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FOREWORD
Appropriate service methods and correct repair procedures are
essential for the safe, reliable operation of all equipment, as
well as the personal safety of the individual performing the
repair.
This Service Manual provides troubleshooting, overhaul, and
pressure-testing instructions using recommended procedures and
equipment. Following these instructions will ensure the safe,
efficient, and timely completion of the service or
repair.
There are numerous variations in procedures, techniques, tools, and
parts for servicing machines, as well as in the skill of the
individual doing the work. This manual cannot possibly anticipate
all such variations and provide advice or cautions as to each.
Accordingly, anyone who departs from the instructions provided in
this manual must first establish that their personal safety, the
safety of others, and the integrity of themachine will not be com-
promised by the choice of methods, tools or parts.
The manual is divided into sections which are subdivided into
chapters. Each chapter contains information on general operating
principles, detailed inspection, overhaul and, where applicable,
specific troubleshooting, spe- cial tools, and
specifications.
Any reference in this manual to right, left, rear, front,
top, or bottom is as viewed from the operator’s seat, looking
forward.
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PRECAUTIONARY STATEMENTS
PERSONAL SAFETY
Throughout this manual and on machine decals, you will find
precautionary statements (“CAUTION”, “WARNING”,and“DANGER”)
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.
CAUTION
The word “CAUTION” is used where a safe behavioral practice
according to operating and maintenance instructions and common
safety practices will protect the operator and others from accident
involvement.
WARNING
The word “WARNING” denotes a potential or hidden hazard which has a
potential for serious injury. It is used to warn operators and
others to exercise every appropriate means to avoid a surprise
involvement with machinery.
DANGER
The word “DANGER” denotes a forbidden practice in connection with a
serious hazard.
FAILURE TO FOLLOW THE “CAUTION”, “WARNING”, AND “DANGER”
INSTRUCTIONS MAY RESULT IN SERIOUS BODILY INJURY OR DEATH.
MACHINE SAFETY
Additional precautionary statements (“ATTENTION” and
“IMPORTANT”) are followed by specific instructions. These
statements are intended for machine safety.
ATTENTION: The word “ ATTENTION ” is
used to warn the operator of potential machine damage if a certain
procedure is not followed.
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SAFETY PRECAUTIONS
Practically all service work involves the need to drive the
tractor. The operator’s manual, supplied with each tractor,
contains detailed safety precautions relating to driving,
operating, and servicing that tractor. These precautions are as
applicable to the service technician as they are to the operator
and should be read, understood and practiced by all
personnel.
Prior to undertaking any maintenance, repair, overhaul, dismantling
or reassembly operations, whether within a workshop facility or in
the field, consideration should be given to factors that may have
an effect upon safety, not only upon the mechanic carrying out the
work, but also upon bystanders.
PERSONAL CONSIDERATIONS
The wrong clothes or carelessness in dress can cause accidents.
Check to see that you are suitable clothed.
Some jobs require special protective equipment.
Skin Protection Used motor oil may cause skin cancer. Follow work
practices that minimize the amount of skin exposed and length of
time used oil stays on your skin.
Eye Protection The smallest eye injury may cause loss of vision.
Injury can be avoided by wearing eye protection when engaged in
chiselling, grinding, discing, welding, and painting.
Breathing Protection Fumes, dust, and paint spray are unpleasant
and harmful. These can be avoided by wearing respiratory
protection.
Hearing Protection Loud noise may damage your hearing, and the
greater the exposure the worse the damage. If the noise is
excessive, wear ear protection.
Lifting Protection Avoid injury by correctly handling
components. Make sure you are capable of lifting the object. If in
doubt get help.
Hand Protection It is advisable to use a protective cream before
work to prevent irritation and skin contamination. After work clean
your hands with soap and water. Solvents such as mineral spirit and
kerosene may harm the skin.
Foot Protection Substantial or protective footwear with reinforced
toe caps will protect your feet from falling objects.
Additionally, oil-resistant soles will help to avoid
slipping.
Special Clothing For certain work it may be necessary to wear flame
or acid-resistant clothing.
EQUIPMENT CONSIDERATIONS
Machine Guards Before using any machine, check to ensure that the
machine guards are in position and serviceable. These guards not
only prevent parts of the body or clothing coming in contact with
the moving parts of the machine, but also ward off objects
that might fly off the machine and cause injury.
Lifting Devices Always ensure that lifting equipment, such as
chains, slings, lifting brackets, hooks and eyes, are thoroughly
checked before use. If in doubt, select stronger equipment than is
necessary.
Never stand under a suspended load or raised implement.
Compressed Air The pressure from a compressed-air line often
exceeds 690 bar (100 PSI). It is perfectly safe if used correctly.
Any misuse may cause injury.
Never use compressed air to blow dust, filing, anddirt away from
your work area unless the correct type of nozzle is
fitted.
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Hand Tools Many cuts, abrasions and injuries are caused by
defective tools. Never use the wrong tool for the job, as this
generally leads either to some injury or to a poor job.
When removing or replacing hardened pins, use a copper or brass
drift rather than a hammer.
For dismantling, overhaul, and assembly of major and
sub-components, always use the Special Service Tools recommended.
These will reduce the work effort, labor time, and the repair
cost.
Electricity Electricity has become so familiar in day to day usage,
that its potentially dangerous properties are often overlooked.
Misuse of electrical equipment can endanger life.
Before using any electrical equipment - particularly portable
appliances - make a visual check to make sure that the wiring is
not worn or frayed and that the plugs and sockets are intact. Make
sure you know where the nearest isolating switch for your equipment
is located.
GENERAL CONSIDERATIONS
Solvents Use cleaning fluids and solvents that are known to be
safe. Certain types of fluids can cause damage to components, such
as seals, and can cause skin irritation. Solvents should be checked
that they are suitable not only for the cleaning of components and
individual parts, but also that they do not affect the personal
safety of the user.
Housekeeping Many injuries result from tripping over or slipping on
objects or material left lying around by a careless worker. Prevent
these accidents from occurring. If you notice a hazard, don’t
ignore it - remove it.
A clean, hazard-free place of work improves the surroundings
and daily environment for everybody.
Fire Fire has no respect for persons or property. The destruction
that a fire can cause is not always fully realized. Everyone must
be constantly on guard.
Extinguish matches, cigars, and cigarettes before throwing them
away.
Work cleanly, disposing of waste material into proper
containers.
Locate the fire extinguishers and find out how to operate
them.
Do not panic - warn those near and raise the alarm.
Do not allow or use an open flame near the tractor fuel tank,
battery, or component parts.
First Aid In the type of work that mechanics are engaged in, dirt,
grease, and fine dusts settle upon the skin and clothing. If a cut,
abrasion or burn is disregarded it may become infected within a
short time. Seek medical aid immediately.
Cleanliness Cleanliness of the tractor hydraulic system is
essential for optimum performance. When carrying out service and
repairs, plug all hose ends and component connections to prevent
dirt entry.
Clean the exterior of all components before carrying out any form
of repair. Dirt and abrasive dust can reduce theefficiency and
working life of a component and lead to costly replacement. Use of
a high-pressure washer or steam cleaner is recom- mended.
OPERATIONAL CONSIDERATIONS
Stop the engine, if at all possible, before performing any
service.
Place a warning sign on tractors which, due to service or overhaul,
would be dangerous to start. Disconnect the battery leads if
leaving such a unit unattended.
Do not attempt to start the engine while standing beside the
tractor or attempt to bypass the safety start switch.
Avoid prolonged running of the engine in a closed building or
in an area with inadequate ventilation as exhaust fumes are highly
toxic.
Always turn the radiator cap to the first stop to allow
pressure in the system to dissipate when the coolant is hot.
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If it is found necessary to raise the tractor for ease of
servicing or repair, make sure that safe and stable supports are
installed beneath axle housings, casings, etc., before starting
work.
Certain repair or overhaul procedures may necessi- tate separating
the tractor, either at the engine/trans- mission or
transmission/rear axle location. These operations are simplified by
the use of the Tractor Splitting Stands. Should this equipment not
be available, every consideration must be given to stability,
balance and weight of the components, especially if a cab is
installed.
Use footsteps or working platforms when servicing those areas of a
tractor that arenot withineasy reach.
Before loosening any hoses or tubes connecting implements to remote
control valves, etc., switch off the engine, remove all
pressure in the lines by operating levers several times. This will
remove the danger of personal injury by oil pressure.
Prior to pressure testing, make sure all hoses and connectors of
the tractor and the test equipment are in good condition and
tightly sealed. Pressure readings must be taken with the gauges
specified. The correct procedure should be rigidly observed to
prevent damage to the system or the equipment, and to eliminate the
possibility of personal injury.
WARNING
Escaping hydraulic/diesel fluid under pressure can penetrate the
skin causing serious injury.
Do not use your hand to check for leaks. Use a piece of cardboard
or paper to search for leaks.
Stop the engine and relieve pressure before connecting or
disconnecting lines.
Tighten all connections before starting the engine or pressurizing
lines.
If any fluid is injected into the skin, obtain medical attention
immediately or gangrene may result.
Use “position control” when equipment or imple- ments are required
to be attached to the hydraulic linkage either for testing purposes
or for transporta- tion.
Always lower equipment to the ground when leaving the
tractor.
If high lift attachments are installed on a tractor, beware of
overhead power, electric or telephone cables when traveling. Drop
the attachment near to ground level to increase stability and
minimize risks.
Do not park or attempt to service a tractor on an incline. If
unavoidable, take extra care and block all wheels.
