FARMTRAC - 60

TRACTOR
REPAIR MANUAL

ESCORTS LIMITED
AGRI MACHINERY MARKETING DIVISION
18/4, MATHURA ROAD, FARIDABAD (HARYANA), INDIA
 FOREWORD

This manual provides information for the proper Servicing, Maintenance and
Repair of the Farmtrac-60 tractors. It is intended for use as a reference book by
all the trained Servicemen engaged in servicing, maintenance and repairs at all
authorised outlets, and, however does not substitute the necessity of getting the
service personnel trained, through the various courses conducted every year.

The manual is divided into several Sections which contain information on general
operation, inspection and repair procedures and specifications of the various
systems individually. For easy reference, each section has been given separate
alphabetical code letter as shown in the index.

All servicing, maintenance and repair operations, take into account the special
service tools which have been illustrated wherever possible and, where trouble
shooting procedures are thought to be of assistance, these have also been
incorporated in the appropriate chapter.

The page and figure number are serially numbered throughout each Section. This
will permit any revised pages to be readily included in the respective Section at
any later date as and when these would be issued.

The material contained in this manual was correct at the time the manual was
approved for printing, and, we reserve the right to discontinue or change
specifications or design of any model without notice and without incurring
obligation whatsoever.

ESCORTS LIMITED
AGRI MACHINERY MARKETING DIVISION (SERVICE)
 INDEX TO SECTION

S.NO. SECTION CODE

1. ENGINE SYSTEM A

2. COOLING SYSTEM B

3. FUEL SYSTEM C

4. ELECTRICAL SYSTEM D

5. SINGLE CLUTCH E

6. DOUBLE CLUTCH F

7. TRANSMISSION SYSTEM G

8. POWER TAKE OFF H

9. REAR AXLE AND BRAKES I

10. HYDRAULIC SYSTEM J

11. STEERING SYSTEM K

(RE-CIRCULATING BALL TYPE)

12. HYDROSTATIC STEERING L

13. FRONT AXLE (MECHANICAL STEERING) M

14. FRONT AXLE (HYDROSTATIC STEERING) N

15. FRONT AND REAR WHEELS O

16. SEPARATING THE TRACTOR P

17. REMOTE CONTROL VALVES Q

 SECTION - 'A'

ENGINE SYSTEM
S.NO. CONTENTS PAGE
1. DESCRIPTION AND OPERATION A-3

2. LUBRICATION SYSTEM A-6

3. CYLINDER HEAD VALVES AND RELATED PARTS A-7

4. ENGINE FRONT COVER AND TIMING GEARS A - 13

5. OIL PAN SUMP AND OIL PUMP A - 16

6. CONNECTING RODS, BEARINGS, PISTONS AND CYLINDER BLOCK A - 19

7. MAIN BEARINGS, FLY WHEEL AND CRANK SHAFT A - 27

8. CAMSHAFT A - 35

9. TROUBLE SHOOTING A - 39

10. SPECIFICATIONS A - 42
 ENGINE SYSTEM
A–2

Figure 1
Sectional View of Three Cylinder Farmtrac Engine
 ENGINE SYSTEM

ENGINE SYSTEM

1. DESCRIPTION AND OPERATION The camshaft is supported by four replaceable

bearings. The camshaft is driven by the camshaft drive
This section of the manual describes the overhaul and gear which is in mesh with the idler gear. Camshaft
repair of Farmtrac direct injection 3-cylinder diesel thrust is controlled by a plate secured to the block
engines. All the engines are of similar design and and located between the camshaft gear and the front
hence, service procedures are basically common journal of the camshaft. A helical gear is mounted on
throughout the range. The engine features cross-flow the rear of the camshaft which drives the hydraulic lift
cylinder head with the inlet and exhaust manifolds on pump.
opposite sides of the head. Figure 1.
The cylinder head has six evenly spaced cylinder head
CYLINDER HEAD ASSEMBLY-INCLUDING VALVE bolts per cylinder. The fuel injectors are mounted
TRAIN COMPONENTS outside the rocker cover.

The cylinder head assembly incorporates the valves, The engine cylinder head has a flat face design. The
valve springs and related components. The valve rocker combustion chambers are in the crowns of the pistons.
arm shaft assembly is bolted to the cylinder block,
through the head. The intake and exhaust manifolds The cylinder head of Farmtrac tractors feature circular
are bolted to the head. The intake manifold is on the section inlet ports which terminate at a tangent to the
right side from the rear of the engine, and the exhaust cylinder bores. Tangential porting improves breathing
manifold is on the left side. and combustion.

Valve guides are an integral part of the cylinder head, The aluminium alloy intake and cast iron exhaust
and valves with oversize stems are available for service. manifolds are on opposite side of the cylinder head
Special replaceable cast alloy valve seats are pressed providing better heat distribution in the head with less
into each valve port of the cylinder head. Valve lash is heat being transferred to the intake manifold.
maintained by self-locking adjusting screws.

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 ENGINE SYSTEM

The crankshaft gear is press fitted on the front of the

crankshaft. The crankshaft gear drives the camshaft
gear and the fuel injection pump gear through the idler
gear and all these are attached to the front of the
cylinder block.

The camshaft gear is attached to the front of the

camshaft by a bolt, lock washer, flat washer and a
spacer.

The gear is keyed to the camshaft to maintain the

position of the gear and drive the shaft.

All the timing gears can be checked by observing the

timing punch marks on the gears.

Figure 2
The crankshaft is supported in the cylinder block by
Intake Manifold Porting (Circular Section) four main bearings.

The bearing liners are copper lead alloy with a flange-

Farmtrac tractors intake manifold has circular section
type thrust bearing liner to control crankshaft end play.
for improved engine breathing. Figure 2.
The thrust bearing is the second intermediate on a 3-
cylinder engine.
Engine air intake manifolds are connected through
tubing to the air cleaner. The engine water outlet is
A slinger is machined on the rear of the crankshaft to
provided with a tapped hole for installation of a
direct oil away from the rear seal. The rear seal is a
thermostat housing.
circular lip-type rubber seal that fits into a pocket
machined into the cylinder block and rear main bearing
cap in Farmtrac 50/55. The cap also has two
CYLINDER BLOCK ASSEMBLY composition side seals.

The cylinder block is alloy cast iron with heavy webbing The crankshaft rear seal arrangement is different for
and deep cylinder skirts. The block features full length Farmtrac 60. The seal is installed on a seal retainer
water jackets for cooling the cylinders, which are bored mounted on the cylinder block rear face.
integral with the block. Cylinder arrangement is vertical
in line with the cylinders numbered from 1 to 3 starting In Farmtrac 50/55 trunk-type pistons with a continuous
at the front of the block. The firing order is 1-2-3. skirt around the entire piston has three compression
rings and one oil control ring, all of which are above
The cylinder diameter for Farmtrac-60 is 4.4 in. (111.76 the piston pin. Piston of Farmtrac 55 also has a ring
mm) which is more than that of Farmtrac-50/55 which carrier for top compression ring.
is 4.2 in. (106.68 mm).
Piston of Farmtrac 60 has a ring carrier on the top and
The oil pan is attached to the bottom of the cylinder one compression and oil control ring below that. Hence
block and is the sump for the lubrication system. The the Farmtrac 60 has 3 rings configuration as compared
engine front cover is attached to the front engine adaptor to 4 rings in case of Farmtrac 50 & 55. All rings are
plate forming a cover for the timing gears. above the piston pin.

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 ENGINE SYSTEM

Figure 3 Figure 4
Piston Combustion Chamber Intake Valve

The piston is connected to the crankshaft by a 'I'- better combustion. Intake valve inserts are installed
Section connecting rod. The crankshaft end of the on all these engines and the seat in the cylinder head
connecting rod has an insert-type copper lead alloy is relieved to further direct the flow of intake air, Figure
bearing. The piston end of the connecting rod has 5.
replaceable bronze bushig. The piston pin is a free-
floating steel pin held in place in the piston by two
snap-rings (circlips).

To match the cylinder head porting system the pistons

on Farmtrac tractors incorporate a combustion
chamber of hemispherical section with a flat center
as shown in Figure 3.

The intake valve profile of the Farmtrac 50, 55 & 60

tractors is shown in Figure 4.
Figure 5
Cylinder Head Relief in Area
of Intake Valve Seat
The valve head has been thickened and the underhead
surface flattened to positively direct the flow of intake 1. Valve Seat
air into the piston combustion chamber to achieve 2. Area of Relief

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 ENGINE SYSTEM

Figure 6
Engine Lubrication System Diagram

2. LUBRICATION SYSTEM a drilled passage in the cylinder block, and from the
main bearing journals through the crankshaft, to the
Oil from the oil sump is pumped through the pressure connecting rod journals. Camshaft bearings are
lubrication system by a rotor-type oil pump mounted lubricated by drilled passages in the cylinder block
on the bottom of the cylinder block and is driven from from each main bearing.
a gear on the camshaft, Figure 6. The pump body
incorporates a spring loaded relief valve that limits the The Idler drive gear bushing is pressure lubricated
maximum pressure in the system by directing excess through a drilled passage from the front main bearing.
oil back to the intake side of the pump. The idler gear has a bushing which has spiral grooves
to direct oil toward the outside of the gear, and on
Oil, passes from the pump to an external replaceable both sides of the gear.
filter incorporating a relief valve. The relief valve permits
oil to by-pass the filter if it becomes clogged, thereby The gear has small oil passages machined on both
maintaining oil to the engine at all times. sides which allow the oil to exhaust. The timing gears
are splash-lubricated by oil from the tappet chamber
From the filter, the oil flows through a drilled passage and from the pressure-lubricated idler gear bushing.
in the block to the main oil gallery. The oil gallery is a
drilled passage running along the full length of the Cylinder walls, pistons and piston pins are splash-
cylinder block which intersects the tappet chambers lubricated by the crankshaft. An intermitting flow of oil
for lubrication of the tappets. The main oil gallery also is fed to the valve rocker arm shaft assembly through
supplies oil to all the crankshaft main bearings through a drilled passage in the cylinder block at the No. 1

A–6
 ENGINE SYSTEM

camshaft bearing which indexes with a hole in the

cylinder head. From the head, the oil flows up around
the No. 1 rocker arm support bolt to the rocker shaft.
The oil from the shaft flows through drilled holes in
each rocker arm to lubricate the valve and the adjusting
screw end of the rocker arm. Oil from the ball ends of
the rocker arms flows down the push rods and assists
in lubricating the tappets and push rods. Excess oil
drains into the push rod chamber through the push
rod holes in the cylinder head and then back to the oil
sump through cored openings in the block.
3. CYLINDER HEAD, VALVES AND RELATED
PARTS
CYLINDER HEAD
Figure 7
The cylinder head can be removed from the engine for Engine with Rocker Arm Cover Removed
service with the engine installed in the tractor. The
following procedure applies to all models. 9. Disconnect the ventilation tube from the rocker
A. REMOVAL cover. Remove the bolts that attach the rocker
arm cover to the cylinder head and remove the
1. Remove the vertical muffler, disconnect the main
rocker arm cover and gasket. Figure 7.
wiring harness from the hood panel assembly and
remove the hood panel assembly. 10. Disconnect the injector leak-off pipe. Remove the
two bolts that retain each injector and remove
2. Remove the battery. Remove the battery tray
each injectors from its bore in the cylinder head,
support bolts from the head and remove the
be sure the area surrounding the injectors is clean
radiator shell support. Drain the radiator and
of any dirt. If the injectors cannot be readily pulled
cylinder block.
by hand, it may be necessary to pry the injectors
3. Bend the lock tabs back, and remove the bolts out.
that secure the exhaust manifold to the cylinder
head. 11. Visually check the push rods for straightness
before they are removed by rotating them with
4. Remove the exhaust manifold and metal gasket.
the valve closed. Loosen the bolts that retain the
5. Remove the injector lines from the injection pump rocker shaft to the cylinder head evenly and
and from the injectors. Cap the exposed openings alternately until all tension has been relieved, and
in the pump and in the injectors, and all pipe ends lift the rocker shaft assembly from the cylinder
to prevent the entry of dirt. head.
6. Disconnect the air inlet hose clamp at the intake NOTE: The rocker shaft retaining bolts should be
manifold and thermostat device connection (where left in place in the rocker shaft supports
fitted). during removal. The bolts hold the rocker
7. Shut off the fuel cock at the tank. Remove the shaft assembly together therefore, only
fuel filters from the manifold by disconnecting the remove the bolts when it is necessary to
fuel lines and cap the openings. disassemble the rocker shaft.
8. Remove the bolts and lock washers that retain 12. Remove the valve push rods from their holes in
the intake manifold, to the cylinder head and the cylinder head and arrange them in a rack in
remove the manifold and gasket. the order which they were removed.

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 ENGINE SYSTEM

Figure 8 Figure 9
Thermostat and Outlet Measuring Cylinder Head Flatness
Connection Exploded View 1. Scale 2. Feeler Gauge
B. DISASSEMBLY NOTE: In Farmtrac-50 tractor, effective from
BSN155331 stainless steel fire ring cylinder
1. Remove the two bolts that attach the water outlet head gasket has been introduced. In
connection to the cylinder head. Remove the combination with current stainless steel fire
connection, thermostat and gasket, as shown in ring thick sandwich type head gasket,
Figure 8. pistons with increased crown height have
been introduced. Subsequently the same
2. Before removing the valves from the cylinder head,
cylinder head gasket is used in Farmtrac 55.
clean any carbon deposits from the area of the
valve heads. CAUTION: Be careful when working with paint
remover, as it is highly combustible.
3. Position the valve spring compressor over the valve
D. INSPECTION AND REPAIR
and spring, and compress the spring.
1. Inspect the cylinder head for cracks, nicks or
4. Lift the valves from the cylinder head and place burrs. Install a new head if necessary. Remove
them in a numbered rack so that they can be all burrs or nicks from the gasket surface with an
reinstalled in their respective guides. oil stone.
C. CLEANING 2. With a straight edge and feeler gauge, check the
flatness of the cylinder head lengthwise,
1. After the valves are removed, clean the valve guide diagonally and crosswise as shown in Figure 9.
bores. Specifications for flatness are 0.006 in. (0.15 mm)
2. Remove all dirt, and grease from the cylinder head maximum over all or 0.003 in. (0.08 mm) in any
six inches (152.40 mm)
with cleaning solvent.
NOTE: If the cylinder head bottom face is not within
3. Scrap all gasket surfaces clean. If necessary, the flatness specifications, it may be
soak the head gasket surface with paint remover skimmed, provided the depth from the lower
to loosen the gasket material. Carefully scrape face of the valve seat insert to the cylinder
the gasket from the head, applying the paint head face after skimming is not less than
remover as required. 0.060 in. (1.5 mm).

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 ENGINE SYSTEM

3. If the head has been skimmed, check to determine

whether the head bolts will bottom. To do this, place
the cylinder head, without the gasket, on the block,
install and finger tight all the head bolts (rocker arm
shaft supports and washers should be used under the
long bolts). Using a feeler gauge, check the clearances
between the underside of the head bolts and the
cylinder head rocker arm support. If the clearance is
0.010 in (0.25 mm) or greater for any bolt, use a thicker
washer or grind the face of the bolt.
IMPORTANT: Valve seat inserts of 0.010 in. (0.25
mm) and 0.020 in. (0.51 mm) oversize
in diameter have been fitted to some
cylinder heads in production. Heads
having oversize inserts fitted are Figure 10
stamped with the following Valve Seat Dimensions
identification marking SO10os and 1. Valve Seat Angle 2. Valve Seat Width
SO20os on the exhaust manifold side
reface the seat. Refacing the valve seat should
of the cylinder head in line with the
always be co-ordinated with refacing of the valve
valve seat concerned.
face so the finished seat will match the valve face
4. The intake and exhaust valve ports in the cylinder and be centered. This is important so that the
head are equipped with removable valve seat valve and seat will have a good compression-tight
inserts. Check the inserts for cracks, looseness, fit. Grind the valve seat to a true 45° to 46° angle.
or excessive wear. If any of these conditions exist, Remove only enough stock to clean up the pits
remove the inserts and install new ones. and grooves or to correct the valve seat runout.
5. To install a larger insert than originally fitted, After the seat has been refaced, measure the seat
machine the counter bore for the seat in the width, to be sure it is to the specification. Narrow
cylinder head to the following dimension shown the seat, if necessary, to bring it within limits. If
in Table-1. the valve seat width exceeds the maximum limits,
remove enough stock from the top edge and/or
The insert must be thoroughly chilled in dry ice the bottom edge of the seat to reduce the width
before installation. to spedifications. Be sure that the refacer grinding
6. Measure the width of the valve seats, and reface stone is properly dressed.
the seats if they do not meet the specifications. 8. With reference to Figure 10. Use a 30° angle
7. Measure the connecentricity of the valve seat with grinding wheel to remove stock from the top of
a suitable gauge, or with Prussian Blue. If the the seats (lowers the seats), and use 60° angle
valve seat runout exceeds 0.002 in. (0.05 mm.) wheel to remove stock from the bottom of the

Exhaust Valve Insert Intake Valve Seat Insert

Counterbore Diameter Counterbore Diameter
Insert Oversize
in Cylinder Head in Cylinder Head
0.010 in. (0.25 mm.) 1.607/1.608 in. (40.82/40.84 mm.) 1.907/1.908 in. (43.44/43.46 mm.)
0.020 in. (0.51 mm.) 1.617/1.618 in. (41.07/41.10 mm.) 1.917/1.918 in. (43.69/43.72 mm.)
0.030 in. (0.76 mm.) 1.627/1.628 in. (41.33/41.35 mm.) 1.927/1.928 in. (43.95/43.97 mm.)

TABLE - 1

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 ENGINE SYSTEM

seats (raises the seats). The finished valve seat

should contact the center of the valve face. Using
a refaced or new valve, check the seat using
Prussian Blue. Rotate the valve with light
pressure. If the blue is transferred to the middle
of the valve face, the contact is satisfactory. If the
blue is transferred to the top edge of the valve
face, lower the seat. If the blue is transferred to
the bottom edge of the valve face, raise the valve
seat.

IMPORTANT: Some production cylinder heads may

have one or more 0.015 in. (0.38
mm.) oversize valve guide and valve
installed. Where this condition
applies, the exhaust manifold side of Figure 11
the cylinder head opposite the valve Critical Valve Tolerances
concerned will be stamped "15" or V-
O15"os. are shown in Figure 11. Inspect the valve face and the
edge of the valve head for pits, grooves, scores, or
9. Measure the valve stem-to-guide clearance. If the
other defects. Inspects the stem for a bent condition
valve stem-to-gude clearance is not with in 0.001-
and the end of the stem for grooves or scores. Check
0.0027 in. (0.03-0.07 mm.) for the intake valve
the valve head for cracks, erosion, warpage, or being
and 0.0020-0.0037 in. (0.05-0.09 mm.) for the
burnt. Minor defects such as small pits or grooves,
exhaust valve, or if excessive oil consumption is
can be removed. Check the valve tip for pits or grooves
indicated through the valve guides affected, valves
and replace the valve if such a condition exists. Discard
with oversize stems are available for service. If it
valves that are severely damaged.
becomes necessary to ream a valve guide to
install valve with oversized stem, use valve reaming Discard any valve springs that show any signs of
Kit. The kit contains the following reamer and pilot erosion or rust. Check each valve spring for
combinations: a 0.003 in. (0.08 mm.) oversize squareness. Discard valve springs that are out of
reamer with a standard diameter pilot: a 0.015 in. square in excess of 1/16 in. (1.59 mm.)
(0.38 mm.) over size reamer with a 0.003 in.
(0.076 mm.) over size pilot: and a 0.030 in. (0.076 Check specified free length and loaded height of the
mm.) over size pilot: and a 0.030 in. (0.076 mm.) valve springs. Weak valve springs cause poor engine
over size reamer with a 0.015 in. (0.38 mm.) performance; therefore, if the pressure of any spring
diameter pilot. is below specification, install a new spring.

NOTE: When going from a standard valve stem to Check the valve spring retainer locks to be sure they
an oversize always use the reamers in are in good condition.
sequence. Always reface the valve seat after Check the ends of the push rods for nicks, grooves,
reaming a valve guide. roughness or excessive wear. If the push rods were
VALVES AND PUSH RODS not straight when checked in Step 12 of "Removal", or
if any of the above wear conditions exist, install new
A. INSPECTION rods.

The critical inspection points and tolerance of the valves NOTE: Do not attempt to straighten push rods.

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 ENGINE SYSTEM

B. REFACING VALVES one end of the shaft. Position the mark upward
and use this end as the front of the shaft. This
The valve refacing operation should be closely co-
puts the oil holes and grooves in the shaft facing
ordinated with the valve seat refacing operation so the
down.
finished angle of the valve is 1° more than the valve
seat to provide an interference angle for better seating. 3. Start reassembly from the rear of the shaft by
Adjust the refacing tool to obtain a face angle of 45° first positioning arm support with the notch on
30' to 45° 45' for Farmtrac 50/55 & 60. the support to the right of the shaft facing forward.
Remove only enough stock to clean up the pits and 4. Be sure the springs and spacers are in their
grooves. Check the edge of the valve head, if less than correct position, then proceed with the assembly.
1/32 in. (0.79 mm.) margin, install a new valve, Figure
CYLINDER HEAD
11.
A. ASSEMBLY
Remove all grooves or score marks from the valve tip,
then chamfer as necessary. Do not remove more 1. Insert each valve in the guide bore from which it
than0.010 in. (0.25 mm.) from the tip. was removed and lap it in position to give an even
ROCKER ARM AND SHAFT seat around the valve. On completion of this
operation remove the valve and carefully clean the
A. DISASSEMBLY valve seat and seat insert of any lapping
To disassemble the rocker shaft assembly, remove compound.
the bolts that attach the rocker shaft to the cylinder
2. Lubricate all moving parts with engine oil prior to
head from the rocker shaft supports. installation.
B. INSPECTION
3. Insert each valve in the guide bore from which it
1. Inspect the rocker arm adjusting screws and the was removed or to which it was fitted. Position a
push rod ends of the rocker arms for stripped or new valve seal over each valve and guide.
worn threads.
4. Install the valve springs and spring retainer over
2. Check the ball end of the screws for nicks, the valve guides.
scratches, or excessive wear.
5. Using valve spring compressor, compress the
3. Check the rocker arm locating springs and spring and spring retainer and install the retainer
spacers for breaks or other damage. locks. Release the compressor and ensure that
4. Inspect the pad end of the rocker arm for the locks have seated properly.
roughness, grooves, or excessive wear. If any of B. INSTALLATION
the above conditions exist, install new parts.
1. Place a new head gasket on the cylinder block,
5. Check the rocker arm and rocker shaft diameters. then carefully position the cylinder head on the
If the diameters are outside the specifications, gasket. Two dowels are incorporated on the top
install a new part. If the shaft meets specifications, of the cylinder block at opposite corners to aid in
clean it thoroughly in solvent. Make sure the oil positioning the cylinder head and gasket.
passages are clean of obstructions.
2. Lubricate the cylinder head bolts and install them
C. INSTALLATION finger tight.
1. Coat the rocker arm shaft with engine oil prior to
3. Install the valve push rod, with cupped end up, in
assembly. Lubricate the valve pads on all rocker
the holes in the cylinder head from which they
arms.
were removed. Be sure the ball ends of the push
2. The rocker shaft has an identification groove at rods are seated in the tappet sockets.

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 ENGINE SYSTEM

Figure 12 Figure 13
Cylinder Head Tightening Sequence Adjusting Valve Lash
1. Adjuster Screw 2. Feeler Gauge
4. Position the rocker shaft assembly on the cylinder engine cold align the arrow on the casing with
head, the long cylinder head bolts and washers the '0' timing mark on the flywheel, to ensure 1st
in the respective holes. Refer to Figure 7. Make cylinder on Top Dead Centre and end of
sure that the ball ends of the rocker arm adjusting compression stroke.
screws are seated in the cupped ends of the push
In the power stroke both valves of No. 1 cylinder
rods.
will be closed. In this condition, check and adjust
5. Tighten the cylinder head bolts in the proper the following valves:
sequence as shown in Figure 12.
No. 1 Cylinder-Inlet Valve No.2 Cylinder-Exhaust Valve
NOTE: To achieve higher clamping force, in No. 1 Cylinder-Exhuast Valve No.3 Cylinder-Inlet Valve
Farmtrac-50 after BSN 179130 the cylinder head
Use a feeler gauge, Figure 13, to check the
bolt diameter has been increased to 9/16 in.
clearance between the valve stem and the rocker
(14.29 mm.) from earlier 1/2 in. (12.70 mm.)
arm. Turn the rocker arm screw to adjust the
diameter. The bolt torque is increased to 160 lbf.
clearnace.
ft. Tighten the bolts progressively in three steps.
First 115 lbf. ft. (16 kgfm.) then to 140 lbf. ft. (20 Rotate the engine one complete revolution until
kgfm) & finally 160 lbf. ft. (23 kgfm) on cold No. 1 cylinder is on TDC of the exhaust stroke.
engine. Farmtrac-55/60 tractors where introduced (Both the valves of no. 1 cylinder will be open
with bigger 9/16 in botls only, hence final with the inlet opening and the exhaust valve
tightening torque is 160 lbf. ft. (23 kgfm). For closing - over lapping position).
Farmtrac 50 tractors before BSN 179130 tighten Check and adjust the remaining valves, as follows:
the bolts progressively in thre steps; First 90 lbf.
ft. (13 kgfm.) then to 100 lbf. ft. (14 kgfm), and No. 2 Cylinder - Inlet Valve
finally 110 lbf. ft. (15 kgfm.). No. 3 Cylinder - Exhaust Valve

IMPORTANT: The cylinder head bolts should be The correct valve clearance is:
torqued only when the engine is cold. Inlet 0.014-0.018 in (0.36-0.46 mm)
6. Rotate the engine and set the preliminary valve Exhaust 0.017-0.021 in. (0.43-0.53 mm)
lash, Figure 13, to the specified limits. Remove Replace the rocker cover, using a new gasket, if
the plug from the flywheel access hole, with the necessary.

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 ENGINE SYSTEM

7. Install a new seat washer in each injector bore in muffler.

the cylinder head. Position new cork seals over 4. ENGINE FRONT COVER AND TIMING GEARS
the injector. Be sure to remove any injector washer
that may have remained in the bores. Engine front cover and timing gears service operation
can be performed after removing the radiator and front
8. Install each injector into the cylinder head and axle.
over the two studs. Install the nut on each stud
and tighten progressively to the specified torque. CRANKSHAFT PULLEY REMOVAL

9. Using new copper washer, install the injector leak- 1. Remove the fan belt. Remove the bolt and washer
off line. from the Crankshaft pulley. Remove the pulley
using Tool No. EF-0300 and shaft protector.
10. Install a new gasket and the intake manifold on
to the cylinder head. Secure the manifold with 2. Check the pulley belt groove to be sure the surface
the bolts and lock washers and tighten the bolts is smooth and the flanges are not cracked or
to the specified torque. broken.

11. Attach the fuel filter to the manifold and connect 3. Check the shaft spacer in the area that contacts
the fuel lines. the front oil seal to be sure it is free of scratches
or grooves that may cause oil leakage past the
12. Connect the air intake hose to the intake manifold seal. Clean the seal contact surface with solvent
and secure with the clamp, and thermostart and polish with crocus cloth prior to installation.
connection.
FRONT COVER REMOVAL
13. Connect the injector lines to the injection pump
and to the injectors. Position the clamp on the 1. Drain the engine oil, and remove the oil pan.
injector lines in the same position from which they 2. Remove the front cover-to-front engine plate bolts.
were removed. 3. Remove the generator/alternator front mounting
14. Position a new metal exhaust manifold gasket bracket bolt.
on the cylinder head and install the exhaust 4. Carefully pry the front cover 'off', of the dowel pins
manifold. Use new lock tabs and tighten the bolts and remove it.
to the specified torque. Bend the lock tabs to
5. Remove the oil slinger (where fitted).
retain the bolts.
6. Clean all the gasket material from the front cover
15. Connect the hose to the water outlet and secure
and from the front engine plate.
it with the clamp.
16. Fill the radiator coolant. FRONT COVER CRANKSHAFT SEAL
17. Install the battery tray support bolts and radiator REMOVAL
shell support. Install the battery and connect the The front cover oil seal should be removed and a new
battery leads. seal should be installed every time the front cover is
18. Bleed the fuel system as outlined in "FUEL removed.
SYSTEM". Start the engine and make a final valve 1. Drive out the old oil seal and dust seal with a
lash adjustment. punch. Be careful not to damage the cover.
NOTE: Do not make valve lash adjustment when the 2. Thoroughly clean the seal bore in the cover.
engine is operating at above normal operating
temperature. 3. Insert the dust seal in the seal bore before
installing the oil seal, Coat the new oil seal with
19. Install the rocker cover using a new gasket and petroleum jelly and install the seal. To install the
tighten the bolts to the specified torque. Connect seal, use Step Plate and a driver handle. Drive
the ventilation tube. the seal in until it is fully seated in the seal bore.
20. Install the hood panel assemblies and reconnect Check after installation to be sure the spring is
the wiring harness to the hood clips. Install the properly positioned in the seal.

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 ENGINE SYSTEM

Figure 14 Figure 15
Checking Timing Gear Backlash Timing Gears
1. Camshaft gear 2. Oil Slinger 1. Camshaft Gear 2. Crankshaft Gear
3. Feeler Gauge 4. Idler Gear 3. Idler Gear 4. Injection pump drive gear

CHECKING TIMING GEAR BACKLASH Remove the three retaining bolts that retain the
injection pump gear, Figure 15 (in line pump engines
1. The timing gears are shown in Figure 14, the gears have three bolts and a triangular plate), to the pump
are correctly assembled when the timing marks adaptor plate and remove the gear.
on the gear teeth line up, as shown in the
illustration, with the No. 1 piston on T.D.C. B. CLEANING AND INSPECTION

2. Check the backlash of the geas with a dial 1. Clean the gear in solvent.
indicator or a feeler gauge, as shown in Figure
14. 2. Inspect gear teeth for scores, nicks and the
condition of the teeth contact pattern.
3. Check between the camshaft drive gear and idler
gear as shown, and also between the injection 3. Use a Carborundum stone to remove minor gear
pump gear and idler gear. Also check between teeth imperfections. If gear teeth wear or damage
the crankshaft gear and idler gear. is severe, install a new gear.

4. Check the backlash at four equidistant points on C. INSTALLATION

the gears.
1. Retime the engine before installing the injection
5. If the backlash is within specifications, the gears
pump drive gear. To do this remove the idler gear,
are suitable for reinstallation. If not, install new
place No. 1 piston at top dead center, and reinstall
gears.
the idler gear in mesh and the timing marks
INJECTION PUMP DRIVE GEAR aligned to the other gears as shown in Figure 15.
Tighten the idler gear adaptor bolt to the specified
A. REMOVAL torque.

Turn the crankshaft until the camshaft gear is in the 2. Install the new injection pump gear on the pump
approximate timed position, Figure 15. adaptor plate, with the timing mark aligned.

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 ENGINE SYSTEM

2. Inspect gear teeth for scores, nicks and the

condition of the teeth contact pattern. Use a
Carborundum stone to remove minor gear teeth
imperfections. If tooth wear or damage is severe
install a new gear.
3. Check the adaptor oil passage. Figure 16, to be
sure that it is clear.
4. Inspect the idler gear bushing, Figure 16, for wear,
nicks or burrs, and install a new gear if any of
these conditions exist.
5. If excessive backlash, existed in the gears when
checked, install a new gear.

Figure 15 C. INSTALLATION
Idler Gear and Adaptor 1. Install the gear and adaptor in mesh with the
timing marks aligned.

3. Install the three bolts and plate and tighten to the 2. Install the adaptor self-locking bolt and tighten
specified torque. the bolt to the specified torque. Check the end
float as outlined under "Camshaft-Removal" on
IDLER GEAR AND ADAPTOR
page A-36 point 5.
A. REMOVAL
CRANKSHAFT GEAR
1. Remove the self-locking bolt that retains the idler
The crankshaft gear should only be removed if it shows
gear and adaptor to the cylinder block.
signs of wear or chipping.
2. Remove the adaptor and idler gear.
A. REMOVAL
B. CLEANING AND INSPECTION
Remove the crankshaft gear with Crankshaft Gear
1. Clean the gear and adaptor in solvent. Remover as shown in Figure 17.

Figure 17
Removing and Installing Crankshaft Gear

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 ENGINE SYSTEM

B. CLEANING AND INSPECTION 2. Install the key in the camshaft keyway.

1. Clean the gear in cleaning solvent. 3. Install the camshaft gear, with timing marks
2. Inspect the gear teeth for scores, nicks and the aligned.
condition of the teeth wear pattern. TIMING THE GEARS
NOTE: With effect from Engine No. NXC-155932 When removing and reinstalling any or all of the timing
(From Jan. 1995) New crankshaft without gears, be sure that the timing marks line up correctly,
keyslot for gear crankshaft mounting has as shown in Figure 15. On all engines, the No. 1 piston
been introduced on all Farmtrac Tractors. must be at T.D.C. on the power stroke, when the timing
Thus to accommodate this change the Gear marks are aligned.
crankshaft, spacer, crankshaft pulley key FRONT COVER INSTALLATION
have also been modified.
1. Position a new gasket on the engine front adaptor
With the removal of key slot the crankgear
plate.
is now interference fit. Key slot on the
crankshaft is provided for locating pulley. A 2. Install the oil slinger dish out, Figure 5.
sealing ring is added in front of spacer to 3. Install the front cover, being sure the cover aligns
avoid any leakage. with the dowel pins.
The new crankshaft and the parts are not 4. Install the front cover-to-front engine plate bolts
inter changeable with previous parts. and tighten to specified torque.
In case either the crankshaft or crankgear 5. Install the oil pan with new gasket and tighten
needs replacement the fullset (ie bolts to the specified torque.
crankshaftalong with the crankgear as a set 6. Install the generator/alternator support front
needs replacement). mounting bolt.
3. Check the key. If there is any evidence of distortion 7. Refill the crankcase with proper grade and
or chipping. Use a new key when installing the quantity of oil.
gear. Install a new gear if any wear or damage is
evident. CRANKSHAFT PULLEY INSTALLATION
C. INSTALLATION 1. Lubricate the crankshaft pulley spacer, align the
keyway in the spacer with the crankshaft keyway
(FOR CRANKSHAFT PRODUCED BEFORE
and slide in back as far as it will go.
ENGINE NO. NXC 155932)
2. Lubricate the hub, align the keyway in the pulley
1. Drive the key into the keyway until it is seated.
with the key in the end of the crankshaft. Tap the
2. Install the crankshaft gear with crankshaft gear pulley onto the crankshaft.
replacer as shown in Figure 17.
3. Install the flat washer and bolt and tighten the
CAMSHAFT GEAR bolt to the specified torque.
A. REMOVAL 5. OIL PAN SUMP AND OIL PUMP
1. Remove the bolt and flat washer as shown in OIL PAN SUMP
Figure 15.
A. REMOVAL
2. Remove the camshaft gear from the end of the
shaft. To remove the oil pan sump from an engine installed
in a tractor:
B. CLEANING AND INSPECTION
1. Drain the engine oil and remove the oil level dip-
1. Clean the gear in solvent. stick.
2. Inspect gear teeth for scores, nicks and the 2. Remove the oil pan sump retaining bolts, and
condition of the teeth wear pattern. remove the oil pan sump.
3. Check the keyway and key on the end of the
B. CLEANING AND INPSECTION
camshaft. If the key is damaged in any way install
a new key before installing the gear. Use a 1. Scrape any dirt or metal particles from the inside
Carborundum stone to remove minor gear teeth of the oil pan sump.
imperfections. If tooth wear or damage is severe 2. Scrape all gasket material from the gasket
install a new gear. surface.
C. INSTALLATION 3. Wash the oil pan sump in a solvent and dry
1. Install the camshaft gear spacer. thoroughly.

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 ENGINE SYSTEM

Figure 18
Oil Pump Exploded View
1. Oil Pump Retaining Bolts 9. Screen
2. Adaptor Retaining Bolt 10. Spring
3. Hourmeter Drive Shaft Assy. 11. Outer Cover
4. Hourmeter Drive Shaft Adaptor 12. Inner Cover
5. Drive Shaft Adaptor Mounting Base 13. Inner Rotor and Shaft Assembly
6. Oil Pump Drive Shaft and Gear Assy. 14. Outer Rotor
7. Intermediate Shaft 15. Body
8. Screw and Washer Assemblies 16. Pressure Relief Valve Assembly

4. Check the pan for crancks, holes, damaged drain bolts first and then tighten from the middle outward
plug threads, or a nicked or warped gasket in each direction to the specified torque.
surface. 5. Install the oil level dip-stick, tighten the drain plug,
5. Repair any damage, or install a new pan if repairs and fill the crankcase with the proper grade and
can not be made. quantity of engine oil.
C. INSTALLATION 6. Operate the engine and check for oil leaks.
To install the oil pan sump to an engine assembled in OIL PUMP
a tractor, reverse the disassembly procedure paying A. REMOVAL
attention to the following points.
1. Remove the oil pan sump, as out lined under "Oil
1. Be sure that the gasket surface on the oil pan pan sump removal".
and block are clean.
2. Remove the oil pump retaining bolts and remove
2. Position the gasket on the cylinder block and the oil pump with the filter screen. When the oil
apply a thin film of gasket sealer on the gasket, pump is removed withdraw the Intermediate shaft.
front cover, and the oil pan sump.
3. Disconnect the hour meter drive cable from the
3. Hold the oil pan in place against the block and drivenshaft adaptor and remove the engine oil filter.
install a bolt, finger tight at each corner of the oil
4. Slacken the retaining bolt, then withdraw the
pan.
driveshaft adaptor assembly and the oil pump drive
4. Install the remaining bolts and tighten the rear gear Figure 18.

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 ENGINE SYSTEM

Figure 19 Figure 19A

Measuring Oil Pump Clearance Measuring Outer Rotor to Pump Body
1. Pump Body 2. Outer Rotor Clearance
3. Inner Rotor 4. Feeler Gauge 1. Pump Body 2. Outer Rotor
3. Feeler Gauge 4. Inner Rotor

B. DISASSEMBLY 4. With the rotor and shaft assembly installed in

the pump body, place a straight edge over the
1. Remove the oil pump screen spring and pump rotor and shaft assembly and the pump body.
screen. Measure the clearance between the straight edge,
the inner rotor, shaft assembly and between the
2. Remove the four cap screws and remove the straight edge and the outer rotor, Figure 19. If the
screen cover and pump cover. Figure 18. Remove measurement is not within specifications, install
the rotor and shaft assembly. a new rotor assembly.

3. Remove retaining screw and washer. NOTE: The shaft rotors are serviced only as an
assembly
4. Insert self-tapping screw of the correct size into
the hole in the relief valve plug and pull the plug 5. Measure the rotor-to-housing clearance by
out of the chamber. Remove the spring and relief inserting feeler blades between the rotor and the
valve, Figure 18. housing. Take the measurements at four places,
90° apart, Figure 19A. If the measurements are
C. CLEANING AND INSPECTION.
not within specifications, install a new rotor
1. Wash all parts in solvent and dry thoroughly. Use assembly. Remeasure clearance, with the new
a brush to clean the inside of the pump housing rotor assembly in the pump body. If the
and the pressure relief valve chamber. Be sure all measurements are still not within specifications
dirt and metal chips are removed. install a new pump body.

2. Check the inside of the pump housing and the 6. Check the relief valve spring tension. If the spring
rotor and shaft assembly for excessive wear. tension is not within specifications, install a new
spring.
3. Check the inside face of the pump cover for wear
or score marks. If these conditions exist, install 7. Check the relief valve for score marks and be sure
a new cover. it is free to move within the bore.

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 ENGINE SYSTEM

8. Check the oil pump drive gear for worn or broken under "Cylinder Head Removal".
teeth. If any of these conditions exist install a 2. Remove the oil pan sump and oil pump assembly
new drive gear and shaft assembly. as outlined under. "Oil Pan Sump Removal" and
9. Check the intermediate drive shaft to be sure the "Oil Pump Removal".
hexagon socket ends are not excessively worn. 3. If necessary, remove the ridge from the top of each
In Farmtrac tractors from BSN 185845 the groove cylinder with a cylinder ridge reamer or hand
from oil pump intermediate shaft has been deleted. scraper. (Ridge removal is not necessary when
reboring or if the old pistons are not to be used.
D. ASSEMBLY However, it may be necessary to remove a ridge
The oil pump assembly is shown in Figure 18. in order to remove an old piston). When removing
the cylinder ridge do not cut down in to the ring
1. Oil all the parts thoroughly. travel more than 1/32 in. (0.79 mm.). It is possible
2. Install the oil pressure relief valve, piston and to cut so deeply into the cylinder wall nd so far
spring, and drive in a new plug. down into the ring travel that reboring, or the
installation of a new engine block is necessary.
3. Install the retaining screw and washer.
Do not attempt to remove and reuse a piston from
4. Install the rotor and shaft and outer race into the a cylinder with an excessive ridge. Forcing the
pump body. The rotor and shaft assembly and piston past the ridge may break the lands on the
outer race are serviced as an assembly. One part piston or the rings.
should not be replaced without replacing the other. 4. Remove the nuts from the connecting rod bearing
5. Install the pump cover and screen cover together cap bolts of the piston that is at bottom of its
and tighten the four screws to the specified torque. stroke. Remove the rod bearing cap and liner, from
the rod. Push the piston and rod assembly away
6. Install the screen assembly and secure it with from the crank pin and remove the bearing liner
the screen spring. from the rod. Push the rod and piston assembly
E. INSTALLATION out of the top of the cylinder, using the handle
end of a hammer. Be careful not to scratch the
1. Prime the pump by filling the inlet port with clean
crank pin or the cylinder. Turn the crankshaft to
engine oil. Rotate the pump shaft to distribute oil bring each piston to the bottom of its stroke and
within the pump. repeat this procedure. Keep the bearing caps and
2. Place the intermediate shaft on the rotor shaft liners with their respective connecting rods.
and using a new gasket install the oil pump 5. Remove the piston rings from the pistons with a
assembly on the cylinder block. Install the two piston ring expander or other suitable means.
mounting bolts and lock washers and tighten to
the specified torque. B. DISASSEMBLY

3. Install the pump drive gear and shaft. Install the 1. Remove the piston pin snap ring (circlip) from each
drive shaft adaptor mounting base with new 'O' side of the piston and remove the pin.
ring. 2. Identify each piston to be sure it will be
reassembled on to the rod from which it was
4. Install a new oil filter.
removed.
5. Install the oil pan sump as outlined under "Oil
C. CLEANING
Pan Sump Installation".
Clean the piston ring grooves with a piston ring groove
6. CONNECTING RODS, BEARINGS, PISTONS
cleaner. Be careful not to scratch or remove metal
AND CYLINDER BLOCK
from the groove sides. Place the piston assembly in
PISTON AND CONNECTING ROD ASSEMBLY liquid cleaner, if available, to soften carbon and lead
deposits. Clean the rod bore and the back of the
A. REMOVAL
connecting rod bearing lines thoroughly. Dry the parts
1. Remove the cylinder head assembly as outlined with compressed air. Do not use a wire brush.

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 ENGINE SYSTEM

Figure 20
Typical Defective Bearings

D. INSPECTION 4. A shiny surface on the pin boss side of the piston

will usually indicate that a connecting rod is bent.
CONNECTING RODS Adnormal connecting rod bearing wear is also an
indication of bent connecting rods. Twisted
1. Inspect the connecting rods for signs of damage connecting rods will not create an easily
and the bearing bores for out-of-round and taper. identifiable wear pattern, but badly twisted rods
If teh bore exceeds the recommended limits or is will disturb the action of the entire piston
damaged, a new connecting rod should be assembly. Refer to "Connecting rod Alignment."
installed.
CONNECTING ROD BEARINGS
2. Check the connecting rod nuts and bolts. Any
part that shows signs of wear or damage should 1. If the bearing liners are scored, have the flash
be replaced. Always use new connecting rod overlay wiped out, show fatigue failure, or are badly
bearing cap nuts. scratched, as shown in Figure 20, Install new
bearing liners.
3. Check piston pin bushings for wear or damage.
Measure outside diameter of piston pin and inside 2. If the bearing liners appear to be serviceable, keep
diameter of piston pin bushing. If bushing is with their respective rods for reassembly in the
damaged, or if the measurements indicate that a engine. If the clearance exceeds the specified
clearance between the bushing and the pin is not limits, new bearings must be installed. Undersize
between 0.0005 in. to 0.0007 in. (0.01-0.02 mm.) connecting rod bearings are available in 0.010 in.
the bushing must be removed. (0.25 mm.) 0.020 in. (0.51) 0.030 in. (0.76 mm.)
and 0.040 in. (1.02 mm.) for service for Farmtrac
NOTE: If a new piston pin bushing is installed, it 50/55 and 60. If new bearings ae required, Follow
must be reamed to provide the clearance the procedure covered under "Fitting main and
listed above. Connecting rod Bearing".

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 ENGINE SYSTEM

2. If the pistons have excessive skirt clearance, wavy

ring lands, fractures, or damage from detonation,
install new pistons.

3. Piston pins having wear or damage should be

discarded and new ones installed. Always use
new piston pin snap rings (circlips).

CONNECTING ROD ALIGNMENT

1. Place each connecting rod in an alignment fixture.

As shown in Figure 22.

2. If the connecting rod is twisted more than 0.012

in. (0.30 mm.) or bent more than 0.004 in. (0.10
mm.) install a new rod.
Figure 21
Checking Piston Ring Side Clearance E. REPAIR
1. New Piston Ring 2. Feeler Gauge
CONNECTING ROD BUSHING

1. Remove the connecting rod bushing from the

PISTONS connecting rod with Driving Mandrel, Adaptor and
an arbor press.
1. Inspect pistons for damage at the ring lands, skirt,
and pin bosses. Check for separation of the top 2. Clean the connecting rod bore and make sure
ring insert from the piston. Check for wear in the there are no burrs or scratches in the bore. Press
ring lands by using a new ring and a feeler gauge a new bushing into the connecting rod, using the
reference Figure 21. same bushing tool that was used for removal.

Figure 22
Connecting Rod Alignment

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 ENGINE SYSTEM

Figure 23 Figure 24
Drilling Connecting Rod Bushing Piston Grading Diameter

3. Using the hole in the top of the connecting rod as the "W" diameter of the piston to be fitted Figure
a guide, drill a ¼ in. (6.350 mm.) diameter hole in 24.
the bushing Figure 23.
6. Subtract the piston diameter from the bore
4. Using an expansion reamer, ream the bushing in diameter. The resultant figure should be within
the connecting rod to obtain the specified bushing- the specified clearance.
to-piston pin clearance. A spiral expansion reamer
is recommended. 7. If the clearance is greater than specified, try a
similar new piston. If the clearance still exceeds
FITTING PISTONS the specified limit, measure the other cylinder
bores and pistons and determine the cylinder with
1. Pistons are available in both standard and teh greatest clearance. Based on the greatest
oversize. New Pistons should be installed if the clearance, rebore the cylinders to take the next
clearance exceeds the specified limits. oversize piston as previously described.
2. The cylinder bores must be checked for taper and If the clearance is less than specified: Hone the
out-of-round before fitting a piston, as outlined bore to obtain the desired clearance as previously
under "Cylinder Block Inspection". described.
3. Before installing a piston and new rings in a used NOTE: Dimension "W" is not the point of largest
block, remove the high polish on the cylinder wall diameter of the piston, but it is the datum
to aid ring seating. This is done by passing a from which bore clearances are calculated.
hone lightly through the cylinder bore a few times.
Do not hone more than enough to rough up the FITTING PISTON RINGS
polish. After honing, bores should be washed with
hot water and detergent, then rinsed in cold water 1. Before installing new rings on a piston, the rings
and dried thoroughly. The bores should then be should be checked for proper ring gap. Each ring
oiled to prevent rusting. should be fitted and checked in the cylinder in
which it is going to be used, and marked
4. Using a bore gauge (or inside micrometer) check accordingly after the cylinders have been checked
and record the cylinder bore diameter in a and reconditioned as required. Push ring down
crosswise direction. into the cylinder bore to the lower unworn portion
of the cylinder, using the head of a piston so that
5. With an outside micrometer, check and record the ring is square with the cylinder wall.

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 ENGINE SYSTEM

Figure 25 Figure 26
Checking Piston Ring Gap Piston Ring Removal and Installation
1. Feeler Gauge 2. Piston Ring

NOTE: When positioning the piston ring inside the 1 Oil Control Ring with coiled expander
cylinder for checking ring gap be very careful
not to damage the ring or the cylinder bore. Top Compression Ring

2. Check the gap between the ends of the ring with Bright chrome finish, chamfer on inside diameter.
a feeler gauge. The ring gap should be as specified. Assemble with identification mark facing upwards.
It is important that all rings have atleast the 2nd Compression Ring
minimum gap clearance to provide for the
expansion that may occur when the engine warms Bright chrome finish, step on inside diameter
up to operating temperature otherwise, the ring Assemble with step facing upwards.
ends may butt together and cause scuffing,
3rd Compression Ring
scoring, or ring breakage reference figure 25.
Dull black finish, step on outside diameter
3. New rings should also be checked for side
clearance in the grooves of the piston on which Oil Control Ring
they are to be installed. This is done as outlined
under "Pistons". Install either way upwards with coiled expander
behind ring. Position the ring gap diametrically
INSTALLING PISTON RINGS opposite the coiled wire ends.
NOTE: When installing the piston rings, it is ii. SPACE THE RINGS ON THE PISTON AS
recommended that a piston ring expander be FOLLOWS:
used. This tool will prevent over-expansion
of the ring, and will expand the ring to a true Position gap in line with piston notch mark. Refer
circle to avoid distortion reference Figure 26. Figure 28.

i. SERVICE & PRODUCTION PISTON RING KIT Oil Control Ring

COMPRISES FOR FARMTRAC 50 & 55:
Position gap 90° from piston notch on the piston
3 Compression Rings crown.

