY S
SWITCH
C
S
SENDER S
SWITCH
C
SO
SOLENOID
O S
SENDER
PRESSURE
SS S
SWITCH
C CO
CONNECTOR
C O
S
STARTING
G MOTOR
O O ALTERNATOR
O
SAFETY SWITCH RELAY
IGNITION SWITCH ROCKER SWITCH

WITH LIGHT
55-7
Symbol Description Symbol Description
FLASHER UNIT FUEL SHUT-OFF
WARNING LIGHT
INSTRUMENT LIGHT DIODE
GAUGE
WITH
GAUGE RESISTERS
TAIL LAMP HEADLAMP
LIGHTS SWITCH FUSES
55-8
50030986
1
Non-Emissionized Engine -- Refer to Legend 1 / Table 1
(Sheet 1 of 2)
55-9
50030985
2
Non-Emissionized Engine -- Refer to Legend 1 / Table 1
(Sheet 2 of 2)
55-10
50032117
3
Emissionized Engine -- Refer to Legend 2 / Table 2
(Sheet 1 of 2)
55-11
50032118
4
(Sheet 2 of 2)
55-12
50032175
5
(Sheet 1 of 2)
55-13
50032176
6
(Sheet 2 of 2)
55-14

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5610S, 6610S, 7610S, 7010, 8010

SECTION 21 - TRANSMISSION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 23 - FRONT AXLE TRANSFER BOX . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 25 - FRONT AXLE -- FOUR WHEEL DRIVE . . . . . . . . . . . . . . . . . . . 10

SECTION 27 - MECHANICAL REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . 10

SECTION 31 - POWER TAKE-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION 33 - BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SECTION 35 - HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION 41 - STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 44 - FRONT AXLE -- TWO WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . 16

SECTION 55 - ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

 2003 NEW HOLLAND NORTH AMERICA, INC. 87032904 4/03

Chapter 1 - Diesel Engines

Section Description Page

Chapter 1 - Diesel Engines (Continued)

Section Description Page

Chapter 2 - Engine Cooling System

Section Description Page

Chapter 3 - Air Cleaning System

Section Description Page

Chapter 4 - Fuel System

Section Description Page

Chapter 4 - Fuel System (Continued)

Section Description Page

Section Description Page

Chapter 1 - Single Clutches

Section Description Page

Chapter 2 - Servicing Clutch Associated Parts

Section Description Page

Section Description Page

SECTION 21 - TRANSMISSION SYSTEMS

Chapter 2 - 16 x 4 Dual Command (Dual Power) Transmission

Section Description Page

Chapter 3 - Reduction Gearbox Assembly

Section Description Page

SECTION 23 - FRONT AXLE TRANSFER BOX

Chapter 1 - Front Axle Transfer Box

Section Description Page

Chapter 1 - Four Wheel Drive

Section Description Page

SECTION 27 - MECHANICAL REAR WHEEL DRIVE

Chapter 1 - Rear Axle

Section Description Page

Chapter 1 - Rear Axle (Continued)

Section Description Page

SECTION 31 - POWER TAKE-OFF

Chapter 1 - Power Take-Off Systems

Section Description Page

Chapter 1 - Power Take-Off Systems (Continued)

Section Description Page

SECTION 33 - BRAKING SYSTEM

Chapter 1 - Braking System

Section Description Page

Chapter 1 - Hydraulic Circuits

Section Description Page

SECTION 35 - HYDRAULIC SYSTEM

Chapter 2 - Hydraulic Pumps

Section Description Page