Observe recommended precautions as indicated in this Service Manual
when dismantling the air- conditioning system as escaping
refrigerant can cause frostbite.
Prior to removing wheels and tires from a tractor, check to
determine whether additional ballast (liquid or weights) has been
added. Seek assistance and use suitable equipment to support the
weight of the wheel assembly.
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HEALTH AND SAFETY PRECAUTIONS
Many of the procedures associated with vehicle maintenance and
repair involve physical hazards or other risks to health. This
section lists, alphabetically, some of these hazardous operations,
materials and equipment associated with them. The precautions
necessary to avoid these hazards are identified.
The list is not inclusive; all operations, procedures, and handling
of materials should be carried out with health and safety in
mind.
ACIDS AND ALKALIS (See Battery Acids, i.e., Caustic Soda, Sulfuric
Acid)
Used in batteries and cleaning materials.
Irritating and corrosive to the skin, eyes, nose and throat. Causes
burns.
Avoid splashes to the skin, eyes, and clothing. Wear suitable
protective gloves and goggles. Can destroy ordinary protective
clothing. Do not breathe mists.
Ensure access to water and soap is readily available for splashing
accidents.
ADHESIVES AND SEALERS (See Fire)
CAUTION
HIGHLY FLAMMABLE, COMBUSTIBLE.
Generally should be stored in “NO SMOKING” areas; cleanliness and
tidiness while in use should be observed, i.e., from applications
where possible, disposable paper should be dispensed to cover
benches. Containers, including secondary contain- ers, should be
labeled.
Solvent-Based Adhesives/Sealers (See Solvents) Follow
manufacturer’s Instructions
Water-Based Adhesives/Sealers Those based on polymer emulsions and
rubber lattices may contain small amounts of volatile toxic and
harmful chemicals.
Skin and eye contact should be avoided, and adequate ventilation
provided during use.
Follow manufacturer’s Instructions
Resin-Based Adhesive/Sealers (i.e., Epoxide and Formaldehyde Resin
Based) Mixing should only be carried out in well- ventilated areas
as harmful or toxic volatile chemicals may be released.
Skin contact with uncured resins and hardeners can result in
irritation, dermatitis, and absorption of toxic, or harmful
chemicals through the skin. Splashes can damage the eyes.
Provide adequate ventilation; avoid skin and eye contact. Follow
manufacturer’s instructions.
Anaerobic, Cyanoacrylate and other Acrylic Adhesives Many are
irritating, sensitizing, or harmful to the skin. Some are eye
irritants.
Skin and eye contact should be avoided and the manufacturer’s
instructions followed.
Cyanoacrylate adhesives (super-glues) must not contact the skin or
eyes. If skin or eye tissue is bonded, cover with a clean moist pad
and get medical attention. Do not attempt to pull tissue apart. Use
in well-ventilated areas as vapors can cause irritation of the nose
and eyes.
For two-part systems: See Resin-Based Adhesive/ Sealers
Isocyanate (Polyurethane) Adhesive/Sealers (See Resin-Based
Adhesives) Individuals suffering from asthma or respiratory
allergies should not work with, or near, these materials as
sensitivity reactions can occur.
Any spraying should preferably be carried out in exhaust
ventilated booths removing vapors and spray droplets from the
breathing zone. Individuals working with spray applications should
wear supplied air respirators.
ANTIFREEZE (See Fire, Solvents, i.e., Isopropanol, Ethylene Glycol,
Methanol)
CAUTION
HIGHLY FLAMMABLE, COMBUSTIBLE.
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Vapors given off from coolant antifreeze (Glycol) arise only when
heated.
Antifreeze may be absorbed through the skin in toxic or
harmful quantities. Swallowed antifreeze is fatal if not
treated; medical attention must be sought immediately.
BATTERY ACIDS (See Acids and Alkalis)
Gases released during charging are explosive. Never use an open
flame or allow sparks near charging or recently charged
batteries.
BRAKE AND CLUTCH LININGS AND PADS (See Legal Aspects)
These items may contain asbestos which, if inhaled, may cause lung
damage and, in some cases,cancer.
The normal handling and fitting of these items should not cause any
hazard, but any drilling, grinding, or filling of friction
materials may produce asbestos dust and should only be carried out
under strictly controlled conditions.
The dust in brake drums, etc., contains very little asbestos, but
care should be taken to avoid inhalation of this dust during
servicing of brakes and clutches. The use of drum cleaning units,
vacuum cleaning, or damp wiping is preferred to the use of air
jets for “blowing-out.”
The dust should be collected in a sealed plastic bag and disposed
appropriately, according to local laws and regulations.
BRAZING (See Welding)
CHEMICAL MATERIALS - GENERAL (See Legal Aspects)
Chemical materials such as solvents, sealers, adhesives, paints,
resin foams, battery acids, antifreeze, oils, and grease should
always be used with caution, stored andhandled with care. They may
be toxic, harmful, corrosive, irritating, or highly flammable,
causing hazardous fumes and dusts.
The effects of excessive exposure to chemicals may be immediate or
delayed, briefly experienced or permanent, cumulative, superficial,
life threatening, or may reduce life expectancy.
CLUTCH LININGS AND PADS (See Brake and Clutch Linings and
Pads)
CORROSION PROTECTION MATERIALS (See Solvents, Fire)
CAUTION
HIGHLY FLAMMABLE, COMBUSTIBLE.
These materials are varied; the manufacturer’s instructions should
be followed. They may contain solvents, resins, and petroleum
products. Skin and eye contact should be avoided. They should only
be sprayed in conditions of adequate ventilation, and not in
confined spaces.
CUTTING (See Welding)
DO’S
Do remove chemical materials from the skin and clothing as
soon as practicable. Change heavily soiled clothing and have it
cleaned.
Do carefully read and observe hazard and precaution warnings
given on material containers (labels) and in any accompanying
leaflets, poster or other instructions. Material health and safety
data sheets can be obtained from manufacturers.
Do organize work practices by wearing protective clothing and
safety devices to avoid contact with chemical materials; breathing
vapors, aerosols, dusts, and fumes; inadequate container labeling;
or fire and explosion hazards.
Do wash before job breaks, before eating, smoking, drinking,
or using toilet facilities when handling chemical materials.
Do keep work areas clean, uncluttered, and free of
spills.
Do store according to national and local regulations.
Do keep chemical materials out of reach of children.
DON’TS
Do not mix chemical materials except under the
manufacturer’s instructions; some chemicals can form other toxic or
harmful chemicals, releasing toxic or harmful fumes, or be
explosive when mixed together.
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Do not apply heat or flame to chemical materials, except
under the manufacturer’s instructions. Some are highly flammable,
and some may release toxic or harmful fumes.
Do not leave containers open. Escaping fumes can build up to
toxic, harmful, or explosive concentra- tions. Some fumes are
heavier than air and will accumulate in confined areas, pits,
etc.
Do not transfer chemical materials to unlabeled
containers.
Do not clean hands or clothing with chemical materials.
Chemicals, particularly solvents and fuels, will dry the skin, and
may cause irritation with dermatitis. Some can be absorbed through
the skin in toxic or harmful quantities.
Do not use emptied containers for other materials, except
when they have been cleaned under supervised conditions.
Do not sniff or smell chemical materials. Brief
exposure to high concentrations of fumes can be harmful or
toxic.
DUSTS
Powder or dusts may be an irritant, harmful or toxic. Avoid
breathing dusts from powdery chemical materials, or those arising
from dry abrasion operations. Wear respiratory protection if
ventilation is inadequate.
ELECTRIC SHOCK
Electric shocks can result from the use of faulty electrical
equipment or from the misuse of equipment even in good
condition.
Ensure electrical equipment is maintained in good condition and
frequently tested.
Ensure flexes, cables, plugs and sockets are not frayed, kinked,
cut, cracked, or otherwise damaged.
Ensure electric equipment is protected by the correct rated
fuse.
Never use electrical equipment or any other equipment which is in
any way faulty. The results could be fatal.
Use reduced voltage equipment for inspection and working lights,
where possible.
Ensure the cables of mobile electrical equipment cannot get trapped
and damaged, such as in a vehicle hoist.
In Cases of Electrocution:
! Switch off electricity before approaching victim.
! Ifthis is not possible, push or drag the victim from the
source of electricity using dry non-conductive material.
! Commence resuscitation if trained to do so.
! SUMMON MEDICAL ASSISTANCE IMMEDIATELY
EXHAUST FUMES
These contain asphyxiating, harmful and toxic chemicals, and
particles such as carbon oxides, nitrogen oxides, aldehydes, lead,
and aromatic hydrocarbons. Engines should only run under conditions
of adequate extraction, or general ventilation, not in confined
spaces.
Diesel Engine Soot, discomfort, and irritation usually give
adequate warning signs of hazardous fume concentration.
FIBER INSULATION (See Dusts)
Used in noise and sound insulation.
The fibrous nature of surfaces and cut edge can cause skin
irritation. This is usually a physical, not a chemical
effect.
Precautions should be taken to avoid excessive skin contact through
careful organization of work practices and the use of gloves.
FIRE (See Welding, Foams, Legal Aspects)
Many of the materials found on, or associated with, the repair of
vehicles are highly flammable. Some release toxic or harmful fumes
if burned.
Observe strict fire safety when storing and handling flammable
materials or solvents, particularly near electrical equipment or
welding processes.
Before using electrical or welding equipment, be sure there is no
fire hazard present.