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 ENGINE SYSTEM

Figure 27 Figure 28
New 3 - Ring Configuration Farmtrac 60 Correct Position of Piston in relation to
Connecting Rod
1. Notch to Front of Engine 2. Cap Numbers

Lower Compression Rings After installing the rings, stagger the ring gaps
around the circumference of the piston.
Position gap 180° from oil control ring gap.
PISTON ASSEMBLY
Remaining Compression Ring
1. Lubricate all parts with engine oil during assembly.
Position gap 120° intervals from lower
compression ring. NOTE: When rings are replaced, cross hone the
Block Bores to remove the ridge & to de-glaze
iii. IN SERVICE & PRODUCTION PISTON RING
the bores.
KIT COMPRISES FOR FT-60
2. Assemble the piston to the connecting rod with
NOTE: In Farmtrac-60 the rings supplied in service
the notch on the piston crown and the dimple on
ring kits are same as that used in production
the connecting rod in line as shown in Figure 28.
Figure 27.
If a new piston is used the connecting rod piston
2 Compression Rings pin bushing may have to be reamed or replaced
to provide the specified pin-to-bushing clearance
1 Conformable Oil Control Ring
(when properly fitted the pin should rotate snugly
Top Compression Ring in both the rod and piston). Before installing the
piston in the block be sure the piston pin retainers
Chrome finished, Nodular iron, Barrel honed. May (circlips) are fully seated in the piston grooves.
be assembled either side upwards.
F. INSTALLATION
2nd Compression Ring
1. Turn the crankshaft to position the No. 1 Crankpin
Chrome faced, compression cum oil control ring.
at the bottom of its stroke.
2 degrees face angle. Inside 30° chamfer facing
down. Identification mark facing upwards. 2. Lubricate the No. 1 piston with engine oil.
Compress the rings with a Piston Ring
Assemble with inside 30° chamfer facing down.
Compressor. Install the bearing liner in the
Oil Ring connecting rod.
Chrome finish, conformable oil ring, install either 3. Position the piston and rod assembly in the
way upward. Position the ring gap diametrically cylinder block with the identification mark on the
opposite the coiled wire ends. piston facing the front of the engine.

A–24
 ENGINE SYSTEM

4. Tap the piston into the cylinder bore with the

handle end of a hammer, until the connecting rod
bearing liner is seated on the crankpin. To avoid
damage to the cylinder wall or the bearing journal
with the connecting rod or rod bolts, use plastic
caps on the bolts.
5. Having ensured correct liner clearance, refer to
"Fitting Main Connecting rod bearings". Lubricate
the crankpin and liners and install the bearing
cap on the rod, with the number on the cap on
the same side as the number on the rod. Figure
28, install new nuts and tighten to the specified
torque.
6. Install the remaining pistons and rods in the same
manner, each time checking the bearing Figure 29
clearance. Cylinder Bore Measurements
7. Install the oil pump and the oil pan sump as detected with a cylinder bore gauge using the
outlined under "Oil Pump Installation", and "Oil procedure given in step 3 see Figure 29.
Pan Sump Installation?.
3. Record the measurements taken lengthwise and
8. Install the cylinder head as outlined under
crosswise at the top and bottom of the piston
"Cylinder head installation".
travel as follows:
9. Fill the crankcase with oil and the radiator with
a) Lengthwise of the block, measure and record
coolant.
as "A" the diameter of the cylinder at the
10. Start the engine and check for leaks. area of greatest ring wear near the top of the
CYLINDER BLOCK cylinder.
The following is the procedure for inspection and repair b) Also lengthwise of the block, measure and
of the cylinder block. record as "B" the cylinder diameter at the
A. INSPECTION bottom of piston skirt travel.

1. Inspect the core plugs for evidence of rust. If rust c) Crosswise of the block measure and record
is present this indicates leakage and new plugs as "C" the diameter at the top of the cylindr
should be installed. Remove the defective plugs. in the same area as measurement of "A".
Apply sealer to the new plugs and install them d) Crosswise of the Block measure and record
securely. as "D" the diameter at the bottom of the
2. Inspect and measure the cylinder bores for piston skirt travel in teh same area as
waviness, scratches, scuffing, out-of-round, wear measurement of "B".
and taper, a wavy cylinder wall has a series of e) Reading "A" compared to reading "B" and
parallel lines of rings worn around the cylinder,
reading "C" compared to reading "D"
generally found at the top or bottom of the piston
indicates whether the cylinder is out-of-round.
ring travel. These irregularities and scratches,
although in most cases are too small to be If the cylinder taper, out-of-roundness or wear
measured with the naked eye, usually can be felt (piston-to-bore clearance) are above the
by running a finger over the cylinder surface. A maximum specification, the cylinder should
scuffed cylinder can be identified by discoloured be honed or bored to fit the next oversize
area. The colour varies from a light straw-to-dark piston. Check the flatness of the cylinder
blue depending on the severity of the scuffing. block gasket surface and the depth of the
Out-of-roundness, wear, and taper can be cylinder head bolt hole taps.

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 ENGINE SYSTEM

B. REPAIR

If the cylinder wall have only minor surface

imperfections, the out-of-round and taper is within
limits, it may be possible to remove the imperfections
by honing the cylinder wall and install new piston rings,
provided the piston clearance is within limits.

Cylinder walls that are severely marked or worn beyong

the specified limits should be honed or bored to the
next over size of pistons.

The exact finished bore size can be determined, by Figure 30

measuring the diameter of the piston at right Figure Dimensions for Machining Cylinder Bore for
24) then add to this dimension the appropriate piston Thin Walled Sleeve
clearance as shown in specifications. A. 0.095-0.099 in. (2.41-2.51 mm.)
B. 4.746-4.753 in. (120.55-120.73 mm.)
Bore the cylinder with the most wear first to determine C. Bore Cylinder to Average Diameter of Sleeve less
the proper oversize. Oversize pistons are available in 0.000-0.002 in. (0.00-0.05 mm.)
0.020 in. (0.51 mm.) 0.030 in. (0.76 mm.) and 0.040 D. 0.020-0.030 in. (0.50-0.75 mm.) x 45° Chamfer
in. (1.02 mm.) oversize. All honing should be E. 0.015 in. (0.38 mm.) Radius Maximum
accomplished with a rigid hone using a grit size of
150-220. When boring a cylinder leave approximately
RE-SLEEVING FOR FARMTRAC-60
0.002-0.003 in. (0.05-0.08 mm.) stock for honing.
Afterthe final operation and prior to installing the piston,
4.4 in. (111.76 mm.) BORE THIN WALLED LIPPED
thoroughly wash the cylinder walls with hot water and
SLEEVE
detergent to remove all abrasive particles, and carefully
dry the walls. Coat the walls with engine oil after drying Following are the guidelines for re-sleeving the block
to prevent rusting. Identify the piston to correspond to bore.
the cylinders to which they are to be installed.
Thoroughly clean the entire block to remove all particles 1. Measure the outside diameter of sleeve in four
from the bearing bores, oil passages, cylinder head places and find the average diameter. Bore the
bolt holes, etc. block to 0 - 0.002 in. (0 - 0.05 mm.) less than this
average diameter.
For cylinders with severely damaged walls or to which
maximum oversize pistons have already been installed 2. Machine the counter bore to the dimensions
cylinder liners are available for sleeving the bore. The shown in Figure 30. The counter bore depth is
procedure for which is discussed separately for critical as the sleeve must be flush with block
Farmtrac 50, 55 & 60. surface when installed.

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 ENGINE SYSTEM

Figure 31 Figure 32
Measuring Piston-to-Block Height Bearing Liner Removal Tools
1. Thrust Bearing Insert 2. Main Bearing Liner Tool

3. Thoroughly clean and dry the bore and outside MAIN BEARINGS
surface of the sleeve.
A. REMOVAL
4. Chill the sleeve in liquid Nitrogen or dry ice and
assemble to the cylinder bore ensuring the lip is 1. Remove teh oil pan sump as outlined under "Oil
bottomed in the counter bore.
Pan Sump Removal".
5. If necessary the sleeve top may be machined to
bring it flush with the block face, or if necessary 2. Remove the oil pump and the intermediate shaft.
the block face may be skimmed by up to 0.005
in. (0.13 mm.) to achieve a flush condition. If the 3. Remove the main bearing cap to which new
block is skimmed ensure the piston crown remain bearing liners are to be installed. Install one
0.011-0.023 in. (0.28-0.58 mm.) above the block bearing at a time, leaving the other main bearing
face reference Figure 31. caps securely in place.

6. Bore and hone the sleeve to the diameter required 4. Installa bearing liner remover in the oil passage
to achieve piston skirt (at right angle to the piston of the crankshaft. Turn the crankshaft counter-
pin) to cylinder clearance of 0.008-0.009 in. (0.20-
clockwise slowly until the tool forces the bearing
0.23 mm.). Only standard size pistons can be
out of the cylinder block.
used with the 4.4 in. (111.76 mm.) bore lipped
sleeve.
NOTE: If a bearing insert tool is not available, flatten
7. MAIN BEARINGS, FLYWHEEL AND the head of a 1in. (25 mm.) x 1/8 in. cotter
CRANKSHAFT pin (split pin) and bend the head at
approximately a 30° angle to conform to the
The main bearings can be overhauled with the engine
angle of the oil passage in the crankshaft.
in the tractor. To remove the flywheelthe engine must
Use the fabricated tool in the same manner
be removed from the tractor, or the tractor separated
between the engine and the transmission, as outlined to remove and install bearing insert. The
under "SEPARATING THE TRACTOR". The engine shorter cotter pin (split pin) must be used to
must be removed from the tractor before the crankshaft remove the thrust bearing insert reference
can be removed. Figure 32.

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 ENGINE SYSTEM

B. INSPECTION
Clean the bearing liners, journals and caps thoroughly.
Inspect each bearing carefully. Bearing liners that have
a scored, chipped or worn surface, as shown in Figure
20, (for connecting rod bearings) should be replaced.
Re-install the liners that appear serviceable, if new
liners are installed, check the clearances, using
Plastiguage. If teh crankshaft is damaged, it should
be reworked or replaced.
C. INSTALLATION
1. Remove the bearing cap and liner and apply a
light coat of engine oil to the journal and bearing
liner.
2. With the bearing liner installation tool in crankshaft
oil hole, hold the bearing liner in place on the Figure 33
crankshaft with the plain end of the bearing at the Checking Flywheel Run-Out
notch side of the cylinder block. Turn the 1. Dial Gauge with Magenetic Stand
crankshaft clock-wise until the bearing ends flush 2. Flywheel
with the bearing cap surface of the cylinder block.
Remove the installation tool. 3. Engines may be assembled with liners of different
3. Lubricate the bearing cap and bearing liner with material. For example, one journal may be fitted
engine oil and install the liner into the cap. Hold with aluminium tin alloy liners, while another
the bearing cap in place with locking tang toward journal may be fitted with copper lead liners.
the camshaft side of the engine and install the However, the top and bottom liners of any one
two bolts. Tighten the bolts to the specified torque. bearing should be of the same material.
4. If a new rear main bearing liner is to be installed, FLYWHEEL
the engine will have to be separated from the
The fly wheel mounts on a flange at the rear of the
tractor and a new rear oil seal installed.
crankshaft and is retained by six bolts. The mounting
5. If a new thrust bearing liner has been installed, holes are unevenly spaced so that it can be mounted
the bearing should be aligned as outlined in in only one position, the starter ring gear is mounted
crankshaft installation. The thrust bearing is the
on the flywheel.
one with the flange type liner on the front
intermediate main bearing. A. REMOVAL
6. Install the oil pump and intermediate shaft. Install 1. Separate the tractor between the engine and
the oil pan sump. transmission as outlined in "SEPARATING THE
BEARING LINES AND CRANKSHAFT TRACTOR".
1. Bearing liners are fitted in production to obtain 2. Remove the pressure plate and clutch disc
the desired liner-to-crankshaft journal clearances. assembly from the flywheel.
In order to maintain the minimum variation in
3. Prior to removal, rotate the flywheel and use a
tolerances; the liners of different colour codes are
used to obtain the desired clearances. (The dial gauge to measure the run out. Figure 33. If
difference between the liners is in the wall the flywheel runout is out of specifications, check
thickness). the mating surfaces of the flywheel and the
crankshaft for correct seating.
2. When fitting standard liners in service, using the
"Plastiguage" it may be necessary to fit colour 4. Remove the six flywheel attaching bolts and the
code red, colour code blue, or a combination of retainer. Grasp the flywheel in the groove around
both liners on the same journal to obtain the the inner edge, and tap it with a soft hammer to
desired clearances. loosen it from the crankshaft.

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 ENGINE SYSTEM

B. INSPECTION
1. Inspect the flywheel ring gear for broken or
excessively worn teeth. Replace if either condition
is found. If broken or worn teeth make gear
replacement necessary. Be sure to inpsect the
starter armature shaft and drive for the possible
cause of failure.
2. Before removing the flywheel from the tractor,
check the flywheel runout. Total amount should
not exceed than the specified.
3. Check the flywheel for damage due to loosely or
improperly fitted ring gear.
4. Check the ring gear teeth for rough edges and for
missing teeth which could scuff or gouge the teeth
Figure 34
on the drive gear. If necessary, dress the teeth
with a wire wheel to smooth up the edges. Clutch Pilot Bearing Removal
1. Internal/External Attachment EF-0601
5. At any time the tractor is separated between the
2. Slide Hammer EF-0600
engine and transmission, the clutch compartment
3. Clutch Pilot Bearing
should be cleaned thoroughly to help prevent
future ring wear, starter drive, or clutch failure due
heat when the 400°F (204°C) crayon mark melts
to abrasives or grease which can accumulate with
and before the 450°F (232°C) crayon begins to
usage.
melt. Quickly spot check the 400°F (204°C)
6. After installing the flywheel, check the gear runout crayon to be sure the gear and not the flame has
to be within the limit as given in "Specifications". melted the crayon marks.
C. FLYWHEEL RING GEAR REPAIR 4. Quickly place the hot gear on the flywheel with
the flat gear face against the shoulder on the
1. Inspect the flywheel ring gear and replace if the
flywheekl. Be sure the gear face is flush with the
teeth are damaged. Check the flywheel for damage
shoulder on the flywheel, then quench the gear
due to a loosely or improperly fitted ring gear.
with water to cool it rapidly.
2. A damaged flywheel ring gear should be removed
D. CLUTCH PILOT BEARING REMOVING/
and replaced as follows:
INSTALLATION
Cut the old ring gear free from the flywheel.
The clutch pilot bearing can be removed without
Thoroughly clean the mating surfaces of the new removing the flywheel, but the flywheel retaining bolts
ring gear and the flywheel. and the bearing retainer must first be removed in order
Use temperature indicating crayons to mark the to gain access to the bearing.
side face of the ring gear at six equally spaced 1. Remove the bearing from the end of the crankshaft
locations. Mark with a 400°F (204°C) crayon at a with a slide hammer EF-0600 and Internal/
point 0.5 in. (13 mm.) below the root of the teeth External attachment EF-0601 Figure 34.
and mark with a 450°F (212°C) crayon at a point
2. Coat the pilot bearing bore in the crankshaft with
just below the root of the teeth.
a small quantity of high melting point lubricant.
3. Heat the gear evenly with an oxy-acetylene torch
3. Using a driver and adaptor of the correct size,
having a tip size not larger than No. 2 and a rich
install the bearing to flush with the bore.
acetylene adjustment. Direct the flame against
the inside of the gear so the heat will travel E. FLYWHEEL INSTALLATION
outwards toward the teeth. Avoid directing the
1. Clean the crabkshaft rear flange and the mating
flame against either face of the gear. Stop applying
surface of the flywheel.

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 ENGINE SYSTEM

2. Determine the correct relationship of the bolt holes

in the flywheel and crankshaft and place the
flywheel in position on the crankshaft. Install the
bearing retainer and six cap screws and tighten
to the specified torque. Re-check flywheel runout.
Install the clutch.
3. Reassemble the tractor as outlined in
"SEPARATING THE TRACTOR".
CRANKSHAFT
A. REMOVAL
1. Remove the engine from the tractor as outlined in
"SEPARATING THE TRACTOR" and place it on
an engine stand or a suitable work bench.
2. Remove the flywheel and the engine rear cover Figure 35
plate. Crankshaft Journal/Pin Measurement
3. Remove the crankshaft pulley and engine front all drilled passages with a rifle brush, then blow
cover, outlined on page A-13 under "Engine Front out the passage with compressed air.
Cover and Timing Gears". 2. Place the crankshaft on V-blocks to check the
NOTE: If at any time the crankshaft is to be removed runout at the intermediate main bearing journals
with the cylinder head in position, it is with a dial indicator. If the crankshaft appears
necessary to first realign all timing marks. damaged or misaligned, or if the runout exceeds
This is necessary to be sure that interference the specified limits, install a new crankshaft.
between the valves and pistons does not 3. Inspect the main and connecting rod journals for
occur during re-assembly. cracks, scratches, grooves or scores. Dress
4. Remove the oil pan sump and oil pump, as minor imperfections with an oil stone refinish
outlined under "Oil Pan Sump Removal", and "Oil severely marked journals.
Pump Removal". 4. Measure the diameter of each journal/crankpin in
5. Remove the Connecting Rod bearing cap and atleast four places to determine out-of-round,
liners. Remove the main bearing caps and liners. taper or wear, Figure 35. Measurement A
compared with B indicates vertical taper whilst
6. Make sure all of the bearing caps and liners are
measurement C compared with D indicates
identified so they can be installed in their original
horizontal taper. Measurements A and B
position.
compared with C and D indicate journal out-of-
7. Carefully lift the crankshaft out of the cylinder block round. If the journal exceeds the specified wear
so that the thrust bearing surfaces are not limit, refinish the journals to the next undersize
damaged. Handle the crankshaft with care to avoid bearing, see "Specifications". Always reproduce
possible damage to the finished surfaces. the original journal side radii and after refinishing
chamfer the oil holes.
B. INSPECTION
C. REPAIR
NOTE: Some production engines may have a
crankshaft with main bearings and/or 1. If the crankshaft gear teeth are excessively worn
crankpin bearing journals ground 0.010 in. or if any teeth are chipped, install a new crankshaft
(0.25 mm.) undersized. These crankshafts gear. Remove the gear as outlined under
can be identified from the letters "010MUS" "Crankshaft Gear Removal".
and/or "010PUS" stamped on one of the
2. Install a new gear as outlined under "Crankshaft
counter balance weight of the crankshaft.
Gear Installation". Be sure the gear is all the way
1. Clean the crankshaft in a tank of solvent. Clean onto the shoulder of the crankshaft.

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 ENGINE SYSTEM

NOTE: For crankshafts from Engine No. 155932.

Crankshaft Gear is not serviceable
seperately. (Reference Crankshaft Gear
Removal).

3. Refinish the journals to give the proper clearance

with the next undersize bearing. If the journals
will not clean up at the maximum undersize
bearing available, install a new crankshaft. Always
reproduce the same journal radius, that originally
existed. Too small a radius will result in fatigue
failure of the crankshaft. Too large a radius will
result in bearing failure due to radius ride of the
bearing. After refinishing the journals, be sure to
chamfer the oil holes.

D. INSTALLATION Figure 36
Checking Crankshaft End Play
1. Be sure the main bearing bores and rear main
1. Dial Gauge with Magnetic Stand
bearing oil seal area are thoroughly cleaned before
2. Crankshaft
installing the bearings in the block. Polish the oil
seal running surface with crocus cloth. Remove 3. Lever
any nicks or burrs that could damage the seal.
Install a new crankshaft if the oil seal surface is flange-type bearing liner, first. Then, install all main
deeply grooved. bearing caps except the rear cap. Be sure they
are installed in their original location. With the
2. Lubricate the main bearing liners and install them
arrow marks pointing towards the front of the
in the block and bearing caps. If the main bearing
engine.
journals have been refinished to undersize, install
the correct undersize bearings. Be sure the 6. Install the thrust bearing cap, with the bolts finger
bearing liners are clean (foreign material under tight, then pry the crankshaft forward against the
the liners will distort the bearing and cause thrust surface of the bearing. Hold the crankshaft
premature failure) and the tangs (lips) on the forward and pry the bearing cap to the rear. Be
bearings are in the slots (counter recess) provided
careful not to pry against the flange of the bearing
in the cylinder block and caps.
liner. This will align the thrust surfaces of both
3. Turn the crankshaft to align the timing mark on halves of the bearing. Hold the forward pressure
the gear with the timing mark on the camshaft on the crankshaft and tighten the bearing cap
drive gear. Lower the crankshaft into place, being bolts to the specified torque.
careful not to damage the bearing surface.
7. Check the crankshaft end play. Install a dial
4. Check the clearance of each main and indicator so that the contact point rests against
connecting rod bearing with Plastiguage, as the rear flange of the crankshaft. Force the
outlined under "Fitting Main and Connecting rod crankshaft toward the rear of the engine. Set the
Bearings (Plastiguage Method)". dial on zero, then pry the crankshaft forward and
note the reading on the dial. If the end play
NOTE: If Plastiguage is not available, the bearing
exceeds the limits, install a new thrust bearing
clearances will have to be checked using
micrometers, before the crankshaft is liner. If the end play is less than the specified
installed. limit, inspect the thrust bearing surfaces for burrs,
scratches, or dirt. If the thrust surfaces are not
5. After the bearing clearances have been measured, defective or dirty, realign the thrust bearings
apply a light coat of engine oil to the journals and following the above procedure reference Figure
bearings. Install the thrust bearing cap with the 36.

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 ENGINE SYSTEM

Figure 37 Figure 38
Scoring of Oil Seal Journal Cleaning Crankshaft Flage
1. Direction of cleaning
2. Emery paper grade 600
8. Scratches & corrosion on the crankshaft rear oil
seal journal can be cleaned from underneath the
engine, or with the engine inverted Figure 37.
of the cylinder block and main bearing cap faces,
Figure 39. Alignment must not vary by more than
9. Inspect the face and flange for signs of damage.
0.003 in. (0.08 mm.) Of the faces are found to be
Small scratches and corrosion can be cleaned
outside the specifications then the procedure of
with a fine grade water proof abrasive paper,
re-alignment should be carried out.
ensuring that the direction of cleaning is around
the circumference and not lengthwise along the
crankshaft, Figure 38. Clean the crankshaft flange
and surrounding area throughly after using
abrasive paper.

10. Install new side seals in the rear main bearing

cap to project slightly beyond the block face of
the cap and assemble the cap in the cylinder
block.

11. Torque the rear main bearing cap bolts 140-150

lbf. ft. (19-21 kgfm) to ensure positive bottoming
of the seals against the block. Cut the side seals
to allow a projection of 1/64 in. (0.37 mm.) above
the pan rail. Figure 39
Checking Alignment with Straight Edge
Apply a light coating of sealer locktite 577 to the 1. Main Bearing Cap
seal bore surface on the cap to block split lines 2. Cylinder Block
(Do not permit sealer on the crankshaft seal 3. Side Seal
journal). Check with straight edge, the alignment 4. Straight Edge

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 ENGINE SYSTEM

Figure 40 Figure 41
Tool Assembled for Installation of Service Seal Fitting the Seal to be Centre Stock
1. Fixing Screws 3. Barrel 1. Centre Stock
2. End Plate 4. Flush End of Barrel 2. Securing Screw
3. Seal
Lubricate the new seal and crankshaft area with clean 14. Assemble the barrel end plate to the centre stock
engine oil before fitting the oil seal by using tool no. and secure with the nut and washer. Figure 42.
OF-1403 Figure 40.
15. Gradually tighten the nut until the seal is pushed
NOTE: New Crankshaft rear seal (Part No. E3NN- fully into position and barrel butts against block
6701-BA) with improved sealing qualities have rear face.
been introduced in production and service.
It should be noted that the oil seals supplied
in service (by Parts Dept.) differ from
production seal. In that the sealing lips are
offset 0.060 in. (1.5 mm.) towards the front
of the engine.

The silicon wax originally coated to the new seal should

not be wiped-off at the time of fitment:

The seal is installed with the rear face of the seal flush
with the block. For this the tool is assembled as shown
in Figure 41.

12. Thoroughly clean the crankshaft flange to ensure

location of the tool and install the tool centre- Figure 42
stock to the flange and secure with the two Assemble the Barrel End Plate
screws, Figure 41. 1. End Plate
2. Nut & Washer
13. Apply a thin film of oil to the tool centre stock. 3. Barrel

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 ENGINE SYSTEM

Figure 43 Figure 44
Checking Rear Main Bearing Crankshaft Oil Checking Connecting Rod Bearing Side
Seal Run-out Clearance
1. Dial Gauge with Magnetic Stand 1. Feeler Gauge
2. Crankshaft
3. Crankshaft oil seal
4. Cylinder Block

16. Remove the tool and check the run out of the are installed with the tangs in the slots in the
seal which must not exceed 0.016 in. (0.4 mm.) rods and caps.
Figure 43.
19. Install the connecting rod caps and tighten the
NOTE: The production seal (Part No. E5NN-6701AA) nuts to the specified torque.
must not be assembled using this tool to
avoid damages to the projected dust lip.
20. After the connecting rod assemblies have been
installed check the side clearance of each
After seal installation, install a new diaper gasket. A connecting rod by inserting a feeler guage
thin film of sealent should be used to hold the gasket between the side of the connecting rod and the
in position.
crankshaft journal reference Figure 44. If the
clearance is not within the limits as indicated,
17. Install the connecting rod bearing liners in the check the crankshaft journals dimensions and
connecting rods and caps. Check the clearance refinish or, if not within specifications, install a
of each bearing with a micrometer or by the new crankshaft.
Plastiguage following the procedure outlined under
"Fitting Main and connecting rod bearing
21. Install the oil pan sump.
(Plastiguage Method)".

22. Install the engine front cover, pulley spacer and

18. If the bearing clearances are to specifications
apply a light coat of engine oil to the journals and crankshaft pulley.
bearings. Install the bearings in the connecting
rods and bearing caps, making sure the bearings 23. Install the engine rear cover plate and flywheel.

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 ENGINE SYSTEM

Pan Sump Removal". Remove the bearing cap

and wipe the oil from the bearing liner and
crankshaft journal.
NOTE: If the main bearing lines are being fitted with
the engine in a tractor, a jack should be used
adjacent to the liner being fitted, and light
pressure applied to hold the crankshaft up
against the upper main bearing liner.
2. Place a piece of the correct size Plastiguage on
the bearing liner surface the full width of the
bearing cap and about ¼ in. (6.35 mm.) off center.
3. Install the cap and tighten the bolts to the
specified torque. Do not turn the crankshaft while
Figure 45 the Plastiguage is in place.
Engine Rear Seal (Sectional View) 4. Remove the cap. Using the Plastiguage scale on
1. Retainer and seal assembly 2. Crankshaft the package. Check the width of Plastiguage.
3. Seal 4. Cap Check at the widest point in order to get the
minimum clearance. Check at the narrowest point
NOTE: The crankshaft rear seal arrangement is in order to get the maximum clearance. The
different for Farmtrac 60. Where the seal is difference between the two readings is the taper.
installed in the seal retainer. The bolts are
torqued in the sequence, from 1 to 8. The NOTE: Normally, main bearing journals wear evenly
edges of the seal in retainer assembly are and will not be out-of-round. However, if a
to be even with the block within 0.020 in. liner is being fitted to an out-off-round journal
(0.51 mm.) - Figure 45. which is with in specifications, be sure to fit
the bearing to the maximum, diameter of the
E. FITTING MAIN AND CONNECTING ROD journal.
BEARINGS (PLASTIGUAGE METHOD)
5. When checking clearances, red liners, having a
Reference Figure 46 thinner wall section than blue liners, will provide
1. Remove the oil pan sump as outlined under "Oil greater clearance. Conversely, blue liners having
a thicker wall section will provide less clearance.
As stated previously a combination of red and
blue liners may be required to obtain the desired
clearance.
6. If one of these combinations of liners does not
bring the clearance within specified limits, refinish
the crankshaft journal to fit undersize bearings.
8. CAMSHAFT
A. REMOVAL
1. With the engine in the work stand/bench and the
flywheel removed, remove the front cover as
outlined under "Front Cover Removal".
2. Remove the cylinder head as outlined under
Figure 46
"Cylinder Head Removal".
Checking Crankshaft Bearing
Clearance Using Plastiguage 3. Remove the engine rear cover plate.

A–35
 ENGINE SYSTEM

rear of the camshaft by removing the bolt and

washer.
B. INSPECTION
1. Visually inspect the camshaft journals and lobes
for roughness, scores, nicks, pits, or
discolouration from heat.
2. Inspect the Oil pump drive gear on the camshaft
for broken or worn teeth, inspect the mating gear
on the oil pump drive shaft for the same
conditions.
3. If any of the above conditions exist install a new
camshaft or oil pump drive gear.
4. Measure the diameter and out-of-round of the
Figure 47
bearing journals. If the camshaft does not meet
Measuring Camshaft End Play
specifications, install a new camshaft.
1. Screwdriver 2. Camshaft Gear
3. Feeler Gauge 4. Thrust Plate 5. Inspect the hydraulic pump drive gear for worn on
broken teeth. If either condition exists, install a
4. Remove the oil pump drive gear from the cylinder new gear.
block as outlined under "Oil Pump Removal". 6. Inpsect the camshaft bearings for pits grooves,
5. Pry the camshaft gear away from the cylinder or score marks. Measure the clearance between
block with a screw driver. Check the clearance the bearing and the camshaft journal. If the
between the hub of the camshaft gear and the clearance between the I.D. of the bearing and O.D.
thrust plate with a dial indicator against the of the camshaft journal exceeds the
camshaft bolt or with a feeler gauge. If the specifications, install new bearings.
clearance exceeds the specified limits, install a C. CAMSHAFT BEARING REMOVAL AND
new thrust plate before reassembly reference INSTALLATION USING CAMSHAFT BUSH
Figure 47. REMOVER AND REPLACER.
6. If the camshaft bearings and/or the partly hollow REMOVAL
mushroom type tappets are to be removed, invert
1. Insert the small diameter spigot of the remover
the engine and remove the oil pan sump.
and guide, into the rear of Number 2 bearing liner
7. Remove the bolt and flat washer, and remove the as shown in "A", Figure 48. Position the
camshaft drive gear. centralizer, in front of Number 1 bearing with the
smaller diameter spigot located in the bearing liner.
8. Remove the two bolts and remove the camshaft
Pass the center screw of camshaft bush remover
thrust plate.
through this centralizer and the guide and fit "C"
9. Remove the Woodruff key and spacer from the washer to the end of the center screw. Place the
front of the camshaft. tommy bar in the hole at the inner end of the
10. Drive out the camshaft rear cover plate with a centre screw and withdraw the bearing liner from
punch and hammer. its location in the block by tightening the wing
nut of the tool.
11. Carefully remove the camshaft by pulling it out
from the rear of the engine. Be careful not to 2. Number 3 bearing liner can be removed in a similar
damage the bearings or the lobes on the manner, but they must be pulled out towards the
camshaft. rear of the cylinder block, the centralizer, being
placed in the rear bearing liner and the remover
12. Renmove the hydraulic pump drive gear from the and guide in the front of the liner being removed.

A–36
 ENGINE SYSTEM

Figure 48
Removing and Installing Camshaft Bearings Using Tool No. SW16
1. Remover Guide 3. Centraliser
2. Intermediate Bearing Replacer 4. Replacer Mandrel

3. Insert the smaller diameter spigot of the remover 1. Insert the remover and guide, into Number 2
and guide in the rear of the front bearing liner, and bearing bore with the smaller diameter towards
the intermediate bearing replacer, in the front of the rear of the block. Place the centralizer, in the
the front bearing liner as shown in "B", Figure 48. front of Number 1 bearing bore with the larger
Install the center screw, lock washer and tommy diameter spigot located in the bore. Locate the
bar as outlined above and pull out the front bearing new bearing liner on the smaller diameter spigot
liner from its location in the block. of the remover and guide and insert the smaller
diameter spigot of the intermediate bearing
4. Repeat this procedure for the rear bearing liner replacer, into the other side of the liner. Insert the
but operate the tool from the rear of the cylinder center screw and install the lock washer and
block. tommy bar as shown in "C" Figure 48.

INSTALLATION 2. Turn the liner until the center of the oil hole is
opposite to the center line of the oil drilling
Clean all bearing bores, making sure that the oil between the crankshaft bearing and camshaft
passages from the crankshaft main bearings to the bore. Draw the liner into the bore by tightening
camshaft bearings are free from obstruction. the wing nut onto the center screw of the tool.
Thoroughly clean the new bearing liners and lightly
coat with oil on the outer surface prior to assembly. It 3. Check that the oil hole in the liner is correctly
is essential that when assembled, the oil holes in the aligned with the oil passage in the cylinder block.
bearing liners coincide with those in the cylinder block. A positive check of this can only be made with
Particular attention should, therefore, be paid to the the crankshaft removed when a 3/16 in. (4.76 mm.)
positioning of the liner before it is drawn into the bore. diameter rod may be passed down the oil passage

A–37
 ENGINE SYSTEM

from the crankshaft main bearing. The liner is 2. On engines fitted with the "Partly Hollow
correctly positioned when the inner end of the Mushroom" type tappet, apply petroleum jelly to
rod will pass through the oil hole in the liner. each tappet foot. Coat the remainder of the tappet
with engine oil, and install the tappets in the bores
4. Bearing liner Number 3 installed in a similar from which they were removed.
manner, but should be pulled in with the tool being
operated from the rear of the block. 3. Oil the camshaft and apply petroleum jelly to all
the lobes. Carefully slide the camshaft into
5. Place a new liner on the replacer mandrel so that position in the bearings. On engines, with the
it contracts the small shoulder, and pass the partly hollow mushroom tappets these should first
mandrel through number 1 bore and number 2 be installed.
bearing liner. Place the intermediate bearing
replacer in the rear bore with larger diameter spigot 4. Install the spacer and new Woodruff key on the
in the bore. Install the center screw and lock front of the camshaft.
washer as shown in "D", Figure 48. Make sure
the main tool body is placed vertically for this 5. Position the thrust plate and install the two bolts
operation so that the center screw is kept central and lock washers. Tighten the bolts to the
by the body locating on the spigot of the mandrel. specified torque.

6. After making sure the oil holes in the liner are 6. Position the drive gear on the front of the camshaft,
opposite to the center of the holes in the core, making sure the timing mark is lined up and
press the liner into the bore by turning the wing secure with the washer and bolts. Tighten the
nut onto the center screw. bolts to the specified torque, and check the
camshaft end play.
7. Repeat this operation for the bearing liner by
operating the tool from the rear of the block. 7. Install the hydraulic pump drive gear cover plate.
Tap the cover with a soft hammer to be sure it is
8. Check the alignment of the oil holes in the liners seated. If the cover does not fit tight, install a
with the corresponding oil passages in the block new one.
by passing a length of 3/16 in. (4.76 mm.) rod
through each oil passage, making sure that the 8. Install the oil pan sump as outlined under "Oil
position of each liner is such as to allow the inner Pan Sump Installation".
end of the rod to pass through the oil hole in the
liner. 9. Install the oil pump drive gear. Be sure the drive
shaft indexes with the intermediate shaft install
D. INSTALLATION the hourmeter drive shaft adaptor.

1. Fit the hydraulic pump gear to the rear of the 10. Install the engine rear cover plate.
camshaft. Align the dowel pin and install the
washer and bolt. Tighten the bolt to the specified 11. Install the engine front cover, as outlined under
torque. "Front Cover Installation".

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 ENGINE SYSTEM

9. TROUBLE SHOOTING
IMPORTANT: When ever effecting a repair the cause of the problem must be investigated and corrected to
avoid repeat failures. The following table lists problems and their possible causes with
recommended remedial action.

PROBLEM POSSIBLE CAUSES REMEDY

Engine does not develop 1. Clogged air cleaner. 1. Clean or renew element.
full power 2. Fuel line obstructed. 2. Clean the fuel lines.
3. Faulty injectors. 3. Clean and reset the injectors.
4. Incorrect Fuel injection pump 4. Correct FIP timing.
timing.
5. Incorrect valve lash adjustment. 5. Check and reset.
6. Burnt, worn or sticking valves. 6. Replace valves with correct stem
size.
7. Blown cylinder head gasket. 7. Check head flatness and fit new
gasket.
8. Incorrect fuel delivery. 8. Check injectors and F.I.Pump.
9. Low cylinder compression. 9. Replace piston rings or rebore/re-
sleeve as necessary.

Engine Knocks 1. Diluted or thin engine oil. 1. Drain and refill with specified oil and
replace engine oil. Ascertain cause
of dilution.
2. Insufficient oil supply. 2. Check engine oil level and top up
as necessary. Overhaul or replace
lub. oil pump as necessary. Check
lub. oil filter not clogged.
3. Low engine oil pressure. 3. Overhaul engine oil 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 fit new ring gear.
excessive.
6. Excessive connecting rod or main 6. Install new bearing liners and/or re-
bearing clearance. grind crankshaft.
7. Bent or twisted connecting rods. 7. Replace connecting rods.
8. Crankshaft journals our-of-round. 8. Re-grind crankshaft and fit
undersize bearing liners.
9. Excessive piston-to-cylinder bore 9. Re-bore/re-sleeve block and fit new
clearance. pistons as necessary.
10. Excessive piston ring clearance. 10. Fit new pistons and rings as
necessary.
11. Broken rings. 11. Fit new rings. Check bore/pistons
for damage.
12. Excessive piston pin clearance. 12. Fit new piston pin and bush.

A–39
 ENGINE SYSTEM

PROBLEM POSSIBLE CAUSES REMEDY

Engine knocks (Contd.) 13. Piston pin retainer loose or 13. Install new retainer. Check bore
missing. pistons for damage.
14. Excessive camshaft end play. 14. Install new thrust plate.
15. Imperfections on timing gear teeth. 15. Install new timing gears.
16. Excessive timing gear backlash. 16. Replace new timing gears.

Low Engine Oil Pressure 1. Engine oil level low. 1. Top up, as necessary.
2. Wrong grade of oil. 2. Drain and refill with correct grade
of oil.
3. Blocked engine oil pump sump 3. Clean pump screen.
screen.
4. Engine oil pump pressure relief 4. Fit new relief valve.
valve faulty.
5. Engine oil pump drive shaft worn. 5. Replace drive shaft.
6. Excessive oil pump rotor and shaft 6. Overhaul engine oil pump and
assembly clearance. replace parts as necessary.
7. Excessive main or connecting rod 7. Install new bearing liners and/or re-
bearing clearances. grind crankshaft.

Excessive Engine Oil 1. Engine oil level too high. 1. Reduce oil level.
Consumption 2. External oil leaks from engine. 2. Renew gaskets/seals, where
necessary. Check mating surfaces
for damage or distortion.
3. Worn valves, valve guides or seals. 3. Replace valves as necessary.
Replace seals and ream the guide
to suit next over size valve stem.
4. Head gasket not sealing. 4. Renew gasket. Check head for
damage or distortion.
5. Oil loss past the pistons and rings. 5. Renew rings and/or re-bore/re-
sleeve the block as necessary.
6. Excessive wear on cylinder bore. 6. Re-bore the engine block to next
oversize or re-sleeve.
7. Check hydraulic pump for engine 7. Replace seal or hydraulic pump as
oil, passing through hydraulic necessary.
pump seal to centre housing.

Engine Overheats 1. Hose connection leaking or 1. Tighten hose connection. Replace

collapsed. hose if damaged.
2. Radiator leakage. 2. Replace radiator cap.
3. Radiator leakage. 3. Repair/Replace radiator.
4. Improper fan belt adjustment. 4. Re-adjust fan belt.
5. Radiator fins restricted. 5. Clean with compressed air.

A–40
 ENGINE SYSTEM

PROBLEM POSSIBLE CAUSES REMEDY

Engine Overheats (Contd.) 6. Faulty thermostat. 6. Renew thermostat.
7. Internal engine leakage. 7. Check for source of leakage.
8. Water pump faulty. Renew gasket or defective parts.
8. Overhaul water pump.
9. Exhaust gas leakage into cooling 9. Renew cylinder head gasket.
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 improperly 11. Renew cylinder head gasket.
installed.
12. Hot spot due to rust and scale or 12. Reverse flush entire cooling
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. Temperature gauge faulty. 15. Replace gauge.
16. Radiator core tube blocked. 16. Clean & check free flow.

Excessive exhaust smoke 1. Exhaust leak on exhaust manifold 1. Fit new gasket.
side.
2. Air cleaner dirty or restricted. 2. Clean.
3. Excessive fuel delivery. 3. Overhaul injection pump, injectors.

Engine tends to keep firing

1. Air cleaner dirty or restricted. 1. Clean or renew element.
after fuel is shut off

Oil pressure gauge fails to 1. Pressure gauge faulty. 1. Renew pressure gauge.
register pressure 2. Pressure pipe clogged. 2. Clean or renew the oil pressure
pipe.

Oil pressure warning light 1. Bulb burn out. 1. Renew bulb.

fails to operate (where 2. Warning light Pressure switch 2. Renew Pressure Switch.
fitted) faulty.
3. Warning light circuits faulty. 3. Check and renew wiring.

Water temperature gauge 1. Faulty temperature gauge. 1. Renew temperature gauge.

fails to reach normal 2. Incorrect or faulty thermostat. 2. Renew thermostat.
operating temperature

A–41
 ENGINE SYSTEM

10. SPECIFICATIONS

DESCRIPTION FARMTRAC-60
ENGINE
Type 3 cylinder, 4 stroke, direct injection, diesel engine water cooled
Rated power 50 HP at 2000 E.R.P.M (B.S.AU 141a)
No. of cylinders 3
Displacement 192 cu.in. (3147 cc)
Compression Ratio 16:3:1
Stroke 4.2 in. (106.68 mm.)
Bore 4.4 in. (111.76 mm.)
Bore/Stroke Ratio 1:0.95
Firing Order 1-2-3-
Rated Engine Speed (rpm) 2000
Idle speed 600-700 rpm
Maximum No. Load Speed (rpm) 2300-2350 rpm
Compression Pressure (at 200 340 ± 50 P.S.I (Cylinder to Cylinder variation)
E.R.P.M) Cranking Speed (With the
throttle closed and stop control out)
Cylinder Block
Material Cast Iron
Cylinder Arrangement In line vertical
Taper of Cylinder Bore (repair limit) 0.001 in. (0.02 mm.)
Taper of Cylinder Bore (Wear limit) 0.005 in. (0.13 mm.)
Cylinder Bore out of Round (Repair limit) 0.0015 in. (0.04 mm.)
Cylinder Bore Out of Round (Wear limit) 0.005 in. (0.13 mm.)
Cylinder Bore Diameter 4.4007-4.4032 in. (111.78 - 111.84 mm.)
Rear Oil Seal Bore Diameter 5.542 - 5.546 in. (140.77 - 140.87 mm.)
Engine Block to Head surface Flatness 0.003 in. (0.08 mm.) in any 6 in. (152.40 mm.) or 0.006 in. (0.15
mm.) overall limit
Gasket surface finish 90 - 150 R.M.S micro inches

A–42
 ENGINE SYSTEM

DESCRIPTION FARMTRAC-60
CYLINDER HEAD
Material Cast Iron Alloy
Valve design Overhead valves
Valve Guide Bore Diameter 0.3728 - 0.3735 in. (9.47 - 9.49 mm.)
Head to Block surface Flatness 0.003 in. (0.08 mm.) in an 6 in. (152 mm.) or 0.006 in. (0.15 mm.)
overall limit.
Gasket Surface Finish 90 - 150 R.M.S micro inches

VALVE SPRING
Number per valve 1
Type Cylinder Coil
Free Length 2.15 in. (54.6 mm.)
Load at 1.74 in. length (44.20 mm.) 61 - 69 lbf. (27.7 - 31.3 kg.)
Load at 1.32 in. length (33.53 mm.) 125 - 139 lbf. (57.8 - 63.1 kg.)

EXHAUST VALVE
Face Angle 45° 30' - 45° 45' (Relative to Head of Valve)
Stem Diameter Standard: 0.3701-0.3708 in.(9.40-9.41 mm.)
0.003 in (0.08 mm.) Oversize: 0.3731-0.3738 in.(9.40-9.50 mm.)
0.015 in. (0.38 mm.) Oversize: 0.3851-0.3858 in.(9.78-9.80 mm.)
0.030 in. (0.76 mm.) Oversize: 0.4001-0.4008 in.(10.16-10.18 mm.)
Head Diameter 1.495-1.505 in. (37.97-38.23 mm.)
Stem to Guide Clearance 0.0020-0.0037 in. (0.05-0.09 mm.)
Valve Lash/Tappet Clearance (Cold) 0.017-0.021 in. (0.43-0.53 mm.)

INTAKE VALVE
Face Angle 45° 30' to 45° 45' (Relative to Head of Valve)
Stem Diameter Standard: 0.3711-0.3718 in.(9.43-9.44 mm.)
0.003 in (0.076 mm.) Oversize: 0.3741-0.3748 in.(9.50-9.52 mm.)
0.015 in. (0.38 mm.) Oversize: 0.3861-0.3868 in.(9.80-9.82 mm.)
0.030 in. (0.76 mm.) Oversize: 0.4011-0.4018 in.(10.19-10.21 mm.)
Head Diameter 1.800-1.810 in. (45.72-45.97 mm.)
Stem-to-Guide Clearance 0.001-0.0027 in. (0.03-0.0+7 mm.)
Valve Lash/Tappet Clearance (Cold) 0.014-0.018 in. (0.36-0.46 mm.)

A–43
 ENGINE SYSTEM

DESCRIPTION FARMTRAC-60
VALVE TIMING
Intake Opening 14° B.T.D.C.
Intake Closing 38° A.B.D.C.
Exhaust Opening 41° B.B.D.C.
Exhaust Closing 11° A.T.D.C.

VALVE SEAT INSERTS

Insert Oversize Intake Valve Seat Insert
Counter Bore Diameter in Cylinder Head
0.010 in. (0.254 mm.) 1.907-1.908 in.
(43.44-43.46 mm.)
0.02 in. (0.508 mm.) 1.917-1.918 in.
43.69-43.72 mm.)
0.030 in. (0.762 mm.) 1.927-1.928 in.
(43.95-43.97 mm.)
VALVE SEATS
Exhaust/Inlet Seats Angle 45° to 46°
Seat Run out 0.0015 in. (0.04 mm.) T.I.R MAX.
Seat Width
Intake 0.080-0.102 in. (2.03-2.59 mm.)
Exhaust 0.084-0.106 in. (2.13-2.69 mm.)

IDLE GEAR
Number of teeth 47
Timing Mark Punch Mark, Three Places
End Play 0.001-0.011 in. (0.03-0.28 mm.)
Bushing Inside Diameter 2.005-2.0015 in. (50.81-50.83 mm.)
Adaptor Outside Diameter 1,9985-1.9990 in. (50.76-50.78 mm.)
Backlash with Crankshaft Gear 0.001-0.009 in. (0.03-0.23 mm.)
Backlash with camshaft Gear 0.001-0.009 in. (0.03-0.23 mm.)
Backlash with Fuel Injection
Pump Drive Gear 0.001-0.012 in. (0.03-0.30 mm.)

CAMSHAFT GEAR
Number of Teeth 52
Timing Mark Punch Mark on Tooth Space

ROCKER ARM SHAFT

Shaft Diameter 1.000-1.001 in. (25.40-25.43 mm.)
Support Diameter (I.D) 1.002-1.004 in. (25.45-25.50 mm.)

ROCKER ARM
Inside Diameter 1.003-1.004 in. (25.48-25.50 mm.)

A–44
 ENGINE SYSTEM

DESCRIPTION FARMTRAC-60
TAPPETS
Type Barrel (shallow push rod socket) or partly hollow mushroom foot
(deep push rod socket)
Clearance to Bore 0.0006-0.0021 in. (0.02-0.05 mm.)
Tappet Diameter 0.9889-0.9894 in. (25.12-25.13 mm.)
Tappet Bore Diameter 0.990-0.991 in. (25.15-25.17 mm.)

CRANKSHAFT DRIVE GEAR

Number of teeth 26
Timing Mark Punch Mark on Tooth

CRANKSHAFT
Main Journal Diameter 3.3718-3.3723 in. (85.64-85.66 mm.) Red
Main Journal Length 3.3713-3.3718 in. (85.63-85.64 mm.) Blue
Main Journal Wear Limits 1.455-1.465 in. (36.96-37.21 mm.)
Main and Crank Pin Fillet Radius 0.005 in. (0.127 mm.) Maximum
Thrust Bearing Journal Length. 0.12-0.14 in. (3.05-3.57 mm.)
Intermediate Bearing Journal Length. 1.459-1.461 in. (37.06-37.11 mm.)
Rear Bearing Journal Length 1.455-1.465 in. (36.96-37.21 mm.)
Crank Pin Journal Length 1.495-1.515 in. (37.97-38.48 mm.)]
Crank Pin Diameter 1.678-1.682 in. (42.62-42.72 mm.)
End Play 2.7496-2.7500 in. (69.84-69.85 mm.) Blue
Crank Pin Out of Round 2.7500-2.7504 in. (69.85-69.86 mm.) Red
Taper-surface Parallel to center line of 0.004-0.008 in. (0.10-0.20 mm.)
Main Journal. 0.0002 in. (0.005 mm.) T.I.R
Crankshaft Rear Oil seal Journal 0.0002 in. (0.005 mm.)
Diameter. 4.808-4.814 in. (122.12-123.28 mm.)
Crankshaft Pulley Journal Diameter. 1.750-1.751 in. (44.45-44.48 mm.)
Crankshaft Timing Gear Journal Diameter 1.820-1.821 in. (46.23-46.25 mm.)
Crankshaft Flange Run Out. 0.0015 in. (0.04 mm.) max.

MAIN BEARINGS
Number 4
Thrust taken by 2nd Main
Liner Length 1.10-1.11 in. (27.94-28.19 mm.)
(except thrust liner)
Liner Length (Thrust Liner) 1.453-1.455 in. (36.91-36.96 mm.)

A–45
 ENGINE SYSTEM

DESCRIPTION FARMTRAC-60
LINER IDENTIFICATION

Colour Code Material Wall Thickness Specified Clearance

Red Copper Lead 0.1245-0.1250 in. 0.0022-0.0045 in.
(3.16-3.18 mm.) (0.06-0.11 mm.)

Blue Copper Lead 0.1249-0.1254 in. 0.0022-0.0045 in.

(3.17-3.18 mm.) (0.06-0.11 mm.)

Red Aluminium Tin Alloy 0.1245-0.1250 in. 0.0022-0.0045 in.

(3.16-3.18 mm.) (0.06-0.11 mm.)