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FIRST AID
Apart from meeting any legal requirements, it is desirable
for someone in the workshop to be trained in first aid
procedures.
Splashes in the eye should be flushed with clean water for at least
ten minutes.
Soiled skin should be washed with soap and water.
Inhalation affected individuals should be removed to fresh air
immediately.
If chemicals are swallowed, consult a doctor immediately with
(label) information on material used.
Do not induce vomiting, unless indicated by manufacturer.
FOAMS - POLYURETHANE (See Fire)
Used in sound and noise insulation. Cured foams are used in seat
and trim cushioning.
Follow manufacturer’s instructions.
Unreacted components are irritating and may be harmful to the skin
and eyes. Wear gloves and goggles.
Individuals with chronic respiratory diseases, asthma, bronchial
medical problems, or histories of allergic diseases should
not work with or near uncured materials.
The component’s vapors and spray mists can cause direct irritation
and/or sensitivity reactions and may be toxic or harmful.
Vapors andspray mists must not be breathed. These materials must be
applied with adequate ventilation and respiratory protection. Do
not remove respirator immediately after spraying, wait until
vapor/mists have cleared.
Burning of the uncured components and the cured foams can generate
toxic and harmful fumes.
Smoking, open flames, or the use of electrical equipment should not
be allowed during foaming operations until vapors/mists have
completely cleared. Any heat cutting of cured foams or partially
cured foams should be conducted with extraction ventilation (see
Legal Aspects).
FUELS (See Fire, Legal Aspects, Chemicals - General,
Solvents)
Used as fuels and cleaning agents.
Gasoline (Petrol)
HIGHLY FLAMMABLE, COMBUSTIBLE.
Swallowing can result in mouth and throat irritation; absorption
from the stomach can result in drowsiness and unconsciousness.
Small amounts can be fatal to children. Aspiration of liquid into
the lungs, i.e., through vomiting,is a very serious hazard.
Prolonged or repeated contact with gasoline dries the skin and
causes irritation and/or dermatitis. Liquid in the eye causes
severe pain.
Motor gasoline may contain high quantities of benzene which
is toxic upon inhalation; the concentrations of gasoline vapors
must be kept very low. High concentrations will cause eye, nose and
throat irritation, nausea, headache, depression and symptoms of
drunkenness. Very high concentra- tions will result in rapid loss
of consciousness.
Ensure there is adequate ventilation when handling and using
gasoline. Great care must be taken to avoid the serious
consequences of inhalation in the event of vapor buildup arising
from spillages in confined spaces.
Special precautions apply to cleaning and mainte- nance operations
on gasoline storage tanks.
Gasoline should not be used as a cleaning agent. It must not be
siphoned by mouth.
Kerosene (Paraffin) Used also as heating fuel, solvent, and
cleaning agent.
CAUTION
FLAMMABLE
Irritation of the mouth and throat may result from swallowing. The
main hazard from swallowing arises if liquid aspiration into the
lungs occurs. Liquid contact dries the skin and can cause
irritation and/or dermatitis. Splashes in the eye may be slightly
irritating.
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CAUTION
COMBUSTIBLE
Gross or prolonged skin contact with high boiling gas oils may
cause serious skin disorders, including skin cancer.
GAS CYLINDERS (See Fire)
Gases such as oxygen, acetylene, carbon dioxide, argon, and propane
are normally stored in cylinders at pressures of up to 137.8 bar
(2000 PSI). Great care should be taken in handling these cylinders
to avoid mechanical damage to them or the valve gear attached. The
contents of each cylinder should be clearly identified by
appropriate markings.
Cylinders should be stored in well-ventilated enclosures and
protected from ice, snow, or direct sunlight. Fuel gases, i.e.,
acetylene and propane, should not be stored in close proximity to
oxygen cylinders.
Care should be exercised to prevent leaks from gas cylinders and
lines and to avoid sources of ignition.
Only trained personnel should undertake work involving gas
cylinders.
GASES (See Gas Cylinder)
GAS WELDING (See Welding)
GENERAL WORKSHOP TOOLS AND EQUIPMENT
It is essential that all tools and equipment are maintained in good
condition and the correct safety equipment used where
required.
Never use tools or equipment for any purpose other than for which
they were designed.
Never overload equipment such as hoists, jacks, axle and chassis
stands, or lifting slings. Damage caused by overloading is not
always immediately apparent and may result in a fatal failure the
next time the equipment is used.
Do not use damaged, defective tools or equipment, particularly
high-speed equipment such as grinding wheels. A damaged grinding
wheel can disintegrate without warning causing serious
injury.
Wear suitable eye protection when using grinding, chiseling, or
sandblasting equipment.
Wear a suitable breathing mask when using sandblasting equipment,
working with asbestos based materials, or using spraying
equipment.
GLUES (See Adhesive and Sealers)
HIGH-PRESSURE AIR, LUBRICATION AND OIL TEST EQUIPMENT (See
Lubricants and Greases)
Always keep high-pressure equipment in good condition and
regularly maintained, particularly joint and unions.
Never direct a high-pressure nozzle at the skin, as the fluid may
penetrate to the underlying tissue and can cause serious
injury.
LEGAL ASPECTS
Many laws and regulations make requirements relating to health and
safety in the use of materials and equipment in workshops.
Workshops should be familiar, in detail, with these laws and
regulations.
LUBRICANTS AND GREASES
Avoid all prolonged and repeated contact with mineral oils,
especially used oils. Gross and prolonged skin contact with used
oils contaminated during service, i.e., routine service change sump
oils, are more irritating and more likely to cause serious effects,
including skin cancer.
Wash skin thoroughly after work involving oil. Proprietary hand
cleaners may be of value provided they can be removed from the skin
with water. Do not use petrol, paraffin, or other solvents to
remove oil from the skin.
Lubricants and greases may be slightly irritating to the
eyes.
Repeated or prolonged skin contact should be avoided by wearing
protective clothing, if necessary. Particular care should be taken
with used oils and greases containing lead. Do not allow work
clothing to be contaminated with oil. Dry clean or launder such
clothing at regular intervals. Discard oil-soaked shoes.
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CAUTION
HIGHLY FLAMMABLE
Paints can contain harmful or toxic pigments, driers, and other
components, as well as solvents. Spraying should only be carried
out with adequate ventilation.
Two-part or catalyzed paints can also contain harmful and toxic
unreacted resins and resin-hard- ening agents. The manufacturer’s
instructions should be followed and the section on resin-based
adhesives, isocyanate containing adhesive and foams should be
consulted.
Spraying should preferably be carried out in exhausted ventilated
booths, removing vapor and spray mists from the breathing zone.
Individuals working in booths should wear respiratory protection.
Those doing small-scale repair work in the open shop should wear
supplied air respirators.
PAINT THINNERS (See Solvents)
PRESSURIZED EQUIPMENT (See High- Pressure Air, Lubrication and Oil
Test Equipment)
RESISTANCE WELDING (See Welding)
SOLDER (See Welding)
Solders are mixtures of metals in which the melting point of
themixture is below that of constituent metals (normally lead and
tin). Solder application does not normally give rise to toxic lead
fumes, provided a gas/air flame is used. Oxyacetylene flames should
not be used, as they are much hotter and will cause lead fumes to
be released.
Some fumes may be produced by the application of any flame to
surfaces coated with grease, etc., and inhalation of these should
be avoided.
Removal of excess solder should be undertaken with care to ensure
fine lead dust is not produced, which can cause toxic effects if
inhaled. Respiratory protection may be necessary.
Solder spillage and filing should be collected and removed promptly
to prevent general air contamina- tion by lead.
High standards of personal hygiene are necessary in order to avoid
ingestion of lead or inhalation of solder dust from clothing.
SOLVENTS (See Chemical Materials - General, Fuels [Kerosene],
Fire)
Acetone, White spirit, Toluene, Xylene, Trichlore-
thane.
Used in cleaning materials, dewaxing, paints, plastics, resins,
thinners, etc.
CAUTION
HIGHLY FLAMMABLE
Skin contact will degrease the skin and may result in irritation
and/or dermatitis following repeated or prolonged contact. Some can
be absorbed through the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation and could lead to
loss of vision.
Brief exposure to high concentrations of vapors or mists will cause
eye and throat irritation, drowsiness, dizziness, headaches and, in
the worst circum- stances, unconsciousness.
Repeated or prolonged exposures to excessive, but lower
concentrations of vapors or mists, for which there might not be
adequate warning indications, can cause more serious toxic or
harmful effects. Aspiration into the lungs, i.e., through
vomiting, is the most serious consequence.
Avoid splashes to the skin, eyes, and clothing. Wear
protective gloves, goggles, and clothing if necessary.
Ensure good ventilation when in use, avoid breathing fumes, vapors,
and spray mists. Keep containers tightly sealed. Do not use in
confined spaces.
When the spraying material contains solvents, e.g., paints,
adhesives, and coatings, use extraction ventilation or personal
respiratory protection in the absence of adequate general
ventilation.
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SPOT WELDING (See Welding)
SUSPENDED LOADS
There is always a danger when loads are lifted or suspended. Never
work under an unsupported, suspended, or raised load, e.g.,
jacked-up vehicle, suspended engine, etc.
Always ensure lifting equipment such as jacks, hoists, axle
stands, slings, etc., are adequate and suitable for the job, in
good condition, and regularly maintained.
Never improvise lifting tackle.
WELDING (See Fire, Electric Shock, Gas Cylinders)
Welding processes include Resistance Welding (Spot Welding), Arc
Welding, and Gas Welding.
Resistance Welding This process may cause particles of molten metal
to be emitted at high velocity; the eyes and skin must be
protected.
Arc Welding This process emits a high level of ultraviolet
radiation which may cause eye and skin burns to the welder and to
other persons nearby. Gas-shielded welding processes are
particularly hazardous in this respect. Personal protection must be
worn and screens used to shield other people.
Metal spatter will also occur; appropriate eye and skin protection
is necessary.
The heat of the welding arc will produce fumes and gases from the
metals being welded and from any
applied coatings or contamination of the surfaces being worked on.
These gases and fumes may be toxic; inhalation should always be
avoided. The use of extraction ventilation to remove the fumes from
the working area may be necessary, particularly in cases where the
general ventilation is poor, or where considerable welding work is
anticipated. In extreme cases where adequate ventilation cannot be
provided, supplied air respirators may be necessary.
Gas Welding Oxyacetylene torches may be used for welding and
cutting; special care must be taken to prevent leakage of these
gases, subsequently reducing the risk of fire and explosion.
The process will produce metal spatter; eye and skin protection is
necessary.
The flame is bright and eye protection should be used, but the
ultraviolet emission is much less than that from arc welding, and
lighter filters may be used.
The process itself produces few toxic fumes, but such fumes and
gases may be produced from coatings on the work, particularly
during cutting away of damaged parts. Inhalation of the fumes
should be avoided.
In brazing, toxic fumes may be released from the metals in the
brazing rod. A severe hazard may arise if brazing rods containing
cadmium are used. In this event, particular care must be taken to
avoid inhalation of fumes; an expert’s advice may be
required.
SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING
TAKES PLACE ON VESSELS WHICH HAVE CONTAINED COMBUSTIBLE MATERIALS,
I.E., “BOILING” OR “STEAMING OUT” THE INSIDE OF FUEL TANKS.
WHITE SPIRIT (See Solvents)
00-14
TRACTOR IDENTIFICATION DATA
The tractor and major components are identified using serial
numbers and/or manufacturing codes. The following provides the
locations of the identification data.
NOTE: Tractor identification data must be
supplied when requesting parts or service.
Identification data is needed to aid in identifying the tractor if
it is ever stolen.
VEHICLE IDENTIFICATION PLATE
The vehicle identification plate on the 70 Series, is located
inside the right front lower side panel of the hood at 1.
The vehicle identification plate on the 70A Series, is located
inside the upper right side panel of the hood at 2.
Owners should record the information on the sample ID plate.
70-340-31
1
TRACTOR NUMBER - Serial numberprefixed by the letter “D.”
MODEL - Production model code.
ENGINE - Serial number.
TRANSMISSION - Serial number.
FRONT AXLE - Serial number.
HYDRAULIC PUMP - Serial number.
00-15
*KEY TO PRODUCTION DATE CODES:
The unit heading on the ID plate represents the production date of
the tractor.
Two types of production date codes are used. One style starts with
a numeral (example 4A03B) while the second style starts with a
letter (example A0314).
The following examples explain each code. Refer to the style code
used on the tractor being worked on.
Example of Production Unit Code 4A03B:
4 = Year of production (4 = 1994, 5 = 1995)
A = Month of year (A = January, B = February, ... H = August, J =
September, ... M = December) NOTE: “I” is not used.
03 = Day of month (03 = third, 04 = fourth, ... 31 =
thirty-first)
B = Shift (A = night, B = day, C = afternoon)
Example of Production Unit Code A0314:
A = Month of year (A = January, B = February, ... H = August, J =
September, ... M = December) NOTE: “I” is not used.
03 = Day of month (03 = third, 04 = fourth, ... 31 =
thirty-first)
1 = Shift (1 = day, 2 = afternoon, 3 = night)
4 = Year of production (4 = 1994, 5 = 1995)
TRACTOR IDENTIFICATION STAMPING
The serial number and identification information, 1, is stamped on
the top of the front support.
70-340-32
4
00-16
FOUR WHEEL DRIVE (FWD) FRONT AXLE IDENTIFICATION
The serial number and axle type for the 70 Series is on the plate,
1, located on the front of the axle housing.
70-340-34
5
The serial number and axle type for the 70A Series is on the plate
located on the right rear of the axle housing, 2.
10001277
2
6
00-17
ENGINE IDENTIFICATION
The engine identification information for the 70 Series, is located
on a tag, 1, on the right side of the engine rocker cover.
70-340-33
7
The engine identification information for the 70A Series, is
located on a tag, 2, on the top front of the engine rocker
cover.
70-340-33
2
8
NOTE: 70 Series art shown in Figure 9.
The serial number and pump information are on the plate, 1, on the
pump.
NOTE: The plate location differs slightly for all the
models.
70-340-2194
9
00-18
! 011 = Factory code (Germany)
! 0400876405 = Supplier order number
! PES6A95D410RS2835 = Alphanumeric production
designation
S = Flange-mounted
6 = Number of cylinders
A = Size pump (A - 8670 and 8770, P - 8870 and 8970)
95 = Plunger diameter in 1/10 mm (915 mm)
D = Pump model (“D” is the latest version of “A” size pumps)
410 = Number code for location of feed pump and governor
R = Rotation of pump as seen from drive end (right hand =
clockwise)
S2835 = Application number (indicates what model New Holland
tractor this is used on)
70-340-2195
10
STARTER MOTOR IDENTIFICATION
The serial number and starter information are on the plate, 1, on
the starter housing.
70-340-2196
11
TRANSMISSION IDENTIFICATION
The serial number and type are located on the plate, 1, on the
lower right side of the transmission.
70-340-36
12
00-19
TANDEM GEAR PUMP IDENTIFICATION
The serial number and pump identification informa- tion are on the
plate, 1, on the pump housing.
70-340-2197
13
AXIAL PISTON PUMP IDENTIFICATION
The serial number and pump identification informa- tion are on the
plate, 1, on the pump housing next to the case drain port.
70-340-2198
14
REAR AXLE IDENTIFICATION
The serial number, 1, is stamped on the left side of the PTO
boss on the rear axle housing.
70-340-37
15
00-20
CAB IDENTIFICATION
The serial number is on the certification plate, 1, on the rear
crossbar.
70-640-38
16
00-21
GENERAL
Clean the exterior of all components before carrying out any form
of repair. Dirt and abrasive dust can reduce the efficient working
life of a component and lead to costly replacement.
Time spent on the preparation and cleanliness of working
surfaces will pay dividends in making the job easier and safer and
will result in overhauled components being more reliable and
efficient in operation.
Use cleaning fluids which are known to be safe. Certain types of
fluid can cause damage to O rings andcause skinirritation. Solvents
should be checked that they are suitable for the cleaning of
components and also that they do not risk the personal safety
of the user.
Replace O rings, seals or gaskets whenever they are disturbed.
Never mix new and old seals or O rings, regardless of condition.
Always lubricate new seals and O rings with hydraulic oil before
installation.
When replacing component parts, use the correct tool for the
job.
HOSES AND TUBES
Always replace hoses and tubes if the cone end or the end
connections on the hose are damaged.
When installing a new hose, loosely connect each end and make sure
the hose takes up the designed position before tightening the
connection. Clamps
should be tightened sufficiently to hold the hose without crushing
and to prevent chafing.
After hose replacement to a moving component, check that the
hose does not foul by moving the component through the complete
range of travel.
Be sure any hose which has been installed is not kinked or
twisted.
Hose connections which are damaged, dented, crushed or leaking,
restrict oil flow and the productivity of the components being
served. Connectors which show signs of movement from the original
swaged position have failed and will ultimately separate
completely.
A hose with a chafed outer cover will allow water entry.
Concealed corrosion of the wire reinforcement will subsequently
occur along the hose length with resultant hose failure.
Ballooning of the hose indicates an internal leakage due to
structural failure. This condition rapidly deteriorates and total
hose failure soon occurs.
Kinked, crushed, stretched or deformed hoses generally suffer
internal structural damage whichcan result in oil restriction, a
reduction in the speed of operation and ultimate hose
failure.
00-22
O RING FLAT FACE SEAL FITTINGS
When repairing O ring face seal connectors, the following
procedures should be observed.
WARNING
Never disconnect or tighten a hose or tube that is under pressure.
If in doubt, actuate the operating levers several times with the
engine switched off prior to disconnecting a hose or tube.
1. Release the fittings and separate the hose or tube assembly,
then remove and discard the O ring seal from the fitting.
2. Dip a new O ringseal intoclean hydraulic oil prior to
installation. Install a new O ring into the fitting and, if
necessary, retain in position using petroleum jelly.
3. Assemble the new hose or tube assembly and tighten the fitting
finger tight, while holding the tube or hose assembly to prevent it
from turning.
4. Use two suitable wrenches and tighten the fitting to
thespecified torque according to thesize of the fitting. Refer to
the following torque chart.
NOTE: To ensure a leak-free joint is obtained, it is
important that the fittings are not over or under
torqued.
O RING FLAT FACE SEAL FITTING TORQUE VALUES
NOMINAL TUBE O.D DASH SIZE THREAD SIZE SWIVEL NUT TORQUE
(mm) (in.) (in.) Nám Ft. Lbs.