Blue Aluminium Tin Alloy 0.1249-0.1254 in. 0.0022-0.0045 in.

(3.17-3.18 mm.) (0.06-0.11 mm.)

CRANK PIN BEARINGS

Number 3
Liner Length 1.40-1.41 in. (35.56-35.81 mm.)

LINER IDENTIFICATION

Colour Code Material Wall Thickness Specified Clearance

Red Copper Lead 0.0943-0.0948 in. 0.0017-0.0038 in.
(2.39-2.41 mm.) (0.04-0.10 mm.)

Blue Copper Lead 0.0947-0.0952 in. 0.0017-0.0038 in.

(2.41-2.42 mm.) (0.04-0.10 mm.)

Red Aluminium Tin Alloy 0.0941-0.0946 in. 0.0021-0.0042 in.

(2.39-2.40 mm.) (0.05-0.11 mm.)

Blue Aluminium Tin Alloy 0.0945-0.0950 in. 0.0021-0.0042 in.

(2.40-2.41 mm.) (0.05-0.11 mm.)

A–46
 ENGINE SYSTEM

DESCRIPTION FARMTRAC-60

CRANKSHAFT RE-GRINDING FARMTRAC-60

When regriding a crankshaft, the main and crank pin journal diameter should be reduced the same amount as
the undersize bearings used. The following dimensions apply. The rear end of the crankshaft should be located
in the 60° chamfer of the pilot bearing bore.

Undersize Bearings available Main Journal Diameters

0.010 in. (0.25 mm.) 3.3618-3.3623 in. (85.39-85.40 mm.)
0.020 in. (0.51 mm.) 3.3518-3.3523 in. (85.14-85.15 mm.)
0.030 in. (0.76 mm.) 3.3418-3.3423 in. (84.88-84.89 mm.)
0.040 in. (1.01 mm.) 3.3318-3.3323 in. (84.62-84.64 mm.)

Undersize Bearings Available for Crank Pin Journal Diameters

Crank Pin Journals

0.010 in. (0.25 mm.) 2.7400-2.7404 in. (69.60-69.61 mm.)

0.020 in. (0.51 mm.) 2.7300-2.7304 in. (69.34-69.35 mm.)
0.030 in. (0.76 mm.) 2.7200-2.7104 in. (69.09-69.10 mm.)
0.040 in. (1.01 mm.) 2.7100-2.7104 in. (68.83-68.84 mm.)

A–47
 ENGINE SYSTEM

DESCRIPTION FARMTRAC-60
CAMSHAFT
Number of Journals 4
Bearing Journal Diameter 2.3895-2.3905 in. (60.69-60.72 mm.)
Bearing Clearance 0.001-0.003 in. (0.03-0.08 mm.)
End Play 0.001-0.007 in. (0.03-0.18 mm.)
Thrust Taken By Thrust Plate-front
CONNECTING RODS
Small End Bushing (I.D) 1.5003-1.5006 in. (38.11-38.12 mm.)
Clearance Bushing-to-Piston Pin 0.0005-0.0007 in. (0.01-0.02 mm.)
Side Float 0.007-0.013 in. (0.18-0.33 mm.)
Maximum Twist 0.012 in. (0.30 mm.)
Maximum Bend 0.004 in. (0.10 mm.)
PISTON PIN
Out Side Diameter 1.4997-1.5000 in. (38.09-38.10 mm.)
FARMTRAC-60
PISTONS
Skirt-to-cylinder Clearance 0.008-0.009 in. (0.20-0.23 mm.)
Taper (Out-of-round) 0.0025-0.0050 in. (0.06-0.13 mm.)
Grading Diameter (at Right Angles to 4.3922-4.3947 in. (111.56-111.62 mm.) in Increments of 0.0005 in.
Piston Pin) (0.013 mm.)
Piston Pin Clearance 0.0003-0.0005 in. (0.0076-0.0127 mm.) at 70°F (21°C)
Piston Crown to Block Face (Protrusion) 0.011-0.023 in. (0.28-0.58 mm.) above

TOP COMPRESSION RINGH (1ST RING)

Quantity and Location One-top
Type Chrome Finished, Nodular Iron, Honed Chamfers
Gap Width (Butt Clearance) 0.013-0.023 in. (0.33-0.58 mm.)
Side Clearance (Land Clearance) 0.0044-0.0061 in. (0.11-0.16 mm.)

2ND RING COMPRESSION RINGH

Quantity and Location One intermediate
Type Compression cum oil control Ring 2° degrees face angle, inside 30°
degrees chamfer facing down.
Gap Width (Butt Clearance) 0.014-0.026 in. (0.35-0.65 mm.)
Side Clearance (Land Clearance) 0.0039-0.0056 in. (0.01-0.14 mm.)

3RD RING COMPRESSION RINGH

Quantity and Location One directly above piston pin
Type Chrome Finish, Slotted with Coil Expander (Conformable)
Gap Width (Butt Clearance) 0.014-0.026 in. (0.35-0.65 mm.)
Side Clearance (Land Clearance) 0.0039-0.0056 in. (0.01-0.14 mm.)

A–48
 ENGINE SYSTEM

DESCRIPTION FARMTRAC-60
FLY WHEEL
No. of Gear Teeth 128
Run out of Clutch Face (between outer 0.0055 in. (0.14 mm.)
edge of friction surface and mounting bolt
holes)
Ring Gear run out 0.025 in. (0.65 mm.)

LUBRICATION SYSTEM
Main Bearing Pressure
Connecting Rod Large Bearings Pressure
Piston Pin Bushing Splash
Cylinder Walls Splash
Camshaft Bearings Pressure
Timing Drive Squirt
Tappets Pressure
Push Rods Drip From Rocker Arms
Rocker Arms Pressure (Intermittent Flow)

ENGINE OIL GRADE SAE 20W 40 or 15W 40; MIL-L-2104 D; API-CD/SF

ENGINE OIL CAPACITY 6.45 Ltrs. with Filter

OIL PUMP
Rotor Clearance 0.001-0.006 in. (0.03-0.15 mm.)
Rotor-to-Pump Housing Clearance 0.006-0.011 in. (0.15-0.28 mm.)
Rotor End Play 0.001-0.0035 in. (0.03-0.09 mm.)
Relief Valve Pressure 60-70 p.s.i (4.2-4.9 Kg.sq.cm.) at 2000 rev/min.
Relief Valve Spring Tension 1.07 in. (27.2 mm.) under 10.7-11.9 lbf load
(4.85-5.4 Kg. load)

A–49
 ENGINE SYSTEM

TORQUE SPECIFICATIONS UNITS FARMTRAC-60

Cylinder Head Bolts in 3 stages lbf.ft 160
(115-140-160) (kgfm) (23)

Main Bearing Bolts lbf.ft 140-150

(kgfm) (19.9-21.3)

Connecting Rod Nuts lbf.ft 77-80

(kgfm) (10.7-11)

Intake Manifold to Cylinder Head lbf.ft 23-28

(kgfm) (3.18-3.87)

Exhaust Manifold to Cylinder Head lbf.ft 25-30

(kgfm) (3.46-4.14)

Flywheel to Crankshaft lbf.ft 160

(kgfm) (23)

Oil Pan Drain Plug lbf.ft 25-35

(kgfm) (3.46-4.84)

Valve Rocker Cover Bolts lbf.ft 10-15

(kgfm) (1.38-2.07)

Crankshaft Pulley to Crankshaft lbf.ft 200-220

(kgfm) (28-31)

Self Locking Screw-valve Rocker Arm lbf.ft 9-26

(kgfm) (1.24-3.59)

Oil Pump to Block lbf.ft 33-38

(kgfm) (4.6-5.3)

Water Pump to Cylinder Block lbf.ft 23-28

(kgfm) (3.18-3.87)

Oil Pan to Cylinder Block lbf.ft 25-30

(kgfm) (3.5-4.2)

Camshaft Drive Gear to Block (Idler Gear) lbf.ft 150-205

(kgfm) (21-28.5)

Front Adaptor Plate to Cylinder Block lbf.ft 15-21

(kgfm) (2.1-3)

Front Cover to Front Adaptor Plate lbf.ft 30-40

(kgfm) (4.2-5.6)

Camshaft Gear Bolts lbf.ft 43-58

(kgfm) (6-8)

Starter Motor to Rear Adaptor Plate lbf.ft 30-35

(kgfm) (4.2-4.84)

A–50
 SECTION - 'B'

COOLING SYSTEM
S.NO. CONTENTS PAGE

1. DESCRIPTION AND OPERATION B-3

2. RADIATOR AND THERMOSTAT B-4

3. WATER PUMP OVERHAUL B-5

4. SPECIFICATIONS B-8
COOLING SYSTEM

B–2
 COOLING SYSTEM

COOLING SYSTEM

1. DESCRIPTION AND OPERATION

The cooling system Figure 1, is of the recirculating

by-pass type with full length water jackets for each
cylinder. As the coolant enters the block it travels
through cored passages to cool the cylinder walls.
Upon reaching the rear of the cylinder block, the
coolant flows into the cylinder head. It then flows
through cored passages to the nozzle tip area. This
flow within the cylinder head water jacket provides
sufficient cooling at maximum temperature cooling
points. The coolant continues to flow through the
cylinder head to the thermostat. The thermostat is
located in the front of the head.

Figure 1
If the thermostat is closed, a recirculating by pass is
Cooling System
provided, allowing a portion of the coolant to recirculate
from the head to the block for faster warm-up.
CLEANING THE COOLING SYSTEM
When the thermostat is open, the coolant flows from
the outlet connection of the head or manifold to the Normally, rust, sludge and other foreign material can
top tank of the radiator. Cooling is accomplished as readily be removed from the cooling system by using
the coolant flows down through the radiator tubes which a cooling system cleaning solvent. However, in severe
are exposed to the cooler air temperatures created by cases, pressure flushing may be required. Various
the fan blast. types of flushing equipment are available. A pulsating
or reversed-flow flushing will loosen sediment more
MAINTENANCE quickly and efficiently than a steady flushing in the
normal direction of coolant flow. If pressure flushing is

B–3
 COOLING SYSTEM

to be used, always remove the thermostat and make B. INSPECTION AND REPAIR
sure the cylinder head bolts ae tightened properly
before flushing. After the cooling system has been 1. Remove the fan shroud.
cleaned and filled, a good commercial rust inhibitor
2. Check the upper tank for leaks.
should be added. However, the rust inhibitor is not
necessary if the cooling system is to be conditioned
3. Check the fins for being bent or clogged.
with permanent antifreeze containing rust inhibitor.
4. Check the lower tank for leaks.
DRAINING AND FILLING COOLING SYSTEM
NOTE: Any repairs on the radiator should be
To drain the cooling system, open the drain plug on performed by a qualified radiator repairer.
the right-hand side of the engine block and the radiator
out let on the lower lef-hand side of the radiator. Open C. INSTALLATION
the radiator pressure cap to speedly drain. To fill the
system, close the drain plug and the radiator outlet, 1. To install the radiator, reverse the procedure
fill the system with coolant and add rust inhibitor or outlined above, "Removal".
antifreeze, according to the season and locality. All
2. Fill the cooling system with coolant and add the
permanent antifreeze sold by reputable manufactures
proper amount of antifreeze, depending upon the
contain an anti-rust additive. Therefore the addition of
weather conditions (where applicable).
rust inhibitor, when permanent antifreeze is used, will
not generally be necessary. 3. Run the engine for several minutes and check
for radiator leaks.
2. RADIATOR
THERMOSTAT
RADIATOR
The thermostat is located in the coolant outlet
A. REMOVAL connection in the front of the cylinder head. Figure 2.
Thermostat opening and full open temperatures are
1. Drain the cooling system as previously out lined. listed in the specifications.

2. Disconnect the air cleaner hose connection, the

headlight and horn wires, and remove the front
sheet metal.

3. Disconnect the radiator hose connection at the

radiator and slide the clamps toward the middle
of the hose.

4. Remove the radiator shell attaching bolts and

remove the shell having removed the air cleaner
previously.

5. Remove the attaching bolts and remove the

radiator.
Figure 2
Location of Thermostat

B–4
 COOLING SYSTEM

A. REMOVAL

1. Drain the cooling system to 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.

B. INSPECTION

Place the thermostat in a container of water and heat

the water. If the thermostat valve does not open at or
near the thermostat opening temperature or if it fails
to close, install a new thermostat. Figure 3
Water Pump Pulley Removal
C. INSTALLATION 1. Pulley 2. Puller Tool EF-0300
2. Sleeve 4. Pump Covers
1. Clean the coolant outlet connection and cylinder
head surface. Coat the new coolant outlet 2. Remove the radiator as outlined under "Radiator
connection gasket with sealer. Position the Removal".
gasket on the cylinder head.
3. Loosen the generator adjusting bolt and two
NOTE: The gasket must be positioned on the cylinder generator pivot bolts and relax the tension on
head before the thermostat is installed. the belt.

2. Coat the edge of the thermostat with grease so If alternator wherever is fitted, remove the guard,
it will stick in the water outlet connection. slacken the mounting bolts and relax the tension
on the belt.
3. Position the thermostat in the recess of the water
outlet connection so that the heat element will 4. Remove the four water pump attaching bolts and
remove the water pump and gasket.
be in the cylinder head.

B. DISASSEMBLY
4. Position the water outlet connection and install
the retaining bolts. Be careful not to disturb the
1. Remove the four attaching bolts and remove the
thermostat. fan from the pump.

5. Fill the radiator and operate the engine. Check 2. Using Puller No. EF-0300 and a sleeve
for coolant leaks. slightly smaller than the pulley shaft, remove the
pump pulley from the shaft. Figure 3.
3. WATER PUMP OVERHAUL
3. Remove the four bolts that retain the front and
A. REMOVAL
rear covers of the pump housing together.
Seperate the pump covers and discard the
1. Drain the cooling system.
gasket.

B–5
 COOLING SYSTEM

Figure 4 Figure 5
Water Pump Bearing Shaft and Slinger Water Pump Disassembled
Assembly Removal
1. Sleeve 2. Front Cover
3. Support 4. Press

4. Using an arbor press with a piece of pipe or a 3. Check both parts of the pump housing for cracks,
sleeve of 1 in. (25.4 mm.) I.D. and 1 1/8 in. (28.6 fractures, or signs of leakage.
mm.) O.D. over the shaft and positioned on the
outer case of the bearing, press the bearing
4. If there are any defective parts, install new ones.
assembly, shaft and impeller out of the pump
housing. Figure 4.

5. Support the flat side of the impeller between two

D. ASSEMBLY
blocks and press the shaft assembly by using a
sleeve slightly smaller than the shaft.
1. Figure 5 is an exploded view of the water pump.
Use it for reference during reassembly.
6. Remove the seal from the shaft. Discard the seal.

2. Using a piece of 15/16 in. (24 mm.) I.D. gas pipe

C. INSPECTION AND REPAIR
and adaptor, press a new seal into the pump
housing by applying sealant.
1. Check the impeller for worn or damaged vanes
and check the seal seat on the rear face of the
3. Press the bearing shaft and slinger assembly
impeller to be sure it is in good condition. Install
into the housing using a sleeve which passes
a new impeller if the seat or vanes are damaged.
over the shaft and rests on the bearing. Press
the bearing to flush with the face of the housing.
2. Check the individual parts of the bearing shaft Use a straight edge to check the final position.
and assembly for nicks, scores, or other damage. Check the edge of the bearing (not the seal).

B–6
 COOLING SYSTEM

Figure 6 Figure 7
Water Pump Impeller Installation Water Pump Pulley Installation
1. Impeller 2. Front Cover A. 2.48 in. (63 mm)
2. Bearing Shaft 4. Press 1. Sleeve 2. Front Cover
2. Pulley 4. Press

4. Support the shaft on a block of wood so as not 7. Install the fan on the pulley. Tighten the bolts to
to damage its end. Using the arbor press, ¾ in. the specified torque.
(19.050 mm.) I.D. gas pipe and Step Plate, press
the impeller onto the shaft, Figure 6, until it is E. INSTALLATION
flush with the rear face of the housing. Check
with a straight edge across the housing and 1. Position a new water pump gasket and place
impeller vanes to ensure correct final position. the water pump onto the front of the cylinder block
and install the four attaching bolts. Tighten the
bolts to the specified torque.
5. Support the shaft on a block of wood and press
the pulley onto the shaft, to the dimension shown
2. Position the drive belt. Tighten the adjusting arm
in Figure 7 is from the rear face of the front cover
bolt and the two generator pivot bolts. For
to the centre of the Pulley V-groove. After
alternator (where fitted) tighten the mounting bolts
installation, be sure the pulley runs true on the
and fix the guard, and adjust tension on the belt.
shaft.

3. Install the radiator.

6. Assemble the front and rear halves of the pump
together using a new gasket. Tighten the bolts 4. Fill the cooling system. Run the engine and check
to the specified torque. for leaks.

B–7
 COOLING SYSTEM

4. SPECIFICATIONS

DESCRIPTION FARMTRAC-60

CAPACITY: 13.5 Ltrs.

Radiator Cap Pressure 13 p.s.i

Fan Belt Deflection ½ in. (12.70 mm.) Maximum

THERMOSTAT
Opening Temperature 71-76° C

Full Open 85-88°C

WATER PUMP
Type Centrifugal

Drive 'V' Belt

Belt Size B54 for Dynamo

B56 for alternator

Fan (Dia.) 311 mm. (12.24 in.)

No. of Blades 6 No. Blades
Seal Height 0.475-0.481 in.
(12.06 - 12.21 mm.)

Impeller level below the rear face of the 0.015 in.

housing (0.38 mm.)
Pully Groove from rear face of the 2.486 - 2.460 in.
housing (63.0 - 62.50 mm.)

TORQUE SPECIFICATIONS UNITS FARMTRAC-60

Water Pump to Cylinder Block lbf.ft 23-28

(kgf.m) 3.18-3.87

Water Pump Cover to Pump lbf.ft 45-50

(kgf.m) 6.3-6-9

B–8
 SECTION - 'C'

FUEL SYSTEM
S.NO. CONTENTS PAGE

1. OIL BATH AIR CLEANER C-3

2. DRY TYPE AIR CLEANER C-4

3. THERMOSTAT C-5

4. FUEL TANK C-5

5. FUEL COCK C-5

6. PRE-FILTER C-5

7. DUAL FUEL FILTERS C-5

8. FUEL INJECTION PUMP, DELIVERY VALVE & GOVERNOR C-7

9. CALIBRATION & TESTING OF FIP - FT-60 C-9

10. F.I.P. - RE-TIMING C - 10

11. DELIVERY VALVE C - 11

12. FUEL FEED PUMP C - 11

13. GOVERNOR C - 12

14. FUEL INJECTION NOZZLES C - 18

15. F.I.P. CALIBRATION CHARTS FT-60 C - 20

16. FOOT ACCELERATOR C - 21

17. TROUBLE SHOOTING C - 22

FUEL SYSTEM

C–2
 FUEL SYSTEM

FUEL SYSTEM

The fuel system consists of the following assemblies:

1. Air Cleaner
2. Fuel Tank
3. Fuel Cock
4. Pre-Filter
5. Dual Fuel Filter
6. Fuel Injection Pump
7. Fuel Injection Nozzles

In this system the fuel from fuel tank is sucked by the

fuel feed pump through pre-filter and delivered to the
dual fuel filter under pressure. After filter action, the
fuel is fed to the fuel gallery of the fuel injection pump.
A relief valve is mounted on the primary filter of the
dual fuel filter. It maintains the low pressure in the fuel
filter. It maintains the low pressure in the fuel filter and
the excessive fuel is fed back tothe fuel tank. Three
separate high pressure pipes, feed the fuel under high Figure 1
pressure to the injectors mounted on the cylinder head. Oil Bath Air Cleaner
A common leak off pipe fitted to the injectors, returns
the leak-off fuel to the fuel tank through overflow pipe deflected upward. Much of the dust and other foreign
connected in between fuel tank and dual fuel filter relief material in the air is caught in the sump at this point,
valve. due to the velocity and abrupt change in the direction
of air flow. The air passes upward through the filter,
1. OIL BATH AIR CLEANER carrying oil droplets with it. As the air passes through
the filter mesh, most of the remaining dirt adheres to
The air cleaner is located in front of the radiator and is the oil-wetted surfaces and drains back into the sump.
mounted on the radiator shroud. It is an oil bath, centre The air outlet is on the side, and the removable cap
tube inlet type. Air enters on top of the air cleaner fitted to the bottom permits convenient cleaning and
after passing through pre-cleaner and passes through servicing. (Figure 1), every 50 hours or daily under
a duct to the surface of the oil bath sump where it is extreme dust conditions.

C–3
 FUEL SYSTEM

The pre-cleaner is mounted on teh inlet tube above

the radiator hood panel assembly. It is for use under
severe dust conditions to protect the air cleaner by
reducing the dust load on it. Vanes fitted into the inlet
induce a rotary motion to the air stream as the air
enters the inlet at hight speed. Centrifugal force,
therefore, causes the heavier dust and other foreign
matter to be thrown into the space between the inner
and outer shells. The pre cleaned air then passes to
the oil bath air cleaner, as stated earlier.
2. DRY TYPE AIR CLEANER
DESCRIPTION AND OPERATION (WHERE FITTED)
Air enters the cleaner in a circular direction and
centrifugal actions results in heavier particles being
thrown to the outside of the container and collecting Figure 2
in the bottom of the air cleaner for ejection through an Dry Element Type Air Cleaner Installed
evacuator tube. The lighter particles are collected on 1. Air Cleaner Assembly
the primary element. 2. Inner Element
An inner (secondary) safety element is located within 3. Dust Collector
4. Outer Element
the outer element. The safety element protects the
5. Wing Nut
engine in the event of dust passing through a damaged
outer outer element.
1. Clean and examine the outer casing. Repair any
IMPORTANT: The safety element must be replaced damaged seams.
if damaged or chocked with dust.
2. Check the condition and security of the rubber
AIR CLEANER OVERHAUL dust collector.
NOTE: The dry air cleaner can be serviced without 3. If undamaged, the outer element should be
being removed from the tractor. cleaned with compressed air at 300 hour Service
REMOVAL and renewed at the 600 hour service.
1. Unscrew the air cleaner cover central retaining The outer element may be washed by agitating
knob. Remove the radiator grill. in luke warm water containing a little non subsing
2. Lift-off the pre-cleaner assembly. detergent. Allow the element to dry.
3. Loosen the outlet hose clamp. 4. When dry check the element for damage by
4. Remove the attaching bolts and withdraw the air inserting a lamp into the middle of the element
cleaner assembly. and observing the element surface. An even, fine
pattern of light indicates the element is clean,
DISASSEMBLY
undamaged and suitable for further service.
1. Remove the wingout and extract the outer
RE-ASSEMBLY
element.
Re-assembly of the dry type air cleaner is the
2. Remove the retaining locknut and washer and
disassembly procedure in reverse.
extract the inner element.
On re-assembly, ensure the outer element sealing ring
INSPECTION AND REPAIR
is secure.

C–4
 FUEL SYSTEM

5. FUEL COCK
The fuel cock is secured to the tank by means of union
nut. Screw type valve and seal assembly is provided
to have two positions. 'off' and 'on'. The fuel is allowed
to flow while the valve is screwed out and vice a versa.
A filter strainer is provided at its inlet side which always
remains inside the fuel tank and acts as a primary
filter of fuel feed pump's pre-filter.
Remove the fuel cock and blow with compressed air
in reverse flow direction to clean it. Replace it after
cleaning and checking for any leakage.
6. PRE-FILTER
The preliminary filter consists of filter housing, filtering
sleeve, housing cover, helical spring, clamp and nut.
It is provided to safeguard and arrest any dirty
contaminated fuel reaching feed pump and ultimately
Figure 3 the fuel injection equipment filtering system.
Intake Manifold Heater Plug Installed
The pre-filter shall be cleaned periodically after 50 hours
1. Heater Plug 2. Intake Manifold
or earlier as per the local conditions and shall be
3. Heater Plug Wire 4. Fuel Feed Tube
proceeded as under:
1. Close the fuel cock supply.
INSTALLATION
2. Loosen the nut on stud to the extent that the
Installation of the dry type air-cleaner is the removal
clamp can be removed.
procedure in reverse.
3. Hold the filter housing with hand and pull lightly
3. THERMOSTAT (WHERE FITTED)
downward.
To aid engine starting in cold weather conditions, a
4. Remove the filter sleeve and helical spring.
thermostart cold start device, incorporating an integral
reservoir system, is available as optional equipment. 5. Blow with compressed air the sleeve and the
housing after dipping in fuel or kerosene. Open
The thermostart cold start device comprises a plug
the fuel cock.
assembly screwed into the intake manifold and a fuel
line connected to the injector leak-off tube. Assemble in the reverse sequence and make sure
that the helical spring is replaced first and the
The plug assembly, Figure 3 consists of a check valve
filter sieve later. Hand tighten the bowl once it
and electrically heated element.
overflows with fuel.
Fuel is gravity fed to the plug assembly and when the
NOTE: The sealing ring should be replaced properly
key-start switch is turned to the heat position, the
between housing cover and housing. Check
element temperature rises to open the check valve
for any leakage between the cover and the
and allow fuel to pass into the intake manifold. As the
housing.
fuel passes the hot element, it is ignited prior to entering
the combustion chamber. 7. DUAL FUEL FILTERS
4. FUEL TANK To prevent harmful abrasive particles finding their way
into vital working parts of the injection pump and the
It is a pressed steel tank of 49 litres capacity and is
injectors and causing excessive wear, dual fuel filter
situated in-between the steering and the engine in such
assembly is incorporated in the fuel system.
a manner that it is not necessary to remove it while
effecting repairs or adjustments on the engine. It is A. DESCRIPTION
designed to ensure that there is a constant level of The dual fuel filter consists of two bowls each
fuel even when the tractor is tilted or when fuel level is containing a filter element. The felt-filter insert element
low. is used as the primary stage filter and the Micro (paper)

C–5
 FUEL SYSTEM

filter insert element is used as the final stage filter.

(The arrow on the filter cover indicates the direction of
flow.) Or sometimes paper filter element can also be
used for both the stages.
Fuel delivered under pressure (1.5 kg/cm2) by the fuel
feed pump, passes through the primary filter element
and flows to the secondary filter and the fuel coming
out of secondary filter is thus relieved of all abrasive Figure 6
particles before flowing into the injection pump for Loosening the Air Vent Screw
delivery to the cylinders through injectors.
c. Loosen the air vent screw (bleeding screw) Figure
B. MAINTENANCE OF MICO DUAL FILTERS
6.
The primary stage filter element should be changed
d. Disconnect the fuel inlet of the fuel injection pump
after 600 hours, and secondary stage filter element
and plug the pump inlet with clean plastic cap.
should be changed after 900 hours, or earlier as per
Loosen the centre bolt and remove the filter bowl
the local conditions and fuel contamination.
(primary or secondary filter - Figure 7).
The primary-filter insert element and secondary filter
insert element should not be cleaned as these are
throw away elements. After the recommended time
replace with genuine MICO filter inserts.
DO NOT REPLACE BOTH THE INSERTS AT A TIME
To change fuel filter element in Farmtrac Tractors
proceed as follows:-
a. Close the fuel tank shut off valve by turning it in a
clockwise direction. Figure 7
b. Clean the filter assembly with a clean piece of Unscrewing the centre bolt
lint free cloth. Figure 4 & 5. of primary fuel filter

e. Remove the filter element (Primary or secondary

filter) from the bowl and discard it. Clean the bowl
with clean fuel oil. Figure 8.

Figure 4

Figure 5 Figure 8
Cleaning the outside of the dual filter assembly Removing the filter element from bowl

C–6
 FUEL SYSTEM

tighten the bleed screw.

d. Push the primer plunger down and turn the cap
clockwise to secure it in the normal operating
position.
e. Wipe the fuel bowls and other areas dry.
f. Start the engine and check to ensure that there
are no fuel leaks.
Figure 9 8. FUEL INJECTION PUMP, DELIVERY
Cleaning the inside of the bowl VALVE AND THE GOVERNOR
FUEL INJECTION PUMP
f. Clean the filter bowl with cleaning medium (diesel
or petrol) Figrue 9. As it is known, the diesel engine which is a
compression ignition engine, utilises the high
g. Install a new element and gasket and reassemble
temperature of highly compressed air to ignite the
them in the reverse order of removal.
injected fuel charge.
h. Tighten the centre bolt to torque of 15 lbs.ft. (2
Therefore, the fuel must be injected at high pressure
kgm). Do notovertighten. Figure 10.
into the combustion chamber within a precisely defined
period of time.
General description and operation of fuel injection pump
fitted on Farmtrac-60 tractor is being given here under,
where as the calibration and testing of these has
individually been detailed on the following pages under
the respective headings.

Figure 10 A. DESCRIPTION
Tightening the centre bolt of the dual fuel filter The PES type pump manufactured by MICO is flange
mounted on the engine with three bolts and spring
Prime the system and bleed the filters. Tighten the
washers. It is single acting plunger type pump in which
bleeding screw. Continue to prime till you get clean
plunger stroke is constant but the effective working
fuel flowing from the connection pipe of the pump inlet
stroke is adjustable. The MICO design of the pump
which is already disconnected.
element consisting of plunger and barrel provides for
Connect the fuel inlet pipe of the pump. Bleed the fuel controlling the quantity of fuel delivered. A separate
injection pump. pump element is required for each engine cylinder.
Open the fuel shut off valve and bleed the system as Each pump element comprises essentially of a
discussed below: plunger and a barrel. The plunger is so accurately fitted
a. Loosen the banjo fitting on the fuel inlet pipe to into the barrel by lapping to a working clearance of
the injection pump. When fuel free of air bubbles about one ten thousandth of an inch. (0.0001 in.) that
flows out, tighten the banjo fitting. it will provide sealing even under very high pressure
and at low speeds, without special sealing rings.
b. The injection pump has a built in hand primer in
Because plunger and barrel are precision fitted by
the form of a plunger. The plunger is normally
lapping to each other, they must be replaced as
screwed down. To operate the primer, unscrew
complete elements only. Never replace a plunger or a
the primer cap. Loosen the bleed screw on the
barrel by itself. To make it possible for the pump to
primary filter and move the plunger up and down
vary the quantity of fuel delivered per stroke, the upper
until fuel free of air bubbles is discharged from part of the plunger is provided with a vertical bore
the bleed screw hole. Tighten the bleed screw. extending from its top face to an annular groove, which
c. Repeat the procedure of the secondary filter, then is milled in the form of a helix, also called control edge.

C–7
 FUEL SYSTEM

The pump plunger is actuated in the delivery stroke PE -

Pump with enclosed camshaft
by cam, in the suction stroke by plunger return spring. S -
Flange mounted
The barrel is closed at its top by a spring loaded valve, 3 -
No. of cylinders
the delivery valve. The delivery pipe connects the valve A -
'A' Size pump
with the respective injection nozzle of the engine. 90 -
Plunger diameter is 9.0 mm.
The control sleeve, fitted over the pump barrel, has D -
'C' or 'D' execution pump which means
two longitudinal steps in the lower end with which the design denotery letter.
vanes of the plunger engage. The upper end of the 410 - Assembly number
control sleeve is provided with a clamped-on toothed R - Right hand rotation
segment engaging the control rack. S2495 - Design number
By this arrangement the movement of the control rack Below this, some numerical numbers are punched
will rotate the plunger even while the engine is running, which is the serial number of the pump. The first three
so that a control of the quantity of fuel delivered by the digits denote the year and month of manufacturing.
pump is possible in an infinitely variable range, from The remaining is the production serial number of that
zero to maximum delivery. type of pump.
B. OPERATION NOTE: In Farmtrac-60, fuel injection pump MICO
The plunger operates, as described above, with a with 9 mm. diameter element is introduced
constant stroke. When the plunger is at the bottom of in place of 9.5 mm. diameter element from
its stroke, the space above the plunger, is filled with BSN 182194 for the smooth operation.
fuel which flows in from the pump gallery through the D. LUBRICATION OF FUEL PUMP
port of the barrel.
Oil chamber for the camshaft and tappets is combined.
As the plunger moves upward, it closes the barrel port A leak-off pipe is provided so as the extra oil filled
and the plunger will discharge the fuel trapped in the leaks out when the pump runs.
pressure chamber through the delivery valve into the
In a new pump or a pump received after repairs, it is
delivery pipe. Delivery of the fuel stops as soon as the
necessary to fill the pump cam shaft chamber with
control helix uncovers the port thus allowing fuel, to
good quality clean engine oil upto the recommended
flow out through the vertical bore and helix respectively,
level.
back into the pump gallery.
The camshaft chamber of the pump must be
When the plunger is rotated to a position where the
sufficiently filled with oil at all times. At each regular
vertical slot or the helical groove meets with the control
engine oil change, proceed as follows:
port, no pressure can build up in the chamber and
hence no fuel is delivered. This means that the delivery 1. Clean the surface around the Inspection Cover.
ends and thus the delivered quantity of fuel is controlled 2. Remove one of the two holding screws of
by the rotation of the plunger. inspection cover for FT-50 & FT-55 and oil filler
The stop mark and the arrow engraved on the control plug at top of the governor hsg, cover for FT-60.
rack indicates direction in which the control rack Loosen the level plug also.
should be moved to set the delivery to zero, i.e. to 3. Fill oil filler plug (FT-60) and inspection cover mtg.
stop the engine. In the opposite direction of the rack, hole (FT-50, FT-55) using oil can until the oil just
the plungers are set to maximum delivery. starts flowing through the level plug hole.
C. READING PUMP DESIGNATION NOTE: If the oil in pump is too thin and needs to be
The design number of the fuel injection pump inscribed replaced then keep adding oil until the fresh
on the plate mounted on the pump gives a complete oil starts flowing through oil level plug and
picture of the design and type of the pump and can be wait till excessive oil comes out.
read as per example given below:- 4. Replace filler plug or inspection cover holding
PE - S 3 A 90 D 410 R S2495 screw and tighten. Replace level plug and tighten.

C–8
 FUEL SYSTEM

5. Replace lubricating oil when removing pump or BASIC SETTING OF PUMP

on the occasion of a periodic overhaul. (to be done on pump less governor)
6. Remove excess oil from fuel pump by loosening Basic setting should be done at 10.3 mm. control rod
level plug, whenever tractor comes for regular travel at 1000 rev/min.
service. Contr. Rack Delivery Max Spread in
NOTE: The location of level plug is on R.H.S. and Speed
Travel Quantity Delivery
L.H.S. of fuel pump in FT-60 and FT-50
respectively. cm3 per cm3 per 100
rev/min mm 100 strokes strokes
Never fill engine oil in governor hsg. of FT-
50/55 fuel pump, to lubricate leather 1000 12.0 7.3-7.6 0.3
diaphragm from breather mgf. hole. (o/check 0.5)
9. CALIBRATION AND TESTING OF 300 7.5 1.0-1.5
FUEL INJECTION PUMP FOR Tighten the max. speed screw until it touches
FARMTRAC-60 the control lever.
1. All test specification apply to BOSCH injection
GOVERNOR SETTING
pump test benches and MICO/BOSCH testing
devices only. Check the control rack for easy and smooth
movement. Push the control rod to the stop position
2. Test oil temperature to be maintained between
and set the control rod measuring scale to zero.
40°C and 45°C.
Release the control rod. It should move by 21 mm.
3. After carrying out phasing and basic setting
Run the pump at 1180 rev/min. and move the control
operations, proceed as follows:
lever to the max. speed position. The governor should
4. Remove stop/idling screw, spring. not cut in. If it does, tighten the notch screw. Increase
5. Adjust the control rack measuring scale to 'O' pump speed until the governor is cut off completely
with control lever in stop position and tighten stop/ and check whether the control rack has gone back to
idling screw until control rack travel is, 0.3-1.0 the 0.3-1.0 mm. position.
mm. If not, change the thickness of the compensating
6. With the control lever in the vertical position, set washer located between the guide sleeve assembly
the scale. Move the control lever to 42° ± 4°. and actuating 'T' of the guide lever. (0.5 mm. of shim
Check that control rack travel is 20-21 mm. equals 1.0 mm of control rack travel).

Figure 11
Operation of Plunger and the Barrel

C–9
 FUEL SYSTEM

1. MAXIMUM SPEED CONTROL system up to fuel pump gallery by operating the

Run the pump at 1000 rev/min. keep the control lever fuel lift pump hand priming lever.
at the max. speed position (42°±4°) and adjust the full 3. Fit the adapter flange on the pump shaft and
load stop screw to 10.3 mm. Check the following ensure that the woodruff key is in position.
values: Replace the spring washer and nut.
1070 - 1110 - 4. Connect the venturi connection tube assembly.
Rev/Min. 1000 1080 1140 1300 RE-TIMING
Contr. Rack 1. Rotate the crankshaft so as to bring No. 1 piston
12.0 11.0 5.5 0.3-1.7
Travel (mm.) 24° before TDC for Farmtrac-60 and 26° TDC for
If the values are not obtained, adjust the maximum Farmtrac-50/55 tractor, on compression stroke.
speed stop screw and notch screw or replace teh The timing marks are inscribed on the flywheel
governor spring. (Ensure that the governor is not cutting which should align with the arrow mark inscribed
in before adjusting the full load stop screw to 12.0 on the window as required.
mm. at 1000 rev/min. 2. Remove the injection pump inspection cover by
2. FULL LOAD DELIVERY removing the two screws.
Run the pump at 1000 rev/min. keep the control lever 3. Remove the delivery valve holder of No. 1 pump
at the max. speed stop and check the delivery. It plunger and take out the delivery valve, valve
should be 37.0-37.6 cm3/500 strokes. (Over checking spring and spring guide. Replace the holder in
value is 36.1-38.6 cm3/500 strokes. If not, adjust the its place and fit a swan Neck Pipe over it.
full load stop screw. 4. From the pump adapter flange nut, rotate the pump
3. IDLING SPEED CONTROL cam clockwise and keep rotating till the fuel stops
flowing from the Swan Neck Pipe in the upward
Run the pump at 300 rev/min. and move the control
stroke of the No.1 pump plunger. This is known
lever from the stop position until the control rack moves
as the "Spill cut-off-timing".
to 7.5 mm. The control lever position should be 16° ±
4°. Screw in the supplementary idling spring and check 5. Without disturbing the position of adapter flange,
the following values: install and secure the fuel pump drive gear &
adapter plate with the help of three mounting bolts
Rev/Min. 100 300 420-480 and spring washers, to the adapter. Tighten the
Control Rack bolts snugly.
17-21 7.3-7.7 2.0
Travel (mm.) 6. Rotate the crankshaft through two revolutions and
If the values are not obtained, re adjust the control align the timing marks again, simultaneously
lever and supplementary idling spring. checking that the fuel cut-off takes place as
observed in step 4 above. If so, you have timed
4. GOVERNOR CUTTING-IN-SPEED
the pump correctly and the three bolts can be
Run the pump. Keep the control lever at the maximum tightened to the specified torque of 28 lbs.ft.
speed stop and increase speed until the control rack
7. Remove the Swan Neck Pipe and replace the
moves back by 1.0 mm. from the full load position.
delivery valve spring and spring guide into the
The speed should not exceed 1070-1080 rev./min.
delivery valve holder. Tighten the delivery valve to
11. RE-TIMING OF FUEL INJECTION the specified torque.
PUMP ON THE ENGINE 8. Connect the respective fuel injection pipes
MOUNTING AND BLEEDING THE PUMP keeping the nozzle end nut loose. Bleed the
1. Mount the pump on to the engine front cover plate system by cranking the engine until the air free
with the help of three mounting bolts and spring fuel is injected from the pipes. Tighten the nozzle
washers keeping the gasket between the plate end pipes nuts, one by one.
and the pump flange. The engine is now timed and ready to start.
2. Connect the respective fuel lines and bleed the 9. Re-connect the fuel cut-off control.

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 FUEL SYSTEM

12. DELIVERY VALVE from the pressure chamber; only after that will the valve
DESCRIPTION AND OPERATION cone embed firmly on its seat. The space for fuel in
the delivery pipe will thus be increased by an amount
When the helix of the plunger uncovers the inlet port,
equal to the volume of the relief plunger. The effect of
pressure will drop abruptly in the barrel, so that the
this increase volume is, of course, a sudden pressure
higher pressure in the delivery pipe and the force of
drop in the delivery pipe so that the nozzle needle can
the valve spring will press the delivery valve onto its
close instantaneously.
seat. The delivery valve, acting as a one way valve,
seals the delivery pipe from the barrel during the intake 13. FUEL FEED PUMP
stroke until the next delivery stroke comes up. (As Fuel has to be fed to the injection pump under pressure
shown in closed position in Figure 12). of about 1 atm. as the quantity of fuel delivered would
Another function of the delivery valve is to relieve otherwise be inadequate. MICO BOSCH fuel feed
(unload) the pressure in the delivery pipe. This is pump is a plunger pump and is provided with a hand
necessary to ensure that the nozzle needle closes priming device and preliminary filter.
instantly and stops the spraying of fuel into the
A. DRIVE
combustion chamber without any after-dribble.
The fuel feed pump is attached to the injection pump
The delivery valve is guided by its stem in the valve
and driven by its camshaft.
holder. During the fuel delivery stroke, the valve is
pushed up from its seat so that the fuel can flow along B. OPERATION
with longitudinal grooves and over the valve face into The revolving eccentric cam presses the plunger of
the delivery pipe. the feed pump by means of the roller tappet and
On top of the stem and above the annualar groove, pressure spindle. A portion of the fuel present in the
immediately below the valve cone, there is also a small suction chamber equal to the swept volume or quantity
cylinderical shaft portion called the relief plunger. This of fuel delivered per stroke is delivered through the
plunger fits by suction precisely into the valve holder. pressure valve to the pressure chamber and the plunger
When the delivery stroke ends and the valve begins to spring is compressed in an intermediate stroke.
resume its seat, the relief plunger will slide into the Towards the end of this stroke the spring loaded
bore of the valve holder, thus sealing the delivery pipe pressure valve closes again.

Figure 12
Delivery Valve

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 FUEL SYSTEM

Pressure spindle, roller tapper and plunger are only in reduction in engine load would tend to make the engine
slight contact with one another. As soon as the cam race away unless the throttle was closed. The operator
or eccentric has passed its max. stroke, plunger is well occupied in watching the implement and
pressure, spindle and roller tappet accordingly move steering the tractor, and teh governor relieves him of
back due to the pressure exerted by the plunger spring. the duty of regulating the throttle, the whole time to
A portion of fuel present in the pressure chamber is meet transient variations in engine load.
thereby delivered to the injection pump through the
B. PRINCIPLES OF OPERATION
filters. Fuel is, however, also sucked simultaneously
from the tank to the suction chamber through the In diesel engines it actuates mechanism controlling
preliminary filter and the suction valve. the amount of fuel delivered to the cylinder on each
stroke of the fuel injection pump with the usual variable-
During the delivery stroke (spring actuated) all fuel
delivery multiple piston pump. This means that the
swept out by the plunger in the pressure chamber is
governor is connected to the pump control rod, the
fed to the injection pump. The volume of this however,
position of which determines the point of spill.
is slightly less than that swept out by the plunger in
the suction chamber. The volume swept out in the THE PNEUMATIC GOVERNOR
pressure chamber is the volume swept out in the A. DESCRIPTIONAND OPERATION
suction chamber less the volume of the spindle
The fuel injection pump fitted in Farmtrac-50/55 tractor
reaching into the pressure chamber. Therefore, during
employs a pneumatic governor type HB-EP/MZ 80 AA
the intermediate stroke a quantity of fuel corresponding
190L.
to the volume of the spindle is fed to the injection pump
via dual fuel filters. Essentially it consists of a diaphragm attached to the
control rod of the fuel pump, and a spring which tends
When the pressure in the feed pipe exceeds a specified
value, the plunger spring lifts the plunger only part of a to hold this rod in the full fuel delivery position. A
stroke. The fuel valve closes while the pressure valve vacuum pipe connects an air tight chamber on one
opens with fuel flowing through the feed pipe and filter side of the diaphragm to a venturi in the inlet manifold.
to the injection. At the throat of the venturi there is a butterfly valve
actuated by the throttle lever.
After use, it is essential to screw the knob tight again.
On moving the throttle lever and hence the butterfly
14. THE GOVERNOR valve, a change is brought about in the sub-atmospheric
A. FUNCTION pressure at the venturi throat. The pressure change is
A governor is a device for keeping the engine at a transmitted via the vacuum pipe to the diaphragm,
constant speed when running. Tractor engines are which then either moves back against the spring or is
always fitted with governors, and the governors are moved outwards by the spring. Thus closing the
always of the variable-speed type. In other words the butterfly valve, to a greater of lesser extent, increases
governed speed can by varied by the operator as the depression in the venturi, which reduces the fuel
required. In this respect there is an important difference supply and slows down the engine. Openng the
in principle between the controls of a tractor and those butterfly valve, reduces the depression in the venturi,
of a motor car, in the later the fuel supply is under allows the control rod to move towards the full fuel
direct control of the accelerator pedal, but in the tractor, delivery position and speed up the engine.
the fuel supply is controlled by the governor, and the At any particular position of the throttle lever the
operator varies the engine speed by movement of the amount of fuel supplied to the engine will vary
governor control lever. The governor is designed to automatically so that the speed remains constant. An
provide variation of speed from idling to maximum. increase in the load on the tractor, causes a fall in
Governor control of engine speed is indispensable on engine speed, thus reducing the depression in the
a tractor. The load on the engine is subject to rapid venturi throat (i.e. increase the pressure there). With
variation and the driver is generally too busy to control this effect the diaphragm moves to increase the amount
the fuel supply direct without difficulty. For example, of fuel injected. The reverse action takes place when
on lifting an implement out of the ground, the sudden the load on the tractor falls.

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 FUEL SYSTEM

Adjustment of the pneumatic governor is effected at screw the set screw firmly and evenly into
the works when the engine is manufactured, and in an position.
operation requiring considerable skill. The idling stop CAUTION: The pneumatic governor depends for its
on the butterfly valve and the adjusting screw in the action upon pressure variations set up in
cap of the governor has to be manipulated alternatively the air intake. Should this, or the vacuum
until smooth running at the desired idling speed is pipe be removed, care must be taken that
achieved. they are replaced securely, for if air enters
No subsequent adjustment is, in fact, needed. Any the system by any other way past the
deterioration in the smoothness of idling is due to some butterfly control in the air intake, the
defect which has arisen elsewhere and should be governor may fail to operate, causing
traced. The tiniest pinhole or crank in the leather serious damage to the engine.
diaphragm will affect the operation of the governor. If In no circumstance should the engine be run without
such a fault is suspected, test in this way. venturi control unit, vacuum or inlet manifold.
(a) Remove vacuum pipe. MECHANICAL GOVERNOR
(b) Move the stop lever, into "stop" position. The fuel injection pump fitted on Farmtrac-60 tractor
(c) Place a finger over the diaphragm housing upon employs a mechanical governor, type RSV 300 1000
in order to seal it. A 2 B 2281L, which is called a variable speed governor.
(d) Release the stop lever. Governors employing the principle of centrifugal force
(e) The control rod should then slowly return to the are called mechanical governors. These are most
maximum speed position after a quick initial widely used on diesel engines.
movement for a fraction of the distance. If it returns The mechanical governor is mounted on the fuel
quickly for the whole movement and the housing injections pump. The control rack of the fuel injection
are clamped firmly together, then the diaphragm pump is connected to the governor through a flexible
is leaking and should be replaced. Instructions joint and governor control lever is connected to the
for replacement are given in the following lines. accelerator.
If the diaphragm appears to be sound as indicated by In mechanical governor type RSV used FIP of FT-60
this test, suspect the vacuum pipe and test in a similar (figure 13) the action of the two flyweights presses the
way. Replace the union of this pipe on the governor guide sleeve against the tension lever, which is drawn
casing and uncouple it at the butterfly end. Repeat in the opposite direction by the governor spring. When
the test as before but placing the finger on the uncovered the speed is set by the control lever, the governor spring
end of the vacuum pipe. is tensioned by an amount corresponding to the
TO REPLACE DIAPHRAGM desired speed.
To replace the leather diaphragm, proceed as follows:
(a) Disconnect the vacuum pipe.
(b) Take out the screws holding the pneumatic
governor cover in place.
(c) The diaphragm will be accessible, after the cover
and spring have been removed. Slide the socket
at the back of the diaphragm off the pin at the
end of the control rod.
Be careful not to damage the face of the fuel
pump onto which the governor casing fits.
(d) To replace the diaphragm, first place the socket
on the pin on the control rod.
(e) Then press the diaphragm squarely and firmly in
its place.
(f) Replace the governor casing, being careful to Figure 13
RSV type governor

C–13
 FUEL SYSTEM

Figure 14
Variable speed governor RSV
The governor springs are so selected that at the desired guide sleeve is connected through the actuating 'T',
speed the centrifugal force and the spring force are in the guide lever has a pin which projects on both the
equilibrium. If this speed is exceeded the increasing sides. The fulcrum lever is fixed on any one side
centrifugal force of the flyweights acts through a (according to the mounting side of the governor on
system of levers to move the control rack in the 'stop' pump end 1 or 2) of the pivot pin. A slider which moves
direction and the fuel delivery is decreased. either in a slot of the supporting lever (for governors
with special stop lever arrangement), locates the
VARIABLE SPEED GOVERNOR-RSV
fulcrum lever at the bottom. A shackle (link member)
Reference Figure 14 & 15 connects the control rack and the fulcrum lever. The
CONSTRUCTION starting spring (weak tension spring) is hooked to the
top of the fulcrum lever. The other end of this starting
The flyweight assembly, assembled to the pump
spring is hooked in to a fastening plate, fixed to the
camshaft consists of two flyweights which pivot on
governor housing. The starting spring is effective only
pins in the link (carrier). The guide sleeve rotates and
below the idling speed.
slides longitudinally along the axis of rotation. The

C–14
 FUEL SYSTEM

Figure 15 Figure 16
Schematic drawing of variable Special stopdevice for RSV governor
speed governor RSV

The tension lever pivots at the top on the same pin in The speed droop (degree of irregularity) can be adjusted
the governor cover, where the guide lever is suspended. within the prescribed limits by adjusting the notch
One end of the governor spring is hooked into the 'eye' screw provided on the swivelling lever.
provided at the middle of the tension lever. The other
end of the governor spring is hooked into the rocker of
the swivelling lever. The swivelling lever is supported, For governors without stop lever arrangement the stop
at both the ends in the governor cover. The control
screw (shut-off screw) is to be adjusted in such a way
lever(s) can be fitted to either end (or both the ends) of
that the rocker of the swivelling lever contacts this
this shaft.
screw inside when the control rack is moved to the
'stop' position. In the case of governors with special
The lower end of the tension lever bears against the stop device this screw is adjusted to act as "Idling
adjustable (only the full load position) full load stop stop screw" (when the rocker touches this screw the
screw. control rack is moved to the idling position).

The torque control device (adaption capsule) is screwed For details of special stop device see Figure 16. As
into the tension lever and is accessible when the the special stop device engages with the fulcrum lever,
governor end cover is removed. Adaption capsule has
it must always be assembled on the same side as
a spring loaded pin. The pretension can be adjusted
the control rack.
by means of shims.

The supplementary idling spring stop is fitted to the Lighter flyweights are required for higher speed ranges.
governor cover. This helps to achieve satisfactory Using weaker tension governor springs it is possible
governing at low idling speed. to set smaller speed droop at lower speeds.

C–15
 FUEL SYSTEM

Figure 17 Figure 18
RSV Governor Starting Position RSV Governor, Idling Position
OPERATING CHARACTERISTICS STARTING THE
ENGINE (Figure 17)
When the engine is stopped, the control rack will move
to the starting fuel delivery position due to the action
of starting spring, so that the engine can be started
with the control lever in 'idling' position.
IDLING SPEED (Figure 18)
When the control lever is in idling position, the governor
spring is almost completely relaxed and stands nearly
in a vertical position. Therefore the spring has only a
marginal effect; the flyweights can swing outward at
even a low speed. The guide sleeve along with the
guide lever move to the right in the direction of arrow Figure 19
as shown in Figure 18. In turn the guide lever swings RSV Governor Characterstic Curves
the fulcrum lever, which pulls the control rack in the
direction of stop, to idling position.
The tension lever is positioned against the
supplementary idling spring which facilitates stable
idling speed.
Governing process in intermediate speeds (Figure
19 & 20)
Even a relatively small movement of the control lever
from the idling position is sufficient to move the control
rack from its initial (idling) poistion (point L). in Figure
19) to its full load position (point B in Figure 19). The
fuel injection pump delivers the full load fuel quantity
into the engine and the speed increases (b'B"-Figure
19). Figure 20
As soon as the speed increases the flyweights swing RSV Governor, full load at low speed, starting
of torque control

C–16
 FUEL SYSTEM

Figure 21 Figure 22
RSV governor full load of maximum speed RSV governor no load regulated from full load
end of torque control, starting of
full load speed regulation in delivery depends upon the adaption travel.
When the maximum full load speed (nvo) is reached,
outward (centrifugal force exceeds the force of the
the centrifugal force overcomes the force of the governor
governor spring corresponding to the position of the
spring and the tension lever is deflected to the right.
control lever) and push the guide sleeve and guide
The guide sleeve, guide lever and the fulcrum lever will
lever. In turn guide lever swivels the fulcrum, lever and
move the control rack in the 'stop' direction until the
the control rack is moved in the 'stop' direction, to a
fuel delivery rate is reduced commensurate with the
point of lesser delivery (point C-Figure 19). The speed
new load conditions.
of the engine does not increase further and is held
constant by the governor as long as the operating If the entire load on the engine is removed the no load
conditions remain uniform. speed nlo is attained.

Governing process in maximum speed range STOPPING THE ENGINE

(Figure 21 & 22 ) (a) Governors without special stop lever
If the control lever is moved to the maximum speed arrangement (Figure 23)
stop position the governor functions in the same way
as explained above. However the swivelling lever
tensions the governor spring completely.
The governor spring thus acts with a greater force and
pulls the tension lever against the full load stop and
control rack to the maximum fuel delivery position.
The engine speed increases and the centrifugal force
steadily rises.
In governors equipped with torque control (adaption
capsule) device, as soon as the tension lever is
positioned against the full load stop, the spring in the
adaption capsule is steadily compressed as the speed
increases (D-E in Figure 19). As a result the guide
Figure 20
lever and fulcrum lever move the control rack in the
RSV Governor, full load at low speed, starting
'stop' direction and reduce the delivery. The reduction of torque control

C–17
 FUEL SYSTEM

it is essential that the engine be not only provided

with fuel in quantities exactly timed and proportional
to the amount of work it is required to do, but also that
it should recieve each charge of fuel in a condition
such that it can be completely consumed without
causing smoke in the exhaust. This is briefly the
function of injector nozzle, which is held in position in
the cylinder head by a nozzle holder. As the nozzle
may have to deal with hundreds of fuel charges per
minute, with widely varying condition of pressure and
temperature, the unerring precision necessary in the
production of these parts will be appreciated.
The Farmtrac engine employs the multi hole nozzles
Figure 24 of following specifications.
RSV Governor - Stopping the Engine with the
Stop Lever FARMTRAC-60
Nozzle Holder : 9 430 031 255 - KBL 805 192/4
Such governors are stopped by pulling the control lever
Nozzle : 9 430 034 273 - DLLA 150 S 990
to the 'stop' position. As this is done the projections
on the swivelling lever (inclined arrow) press on the Opening Pressure : 210-220 bar (kgf/cm2)
guide lever. The guide lever swings to the right, taking B. ADJUSTING AND TESTING OF NOZZLE
the fulcrum lever and thus the control rack to the 'stop'
NOZZLE CLEANING
position. Parallelly the swivelling lever rocker touches
the 'stop' screw. Since the pressure exerted by the Remove the injector from the cylinder head and clean
governor spring on the guide sleeve is released the the carbon deposits, if any, by washing them thoroughly
flyweights swing outward. in petrol. Remove the nozzle and dip it in the clean
fuel oil and the nozzle needle too. After cleaning the
(b) Governors with special stop lever (Figure 24)
needle, insert into the nozzle body.
In the case of governors with special stop lever
arrangement (irrespective of the flyweight and control NOTE: Nozzle needle and body are lapped together
lever positions) the control rack can be moved to 'stop' and must not be exchanged.
position by operating the stop lever. INITIAL TEST
When the stop lever is pressed to 'stop' position, the 1. Visual Test (Only on used nozzles): After
upper part of the fulcrum lever is swung to the right cleaning, used nozzles should be visually
around the pivot point C in the guide lever. As a result inspected. Look on nozzle needle for damaged
the control rack is pulled by the shackle (line member) or rough needle seat, for worn or damaged or
to the 'stop' position. When the stop lever is released, carboned seat and for out of round of needle hole.
a return spring (not shown in the Figure) brings to its
2. Slide Test: After visual test all nozzles should be
original position (starting position).
given slide test.
15. FUEL INJECTION NOZZLES
First dip the nozzle needle in clean fuel oil and
A. DESCRIPTION AND OPERATION insert into the nozzle body. Holding the body
The performance of a modern high speed diesel engine almost vertically, pull up the needle by one third
depends largely upon proper functioning of its fuel of its engaged length. When released, the needle
injection system. For maximum efficiency in operation, should slide down by its own weight.

C–18
 FUEL SYSTEM

OPENING PRESSURE

The opening pressure is specified under description

and operation for individual engine and should be
adjusted correspondingly. With the pressure gauge
open to pressure slowly depress hand lever until the
nozzle ejects with slight chattering. Take reading on
the pressure gauge, if this pressure differs from the
specified opening pressure, it is necessary to change
total shim thickness.

CAUTION: When the pressure gauge is open to

pressure, increase and decrease
pressure slowly, otherwise the gauge may
Figure 25
be damaged.
Bosch Nozzle Testing Outfit
LEAKAGE TEST

TESTING WITH NOZZLE TESTER Operate hand lever of the nozzle tester until pointer
on the pressure gauge indicates 20 kg/cm2 (285 p.s.i)
Reference Figure 25
below the specified opening pressure.
The following is tested on the nozzle tester:
The nozzle is considered leak-proof if no drop of fuel
(a) Opening Pressure emerges out at the end of the nozzle within 10
seconds.
(b) Leakage
CHATTER TEST AND SPRAY PATTERN

(c) Chattering characteristics and spray pattern For these tests, it is absolutely necessary that the
pressure gauge be by passed.
Use clean test oil for testing. It is very important
that the oil is clean. The nozzles are adjusted by Testing speed range : 1 stroke in approx. 0.2 to 2
Sec. (5 to ½ downward movements per sec.)
their respective nozzle holders.
CHATTER TEST
When clamping the nozzle into nozzle holder take
care that the sealing surface is clean and undamaged. These types of nozzles chatter in the entire range of
Place nozzle on sealing surface of nozzle holder, attainable lever velocity (lowest test velocity; One
tighten cap nut first by hand and then with a well fitting downward movement per second). Slight non-
wrench to torque 6-8 kgm. chattering in intermediate range is of no significance.

Connect nozzle holder with its respective delivery pipe SPRAY PATTERN
to the outfit. To test for nozzle jamming, press the
At low test velocity, atomisation is coarse. In the non-
hand lever of the nozzle tester down vigorously a few
chattering range, non-atomised streams are formed.
times (approximately 6-8 downward movements per
second) with a pressure gauge by pass. With nozzle When the lever movement is accelerated (about 4 to 6
needle moving properly, the nozzle should chatter with downward movements per second), the spray must
shrill whistling buzz. there be compact, well atomised and equally spaced.

C–19
 FUEL SYSTEM

CALIBRATION OF F.I.P. & INJECTORS - FARMTRAC-60

For testing and calibration of fuel injection pump and injectors
(Subject to alteration)
refer Mico specification chart as below.
For Field Service Only
INJECTION PUMP AND GOVERNOR NO. VKD - TS - FT 3.2a
PES 3A 90D 410 RS 2862 RSV 300..... 1000 A2B 2281L Edition : 03.1996 Replaces : 12. 1994
(SI No. 0470300 onwards) Manufacturer : Escorts Tractor Ltd.
Combination No. 9 400 030 670
Engine Model : Farmtrac 60 (F3620)
E 040 0548 00
Engine Code : 55106
Application : Tractor
Features : Element : 9 411 038 358 Adaption capsule : Nil
Delivery valve : 9 413 038 520 Nozzle : 9 430 034 273 (DLLA 150 990
Flyweight assembly : 9 421 038 105 Operating Pressure : 210-220 bar
Governor spring : 1 424 650 005
(A) CALIBRATION OF PUMP WITHOUT GOVERNOR ACTION
Dirction of rotation : Clockwise Delivery Max. Spread in
Cam sequence : 1-2-3 Speed C.Tr. quantity X delivery qty.D
Cam displacement : 120° min-1 mm cm /100 strokes cm3/100 strokes
3

Test of temperature : 40° - 45°C

1000 12.0 7.3 - 7.6 0.3 (0.5)
Pre-stroke : 2.85 - 2.95 (2.8 - 3.0) mm
Tappet Clearance : 0.2 mm. (minimum) 300 7.5 1.0 - 1.5
Adjust equal delivery according to farmed values (Basic setting)
(B) ADJUSTMENT OF PUMP AND GOVERNOR (Calibrate pump with overflow valve 9.451 037.430)
Maximum speed control † Full load delivery Torque control Course of delivery Idling speed control
1 2 3 4 5
Control C. Tr. mm Delivery C. Tr. mm Delivery Control C. Tr. mm
lever Speed Speed quantity Speed Speed quantity lever Speed
position min-1 min-1 x cm3/ min-1 min-1 x cm3/ position min-1
degrees 500 strs. 500 strs. degrees

42°±4° 1000 12.0 1000 37.0-37.6 600 31.0-32.5 16°±4° 300 7.5
1070 (36.1-38.6) (30.0-33.5) 100 17.0-21.0
1080 11.0 300 7.3-7.7
1110- 420 -
1140 5.5 480 2.0
1300 0.3-1.7 1.5 (2.5) 2.0 (2.8)

Maximum speed Governor Degree of Starting travel Starting quantity

control † cutting-in-speed irregularity (minimum)
6 7 8 9 10
Speed Altered Speed Speed Speed Speed Delivery quantity x
C. Tr. mm C. Tr. mm C. Tr. mm
min-1 min-1 min-1 min-1 min-1 min-1 cm2/100 strokes

1070- Max
*
While overchecking, if the cutting-in speed is above the
1080* 1180 rated speed and if.
5.5
2 The delivery values are within the over checking
Control rack moves No. of notches tolerance
back by 1mm from »15 1 Control rack remains at full load position even at 50 min.
< the rated speed.
the full load C. Tr. The cutting-in speed should be declared OK.
1...10 Indicate sequence of operation C.Tr. = Control rack travel x Average of the cylinder
min-1 = rpm bar = Kgf/cm2
† Without supplementary idling spring ‡ With supplementary idling spring D Max. spread in delivery qty.
(...) Overchecking values
Applicable only BOSCH and MICO Test Benches

C–20
 FUEL SYSTEM

Figure 26
Foot Accelerator Adjustment
1. Upper Ball Stud 7. Locknut
2. Lock Nut 8. Maximum Speed Position
3. Maximum Speed Position 9. Idle Speed Position
4. Idle Speed Position 10. Foot Accelerator Linkage
5. Injection Pump Linkage 11. Maximum Speed Position
6. Lower Ball Stud 12. Idle Speed Position

17 FOOT ACCELERATOR (maximum, speed position). Figure 26.

Foot accelerator is provided on all Farmtrac tractors Pull the rod assembly (5) fully rearwards until the
to drive the tractor confortably on road and highway. injection pump lever makes contact with the maximum
Foot accelerator is provided on right hand side foot speed stop on the pump.
rest.
Loosen the lock nut (2) and adjust the length of the
FOOT ACCELERATOR ADJUSTMENT rod so as to fit onto the lower ball stud (6), Tighten the
lock nut (2).
Stop the engine and apply parking brake. Remove the
steering gear shroud from beneath the instrument With the hand throttle set at the maximum speed
console for access. position, depress the foot throttle until the pedal
contacts the foot plate. Loosen the lock nut (7) and
Disconnect the linkage rods from the upper and lower adjust foot accelerator linkage (10) so as to fit onto
ball studs. Move the hand throttle lever fully rearwards the upper ball stud (1). Tighten the lock nut (7).

C–21
 FUEL SYSTEM

18. TROUBLE SHOOTING

IMPORTANT: Whenever effecting a repair the cause of the problem must be investigated and corrected to
avoid repeat failures. The following table lists problems and their possible causes with
recommended remedial action.
DIESEL FUEL SYSTEMS-GENERAL
PROBLEM POSSIBLE CAUSES REMEDY

Fuel not reaching injection 1. Fuel shut-off valve closed or 1. Check if the fuel shut-off valve at
pump chocked fuel cock strainer. the fuel tank is in the 'ON' position
2. Restricted fuel filters. or clean fuel cock.
2. Check and flush the fuel filters
clean.
3. Air in system. 3. Bleed the fuel filters.
4. Fuel leakage. 4. Check the fuel lines and conectors
for damage.
5. Fuel tank cap breather hole 5. Clean or change cap.
blocked.

Fuel reaching nozzles but 1. Low cranking speed. 1. Check the Battery condition and
engine will not start starter assembly.
2. Incorrect throttle adjustment. 2. Check the throttle control rod travel
re adjust.
3. Incorrect pump timing. 3. Check the fuel pump timing.
4. Fuel leakage. 4. Check the fuel lines and
connectors for leakage.
5. Faulty injectors. 5. See injectors trouble shooting.
6. Low Compression. 6. Check the engine compression.
7. Chocked air cleaner. 7. Check and clean.

Engine hard to start 1. Low cranking speed. 1. Check the Battery condition and
starter assembly.
2. Incorrect F.I. Pump timing. 2. Check the F.I. Pump timing.
3. Restricted fuel filters. 3. Check and flush the fuel filter clean.
4. Contaminated Fuel. 4. Check for water in the fuel.
5. Low Compression. 5. Check the engine compression.
6. Air in Fuel System. 6. Check for air leaks on the suction
side of the system.

C–22
 FUEL SYSTEM

PROBLEM POSSIBLE CAUSES REMEDY

Engine starts and stops 1. Fuel starvation. 1. Check and flush clean restricted
fuel lines or fuel filters.
2. Contaminated fuel 2. Check for water in the fuel.
3. Restricted air intake. 3. Check for restrictions in teh air
intake.
4. Engine ovrheating. 4. Check cooling system.
5. Air in the Fuel System. 5. Check for air leaks on the Suction
side of the system.

Erratic engine Operation 1. Fuel leakage. 1. Check the injector lines and
(surge, misfiring, poor connectors for leakage.
governor regulation) 2. Fuel starvation/restriction in Fuel 2. Check the flush clean restricted
lines. fuel lines or filters.
3. Incorrect pump timing. 3. Check the pump timing.
4. Contaminated fuel. 4. Check for water in the fuel.
5. Air in Fuel System. 5. Bleed the Fuel System.
6. Faulty or sticking injector nozzles. 6. See injector trouble shooting.
7. Incorrect engine valve timing. 7. Check for faulty engine valves.

Engine does not develop 1. Incorrect throttle adjustment. 1. Check for insufficient throttle
full power or speed control movement.
2. Incorrect maximum no-load speed. 2. Check maximum no-load speed
adjustment.
3. Fuel starvation. 3. Check and flush clean restricted
fuel lines and filters.
4. Air in system. 4. Check for air leaks on the suction
side of the system.
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.

Engine emits black smoke 1. Restricted air intake. 1. Check for a restricted air intake.
2. Engine overheating. 2. Check cooling system.
3. Incorrect timing. 3. Check the fuel pump timing.
4. Faulty injectors. 4. See injector trouble shooting.
5. Low compression. 5. Check the engine compression.
6. Incorrect engine timing. 6. Check the engine valves.

C–23
 FUEL SYSTEM

PROBLEM POSSIBLE CAUSES REMEDY

Pump fails to deliver fuel 1. Blocked fuel lines to pump. 1. Remove fuel lines and flush or
to all three injectors. replace.
2. Fuel pump is defective. 2. Repair or replace pump.
3. Air in fuel lines to injectors. 3. Bleed fuel lines.
4. Control rod seized in OFF position. 4. Repair or replace control rod.

Pump fails to deliver fuel 1. Air in fuel line to injector. 1. Bleed fuel line.
to one injector. 2. Plunger spring broken. 2. Replace spring.
3. Plunger seized. 3. Repair or replace barrel and plunger
assembly.
4. Devliery valve seized. 4. Repair or replace delivery valve.
5. Badly scored plunger and barrel. 5. Replace barrel and plunger
assembly.

Governor fails to maintain 1. Control spring broken. 1. Replace control spring.

maximum or minimum no- 2. Governor weight carrier broken. 2. Replace weight assembly.
load fuel delivery. 3. Thrust pad seized. 3. Replace thrust pad and/or
camshaft.
4. Cross-shaft bolt broken or missing. 4. Replace bolt.
5. Pump link spring broken. 5. Replace spring.

Engine races after starting 1. Accelerator linkages sticky. 1. Check and rectify.
speed gets uncontrollable. 2. Pump control rack stickty. 2. Get FIP control rack repair/
replaced.
3 Governor linkage broken/seized. 3. Replace parts and recalibrate FIP
at Mico Authorised Dealer.
4. Pneumatic governor diaphragm cut/ 4. Replace diaphragm.
punctured.
5. Vacuum chamber/connections 5. Check and rectify.
leaky.

Nozzle does not 'buzz' 1. Needle valve stuck. 1. Check needle valve is clean and
whilst injecting. not binding.
2. Leakage. 2. Check valve seat is not leaking.
3. Nozzle damaged. 3. Examine nozzle retaining cap for
damage.

C–24
 FUEL SYSTEM

PROBLEM POSSIBLE CAUSES REMEDY

Nozzle leak-back 1. Needle valve worn. 1. Replace nozzle assembly.
2. Blocked nozzle assembly. 2. Check for carbon or foreign matter
on faces of nozzle and nozzle
holder. Flush clean or replace.
3. Loose nozzle retaining nut. 3. Inspect faces and tighten nozzle
retaining nut.

Nozzle opening pressure 1. Incorrectly adjusted nozzle 1. Check adjusting nut for looseness
incorrect retaining nut. and re-set.
2. Damaged nozzle or seized needle 2. Replace nozzle assembly.
valve.
3. Blocked nozzle holes. 3. Check nozzle holes for carbon or
foreign matter. Flush clean or
replace.

Nozzle seat leakage 1. Nozzle incorrectly seated. 1. Check for carbon or foreign matter
or faces of nozzle or nozzle holder.
2. Sticking or binding needle valve. 2. Repair or replace nozzle assembly.

Spray pattern distorted 1. Obstructed needle valve. 1. Check for carbon or foreign matter
on needle valve tip. Flush clean or
replace nozzle assembly.
2. Obstructed needle valve holes. 2. Check for carbon in needle valve
holes. Flush clean or replace
nozzle assembly.
3. Damaged nozzle or needle valve. 3. Replace nozzle assembly.

C–25
 SECTION - 'D'

ELECTRICAL SYSTEM
S.NO. CONTENTS PAGE

1. ELECTRIC CIRCUIT, WIRING, LIGHTS, SWITCHES AND D-3

DESCRIPTION AND OPERATION

2. CHARGING SYSTEM, DYNAMO, VOLTAGE REGULATOR, BATTERY, D-7

STARTER MOTOR TESTING AND MAINTENANCE

ALTERNATOR WITH INTEGRAL REGULATOR

3. DESCRIPTION AND OPERATION D - 16

4. CHARGING SYSTEM - ALTERNATOR WITH INTEGRAL REGULATOR D - 20

SERVICE PRECAUTIONS & CHECKS

5. CHARGING SYSTEM - ALTERNATOR WITH INTEGRAL REGULATOR - D - 26

OVERHAUL

6. SPECIFICATIONS D - 32

7. TROUBLE SHOOTING D - 33
ELECTRICAL SYSTEM

D–2
 ELECTRICAL SYSTEM

ELECTRICAL SYSTEM

ELECTRIC CIRCUIT A new bulb may be installed by first unscrewing

the screw of the head lamp rim and then take off
The Farmtrac Tractor electric equipments is of single
the rim and the reflector assembly with a screw
lead type, employing the tractor as the earth conductor.
driver. The bulb socket, which is held by the
The Negative (-ve) pole of the battery, dynamo/alternator
reflector with a spring action, can be removed
and starter motor are earthed. See Electric Circuit
from the reflector by rotating anti-clockwise after
diagrams for FT-60 & 60E in the end of the section for
pressing down. The bulb is now accessible for
any reference.
replacement. The re-assembly is in the reverse
The complete electric system consists of three groups, order of dismantling.
as under:
NOTE: The inner surface of the reflector should not
Lights, Switches and Horn.
be touched, otherwise, it will affect its highly
Charging System. polished finish.
Starter Motor.
PLOUGH LIGHT (WHERE FITTED)
1. LIGHTS, SWITCHES AND HORN
HEAD LIGHTS At the rear of the R.H. side fender, a ploughing light
has been provided. A separate switch has been fixed
There are two headlights provided at the front end on the plough lamp body itself, to operate the light.
of the bonnet on radiator shell assy. The bulbs
The light is similar to front head lights in construction
used are of double filament, 12V, 35/35 Watts,
and service, but with different fittings of lens and rim
providing full beam and dipped beam of light. In mounting screw brackets etc. and has a single filament
some territories either single beam or twin beam
bulb. (35 Watts). The light mounting is on a bolt and
(55 Watts) sealed head lamps are installed in
bracket assembly for aiming the light as required.
the radiator grille. This is operated by a light
switch provided on the rear face right hand side TAIL LIGHT (WHERE FITTED)
of the instrument panel.
Two tail lights are provided, one each on the rear wheel
When the light switch is turned clockwise to
fenders, and are operated by the head light switch,
second position, the dipped head light beam
which is common for the head light and instrument
comes on. Turning it further to third position in
lights. The bulb tube is accessible for replacement
the same direction switches on the full beam.
after removing two screws of the lens and easing off
When the switch is turned anti-clockwise fully,
the light lens.
the head lamps are off.

D–3
 ELECTRICAL SYSTEM

Figure 1
Instrument Panel FT-60 & 60E
1. Tachometer 8. Engine Stop Control
2. Engine coolant temperature gauge 9. Key-start switch
3. Engine oil pressure warming light (provided only 10. Combination switch
on tractors fitted with Alternator) 11. Charging indicator
4. Hand throttle 12. Fuel gauge (provided on tractors fitted with
5. Hazard warming lights switch alternator) or Oil pressure gauge (provided on
6. Indicator lights tractors fitted with dynamo)
7. Tractor lights switch
INSTRUMENT LIGHTS BRAKE LIGHT
The Generator/alternator (where fitted) warning light, It is integral part of tail light. Two bulbs of 21W are
technometer, water (coolant) temperature gauge, oil provided one each on rear wheel fender & are operated
pressure gauge or Oil pressure, warning light (where by brake switch, when brakes are applied. The blub is
fitted), and fuel gauge (where fitted) are provided with accessible for replacement after removing two screws
small bulbs to illuminate their dials. The small bulb of the lens & easing off the light lens.
holder which is push fitted in the barrels, provided at PARKING LIGHT
the back of instruments, can be pulled out. The head
It is integral part of tail light. Four bulbs (SW each) are
light switch operates these lights. Refer Figure 1 for
provided one each on rear & front of rear wheel fender.
FT-60 & 60E.
These lights are operated by light switch.
INDICATOR LIGHTS
CHARGING INDICATOR
The upper indicator lights of the pair will illuminate
when head lamp main beam is selected. When either When glow it indicates that the dynamo/alternator is
of the turn signal is operated, the lower indicator light not charging the battery and should extinguish when
will flash in unison with the turn signals. the engine speed is increased above idle.

D–4
 ELECTRICAL SYSTEM

Figure 2 Figure 3
Key-start Switch Key-start Switch
1. Electrical equipment 'OFF' 1. Electrical equipment 'OFF'
2. Accessories 'ON' 2. Accessories 'ON'
3. Warning lights and instruments 'ON' 3. Warning lights and instruments 'ON'
4. Starting motor operates 4. Thermostat heater 'ON' (where fitted) or Starting
motor operates (where thermostat is not fitted).
5. Starting motor operates (where thermostart is
fitted) or Unconnected (where thermostart is not
fitted).
FUEL GAUGE (PROVIDED ON TRACTORS FITTED A five-position key-start switch is installed on all the
WITH ALTERNATOR) tractors. For starting in temperatures down to - 180°C
The gauge indicates the level of fuel in the tank and is (0°F) the thermostart option may also be installed.
only operative with the key-start switch in the 'ON' Basically the thermostart consists of an electrically
position. heated element in the air intake manifold which, when
operated, ignites a measure of diesel fuel and
NOTE: When the key-start switch is turned off the
introduces it into the combustion chamber. With the
gauge needle may assume a random position
thermostart installed, all the five positions of the key-
and may indicate a fuel level greater than
start switch are connected as shown in Figure 4.
the true level. Always check the fuel level
However, if the automatic thermostart is not installed,
with the key-start switch on.
the starting motor operates at positin (4) white as
KEY START SWITCH (DOMESTIC)
position (5) is left unconnected.
The key start switch is provided on the rear face left
LIGHT SWITCH FOR - FT-60
hand side of the instrument panel. When a key is
The light switch is of the push pull type and has three
inserted in it and rotated to first stage, current begins
positions. It's operation is as follows.
to flow in the circuit i.e. to all accessories. On rotating
to second stage current flows to warning lights and Position 1 (fully in) all lights 'OFF'
instruments. On further rotating to 3rd stage, it Position 2 (midway) side and rear lights and
operates the starter motor, which in turn starts the instrument light 'ON'.
engine. See Figure 2. Position 3 (fully out) side & rear lights, instrument
KEY START SWITCH (TRACTORS FITTED WITH lights & main beam head lights
AUTOMATIC THERMOSTART) 'ON'.

D–5
 ELECTRICAL SYSTEM

HAZARD WARNING LIGHTS SWITCH FUSE BOX FT-60

The hazard warning light switch is provided on the right Twin fuse box provided on L.H. side of stg. gear cover.
hand side of instrument panel with the turn indicator Fuse links can be replaced by removing the Fusebox
switch. When pressed the switch operates both turn cover.
signals simultaneously. The switch, which is internally Fuse Wire Colour Amp.
No. Circuit Protected In Out rating
illuminated, will flash in usison with the turn signals.
1. Ignition switch to hazard Purple Purple 10
COMBINATION SWTICH - FT-60
switch

2. Ignition switch to implement Red/blue Red/blue 10

The stalk type switch is mounted on the steering
lamp
column of Farmtrac-60 tractor. The switch operates
3. Combination switch to main Yellow Yellow/Green 10
the horn (where fitted) and the turn signals and is used
beam (if fitted)
to select main and dipped beam headlights.
4. Blank

Press in the ends of stalk to actuate the horn. If moved

clockwise, the stalk will actuate the right hand turn 5. Ignition switch to brake light Red/White Red/White 10
switch (if fitted)
signals. If it is moved anti clockwise, the left hand turn
6. Combination switch to dipped White White/Red 10
signal will be actuated. The turn signal indicator lights
beam
on the instrument panel will also flash when the turn
7. Combination switch to horn Black/Yellow Black/Yellow 10
signals are actuated.
(if fitted)

When the headlights are switched on, push the stalk 8. Blank

downward to select main beam & pull the stalk up to

9. Light switch to parking lights Grey/Red Grey/Red 5
select dipped beam (in some territories only single
beam head lights are provided).
10. Light switch to instrument Green Green 5

HORN panel

Where as in Farmtrac-60 Horn push button is provided

2. CHARGING SYSTEM
on the combnation switch. When the key is inserted
in the key start switch and turned clockwise on 1st A belt driven, two poles, two brush generator supplies
position, the horn switch becomes operative. the current to the charging system when the engine is
running above idling speed. The output of the dynamo
BRAKE SWITCH
depends directly upon dynamo speed and the condition
Brake switch is provided below the platform board RH of the charge in the battery. With these limits, the
above the brake pedal shank. The switch is output is regulated by a control box, Voltage Regulator.
automatically operated when brake pedals are in
The Voltage Regulator whilst enabling, rapidly controls
operation.
the charging rate so that no damage occurs to the
FLASHER UNIT battery during the charging period and thus prevents
overcharging. When the battery approaches fully
3-pin (for domestic) and 6-pin (for certain tractors) charged condition, the charging rate is automatically
flasher unit is provided on the rear hood mounting reduced. A cutout incorporated in the control box
bracket. It is operated by the combination switch in prevents the battery from discharging through the
case of FT-60 by indicator light switch. dynamo wingdings when engine is idling or stopped.

D–6
 ELECTRICAL SYSTEM

Figure 4
Exploded View of Dynamo Type C40 AQ
1. Shaft Nut 11. Key
2. Spring Washer 12. Bearing collar retaining cup
3. Plain Washer 13. Armature
4. Pulley 14. Spacer
5. Spacer 15. Ball Bearing "CE" END
6. "O" Ring 16. Through Bolt (2 OFF)
7. Drive end Bracket 17. Commutator end bracket
8. Ball Bearing - "DE" end 18. Brush (2 OFF)
9. Bearing Retianing Plate 19. Gasket (2 OFF)
10. Screws (OFF) 20. Yoke Assy.
DYNAMO (b) Loosen the terminals and remove the cable
connections to the dynamo.
The C40AQT dynamo is non-ventilated, DC shunt
(c) Loosen the belt tension adjusting bolt and
wound, self-excited, clockwise rotating machine, with
mounting bolts.
an insulated and earth brush being directly riveted on
the CE bracket. The dynamo has a 'D' (Dynamo), 'F' (d) Swing the dynamo loose, and remove the belt.
(Field) and 'E' (Earth) terminals. The dynamo has one
(e) Remove all the mounting bolts and remove the
ball bearing at the drive end and another bearing at
dynamo from the tractor.
the commutator end.
DISMANTLING THE DYNAMO
Removal of Dynamo from the Tractor
REMOVE THE THROUGH BOLTS
(a) Remove earth terminal of the battery to eliminate Remove the CE Bracket, taking care to prevent brush
any accidental short circuit. damage.

D–7
 ELECTRICAL SYSTEM

Remove the Yoke and the armature drive and bracket

assembly.

The armature can be removed from the drive end

bracket using a puller, taking care to prevent damage
to the armature.

DIS-ASSEMBLING

- Clamp the pully on a soft jaw and remove the

pulley nut reference figure 5.

Figure 7a & 7b
- Remove the C.E. bracket reference figure 8.

Figure 5

- Remove the fixing bolts 2 nos. reference figure

6. Figure 8
- Ensure that the brushes move freely in their
holders. If the movement is stickey clean with a
good cloth and petrol reference figure 9.

Figure 6

- Remove the key from the shaft as shown in figure

Figure 9
7a & 7b.

D–8
 ELECTRICAL SYSTEM

Remove the Yoke from the D.E. shield reference figure - Remove the D.E. bracket gently with the help of
11. puller reference figure 12.

Figure 10 Figure 12

- Remove the ball bearing from the commutator REMOVAL OF D.E. BEARING
end gently with the help of puller. Keep the
- Remove the screws (3 nos.) from the retaining
removed ball bearing with C.E. bracket separately
plate and place the D.E. Bracket assembly in a
to avoid mix up reference figure 12.
fly press and press down the ball bearing from
the D.E. Bracket as shown in figure 13.

Figure 11 Figure 13

D–9
 ELECTRICAL SYSTEM

A. ROUTINE MAINTENANCE FIELD COIL

BEARINGS FIELD RESISTANCE

No routine lubricationfor the ball bearings is necessary. With field coil assembled on the yoke, the resistance
However, during major overhaul of the engine, it is of the field can be checked by connecting an Ohm
recommended that the dynamo is removed, stripped, meter between the 'F' terminal of the yoke and the
cleaned and examined. Bearing at both the ends must earth terminal. The resistance for a good coil should
be inspected and if found noisy should be changed. be 5.7 to 6.3 Ohms at 20°C. For other ambient
temperatures, the value would be different.
INSPECTION OF BRUSH

After every 2,500 hours, the brushes are to be removed

and checked for wear, and freedom of movement inside FLASH TEST 'INSULATION'
brush box. Brushes should be renewed if the length of
The flash test on the coil can not be conducted on the
the worn out brush is less than 9/32" (7.14 mm.)
assembled yoke and field coil. For this test, the
BELT ADJUSTMENT terminal must be loosened and the two ends of the
field coil are removed. Then with a 15W bulb in series
After initial fitment, a new belt is to be checked for
apply 220V with a pair of probes between one tag of
tension after about 3 days or about 5 to 6 hours of
the field coil and the yoke. The bulb should not light
continuous run. For re-tensioning the belt, mounting
up.
and adjusting bolts are to be loosened, the tension of
the belt increased so that about half an inch. movement NOTE: Before conducting the flash test, ensure the
of the belt is obtained at one inch before the contact field coil is dry by the same procedure
of the belt on the generator pulley. recommended for the armature.

Belt tension is to be checked occasionally. While

checking, it should also be ensured that the belt does
BEARINGS
not touch the bottom of the pulley groove or is frayed.
Bearings are to be inspected as assembled to the
B. INSPECTION
drive end and commutator end bracket. If found worn
ARMATURE replace.

The armature is to be placed on a growler to check for Remove the rivets by carefully drilling of the rollover of
open or shorted turns. the rivets. Remove the bearing retainer plate and using
a puller, remove the bearing from the drive end bracket.
FLASH CHECK-EARTH FAULT

Use 110 Volt. A.C. supply and check the armature for
earthing, placing one of the probes on the commutator PERFORMANCE
and the other on armature shaft, connecting a 15W
Max. Output : 11A at 1850 RPM
bulb in series. The bulb should not light up for a good
armature. Cut-in : 13V 1450 RPM

NOTE: Before conducting the flash check, to ensure Max. load speed : 13.5V at 2050 rpm
the armature is dry and free from moisture,
place the armature in oven at 65°C overnight. Max. Permissible speed : 4500 RPM

D–10
 ELECTRICAL SYSTEM

Figure 14 Figure 15
Voltage Regulator-Relay Settings Circuit Diagram for 3GC-12V Regulator
VOLTAGE REGULATOR The battery has three major functions to perform. These
With ref. to Figure 14 & 15. being:
The 3 GC regulator is three element device, which (a) To provide a source of current for starting, lighting
regulates the voltage, current and also connects the and horn.
dynamo with the battery when the voltage of the former (b) To help control the voltage in the electrical
is greater than the voltage of the later. system.
The regulator is a riveted-up construction and should (c) To store the current produced by dynamo and to
be services only by authorised Lucas TVS service furnish the current when the electrical demands
agents. momentarily exceed the dynamo output.
NOTE: The regulator must be earthed properly. It is CONSTRUCTION
recommended that the Dynamo 'E' (earth) The battery is constructed in such a manner that each
terminal is connected with the regulator earth cell contains positive and negative plates alternately
terminal by a cable. placed next to each other. Each negative plate is
BATTERY separated from the positive plate by a non-conducting
The tractor is provided with a 12 volt battery. The battery porous separator, which prevents the plates from
is of six cell construction and each cell produces touching each other. All the positive plates are joined
approximately 2 volts for total battery output of 12 volts. together to a post strap, forming a positive (+ve) group,
The battery is located above the tractor engine and is and all the negative plates are joined together to a
securely mounted to a swing out type tray for easy similar post strap, forming a negative (-ve) group. There
servicing. The negative terminal is earthed at the starter are always one less positive plate then negative plates
motor body. in each cell.

SPECIFIC GRAVITY READINGS

Battery Condition
Climate normally below 28°C Climate normally above 28°C
Fully charged 1.270 - 1.290 1.210 - 1.230
Half discharged 1.230 - 1.250 1.170 - 1.190
Fully discharged 1.100 - 1.120 1.050 - 1.070
For initially filling of the 1.200 1.215
electrolyte.

D–11
 ELECTRICAL SYSTEM

The terminals are built up through the covers from the from obstruction. If not, any dirt should be
negative and positive group plate straps. Each cell removed by means of a piece of wire. Clogged
has an opening at the top through which liquid plugs will cause pressure to build up in the cells
electrolyte can be added when the filler caps are due to the production of gases during charging
unscrewed. and may result in damage.
CHEMICAL ACTIVITY IN THE BATTERY 2. Always keep the top of battery clean and dry.
The liquid, called the electrolyte, is made up of about 3. Examine the level of the electrolyte in each cell,
40 percent sulfuric acid and abot 60 percent distilled and if necessary, add distilled water to bring the
water. When sulfuric acid is placed between the plates, electrolyte level just above the top of the
the chemical action takes place that removes the separators to have the better performance and
electrons from one group of plates and masses them long life of battery.
at the other. This transfer of electrons is carried on by 4. Check battery terminal poles and if badly
chemical activity until there is sufficient imbalance of corroded, clean with diluted ammonia. Also
electrons to create a 2 volt pressure between the two examine the connections and see that the
groups of plates. This results in a pressure of 2 volts terminal clamp bolts are tight.
between the two terminals of the battery cell. After a 5. Smear the terminals with petroleum jelly.
certain amount of current has been withdrawn, the 6. Check and ensure that the earthing lead
battery is discharged and is not capable of delivering connection from the battery is making a good
any additional current. When the battery has reached clean contact and that the securing nut is tight.
this state, it may be charged. This is done by supplying
7. Check the specific gravity of the electrolyte in
it with a flow of current from some external source
each cell to examine the state of charge of the
such as dynamo, which forces current through the
battery.
battery in reverse direction. This reverses the chemical
8. Take the voltage test of each cell to check the
acitivities in the battery. Thus the chemicals are
condition of the cells.
restored to their original form and the battery becomes
9. Always see that the battery is charged properly
recharged. It is then ready to deliver additional current.
by the current produced by dynamo and avoid
SPECIFIC GRAVITY
over charging the battery. The temperature should
The electrolyte in a fully charged battery is 1.215 to
not exceed 125°F (52.7°C) while fast charging,
1.235 (for temperatures above 28°C) times as heavy
otherwise it may be severely damaged.
as pure water when both liquids are at the same
10. Under normal conditions of operation, water is
temperature. Therefore, the electrolyte of a fully
the only chemical, lost as a result of charging.
charged battery will be having a specific gravity of 1.215
Never add sulfuric acid to top up the battery unless
to 1.235 (for temperatures above 28°C)
the electrolyte level has been lost through spillage,
Removal and Installation
and electrolyte, if added, must be of the correct
1. Swing out the battery tray by loosening the wing specific gravity.
nut.
11. Battery should not be left in discharged state,
2. Disconnect the cable battery to earth and cable, as this will have a bad effect upon the plates and
battery to starter motor from the negative and may ruin them completely. If the battery is left
positive poles of battery correspondingly. out of use, see that this is fully charged every
3. Remove the wing nuts and washers from the hold fortnightly by a short charge to prevent, by
down clamp bolts. Remove the battery hold down tendency of the plates, to deteriorate.
clamp.
BATTERY TESTS
4. Lift the battery from the battery tray.
A. SPECIFIC GRAVITY TEST
5. For reinstalling the battery proceed in reverse
Check the specific gravity of a battery with hydrometer.
order of removal.
1. With the float in a vertical position, away from
PERIODICAL MAINTENANCE
the side of the barrel, take the reading with eye
1. Swing out the battery. Unscrew the vent plugs
at the level of the bottom of the curved portion of
and ensure that the holes in each plug are free
the liquid.

D–12
 ELECTRICAL SYSTEM

Figure 16
Exploded View of Starter Motor

1. Screw Brush Carrier Assy. 21. Field Terminal 41. Leaver & Peg Assy.
2. Sealing Bush 22. Solenoid Terminal Nut 42. Grommet
3. C.E. Bracket Assy. 23. Spring Washer 43. Drive Assy.
4. Sealing Ring C.E. 24. Solenoid Terminal 44. Lock Nut
5. Dowel 25. Main Terminal Nut 45. Pivot pin
6. C.E. Bush 26. Spring Washer 46. Dowel
7. Thrust Washer Steel 27. Main Terminal 47. Sealing Bush
8. Thrust Washer Insul 28. Solenoid Base Assy. 48. Gasket
9. Brush Assy. 29. Pole Screw 49. Thrust Collar
10. Brake Shoe Spring 30. Spring Washer 50. Jump Ring
11. Brake Shoe 31. Tab Washer 51. Fixing Bracket Assy.
12. Brush Carrier Assy. 32. Sealing Bush 52. Spring Washer
13. Brush Spring 33. Through Bolt 53. Screw Sol. Fixing
14. Armature Assy. 34. Solenoid Switch 54. Earth Terminal Nut
15. Connector 35. Plunger Spring 55. Spring Washer
16. Field Terminal Nut 36. Plunger Assy. 56. Plain Washer
17. Spring Washer 37. Field Coil Assy. 57. Earth Terminal
18. Insul Bush 38. Sealing Ring D.E. 58. Bearing Bush Fixing Bracket
19. Plain Washer 39. Intermediate Bracket Assy.
20. Insul Bush 40. Bearing Bush Intermediate Bracket

D–13
 ELECTRICAL SYSTEM

2. Specific gravity should not vary more than 0.025 CHECKING OF THE STARTER MOTOR
points from cell to cell. In the event of the starter motor failing to crank the
3. If the specific gravity is below 1.250, charge the engine at a high engine speed to allow it to start, first
battery and inspect the charging system to check the state of charge of the battery and the
determine the cause of the low battery charge. tightness and cleanliness of all the heavy duty
B. CHARGE electrical joints.
The voltage of the individual cell can be checked with FREE RUN & LOCK TORQUE TEST
the help of a battery tester.
1. A voltage of 2 to 2.2 volt. per cell with a
hydrometer reading of 1.235 indicates that the
battery is fully charged and in good condition.
2. A voltage of less than 1.0 volt per cell with a
hydrometer reading of 1.050 or less, indicates
that the battery is nearly discharged.
3. A voltage reading of 1.2 volt or less per cell, with
hydrometer reading of 1.200 or more, indicates
that excessive acid gravity has been added to
the cell.
3. STARTER MOTOR
The tractor employes a Lucas-TVS model 5SM114 for Figure 17
FT-60 starter motors. Figure 16 shows Exploded view Note: a. Amps meter 0-300 Amps with external
of Starter Motor. shunt.
TECHNICAL CHARACTERISTICS b. Volt meter 0-20 Volt.
The starter motor is four pole series connected D.C. This usually solves most of the starting problems. If
Unit. The armature shaft runs on self-lubricated the slow speed cranking still persists or the starter
bearings. Drive engagement into the ring gear is made motor fails to function at all, it is necessary to remove
by energising a solenoid switch, which actuates a roller the unit from the engine. After its removal from the
clutch mounted on a helical spline formed on the end engine a simple functional check can be made on the
of the armature shaft. Only following drive engagement solenoid switch and the motor separately. To check
with the ring gear is the electrical supply made to the the solenoid, connect the one lead from a 12 volt battery
starter, thereby ensuring a long life for the pinion and to the supply terminal and the other battery lead to
ring gear. Over speed the roller switch gives protection the body of the starter. This should cause the starter
for the starter armature. drive to move along the armature shaft. If an ammeter
PERFORMANCE DATA is put in series with teh solenoid and a connectin also
made between the solenoid terminal and the top main
Performance with 120Ah fully charged battery at
terminal, then, with 12V applied, the ammeter should
+20°C.
read approximately 20 amps. when the drive is fully
5SM 114
engaged.
(FT -60)
A high current reading (20A) of failure of the drive to
Power Output 2.2 Kw move at all, means the solenoid is faulty and should
be returned to recognised LUCAS SERVICE CENTRE
Lock torque 3.6 Kg.m.(min) at 5.6 volts for rectification or replacement. A direct light run check
current 1020 Amps (max) can also be made on the starter at this time. Free run
test can be carried out with reference to chart-I. If the
Run torque 0.97 Kg.m. (min) at 9.3V
motor fails to rotate is sluggish or takes a high current,
current 390 Amps (max)
1600 RPM (min) it should be returned to a recognised LUCAS
SERVICE CENTRE.
CHART-1

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 ELECTRICAL SYSTEM

If prior to removing the starter from the engine, the wheel the drive pinion in a clockwise direction, but the
starter rotates but the engine does not, this indicates whole armature should rotate when the pinion is turned
either a sticky or faulty roller clutch drive. The anti-clockwise. If the pinion rotates freely in both
subsequent solenoid check will reveal whether the drive directions, the drive will need to be replaced as a unit.
is sticky on teh shaft and a simple hand check can be Similarly, if the drive slips under load, replacement is
made on the drive itself. It should be possible to free also necessary; this fault, however, is unusual.

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 ELECTRICAL SYSTEM

ELECTRICAL SYSTEM
CHARGING SYSTEM-ALTERNATOR WITH
INTEGRAL REGULATOR

1. DESCRIPTION AND OPERATION This Section deals with the overhaul and repair of the
alternators featuring an integral regulator.
The Farmtrac Tractors feature a negative ground,
alternating current charging system comprising an
alternator, with Built in Regulator, storage battery and NOTE: ACR means Alternating Current charging
the necessary wires to connect the circuit. system with integral regulator.

Alternators provide a higher maximum output than the

The alternator is mounted at the front of the engine
equivalent direct current generators and also increased
being belt driven from the crankshaft pulley, Figure 2.
charge rates at lower engine speeds. Unlike a direct
current generator, the alternator does not require a
commutator and can be run safely at higher speeds. The alternator terminals are identified in Figure 1.

Figure 1 Figure 2
Alternator Terminal Indentification Alternator Installed on Tractor
1. IND (Indicator) Terminal 1. Alternator Assembly
2. Main Output Terminals (+ve) 2. Alternator Main Connector Plug
3. Battery Temperature Sensing Terminal 3. Battery Temperature Sensor Lead
4. Regulator and Brush box 4. Mounting Bolt
5. Radio Interference Suppressor 5. Regulator and Brush Box
6. Tachnometer/Overspeed Terminal 6. Belt Adjustment Bolt

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 ELECTRICAL SYSTEM

Figure 3
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/Brush Box 20. Rectifier 28. Fan
5. Nut 13. Bearing 21. Insulator 29. Double Spacer
6. Suppressor 14. Nut 22. Nut 30. Front End Bracket
7. Washer 15. Washer 23. Washer
8. Nut 16. Insulator 24. Pulley
With reference to Figure 3, the alternator comprises Current is supplied to and returned from the rotor field
principally: coil via two carbon brushes which bear against slip
Rotor rings on the rotor shaft.

Stator As current passes through the copper wire of teh rotor

field coil a magnetic field is produced and contained
Rectifier Pack
within an armature formed into pole shoes. The
Regulator/Brush Box configuration of the pole shoes ensures concentration
ROTOR of the magnetic field.

The rotor and brush gear provide the magnetic field of STATOR
the alternator unlike a direct current generator where The stator contains the windings into which current is
the field is stationary. induced by the revolving magnetic field of the rotor.
The rotor is belt driven from the engine through a pulley The stator is fabricatd from laminations of thin steel
keyed to the rotor shaft which runs in heavy-duty sealed pressings onto which three separate wires are wound.
ball race bearings. An integral fan, adjacent to the The laminations are specially formed to concentrate
pulley, draws cooling air through the alternator. and collect the magnetic field.

D–17
 ELECTRICAL SYSTEM

Figure 4 Figure 5
Rectifier Assembly Regulator and Brush Box Assembly
1. Field Diode Module 1. Brushes
2. IND (Indicator) Terminal
3. Alternator Output Terminal (+ve)
4. Positive Plate Diodes
5. Negative Plate
6. Positive Plate Diodes
7. Radio Interference Suppressor Terminal

During each complete revolution of the rotor, all three which allows current to flow in one direction only.
stator windings have induced currents passing first in
Three of the six output diodes are mounted in a positive
one direction and then the other; in other words a 3-
plate and three in a negative plate. The two plates are
phase alternating current.
separated and terminal links enable each of the three-
Because alternating current is generated in a series stator output wires to connect to a different diode in
of pulsations, the rotor featurs six pairs of poles to each plate.
provide an overall smoother output. For every revolution
As the rotor revolves, the diodes rectify or convert the
of the rotor the output characteristic of each stator
alternating current of the stator to a direct current,
winding completes six cycles.
which may be used to effectively charge the battery.
Alternating current (AC) is unsuitable for charging the
The three field diodes are mounted in a third plate,
battery, which requires pure direct current (D.C.).
similar to the output diodes, and each of the three
Therefore the three-stator windings are connected to
stator output wires also connects to one of these
a rectifier pack, which rectifies or converts the alternator
diodes. The field diodes supply direct current to the
output to direct current.
rotor field winding and can only be replaced as a
RECTIFIER compelte unit.