6.35 0.250 -4 9/16-18 16 12
9.52 0.375 -6 11/16-16 24 18
12.70 0.500 -8 13/16-16 50 37
15.88 0.625 -10 1-14 69 51
19.05 0.750 -12 1 3/16-12 102 75
22.22 0.875 -14 1 3/16-12 102 75
25.40 1.000 -16 1 7/16-12 142 105
31.75 1.250 -20 1 11/16-12 190 140
38.10 1.500 -24 2-12 217 160
00-23
SEALER SPECIFICATIONS
The following sealers should be used as directed in the
manual:
Anaerobic sealer LOCTITE GASKET ELIMINATOR 518
RTV silicone sealer LOCTITE SUPERFLEX 593, 595 or 596 LOCTITE ULTRA
BLUE 587 DOW CORNING SILASTIC 732 GENERAL ELECTRIC RTV 103 OR
108
Pipe sealant PST 592 PIPE SEALANT WITH TEFLON
Thread-locking compound LOCTITE 271 THREADLOCKER/SEALANT
(red)
HARDWARE TORQUE VALUES
Check the tightness of hardware periodically.
Use the following charts to determine the correct torque when
checking, adjusting or replacing hardware on the tractor.
IMPORTANT: DO NOT use the values listed in the charts if
a different torque value or tightening procedure is specified
in this manual for a specific application. Torque values
listed are for general use only.
Make sure fastener threads are clean and not damaged.
00-24
M4 15* (1.7) 19* (2.2) 23* (2.6) 30* (3.4) 33* (3.7) 42* (4.8) 16*
(1.8)
M6 51* (5.8) 67* (7.6) 79* (8.9) 102* (12) 115* (13) 150* (17) 56*
(6.3)
M8 124* (14) 159* (18) 195* (22) 248* (28) 274* (31) 354* (40) 133*
(15)
M10 21 (28) 27 (36) 32 (43) 41 (56) 45 (61) 58 (79) 22 (30)
M12 36 (49) 46 (63) 55 (75) 72 (97) 79 (107) 102 (138) 39
(53)
M16 89 (121) 117 (158) 137 (186) 177 (240) 196 (266) 254 (344) 97
(131)
M20 175 (237) 226 (307) 277 (375) 358 (485) 383 (519) 495 (671) 195
(265)
M24 303 (411) 392 (531) 478 (648) 619 (839) 662 (897) 855 (1160)
338 (458)
NOTE: Torque values shown with * are inch pounds.
IDENTIFICATION HEX CAP SCREW AND CARRIAGE BOLTS
CLASSES 5.6 AND UP
METRIC HARDWARE AND LOCKNUTS
SIZE UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED W/CL8.8 W/ZnCr
W/ZnCr W/ZnCr BOLT
CLASS 5.8 CLASS 8.8 CLASS 10.9
PROPERTY CLASS
LOCKNUT CL.8NOMINAL
CLOCK MARKING
00-25
IDENTIFICATION CAP SCREWS AND CARRIAGE BOLTS
LOCKNUTS
1 213 (289) 275 (373) 547 (742) 708 (960) 773 (1048) 1000 (1356)
386 (523) 545 (739) 1
7/8 142 (193) 183 (248) 365 (495) 473 (641) 515 (698) 667 (904) 258
(350) 364 (494) 7/8
3/4 146 (198) 189 (256) 226 (306) 293 (397) 319 (432) 413 (560) 160
(217) 226 (306) 3/4
5/8 83 (112) 107 (145) 128 (174) 165 (224) 180 (244) 233 (316) 90
(122) 127 (172) 5/8
9/16 60 (81) 77 (104) 92 (125) 120 (163) 130 (176) 169 (229) 65
(88) 92 (125) 9/16
1/2 42 (57) 54 (73) 64 (87) 83 (113) 91 (123) 117 (159) 45 (61) 64
(88) 1/2
7/16 27 (37) 35 (47) 42 (57) 54 (73) 59 (80) 77 (104) 30 (41) 42
(57) 7/16
3/8 17 (23) 22 (30) 26 (35) 34 (46) 37 (50) 48 (65) 19 (26) 26 (35)
3/8
5/16 115* (13) 149* (17) 178* (20) 229* (26) 250* (28) 324* (37)
125* (14) 176* (20) 5/16
1/4 55* (6.2) 72* (8.1) 86* (9.7) 112* (13) 121* (14) 157* (18) 61*
(6.9) 86* (9.8) 1/4
MINIMUM HARDWARE TIGHTENING TORQUES
INCH HARDWARE AND LOCKNUTS
NOMINAL UNPLAT ED PLAT ED UNPLAT ED PL ATED UNPLAT ED PL ATED GR.B
GR.C NOMINAL SIZE or W/ZnCr or W/ZnCr or W/ZnCr w/GR5 w/GR8
SIZE
PLATED PLATED PLATED BOLT BOLT SILVER GOLD SILVER GOLD SILVER
GOLD
SAE GRADE 2 SAE GRADE 5 SAE GRADE 8 LOCKNUTS
SAE GRADE 2 SAE GRADE 5 SAE GRADE 8
REGULAR NUTS SAE GRADE 5 HEX NUTS
SAE GRADE 8 HEX NUTS
GRADE IDENTIFICATION
GRADE IDENTIFICATION
GRADE IDENTIFICATION
AT CORNERS
00-26
LUBRICATION
New Holland (North America) Adequate lubrication and
maintenance on a regular schedule is vital to maintaining your
equipment. To ensure long service and efficient operation, follow
the lubrication and maintenance schedules outlined in this manual.
The use of proper fuels, oils, grease and filters, as well as
keeping the systems clean, will also extend machine and component
life.
IMPORTANT: Always use genuine New
Holland replacement parts, oils and filters to ensure
proper operation, filtration of engine and hydraulic systems. See
your New Holland dealer for additional oil
quantities.
RECOMMENDED LUBRICANTS AND COOLANTS
Lubricant Location Used Type and Description Part Number Quart or
Liter
Gallon or Tube
SAE 30 API CF--2SJ 9613286 1Qt.
SAE 30 API CF--2SJ 9613289 2.5 Gal.
SAE 30 API CF--2SJ 9613366* 4 L
5W--30 API SG/CD 9673589DS 1 Qt.
5W--30 API SG/CD 9624590* 4 L
10W--30 API SG/CD 9613313 1 Qt.
10W--30 API SG/CD 9613314 2.5 Gal.
10W--30 API SG/CD 9673508DS 5 Gal.
10W--30 API SG/CD 9613358* 1 L
10W--30 API SG/CD 9613359* 4 L
15W--40 API CF--4 9613290 1 Qt.
15W--40 API CF--4 9673730DS 1 Gal.
15W--40 API CF--4 9613303 2.5 Gal.
15W--40 API CF--4 9613292 5 Gal.
15W--40 API CF--4 9613350* 1 L
15W--40 API CF--4 9613351* 4 L
Coolant Engine ESE-- M97B18--D, Ethylene Glycol New Hol- land Spec.
Coolant Concentrate
FGCC2701DS 1 Gal.
Hydraulic Oil Hydraulic System, Hydrostatic System Front Axle
Oil
134D – ESN--M2C134--D New Holland Spec. Hydraulic oil
9624450 2.5 Gal.
Hydraulic Oil Optional, Multi-Seasonal Use, Recommended for Low
Temperatures
F200 86523625DS 1 Qt.
F200 86523626DS 5 Gal.
F200 86509446* 20 L
Gear Oil Gearboxes 80W90 EP Gear Oil API GL5 9613295 1 Qt.
80W90 EP Gear Oil API GL5 9613294 2.5 Gal.
80W90 EP Gear Oil API GL5 9613375* 5 L
85W140 EP Gear Oil API GL5 9613297 1 Qt.
85W140 EP Gear Oil API GL5 9613296 2.5 Gal.
85W140 EP Gear Oil API GL5 9613376* 4 L
Grease All Grease Fittings Lithium base EP high temperature
9861804DS Tube
Lithium base EP high temperature 9861804CDS* Tube
Brake Fluid Mineral Based Oil 1QM6C34A or 86541699DS
1 Qt.
00-27
Europe (All Markets Except North America)
Adequate lubrication and maintenance on a regular schedule is
vital to maintaining your equipment. To ensure long service and
efficient operation, follow the lubrication and maintenance
schedules outlined in this manual. The use of proper fuels, oils,
grease and filters, as well as keeping the systems clean, will also
extend machine and component life.
IMPORTANT: Always use genuine New
Holland replacement parts, oils and filters to ensure
proper operation, filtration of engine and hydraulic systems. See
your New Holland dealer for oil
quantities.
RECOMMENDED LUBRICANTS AND COOLANTS
Oil Engine and Pivot Points without Grease Fittings, Chains
SAE 30 Ambra Super 30
5W--30 API SG/CD Ambra Super Gold 5W--30
10W--30 API SG/CD Ambra Super Gold 10W--30
15W--40 API CF--4 Ambra Super Gold 15W--40
Coolant Engine ESE--M97B18--D, Ethylene Glycol New Holland Spec.
Coolant Concentrate
Ambra Agriflu (50% mix)
134D – ESN--M2C134--D New Holland Spec. Hydraulic oil
Ambra Multi G Trans- mission Oil
134D – ESN--M2C134--D New Holland Spec. Hydraulic oil
Ambra Multi F Transmission Oil
Hydraulic Oil Optional, Multi--Seasonal Use, Recom- mended for Low
Temperatures
F200 Ambra Multi H Transmission Oil
F200 Ambra Multi F/10 Transmission Oil
Gear Oil Gearboxes 80W90 Hypoide 90 LS
Grease All Grease Fittings Lithium base EP high temperature Ambra
GR75MD9
Brake Fluid Mineral Based Oil Ambra Brake LHM
10-4
70-150-1592
1
2. Close the supply, 2, and return, 1, valves.
3. Open the drain valve,3, and drain the fuel intoan approved
container.