The rectifier consists of a pack of six outputs and three REGULATOR AND BRUSHES
field diodes, Figure 4.
The regulator controls and maintains the alternator
NOTE: A diode is basically an electronic 'check valve' output voltage at a safe working level.

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 ELECTRICAL SYSTEM

Figure 6
Alternator Charging Circuit (With Battery Temperature Compensation)
A. To Starter Motor B. To Load

1. Solenoid 5. Regulator 9. Surge Protection Diode

2. Battery 6. Frame 10. Charge Indicator Light
3. Battery Temperature Sensor 7. Stator Output Windings 11. Key Start Switch
4. Rotor Field Winding 8. Rectifier Pack

The regulated voltage level is established in This direct current is fed back to supplement the
manufacture and can not be adjusted in service: The current flowing through the rotor field winding. This
regulator components are housed in a sealed assembly action results in an ever increasing magnetic influence
which is integral with the alternator brush box. of the rotor along with an associated rapid rise in
Individual brush box and regulator components are not generated output current and voltage.
serviceable and have to be replaced as a complete During the rise in generated output voltage (reflected
assembly. at terminal IND) the brilliance of the warning light is
ALTERNATOR OPERATION reduced and when the voltage at the IND terminal
equates to that at the battery side of the warning light
With reference to Figure 6. When the key start switch
the lamp is extinguished.
is turned on a small current flows from the battery
through the rotor field winding. The circuit is made via The voltage continues to rise until the predetermined
the charge indicator warning light, alternator terminal regulated voltage level is reached.
IND, the rotor field winding, the alternator regulator In the event of drive belt breakage the voltage will not
and ground. build up within the alternator and so the charge indicator
At this stage the warning light is illuminated and the light will remain on to indicate failure.
rotor partially magnetised. BATTERY TEMPERATURE
When the engine is started and teh partially magnetised COMPENSATION
rotor revolves within the stator windings a 3-phase Because charging systems are directly affected by
alternating current is generated. A constant portion of changes in battery temperature and loading, the
the generated current is converted to direct current by alternator charging system features combined battery
the three field diodes incorporated in the rectifier pack. temperature and system voltage sensing.

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 ELECTRICAL SYSTEM

Figure 7 Figure 8
Battery Temperature Sensor Drive Belt Deflection
1. Battery Tray
2. Sensor

A circular temperature sensing pad is locatd directly ALWAYS disconnect the battery ground
under and in contact with the battery, Figure 7. cable when charging the battery in the
tractor using a battery charger.
The sensor detects any changes in battery temperature
and relays this information to the voltage regulator ALWAYS observe correct polarity when
installing the battery or using a slave battery
which adjusts the charge rate accordingly.
to start the engine.
2. CHARGING SYSTEM-A 127/55 AMP
CONNECT POSITIVE TO POSITIVE AND NEGATIVE
ALTERNATOR WITH INTEGRAL
TO NEGATIVE
REGULATOR SERVICE
PRELIMINARY CHECKS
PRECAUTIONS, PRELIMINARY
CHECKS, INITIAL TESTS AND Prior to electrical testing, thoroughly inspect the
ALTERNATOR COMPONENT TESTS charging and electrical system.
Check all leads and connections for continuity and
SERVICE PRECAUTIONS
tightness.
To avoid damage to the components of the alternator
1. Check the Battery
charging system, service precautions must be
observed as follows: With an hydrometer, check the battery is at least
70% charged and in good condition.
NEVER make or break any of the charging
2. Check the Drive Belt
circuit connections, including the battery,
when the engine is running. Ensure the alternator drive belt and pulley are in
satisfactory condition. Allow 0.50-0.75 in. (13-19
NEVER short any of the charging components mm.) deflection when moderate finger pressure
to ground. is applied to the longest run of teh belt, Figure 8.
ALWAYS disconnect the battery ground 3. Check the Warning Light
cable when installing or removing the
Turn on the key start switch and check the
alternator. warning light is fully illuminated.

D–20
 ELECTRICAL SYSTEM

If the warning light is not fully illuminated, check the

bulb. If the bulb is not the cause of the fault, carry out
the Alternator Plug Connections Test as detailed under
"Initial Tests" in this Chapter.
If the warning light is illuminated, start the engine and
run above the idling speed when the warning light should
be extinguished.
If the warning light does not go out, stop the engine
and remove the alternator main terminal connector plug.
If the warning light is extinguished, a faulty surge
protection diode, temperature sensor or alternator
component is indicated. Conduct the "Alternator
Components Tests" as detailed in this Chapter.
If the warning light remains illuminated, check for a
Figure 9
shorting to frame in the area between the "IND" cable
Alternator Plug Connections Test
end and the warning light.
1. Alternator Main Connector Plug
Initial Tests 2. Voltmeter (0-30 Volts)
The initial tests may be performed without removing 3. Alternator Frame
any of the charging circuit components from the tractor
and enable the following items to be checked: 2. Remove the main connector plug from the
Alternator Plug Connections. alternator and connect a voltmeter in turn
Battery Temperature Sensor Circuit. between each of the plug terminals and the
alternator frame (negative side of voltmeter to
Alternator Charging Current and Controlled
frame). Battery voltage should be registered.
Voltage.
NOTE: In some cases only one of teh two main
Alternator Charging Circuit Volt Drops
terminals in teh connector plug is actually
Alternator Maximum Output Performance connected to the harness.
Test equipment required: If battery voltage is not registered, a continuity
Voltmeter (0-20 Volts) fault in the external cable circuitry must be traced
Millivoltmeter (0-1 Volt) and remedied, refer to the circuit diagram shown
Ammeter (0-60 Amperes Moving Coil Type) in Figure 6.

1.5 Ohm 40 Amperes Variable Load Resistor 3. Connect one end of a jumper lead to the "IND"
terminal of the connector plug and the other end
205 Ohm Resistor
to the alternator frame. The warning light should
Jumper Lead 0.25 in. (6.35 mm.) Male to Female be illuminated.
Blade Terminal.
4. Disconnected the jumper lead and reconnect
NOTE: Most commercial test equipment the plug to the alternator.
incorporates several testing devices within a
NOTE: If the warning light fails to illuminate when
single unit. Use such equipment according
the plug is reconnected to the alternator
to the manufacturer's instructions.
regulator or rotor circuits. Ensure the
1. ALTERNATOR PLUG CONNECTIONS TEST alternator "IND" terminal is clean and tehn
1. With reference to Figure 9. Turn the key start conduct the "Alternator Component Tests"
switch on but do not start the engine. as detailed in this Chapter.

D–21
 ELECTRICAL SYSTEM

Figure 10 Figure 11
Battery Temperature Sensor Circuit Test Connection of 205 Ohm Test Resistor
1. Sensor Lead 1. 205 Ohm Resistor 3. Battery Tray
2. Voltmeter (0-30 Volts) 2. Harness to Sensor Plug 4. Temperature Sensor
3. Alternator Frame

2. Battery Temperature Sensor Circuit Test 3. Charging Current and Controlled Voltage
Tests
1. Reference to Figure 10. Remove the sensor lead
from the alternator "S" terminal. 1. With reference to Figure 12. Ensure all tractor
electrical components are switched off and the
2. Connect a voltmeter between the sensor lead and
key start switch is in the "OFF" position.
the alternator frame (negative side of voltmeter
to frame). Battery voltage should be registered.
If battery voltage is not registered, disconnect
the harness to sensor plug and connect a 205
ohm resistor across the plug terminal, Figure 11.
NOTE: It is recommended that a permanent test
piece be made by removing the plug and
leads from an old sensor unit and connecting
a 205 ohm resistor as shown in Figure 11.
If battery voltage is now registered, the sensor
unit is faulty (open circuit) and must be replaced.
If battery voltage is not registered a continuity
fault in the external circuitry must be traced and
rectified. Reconnect the sensor and confirm Figure 12
battery voltage is registered. Charging Current and Controlled Voltage Tests
1. Jumper Lead
NOTE: It is very difficult to test prove the effective
2. Alternator Main Connector Plug
resistance of a temperature sensor. If such 3. Voltmeter (0-30 Volts)
a unit is suspected of being faulty it should 4. Alternator Frame
be replaced and proved in service. 5. Ammeter

D–22
 ELECTRICAL SYSTEM

2. Disconnect the battery ground cable (negative

and remove the main connector plug from the
alternator but leave the sensor lead connected
to the "S" terminal.
3. Connect a jumper lead between the "IND"
terminals of the connector plug and the alternator.
4. Securely connect an ammeter negative side to
the connector plug main terminal and positive
side to the alternator output terminal.
5. Connect a voltmeter between the alternator
output terminal and the frame (negative side to
frame).
6. Reconnect the battery and turn the key start
switch to the "ON" position. Figure 13
7. Start the engine and increase the speed to 2000 Insulated-side Volt Drop Test
rev/min. and observe the ammeter and voltmenter (Inset showing connection of Millivoltmeter and
readings. variable Load Resistor to Battery)
1. Alternator Main Connector Plug
If the ammeter registers a charging current stop
2. Ammeter
the engine. 3. Jumper Lead
If the ammeter registers zero amperes a faulty 4. Millivoltmeter (0-1 Volts)
alternator component is indicated. Turn off the 5. Variable Load Resistor
engine and conduct the "Alternator Components
Tests" as detailed in this Chapter. 2. Disconnect the battery ground cable (negative)
and remove the main connector plug from the
8. Disconnect the harness to sensor plug and
alternator but leave the sensor lead connected
connect a 205 ohm resistor across the plug
to the "S" terminal.
terminals.
3. Connect a jumper lead between the "IND"
9. Restart the engine and increase the speed to
terminals of the connector plug and the alternator.
2000 rev/min. Observe the ammeter and voltmeter
readings. 4. Connect a millivoltmeter between the battery
positive terminal and the connector plug main
The voltmeter reading exceeds 14.5 volts, the
terminal (positive side to plug).
alternator regulator must be replaced as
5. Securely connect an ammeter between the main
described in this Chapter. (When a new regulator
output terminal of the alternator and teh connector
has been installed, conduct Tests 4 and 5).
plug main terminal (negative side to plug).
If the voltmeter reading is below 13.8 volts a faulty
6. Re-connect the battery earth cable and connect
alternator component or a high resistance fault
a variable load resistor, with the slider in the
in the external connections of the charging
minimum current draw position (maximum
system is indicated.
resistance), across the battery terminals.
10. Stop the engine.
7. Start the engine and increase the speed to 2000
4. Charging Circuit Volt Drop Tests rev/min.
a. Insulated-side Volt Drop Tests 8. Slowly increase the current loading of the resistor
1. With reference to Figure 13. Ensure the key start (decrease resistance) until the ammeter registers
switch is in the "OFF" position. 55 amperes.

D–23
 ELECTRICAL SYSTEM

Figure 14 Figure 15
Ground-side Volt Drop Test Maximum Output Performance Test
(Inset showing connection of Millivoltmeter and (Inset showing connection of variable Load
variable Load Resistor to Battery) Resistor to Battery)
1. Alternator Main Connector 1. Alternator Main Connector Plug
2. Ammeter 2. Voltmeter (0-30 Volts)
3. Jumper Lead 3. Jumper Lead
4. Millivoltmeter (0-1 Volt) 4. Ammeter
5. Variable Load Resistor 5. Variable Load Resistor
9. Observe teh millivoltmeter reading which should 3. Start the engine and increase the speed to 2000
not exceed 400 millivolts. rev/min.
If the reading in excess of 400 millivolts, a high 4. Slowly increase the current loading of the resistor
resistance fault is indicated in the external (decrease resistance) until the ammeter registers
circuitry. 50 amperes.
If the required alternator output can not be 5. Observe the voltmeter reading which should not
achieved, and the millivoltmeter reading is less exceed 200 millivolts.
than 400 millivolts, then a faulty alternator If the reading is in excess of 200 millivolts, a
component is indicated. Conducted the high resistance fault is indicated in the external
circuitry.
"Alternator Component - Tests" as detailed in this
Chapter. If the required alternator output can not be
achieved, and the millivoltmeter reading is
10. Stop the engine.
component is indicated. Conduct the "Alternator
b. Ground-side Volt Drop Test Component" Tests? as detailed in this Chapter.
1. With reference to Figure 14. Ensure the key start 6. Stop the engine.
switch is in the "OFF" position. 5. Aleternator Maximum Output Performance
2. The circuit is the same as that used in the previous Test
test except for the millivoltmeter which is now 1. With reference to Figure 15. Ensure the key start
connected between the battery negative terminal swtich is in the "OFF" position.
and the alternator frame (negative side to frame). 2. Disconnect the battery ground cable (negative)
NOTE: Ensure the variable load resistor is in the and remove the main connector plug from the
minimum current draw position (maximum alternator, but leave the sensor lead connected
resistance). to the "S" terminal.

D–24
 ELECTRICAL SYSTEM

3. Connect a jumper lead between the "IND"

terminals of the connector plug and the alternator.
4. Securely connect an ammeter negative side to
the connector plug main terminal and positive
side to the alternator output terminal.
5. Connect a voltmeter between the alternator
output terminal and the frame (negative side to
frame).
6. Disconnect the harness to sensor plug and
connect a 205 ohm resistor across the plug
terminals.
7. Reconnect the battery and turn the key start
switch to the "ON" position.
8. Start the engine and increase the speed to 2000 Figure 16
Regulator and Rotor Field Circuit Test
rev/min.
1. 2.2 Watt Test Lamp
9. Slowly increase the current loading of the resistor 2. IND (Indicator) Terminal
(decrease resistance) unitl the ammeter registers 3. 12 Volt Battery
50 amperes. 4. 205 Ohm Resistor
10. Observe the voltmeter reading which should not 5. Sensor Terminal
fall below 13.4 volts.
and the battery ground cable
If the reading falls below 13.4 volts a faulty alternator
(negative) is disconnected.
component is indicated. Conduct the "Alternator
Component Tests" as detailed in this Section. Test equipment required:

ALTERNATOR COMPONENT TESTS 12 Volt Battery

The component tests, which should only be conducted 12 Volt 2.2 Watt Test Lamp
if the INITIAL TESTS have indicated a faulty alternator 1. Regulator Test
component, enable the following items to be checked: 1. With reference to Figure 16. Connect a 12 volt
Regulator battery and a 2.2 Watt test lamp in series
Brushes-and-Springs and Rotor Slip Rings between the "IND" terminal and the alternator
frame (negative side to frame).
Rotor Field Winding Continuity
2. Connect a 205 Ohm resistor between the positive
NOTE: The component tests may be performed
terminal of the battery and the sensor terminal.
without removing the alternator from the
tractor but will necessitate removal of the The test lamp should be illuminated.
alternator moulded slip ring end cover. Testing If the test lamp is not illuminated make the
of any other alternator components will regulator inoperative by linking the regulator case
necessitate removal of the alternator from to the alternator frame.
the tractor. Refer to "Overhaul-Electrical If the test lamp is now illuminated the regulator
Tests" as detailed in this Section. is faulty and must be renewed as detailed in this
IMPORTANT: Prior to removal of the main connector Section.
plug from the alternator ensure the key If the test lamp is not illuminated, a fault is
start switch is in the "OFF" position indicated in the rotor circuit.

D–25
 ELECTRICAL SYSTEM

Figure 17 Figure 18
Rotor Field Winding Continuity Test Alternator Installed on Tractor
1. Rotor 1. Alternator Assembly 4. Mounting Bolt
2. Slip Rings 2. Alternator Main 5. Regulator and
3. Ohmmeter Connector Plug Brush Box
3. Battery Temperature 6. Belt Adjustment Bolt
Sensor Lead

2. Brushes-and-Springs and Rotor Slip Rings lamp in series across the rotor slip rings.

1. Remove the brush box moulding as described in The test lamp should be illuminated.
this Section.
If the test lamp is not illuminated renew the rotor
2. Ensure the brushes and slip rings are clean and as detailed in the following Overhaul Section.
check for freedom of movement in the brush box
3. Connect on ohm meter between the two slip
moulding.
rings. The resistance is outside of the
If the visible length of the brushes, in the free specification renew the rotor assy.
position, is less than 0.25 in. (6 mm.) this is a 3. CHARGING SYSTEM-ALTERNATOR
probable cause of non-continuity in the field WITH INTEGRAL REGULATOR-
circuit. The brush-and-spring assemblies should OVERHAUL
be renewed if the overall length of the brushes is
less than 0.3 in. (8 mm.). Reference Fig. 5. REMOVAL

3. Rotor Field Winding Continuity Test 1. Disconnect the battery negative cable.

With reference to Figure 17. 2. Disconnect the alternator connector plug, Figure
18.
1. Remove the regulator and brush box assembly
3. Withdraw the adjustment and mounting bolts and
as described in this section.
remove the alternator and pulley guard from the
2. Connect a 12 volt battery and a 2.2 watt test tractor.

D–26
 ELECTRICAL SYSTEM

Figure 19
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/Brush Box 20. Rectifier 28. Fan
5. Nut 13. Bearing 21. Insulator 29. Double Spacer
6. Suppressor 14. Nut 22. Nut 30. Front End Bracket
7. Washer 15. Washer 23. Washer
8. Nut 16. Insulator 24. Pulley
DISASSEMBLY
With reference to Figure 19.
1. Remove the nut from the alternator through bolt,
allowing the radio interference suppressor to be
disconnected and removed.
2. Remove the nut from the battery temperature
sensor terminal.
3. Remove the three securing bolts and withdraw
the regulator/bush box assembly. Separate the
wiring connection to the regulator.
4. Unscrew and remove the remaining three nuts
from the alternator through bolts. With a soft
mallet tap the threaded end of the through bolts
to release the spline at hexagon head end.
5. Mark the alternator front end bracket, stator, and
Figure 20
rear end bracket to ensure correct alignment on
Soldering and Unsoldering Diode Connections
re-assembly. Using Pliers as a Heat Guard
6. Gently tap the rear face of the alternator front 1. Diode
end bracket to separate the front end bracket 2. Stator Output Wire
and rotor assembly from the rear end bracket, 3. Pliers Placed Between Diode and Solder Point
stator and rectifier assembly. 4. Soldering Iron

D–27
 ELECTRICAL SYSTEM

7. Remove the nuts, washers and insulators from lamp in series with one of the diodes. One test
the stud terminals on the alternator rear end lead is applied to the diode connecting pin and
bracket and the two rectifier retaining screws. the other lead to the plate into which the diode is
Remove the stator and rectifier from the rear end mounted Figure 21.
bracket.
8. Unsolder the stator leads from the tags on the
rectifier, using a pair of pliers as a heat sink to
prevent the diodes from becoming overheated.
Figure 20.
9. Remove the nut, washer, pully spacer, washer,
fan and double spacer from the rotor shaft.
10. Press the rotor shaft out of the front and bracket
bearing.

Figure 22
Field Diode Test
1. IND (Indicator) Terminal
2. 2.2 Watt Test Lamp
3. 12 Volt Battery
4. Field Diode Connections

2. Note if the lamp lights.

3. Reverse the test lead connections.
The lamp should light during one half of this test only.
Figure 21 If any one diode fails this test, the complete rectifier
Output Diode Test assembly must be renewed.
1. Diode Connecting Pin
Rectifier Assembly - Field Diodes
2. 2.2 Watt Test Lamp
3. 12 Volt Battery Three separate field diodes are contained within the
field diode module. Test each diode separately as
COMPONENT TEST follows:

The following electrical equipment is required to test 1. Connect a 12 volt battery and a 2.2 watt test
the rotor, stator windings and rectifier diodes. lamp in series with the field diode module. Apply
the negative test lead to the "IND" terminal and
12 Volt Battery
the other lead in turn to each of the field diode
Test Lamp (12 Volts 2.2 Watts) module connections. Figure 22.
Test Lamp (12 Volts 36 Watts Minimum) 2. Note if the lamp lights.
110 Volt Insulation Tester or 250V Megohm Meter/ 3. Reverse the test lead connections.
Rectifier Assembly-Positive/Negative Diodes The lamp should light during one half of this test only.
Test each of the six diodes separately as follows: If any one diodes fails this test, the complete rectifier
1. Connect a 12 Volt battery and a 2.2 Watt test assembly must be renewed.

D–28
 ELECTRICAL SYSTEM

STATOR
Winding Insulation Test
1. Using a 110V insulation tester or 250V megohm
meter test the insulation between each of the
three stator output leads and the stator
laminations.
If the test results prove unsatisfactory the stator
assembly must be renewed.

Figure 24
Stator Winding Continuity Test
1. Stator Windings
2. Stator Output Wires
3. 12 Volts Battery
4. 36 Watt Test Lamp
and require re-finishing use very fine glass paper
(not emery cloth) and wipe clean.
NOTE: Ensure the re-finishing glass paper is
sufficiently fine to produce a highly polished
Figure 23 slip ring surface otherwise excessive brush
Stator Winding Insulation Test wear will occur.
1. Stator Laminations 2. If the slip rings are excessively worn a new rotor
2. Stator Output Wires must be installed.
3. 110V/Insulation Tester or 250V Megohm Meter Field Winding Continuity/Resistance Test
Windings continuity Test With reference to Figure 25.
With reference to Figure 24.
1. Connect any two of the three stator output wires
in series with a 12 volt battery operated test lamp
of not less than 36 watts. The test lamp should
light.
2. Transfer one of the test lamp leads to the third
wire. The test lamp should light.
If the test results prove unsatisfactory the stator
assembly must be renewed.
Rotor
Prior to performing component tests on the rotor
the following slip ring inspection should be carried
Figure 25
out. Field Winding Continuity/Resistance Test
1. Ensure the slip rings are clean and smooth. If 1. Rotor
necessary the slip rings may be cleaned with a 2. Slip Rings
petrol-moistened cloth. If the slip rings are burnt 3. Ohm Meter

D–29
 ELECTRICAL SYSTEM

1. Connect an ohmmeter between the two rotor slip

rings. Check that the rotor field winding
resistance is within acceptable tolerances, see
"Specifications".
If the test result proves unsatisfactory, the rotor must
be renewed.
Field Winding Insulation Test
With reference to Figure 26.

Figure 27
Rear End Bearing Removal
1. Bearing
2. Housing (Rear End Bracket)

size mandrel, carefully drive out the bearing,

Figure 27.
5. Clean and examine all components.
Figure 26 6. Press the new bearing into the housing. The
Field Winding Insulation Test bearing should be positioned 0.50-0.70 mm.
1. Rotor Pole (.020-.028 in.) proud of the inner face of the
2. Slip Rings bearing boss, Figure 28.
3. 110V/230V insulation Tester qr250V Megohm Meter

Using a 110V insulation tester or 250V megohm meter

test the insulation between each of the slip rings and
the rotor poles.
If the test results prove unsatisfactory the rotor
assembly must be renewed.
INSPECTION AND REPAIR
1. Inspect the roto poles and stator for signs of
rubbing. Areas of rubbing indicate both bearings
are excessively worn and need replacing.
2. If the front (drive) end bearing is defective the
complete housing (front end bracket) and bearing
assembly must be renewed.
Figure 28
3. Inspect the roller bearing located in the rear (slip
Rear End Bearing Installation
ring) end bracket for wear and damage. 1. Housing
4. If bearing replacement is necessary support the 2. Bearing
housing (rear end bracket) and, using a suitable 3. Bearing Protrusion

D–30
 ELECTRICAL SYSTEM

RE-ASSEMBLY On installation observe the following requirement:

1. Re-assembly of the alternator follows the Ensure the battery ground (negative) cable is
disassembly procedure in reverse. disconnected from the battery when installing the
alternator.
On re-assembly observe the following requirement:
Adjust the alternator drive belt tension as
To avoid misalignment of the end brackets, install
previously described in this Chapter.
the stator assembly in the drive end bracket then
assemble the slip ring end bracket to the stator
laminations.
INSTALLATION
1. Installation of the alternator is the removal
procedure in reverse.

D–31
 ELECTRICAL SYSTEM

D. CHARGING SYSTEM A127-55 AMP

ALTERNATOR WITH INTEGRAL REGULATOR
SPECIFICATIONS

DESCRIPTION FARMTRAC-60

Alternator Type A127 - 55

Polarity Negative Ground
Nominal Voltage 12.0 V
Maximum Rev./Min. 15.000
Maximum Output 55A
Regulator Controlled Voltage 13.6 - 14.4 V
Rotor Field Winding Resistance -
Stator Winding Resistance (Per Phase) -
New Brush Length 17.0 mm.
Minimum Brush Length 5.0 mm.
Brush Spring Pressure 1.3 - 2.7N (4.7 - 9.8 oz)

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS UNITS FARMTRAC-60

Alternator Through Bolt lbf.ft 4.0

(kgf.m) (0.55)

Shaft Nut lbf.ft 27.5

(kgf.m) (3.82)

Rectifier Attaching Screws lbf.ft 2.5

(kgf.m) (0.35)

Regulator And Brush Box Screws lbf.ft 2.0

(kgf.m) (0.27)

Main Output Terminal Nut lbf.ft 2.0

(kgf.m) (0.27)

Phase Terminal Nut lbf.ft 3.0

(kgf.m) (0.42)

D–32
 ELECTRICAL SYSTEM

4. TROUBLE SHOOTING
IMPORTANT: Whenever effecting a repair the cause of the problem must be investigated and corrected to
avoid repeat failures. The following table lists problems and their possible causes with
recommended remedial action.
LIGHTING SYSTEM
PROBLEM POSSIBLE CAUSES REMEDY

Several or all lights do not 1. Battery discharged. 1. Check battery and charge or
illuminate renew.
2. Loose or defective battery cable 2. Inspect, clean and tighten
connections. connections.
3. Loose harness connection. 3. Check and ensure connections
securely engaged.
4. Fuse(s) burnt out. 4. Inspect and renew, check circuit
before reconnecting power.
5. Faulty wiring. 5. Check lighting circuit wiring and
repair or renew.
6. Defective light switch. 6. Check and renew.
7. Several light bulbs burnt out due 7. Check and renew voltage regulator.
to defective voltage regulation.

Individual lights do not 1. Burnt out bulb. 1. Check and renew.

illuminate 2. Defective or corroded bulb 2. Inspect, clean or renew.
contacts.
3. Fuse burnt out. 3. Inspect and renew, check circuit
before reconnecting power.
4. Loose or broken wires. 4. Inspect, secure, repair or renew
wiring.
5. Poor ground connection. 5. Inspect, clean and tighten ground
connections.

Lights burn not repeatedly 1. Loose or corroded wiring 1. Inspect, secure, repair or renew
connections. wiring.
2. Loose bulb or lamp mounting 2. Inspect, tighten or renew.
bracket.
3. Faulty Voltage Regulator. 3. Check and renew voltage regulator.

Plough lamps inoperative 1. Side lights switch not turned on. 1. Ensure side lights are illuminated.
2. See "Individual lights do not 2. See "Individual lights do not
illuminate. illuminate".

D–33
 ELECTRICAL SYSTEM

PROBLEM POSSIBLE CAUSES REMEDY

Flasher lamps do not 1. Fuse blown. 1. Inspect and renew, check circuit
illuminate before reconnecting power.
2. Flasher unit inoperative. 2. Check and renew.
NOTE: Flasher unit may be by
passed by interconnecting terminals.
This enables circuit continuity to be
checked.
3. Flasher switch inoperative. 3. Check and renew.
4. Defective wiring or connections. 4. Inspect circuit, clean and tighten
connections or renew wiring.

Individual flasher lamp 1. Burnt out bulb. 1. Check and renew.

does not illuminate. 2. Corroded or loose bulb contacts. 2. Inspect, clean, tighten or renew.
3. Poor ground connection or damaged 3. Inspect, clean and tighten connection,
wiring. repair or renew wiring.

Turn indicator pilot 1. Faulty bulb(s). 1. Check and renew.

bulb(s) inoperative. 2. Defective flasher unit. 2. Check and renew.
3. Faulty wiring or connections. 3. Inspect, clean and tighten connections
or renew wiring.
4. Main flasher lamp bulb contacts or 4. Inspect, clean and tighten connections
ground connection corroded (failing to and ground connections.
draw full current).

INSTRUMENTATION 1. Faulty key start switch. 1. Inspect and check.

Warning lights and 2. Fuse(s) burnt out. 2. Inspect and renew, check circuit
gauges inoperative before reconnecting power.
3. Loose or broken wiring. 3. Inspect circuit, tighten connections or
renew wiring.

STARTING SYSTEM 1. Battery discharged. 1. Check battery and charge or renew.

Engine will not crank 2. Key start switch, safety start switch, 2. Check circuit and repair or renew
and starting motor relay or solenoid inoperative. faulty components.
relay or solenoid does 3. Starting circuit open or high resistance. 3. Check circuit connections and repair
not engage or renew faulty wiring.

Engine will not crank 1. Battery discharged. 1. Check battery and charge or renew.
but starting motor 2. Defective starting motor connections 2. Check, clean and tighten connection.
relay or solenoid or loose battery connections.
engages 3. Starting motor faulty. 3. Inspection, repair or renew.
4. Relay or solenoid contacts burnt. 4. Renew relay or solenoid.
5. Engine Seized. 5. Check engine crankshaft free to turn.

D–34
 ELECTRICAL SYSTEM

PROBLEM POSSIBLE CAUSES REMEDY

Starting motor turns 1. Defective starting motor drive 1. Inspect and repair or renew.
but does not crank assembly.
engine 2. Defective solenoid or pinion 2. Inspect and repair or renew.
engagement levers.
3. Defective flywheel ring gear. 3. Inspect and renew.

Engine crank slowly 1. Discharged battery. 1. Check battery and charge renew.
2. Excessive resistance in starting 2. Check circuit connections and repair
circuit. or renew faulty wiring.
3. Defective starting motor. 3. Inspect and repair or renew.
4. Tight Engine. 4. Investigate cause and effect repair.

CHARGING SYSTEM 1. Loose or worn dynamo/alternator drive 1. Check & adjust tension or renew.
Battery low in charge belt.
or discharged 2. Defective battery, will not accept or 2. Check condition of battery and renew.
hold charge.
3. Electrolyte level low. 3. Check, fill and charge.
4. Excessive resistance due to loose 4. Check, clean and tighten circuit
charging system connections. connections.
5. Defective voltage regulator. 5. Check and renew.
6. Defective dynamo/alternator. 6. See dynamo/alternator trouble
shooting guide.

Dynamo/Alternator 1. Defective battery. 1. Check condition of battery and renew.

charging at high rate 2. Defective voltage regulator. 2. Check and renew.
(battery consumes 3. Defective dynamo/alternator. 3. See dynamo/alternator trouble
more Electrolyte) shooting.

Dynamo/Alternator 1. Dynamo/Alternator drive belt broken. 1. Renew and tension correctly.

charging at high rate 2. Loose connection or broken cable in 2. Inspect system, tighten connections
(battery consumes charging system. and repair or renew faulty wiring.
more Electrolyte) 3. Defective voltage regulator. 3. Check and renew.
4. Defective dynamo/alternator. 4. See dynamo/alternator trouble
shooting.

Intermittent or low 1. Dynamo/Alternator drive belt slipping. 1. Check and adjust tension or renew.
d y n a m o / a l t e r n a t o r 2. Loose connection or broken cable in 2. Inspect system, tighten connections
output charging system. and repair or renew faulty wiring.
3. Defective voltage regulator. 3. Check and renew.
4. Defective dynamo/alternator. 4. See dynamo/alternator

D–35
 ELECTRICAL SYSTEM

PROBLEM POSSIBLE CAUSES REMEDY

ALTERNATOR 1. Faulty external charging circuit 1. Inspect system, clean and tighten
Alternator light dims connections. connections.
and/or battery low 2. Faulty rotor slip rings or brushes. 2. Inspect and repair or renew.

Warning light goes 1. Faulty external charging circuit 1. Inspect system, clean and tighten
out-becomes brighter connections. connections.
with increased speed 2. Faulty rectifier or rectifying diodes. 2. Check and renew.

Warning light normal 1. Defective voltage regulator. 1. Check and renew

but battery boiling 2. Faulty battery temperature sensor 2. Check and renew.
(where fitted).

Warning light normal 1. Defective voltage regulator. 1. Check and renew

but battery discharged 2. Faulty stator. 2. Check and renew.
3. Faulty rectifier or rectifying diodes. 3. Check and renew.

Warning light 1. Loose or worn alternator drive belt. 1. Check and adjust tension or renew.
illuminated 2. Faulty battery temperature sensor 2. Check and renew
continuously and/or (where fitted).
flat battery 3. Faulty rotor, slip rings or brushes. 3. Inspect, repair or renew.
4. Faulty voltage regulator. 4. Check and renew
5. Defective stator. 5. Inspect and renew
6. Defective rectifier or rectifying diodes. 6. Check and renew.

Warning light 1. Burnt out bulb. 1. Check and renew

extinguished 2. Alternator internal connections. 2. Inspect & test circuitry, repair or
continuously and/or renew.
flat battery 3. Defective voltage regulator. 3. Check and renew.
4. Faulty rotor, slip rings or brushes. 4. Check, repair or renew.
5. Defective stator. 5. Check and renew.

Warning light flashes 1. Faulty external charging circuit. 1. Inspect circuit, clean and tighten
intermittently connections, repair or renew faulty
wiring.
2. Alternator internal connections. 2. Inspect and test circuitry, repair or
renew.

Warning light dims

1. Defective rotor, slip rings or brushes. 1. Check, repair or renew.
continuously and/or
2. Defective voltage regulator. 2. Check and renew.
flat battery

D–36
 SECTION - 'E'

SINGLE CLUTCH
S.NO. CONTENTS PAGE

1. DESCRIPTION AND OPERATION E-3

2. ADJUSTMENTS E-3

3. REMOVAL AND INSTALLATION E-4

4. SEALED RELEASE BEARING E-5

5. PILOT BEARING E-6

6. TROUBLE SHOOTING E-7

7. SPECIFICATIONS E-9
 SINGLE CLUTCH

Figure 1
Sectional View of Clutch and it's Related Components

E–2
 SINGLE CLUTCH

SINGLE CLUTCH

1. DESCRIPTION AND OPERATION

With reference to Figure 1.
Farmtrac-60 tractor utilise a single plate clutch, the
disc of which incorporates friction linings and a splined
hub which locates the disc on the splines hub which
locates the disc on the splines of the trnasmission
input shaft. The disc is installed between the flywheel
and a pressure plate assemly which itself is attached
to the flywheel.
In the clutch "engaged" position the spring loaded
pressure plate presses the clutch disc into contact
with the engine flywheel and the drive from the engine
is transmitted to the transmission by the friction
between the linings, of the disc and the surfaces of Figure 2
the flywheel and pressure plate. Clutch Pedal Adjustment
"X" - Clutch Pedal Free Travel
A clutch pedal is connected by a rod to a lever and 1. Split Pin 3. Clevis 5. Locknut
cross-shaft assembly on which is mounted a fork. This 2. Clevis Pin 4. Release Rod 6. Cross-shaft Lever
fork engages a sliding release bearing and hub
The main springs of the pressure plate assembly then
assembly, the bearing of which contacts the ends of
re-assert pressure on the plate moving it forward to
release levers in the pressure plate assembly.
press the clutch disc into contact with the flywheel
Depression of the clutch pedal causes the cross shaft and re-establish the drive to the transmission.
and fork to move the release bearing forward and
2. ADJUSTMENTS
depress the pressure plate release levers, thus
drawing the pressure plate, away from the clutch disc CLUTCH PEDAL FREE PLAY
and releasing the disc from contact with the flywheel.
The only routine adjustment required is to check and,
The frictional drive to the transmission is hereby
where necessary, adjust the clutch pedal free travel
disconnected to enable gear changing to take place.
every 50 operating hours. The exact amount of free
After a gear change is made and the clutch pedal is travel is listed under "Specifications". Clutch pedal free
released, a spring returns the pedal to its free position travel is the amount of movement from the fully released
and the release bearing is drawn away from the release position of the pedal to the point where resistance is
levers of pressure plate assembly. just felt dimension "X" Figure 2.

E–3
 SINGLE CLUTCH

Figure 3
Single Clutch release lever setting procedure
1. Pillar Spacer 3. Centre Spacer 5. Gauge Finger
2. Bridge Spider 4. Gauge Finger Body 6. Locknut

To adjust the pedal free travel: be used and adjust release levers individually by turning
1. Remove the split pin, Figure 2, loosen the locknut the eye bolt nut until the specified height of 1.96 in. ±
and then remove the clevis pin. 0.020 in. (50 ± 0.5 mm.) is achieved at the contact tip
of release lever. Lock the nuts with the help of a centre
2. Turn the clevis to increase or decrease the
punch refer Figure 3.
effective over all length of the release rod after
loosening the lock nut increasing the effective 3. CLUTCH REMOVAL AND
length will give greater free travel, reducing the INSTALLATION
length will give less free travel. REMOVAL
3. Re-connect the clevis to the clutch cross-shaft
1. Separate the front axle and engine as an
lever, Figure 2 and check the pedal free travel.
assembly from the front transmission. See
Repeat the adjustment as necessary until the
"SEPARATING THE TRACTOR".
correct free travel is obtained then tighten the
locknut and install a new split pin to retain the 2. Remove the bolts securing the clutch pressure
clevis pin. plate and cover assembly to the flywheel, and

CLUTCH RELEASE LEVERS ADJUSTMENT remove the pressure plate assembly and the
clutch disc.
Satisfactory clutch operation is entirely dependent on
the correct adjustment of the release levers and should NOTE: Care should be taken to slacken the bolts
only require attention if new parts have been fitted. progressively across the clutch to avoid
distortion of the cover plate.
Place the clutch cover assembly on a surface plate,
or, in the absence of a surface plate the flywheel can INSPECTION

E–4
 SINGLE CLUTCH

1. Inspect the clutch disc to make sure that the

linings are not loose, cracked, worn or oil soaked,
and that the rivets are secure. The disc should
be discarded and a new one installed if ther are
signs of overheating due to clutch slippage or
excessive wear, or if the friction faces are
contaminated with oil.

NOTE: Investigate the source of any oil or grease

on the facings and rectify before installing a
new disc.

2. Examine the pressure plate assembly to make

sure the release levers are free to operate
smoothly and that the pressure plate and springs
Figure 4
are not discoloured due to overheating. Check
Clutch Release Bearing Install
the face of the pressure plate for cracks, scoring 1. Clutch Release Bearing
and distortion. 2. Clutch Release Shaft
3. Inspect the surface of the pressure plate and 3. Clutch Fork Pinch Bolt
4. Clutch Release Shaft Fork
flywheel for grooving, cracking or distortion.

NOTE: Do not attempt to re-assemble or adjsut the

clutch cover assembly without the use of
recommended service tools. 2. Place the pressure plate assembly on the flywheel
and install the locating bolts and lock washers.
4. Grooving of the Pressure plate is not considered
Tighten the bolts evenly to the specified torque.
to be detrimental unless the depth of the grooves
Remove the disc locator tool.
exceeds 0.025 in. (0.65 mm.) in which case the
pressure plate and release lever assembly should 3. Re-connect the front axle and engine assembly
be discarded and a new assembly installed. to the transmission

5. Similarly, grooving of the flywheel is not 4. Check and adjust the clutch pedal free play.
considered to be detrimental unless the depth of 5. Check that there is sufficient travel of the clutch
the grooves exceeds 0.,025 in. (0.65 mm.) Where pedal to ensure total release of the clutch when
groove depth exceeds this amount the flywheel the pedal is fully depressed.
may be refaced provided not more than 0.080 in.
(2.03 mm.) of material is removed.
4. CLUTCH SEALED RELEASE
BEARING
6. Short heat cracks on the pressure plate and
The clutch release bearing, which is of the self
flywheel surfaces are of no consequence provided
lubricating type, is packed with the high melting point
they are not more than 3/8 in. (9.5 mm.) in length
grease on assembly and does not need any periodical
and do not extend to the outside or the inside
lubrication. To remove this bearing, proceed as for
edges of the pressure plate or flywheel.
clutch removal and expose the assembly. With the
INSTALLATION transmission end withdrawn from the front end, the
1. Position the clutch disc on the flywheel, release bearing will remain in position on its hub,
centralising it with a Single Clutch Plate, Locator. floating on the main drive bearing retainer. Figure 4.

E–5
 SINGLE CLUTCH

Figure 5 Figure 6
Separating Clutch Relase Bearing and Hub Removing Clutch Pilot Bearing
1. Puller EF-0800 1. Tool No. EF-0400
2. Bearing and hub assembly 2. Slide Hammer
3. Puller attachment EF-0501 3. Bearing
4. Step Plate

By with drawing the clutch release shaft out of the 5. CLUTCH PILOT BEARING
fork, the fork and the release bearing with its hub can
be removed. The front end of transmission main shaft is supported
in a self lubricating sealed ball bearing, housed in the
The release bearing can further be pressed out of the
rear of the crankshaft.
hub and replaced. Figure 5.

It is recommended that the release bearing should be

replaced at major tractor overhauls. Bearing adjustment It can be removed for inspection and replacement by
is the same as clutch pedal free play adjustment which first removing the bearing retainer and then using
ensures that the bearing will not foul with the release special service Tool No. EF-0400. Figure 6. Install the
levers when in the disengaged position. bearing a correct size adaptor in the bore.

E–6
 SINGLE CLUTCH

6. TROUBLE SHOOTING
PROBLEM POSSIBLE CAUSES REMEDY

Difficulty in engaging 1. Incorrect clutch pedal adjustment. 1. Check Clutch Pedal free travel and
Gears adjust as necessary.
2. Damaged or mal-adjusted release 2. If the release levers are damaged
levers. replace with new ones. Check the
release lever heights as specified &
correct as necessary.
3. Release bearing hub sticking on 3. Apply Silicon grease on release
support. bearing hub support.
4. Distorted clutch Disc or the clutch 4. Examine the clutch disc and replace
disc hub binding on the clutch shaft if necessary. Lightly smear the disc
splines. hubs splines with silicon grease.

Clutch drag or spin 1. Oil or grease on the friction linings of 1. Fit new friction lining or clutch plate.
the clutch plate.
2. Improper pedal adjustment not 2. Correct the pedal adjustment by
allowing free movement of the clutch restoring recommended clearance
release bearing. between the clutch release bearing
and the clutch release levers.
3. Damaged perssure plate or clutch 3. Replace defective part.
cover.
4. Clutch plate hub binding on the 4. Clean up the splines and smear with
splined gear box driving shaft. a small quantity of silicon grease.
5. Distorted clutch plate. 5. Fit new clutch plate.
6. Broken friction linings of the clutch 6. Fit new friction linings.
plate.
7. Dirt or foreign material in the clutch. 7. Dismantle the clutch from the flywheel
and clean oil from the friction surfaces
with a dry rag. See that all the working
parts are free, from dirt/oil and foreign
material.
8. Pilot ball bearing seized. 8. Replace the bearing.

Clutch slippage 1. Oil or grease on the friction linings of 1. Fit new friction linings or clutch plate.
the clutch plate.
2. Weak thrust springs. If excessive slip 2. Fit a new set of thrust springs.
is allowed to occur, the heat
generated will soften the thrust
springs and aggravate the trouble.
3. Binding of the clutch pedal 3. Free engaging fork shaft and clutch
mechanism. engaging sleeve.

E–7
 SINGLE CLUTCH

PROBLEM POSSIBLE CAUSES REMEDY

Clutch Slippage 4. Improper pedal adjustment preventing 4. Correct pedal adjustment by restoring
(Continued.)
full engagement. recommended clearance between the
clutch release bearing and the clutch
release levers.

Clutch fierceness or 1. Oil on friction linings. 1. Fit new friction linings or clutch plate.
snatch 2. Bindings of clutch pedal mechanism. 2. Free engaging fork shaft and clutch
engaging sleeve.
3. Worn-out clutch plate friction linings. 3. Fit new friction linings or clutch plate.

Clutch Judder 1. Oil, grease or foreign material on 1. Fit new friction linings or clutch plate.
clutch plate friction linings.
2. Contact area of friction linings not 2. Adjust clutch engaging levers
evenly distributed. Not that full contact correctly. If this does not cure the
will not occur until the clutch has been trouble, fit new clutch plate.
in the use for sometime, but contact
area should be evenly distributed round
the friction lining.
3. Buckled clutch plate. 3. Replace the part.

Clutch rattle 1. Anti-rattle spring broken. Damaged 1. Fit new parts as necessary.
clutch plate. Excessively worn parts
in clutch engaging lever mechanism.
Excessive backlash in gear box
transmission bearings.
2. Clutch engaging levers loose. 2. Adjust as recommended.
3. Broken thrust springs. 3. Replace affected springs.

Abnormal clutch lining 1. Usually produced by over-loading & by 1. In hand of the operator.
wear excessive slip when starting.
2. Over-riding the clutch pedal. 2. Caution the operator to avoid this.
3. Not maintaining recommended all 3. Follow periodical maintenance rigidly.
round clearance between clutch thrust
ball bearing and clutch release levers.

E–8
 SINGLE CLUTCH

7. SPECIFICATIONS

DESCRIPTION FARMTRAC-60

Type Dry, Single Plate

Clutch Disc Diameter 11" (280 mm.)

Clutch Disc Thickness with New Lining 9.8 mm.

Release lever height from surface plate 50 ± 0.5 mm.

Height of Pressure Plate from surface plate 9.6 mm.

Clutch pedal free play 1.25" - 1.5" (32-38 mm.)

TORQUE SPECIFICATIONS UNITS FARMTRAC-60

Clutch Cover to Flywheel Bolts lbf.ft 23 - 28

(Single Clutch) (kgf.m) (3.2 - 4.0)

Flywheel to Crankshaft Bolts lbf.ft 160

(kgf.m) (23)

Clutch Release Shaft lbf.ft 30 - 39

Fork Pinch Bolt (kgf.m) (4 - 5.4)

E–9
 SECTION - 'F'

DOUBLE CLUTCH
S.NO. CONTENTS PAGE

1. DESCRIPTION AND OPERATION F-2

2. DOUBLE CLUTCH OVERHAUL F-7

3. TROUBLE SHOOTING F - 17

4. SPECIFICATIONS F - 18
DOUBLE CLUTCH

F–2
 DOUBLE CLUTCH

DOUBLE CLUTCH

DOUBLE CLUTCH The transmission clutch disc and pressure plate are
located within the flywheel recess and three lugs on
1. DESCRIPTION AND OPERATION the transmission pressure plate locate between the
The Double Clutch is optional fitment on Farmtrac ears of the intermediate pressure plate. Torque is
Tractors. The double clutch as installed on the transmitted from the flywheel to the transmission
Farmtrac models with live P.T.O., permits the drive to pressure plate via the intermediate pressure plate.
be disconnected from the main transmission to The P.T.O. clutch disc is located between the
facilitate gear changes without stopping the drive to intermediate pressure plate and the P.T.O. pressure
the P.T.O. plate.

Three lugs on the P.T.O. pressure plate engage with

In the double clutch, an 11 in. (279 mm) diameter slots in the pressed steel cover. Torque is transmitted
transmission clutch disc transmits the drive from the from the flywheel to the P.T.O. pressure plate via the
engine to the input shaft of the transmission whilst an cover.
8.5 in. (216 mm) diameter PTO clutch disc transmits
the drive to the P.T.O. input shaft, Figure 1. Three release levers pivot on knife-edged fulcrum
brackets which are attached to the pressed steel cover
by rivets. One rivet per lever extends upwards to act
The double clutch is attached to a recessed flywheel, as a position post. The release levers actuage the
Figure 2, by six dowel bolts which pass through both transmission pressure plate through struts and pairs
the cover and three pairs of ears located on the periphery of links which are attached by pins to the drive lugs of
of an intermediate pressure plate. the transmission pressure plate.

F–3
 DOUBLE CLUTCH

Figure 1
Double Clutch Components and Transmission Clutch Disc
1. Transmission Clutc Disc 11. Split Pin
2. Transmission Pressure Plate 12. Clip
3. Transmission Clutch Springs 13. Release Lever
4. P.T.O. Clutch Disc 14. Strut
5. P.T.O. Clutch Springs 15. P.T.O. Pressure Plate Connecting Link Pin
6. Transmission Pressure Plate Connecting Links 16. Transmission Pressure Plate Connecting Link Pin
7. Snap Ring 17. P.T.O. Pressure Plate Connecting Link
8. Split Pin 18. Cover
9. Spacer 19. P.T.O. Pressure Plate
10. Shims 20. Intermediate Pressure Plate

The P.T.O. Pressure Plate connecting links are located Hardened, spherical-headed screws, located at the
between the transmission plate links and are attached inner ends of the release levers, provide adjustment
to the P.T.O. Pressure Plate by pins which pass for the levers.
through slotted holes in the transmission plate links.
Adjusting the socket-headed screws alters the gap
The release lever struts bear on adjustable, socket- between their hardened ends and the release lever
headed screws located in the tops of the P.T.O. struts. This gap determines how far the release levers
pressure plate links. travel before they actuate the P.T.O. clutch pressure
plate.