4. Disconnect the fuel lines at the shutoff valves.
70-150-1593
2
5. Remove the fuel tank front, 2, and rear, 1, lower support
pins.
70-150-1594
3
10-5
6. Disconnect the top to lower fuel tank hose at the top rear of
the lower tank.
70-150-1595
4
7. Support the fuel tank on a floor jack. Raise and disconnect the
tank from the upper support pins.
8. Carefully lower the tank assembly 10 mm (3").
70-150-1596
5
9. Disconnect the fuel sender, 1, (white) and work light, 2,
(black) connectors located at the topfront of the fuel tank and
lower the tank from the tractor.
10. Remove the mount brackets from the tank by removing the
retaining straps. Note the large center bolt and spacer.
11. Cap all tank openings and store the tank in a suitable
location.
LOWER TANK INSTALLATION
1. The tank is installed in the reverse order of disassembly.
Torque the retaining straps to 64 N!m (47 ft lbs). The center bolt
and spacer is torqued to 115 N!m (85 ft lbs).
70-530-1597
6
10-6
TOP TANK REMOVAL
1. The top tank can only be removed after the cab has been removed.
See Section 90, Chapter 3 - “Cab Removal” in this manual for
details.
2. With the cab removed and supported, remove the tank vent
connection, 1, from the right rear corner of the tank.
70-150-1598
7
3. Carefully loosen the four tank attaching straps and lower the
tank from the bottom of the cab.
TOP TANK INSTALLATION
The tank is installed in the reverse order of disassembly.
Torque the retaining straps to 64 N!m (47 ft lbs).
70-150-1599
8
10-1
10-2
SPECIFICATIONS
Engine size 7.5 L (456 in.3). . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
Engine weight 738 kg (1625 lbs). . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
Cylinders, bore x stroke 6, 112 mm x 127 mm (4.4! x 5!). . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . .
Coolant capacity: 8670, 8770 8670/8670A, 8770/8770A 25 L (6.6 U.S.
gal.). . . . . . . . . . . . . . . . . . . . . . . . 8870, 8970
8870/8870A, 8970/8970A 26.4 L (7 U.S. gal.). . . . . . . . . . . .
. . . . . . . . . . . .
Torques
Engine to transmission bolts (top) 488 N"m (360 ft lbs). . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . .
Engine to transmission bolts (center) 240 N"m (177 ft lbs). . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . .
Engine to transmission bolts (bottom) 55 N"m (41 ft lbs). . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . .
Fan mount bolts to pulley 55 N"m (41 ft lbs). . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .
Air-conditioner compressor 54 N"m (40 ft lbs). . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
Side rail bolts 528 N"m (390 ft lbs). . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
10-3
DESCRIPTION OF OPERATION
The tractor engine is mounted to the front surface of the
transmission. The engine is not attached or supported at the front
bolster. The axle and front bolster are connected to the
transmission by the use of side rails.
10-4
ENGINE REMOVAL
If major engine repair is required, the engine assembly can be
removed from the tractor as follows:
1. Park the tractor on a level surface and apply the parking brake.
Ensure that there is a clear area to use a lifting hoist to lift
the engine from the tractor.
2. Remove the battery cover and the negative battery cables,
1.
3. Remove the engine hood as described in this section, Section 90,
Chapter 2, “Hood Removal.”
4. Remove the left hood access door and hinge mount.
70-510-65
1
5. Remove the exhaust pipe, 1, from the right side of the tractor
and the hood access door, 2, and hinge mount.
70-160-1615
2
6. Drain the engine coolant into a suitable container using the
drain tap at the bottom of the radiator.
7. Remove the fan shields, 1, and the fan assembly, 2.
8. Remove all hoses, 3, from the front of the engine to the
radiator.
70-110-1626
3
10-5
9. Turn the cab heater valves, 1, off and disconnect the hoses from
the front and rear of the intake manifold.
70-610-1186
4
NOTE: 70 Series art shown in Figure 5.
10. Remove the starter, 1, from the right rear of the engine. A 16
mm curved obstacle wrench is required to remove the inner retaining
nut. The fuel filter, 2, may have to be removed for better access
to the starter.
11. Remove the throttle cables, 3, from the injection pump on the
right side of the engine.
12. Remove the fuel supply and return lines, 4, from the right side
of the engine.
70-110-1627
5
13. Remove the cab doorsill plates, then the front floor mats and
the center floor cover to gain access to the two transmission to
engine retaining bolts.
70-660-1611
6
10-6
14. Remove the intercooler supply, 1, and return tube, 2.
70-160-1628
7
50015833
2
8
15. Remove the air-conditioner compressor and hoses from the
engine.
NOTE: DO NOT disconnect the hoses or discharge the
system.
70-610-1168
9
10-7
NOTE: 70 Series art shown in Figure 10.
16. If additional air-conditioner hose clearance is required to
clear the engine, remove the air- conditioner condenser, 1.
NOTE: DO NOT disconnect the hoses or discharge the
system.
17. Remove the air cleaner inlet horn, 2.
70-160-1608
10
18. Disconnect the front main harness from the rear main harness
(C008 connector), 1, above the batteries.
70-530-1629
11
19. Attach a suitable lift to the center attaching point in the
upper engine frame.
NOTE:Removal of the transmission and rear axle oil
cooler lines may be required for additional clearance.
70-110-1630
12
10-8
20. Remove thetwo toptransmission to engine bolts, 1, from inside
the cab.
21. With the engine weight supported with a hoist, carefully remove
the two lower bolts, 3, and the four center engine to transmission
retaining bolts, 2.
70-110-1631
13
22. Pull the engine forward and up to clear the transmission and
side frame rails.
23. Place the engine in a stand or on suitable blocks to allow
further disassemble and repair of the engine.
70-110-1632
14
1. Installation of the engine is the reverse of
removal.
2. Ensure that the engine is properly aligned without damage to
wiring, lines and fittings during installation.
3. Torque all retaining bolts as indicated in the “Specifications”
portion of this chapter.
70-110-1633
15
10-1
Special Tools 4. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . .
Fuel Tank Valves 20. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
High Pressure Fuel System 25. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection Timing Check 25. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
Preliminary Setup Procedure 29. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
Perform Nozzle Seat Leakage Test 30. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Perform Chatter and Spray Pattern Test 31. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surging 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . .
Adjustment of Foot and Hand Throttle Cables 35. . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment of High Idle Speed 35. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
Adjustment of Low Idle and Antisurge 36. . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
Removal and Installation 37. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
10-2
High-pressure Fuel Lines 48. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
Injector Leak-off Line 50. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .
10-3
SPECIFICATIONS
8670/8670A 8770/8770A 8870/8870A 8970/8970A
Fuel tank capacity Lower (main) 246 L (65 U.S. gal). . . . . . . .
. . . . . . . . . . . . . . . . . . . . . Upper (auxiliary) 170 L
(45 U.S. gal) Total - 416 L (110 U.S. gal)
Injection pump Bosch A2000 Bosch P3000. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
Timing static deg. BTDC (non-emissionized) 24 21 16 16. . . . .
.
Timing static deg. BTDC (emissionized) 18 18 16 16. . . . . . . . .
.
Injectors - type Bosch, 5 Hole, Type - Differential Needle. . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector opening pressure (new) 241 bar 241 bar 255 bar 255 bar. .
. . . . . . . . . . . . . . . (3500 PSI) (3500 PSI) (3700 PSI)
(3700 PSI)
Injector opening pressure (used) 213 bar 213 bar 227 bar 227 bar. .
. . . . . . . . . . . . . . (3100 PSI) (3100 PSI) (3300 PSI) (3300
PSI)
Recommended injector service 2400 Hours
Governor type Bosch “RSV”/All Speed. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
Governed range (RPM) 750-2310. . . . . . . . . . . . . . . . . . .
. . . . .
High idle speed (RPM) 2305 ! 25. . . . . . . . . . . .
. . . . . . . . . . . . .
Rated engine speed (RPM) 2100. . . . . . . . . . . . . . . . . . .
. .
Fuel filter Sedimenter and Micronic Filter. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
Water separator Integral with Filter. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
Recommended fuel filter service 600 Hours. . . . . . . . . . . . .
. . . .
10-6
Supply Tanks Two fuel tanks are standard equipment. The lower, or
main, tank, 4, having a capacity of 246 L (65 U.S. gallons), is
located along the left side of the center axle housing. The upper,
or auxiliary, tank, 2, having a capacity of 170 L (45 U.S.
gallons), is located below the cab toward the rear of the tractor.
Fuel tank filling, 8, as well as the engine supply and return, are
accomplished through the lower tank. A large, diameter tube, 3,
connects the upper and lower tanks. There is no valve on this tube,
so it is not possible to isolate the upper and lower tanks. The
tanks are vented through a tube attached to the upper tank. The
vent tube, 1, extends up therightrear cab post. Both the supply, 6,
and return fittings, 7, on the lower tank contain shutoff valves to
ease service. The supply fitting threads into a 24 mesh inlet
screen, 5, approximately 76 mm (3#) long, which in turn threads
into the fuel tank. The return fitting contains a drain cock.
70-15-2200
2
10-7
NOTE: Figure 3 is 70 Series art.
NOTE: Figure 4 is 70A Series art.