F–4
 DOUBLE CLUTCH

Figure 2
Double Clutch Installation

1. P.T.O. Clutch Disc 11. P.T.O. Pressure Plate Link Pin

2. P.T.O. Clutch Springs 12. Transmission Pressure Plate Link Pin
3. P.T.O. Pressure Plate 13. Transmission Pressure Plate Link
4. Release Lever Adjusting Screw 14. Intermediate Pressure Plate
5. Position Post 15. Transmission Pressure Plate
6. Release Lever 16. Transmission Clutch Disc
7. Socket-Headed Adjusting Screw 17. Flywheel
8. Strut 18. Cover
9. Fulcrum Bracket 19. Transmission Clutch Spring
10. P.T.O. Pressure Plate Link

F–5
 DOUBLE CLUTCH

Figure 3
Power Flow Through the Double Clutch
1. Clutch Pedal 5. P.T.O. Clutch Disc
2. P.T.O. Input Shaft 6. Transmission Clutch Pressure Plate
3. Transmission Input Shaft 7. Transmission Clutch Disc
4. P.T.O. Pressure Plate 8. Flywheel

OPERATION This is the amount of pedal movement from the fully

released position to the point where resistance is first
With reference to Figure 3.
encountered.
When both clutches are engaged, View 'A', the drive
from the engine is transmitted to both the transmission
input shaft and the P.T.O. input shaft. By depressing
the clutch pedal approximately half way the
transmission clutch pressure plate is withdrawn, View
'B'. This releases the transmission clutch disc from
the flywheel and disconnects the drive to the
transmission. The P.T.O. clutch is still engaged thus
maintaining the drive to the P.T.O. whilst transmission
gear changes are being made.
By fully depressing the clutch pedal the P.T.O. pressure
plate is also withdrawn, View 'C', thereby releasing
both the transmission disc and the P.T.O. disc and
disconnecting the drive to the transmission and P.T.O.
DOUBLE CLUTCH PEDAL FREE PLAY Figure 4
ADJUSTMENT FT-60 WITH LIVE P.T.O. Double Clutch Pedal Linkage Adjustment "X"
Clutch Pedal Free Travel
With reference to Figure 4. The only double clutch 1. Split Pin 4. Release Rod
adjustment required is to check and if necessary, 2. Clevis Pin 5. Lock Nut
adjust the clutch pedal free travel. 3. Clevis 6. Cross-shaft Lever

F–6
 DOUBLE CLUTCH

Figure 5 Figure 6
Installing Release Lever Hold Down Clips Double Clutch Tool Disc Spacers, Riser Spacers
1. Release Lever Hold Down Clips-Tool No. SW13A/g and Fixing Bolts
2. Release Lever 1. Fixing Bolt-5/16in. Whit.x5 in.-Tool No. SW12B/23
3. Split Pin 2. Rising Spacer - Tool No. SW12B/9
4. Release Lever Compressor-Tool No. SW13A/b 3. Disc Spacer - Tool N. SW12B/8
4. Release Lever

1. Loosen the locknut and remove the split pin and to-flywheel retaining bolts. Withdraw the double
clevis pin from the end of the clutch control rod. clutch assembly and the transmission clutch disc
from the flywheel.
2. Turn the clevis to adjust the length of the control
rod until, on installation, the pedal free travel is DISASSEMBLY
as specified i.e. 1.25 in. (32 mm) to 1.5 in. (38
mm.) Figure. 4. No attempt should be made to overhaul a double clutch
assembly without using the special tool.
3. Replace the split pin and clevis pin and tighten
the locknut to the specified torque. Basically these are the same tools, with the addition
of adaptors, which are used to overhaul the single
2. DOUBLE CLUTCHES-OVERHAUL clutch.

REMOVAL The following disassembly and re-assembly sections

cover the use of both Tool Nos. SW12B and SW510
1. Separate the tractor between the engine and the which incorporate the requisite adaptors.
front transmission. Refer separating the Tractor.
DISASSEMBLY USING TOOL NO. SW12B
2. Using Compressor Tool No. SW13A/b (where
available), depress each release lever of the With reference to Figures 6 & 7.
double clutch and install the Hold-Down Clip, Tool
No. SW13A/g, Figure 5. 1. Thoroughly clean the clutch assembly and tool.
Mark the three pressure plates and the cover to
3. Support the double clutch and remove the clutch- facilitate re-assembly.

F–7
 DOUBLE CLUTCH

Figure 7
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. Centre Spacer-SW12B/5
3. Actuator Assembly-SW12B/28 14. Pillar Spacer-SW12B/1
4. Actuator Cam Platform-SW12B/20 15. Centre Spacer-SW12B/4
5. Riser Spacers-SW12B/9 16. Centre Spacer-SW12B/7
6. Washer-SW12B/26 17. Centre Spacer-SW12B/3
7. Bolt-SW12B/23 18. Centre Spacer-SW12B/2
8. Washers-SW12B/27 19. Centre 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

F–8
 DOUBLE CLUTCH

Figure 8 Figure 9
Release Lever Assembly Installing Clutch Release Levers
1. Split Pin 1. Transmission Pressure Plate Connectng Links
2. Retaining Clip 2. Strut
3. Shim (s) 3. Release Lever
4. Release Lever 4. P.T.O. Pressure Plate Connecting Links
5. Spacer

2. Place three transmission Disc Spacers, Tool No. 7. Gradually slacken the bolts retaining the clutch
SW12B/8, on the Base Plate, Tool No. SW12B/ cover to the base plate of the tool until all spring
15. Locate a spacer adacent to each pair of fixing pressure is released, then remove the bolts and
bolt holes. the cover.

3. Install the double clutch assembly on the spacers NOTE: The bolts must be slackened evenly and
and insert Riser Spacer, Tool No. SW12B/9, diagonally across the clutch to prevent distortion
between the intermediate pressure plate and the of the cover.
base plate of the tool. Position a riser spacer at
each of the fixing bolt locations. 8. Remove the coil springs from their locations on
the P.T.O. and transmission pressure plates.
4. Centralise the clutch on the base plate and install
the special fixing bolts, Tool No. SW12B/23, 9. Remove one of the snap rings and push out each
through the clutch cover and the riser spacers. P.T.O. pressure plate connecting pin. Withdraw
Tighten the bolts then remove the lever hold-down the P.T.O. pressure plate connecting links from
clips (where fitted). between the transmission plate connecting links.

5. Remove the split pin, Figure 8 and extract the 10. Remove the P.T.O. pressure plate, the P.T.O. disc
shims and release lever retaining clips from each and the intermediate pressure plate.
release lever fulcrum bracket.
11. Push out the transmission pressure plate link
6. Remove one of the split pins and withdraw each retaining pins and remove the links.
release lever strut, Figure 9, then remove the
release levers and spacers. 12. Lift the transmission pressure plate from the tool.

F–9
 DOUBLE CLUTCH

Figure 10 Figure 11
Universal Clutch Fixture Tool No. SW510 Preparation for Disassembly of Double Clutch
(Double Clutch Application) 1. Bridge
1. Spindle Nut-SW510-9 2. Long Cap Screws
2. Gauge Spacer-SW510-6 3. Short Cap Screw
3. Guide Pin-SW510-12 4. Riser Block
4. Short Cap Screw-SW510-64C 5. Strut
5. Long Cap Screw-SW510-63B 6. Intermediate Pressure Plate
6. Gauge Pin-SW510-7 7. Identification Marks
7. Fixture Base-SW510-60 8. Spacer
8. Riser Block-SW510-61A 9. Clutch Cover Assembly
9. Spring Compressor Bridge-SW510-3 10. Release Lever Hold-Down Clip
10. Fixture Spindle-SW510-62 11. Spindle Nut
11. Gauge Spacer-SW510-5B 12. Thrust Washer
12. Release Lever Gauge-SW510-2
13. Thrust Washer-SW510-13
NOTE: Only remove the socket headed adjusting IMPORTANT: Ensure the mounting area is level and
screws from the P.T.O. pressure plate links the mounting bolts are torqued equally
to eliminate the possibility of warping
and the adjusting screws and nuts from the
the fixture.
release if any of these parts are to be renewed.
3. Thoroughly clean the mating surfaces on the
DISASSEMBLY USING TOOL NO. SW510 clutch pressure plate and cover assembly in
With reference to Figure 10. addition to cleaning the fixture base.
4. Attach the riser blocks to the fixture base by
1. Insert the serrated end of the Fixture Spindle,
installing one short cap screw in each block.
Tool No. SW510-62, into the hub of the Fixture Figure 11 illustrates two of the blocks installed.
Base, Tool No. SW510-60. Position the fixture Ensure the cap screws are torqued equally.
base on the edge and install the Washer, Tool 5. Place the assembled clutch pressure plate and
No. SW510-66 and Jam Nut, Tool No. SW510- cover assembly on the fixture.
65 on the end of the spindle that protrudes from Align the mounting holes in the clutch cover
the bottom of the base. Tighten the nut until the assembly with the holes in the riser blocks and
install one guide pin and one long cap screw in
spindle bottoms in the hub.
each block. Do not tighten the long cap screws
2. Bolt the assembled fixture base to a work bench. at this time.

F–10
 DOUBLE CLUTCH

Figure 12
Assembly and Disassembly of the Double Clutch
1. Short Cap Screw 11. Strut
2. Release Lever 12. Release lever Retaining Clip
3. Spacers 13. P.T.O. Pressure Plate Connecting Link
4. Clip Shims 14. Long Cap Screw
5. Intermediate Pressure Plate 15. Transmission Pressure Plate Connecting Links
6. Guide Pin 16. P.T.O. Clutch Spring and Cap
7. Transmission Pressure Plate 17. P.T.O. Pressure Plate Connecting Pin
8. Transmission Clutch Spring 18. Clutch Cover Assembly
9. Riser Block 19. P.T.O. Pressure Plate
10. Split Pin

NOTE: The step on the base of the fixture substitutes 9. Withdraw the split pins and remove the release
for the transmission clutch disc assembly, lever retaining clip shims and clips, Figure 12.
therefore, this disc is not required when using
the Universal Clutch Fixture Tool No. SW510. NOTE: The step on the base of the fixture substitutes
6. Install the bridge, the thrust washer and the
spindle nut. Ensure the legs of the bridge are 10. Withdraw the split pin from one end of each strut,
positioned at the centre of each row of spring then remove the release levers by extracting the
cups. struts. When removing the struts, exercise care
to prevent loss of the spacers.
7. Relieve the spring tension on the release levers
by tightening the spindle nut until the clutch cover
11. Remove the snap ring from one end of each P.T.O.
assembly is drawn down to the intermediate
pressure plate connecting pin, then withdraw the
pressure plate.
P.T.O. pressure plate connecting links by
To prevent distorting the top of the cover extracting the pins.
assembly, do not overtighten the nut.
8. After relieving spring tension on the release levers, 12. Remove the guide pins and the long cap screws,
tighten the long cap screws finger tight, then then back off the spindle nut. Remove the nut,
remove the release lever hold-down clips (where thrust washer and bridge, then lift the clutch cover
fitted). assembly from the clutch.

F–11
 DOUBLE CLUTCH

Figure 13
Double Clutch Assembly Adjustment
1. Strut 11. Intermediate Pressure Plate
2. P.T.O. Pressure Plate Connecting Link Pin 12. P.T.O. Clutch Pressure Plate
3. Transmission Pressure Plate Connecting Link 13. Centre Spacer, Tool No. SW12B/5
4. Riser Spacer, Tool No. SW12B/9 14. Gauge Finger Body, Tool No. SW12B/11
5. Base Plate, Tool No. SW12B/15 15. Gauge Finger, Tool No. SW12B/13
6. Bridge Spider, Tool No. SW12B/14 16. Locknut, Tool No. SW12B/12
7. Pillar Spacer, Tool No. SW12B/1 17. Release Lever Adjusting Screw
8. Disc Spacer, Tool No. SW12B/8 18. Socket Headed Adjusting Screw
9. Transmission Clutch Pressure Plate X GAP=0.050-0.054 IN. (1.27-1.37 mm.)
10. P.T.O. Clutch Disc

Remove the P.T.O. clutch springs and cups and wear are evident, the discs must be discarded
the transmission clutch springs. Lift the P.T.O. and new ones installed.
clutch pressure plate and clutch disc from the IMPORTANT: Investigate the source of any oil or
clutch. grease on the facings and rectify before
13. Left the intermediate pressure plate from the riser installing new discs.
blocks, then remove the transmission pressure 2. Examine the pressure plate assemblies to
plate connecting links by extracting the ensure the release levers are free to operate
connecting pins. Lift the transmission clutch smoothly and the pressure plates and springs
pressure plte from the fixture base. are not discoloured due to overheating. Check
NOTE: Do not remove the adjusting screws and nuts the faces of the pressure plates for cracks,
from the P.T.O. pressure plate connecting scoring or distortion. Discard and replace any
links, or the hexagon nuts and adjusting faulty parts.
screws from the release levers, unless these NOTE: Do not attempt to re-assemble or adjust the
parts are to be replaced. double clutch assembly without the use of the
INSPECTION AND REPAIR recommended service tools.
1. Inspect the clutch discs to ensure the linings RE-ASSEMBLY
are not loose, cracked, worn or contaminated by Prior to re-assembly coat the following
oil. Check the rivets are secure. If signs of components with a silicon base grease as
overheating due to clutch slippage or excessive specified:

F–12
 DOUBLE CLUTCH

The sides of the drive lugs of the transmission

and P.T.O. pressure plates.

The contact edges of the release lever fulcrum

brackets.

The overall length of the release lever struts.

The transmission and P.T.O. pressure plate

connecting links and pins.

The full length of the release lever position

posts.

RE-ASSEMBLY USING TOOL NO. SW12B Figure 14

Position of Double Clutch Springs
1. Transmission Clutch Springs
With reference to Figure 13.
2. Transmission Clutch Pressure Plate
3. Intermediate Pressure Plate
Re-assembly of the double clutch assembly follows
4. P.T.O. Clutch Pressure Plate
the disassembly procedure in reverse. When using 5. P.T.O. Clutch Springs
Tool No. SB12B to re-assemble the double clutch
assembly, observe the following requirements:

Prior to locating the double clutch assembly

on the Base Plate, Tool No. SW12B/15,
position three spacers, Tool No. SW12B/8,
equidistant apart, on the base plate.

Locate the transmission pressure plate on

the spacers with the smooth surface of the
plate facing downwards, Figure 13.

The transmission and P.T.O. clutch springs

are identified and their relative positions
indicated in Figure 14.

After installation of the release lever retaining

clips over the fulcrum brackets of the clutch
cover, install shims above the clips and retain Figure 15
by inserting new split pins, Figure 15. Check Installing Release Lever Retaining Clip Split
Pin
sufficient shims have been installed to
1. Compressor, Tool No. SW13A/b
eliminate any up and down free play of the 2. Release Lever Retaining Clip nd Shims
clip. If necessary, add shims until a slight 3. Release Lever
preload exists on installation of the split pin. 4. Split Pin

F–13
 DOUBLE CLUTCH

Figure 16 Figure 17
Setting the Double Clutch Linkage Checking Height of Release Lever Adjusting
1. Actuator Cam Platform Extension, Tool No. Screws
SW12B/20 1. Locknut, Tool No. SW12B/12
2. Bridge Spider, Tool No. SW12B/14 2. Gauge Finger, Tool No. SW12B/13
3. Base Plate, Tool No. SW12B/15 3. Centre Spacer, Tool No. SW12B/5
4. Actuator Assembly, Tool No. SW12B/28 4. Gauge Finger Body, Tool No. SW12B/11
5. Release Lever Adjusting Screw
6. Pillar Spacer, Tool No. SW12B/1

At the completion of re-assembly, locate the ground side of the finger facing downwards.
Actuator Cam Platform Extension, Tool No. Secure with the locknut, Tool No. SW12B/12,
SW12B/20, on the threaded pillar of the Figure 17.
Actuator, Tool No. SW12B/28, with the flange 2. Rotate the gauge finger over each release lever
of the extension against the cam platform of adjusting screw. Turn each screw to just touch
the actuator, Figure 16. Screw the actuator the underside of the finger gauge.
pillar into the Bridge Spider, Tool No. SW12B/
Tighten the adjusting screw locknuts to the
14, until the platform extension contacts the
specified torque.
adjusting screws of the release levers then
3. Hold the pressure plate connecting link centrally
operate the actuator lever several times to
and use the shank of a suitable size drill as a
settle the clutch linkage.
gauge to set the gap 'X' between the lower end of
DOUBLE CLUTCH SETTING PROCEDURE each socket headed adjusting screw and the
corresponding connecting link strut, Figure 13.
IMPORTANT: Remove the release lever hold-down
clips (where fitted) prior to conducting For dimension 'X' see "Specifications".
the double clutch setting procedure. Insert the drill shank in the gap, loosen the
1. Remove the cam actuator and platform extension socket-headed screw locknut and turn the screw
assembly and install the Pillar Spacer, Tool No. to just touch the drill. Tighten the locknuts to the
SW12B/1, in the Bridge Spider, Tool No. SW12B/ specified torque, see "Specifications".
14. Locate the Centre Spacer, Tool No. SW12B/ 4. Replace the release lever hold-down clips (where
5, Gauge Finger Body, Tool No. SW12B/13 with fitted).

F–14
 DOUBLE CLUTCH

Figure 18 Figure 19
Adjusting Release Levers Location of Gauge Spacer Assemblies
1. Release Lever Gauge, Tool No. SW510-2 1. Spindle Nut, Tool No. SW510-9
2. Adjusting Screw Locknut 2. Gauge Spacer Assembly, Tool No. SW510-6
3. Release Lever 3. Thrust Washer, Tool No. SW510-13
4. Release Lever Adjusting Screw 4. Bridge, Tool No. SW510-3

After installation of the release lever retaining 1. Install the Gauge Spacer, Tool No. SW510-5B,
clips over the fulcrum brackets of the clutch over the fixturre spindle with the identification
cover, install shims above the clips and retain number uppermost then install the Release Lever
by inserting new split pins, Figure 12. Check Gauge, Tool No. SW510-2, Figure 18.
sufficient shims have been installed to
eliminate any up and down free play of the 2. Rotate the gauge over each release lever
clip. If necessary, add shims until a slight adjusting screw. Turn each screw to just touch
preload exists on installation of the split pin. the underside of the gauge foot. Tighten the
adjusting screw locknuts to the specified torque,
The transmission and P.T.O. clutch springs see "Specifications".
are identified and their relative positions
indicated in Figure 14. 3. Remove the release lever gauge and install the
Bridge, Tool No. SW510-3, Thrust Washer, Tool
DOUBLE CLUTCH SETTING PROCEDURE No. SW510-13 and Spindle Nut, Tool No. SW510-
9, Figure 19. Tighten the spindle nut to raise the
IMPORTANT: Remove the release lever hold-down P.T.O. clutch pressure plate until the Gauge
clips (where fitted) prior to conducting Spacer Assemblies, Tool No. SW510-6, can be
the double clutch setting procedure. installed.

F–15
 DOUBLE CLUTCH

Figure 20 Figure 21
P.T.O. Clutch Adjustment Installing Transmission Clutch Disc
1. Connecting Link 1. Transmission Clutch Disc
2. Gauge Pin, Tool No. SW510-7 2. Locator, Tool No. SW13-1
3. Adjusting Screw Locknut 3. Disc Hub
4. Adjusting Screw 4. Flywheel

4. Release the spindle locknut and insert the Gauge 2. Position the transmission clutch disc on the
Pin, Tool No. SW510-7, through each connecting flywheel with the longer hub protrusion facing
link, Figure 20. Loosen the adjusting screw towards the flywheel. Use Locator, Tool No.
locknuts and turn each screw to just touch the SW13-1, to centralise the disc, Figure 21.
gauge pin. Tighten the locknuts to the specified
torque, see "Specifications". 3. Locate teh double clutch assembly on the
flywheel then install the bolts and washers and
5. Replacer the release lever hold-down clips (where tighten to the specified torque, see
fitted). "Specifications".

INSTALLATION 4. Remove the locator tool from the clutch disc and
the three release lever hold-down clips (where
IMPORTANT: When installing a new double clutch fitted).
assembly, the transmission clutch
pressure plate friction face must be 5. Re-connect the engine to the front transmission
wiped clean with white spirit to remove assembly, see "SEPARATING THE TRACTOR".
the protective film.
6. Check and adjust the pedal free play and confirm
1. Lightly lubricate the hub splines of the there is sufficient pedal travel to ensure total
transmission input shaft with the specified grease, release of both clutches when the pedal is fully
see "Specifications". depressed.

F–16
 DOUBLE CLUTCH

6. TROUBLE SHOOTING

PROBLEM POSSIBLE CAUSES REMEDY

P.T.O. and transmission 1. If both the clutches disengage at the 1. Disassemble the clutch from the
Clutch disengage at same point of pedal travel the fault flywheel. Install a new P.T.O. Disc.
same time lies on P.T.O. disc which has worn
out more than Transmission disc.

P.T.O. Clutch Drags 1. If the P.T.O. Clutch does not 1. Separate the tractor and with the
even after depressed disengage ever after the clutch pedal clutch in place on the flywheel adjust
Clutch Pedal Fully is fully depressed the fault is due to the socket headed screws to give the
the P.T.O. clutch gap is more than specified gap using the gauge pin.
the specified 0.055 in. (1.397 mm.) 0.055"
2. If the Clutch Pedal Free Play is more 2. Re-adjust to 1.25" to 1.50" as
than the specified. specified.

F–17
 DOUBLE CLUTCH

4. SPECIFICATIONS

DESCRIPTION FARMTRAC-60

Type Dry, Double Plate

Disc Assemblies
Diameter
Transmission Disc 11 in. (279 mm.)
P.T.O. Disc 8.5 in. (216 mm.)
Type of Hub Splines
Transmission Disc Square Splines
P.T.O. Disc Involute
P.T.O. Speed at 1800 ERPM 540 RPM
Total Friction Area (both sides of disc)
Transmission Disc 111.0 in.2 (716 cm2)
P.T.O. Disc 64.0 in.2 (413 cm.2)
Pressure Plate and Cover Assemblies
Diameter
Transmission Pressure Plate 11.2 in. (28.5 cm.)
P.T.O. Pressure Plate 8.6 in. (21.8 cm.)
Transmission Clutch Springs Spring Load at Compressed Length of
2.27 in. (57.7 mm.)
No. of Springs 12 (yellow) 97 lb. (44.0 kg.)
P.T.O. Clutch Springs Spring Load at Compressed Length of
1.95 in. (49.5 mm.)

No. of Springs 9 (violet) 115 lb. (52.2 kg.)

Gap-Socket-headed Screw to Release 0.050 to 0.054 in.

Lever Strut-"X" (1.27 to 1.37 mm.)

Release lever height from the flywheel surface 5.010-5.070 in.

(127.3 to 128.8 mm.)

Clutch Linkage
Clutch Pedal Free Travel 1.25 - 1.50 in.
(32 - 38 mm.)

F–18
 DOUBLE CLUTCH

TIGHTENING SPECIFICATIONS

TORQUE SPECIFICATIONS UNITS FARMTRAC-60

Clutch Cover to Flywheel Bolts lbf.ft 13-15

(kgf.m) (1.8 - 2.1)

Flywheel to Crankshaft Bolts lbf.ft 160

(kgf.m) (23)

Release Lever Adjusting Screw Locknut lbf.ft 24 - 26

(kgf.m) (3.3 - 3.6)

Socket Headed Bolt Locknut lbf.ft 15-18

(kgf.m) (2.1 - 2.5)

Clutch Release Shaft Fork Pinch Bolt lbf.ft 30-39

(kgf.m) (4.2 - 5.4)

F–19
 E
TRANSMISSION SYSTEM
 SECTION - ‘E’

TRANSMISSION SYSTEM (FT -65 EPI)

CONTENTS PAGE
1. DESCRIPTION & OPERATION E-3

2. GEAR SHIFT COVER & SAFETY START SWITCH OVERHAUL E-7

3. SAFETY START SWITCH AND ACTUATOR ASSEMBLY E-8

4. EIGHT SPEED TRANSMISSION OVERHAUL E-10

5. SPECIFICATIONS E-27
 TRANSMISSION SYSTEM

TRANSMISSION SYSTEM
EIGHT SPEED TRANSMISSION
AND POWER TAKE - OFF

1. DESCRIPTION AND OPERATION The Live PTO incorporates an extra pair of

constant mesh helical drop gears which transmit
the drive from the PTO. clutch (part of the double
The transmission assembly provides eight clutch assembly) to the P.T.O. countershaft.
forward and two reverse speeds which are
The upper gear forms an integral part of the P.T.O.
manually selected by two levers. The main gear
input shaft which revolves around the outside of
shift lever is used to select anyone of four forward
the main drive input shaft. The lower gear is
speeds or a single reverse speed with a second
splined onto the front end of the P.T.O.
shorter lever is used to select an overall high or
countershaft and is driven by the P.T.O. input
low gear ratio.
shaft.
The transmission assembly also incorporates a Transmission assemblies contain all spur type
PTO drive from the engine. gears main countershafts. All gears are in
constant mesh, gear train connections being
The FARMTRAC 65 EPI is available with Live
made by sliding coupling and connectors.
Power Take-Off system.
A safety start switch which interrupts the starting
The transmission assembly with transmission motor circuit is incorporated in the gear selection
with Live Power Take-Off is shown in Figure 1. system and allows the engine to be started only
when the high/Low gear ratio lever is in the
The double clutch assembly provides a drive to
neutral position.
both the gearbox and the live power takeoff shaft.

E-3

Printed in India–Escorts Limited, STC FBD

 TRANSMISSION SYSTEM

Figure 2
Power Flow and Gear Shift Positions
L. Low N. Neutral
H. High R. Reverse

E-4

Printed in India–Escorts Limited, STC FBD

 TRANSMISSION SYSTEM

Figure 3 Figure 4

Figure 5

E-5

Printed in India–Escorts Limited, STC FBD

 TRANSMISSION SYSTEM

5. Inspect the safety start switch wiring

harness for damage.Renew the harness
as necessary.

RE-ASSEMBL Y

1. Lubricate the ball seats with a good quality

grease and pass the shift levers through
the shift cover.

2. Assemble the ball retainers and springs,

compress the springs and install new
retaining snap rings.

Figure 6 3. Re-assemble the two oil baffle washers

to the underside of the shift cover, the oil
baffle plate and the retaining bolts.
1. Retaining Snap Ring
2. Spring
3. Gear Shift Lever

2. Unscrew and remove the gear shift lever

knobs (if not previously removed).
INSTALLATION
3. Use hacksaw to partially cut the lever
retaining snap rings, Figure 8 then use a 1. Install a new shift cover gasket and re-
chisel to finally break the rings. During install the shift cover following the removal
this operation, ensure the retaining rings procedure in reverse.
are not dangerously ejected from the
grooves on the levers. l On installation observe the following
requirements:
4. Remove the levers, springs and ball
retainers from the shift cover. l Ensure the safety start switch actuator
housing is aligned with the locating pin of
INSPECTION the shift cover.

1. Wash the shift cover and shift lever l Tighten the retaining bous to the specified
assemblies in a suitable solvent and dry torque, see “Specifications”.
with a clean, lint free cloth or compressed
air.

2. Inspect the shift cover for cracks or other

damage. 3. SAFETY START SWITCH AND
ACTUATOR ASSEMBLY
3. Inspect the shift lever ball seats and ends
for wear and the locating pins in the high/
low lever. Renew the pins if worn or
damaged. New pins should be pressed REMOVAL
into the lever. 1. Remove the shift cover assembly as
4. Inspect the lever retaining springs for previously described.
cracks or distortion, also inspect the
2. Loosen the locknut and remove the
retaining snap ring grooves on the levers.
retaining screw from the high/low shift rail
connector. Slide the connector off the rail.
E-6

Printed in India–Escorts Limited, STC FBD

 TRANSMISSION SYSTEM

Figure 7 Figure 8

1. Actuating Ball 4. Dowel

2. Actuator Housing 5. Safety Start Switch
Start Switch 3. Spring
2. High/Low Shift Connector
3. Switch Actuator Housing
shift rail away from the centre line of the
4. Actuating Dowel actuating dowel. The test bulb should be
illuminated only with the actuator housing
3. “Unscrew the safety start switch. Place a
centred over the actuating dowel.
clean cloth beneath the safety start switch
actuator housing and slide the actuator NOTE: Do not move the actuator housing more
housing from the high/low shift rail. Take than 0.25 in. (6 mm) from the actuating
care to ensure the ball, spring and actuating dowel centre line or the dowel may come
dowel are collected from within the housing out of the shift rail.
and rail, Figure 7.
INSPECTION
1. Inspect the safety start switch components
for wear or damage. If the spring, ball or
actuating dowel are damaged, renew these
components.
RE-ASSEMBlY AND INSTAllATION
1. Re-assembly and installation of the safety
start switch follows the removal procedure
in reverse. Ensure the actuator housing is
assembled with the spring and ball in the
correct position, Figure 8, and the
actuating dowel is positioned in the drilling
in the high/ low shift rail.
2. Test the switch operation by connecting a
test bulb in series with the switch terminals
and the battery as shown in Figure 9. Move
the switch actuator housing along the high/low Figure 9
Safety Start Switch Components
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 TRANSMISSION SYSTEM

4. EIGHT SPEED TRANSMISSION

OVERHAUL
TRANSMISSION ASSEMBLY
The construction and assembly / dismantling
procedure for the Transmission is exactly similar
to FT 60, except for the following changes:
INPUT SHAFT
The Input Shaft, along with the Bearing, is
mounted inside a Retainer which is Bolted to
the Case Transmission For removal of Input Shaft
and Bearing Assy withdraw the Input Shaft
Bearing Retainer Plate Bolts and remove the
Input Shaft and Bearing Assy.

Figure 110
It is recommended that where a major repair is
to be performed then the whole transmission
should be removed from the tractor.

REMOVAL

1. Drain the oil from the transmission.

2. Separate the engine and rear axle
assemblies from-the transmission,

DISASSEMBLY

FRONT END COMPONENTS

1. Remove the clevis pin securing the external

clutch release rod from the clutch release
cross-shaft.
2. Remove the gear shift cover as previously
detailed.

3. Unscrew the self-locking nut from the bolt

securing the clutch release fork to the
release shaft, Figure 10, and withdraw the
shaft from the transmission housing.

4. Remove the release fork and bearing

assembly.

5. Remove the clutch release bearing hub Figure 11

support retaining bolts and remove the hub
support, Figure 11.

NOTE: On live P. T.O. type transmissions,

removal of the clutch release bearing hub
support will also remove the P. T.O. input
shaft assembly.
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 TRANSMISSION SYSTEM

Figure 12 Figure 13
P.T.O. Countershaft Front Bearing Removal
FT 65 EPI with Live P.T.O.

6. Remove the retaining bolts and withdraw the

front support plate and gasket, Figure 12.

NOTE: FARMTRAC - Models with LIVE Trans -

mission P. T.O. the front support plate
locates the P. T.O counter shaft front
bearing. To ensure the bearing remains on
the countershaft, pull the plate squarely
from the housing.

7. Farmtrac 65 EPI with Live P.T.O. use Puller,

Tool No. EF-0800 to remove the
countershaft front bearing, Figure 13.

8. FT 65 EPI with Live P.T.O. Remove the

Figure 16
P.T.O. coupling retaining snap ring from the P.T.O. Coupling Removal FT 65 EPI
rear of the P.T.O. countershaft and slide with Live P.T.O.
the coupling from the shaft,
Figure 14.
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Printed in India–Escorts Limited, STC FBD

TRANSMISSION SYSTEM

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Printed in India–Escorts Limited, STC FBD

 TRANSMISSION SYSTEM

1. Output Shaft
2. Secondary Countershaft
3. Rear Support Plate
4. Output Shaft Bearing Retainer

REAR END COMPONENTS

1. Remove the gear support plate retaining
bolts and lever the plate assembly away
from the transmission rear face, Figure 18
2. Remove the output shaft bearing housing
retaining bolts and remove the housing.
3. Partially with draw the secondary counter
shaft until the front bearing is free from its
location. Rest the assembly on the bottom
of the compartment and withdraw the
output shaft assembly, Figure 19. The
secondary countershaft can then be lifted
out.
MAIN GEAR ASSEMBLY AND GEAR SHIFT
MECHANISM
1. Extract the four shift rail plungers and
springs from their bores, Figure 23. Pull
the high/low shift fork rearwards and remove
the sliding
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Printed in India–Escorts Limited, STC FBD

 TRANSMISSION SYSTEM

1. High/Low Shift Fork

2. High/Low Sliding Coupling

coupling, Figure 21. Loosen the locknut,

remove.the fork retaining screw and
withdraw the fork from the rear.
2. Rotate the high/low rail until the shift
connector retaining screw and locknut are
uppermost. Figure 22. Loosen the locknut,
remove the screw, and slide the rail out to
the rear, removing the shift connector and
safety start switch assembly from the rail.

NOTE: As each shift rail is removed, ensure

the detent bal is colected from the relevant
locating bore.

3. Loosen the locknuts and remove the

retaining screws from the remaining shift
forks and connectors. Remove the forks
and connectors as each rail is withdrawn
rearwards.

NOTE: Due to inaccessibility, the 4th/8th shift

fork is removed at a later stage.
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 TRANSMISSION SYSTEM

Figure 24 Figure 25
Main Countershaft Rear Bearing Installed
Mainshaft Retaining Srtap Ring and Washer 1. Main Countershaft
1. Snap Ring 2. Washer 2. Rear Bearing
3. Secondary Countershaft Front Bearing
retaining Snap Ring
4. RearBearing Retaining Snap Ring
5. Remove the mainshaft assembly retaining
s.nap ring and washer from the front of the
“main shaft, Figure 24.
11. Using suitable wooden or copper blocks
Carefully withdraw the main shaft rearwards placed behind the cluster gear, drive the
removing the gears, sliding couplings, main countershaft rearwards through the
connectors and thrust washers as the front bearing and cluster gear.
components become free.
12. Remove the main countershaft through the
6. NOTE: Position the components in the rear compartment and remove the cluster
correct order to facilitate re-assembly. gear and front bearing from the main
7. Unscrew the reverse idler shaft retaining transmission compartment.
bolt, located on the left-hand side of the
transmission case, Figure 23. Push the
idler shaft forwards and remove the 4th/8th
shift fork.
8. Withdraw the 4th/8th coupling gear to the
rear.
9. Push the reverse idler gear shaft out to the
rear and lift the gear from the transmission
coupling.
10. Remove the main countershaft rear bearing
retaining snap ring from the transmission
housing, Figure 25. Using a step plate of
suitable diameter drive the countershaft
rearwards until both front and rear bearings
are out of their locations and the main
countershaft assembly is loose in the
bottom of the transmission.
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 TRANSMISSION SYSTEM

Figure 26 Figure 27

P.T.O. Input Shaft Rear Bearing Removal P.T.O. Input Shaft Front Oil Seal

FT - 65 EPI with Live’P.T.O. and Roller Bearing Removal

1. Puller, Tool No. EF-0800
FT - 65 EPI with Live P.T.O.
2. Rear Bearing
3. Pulling Attachment, Tool No. EF-0501 1. Puller, Tool No. EF-0400
4. P.T.O. Input Shaft
5. Step Plate, tool No. EF-0630 5. Use Puller, Tool No. EF-0800, Pulling
Attachment Tool No. EF-0501 and a
INSPECTION AND REPAIR suitable Step Plate, tool No. EF-0630S and
FRONT END COMPONENTS Shaft Protector, Tool No. EF-0625A to
FARMTRAC - 65 EPI WITH LIVE P.T.O. install a new rear bearing. Secure the
bearing to the shaft with the appropriate
1. Remove the large snap ring at the rear of snap ring.
the hub support and drive the P.T.O. input
shaft and rear bearing assembly out of the 6. If necessary, remove the front oil seal and
hub support. needle roller bearing from the P.T.O. input
shaft. Use Puller, Tool No. EF-0400 to
2. Inspect the oil seal in the hub support and withdraw the seal and bearing in one
.if worn or damaged, use Puller, Tool No. operation, Figure 27.
EF-0601, Slide Hammer, Tool No. EF-0600
and Adaptors to remove the seal.
3. Lightly grease the new seal and use a
suitable Step Plate, Tool No. EF-0630S
and a driver to install the seal with the
sealing lip towards the rear. .
4. Inspect the gear teeth and the oil seal
journals on the P.T.O. input shaft for
damage or wear and check the rear bearing
for wear or damage, if necessary, remove
the snap ring and use Puller, Tool No. EF-
0800, Pulling Attachment, Tool No. EF-
0501 and a suitable step plate Tool No.
EF-0630S to withdraw the rear bearing
Figure 26.
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Printed in India–Escorts Limited, STC FBD

 TRANSMISSION SYSTEM

Figure 29
P.T.O. InputShaft Front Oil Seal I11stallation
FT - 65 EPI & 60 with Live P.T.O.
1. Punch
2. P.T.O. Input Shaft

8. Lightly oil and position a new seal on the

spigot of a Step Plate, Tool No. EF-0630
then use a punch and hammer to instali
the seal in the P.T.O. input shaft, Figure 29
NOTE: Ensure the step plate is free from burrs
or sharpedges to avoid damage to the
seal.
9. Install the P.T.O. input shaft and bearing
assembly into the hub support and secure
with the snap ring.
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Printed in India–Escorts Limited, STC FBD

 TRANSMISSION SYSTEM

Figure30

Main Drive Bearing Removal Farmtrac FT - 65 EPI with Live Transmission P.T.O.
2. Ratchet, Tool No. OF-0800
REAR END COMPONENTS
1. Inspect the P.T.O. countershaft and rear 4. Main Drive Input Shaft
bearing for wear or damage. 6. Pulling Attachment, tool No. EF-0501
If necessary, use Puller, Tool No. EF-0800, 8. Shaft Protector, tool No. 625A
PulerAttachment, Tool No. EF-0501and a
suitable Shaft Protector, Tool No. 625A to
remove the rear bearing from the P.T.O.
countershaft, Figure 33.

Gear counter shaft:

Gear Counter Shaft is Splined onto the front end

of P.T.O Counter Shaft and is driven by PTO Input
Shaft. Number of teeth Gear Transmission
Counter Shaft are 46/30 where as in case
Farmtrac-60 56/30. Assy and dismantling
procedure is similar to Farmtrac-60

Figure 32
1. P.T.O. Countershaft
2. Pulling attachment, Tool No. EF-0501 3.
Puller, Tool No. OF-0800
4. Shaft Protector, Tool No. 625A
5. Rear Bearing
Figure 31
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Printed in India–Escorts Limited, STC FBD

 TRANSMISSION SYSTEM

Figure 33 Figure 34
P.T.O. Countershaft Oil Seal Installed Output Shaft Retainer Assembly
1. Retainer 2. Oil Seal
1 . Oil Seal 3. Bearing Cup
5. Inspect the output shaft assembly for wear
2. Retaining Snap Ring
or damage. Use Puller, Tool No. EF-0800
Use a suitable length sleeve of 1.5 in. and a suitable Shaft Protector, Tool No.
(37 mm) internal diameter and a 1.75 in. 625A to remove defective components,
(44 mm) external diameter to install a new Figure 36.
bearing.
2. Inspect the rear support plate for wear or
damage and, if necessary, replace on re-
assembly.
3. Examine the p.T.a. countershaft oil seal,
Figure 34. If worn or damaged, remove the
retaining snap ring and remove the seal
with a suitable punch. Use a suitable Step
Plate, Tool No. 630S and a soft faced
hammer to install a new seal.
4. Inspect the output shaft retainer, oil seal
and bearing cup, Figure 34. If new
Figure 36
components are required, use a punch to
remove the oil seal and bearing cup; Use Output Shaft Gear Removal
a suitable Step Plate, Tool No. 630S to 1. Puller, Tool No. OF-OaOO
install the new components. Ensure the 2. Shaft Protector, Tool No. 625A
oil seal is installed before the bearing cup. 3. Output Shaft Gear

OUTPUT SHAFT
The Output Shaft is smaller (5mm) in length than
that for FT 60. Identification groove is provided
on the Shaft. The Output Shaft Pilot Bearing Cup
can only be removed from the Mainshaft after
the Mainshaft Rear Bearing has been removed.
Assy for Output Shaft is shown below

Figure 35
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Printed in India–Escorts Limited, STC FBD

 TRANSMISSION SYSTEM

Figure 36 Figure 37
Secondary Countershaft Rear’Bearing Removal Insertion of Steel Rods Facilitate
1. Puller, Tool No. OF-0800 . Secondary
Counters haft Front Bearing Removal
2. Pulling Attachment, Tool No. EF-0501 1. Steel Rod 2. Secondary Countershaft Gear
3. Rear Bearing
9. To remove the secondary countershaft front
4. Step Plate, Tool No. 630S bearing, insert two steel rods, 0.18 in. (4.5
mm) diameter and 2.0 in. (50 mm) long
through the two holes in the larger gear,
6. Re-assemble the components onto the Figure 38. Then use Puller, Tool No. EF-
shaft with the output shaft gear dog teeth Q800, Pulling Attachment, Tool No. EF-
towards the sliding coupling gear. Install 0501 and a suitable Step Plate, Tool No.
the thrust washer and aligh the flats on 6308 to remove the front bearing, Figure 39.
the washer with the flats on the output
shaft. Use Puller, Tool No. EF-0800 Pulling
Attachment, Tool No. EF-0501 a suitable
Shaft Protector, Tool No. 625A and a
suitable length of tube, 1.56 in. (40 mm)
internal diameter and 2.06 in. (52 mm)
external diameter, to pull the bearing into
position.
NOTE: The output shaft gear and bushing, and
the output shaft and high/low sliding
couplings are serviced as matched
assemblies.
7. Use a hammer and a suitable length of
tube 1.06 in. (27 mm) internal diameter and
1.25 in. (31.5 mm) external diameter to
install a new pilot bearing on the output
shaft.
8. Inspect the secondary countershaft Figure 38
assembly for wear or damage. If Secondary Countershaft Front Bearing
necessary, use Puller, Tool No. EF-0800, Removal
Pulling Attachment, Tool No. EF-0501 and 1. Pul!er, Tool No. EF-0800
2. Pulling Attachment, Tool No. EF-0501
a suitable Step Plate, Tool No. 630S to
3. Steel Rods 4. Step Plate, Tool No. 630S
remove the rear bearing, Figure 36.
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Printed in India–Escorts Limited, STC FBD

 TRANSMISSION SYSTEM

Figure 39 Figure 40
Mainshaft Rear Bearigg Cup Removal 1. Rear Mainshaft Rear Bearing Removal
Bearing Cup 1. Puller Tool No. EF-0800
2. Puller, Tool No. EF-0601 2. Pulling Attachment, Tool No. EF-0501
3. Slide Hammer, Tool No. EF-0600 3. Rear Bearing
4. Shaft Protector, Tool No. 625A
10. Use Puller, Tool No. OF-OaOO, Pulling
Attachment. Tool No. EF-0501 and a 3. Inspect the output shaft pilot bearing cup.
suitable Step Plate, Tool No. 630S to install If worn or damaged, remove the cup using
new front and rear bearings on to the a small punch inserted through the holes
countershaft. in the mainshaft gear, Figure 41.

TRANSMISSION CASE NOTE: The output shaft pilot bearing cup can
only be removed from the mainshaft after
1. If the transmission has been completely the mainshaft rear bearing has been
disassembled, clean the case intemally removed.
and externally. Inspect the c~se for
damage and cracks. If necessary, replace
the case on re-assembly.
MAIN SHAFT ASSEMBLY
1. Examine the mainshaft assembly for wear
or damage. Worn or damaged components
must be replace on re-assembly.lf
necessary use Puller Tool No. EF-0601
and slide hammer Tool No. EF-0600, to
remove bearing cup from transmission
case,
2. If necessary, use Puller, Tool No. EF- Figure 41
OaOO Pulling Attachment, Tool No. EF-
0501 or EF-0600 and suitable Shaft Output Shaft Pilot Bearing Cup Removal
Protector, Tool No. 625A to remove the
mainshaft rear bearing, Figure 39.
MAIN SHAFT
The Main shaft is supported on the front side by
a Ball Bearing (instead of Needle Roller Bearing)
mounted inside the Input Shaft and on the rear
side by a Taper Roller Bearing (32211 Larger).
The Free Gears mounted on the Main Shaft are
fitted with Bi-metallic Bushes for better
Lubrication and increased life.
The following figure shows the exploded view of
Main Shaft sub assembly: Figure 42
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 TRANSMISSION SYSTEM

19T.

Figure 43
Gear Identification Diagram

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 TRANSMISSION SYSTEM

4. Use Puller Tool No. EF-0800 and a suitable RE-ASSEMBLY

Step Plate Tool No. 630S to install a new
MAIN COUNTERSHAFT
pilot bearing cup in the main shaft.
1. Ensure the snap ring, located immediately
5. Use Puller,Tool No. EF-0800 Pulling in front of the main countershaft front
Attachment, Tool No. 951 or EF-0501 a bearing in the transmission case, is
suitable Step Plate, Tool No. 630S and a correctly seated in the groove.
sleeve of suitable length and diameter to
install a new mainshaft rear bearing. 2. Install the countershaft front bearing into
the transmission case to seat against the
6. Inspect all mainshaft gears, sliding snap ring.
couplings and dog-teeth for wear and
3. Rest the countershaft cluster gear in the
damage and, if necessary, replace with
bottom of the main compartment to with
new components on re-assembly. Check
the larger helical gear to the front.
all bushings, where installed, for wear.
4. Pass the main,counter shaft and rear
NOTE: All mainshaft gears and bushings are
bearing assembly in from the rear
serviced as complete assemblies.
compartment to engage in the internal
splines of the cluster gear.
MAIN COUNTERSHAFT ASSEMBLY 5. Use a suitable Step Plate, Tool No. 630S
and, with a drift and hammer, drive the main
1. Inspect the main countershaft, cluster countershaft assembly forward into the
gear and front and rear’ bearings for wear front bearing. When in position, retain with
or damage. the snap ring behind the rear bearing.
2. If necessary, use Puller, Tool No. EF-0800 6. Install the 4th/8th coupling gear onto the
or Pulling Attachment, Tool No. EF-0501 rear of the main countershaft with the shift
and a suitable Step Plate, Tool No. 630S fork groove to the front.
to !emove the rear bearings.
REVERSE GEAR IDLER ASSEMBLY
1. Insert the reverse idler shaft through the
REVERSE IDLER ASSEMBLY rear compartment, larger diameter forward,
1. Install the reverse idler shaft in the idler into the main compartment. Hold the
gear and check for wear of the gear bushing. reverse idler gear in position with the hub
Inspect the idler gear for teeth wear or of the gear facing forward and install the
damage and replace as necessary. shaft through the gear~

NOTE: The reverse idler gear and bushing are 2. Push the shaft forward enough to allow the
4th/8th shift fork to be mounted on the
serviced as a complete assembly.
small diameter of the shaft. Ensure the
2. Replace the sealing washer on the reverse fork is located in the groove in the 4th/8th
idler shaft retaining bolt. sliding coupling.
GEAR SHIFT MECHANISM 3. Secure the shaft with the locking bolt and
sealing washer located in the left-hand
1. Inspect the shift forks, couplings and side of the transmission case.
connectors for wear or distortion. Mount
the 4th/8th shift fork on the reverse idler NOTE: It will be necessary to align the recess
gear shaft and ensure the fork slides freely. in the shaft with the bolt hole in the casing.
MAIN SHAFT ASSEMBLY
2. Examine the detents on the shift rails for
wear and check the rails for straightness. 1. Pass the mainshaft complete with rear
Renew worn parts on re-assembly. bearing through the rear compartment.
Assemble the gears to the shaft in the
3. Ensure the detent balls and plungers following sequence Figure 43.
operate freely in the bores. If necessary,
l 2nd-6th gear (dog-teeth forward)
the plungers may be cleaned with a fine
abrasive; ensure such parts are thoroughly l Reverse/2nd-6th sliding coupling and
washed before re-assembly. connector.
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 TRANSMISSION SYSTEM

3. Slide the rail forwards to locate in the front

support bore. Install the shift arm retaining
screw and locknut and tighten to the
specified torque, see “Specification”

NOTE: When installing the remaining shift rails,

ensure the rails already in place are in the
neutral position.

4. Install the Reverse/2nd-6th shift rail, with

the three detents to the rear, into the
second bore from the left-hand side and
assemble the Reverse/2nd-6th shift fork
onto the rail.

Figure 44
Transmission Gear Shift Fork and Rail Assembly 5. Slide the rail forwards to locate in the front
1. High-Low Gear Shift Fork,
support bore. Install the shift fork retaining
2. 1st-5th/3rd-7th Gear Shift Lever Connector
3. 4th-8th Gear Shift Selector Arm screw and locknut and tighten to the
4. 4th-8th/Low Gear Shift Fork specified torque, see “Specifications”
5. Reverse/2nd-6th Gear Shift Fork
6. 4th-8th Gear Shift Rail
7. Reverse/2nd-6th Gear Shift Rail 6. Install the 3rd-7th/1st—5th rail, single
8. 1st-5th/3rd-7th Gear Shift Rail detent forward, into the third bore from the
9. 1st-5ttV3rd-7th Gear Shift Fork left-hand side. Assemble the shift gate and
10. High/Low Gear Shift Connector the shift fork onto the rail and push the rail
11. Safety Start Switch Actuator Housing forward into the front support bore.
l Phosphor-bronze thrust washer
l Reverse gear (dog-teeth rearwards) 7. Install the respective retaining screws and
l Phosphor-bronze thrust washer locknuts and tighten to the specified
l 1 st-5th gear (dog-teeth forward) torques, see “Specifications.”
l 3rd-7th/1 st-5th sliding coupling and
connector 8. Install the High/Low rail into the right hand
l 3rd-7th gear ((dog-teeth rearward) bore and assemble the shift connector
l Steel thrust washer onto the forward end. Assemble the High/
Low fork to the rear end of the rail in the
l Snap ring
secondary compartment. Install the
GEAR SHIFT MECHANISM respective retaining screws and locknuts
1. If necessary, install the two interlock and tighten to the specified torques, see
plungers in the bore from the left-hand side “Specifications”.
of the transmission case. Replace the
threaded plug.
2. Pass the 4th-8th shift rail with the single 9. Locate the High/Low shift fork on the High/
detent to the front, Figure 44 into the rear Low sliding coupling and position the
of the bore nearest the left-hand side of coupling on the dog-teeth at the rear of
the casing,. Assemble the 4th/8th shift the mainshaft.
arm assembly onto the rail with the
operating arm located into the hole in the
4th-8th shift fork which is mounted on the 10. Install the four shift rail detent balls,
reverse idler shaft. springs and plungers.
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 TRANSMISSION SYSTEM

Figure 45
Output Shaft Assembly Installation Figure 46
1. High/Low Sliding Coupling Checking Output Shaft End Play
2. Secondary Countershaft 1. Dial Indicator Gauge
3. Output Shaft Assembly 2. Output Shaft

REAR END COMPONENTS 7. To eliminate all end play in the mainshaft

1. Locate the High/Low sliding coupling and output shaft taper roller bearings,
groove in the High/Low shift fork and install shims of appropriate thickness have to be
the sliding coupling onto the dog teeth on installed between the rear support plate
the rear of the mainshaft. and the output shaft bearing retainer
according to the following procedure.
2. Ensure the snap ring that locates the
secondary countershaft front bearing is (i) Install shims to a thickness’ of
correctly located in the groove in the approximately 0.060 in. (1.5 mm) and
transmission case. locate the output shaft bearing retainer
assembly on the rear support plate.
3. Place the secondary countershaft
assembly in the rear compartment and rest (ii) Install the four retaining bolts and
at the bottom of the casing. tighten to the specified torque, see
“Specification”
4. Locate the output shaft above the
secondary countershaft, Figure 45 and (iii) Position the plunger of a dial indicator
push into position. gauge against the end face of the
outputs haft, Figure 46. Move the shaft
5. Lift the secondary countershaft until the
in and out and note the end play
front bearing locates squarely with the
reading. If no end play is registered,
casing and drive the countershaft forwards
add additional shims to produce a
until the front bearing seats against the
gauge reading.
snap ring.
6. Position a new gasket and install the rear (iv) Remove the indicator gauge and the
support plate without the output shaft rear four retainer bolts. Withdraw the
bearing retainer. Locate the rear support retainer and shims.
plate onto the two dowels and tap into (v) Remove a number of shims whose total
position. Install the retaining bolts and thickness correspoonds with the
tighten to the specified torque. see reading obtained on the dial indicator
“Specifications”. gauge.
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 TRANSMISSION SYSTEM

NOTE: The ,,)tal tickness of shims removed can

t)e up to 0,002 in. (0.05 mm) more than Shrouds
the reading obtained on the indicator (i.e,
Two number of shrouds are used :-
0,002 in. (0.05 mm) preload is achieved)
but must not be less than the rea fling One is located below the Counter Shaft
obtained on the indicators. shims are named as Shroud Gear Counter Shaft
available in thicknesses of 0.003 in. 0.005 Transmission.
in. and 0.012 in. (0.08 mm 0.13 mm and Other is mounted on the Retainer
0.31 mm) transmission named as Shroud Gear
High-Low Transmission.