Fuel Filter/Water Separator/Primer Pump The primary purpose of this
assembly is to remove water and solid contaminants from the fuel
before the fuel enters the gallery of the injection pump. The
plunger and barrel assemblies (pumping elements) of the injection
pump are matched to each other with an accuracy of a few ten
thousandths of an inch. Impurities of this size can cause severe
damage, or excessive wear, to the injection pump and injector
assemblies. The fuel filter assembly consists of a manifold, or
base, containing the primer pump, 3, along with a bleed port. For
the 70A Series tractor, the primer pump, 3, is now on the top of
the supply pan. The primer and bleeder (70 Series only) are used
when the engine has run out of fuel or a new filter element has
been installed. Threaded onto the manifold is the filter element.
The water separator, 1, is in turn threaded onto the filter
element. The separator bowl contains a drain, 2, that can be used
if water or sediment are observed.
70-150-151
3
10-8
NOTE: 70 Series art shown in Figures 5 and 6.
Fuel Injection Pump Models 8670/8670A and 8770/8770A are equipped
with the Bosch Type “A2000” pump.
70-150-2201
5
Models 8870/8870A and 8970/8970A are equipped with the Bosch Type
“P3000” pump.
NOTE: Operation of both pump types is very similar.
70-150-2202
6
10-9
1. Deliver valve holder
10. Control Rod
10-10
NOTE: 70 Series art shown in Figures 8, 9 and 10.
The fuel injection pump, the heart of the fuel system, consists of
a number of subassemblies.
70-150-2203
8
The supply pump is the entry point into the engine fuel system from
the tanks. The supply pump is mechanically driven by the injection
pump camshaft. The purpose of the supply pump is to draw fuel from
the tank, and pressurize the fuel to a minimum of 1.4 bar (20 PSI)
in order to cause fuel to flow through the filter, and to provide
sufficient pressure for pumping element filling. The supply pump
housing also contains a sedimenter assembly consisting of a clear
bowl, 1, and strainer screen, 2. The clear bowl should be inspected
for sediment every 50 hours and cleaned every 300 hours.
70-150-152
9
The rear portion of the injection pump assembly houses the
all-speed “RSV” mechanical governor. The governor receives inputs
from the following:
$ Throttle control lever, 1
$ Intake manifold pressure, 3
$ Engine oil pressure, 2
$ Mechanical fuel shutoff lever, engine side of pump
(not shown), which is, in turn, controlled by the fuel shutoff
solenoid
70-150-2204
10
10-11
70-150-2205
11
10. Torque control & idle speed helical compression
spring
11. Full load stop (fuel delivery)
12. Fulcrum lever
13. Guide bushing
18. Control rod
Receiving these inputs, the governor, by moving the pumping element
control rack, 18, controls engine- off, excess fuel for starting,
minimum and maximum idle speeds, and any midrange speeds
independent of load. A pair of flyweights, 14, are attached to the
pump camshaft. The force of the flyweights increases with engine
speed. The force of the weights operates against that of the
governor spring, 8. The tension on the governor spring is varied by
the
10-12
Aneroid assembly The aneroid assembly prevents excessive smoke
under load by limiting maximum fuel delivery until the turbocharger
is providing sufficient air to effect clean combustion. An example
of this operation would be starting a load out onto a roadway, when
the engine is idling, and throttle position and load are increased
simultaneously.
1 Headless setscrew
2 Plate washer
3 Governor cover
70-150-2206
12
The aneroid also contains a hydraulic activator, 1, which is
controlled by engine oil pressure, A. When there is no oil
pressure, B, the activator allows the control rack full travel to
the excess fuel position. Without this feature, during starting,
fuel delivery would be extremely limited due to lack of
turbocharger boost pressure.
1 Hydraulic activator
2 Bell crank
10-13
NOTE: 70 Series art shown in Figure 14.
Overflow Valve Assembly The supply pump has a capacity of about
twice that of the requirements of the high-pressure pumping
elements. This excess flow provides cooling and lubrication for the
injection pump. Flow from the supply pump travels through the
filter element and then to the fuel gallery of injection pump,
where it is available to fill the pumping elements. The fuel must
be pressurized in order to properly fill the pumping elements. The
job of the overflow valve, 1, is to maintain a pressure of
approximately 1.5 bar (22 PSI) in the fuel gallery. Once that
pressure is reached, the overflow valve opens and allows the excess
fuel to return to the tank.
70-150-2208
14
High-Pressure Pumping Elements The high-pressure pumping elements,
one for each engine cylinder, supply fuel at a pressure of
approximately 240 bar (3500 PSI) to the injectors. The pumping
elements must provide the fuel in a precisely measured amount at
the proper time.
Operation of the individual element is as follows:
70-150-2209
15
10-14
Fuel in
Reference (C) -- Spill port opening / Fuel delivery
ends
(A) With the plunger, 1, at the bottom of the stroke, fuel flows
into the barrel through the spill port, 2, and fills the space
above the plunger.
(B) As the plunger, 1, rises, the spill port in the barrel, 3, is
covered and the fuel is trapped. This is the point of port closure.
The continued upward movement of the plunger pressurizes the
trapped fuel until the delivery valve (at the base of each
high-pressure injection line) is lifted from its seat. High-
pressure fuel is transmitted through the line to the injector and
injection takes place through the injector nozzle.
(C) Injection stops when the upper edge of the helix, 4, uncovers
the lower edge of the spill port. Pressure escapes to the fuel
gallery. The drop in pressure causes the injector to close and
injection to stop. After fuel delivery ceases, the plunger
continues to the top of the stroke and is returned by a spring for
the next cycle.
FUEL
FUEL
16
Because the end of delivery is reached when the helix on the
plunger uncovers the spill port, 1, the amount of fuel delivered is
varied by turning the pump plunger as shown at D. If the plunger is
turned until the vertical groove completely uncovers the spill port
as shown at E, during the entire lift of the plunger, there will be
no fuel delivered to the engine. This is because injection pressure
cannot be reached, thereby shutting off the engine.
The plungers are rotated by a control rack splined to each plunger.
Rack movement is determined by the control rod, actuated by the
governor.
17
10-15
Fuel Delivery and Timing During Starting The plungers, 1, are
equipped with starting grooves, 2, on their crown. The purpose of
this groove is to assist in starting the engine by providing both
excess fuel and slightly retarded timing. When the key switch is
turned on, the fuel shutoff solenoid retracts, moving the
mechanical shutoff lever to the “RUN” position. The starting spring
in the governor housing pulls the control rack fully forward,
beyond the normal maximum fuel position. This aligns the starting
groove with the spill port. With the starting groove aligned with
the spill port, there is a delay in spill port closure which, in
turn, delays the start of injection. Note also that there is
no helix in this region of the plunger, so once injection begins,
it is not cut off until the plunger reaches the end of its stroke.
This provides a very large amount of fuel to aid starting.
18
Delivery Valves A delivery valve is located above each
plunger. The delivery valve serves as a one-way valve which allows
fuel under injection pressure to move into the high pressure tubes
and prevents fuel from coming back. The valve also serves to
rapidly reduce pressure in the injection line once pressure from
the plunger has ceased. Rapid pressure reduction is required to
ensure the injector valve snaps shut to prevent fuel “dribble,” a
condition which can cause carbon formation on the injector
tip.
(a) Valve closed
Components are identified as follows:
1 Delivery valve holder
10-16
Fuel Injector Assemblies The job of the injector assembly is to
atomize the fuel in order to facilitate proper combustion. The
injector must cleanly deliver the fuel into the combustion chamber
with a good spray pattern. There must also be a “crisp” start, and
end of, injection with no drips either before or after the
injection cycle.
The nozzle is housed within a nozzle holder. In order to properly
place the fuel charge into the combustion chamber, dowel pins
orient the nozzle within the holder, and a clamp ring orients the
holder within the engine cylinder head.
Operation of the injection nozzle is as follows:
1 High pressure inlet line
2 Edge-type filter
3 Pressure channel
4 Intermediate disc
5 Nozzle-retaining nut
7 Holder body
8 Leak-off port
9 Pressure-adjusting shims
10 Pressure spring
11 Pressure spindle
13 Injection nozzle
10-17
The high-pressure line delivers the fuel charge from the injection
pump. Fuel enters the inlet and passes through the edge-type
filter. Coarse foreign particles are retained by the filter.
A passage routes fuel through the nozzle holder to the nozzle
valve. The nozzle valve is lifted off its seat by the high-pressure
inlet fuel, 1, acting on the annulus in the valve.
When the nozzle valve opens, a definite quantity of fuel
(determined by the injection pump output for each plunger stroke)
is forced out through the orifices. The fuel becomes finely
atomized as it is sprayed into the combustion chamber at high
velocity. Once fuel flow from the pump ceases, the spring pressure
forces the needle valve back onto its seat via the spindle and
needle valve stem. Fuel dribble should not occur, as might happen
if the nozzle showed excessive wear.
The nozzle assembly is lubricated by a small amount of fuel which
seeps between the lapped surfaces of the nozzle and valve
which accumulates around the spring.
The leakage fuel, 2, is routed out the nozzle holder through a
leak-off connector and returned back to the fuel tank.
70-150-2211
21
NOTE: 70 Series art shown in Figure 22.
Fuel Shutoff Solenoid The purpose of the fuel shutoff solenoid, 1,
is to move the mechanical fuel shutoff lever to the “RUN” position
when the key switch is turned on, and to keep the lever in that
position while the key switch remains in the “RUN” position. When
the key switch is turned “OFF,” the solenoid is de-energized, and
allows spring force within the governor housing to move the
mechanical shutoff lever to the “FUEL- OFF” position.