(vi) Having selected the correct shims, install

the bearing retainer, shims and bolts. ALL TRANSMISSIONS
Tighten the bolts to the specified torque, 1. Position a new gasket on the clutch release
see “Specifications”. Re-position the dial bearing hub support and install the support
indicator gauge and re-check for end play. assembly over the main drive input shaft.
Ensure the oil seal is not damaged. Install
the retaining bolts and tighten to the
FRONT END COMPONENTS’
specified torque. See “Specifications”.
MAIN DRIVE INPUT SHAFT ASSEMBLY
2. Position the clutch release bearing and
Farmtrac 65 EPI with Live or Transmission hub assembly on the release bearing hub
support.
P.T.O.
3. Locate the release fork arms in the slot in
1. Asser:;nble the main drive input shaft
the release bearing hub and install the
assembly to the transmission case and
release shaft through the transmission
secure with the snap ring.
case and release fork. Install the fork
2. Position the P.T.O. countershaft gear in retaining bolt and tighten the nut to the
the front compartment and install the P.T.O. specified torque, see “Specifications” .
countershaft through the transmission
from the rear to locate in the countershaft
gear.
3. Drive the P.T.O. countershaft forward to II\lST ALLA TION
seat the rear bearing and retain with the
1. Re-connect the engine and rear axle
snap ring.
assemblies to the transmission, see
4. Assemble the coupling sleeve to the rear “SEPARATING THE TRACTOR”.
of the P.T.O. countershaft and secure with
2. Fill the transmission with the correct grade
the snap ring.
and quantity of oil see “Specifications”.
5. Use a suitable length sleeve of 1.0 in. (25.4
mm) internal diameter and 1.38 in. (35 mm)
external diameter to drive the front bearing
onto the P.T.O. countershaft and seat
against the gear.
6. Install the front support plate with a new
gasket and tighten the retaining bolts to
the specified torque, see “Specifications”.
NOTE: For transmission with Live P T. O. the
front support plate must be driven onto the
P. T.O. countershaft front bearing and the
retaining bolts tightened evenly to draw the
support plate into position.

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 TRANSMISSION SYSTEM

5. TRANSMISSION SPECIFICATIONS
DESCRIPTION FARMTRAC 65 EPI
Number of Speeds:
Forward 8
Reverse 2
Type of Drive Line In line
Main Drive Input Ratio 29 : 46
Number of Shift Levers 2
Bearing Types Ball, Taper and Straight Roller
Gear Bushings (i) Revers Idle- Gear
(ii) Output Sh&-’-: Gear
Output Shaft End Float Nil
Maximum Permissible Pre-load 0.002 in. (O.C:: mm)
End Float Shims Available 0.003 in. (0.02 mm.)
0.005 in. (0.1:: mm.)
0.012 in. (0.3': mm.)
Oil Capacity 10 ltr
Oil Grade UTTO (Tract ELF SF-3I)

FARMTRAC 65 EPI
FT - 65 EPI : BUILD SPECIFICATIONS
Aggregate Specifications

Cluth Dual Clutch

(Optional : Independent PIO)

Transmission & Rear Axle 8+2 Gear box with Epicyclic Rear Axle & Wet Disc Brakes

PTO speeds 1st: 495; 2nd: 590; 3rd: 1035; 4th: 1410; rev: 680)
Tractor road s peeds : The following chart shows the road speeds in K.M./H for tractor fitted with 16.9 x
28 Rear and 7.5 x 16 Front tyres. at @ 2100 erpm.

Gear Road Speed (km/h)

( @ 2100 erpm amd 680 mm RR)

1 2.9
2 3.6
3 6.4
4 8.7
5 10.4
6 13
7 22.7
8 31
R1 4.2
R2 15
Rear Tyres 16.9 x 28
Front Tyres 7.5 xx 16

E-25

Printed in India–Escorts Limited, STC FBD

 TRANSMISSION SYSTEM

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS UNITS FARMTRAC-50/55 & 60

Release Bearing Hub Support Bolts Ibf. ft. 27 - 37
kgfm. (3.7-5.1)

Front Suport Plate Bolts Ibf. ft. 27 - 37

kgfm. (3.7 - 5.1)

Gear Shift Cover Assembly Bolts Ibf. ft. 23 - 29

kgfm (3.18 - 4.00)

Gear Shift Forks (Bolts & Lock nuts) Ibf. ft. 20 - 25

kgfm (2.8 - 3.5)

Output Shaft Retainer Bolts Ibf. ft. 27 - 37

kgfm (3.7-5.1)

Rear Support Plate Bolts Ibf. ft. 27 - 37

kgfm (3.7-5.1)

Reverse Idler Shaft Retaining Bolt Ibf.ft 15-19

kgfm (2.1 - 2.6)

P.T.O. Selector Retaining Bolt Ibf. ft. 35- 47

kgfm (4.9 - 6.5)

P.T.O. Cover Retaining Bolt Ibf. ft. 35 - 47

kgfm (4.9 - 6.5)

E-26

Printed in India–Escorts Limited, STC FBD

 SECTION - ‘H’

POWER TAKE OFF

 SECTION - ‘H’

POWER TAKE-OFF
CONTENTS PAGE

1. DESCRIPTION & OPERATION - TRANSMISSION P.T.O. AND LIVE P.T.O. H-3

2. OPERATION - TRANSMISSION P.T.O. AND LIVE P.T.O. H-4

3. POWER TAKE-OFF REAR SHAFT ASSEMBLY OVERHAUL H-5

4. POWER TAKE-OFF SHIFTER MECHANISM OVER-HAUL H-6

5. SPECIFICATIONS H-8
 POWER TAKE OFF

POWER TAKE - OFF

TRANSMISSION P.T.O. AND LIVE P.T.O. - ON
FARMTRAC TRACTORS

1. DESCRIPTION AND OPERATION On eight speed transmission a P.T.O. counter

shaft locates in the hollow, internally splined.
center of the transmission counter shaft and
TRANSMISSION P.T.O. carries at its rear end an internal toothed sleeve.
The P.T.O. drive is therefore, transmitted from
Transmission P.T.O. is available on Farmtrac-50/ the transmission counter shaft to the P.T.O.
55 and 60 tractors (Domestic). with this type of counter shaft and thence to the sliding coupling
P.T.O. the drive is taken from the standard clutch on the P.T.O. output shaft is connected to a le-
by the transmission input shaft to the transmis- ver on the out side of the tractor and when this
sion counter shaft, assembly through a set of lever is moved rearwards the coupling engages
drop gears as shown in Figure No. 1. with the sleeve on the P.T.O. counter shaft.

1. P.T.O. Rear Shaft Cap 6. P.T.O. Countershaft (Hollow)

2. P.T.O. Rear Shaft 7. Transmission Input Shaft
3. Sliding Coupler 8. Drop Gear
4. Selector Fork 9. Shaft Sleeve
5. P.T.O. Countershaft (Rear) 10. P.T.O. Selector Lever

H-3
 POWER TAKE OFF

1. P.T.O. Rear Shaft Cap 6. P.T.O. Countershaft (Hollow)

2. P.T.O. Rear Shaft 7. Transmission Input Shaft
3. Sliding Coupler 8. Drop Gear
4. Selector Fork 9. Shaft Sleeve
5. P.T.O. Countershaft 10. P.T.O. Selector Lever

LIVE POWER TAKE - OFF The rear of the P.T.O. output shaft is supported
Live P.T.O. is available as on option for Domes- by a ball bearing in a cover housing which is
tic supply of Farmtrac tractors as a standard for attached to the rear of the rear axle center hous-
Export Farmtrac model of tractors. ing. An oil seal is incorporated behind the bear-
With this type the P.T.O. drive is taken from the ing and the end of the shaft is protected by a
Power Take Off disc of a special double clutch cap, which screws into the P.T.O. cover.
by a Live P.T.O. input shaft which runs on the
outside of the transmission input shaft. From the 2. OPERATION - TRANSMISSION P.T.O.
gear on the P.T.O. input shaft the drive is taken AND LIVE P.T.O.
to a gear on the P.T.O. counter shaft. This shaft
passes completely through the inside of the Transmission P.T.O. may only be operated whilst
hollow transmission Countershaft and carries at the transmission clutch and the P.T.O. selector
its rearend the same internal toothed sleeve. lever are in the engaged positions.
To engage the P.T.O. fully depress the clutch
The sliding coupling, P.T.O. output shaft and pedal then pull the P.T.O. selector lever rear-
operating lever arrangement are also identical wards. Release the clutch pedal and the P.T.O.
ith that used with the ‘Transmission’ type P.T.O. shaft will start to rotate. To disengage the P.T.O.
on eight speeds, as shown in Figure No. 2 fully depress the clutch and push the selector
lever forward. Live P.T.O. is operated in a similar
TRANSMISSION P.T.O./LIVE P.T.O. - OUTPUT manner to transmission P.T.O. with one main
SHAFT. difference. Depressing the clutch pedal half-way
Irrespective of whether a ‘Transmission’ type or will disengage the transmission clutch pedal half-
a ‘Live’ P.T.O. is incorporated on Farmtrac Trac- way will disengage the transmission clutch but
tors having eight speed transmission the P.T.O. leave the P.T.O. clutch fully engaged.
output shaft is supported at its front end by a NOTE : When the clutch is depressed to facili-
spigot on the P.T.O. output shaft. tate gear changes, the P.T.O. drive is maintained
without interruption.

H-4
 POWER TAKE OFF

Figure 3 Figure 4
Removing I Installing
Rear Section of the P.T.O. Rear Shaft
P.T.O. Shaft Bearing
1. Cap 5. Shaft
2. Cover 6. Snap Rings 8. Remove the snap ring locating at the front
3. Oil Seal 7. Bearing of the power take-off shaft bearing.
4. Sleeve 8. Gasket
9. Using Tool Nos. EF 800 and EF 501 pull the
To engage or disengage the live P.T.G. the clutch bearing, also the collar from the shaft.
pedal must be fully depressed and the P.T.G. Figure 4.
selector lever actuated in ~he same manner as
for the transmission P.T.G.

3. POWER TAKE-OFF REAR SHAFT B. CLEANING, INSPECTION AND REPAIR

ASSEMBLY OVERHAUL
1. Clean all parts with a suitable solvent and
A DISASSEMBLY air dry.

With Reference Figure NO.3 2. Inspect the ball bearing for excessive wear
1. Drain the oil from the rear axle center or discolouration due to overheating.
housing. 3. Inspect the bearing-retaining collar for wear
2. Move the power-take-off lever rearward to or scoring as it provides a bearing surface
the engaged position, and remove the P.T.G. for the oil seal, and if damaged, replace.
cap.
4. Inspect the power take off shaft for worn or
3. Remove the bolts retaining the P.T.G. cover
chipped splines and for distortion.
to the center housing. It is necessary to
disconnect the lower link check chains and
remove the rear plate.
4. Withdraw the shaft and cover as an C. ASSEMBLY
assembly from the center housing.
1. Press the collar onto the shaft from the front
5. Remove the snap ring retaining the shaft and using Tools Nos. EF 501 and EF 800.
bearing assembly in the cover.
6. Tap the rear end of the shaft with a soft 2. Press the ball bearing onto the shaft from
headed mallet to remove the shaft and the front usingTools Nos. ‘EF 501 and
bearing assembly from the cover. EF800-until it seats against the collar,
Figure 4 and install a neW locating snap ring.
7. Remove the oil seal from the cover using
Tool No. EF 601 and slide hammer.

H-5
 POWER TAKE OFF

4. POWER TAKE - OFF SHIFTER

MECHANISM OVERHAUL

A. DISASSEMBLY
1. Drain approximately half of the oil from the
rear axle center housing.
2. Remove the left hand platform, and remove
the handbrake the tractor is so equipped.
3. Move the shifter lever to the disengaged
position.
4. Unscrew the three shifter lever plant
retaining screws, the upper screw can not
be removed from the plate at this stage as
the Dperating lever prevents its removal.
Figure 5 5. Remove the shifter fork from the if1er arm.
P.T.D. Shaft and Bearing Retainer 6. Remove the cotter pin retaining the shifter
lever clevis pin. Remove the cleans pin and
3. Install a new oil seal in the p.T.a. bearing the lever.
retainer using step Plate adaptor. Figure 5. 7. Remove the ‘a’ ring and shifter a from the
cover plate. Remove the steel ball and
spring.
4. Install the sleeve, bearing assembly into and
shaft the cover taking care not to damage
the oil seal.
B. CLEANING, INSPECTION AND REPAIR

5. Install a new snap ring in the cover to retain 1. Inspect the shifter fork for excessive wear.
the bearing. 2. Inspect the shifter arm spring for breakage
or weakness.

6. Ensure that the shaft is clean and the end is C. ASSEMBLY

free from burrs.
1. Install the spring and steel ball in the shifter
arm, and replace the assembly in cover
7. Use a new gasket between the rear face of
plate.
the centre housing and the p.T.a. Cover.
2. Position the retaining bait in the upper hole
8. Install the shaft assembly into the rear trans- of the shifter plate. install the ‘0’ ring and the
mission housing, engaging the splines at the shifter lever and retain with a new pin.
forward end with the sliding coupling and the
spigot with the bushed hole.

9. Install the cover retaining bolts and tighten

to the specific torque (see Torque Specifi-
cation).

10. Install the p.T.a. cap.

11. Refill the rear axle center housing with the

specified oil to tile correct level.

H-6
 POWER TAKE OFF

3. Install the shifter fork on the shifter arm.

4. With a new gasket in position install the

shifter mechanism on the rear axle center
housing. Figure 6 making sure that the fork
is engaged with sleeve.

5. Install and tighten the three retaining bolts

to the specified torque.

6. Install the hand brake where fitted and

replace the platform.

7. refill the rear axle center housing with the

Figure 6 specified oil to the correct level.
Installing P.T.O. Selector Mechanism

H-7
 POWER TAKE OFF

5. SPECIFICATIONS

DESCRIPTION FARMTRAC - 60XT

POWER TAKE OFF

Ratio of Engine to P.T.O. Speed
- Transmission P.T.O. 2.95 : 1
-Live P.T.O. 3.35 : 1
P.T.O. - HP at 540 P.T.O. RPM 38.6 HP
P.T.O. - HP at Rated Engine RPM
P.T.O. Output Shaft Speed/ Engine Speed 540 @ 1600 e.r.p.m.
- Transmission P.T.O. Speed 540 @ 1600 e.r.p.m.
- Live P.T.O. Speed 1.375 in.
Output shaft O.D.

Number of Splines 6

Selector arm springs free length 0.94 in. (24 mm.) min.

Selector arm Spring compressed length 0.72 in. (18 mm.) with
22/26 lbf. ft (10/11 kgm.) Load

DESCRIPTION UNITS FARMTRAC- 60XT

P.T.O. Cover Retaining Bolts ibf. ft. 35-47

(kgf.m.) (4.9-6.5)

Selector Lever Plate Retaining Bolts ibf. ft. 35-47

Coupling 2 Nos. Bolts (kgf.m.) (4.9-6.5)_

H-8
 SECTION - 'I'

REAR AXLE AND BRAKES

S.NO. CONTENTS PAGE

1. DESCRIPTION AND OPERATION I-2

2. ADJUSTMENTS I-7

3. REAR AXE SHAFT ASSEMBLY OVERHAUL DISC BRAKES I-8

4. OVERHAUL DIFFERENTIAL AND DIFFERENTIAL LOCK ASSEMBLY I - 11

5. OVERHAUL DRIVE PINION ASSEMBLY FARMTRAC-60 I - 14

6. OVERHAUL DISC BRAKES FARMTRAC-60 I - 18

7. OVERHAUL BRAKE PEDALS AND LINKAGE I -18

8. SPECIFICATIONS I -20
 REAR AXLE AND BRAKES
I–2

Figure 1
Sectional View of Rear Axle & Brakes
 REAR AXLE AND BRAKES

REAR AXLE AND BRAKES

FARMTRAC - 60

1. DESCRIPTION AND OPERATION The rear axle centre housing extends forward forming
(With Refer to Figure 1) a compartment which houses the hydraulic lift cylinder.
A common supply of oil is used for lubricating the rear
In the Farmtrac-60 tractors, the drive from the
axle and differential assenvktm and operating the
transmission output shaft is transmitted by the drive
hydraulic power lift. The differential ring gear and
shaft coupling to the spiral bevel pinion. The pinion is
differential assembly is partly immersed in oil thus
held by pre-loaded opposed taper roller bearings and
providing adequate lubrication for bearing and bushings.
meshes with teh differential ring gear. The ring gear is
bolted to the differential case which transmit the drive The rear axle of Farmtrac-60 is unchanged except that
through a conventional 4-pinion differential to the the left and right hand axle housing and axle shafts
differential side gears. The side gears are splined to are unique to the model. They are shorter in length to
the rear axle shafts which deliver the drive to the rear accommodate the disc brake housing that are installed
wheels. in place of the drum brakes. Reference Figure 2.

The differential locking device, consists essentially of The brake assembly consists of inner and outer
a sliding coupling which is mounted on the right hand housing (mounted on the axle housing). The inner
differential side gear and is connected through suitable housing contains the brake discs with the actuator
linkage with a foot pedal. Operation of the differential assembly between them. Discs are driven by the rear
lock pedal moves a fork which forces the differential axle shaft via the splined hub.
lock pedal coupling, through an adaptor in to mesh
The actuating assembly consists of two plates having
with the differential case. This action locks the right-
ramped pockets into which steel balls are located.
hand side gear to the differential case, thus producing
The plates are held together by means of four springs.
the differential lock.
The camshaft is supported in the outer brake housing.
Each axle shaft is supported at its outer end by a
The arm assembly is actuated through a lever
single taper roller bearing and as the inner ends of the
connected to the brake pedal, operating through a turn
two shafts are in direct contact at the centre of the
buckle.
differential assembly, an inward loading on one axle
shaft will be transmitted to the opposite axle shaft will The brakes are actuated by means of foot pedals
be transmitted to the opposite axle shaft and bearing. located on the right hand side of the tractor. The pedals
Each axle shaft bearing will, therefore, withstand the may be operated independently or locked together by
verticle loading of the wheel it supports and any outward means of a pin located on the underside of the left
thrust imposed on the wheel, while any inward thrust pedal. The pedals are connected by rods and levers
will be transmitted through the axle shafts to the to the brake actuating camshaft. Reference Figure 3.
opposite bearing. Disc brakes Pedal linkage.

I–3
 REAR AXLE AND BRAKES

Figure 2
Sectional View of Disc Brakes

I–4
 REAR AXLE AND BRAKES

Figure 3
Disc Brake Pedal Linkages0

I–5
 REAR AXLE AND BRAKES

Figure 4
Parking Brake
1. Brake Pedal 2. Latch 3. Brake Pull Rod 4. T-handle (handbrake)

Depressing the brake pedals resulting in contrarotation When one rear wheel of a tractor strikes a soft patch
of the actuating plates thus causing the steel balls to of ground and spins, the normal type differential action
roll up the recesses, forcing the plates apart and allows virtually all the drive to be applied to this wheel
causing them to press the rotating discs against the and a little to the opposite rear wheel which may be
housing walls and thus effecting a braking action. on firm ground. The result is that the tractor is either
brought to a complete halt or considerably slowed
Upon releasing the pedals, spring retract the actuating
down.
plates to their original position.
When a differential lock is installed, improved traction
A breather tube is provided for efficient heat dissipation. is possible because the lock enables additional traction
PARKING BRAKE to be obtained from the wheel which is on firm ground,
thus enabling the tractor to pull through the soft patch.
The parking brake consists of a latch that is used to
Basically, this locking device consists of a dog-type
secure the foot brake pedals in the applied position.
coupling which is splined but free to slide on, the right-
To operate the parking brake the foot pedals must be
hand differential side gear and is designed to positively
locked together.
lock the differential side gear to the differential case.
With the brake pedals depressed, the latch is engaged The connection is made through the differential lock
by pulling up the T-handle and rotating it one quarter- adaptor which has dog teeth on both side faces, those
turn, see Figure 4. This locks the pedals in the on the inside engaging with teeth machined on the
depressed position, holding the brakes in applied differential case and those on the outside with the
position. differential lock coupling. Refer Figure 5.

To disengage the brake, rotate the T-handle back one In operation, depression of the foot pedal will first move
quarter turn and release. Momentarily depress the foot the sliding coupling into contact with the fixed adaptor
pedals to disengage the ratchet. and then compress the spring in the operating rod
assembly. As the teeth of the coupling come into
DIFFERENTIAL LOCK OPERATION alignment with the tooth spaces in the fixed adaptor

I–6
 REAR AXLE AND BRAKES

Figure 5
The Differential Lock

the operating rod spring tension will move the coupling the operating lever to the spring-loaded operating
into engagement with the adaptor. The fact that the rod. Depress the lever until the operating fork is
spring supplies the final operating force prevents the felt to contact the differential lock sliding
possibility of damage should excessive force be applied coupling.
to the foot pedal. 2. Loosen the stop screw lock nut and rotate the
When full engagement has taken place (this will be differential lock stop screw clockwise until it
noticeable by the reduced pedal pressure) the foot contacts the bottom of the slot in the differential
pedal should be released. The coupling and adaptor lock fork. The point of contact can be observed
teeth side forces, resulting from the transfer of power when the operating lever begins to move.
from one wheel to another, will keep the coupling and 3. Turn back the adjusting screw a quarter turn and
adaptor teeth in mesh. As the drive becomes more tighten the lock nut.
equally distributed, the compressed operating spring
4. With the foot pedal resting on the platform depress
overcomes the reduced teeth side forces and
the operating lever until the differential coupling
automatically disengages the differential lock.
is fully engaged. Loosen the lock nut and adjust
2. ADJUSTMENTS the length of the operating rod, until the clevis
DIFFERENTIAL LOCK ADJUSTMENTS pin can be inserted to contact the operating rod
It is important that sufficient clearance exists between to the lever without compressing the spring in
the differential lock pedal and the platform to ensure the operating rod.
full engagement of the lock. To provide adequate 5. Remove the clevis pin and shorten the operating
clearance the following adjustments should be made: rod by one turn then re-insert the clevis pin.
1. Remove the cotter pin and clevis pin securing Tighten the lock nut and fit the cotter pin.

I–7
 REAR AXLE AND BRAKES

Figure 6 Figure 7
Brake Disc Adjustment Brake Linkage Adjustment
1. Locknut 2. Adjusting Screw 1. Locknut 2. Brake pull rod turnbuckle

DISC BRAKES ADJUSTMENT (FT-60) (2/3 of a turn) using a 5/16 in. spanner. Tighten

IMPORTANT: Prior to adjustment, ensure that the the lock nut.

tractor is on level ground, chock the Road test the tractor, as follows:
front and rear of the front wheels, jack
Lock the brake pedals together. Drive the tractor
up the rear wheels and release the
in top gear on a flat stretch of road, disengage
parking brake.
the clutch and apply the brakes.
1. Loosen the adjusting screw lock nut on one brake
The tractor should come to a stop in a straight
and tighten the adjusting screw fully, see Figure
line. If the tractor pulls to one side, loosen off
6. Repeat on the other brake.
brake adjustment on that side and road test again.
2. Loosen the lock nut on the left and right hand
brake linkage. Figure 7. 3. REAR AXLE SHAFT ASSEMBLY
OVERHAUL DISC BRAKES-60
3. With the left hand brake pedal fully released, rotate
the turn buckle on the right hand brake pull rod Rear Axle Shaft overhaul procedure for Farmtrac-60
until the right-hand pedal is 30 mm. below the differs in the following areas:
left hand pedal when it is depressed by hand. a. The axle shaft outer bearing nut is bigger (M-64).
4. With the right hand brake pedal fully released, Use Remover Tool No. OF-1402.
rotate the turn buckle on the left hand brake pull b. Unique design disc brakes are installed in place
rod until the left hand pedal is 30 mm. below the of drum brakes.
right hand pedal when it is depressed by hand.
c. There is unique rear axle shaft seal arrangement.
5. Tighten the lock nuts and ensure that both pedals
See Figure 8.
are level within ± 1 mm. when pressed down
together by hand. Adjust, as required. REMOVAL

6. Loosen, the adjusting screw Figure 6, by 4 flats Use the following removal procedure:

I–8
 REAR AXLE AND BRAKES

Figure 8 Figure 9
Measuring Axle Shaft End-play Rear Axle Shaft Outer Seal
1. Cup 2. Hub-axle shaft
3. Seal 4. Mud Shield

IMPORTANT: Prior to removal, ensure that the tractor with internal external attachment, Tool No. EF-
is on level ground, check the front and 0601.
rear of the front wheels and release the
8. Remove the seal from the shaft and the seal cup
parking brake.
from the housing using by Tool No. EF-0600 and
With reference to Figure 8. EF0601.

1. Place a suitable container under the tractor and NOTE: Inspect the seal cup inside the housing.
drain the rear axle oil. Replacement of the cup and seal will restore the
assembly to 'as new' condition.
2. Raise and support the rear of the tractor, then
remove the rear wheels and fenders. ASSEMBLY

3. Remove the bolts securing the outer and inner Press the seal onto the axle shaft.
brake housings. Withdraw the shaft and outer
Press the cone and roller assembly onto the axle shaft.
housing assembly, holding the brake
components inside. Place them carefully to one For tightening torque values, refer "Specification".
side in a clean area.
For inpsection and re-assembly follow the guideliness
4. Remove the axle shaft retaining nut using Tool given in FT-50 overhaul of rear axle shaft assembly
No. OF-1402. procedure with a little difference in measuring of axle
shaft end play by placing the magnetic stand base on
5. Remove the spacer and oil seal.
the outer housing and dial gauge needle on the axle
6. Remove the bearing on the axle shaft. shaft flange and follow the balance procedure to check
and adjust the end float of 0.004 in. to 0.012 in.
7. Remove the outer housing. Take out the bearing
cup from the housing using, Tool No. EF-0600 THRUST BLOCK SHIMMING PROCEDURE - 60

I–9
 REAR AXLE AND BRAKES

Figure 10
Thrust Block Shims
1. Crown Wheel 5. Gasket C5NN-4885
2. Roll Pin in Thrust Block 6. Rear Axle Centre Housing
3. Thrust Block Shim Location 7. Pinion Assembly
4. Rear Axle Housing (L.H.)

The correct procedure for shimming the thrust block 3. Disassemble the rear axle housing and measure
to rear axle housing (L.H.) is as follows: the distance that the roll pin protrudes from the
thrust block (dimension X).
1. Insert a roll pin, Part No. 305023 (0.131-0.135
in. dia.) into the thrust block so that it protrudes 4. Refer to the shim selection chart below and select
from the face of the thrust block by approximately the shim (s) to be assembled between the L.H.
0.040 in. (1.016 mm.) Install the thrust block
rear axle housing and the thrust block according
without shims.
to the dimension measured in step 3.
2. With reference to Figure 10, reassemble the left-
hand rear axle housing to the centre housing
(using gasket Part No. C5NN-4885). Tighten the
EXAMPLE:
bolts to the specified torque.
X=0.019 in.
This will cause the roll-pin to be partially pushed
back into the thrust block. The amount by which Therefore, from the shim selection chart above, select
the roll pin protrudes equals the gap between two shims 92 NH-4A194-AA plus one shim 92NH-4A
the thrust block face and the back of the crown
194-CA.
wheel (dimension X).

I–10
 REAR AXLE AND BRAKES

Figure 11
Exploded View of Differential Assembly

Dimension X Shim Selection Drain the oil from the rear axle centre housing.
92NH-4A194-AA 92NH-4A194-CA A. DISASSEMBLY
0.008-0.010 in. 1 -
1. Remove the thirteen left-hand axle housing to rear
0.011-0.012 in. - 1 axle centre housing bolts and remove the axle
0.013-0.014 in. 2 - centre housing, axle shaft and brake assembly.
0.015-0.016 in. 1 1 Remove the differential assembly from the rear
0.017-0.018 in. 3 - axle centre housing. Be careful not to damage
0.019-0.020 in. the gaskets that are removed.
2 1
0.021-0.022 in. 1 2 2. Remove the differential lock ring retaining the
Step-3 differential lock coupling to the right-hand side
gear. Remove the stop washer, coupling, coupling
5. Remove the roll pin or tap it into the thrust block
spring and gear case adaptor, Figure 11.
so that it does not protrude then reassemble the
rear axle housing using the selected shim (s). 3. Mark the two halves of the diffential case so that
Tighten all bolts to the specified torque. they may be assembled in the same relative
position, extract the lock wire and remove the
4. OVERHAUL DIFFERENTIAL AND
bolts. If a differential lock is fitted it will be
DIFFERENTIAL LOCK ASSEMBLY necessary to gradually remove the bolts at the
Prior to disassembly of the differential remove the left- same time lifting the right-hand half of the case.
hand wheel and fender and disconnect electrical wiring The bearing will prevent individual bolts from being
and brake linkage to gain access to the rear axle. removed.

I–11
 REAR AXLE AND BRAKES

Figure 12 Figure 13
Differential Spider and Pinions Differential Cone and Roller Assembly Removal
1. Puller EF-0800
4. Remove the right-hand half of the case from the 2. Pulling Attachment EF-0501
rest of the assembly. 3. Cone and Roller Assembly
4. Step Plate Adaptor
5. Remove the right-hand thrust washer, right hand
side gear, spider and pinion assemblies, left-hand
side gear and left-hand thrust washer. Refer Figure
12.

6. If it is necessary to remove the right-hand cone

and roller assembly use Tool Nos. EF-0501, EF-
0800 & step plate adaptor. Refer Figure 17.

B. INSPECTION AND REPAIR

1. Clean and inspect all parts and install new parts

where worn or damaged.

2. If it is necessary to install new differential case

bushings, they should be removed with a suitale
drift. Figure 14
3. If a new differential case and/or differential ring Removing a Differential Bearing Cup
gear are to be installed, remove the eight bolts NOTE: If a new differential ring gear has been
and nuts retaining the differential ring gear to the installed a new drive pinion must also be
left-hand half of the differential case by using Tool fitted. This should be carried out as outlined
No. OF-0800. in 'Overhaul Drive Pinion Assembly'.

Assemble the new differential ring gear and/or 4. If it is necessary to intsall a new bearing cup in
left-hand differential case with replacement bolts the left or right-hand axle housing, use push puller,
and nuts. Be sure the ring gear does not cock push puller legs, push puller adaptor and
on the differential case pilot. Tighten the nuts to external/internal pulling attachment to remove the
torque specified in the Torque Specifications. cup, Figure 14. It will be necessary to remove

I–12
 REAR AXLE AND BRAKES

6. Lubricate the assembly and turn the gears to

check freedom of movement. Lock the heads of
the bolts with wire.
7. Install the differential lock gear case adaptor,
spring, sliding coupling and thrust washer and
retain with a new lock ring.
8. Install the right-hand axle housing assembly if
removed.
9. Position the differential assembly in the rear axle
centre housing
10. Locate the left-hand axle housing using the same
number of gaskets as removed during
disassembly procedure (see Note).
Figure 15
Install the wheel and tender and connect the
Tightening Differential Case Bolts
brake linkage and electrical wiring. Refill the rear
axle centre housing with the correct quantity and
the axle housing and to remove the axle shaft
grade of lubricant (See Specifications Section).
from the axle housing to use these tools. (This
should be carried out as described in Section NOTE: The differential bearing pre-load must be
3A, steps 1 and 2. 'Overhaul Rear Axle Shaft checked if any of the following components
Assembly Shoe-Brakes. have been damaged and new parts installed.

5. Remove the differential lock operating fork and A. Differential Assembly

cross shaft, from the right-hand axle housing. (with differential lock)

C. ASSEMBLY 1. Rear axle differential cone and roller

assemblies.
1. Insert the eight retaining bolts in the holes in the
2. Differential case.
right-hand half of the differential case then, install
the right-hand cone and roller assembly. 3. Differential ring gear and drive pinion.
2. Install the left-hand cone and roller assembly. B. Rear axle centre housing
3. Place the left-hand half of the case on the bench C. Rear axle housing
and install a side gear thrust washer and theleft- THE DIFFERENTIAL BEARING PRE-LOAD
hand side gear. Assemble the pinions and thrust ADJUSTMENT SHOULD BE CARRIED OUT AS
washers to the spider and locate in the differential FOLLOWS:
case. Locate the right-hand side gear and thrust
1. Using a new gasket, bolt the right-hand axle
washer on top of the assembly.
housing to the rear axle centre housing.
4. Lower the right-hand half of the differential case
2. Rotate the rear axle centre housing until the right-
over the right-hand side gear and line up the
hand axle housing is pointing downward.
mating marks, placed on the left-hand right-hand
halves of the case before disassembly. 3. Locate the differential assembly in the cup of the
right-hand axle housing.
5. Tighten the retaining bolts to the specified torque
see Torque Specifications. Use Special adaptor, 4. Position the left-hand axle housing over the
Tool No. OF-800 or similar crow foot adaptor, to differential assembly and rotate to ensure the
enable a torque wrench to be used. (Figure 15) bearing cones seat correctly.

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 REAR AXLE AND BRAKES

Figure 16
Rear Axle Drive Pinion
1. Drive Pinion 2. Cone & Roller Assembly 3. Retainer Assembly
4. Threaded clamp 5. Clamp Locknut 6. Washer
7. Washer

5. Fit four bolts equally spaced around the axle 5. OVERHAUL DRIVE PINION
housing and screw down finger tight. ASSEMBLY FARMTRAC-60
6. With feeler gauge measure the gap between the To gain access to the drive pinion assembly it will be
axle housing and centre housing ensuring that it necessary to split the tractor between the rear axle
is equal at all points around the circumference. centre housing and the gear box.
Do not tighten the nuts beyond finger-tight. NOTE: The P.T.O. shifter plate assembly must be
7. From the table below the correct number of removed from the rear axle centre housing
gaskets required can be determined: before the rear axle is split from the gear
0.0055-0.013 0.014-0.019 in. 0.020-0.0255 in. box.
Width of in. (0.140- (0.356-0.483 (0.508-0.648
gap 0.330 mm.) mm.) mm.) Prior to disassembling the drive pinion assembly it
Number of 1 OFF 2 OFF 3 OFF will be necessary to remove the differential from the
G a s k e t s Thickness 0.011 to 0.013 in. 0.015 to 0.017 in. rear axle centre housing (Refer to 'overhaul Differential
required 0.006" to .008
and Differential Lock Assembly').
8. Having determined the correct number of gaskets A. DISASSEMBLY
remove the left-hand axle housing and rebuild the
With Refer to Figure 16.
axle as described in 'Overhaul Differential and
Differential and Differential Lock Assembly'. 1. Remove the three bolts and lock washers
securing the P.T.O. selector lever plate to the
NOTE: It is advisable always to check on
reassembly that the differential ring gear can left-hand side of the rear axle centre housing.
be turned by hand and that backlash exists Lift out the P.T.O. selector lever, plate and fork.
between the drive pinion and differential ring Slide the selector ring off the splines of the P.T.O.
gear. Excessive pre-loading or end float shaft and remove the hydraulic filtes. Remove
conditions are both detrimental to the life of the lower right-hand bolt on the drive pinion
taper roller and pilot bearings. retainer, to remove the inlet filter.

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 REAR AXLE AND BRAKES

Figure 17 Figure 18
Removing Drive Pinion Pilot Bearing Drive Pinion Rear Cone and Roller Assembly Removal
1. Puller, Tool No. EF-0800
2. Remove the four retaining bolts and lock washers 2. Pinion Shaft
securing the drive pinion assembly to the rear 3. Pulling Attachment, Tool No. EF-0501
axle centre housing and, using two 9/16 in. N.C. 4. Cone and Roller Assembly
bolts as jacking screws, remove the drive pinion
assembly. 3. If it is necessary to install a new rear pinion cone
and roller assembly, the assembly may be
3. Place the drive pinion assembly in a vice and
removed using Tool Nos. EF-0800 and EF-0501.
remove the internal threaded clamp locking nut
The new cone and roller is installed using the
and bolt. Unscrew the threaded clamp.
same tools and a suitable sleeve to enable the
4. Remove the thrust washer.
tool to press on the inner bearing race, Refer
5. Remove the drive pinion cone and roller Figure 18 and 19.
assemblies and pinion from the bearing retainer
assembly.
6. Remove the lock ring from the rear end of the
pinion gear and using Tool Nos. EF-0800 and
EF-0501 pull the pilot bearing off the pinion gear,
Figure 17.
NOTE: On dismantling, first ensure that taper roller
bearing outer cone fitted in the retainer
housing is fully seated and no gaps or metal
chips exist between the cone face and
shoulder of the step in the retainer casting.
In case these gaps and chips are observed,
the retainer housing must be replaced.
Excessive pre-loading or end float conditions are both
detrimental to the life to taper roller and pilot bearings.
B. INSPECTION AND REPAIR Figure 19
1. Clean and inspect all parts and install new parts Drive Pinion Rear Cone and Roller Assembly Replacement
where worn or damaged. 1. Cone and Roller Assembly
2. If it is necessary to install new retainer bearing 2. Sleeve
cups they may be removed from the housing using 3. Pulling Attachment, Tool No. EF-0501
Tool Nos. EF-0601 and EF-0600. 4. Puller, Tool No. EF-0800

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 REAR AXLE AND BRAKES

Figure 20 Figure 21
Pinion Bearing Pre-load Check Checking Drive Pinion Pre-Load
1. Gauge, Tool No. EF-1300 1. Bearing Retainer
2. Adaptor, Tool No. EF-1301 2. Pull Scale
3. Pinion Shaft 3. Drive Pinion
4. Bearing Retainer

NOTE: If a new drive pinion is to be installed a new 5. Tighten the Grab Bolt nut to 17-21 lbf.in. (2.5-2.9
differential ring gear must also be fitted. This kgm.) and recheck pre-load after turning the
should be carried out as outlined under pinion several times re-adjust if required.
'Overhaul Differential and Differential Lock
6. Install the drive pinion assembly into the centre
Assembly' Shoe Brakes.
housing and secure with five bolts and lock
C. ASSEMBLY washers. Do not secure the bolt that retains the
1. Install the pilot bearing on the pinion, using a inlet filter. It may be necessary to tap the retainer
suitable hollow sleeve, and fit a new lock ring. in to position with a drift if a tight assembly is
encountered.
2. Position the pinion shaft assembly and front
pinion cone and roller assembly in the retainer 7. Fit the hydraulic filters. The lower right hand bolt
assembly. Instal the thrust washers. securing the retainer assembly to the rear axle
centre housing also secures the hydraulic inlet
3. After assembly of bearings, pinion, install the
filter support tab to the retainer assembly. Tighten
threaded clampnut on to drive pinion. Hold the
the bolts to torque shown in the "Torque
retainer assembly in a soft Jaw bench vice.
Specifications".
Screw in the threaded clamp nut to nearly pre-
load position and tighten the Grab bolt, nut to 12 8. Slide the selector ring on to the splines of the
lb.ft. (1.7 kgm) so that clamp nut can be turned P.T.O. shaft and fit the selector lever, fork and
with a drag. plate. Secure with three bolts and lock washers.
Replace the hand brake assembly (where fitted).
4. Now by using Gauge Tool No. EF-1300 with
adaptor Tool No. EF-1100 adjust pre-load to 12- Replace the differential and the axle housing
16 lbf.in. in or using spring balance Tool No. EF- assembly. (Refer to "Overhaul Differential and
1301, adjust to 16-21 lb.in. (7.2-9.5 kg.). Refer Differential Lock Assembly"). Reconnect the
Figure 20 and 21. tractor.

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 REAR AXLE AND BRAKES

Figure 22
Brake Assembly
1. Bush-brake housing outer 16. Ring 34. Clamp bolt 55. Shaft
2. Bolt 17. Gasket 35. Arm 56. Washer
3. Washer 18. Ring-snap 36. Bracket-cross-shaft L.H. 57. Seal assembly-shaft
4. Seal assembly-housing 19. Thrust washer 37. Bracket-cross-shaft R.H. 58. Split pin
5. Bleed Screw 20. Brake housing inner-left 38. Bush 59. Clevis pin
6. Grease fitting hand 39. Woodruff key 60. Brake pedal lock
7. Brake housing outer 21. Brake housing inner-right- 40. Locknut 61. Roll pin
8. Cup bearing hand 41. Bolt 62. Clamp bolt
9. Cone and roller bearing 22. Stud 42. Washer 63. Brake pedal-left-hand
10. Spacer-rear axle shaft 23. Nut 43. Bracket 64. Brake pedal-right-hand
11. Seal assembly-hosing outer 24. Seal assembly-housing 44. Washer 65. Brake Pedal assembly-right
12. Nut-rear axle shaft inner 45. T-handle hand, consists of brake
13. Disc assembly 25. Bolt 46. Split Pin pedal plus
14. Brake actuator assy. 26. Copper washer 47. Pawl 65a. Stud
consists of actuator plates 27. Washer 48. Snap ring 65b. "O" ring
plus 28. Bolt 49. Brake pull rod 65c. Busing pedal
14a. Ball - Actuating 29. Brake camshaft-left-hand 50. Locknut 65d. Grease fitting
14b. Spring-disc return 30. Brake camshaft-right-hand 51. Turnbuckle (clevis) 66. Spring-pedal return
14c. Push rod 31. Boot assembly seal 52. Woodruff key 67. Circlip
14d. Clip-rod retaining 32. Retainer-boot 53. Bolt
15. Sleeve 33. Spring clip 54. Lever

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 REAR AXLE AND BRAKES

6. OVERHAUL DISC BRAKES-60 C. RELINING THE DISCS

A. REMOVAL Before proceeding with relining, inspect the discs for

excessive wear or damage to the splines. If damaged,
With reference to Figure 28.
replace with a new disc.
IMPORTANT: Prior to brake overhaul, ensure that
Inspect the lining surface. It must not be allowed to
the tractor is on level ground and check the front and
wear down to the rivet heads.
rear of the front wheels.
If it is required to reline the discs, carefully drill out the
1. Engine the parking brake, move both gear shift
rivets and discard the old linings. Ensure that the holes
levers to neutral and jack up the rear wheels clear
in the disc are not enlarged when drilling out the rivets.
of the ground.
Clean the discs to ensure a smooth, even surface for
2. Loosen the wheel nuts and remove the wheels.
relining. Check the discs for flatness.
3. Disengage the parking brake and un latch the
Clamp the lining evenly to the disc and start riveting
pedals.
diametrically opposite rivets. A flat ended anvil of the
4. Remove the split pin holding the brake lever turn correct diameter should be used against the rivet head
buckle. and the tubular shank of the rivet properly spread over
5. Unscrew the brake adjuster screw. to form a 'star' shape.

6. Unscrew the 8 bolts holding the brake housing Care should be taken when riveting to avoid cracking
outer to the inner. the lining. Ensure that the lining is flat against the
disc and that no clearance exists between the lining
7. Remove the rear axle shaft with the brake housing
and disc after riveting.
outer.
D. INSTALLATION
8. Remove the actuator assembly and brake discs.
Installation of the wheel brake assembly follows the
9. Remove the spring-loaded push rods with the aid
removal procedure in reverse. On installation, observe
of a scrw driver. Remove the four actuating plate
the following:
springs using a thin rod formed at the end into a
letter 'J'. Separate the discs and remove the balls. IMPORTANT: Do not apply oil or grease to the ball
pockets. They should be clean and dry.
B. INSPECTION AND REPAIR
Tighten the bolts to the correct torque, see "Torque
Clean all parts thoroughly in a suitable solvent, Specification".
particularly the balls, recesses, the brake surfaces
7. OVERHAUL BRAKE PEDALS AND
on the inner and outer housing and the camshaft push
LINKAGE
rod cavities. Check all parts of the brake for any wear
or damage and replace, if necessary. 1. Drain the oil from the rear axle housing.

Whenever the brakes are overhauled, installation of a 2. Disconnect the right-hand left-hand brake rods,
new set of return springs is strongly recommended. at their forward ends, from the right-hand brake
pedal and the brake cross-shaft lever respectively.
Ensure that the friction disc slides freely on the splined
3. Release the brake pedal return springs connected
shaft-check in four positions.
to the underside of the plateform.
Check for any oil leaks from the axle housing and
4. Remove the snap ring and washer from the end
replace oil seals, if required.
of the cross-shaft and slide off the right-hand
Replace the dowels in the brake housing inner. brake pedal spacing washer.

I–18
 REAR AXLE AND BRAKES

5. Loosen the pinch bolt on the left-hand brake pedal C. INSTALLATION

and slide the pedal from the key and shaft.
1. Install the brake cross-shaft with the clutch pedal
6. Remove the key and right-hand thrust washer
from the cross-shaft. and left-hand thrust washer in position. Position
the right-hand thrust washer with the flat on the
7. Ensure that the cross-shaft is free from burrs
washer facing forward.
before sliding the shaft through the oil seals.

B. INSPECTION AND REPAIR 2. Locate the key in the cross-shaft groove, slide
1. Clean and inspect all parts and install new parts the left-hand brake pedal on to the key and secure
where worn or damaged. the pinch bolt.

2. To install a new bushing in the right-hand brake

3. Install the spacing washer, right-hand brake
pedal, drive out the old bushing and fit a new
pedal, washer and snap ring on the brake cross-
bushing. Ensure that the hole in the bushing is
in line with the lubrication hole in the pedal. shaft.

3. If the cross-shaft oil seals are damaged they 4. Connect the brake pedal return springs to the
should be removed and new seals installed. underside of the platform.
Press the new oil seals into the rear axle centre
housing with the steel case of the seal facing 5. Connect the brake rods at their forward ends to
outwards.
the right-hand brake cross-shaft lever.
4. Inspect the brake cross-shaft bushings and if
they appear to be worn or deeply scored, remove 6. Fill the rear axle housing with the correct quantity
the bushings and install the new bushings. and grade of lubricant.

I–19
 REAR AXLE AND BRAKES

8. SPECIFICATIONS

DESCRIPTION FARMTRAC-60

Type Semi floating

Axle Ratio 6.16:1
Capacity 23.3 Litres
Grade EP-80W 90 (MIL-L-2105C, API GL-5)

Differential ring gear

Diameter 14.00 IN. (35.60 cm.)
Number of Teeth 37

Drive Pinion
Number of Teeth 6
Number of Splines 23
Pinion bearing pre-load 12-15 lbf.in. (0.138-0.184 Kgfm.)
(Using Tool No. EF-1300 & OF-1301)

Pinion bearing pre-load 16-21 lbf.in. (7.26 - 9.53 Kgfm)

(Using Pull Scale EF-1100)
Pinion and Crown Wheel teeth backlash 0.010 - 0.013 in. (0.25 - 0.33 mm)

Axle Shafts
Number of splines 38
End Play 0.004 - 0.012 in. (0.102 - 0.305 mm.)

Shim Sizes i. 0.004 - 0.006 in. (0.10 - 0.15 mm.)

ii. 0.008 - 0.010 in. (0.20 - 0.25 mm.)
iii. 0.015 - 0.017 in. (0.38 - 0.43 mm.)
iv. 0.020 - 0.022 in. (0.51 - 0.56 mm.)
v. 0.030 - 0.032 in. (0.76 - 0.81 mm.)
vi. 0.049 - 0.051 in. (1.25 - 1.30 mm.)

Crown wheel face to thrust pad gap 0.004 - 0.006 in. (0.10 - 0.15 mm.)

Shim Sizes 0.004 in. (0.1 mm.)

0.006 in. (0.15 mm.)

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 REAR AXLE AND BRAKES

DESCRIPTION FARMTRAC-60

Brakes
Type Multiple Plate Disc Brake (Mechanical Internal
Exp. Disc type sealed)

No. of brake disc 2 per side

Brake disc lining effective 9 in. dia x 7.5 in. dia

diameter (Size) (22.9 cm. x 19.1 cm. dia)

Lining Area 141.1 in. sq. (904.8 sq.cm.)

Brake Pedal Free Play 1.00 - 1.25 in. (25-32 mm.)

Rear Axle Shafts Seals Three lip outer seal to maximise restraining the
ingress of water in paddy.

Grease point for purging residual mud from the

outer seal.

Two seals between the trumpet and inner brake

housings with an oil trap & drain plug to avoid
rear axle oil contaminating the brakes.

Rear Axle Shafts Free floating splined sleeves for brake discs to
eliminate stress risers on the rear axle shafts.

Larger Taper roller bearings and larger retaining

nut.

Brake Periodic Maintenance Greasing Grease all brake linkages and grease points
on each side of the Outer brake housing every
50 hrs. normally and Grease daily in puddling.