70-150-2212
22
10-18
NOTE: 70 Series art shown in Figures 23 and 24.
The fuel shutoff solenoid is connected to the tractor electrical
systemwith a 3-wire connector. Wire colors (noted on the TRACTOR
harness, NOT the fuel solenoid) are as follows:
Ref Color Function Maximum
1 Black Ground N/A
2 Orange Pull 60
3 Purple Hold 0.87
When the key switch is first turned to the “RUN” position, power is
supplied to both the “pull” and “hold” circuits. After
approximately 2 seconds, power to the “pull” circuit is removed,
and only the “hold” circuit continues to be powered.
See the Electrical System - Section 55 for further information on
electrical operation of the fuel shutoff solenoid.
The solenoid linkage must be free to travel fully. If the
mechanical shutoff lever is not moved fully to the “RUN” position,
difficult starting or failure to develop full power may
occur.
70-150-2213
1
2
3
23
Plumbing
Low-Pressure Fuel Lines The purpose of the low-pressure fuel lines,
1, is to carry fuel from the tank to the injection pump gallery and
to return excess fuel from the pump and injectors to the
tank.
High-Pressure Fuel Lines The purpose of the high-pressure fuel
lines, 2, is to carry fuel, under high pressure, from the injection
pump to the injector assemblies. These lines are a precise length
to provide proper fuel delivery. For this reason, always use the
correct line if replacement is required.
70-150-2214
24
10-19
TESTING AND DIAGNOSIS
The fuel system can be divided into 4 basic components. See the
“Description of Operation” section for details on each of these
components.
$ The low-pressure system consists of the fuel supply tanks,
supply (lift) pump, filter assembly, overflow valve, injector
leak-off lines, and the associated plumbing. The job of the
low-pres- sure system is to present to the high-pressure pumping
elements a supply of clean fuel, with very little entrained air, at
a regulated pressure of approximately 1.52 bar (22 PSI). An
unrestricted return of excess fuel to tank also must be provided.
The low-pressure system also must prevent or “check” the flow of
fuel out of the injection pump gallery when the engine is not
operating.
$ The high-pressure system consists of the pumping elements,
delivery valves, fuel injector assemblies, and the lines connecting
the pump to the injectors. The job of the high-pressure system is
to delivery a measured, atomized chargeof fuel into thecombustion
chamber at the proper time.
$ The governor controls high and low idle speeds and
attempts to maintain constant engine speed at the various throttle
lever positions selected by the operator.
10-20
NOTE: 70 Series art shown in Figures 25 and 26.
Initial Test Conduct the following test FIRST. If the system passes
this test, along with the leakback test, then the problem is not
with the low- pressure fuel system.
Check the system for air ingress, and correct pressure. Required
gauges and fittings will be found in Pressure Test Kits FTC213312
and FTC61682.
Install a clear line, with tee, between the filter manifold and the
pump gallery inlet. This also will be referred to as the Filter
Outlet Pressure Test below. With the engine operating under load,
such as on a dynamometer, the fuel stream should be clear, and
under a pressure of approximately 1.52 bar (22 PSI).
If insufficient pressure is found, check the following:
FUEL TANK VALVE(S)
Ensure that both the supply and return valves at the lower fuel
tank are open.
70-150-2215
25
FILTER INLET AND OUTLET PRESSURE TESTS
Leave the gauge and clear line installed between the filter and
pump gallery inlet. Install a second gauge between the supply pump
and filter.
Operate the engine at full load. Monitor filter inlet and outlet
pressures. Specifications are as follows:
Filter Outlet Pressure 1 - 2 bar (15-28 PSI). . . . .
Filter Inlet Pressure 1 - 2.1 bar (15-30 PSI). . . . . . .
Difference Between Inlet and Outlet Pressures 0.5 bar max. (7 PSI).
. . . .
If pressure drop across the filter is excessive, first replace the
filter element. If pressure drop continues to be excessive, replace
the filter base.
70-150-2216
26
10-21
Supply Pump Sedimenter
Clean, or replace, the screen in the sedimenter. Be sure that the
bowl is sealing well against the housing.
IMPORTANT: Before loosening or disconnecting any
part of the fuel injection system, thoroughly clean the area to be
worked on.
To clean the sedimenter:
1. Remove the sedimenter bowl, 1, from the lift pump, 2. Catch the
fuel in a suitable container and dispose of properly.
2. Inspect the O ring, 3, and replace if damaged.
3. Remove the screen, 4, and spring, 5.
4. Clean screen and bowl.
5. Inspect screen and replace if damaged.
6. Install the spring and screen in the bowl.
7. Fill the bowl with clean, fresh fuel.
8. Install the bowl. Hand tighten only.
9. Depress the hand primer on the fuel filter manifold repeatedly
until resistance is felt and the sedimenter bowl is full.
10. Start the engine and check for leaks.
NOTE: A partially plugged filter screen can cause
reduced fuel supply to engine. This can cause low
power performance.
IMPORTANT: If the engine does not start after
cranking for 20 seconds, the fuel system must be purged of
air.
70-150-178
27
Supply Pump - Perform Pump Output Test
1. Connect a 0 - 60 PSI gauge to one end of a pressure hose 10 -
12# long. Connect the other end ofthe hose to the
pumpoutlet.All air mustbe out of the system.
2. Crank the engine for 10 seconds with the starter motor
(approximately 200 RPM). Supply pump minimum pressure should be 2.0
bar (29 PSI).
IMPORTANT: The starter motor must crank the engine at
normal cranking speed. Use booster batteries if
necessary.
3. If pressure is below the minimum specified above, check the
in-tank strainer and supply line from the tank to pump. If no
obstruction is found, replace the pump.
70-150-2217
28
10-22
NOTE: 70 Series art shown in Figure 29.
Overflow Valve Temporarily replace the valve with a known good
valve. If the overflow valve is at fault, it must be replaced as an
assembly.
70-150-2208
29
In-Tank Strainer The strainer can be accessed by removing the inlet
fitting. It will be necessary to first drain the fuel tanks. Both
tanks drain through the cock at the return fitting.
70-150-2218
30
10-23
NOTE: 70 Series art shown in Figure 32.
Test for Air Ingress If air ingress is indicated by foam and
bubbles during the initial test, conduct the following test:
1. Disconnect the fuel supply line, 1, and return line, 2, at the
fuel tank.
2. Direct the return line to a drain pan.
3. Using an air source regulated to not more the 2.75 bar (40 PSI),
pressurize the fuel system at the fuel supply line. Most of the
fuel will be forced out of the system and into the drain pan.
NOTE: This procedure is necessary since air is less viscous
(is thinner) than diesel fuel, and air will leak both
in and out of a system component where fuel will
not.
4. Once the fuel is purged from the system, shut off the air
source.
5. Reinstall the return line to the tank fitting and ensure that
the return valve is closed.
6. Using an air source regulated to not more the1.4 bar (20 PSI),
pressurize the fuel system at the fuel supply line.
70-150-2219
31
7. Apply liquid soap and water solution to all joints and
connections in the fuel system and inspect for leaks.
8. If any leaks are found, take the necessary steps to
repair.
9. Reconnect the supply and return lines and prime the
system.
10. Start the engine and run it for approximately 10 minutes.
70-150-2220
32
10-24
NOTE: 70 Series art shown in Figure 33.
Leakback to Tank with Engine Off When the engine is shut off, it is
important that the injection pump fuel gallery remain full of fuel.
If fuel trapped in the gallery is allowed to drain back to the
tank, a void develops in the gallery. This void must be refilled
with fuel before the engine will start. This situation can cause
very difficult cold starting.
The fuel is trapped in the gallery by a one-way check valve in the
supply pump and by the overflow valve.
To Test Leakback Install a clear line several feet long to the
supply pump inlet port.
Install a clear line several feet long to the return port on the
pump.
Place a container of CLEAN fuel onto the floor, and insert both
clear lines into the container.
Start the engine.
You will observe the fuel being drawn out of the container
through the supply line and returned through the return line.
Continue to operate the engine until all air is cleared from the
system.
Shut off the engine.
70-150-2221
33
Leave the engine shut off for a period of at least 4 hours.
Overnight is better.
Using the same principal as the finger over the straw, the clear
lines should remain nearly full of fuel.
If the fuel leaks out of the supply line, the problem is with the
supply pump which should be replaced.
If the fuel leaks out of the return line, the problem is with the
overflow valve which should be replaced.
70-150-2222
34
10-25
HIGH-PRESSURE FUEL SYSTEM
The job of the high-pressure system is to deliver a measured,
atomized charge of fuel into the combustion chamber at the proper
time.
The high-pressure pumping elements are housed within the injection
pump.
IMPORTANT: Internal repairs to the fuel injection
pump must be accomplished through a Bosch
authorized Diesel Service Dealer (DSD). The only
adjustment that can be accomplished to the pump on-vehicle is
low speed idle adjustment.
Should symptoms arise that indicate a problem with the
high-pressure portion of the fuel system, the following procedures
should be used.
INJECTION TIMING CHECK
The spring-loaded go/no-go pin, tool number FNH00536-2, 1, can be
used to verify correct timing.
The rigid pin, 2, should be used during injection pump
installation.
70-150-2223
35
70-150-2224
36
10-26
70-150-2225
37
3. Locate the timing pin hole on the front of the injection
pump.
70-150-2226
38
4. Using a 29 mm (1-1/8#) socket on the bolt at the front of the
crankshaft, rotate the engine