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 REAR AXLE AND BRAKES

TORQUE SPECIFICATIONS UNITS FARMTRAC-60

Center housing to axle housing bolts lbf.ft 110-135

(kgf.m) (15.2-18.6)

Differential case bolts lbf.ft 68-92

(kgf.m) (9.4-12.7)

Differential ring gear nuts lbf.ft 50-55

(kgf.m) (6.9-7.6)

Pinion bearing retainer bolts lbf.ft 100-125

(kgf.m) (13.8-17.26)

Rear Axle shaft lock nut lbf.ft 425-475

(kgf.m) (58.7-65.6)

Rear wheel nuts lbf.ft 180-200

(kgf.m) (24.9-27.6)

Brake housing inner to axle housing lbf.ft 130-150

Bolts/Nuts (kgf.m) (18.0-21.0)

Brake housing inner to Brake housing lbf.ft 76-84

outer bolts (kgf.m) (10.5-11.6)

Brake housing inner to boot retainer bolts lbf.ft 11-15

(kgf.m) (1.5-2.1)

I–22
 SECTION - 'J'

HYDRAULIC SYSTEM
S.NO. CONTENTS PAGE

1. HYDRAULIC SYSTEM CIRCUIT DESCRIPTION AND OPERATION J-3

2. EXTERNAL CONTROL J-4

3. VALVES IN THE LIFT CYLINDER ASSEMBLY J-4

4. HYDRAULIC POWER LIFT OPERATION J-5

5. HYDRAULIC OIL CIRCUIT J - 10

6. ADJUSTMENTS J - 20

7. OVERHAUL LIFT CYLINDER ASSEMBLY J - 22

8. OVERHAUL LIFT COVER ASSEMBLY J - 28

9. FLOW CONTROL VALVE PLATE AND LINKAGE (WHERE FITTED) J - 31

10. HYDRAULIC PUMP-ENGINE MOUNTED GEAR TYPE J - 33

11. HYDRAULIC PUMP-ENGINE MOUNTED GEAR TYPE OVERHAUL J - 35

12. HYDRAULIC SYSTEM-TROUBLE SHOOTING J - 40

13. HYDRAULIC SYSTEM VALVES FUNCTION & OPERATION J - 46

14. SPECIFICATIONS J - 48
 HYDRAULIC SYSTEM

Figure 1
Hydraulic System - Schematic

1. Lift Arm 12. Pump Pressure Tube

2. Draft Control Spring 13. Engine Mounted Pump Gear
3. Draft Lever 14. Micronic Suction Filter
4. Position Lever 15. Flow Control Valve Restrictor Knob
5. Actuating Lever 16. Cooler Valve
6. Control Valve Lever 17. Flow Control Valve
7. Feathering Valve 18. Check Valve
8. Control Vlave 19. Draft Control Lever
9. Unload Valve 20. Position Control Lever
10. Hydraulic Pump Inlet Tube 21. Lift Cylinder Safety Valve
11. Pressure Relief Valve

J–2
 HYDRAULIC SYSTEM

HYDRAULIC SYSTEM

1. HYDRAULIC SYSTEM CIRCUIT

DESCRIPTION AND OPERATION
On Farmtrac-60 tractors, hydraulic system consists
mainly of an oil reservoir, hydraulic pump, lift cylinder
and piston and lift arms. The hydraulic circuit is an
open center design. When the engine is running,
hydrauli oil is continuously pumped through the system
irrespective of operational requirements. A control valve
spool directs the flow of oil to effect a raise, neutral or
lowering action of the lift arms.

Various circuit relief valves and check valves protect

the system components from any overload conditions
which may be encountered during normal or arduous Figure 2
operations. Location of Hydraulic Inlet Filter FT-60
1. Micronic Inlet Filter
Figure 1 Illustrates the hydraulic system for Farmtrac- 2. Engine Mounted Gear Pump
60 with an engine mounted gear type hydraulic pump.
housing, which requires regular cleaning. Also a full
The rear axle center housing serves as a oil reservoir
flow micronic suction filter featured with engine
and supplies oil to the hydraulic pump.
mounted gear type hydraulic pump on all Farmtrac
On Farmtrac-60 model the hydraulic gear type pump tractor models. The micronic suction filter is located
is mounted on the rear left hand side of the engine, externally adacent to the engine mounted gear pump
the drive is taken from the camshaft. as shown in Figure 2.

HYDRAULIC OIL FILTERS LIFT COVER ASSEMBLY

Farmtrac-60 tractor with gear type hydraulic pump and The lift cover assembly acts as a housing for control
a tubular wire mesh type suction filter is positioned linkage and lift cylinder assembly which alters the
horizontaly at the bottom of the rear axle center working depth of the implement.

J–3
 HYDRAULIC SYSTEM

2. EXTERNAL CONTROLS
LIFT CONTROL LEVERS

Farmtrac-60 tractors have two lever control system.

The two-lever control system incorporates separate
levers for draft and position control situated at the right-
hand side of the operator's seat.

The system enables operator to select full draft control

(inner lever), full position control (outer lever) or a
combination of both for maximum implement depth
control, in addition to draft response.

The two-lever control system provides more accurate

positioning and finer increments of control.
Figure 3
CONTROL CONTROL Hydraulic Lift Control Valve and
Bushing Assembly
When an implement is pulled through the ground; the
draft caused by soil resistance has the effect of trying
to rotate the implement around the lower link hitch DRAFT CONTROL MAIN SPRING
points. This creates a pushing or compressive force
Forcess applied to the top link by the implement are
in the top link.
relayed to the internal draft control linkage by the draft
When changes in working depth or soil resistance control main spring.
cause the draft to increase or decrease; the
The spring is double acting and ensures draft control
compressive force in the top link also increases or
is maintained whether the forces in the top link are
decreases.
compressive or tensile.
The system of Draft Control uses the top link signal to
raise or lower the implement working depth to maintain
3. VALVE IN THE LIFT CYLINDER
a constant draft; when the position control lever is in
ASSEMBLY
the lowest position. CONTROL VALVE

POSITION CONTROL With reference to Figure 3.

Position control is selected by pushing the draft control The control valve is connected through internal linkage
lever to the bottom of the quadrant (there by making to the lift control levers and either directs the flow of
the draft control linkage inoperative) and moving the hydraulic oil from the pump to the lift cylinder, to effect
position control lever. a raise condition, or to the reservoir for a neutral or
lowering cycle.
DRAFT CONTROL WITH POSITION CONTROL
(BLENDING) To cater for the increased flow of hydraulic oil, the
control valve has narrow section lands. The land
When the system is in draft control, the position control
positions are designed for compatibility with the
lever can be utilized to set a desired maximum
feathering valve flow control system, Figure 4.
implement working depth. Draft control is maintained
but the implement depth is regulated by the position The control valve spool is matched with a unique colour
control setting which overrides the draft control linkage. coded bushing.

J–4
 HYDRAULIC SYSTEM

Figure 4 Figure 5
Feathering Valve and Bushing Unload Valve and Bushing Assembly

FEATHERING VALVE To cater for the increased flow of hydraulic oil and for
The feathering valve monitors the flow of hydraulic oil compatibility with the feathering valve flow control
across the control valve and varies the flow of oil to the system, the check valve housing and seat incorporate
lift cylinder accordingly. This valve effectively improves larger ports and revised land respectively and check
the performance of the hydraulics in work by valve guide has been removed.
automatically providing finer control to lift. This LIFT CYLINDER SAFETY VALVE
feathering valve is featured on all Farmtrac-60 lift control
system. This spring operated valve is mounted directly into the
lift cylinder wall. If shock loadings are encountered,
The feathering valve is located within a colour coded
for example when transporting implements over rough
bushing. Figure 4.
ground, the valve opens to relieve excess pressure
The feathering valve flow control system is described and protect the system.
in detail in this chapter.
4. HYDRAULIC POWER LIFT OPERATION
UNLOAD VALVE
The hydraulic power lift is regulated both in position
The unload valve is operated by oil pressure as directed control and draft control by movement of the control
by the control valve and has two positions. In the lower valve. Depending upon the position of this valve,
position the valve allows oil to flow from the rear of the
hydraulic oil pressure is directed to effect a raising,
feathering valve to the reservoir thereby unloading the
lowering or neutral action.
system. In the raised position the unload valve seals
off the connection to the reservoir and oil from the The position of the control valve can be altered either
control valve is directed to the lift cylinder. by moving the lift control levers or by a force acting on
the draft control main spring when in draft control.
The land form of the unload valve is shown in the Figure
5. DRAFT CONTROL
CHECK VALVE The system of Draft Control uses the top link signal
A Simple one-way ball valve which allows hydraulic oil for raising or lowering the implement working depth to
to pass to the lift cylinder or auxiliary equipment but maintain a constant draft. When the position control
prevents the return. lever is in the lowest position, the double acting draft

J–5
 HYDRAULIC SYSTEM

Figure 6
Draft Control Linkage - Lowering into Work

Figure 7
Draft Control Linkage - Raising in Work

1. Yoke 6. Torsion Spring 11. Draft Lever

2. Draft Control Main Spring 7. Adjustable Stop 12. Draft Control
3. Draft Control Link 8. Control Valve Spring 13. Draft Control Roller
4. Control Vavle Lever 9. Control Valve 14. Lift Cross Shaft
5. Actuating Lever 10. Pivot Pin

J–6
 HYDRAULIC SYSTEM

control system of the Farmtrac-60 tractor functions neutral position.

as follows: A decrease in draft at the implement will reduce the
LIGHT IMPLEMENTS compression of the draft control main spring and allow
LOWERING INTO WORK the draft control link and hence the control valve lever
to move rearward.
With reference to Figure 6.
This allows the control valve spring to extend and move
Downward movement of the draft control lever swings
the control valve rearward into a lowering position.
the roller forward and away from the draft lever which
is connected by the pivot pin to the actuating lever. As the implement runs deeper the draft increases to
The actuating lever is coupled via a torsion spring to the original amount and the control valve again returns
the control valve lever. to the neutral position.

NOTE: The torsion spring is in permanent torsion to HEAVY IMPLEMENTS

ensure that any movement of the actuating LOWERING INTO WORK
lever is transmitted directly through the spring With reference to Figure 6.
to the control valve lever. An adjustable stop The following action occurs when the implement always
positions the levers relative to one another produces tension at the top link. Downward movement
but does allow the control valve lever to move of the draft control lever swings the roller forward. As
rearward relative to the actuating lever. the roller moves forward, the connecting linkage allows
As the draft control roller moves forward and away the control valve spring to extend and pull the control
from the draft lever, the control valve spring extends valve rearward to the slow drop position. As the
and pushes the control valve and actuating levers implement descends, the tensile fore on the yoke
rearwards. The draft lever pivots about the connection increases and further compresses the draft control
in the slotted draft control link until it again contacts main spring against the spring rear seat. At the same
the draft control lever roller. At this point all the linkages time the slotted draft control link is moved rearward
come to rest with the control valve held in the drop allowing the draft lever also to pivot rearward about the
position. roller. As the draft lever pivots, the control valve lever
Lowering stops when the implement draft compresses and the actuating lever swing rearward due to the force
the draft control main spring in a forward direction a of the control valve spring which allow the control valve
sufficient amount as to cause the draft control link to to move further into lowering position, thereby
pivot the draft control lever about the roller and hence increasing the rate of drop.
push the control valve lever forward. This action Lowering stops when the implement draft reduces the
overcomes the rearward pressure of the control valve tension in the top link a sufficient amount for the draft
spring and moves the control valve into the neutral control main spring to push the draft control link and
position. hence the control valve lever forward. This action
DRAFT PRODUCING COMPRESSION IN TOP LINK overcomes the rearward pressure of the control valve
spring and moves the control valve into the neutral
With reference to Figure 7.
position.
When working in Draft Control an increase in draft at
DRAFT INSUFFICIENT TO PRODUCE
the implement will compress the draft control main
COMPRESSION IN TOP LINK
spring in a forward direction and push the draft control
link and hence the control valve lever forward. This When the implement draft is constant but is insufficient
action moves the control valve forward into a raise to overcome the weight of the implement, the top link
position and as the implement is lifted the draft force, will be in tension and the draft control main spring
and hence the force on the draft control main spring, compressed rearward against the spring seat.
decreases to the original amount. The control valve With reference to Figure 7.
spring now moves the control valve rearward into the An increase in draft will produce a decrease in tension

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 HYDRAULIC SYSTEM

in the to link and allow the draft control spring to The system of Position Control enables the working
compress in a forward direction, thus pushing the draft depth or height of an implement to be preset and
control link and hence the control valve lever forward. maintained. When the draft control lever is in the lowest
This action moves the control valve into a raise position position, the position control system function as
and as the implement is lifted the draft force decreases follows:
but the tension in the top link increases. The yoke is RAISING
pulled rearward until the original draft is obtained. The With reference to figure 8.
control valve spring now moves the control valve into Upward movement of the position control lever causes
the neutral position. the position lever to pivot about the forward roller.
With reference to Figure 6. NOTE: The two rollers are fixed in position relative
A decrease in draft will produce an increase in tension to one another but rotate freely about the
in the top link and increase the rearward compression position control lever horizontal shaft.
of the draft control main spring. This action allows the When the position lever pivots it pushes against a roller
control valve spring to move the control valve into a attached to the actuating lever which moves forward.
lowering position. As the implement runs deeper the The torsion spring transmits the movement to the
draft increases until the original draft is obtained and control valve lever which in trun moves the control valve
the draft control main spring expands in a forward forward in to the raise position.
direction there by moving the control valve into the As the lift cross shaft rotates, a cam allows the two
neutral position. rollers to move rearwards. Due to the force of the control
RAISING IMPLEMENT TO TRANSPORT POSITION valve spring all the linkage follow the rollers allowing
When the draft control lever is pulled to the top of the the control valve to move rearward to the neutral
position. As soon as the valve is in this position the
quadrant to the transport position, the draft control
lifting action stops. If a further lift is required, the
roller pushes the draft lever rearwards and causes the
position control lever is moved further up the quadrant
lever center pivot to move to the top of the slot in the
and the above procedure is repeated.
draft control link. In this position the draft lever pivots
about the slotted link and forces the actuating leve LOWERING
forward. The torsion spring transmits the movement With reference to Figure 9.
to the control valve lever which in turn moves the control Downward movement of the position control lever tends
valve fully forward into the fast raise position. to allow the position lever to swing free of the forward
To limit the maximum height to which the implement roller but the rearward force of the control valve spring
can be raised, the linkage is designed so that the pushes the control valve lever and actuating lever roller
piston skirt projects slightly beyond the end of the lift against the foot of the position lever which maintain
cylinder. On reaching the fully raised position, the contact with the forward roller. The rearward movement
of the control valve spring pulls the control valve into
piston contacts the control valve lever which moves
the lowering position.
rearwards.
As the lift cross-shaft rotates in a clockwise direction,
NOTE: The torsion spring allows the control valve
the increasing radius of cam pushes the two rollers
lever to move rearwards relative to the
forward. This action forces the position lever and hence
actuating lever.
the control valve lever, forward until the control valve
This action moves the control valve rearwards into the moves to the neutral position. Further downward
neutral position and stops any further movement of movement of the position control lever will cause the
the piston. The piston stop mechanism operates both lift arms to drop until such times as the valve is
in Draft Control and Position Control. neutralised or the implement reaches the lowest
POSITION CONTROL position.

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 HYDRAULIC SYSTEM

Figure 8
Position Control - Raising

Figure 9
Position Control - Lowering

1. Yoke 6. Torsion Spring 11. Position Lever

2. Draft Control Main Spring 7. Adjustable Stop 12. Position Control Lever
3. Draft Control Link 8. Control Valve Spring 13. Position Control Rollers
4. Control Vavle Lever 9. Control Valve 14. Lift Cross Shaft
5. Actuating Lever 10. Actuating Lever Roller

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 HYDRAULIC SYSTEM

HIGH PRESSURE OIL REDUCED PRESSURE OIL RESERVOIR & EXHAUST OIL
Figure 10
System Pressure Relief Valve FT-60
A. To Hydraulic Circuit B. To Reservoir C. From Hydraulic Pump
1. To Hydraulic Circuit 5. Back-up Washer 9. Piston
2. Valve Seat 6. Spring 10. Rear Axle Centre Housing
3. Valve Land 7. Shims
4. Frictin Seal 8. Cap Nut
DRAFT CONTROL WITH POSITION CONTROL pressure passes through the ports in the valve seat
When the system is in draft control the position control and acts on the valve land. The valve is restrained by a
lever can be adjusted to maintain a selected maximum spring and piston and at normal system pressures
implement working depth. The draft control lever can the force exerted on the valve land is insufficient to
overcome that of the spring.
simultaneously be adjusted to maintain the desired
draft load within the limits of the pre-selected maximum If ever the system pressures is excessive, the force
implement working depth. on the valve land overcomes that of the spring and
pushes the valve and piston rearwards. As the valve
5. HYDRAULIC OIL CIRCUIT lifts off the seat, the high pressure system oil is allowed
PRESSURE VALVES IN THE HYDRAULIC CIRCUIT to exhaust directly to the reservoir.
SYSTEM PRESSURE RELIEF VALVE During valve lift off oil is allowed to pass, via two bleed
The system relief valve is positioned at the beginning holes, from the spring to the valve side of the piston,
of the hydraulic circuit in the lower right hand side of thereby effectively damping the piston movement and
the rear axle center housing. when combined with the effect of hydraulic damping,
ensures controlled relief valve lift off.
The valve is direct operated and features both hydraulic
and friction damping to ensure controlled lift off and After the excessive system pressure condition has
passed the spring overcomes the force on the valve
re-sealing. Figure 10.
land and pushes the piston forward until the valve
Controlled lift off and re-seating eliminates relief valve reseats thereby preventing system oil exhausting to
"chatter" caused by the valve continuously lifting-out the reservoir.
and re-seating at critical system pressures.
The valve re-seat action is also controlled by the piston
OPERATION which, on moving forward, tends to compress the oil
With reference to Figure 10. Hydraulic oil at system which had previously passed to the valve side of the

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 HYDRAULIC SYSTEM

piston. This trapped oil now passes back, via the two
bleed holes, into the cap nut chamber and out, through
the hollow valve, to the reservoir. So the piston
movement is again effectively damped and when
combined with the resistance of the friction seal,
maintains controlled valve re-seating. The valve may
be adjusted by adding or removing shims from behind
the spring.
NOTE: The flow of relieved oil across the nose of
the valve ensures any foreign matter is
carried to the reservoir and not embedded in
the head of the valve.
FLOW CONTROL VALVE (WHERE FITTED)
Flow control valve is manually operated and controls
the volume of oil flowing to the lift cylinder or auxillary
equipment. The valve is situated on the right-hand side
Figure 11
of the rear axle centre housing. By rocking the flow
Location of Hydraulic System Controls
control valve knob (Figure 11) in the forward position
1. Selector Valve 4. Position Control Lever
gives a slowflow (S) and a fast flow (F) rocking the
2. Cooler Valve 5. Draft Control Lever
knob in the rearward position.
3. Flow Control Knob
OPERATION
With reference to Figure 11A. Regardless of the flow the lift cylinder valves.
control valve setting, the rate of flow is at a maximum In maximum flow the restrictor position allows
when the draft control lever is moved to the top of the maximum pump pressure oil flow to the HPL.
quadrant to effect a fast raise of the implement. Oil pressure on both ends of the flow control valve are
HPL Pump pressure oil enters at port A and flows past equal; the flow control spring holds the valve to the
the restrictor to port B. From port B pump oil flows to right closing dump port to the cooler valve.

PUMP PRESSURE OIL REDUCED OIL FLOW RESERVOIR & RETURN OIL
Figure 11A
Flow Control Valve Assembly
1. Restrictor 5. HPL Pump Supply 9. Flow Control Valve Spring
2. Return 6. To Cooler 10. Flow Control Valve
3. Valve Body 7. Cooler Bypass Valve Spring 11. Flow Control Knob
4. Dump to Rear Axle 8. Cooler Bypass Valve 12. HPL Supply

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 HYDRAULIC SYSTEM

In reduced flow the restrictor reduces the oil flow to

the HPL, higher pressure oil acting on the right hand
end of the flow control valve moves the valve against
the combined spring and reduces pressure oil acting
on the opposite end; the dump port is opened allowing
surplus pump oil to flow to the cooler valve.
COOLER VALVE
The cooler vlave has a 2 stage operation. Under normal
conditions return oil fromthe hydraulic system flows
from gallery C to gallery D and to the cooler.
The spring loaded cooler valve maintains a back
pressure of 3 bar (45 lbf/in2) in the return circuit and
adequate supply of oil to the cooler.
If the cooler pressure becomes excessive, the valve
will allow surplus oil to return directly to rear axle
Figure 12
through gallery F. Figure 11A.
Check Valve Assembly
AUXILIARY SERVICE CONTROL 1. Check Valve Seat
(WHERE FITTED) 2. Ball
To facilitate control of external hydraulic equipment, 3. Spring
the three position selector valve, Figure 21, fitted in 4. Check Valve Spring Housing
place of the accessory cover enables hydraulic oil flow Pump pressure oil is then circulated to the hydraulic
to be directed as follows: system.
1. Knob pushed "IN" : Oil flow to the lift cylinder The oil firstly flows past the system relief valve and
only. then flowing vertically upwards, through a pressure
2. Knob Pulled to "MIDDLE" position : Oil flow to tube, enters the hydraulic lift cover. The pressure tube
the lift cylinder and Auxiliary services port. has two "O" rings fitted in the annular grooves provided
3. Knob Pulled fully "OUT"; Oil flow to Auxiliary at each end of the tube is held in position with a snap
services port only. ring.
CHECK VALVE OIL FLOW IN NEUTRAL - WITH FLOW CONTROL
VALVE (WHERE FITTED)
To cater for the increased flow of hydraulic oil and for
compatibility with the feathering valve flow control Then oil flows firstly past the system relief valve and
system, the check valve housing and seat incorporate then vertically upwards, past the flow control valve to
larger ports and revised lands respectively and the the restrictor. According to the position of the restrictor
check valve guide has been removed, Figure 12. only a certain percentrage of oil is allowed to pass
and the pressure of this oil is registered, via a bleed
OIL FLOW
gallery, at the rear face of the flow control valve. The
Figure 13, 14, 15 and 16 shows the hydraulic system pressure of the restricted oil builds up on the face of
oil flow for the neutral, lowering, slow raise and fast the flow control valve spool which moves back and
raise functions. allows the oil to be dumped to the return circuit. Actual
To facilitate detailed explanation of the hydraulic oil movement of the flow control valve depends upon the
flow in the lift cylinder assembly simplified diagrams pressure differential between the force to the restricted
for the neutral, lowering, slow and fast raise functions oil on the front face and the combined coil spring force
are shown in Figure 17, 18, 19 and 20. and bleed oil pressure on the rear face.
OIL FLOW IN NEUTRAL The excess oil joins forces with returning system oil
With reference to Figure 13. Hydraulic oil is drawn before passing to the reservoir.
from the rear axle centre housing reservoir by the With reference to Figure 17. The oil passes through
hydraulic pump via a full flow micronic intake filter. passages in the lift cover and lift cylinder assembly

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 HYDRAULIC SYSTEM

Figure 13
Oil Flow in Neutral

PUMP PRESSURE OIL REDUCED OIL FLOW RESERVOIR & RETURN OIL TRAPPED OIL
Figure 14
Oil Flow When Lowering
1. Lift Cylinder 5. Control Valve Bushing 9. Intake Filter 13. Check Valve
2. Piston 6. Feathering Valve Spring 10. System Relief Valve 14. Unload Valve
3. Control Valve Spring 7. Feathering Valve 11. Hydraulic Pump 15. Unload Valve Spring
4. Control Valve 8. Return Filter 12. Auxiliary Services Feed 16. Lift Cylinder Safety Valve

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 HYDRAULIC SYSTEM

Figure 13A
Oil Flow in Neutral

PUMP PRESSURE OIL REDUCED OIL FLOW RESERVOIR & RETURN OIL TRAPPED OIL
Figure 14A
Oil Flow When Lowering
1. Lift Cylinder 6. Feathering Valve Spring 11. Cooler Valve 16. Unload Valve
2. Piston 7. Feathering Valve 12. Hydraulic Pump 17. Check Valve
3. Control Valve Return Spring 8. System Relief Valve 13. Micronic Intake Filter 18. Auxiliary Services Feed
4. Control Valve 9. Flow Control Valve 14. Flow Control Valve Restrictor 19. Lift Cylinder Safety Valve
5. Control Valve Bushing 10.Bleed Gallery 15. Unload Valve Spring

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 HYDRAULIC SYSTEM

Figure 15
Oil Flow When Slow Raising

PUMP PRESSURE OIL REDUCED OIL FLOW RESERVOIR & RETURN OIL
Figure 16
Oil Flow When Fast Raising

1. Lift Cylinder 5. Control Valve Bushing 9. Intake Filter 13. Check Valve
2. Piston 6. Feathering Valve Spring 10. System Relief Valve 14. Unload Valve
3. Control Valve Spring 7. Feathering Valve 11. Hydraulic Pump 15. Unload Valve Spring
4. Control Valve 8. Return Filter 12. Auxiliary Services Feed 16. Lift Cylinder Safety Valve

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 HYDRAULIC SYSTEM

Figure 15A
Oil Flow When Slow Raising

PUMP PRESSURE OIL REDUCED OIL FLOW RESERVOIR & RETURN OIL
Figure 16A
Oil Flow When Fast Raising
1. Lift Cylinder 6. Feathering Valve Spring 11. Cooler Valve 16. Unload Valve
2. Piston 7. Feathering Valve 12. Hydraulic Pump 17. Check Valve
3. Control Valve Return Spring 8. System Relief Valve 13. Micronic Intake Filter 18. Auxiliary Services Feed
4. Control Valve 9. Flow Control Valve 14. Flow Control Valve Restrictor 19. Lift Cylinder Safety Valve
5. Control Valve Bushing 10.Bleed Gallery 15. Unload Valve Spring

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 HYDRAULIC SYSTEM

Figure 17 Figure 19
Oil Flow in Neutral Oil Flow When Slow Raising
1. Unload Valve 4. Feathering Valve
2. Control Valve 5. Control Valve Front Land
3. Control Valve Bushing 6. Check Valve

Figure 18 Figure 20
Oil Flow When Lowering Oil Flow When Fast Raising

FULL FLOW OIL RESERVOIR SUCTION & EXHAUST OIL

REDUCED OIL FLOW TRAPPED OIL

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 HYDRAULIC SYSTEM

to the unload valve. Due to the position of the control OIL FLOW WHEN SLOW RAISING
valve, the oil on the left-hand side of the unload valve With reference to Figure 19. Partial movement of the
is allowed to escape to the reservoir via a hole drilled control valve to the raise position, that is to the left
in the control valve. The supply oil entering the unload blocks off the lowering port at the base of gallery 'A'
gallery 'C' forces the valve to the left. and allows supply oil to pass into gallery 'B' where it
The supply oil then continues to pass through and is directed to the front face of the unload valve. The
around the control valve bushing, which incorporates combined force of the coil spring and oil pressure acting
ports of increasing diameter machined in a helical on the large frontal area overcomes the lesser force of
formation, then on to the feathering valve. Due to the the same oil pressure on the small rear face, so the
position of the control valve, the first ports in thecontrol valve moves to the right. This action prevents oil flowing
valve bushing are uncovered and allow oil to pass to from the lift gallery 'E' to the exhaust gallery 'D'.
the lift gallery 'E' and to the rear of the feathering valve. Due to the position of the control valve, several ports
in the control valve bushing are uncovered and supply
The feathering valve movement depends upon the
oil not only passes to the front faces of the feathering
pressure differential between the force of the supply
valve but a restricted supply also flows to the lift gallery
oil on the front face and the combined coil spring and
'E' and the rear faces of the feathering valve. The
reduced pressure oil on the rear face.
pressure differential causes the feathering valve to move
In the neutral position the lift gallery 'E' is connected to the left a sufficient distance as to partially close the
to the exhaust gallery 'D' via a hole drilled in the unload port leading to the exhaust gallery 'D'.
valve, so the oil pressure at the rear of the feathering
The oil pressure in the lift gallery 'E' forces the check
valve.
valve ball off the seat and oil flows to the lift cylinder.
Therefore, as supply oil passes to the front faces of Because a certain percentage of the supply oil is
the feathering valve, the pressure differential forces the allowed to escape across the feathering valve
valve to the right, thereby uncovering the port leading restriction into the exhaust gallery 'D', the raise function
to the exhaust gallery 'D'. is necessarily slow.
The supply oil drops in pressure as it passes across OIL FLOW WHEN FAST RAISING
this feathering valve restriction before returning, via the With reference to Figure 20. Movement of the control
exhaust gallery 'D'. valve to the fast raise position, that is fully to the left,
Hydraulic oil trapped in the lift cylinder and gallery 'A' uncovers all the ports in the control valve bushing. Due
is prevented from exhausting by the check valve and to the lesser restriction, the oil passing the rear faces
the position of the control valve front land. of the feathering valve is of sufficiently high pressure
OIL FLOW WHEN LOWERING to ensure the valve moves fully to the left. This action
completely closes the port leading to the exhaust
With reference to Figure 18. When the control valve is gallery 'D' therefore all the supply oil passes into the
moved to the lowering position, which is to the rear, lift gallery 'E' and is utilised to effect a fast raise
the front land of the valve uncovers the lowering port at function.
the base of gallery 'A' and oil from the lift cylinder is
The feathering valve modulates the flow of hydraulic
allowed to exhaust directly to the reservoir.
oil to the lift cylinder proportional to the size of the lift
As in the neutral position, the oil on the left hand side signal, therefore after the manual flow control valve
of the unload valve is allowed to escape to the reservoir, (where fitted) has been adjusted for initial system
via the control valve, and the pump oil forces the unload setting the feathering valve will minimise the need for
valve to the left. The unload valve connects the lift gallery any further adjustment.
'E' to the exhaust gallery 'D'. The system will continue to raise until the control valve
Therefore supply of oil Pressure on the front faces is move to the neutral position by a draft correction
forces the feathering valve to the right, thereby fully movement of the lift control lever or the lift position
uncovering the port leading to the exhaust gallery 'D'. striking the control valve lever.
The pump oil passes across the feathering valve The Auxiliary Services Selector valve output is
restriction and returns via the exhaust gallery 'D'. regulated by the flow control and feathering valves.

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 HYDRAULIC SYSTEM

PUMP PRESSURE OIL RESERVOIR & RETURN OIL TRAPPED OIL

Figure 21
Auxiliary Services Control Valve Operation
1. Auxiliary Service Supply 5. Lift Cylinder Supply Oil Gallery Identification
2. A.S.C. Valve 6. Detent Ball A - Lift Cylinder Check Valve Gallery
3. Top Cover Face 7. Control Spool C - Lift Cylinder Unload Valve/Control Valve Gallery
4. HPL Oil Supply D - Lift Cylinder Return Gallery
G - To Flow Control Cooler Valve
IMPORTANT: Where a high external hydraulic power The hydraulic oil flow is the same as for the raising
requirement is expected, remote valves circuits but alters on operation of the three position
should be used instead of the Auxiliary selector valve as follows:
Services Selector valve in order to have When the knob is pushed "FULLY IN", the valve
the full power of the hydraulic system spool blocks off the auxiliary service port and
directs the flow of hydraulic oil to the flow of
available.
hydraulic oil to the lift cylinder.
OIL FLOW FOR AUXILIARY SERVICE - WITH
When the knob is "PULLED OUT" one step, the
SELECTOR VALVE (WHERE FITTED) valve spool allows hydraulic oil to flow to both
With reference to Figures 21. the lift cylinder and the auxiliary service port.

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 HYDRAULIC SYSTEM

Figure 22 Figure 23
Draft Control Main Spring Adjustment Draft and Position Control Linkage Adjustment
1. Yoke 5. Front Seat 1. Eccentric Adjustable Stop
2. Draft Control Plunger 6. Draft Control Main Spring 2. Position Control Lever 1.00 in. (25.4 mm.) from
3. Draft Lever 7. Rear Seat Bottom of Quadrant
4. Shims 8. Housing 3. Draft Contol Lever at Bottom of quadrant
4. Tool No. OF-1100

NOTE: Hydraulic oil takes the path of least and front spring seat in to the draft control main
resistance, therefore, in this particular spring housing.
position, operation of the lift arms will depend 2. Note the distance between the top face of the
upon the type of auxiliary equipment being front seat and the surface of the housing. The
used. front seat should be 0.000 - 0.010 in (0.000 -
When the knob is pushed "FULLY OUT", the valve 0.254 mm.) above the housing face.
spool blocks off the lift cylinder auxiliary port and 3. Add shims between the spring and front spring
the hydraulic oil is directed to auxiliary service seat to obtain the correct setting. The amount of
port. front spring seat protruding above the housing
face should be between 0.000 in. and 0.010 in.
OIL FLOW FOR AUXILIARY SERVICE - LESS
(0.000 - 0.254 mm.)
SELECTOR VALVE
4. Re-assemble the housing to the lift cover,
The hydraulic oil flow is the same as for the raising
assemble with the draft control plunger guide
circuits but, removal of the auxiliary service plug on
groove aligned with the front seat and the
the accessory cover allows oil to be directed to both complete assembly located in the main spring
external equipment and the lift cylinder. housing. Secure the three attaching bolts.
NOTE: As hydraulic oil is still being fed to the lift 5. Screw the Yoke in until all play is eliminated then
cylinder, the lower links should be held down turn the yoke the least amount until the hole in
to prevent them lifting and moving the control the yoke is horizontal.
valve in to neutral, which would stop the flow DRAFT AND POSITION CONTROL LINKAGE
of oil to both the external equipment and the ADJUSTMENT
lift cylinder.
Draft and Position Control Linkage adjustment are
6. ADJUSTMENTS made simultaneously.
DRAFT CONTROL MAIN SPRING ADJUSTMENT With reference to Figure 23.
FARMTRAC-60 1. With the lift cover removed, place the Draft Control
1. Assemble the rear seat, draft control main spring lever at the bottom of the quadrant.

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 HYDRAULIC SYSTEM

Figure 24 Figure 25
Draft Control Selector Shaft Adjustment Flow Control Valve Override Linkage
Farmtrac-60 1. Actuating Cam 5. Flow Control Knob
1. Draft Lever 2. Shims 6. Draft Control Lever
2. Draft Control Selector Shaft Roller 3. Lift Cover Face 7. Follower
3. Draft Control Lever 4. Adjuster
4. Retaining Bolt
5. Spacers

2. Set the Position Control Lever 1.00 in. (25.4 mm.) 3. Add or remove spacer between the quadrant plate
from the bottom of the quadrant. and the support as required to centralise the draft
control selector shaft roller on the draft lever.
3. Place the lift arms in the fully down position.
NOTE: The shims also establish the location of the
4. Withdraw the three bolts securing the front cover
position control components. Therefore the
plate to the lift cylinder and remove the plate.
centralisation of the position lever on the
5. Slacken the adjustable stop locknut and adjust activating lever roller and the position control
the eccentric to obtain 0.030 in. (0.76 mm.) from rollers on the position control cam must also
the end of the control valve to the front cover face be considered when making this adjustment.
of the lift cylinder, using Setting Gauge Tool No. 4. Replace and tighten the quadrant retainign bolts
of OF-1100 to check this dimension. to a torque of 23-30 lbf. ft. (4 - 4.15 kgfm.)
6. Tighten the adjustable stop locknut to a torque FLOW CONTROL VALVE CAM FOLLOWER
of 23-30 lbf.ft. (3.2 - 4.2 kgm.) ADJUSTMENT
DRAFT CONTROL SELECTOR SHAFT With reference to Figure 25.
ADJUSTMENT
1. With the lift Cover removed, place the Draft Control
With reference to Figure 24. Lever at the bottom of the quadrant.
1. With lift cover removed, place the draft control 2. Measure the distance between the bottom of the
lever in the raise position. actuating cam and the lift cover face less gasket.

2. Remove the two quadrant retaining bolts and lock 3. Rotate the flow control knob clockwise as far as
washers. possible to the slow flow (S) position.

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 HYDRAULIC SYSTEM

4. Adjust the cam follower by adding or removing

shims between the follower and the adjuster until
dimension "A" from the top of the rear axle centre
housing less gasket to the top of the follower is
0.000 to 0.010 in. (0.000 to 0.254 mm.) more
than the distance measured in step 2.
7. OVERHAUL LIFT CYLINDER
ASSEMBLY
A. REMOVAL
With reference to Figure 26 & 27.
1. Remove the hydraulic lift cover as detailed in this
Figure 26 Chapter.
Removing Draft Lever to Actuating Lever Pivot
2. Withdraw the three remaining bolts securing the
Pin Snap Ring
accessory cover and remove the accessory cover.
1. Pivot Pin 4. Roller
2. Snap Ring 5. Actuating Lever 3. Remove the snap ring from the end of the draft
3. Draft Lever lever to actuating lever pivot pin, Figure 26.

Figure 27
Lift Cylinder Assembly
1. Feathering Valve 9. Unload Valve
2. Feathering Valve Spring (5.8 cm.) 10. Unload Valve Spring (4.5 cm.)
3. Feathering Valve Rear Plug 11. Unload Valve Front Plug
4. Control Valve 12. Lift Cylinder Safety Valve
5. Control Valve Spring 13. Gasket
6. Control Valve Bushing 14. Lift Cylinder Housing
7. Unload Valve Rear Plug (where fitted) 15. Feathering Valve Front Plug
8. Unload Valve Bushing 16. Feathering Valve Bushing

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 HYDRAULIC SYSTEM

turn the lift cylinder to rest on the top face.

(Alternatively hold the assembly in a soft jawed
vice.)

4. Withdraw the three bolts securing the front cover

plate to the lift cylinder and remove the plate.

5. Withdraw the three bolts securing the bracket to

the rear of the lift cylinder. Carefully remove the
bracket together with the control valve, control
valve spring, control valve lever, torsion spring and
actuating lever assembly as shown in Figure 28.

6. Remove the actuator pin snap ring, the actuator

Figure 28 pin and the actuator. Then compress the control
Control Valve and Actuating Linkage valve spring and carefully slide the control valve
1. Pivot Pin 6. Control Valve Spring
face off the bracket.
2. Actuating Lever 7. Control Valve
3. Torsion Spring 8. Bracket 7. Insert Tool No. OF-0300 screw into the unload
4. Control Valve Lever 9. Actuator valve front plug and using a pair of pliers carefully
5. Snap Ring 10. Actuator Pin
withdraw the plug and spring.
4. Remove the four bolts securing the lift cylinder Discard the two "O" rings fitted to the plug.
assembly to the lift cover. Move the lift arms to
the raised position and remove the lift cylinder 8. Insert SST Tool No. OF-0300 screw into the
unload valve rear plug and using a pair of pliers
by carefully lifting off the locating dowels and
carefully withdraw the plug. Discard the "O" ring
moving sideways thereby enabling the draft lever
fitted to the plug.
to disengage from the pivot pin.
9. Remove the unload valve from the front end of
5. Place the lift cylinder assembly on a bench with
the lift cylinder and discard the "O" ring fitted to
the top face exposed.
the large end of the valve.
B. DISASSEMBLY
10. Insert SST No. OF-0300 screw into the feathering
With reference to Figure 27. valve front plug and using a pair of pliers carefully
1. Remove the lift cylinder safety valve and gasket. remove the plug. Discard the two "O" rings fitted
to the plug.
NOTE: For FT-60 model, the lift cylinder safety valve
may be withdrawn without first removing the 11. Insert SST No. OF-0300 screw into the feathering
lift cover assembly. Removal of the valve rear plug and using a pair of pliers carefully
accessory cover or selector valve (where remove the plug and spring. Discard the two "O"
fitted) will provide direct access to the valve. rings, fitted to the plug.
The lift cylinder safety valve is not
12. Remove the feathering valve from the lift cylinder.
serviceable.
13. Screw the adaptor Tool No. OF-1401 on the
2. Discard the five 'O' rings fitted in the counter bores
extension of Lift Cylinder Bushing Remover and
of the various oil passages.
Replacer Tool No. OF-1400 and pass the
3. Ensure that the bench is smooth and clean then Extension through the Control valve bushing from

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 HYDRAULIC SYSTEM

Figure 29 Figure 30
Removing Control Valve Bushing Removing Unload Valve Bushing
1. Adaptor Tool No. OF-1401 1. Adaptor Tool No. OF-1401
2. Extension of Tool No. OF-1400 2. Extension Tool No. OF-1400
3. Control Valve Bushing 3. Unload Valve Bushing
4. Tool No. OF-1400 4. Tool No. OF-1400

the front end of the lift cylinder. The taper on the the feathering valve bushing from the rear end.
Adaptor locates squarely in the rear end of the Screw the adaptor Tool No. OF-1401 on to the
bushing as shown in Figure 29. Extension until the taper of the special Nut
locates squarely in the front end of the bushing.
14. Steadily turn the tool handles and withdraw the
Figure 31.
bushing. Unscrew the Adaptor and remove the
bushing from the Extension. Alternatively use Lift
Cylinder Bushing Remover and Replacer to
remove the control valve bushing.

15. Pass the Adaptor Tool No. OF-1401 through the

unload valve bushing from the front end. Screw
the adaptor Tool No. OF-1400 onto the extension
until the taper on the adaptor locates squarely in
the rear end of the bushing. Figure 30.

NOTE: The unload valve bushing is of a one piece

design.

16. Steadily turn the tool handles and withdraw the

bushing. Unscrew the adaptor and remove the Figure 31
bushing from the Extension. Alternatively use Lift Removing Feathering Valve Bushing
Cylinder Bushing Remover and Replacer to 1. Tool No. OF-1400
2. Feathering Valve Bushing
remove the unload valve bushing. Figure 30.
3. Adaptor Tool No. OF-1401
17. Pass the Extension Tool No. OF-1400 through 4. Extension of Tool No. OF-1400

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 HYDRAULIC SYSTEM

18. Steadily turn the tool handles and withdraw the

bushing. Unscrew the adaptor and remove the
bushing from the Extension. Alternatively use Lift
Cylinder Bushing Remover and Replacer to
remove the feathering valve bushing from the rear
end.
19. Withdraw the lift piston and discard the piston
seal and ring. A new seal and ring must be
installed before re-assembly.
CAUTION: Do not use excessive pressure or the
piston may fly out suddenly and cause
injury or damage. Ordinary foot pump
pressure is sufficient to move the Figure 32
piston. Feathering Control and Unload Valves and
Bushings
C. INSPECTION AND REPAIR 1. Control Valve Spring
1. Wash all parts in a suitable solvent and dry with 2. Control Valve
3. Feathering Valve Spring
a clean lint free cloth or compressed air.
4. Feathering Valve
2. Examine the valves, bushings and plugs for wear, 5. Feathering Valve Bushing
burrs or scratches. Any minor burrs or scratches 6. Control Valve Bushing
may be removed with a fine abrasive, ensure such 7. Unload Valve Spring
8. Unload Valve
parts are thoroughly washed before re-assembly.
9. Unload Valve Bushing
Ensure the bushing location bores in the lift
cylinder housing are not scored. Any heavy NOTE: The relative position of the valves and
scoring of the bores will necessitate installation bushing & are shown in Figure 32.
of a new lift cylinder assembly.
1. Observe the colour on the outside of the lift
3. Ensure the valve spring are not broken or cylinder housing adjacent to the front end of the
damaged. relevant valve chamber and select the requisite
4. Check all bushing ports and lift cylinder housing valve bushing with the corresponding colour
oil passages are free from obstruction. markings.

5. Ensure all valves move freely in their respective 2. Insert the Guide of Adaptor Tool No. OF-1401
bushings. (spigot end first) into the front of the respective
bushing locating bore in the lift cylinder housing.
6. Renew all "O" rings and seals
Screw the short threaded end of Extension Tool
D. ASSEMBLY No. OF-1400 and pass the Extension through
The installation procedure is identical for each of the Stop Adaptor from the front end of the lift
the following components: cylinder. Locate the valve bushing over the
a. Feathering Valve Bushing Extension and screw the adaptor Tool No. OF-
1401 onto the rear end of the Extension until the
b. Unload Valve Bushing
taper on the adaptor locates squarely in the rear
c. Control Valve Bushing end of the bushing. Figure 33, 34 and 35.

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 HYDRAULIC SYSTEM

Figure 33 Figure 34
Installing Feathering Valve Bushing Installing Unload Valve Bushing
1. Special Nut No. OF-1401 1. Adaptor Tool No. OF-1401
2. Extension Tool No. OF-1401 2. Extension Tool No. OF-1400
3. Tool No. OF-1400 3. Tool No. OF-1400
4. Guide and Stop Adaptor Tool No. OF-1401 4. Guide of Adaptor Tool No. OF-1401
5. Feathering Valve Bushing 5. Unload Valve Bushing

3. Lubricate the bushing and steadily turn the tool

handles to pull the bushing into the bore until the
front face of the bushing meets the inner face of
the Step Adaptor.

4. Slacken the tool and reverse the step Adaptor

so that the spigot end locates in the body of the
tool and the larger face is presented to the front
face of the housing. Re-tighten the tool and draw
the bushing fully into the bore to seat against
the step adaptor so that the front end of the
bushing is flush with the front face of the housing.

5. Releasing the Special Nut and withdraw the tool, Figure 35

Step adaptor, and Extension from the bushing. Installing Control Valve Bushing
1. Adaptor Tool No. OF-1401
Alternatively use Lift Cylinder Bushing Remover 2. Extension Tool No. OF-1401
and Replacer to install each of the feathering 3. Tool No. OF-1400
unload and control valve bushings, from the rear 4. Guide of Adaptor Tool No. OF-1401
5. Control Valve Bushing
end of the cylinder.

6. Lubricate and insert the feathering valve into the 7. Install two new "O" rings onto a feathering valve
corresponding bushing in the lift cylinder housing. plug and insert the plug, with the threaded hole
Install the valve from the front with the multiple facing outwards, into the front of the feathering
lands facing towards the rear. valve bushing.

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 HYDRAULIC SYSTEM

NOTE: The two feathering valve plugs are identical NOTE: The control valve is colour coded only as a
and are not colour coded. guide for matching the valve to the bushing.
Press the plug into the bushing until the outer To obtain an optimum fit, a proprietary brand
faces flush with the front face of the lift cylinder of metal polish may be used to lap a slightly
housing. oversize valve into the bushing. Ensure all
8. Insert the feathering valve spring into the rear end traces of polish are washed away and the
of the feathering valve. components air dried prior to final assembly.
15. Install the control valve spring on the control valve
NOTE: The feathering valve spring is longer than the
and whilst compressing the spring, position the
unload valve spring.
control valve in the actuating linkage bracket.
9. Install two new "O" rings onto the second
16. Carefully push the control valve into the bushing
feathering valve plug and insert the plug, with the
and secure the bracket with the three bolts.
threaded centre hole facing outwards, into the
rear of the feathering valve bushing. Press the 17. Install the front cover plate and retain with the
plug into the bushing until the outer face is flush three bolts.
with the rear face of the lift cylinder housing. 18. Ensure the two ring dowels are installed in the
10. Install a new "O" ring at the large end of the diagonally opposite counter bore holes in the top
face of the cylinder.
unload valve then lubricate the valve and "O" ring
and insert into the corresponding bushing in the 19. Install a new ring and seal on the lift position.
lift cylinder housing. NOTE: The "O" ring seal should be pre-soaked in
Install the valve from the front with the small end oil for about 5 minutes before installation on
facing towards the rear. the piston. The "O" ring is to be nearest to
the closed end and the back-up seal nearest
11. Install a new "O" ring (where fitted) onto the
the open end of the piston.
unload valve rear plug and insert the plug, with
the threaded centre hole facing outwards, into 20. Lubricate the lift piston and install in the lift
the rear end of the unload valve bushing. cylinder.

NOTE: The unload valve rear plug is smaller than 21. Install the lift cylinder safety valve with a new
gasket between the valve and the cylinder.
the front plug and the plugs are not colour
coded. E. INSTALLATION
Press the plug into the bushing until the outer 1. Ensure the top surface of the cylinder and the
face is flush with the rear face of the lift cylinder mating face on the lift cover are clean and free
housing. from scores and burrs.

12. Insert the unload valve spring into the front end of 2. Install new "O" rings in the counter bores of the
the unload valve. oil passages and place the forward end of the lift
piston connecting rod into the piston. Locate the
13. Install two new "O" rings onto the unload valve
draft lever on the pivot pin by lateral movement of
front plug and insert the plug, with the threaded
the lift cylinder. Position the lift cylinder on the
hole facing outwards into the front of the unload
locating dowels and reinstall the snap ring on
valve bushing. Press the plug into the front face
the actuating lever pivot pin. Tighten the retaining
of the lift cylinder housing.
bolts to the correct torque. (See Torque
14. Select the largest control valve spool which, when "Specifications").
lightly lubricated and regardless of colour, when 3. Ensure the actuator is located within the control
inserted into either end of the bushing and turned valve sleeve and carry out the Draft and Position
through 360° will operate along the full length Control Linkage Adjustment as described in this
without binding. Chapter.

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 HYDRAULIC SYSTEM

Figure 36 Figure 37
Check Valve Assembly Removing Draft Lever to Actuating Lever Pivot
1. Check Valve Seat 2. Ball Pin Snap Ring
3. Spring 4. Check Valve Spring Housing 1. Pivot Pin 4. Roller
2. Snap Ring 5. Actuating Lever
4. Install the accessory cover with a new set of "O" 3. Draft Lever
rings, assemble the lift cover assembly to the
tractor and install the driver's seat. 8. Withdraw the three bolts securing the bracket to
the rear of the lift cylinder. Carefully remove the
8. OVERHAUL LIFT COVER ASSEMBLY
bracket together with the control valve, control
A. REMOVAL valve spring, control valve lever, torsion spring and
1. Remove the hydraulic lift cover assembly from actuating lever Figure 38.
the tractor.
B. DISASSEMBLY
1. Secure the lift cover assembly in a vice with the
Lifting Bracket attached to the lift cover and
secured in the jaws.
2. Remove the check valve plug from the lift cover.
3. Using a pair of long nosed pliers, remove the
check valve spring housing, spring and ball from
the lift cover. Remove and discard the "O" rings.
4. Remove the check valve seat. Figure 36.
5. Remove the accessory cover from the lift cover
by removing the remaining three bolts.
6. Remove the snap ring from the end of the draft
lever to actuating lever pivot pin, Figure 37. Figure 38
7. Remove the four bolts securing the lift cylinder Control Valve and Actuating Linkage
assembly to the lift cover. Move the lift arms to 1. Pivot Pin 6. Control Valve Spring
the raised position and remove the lift cylinder 2. Actuating Lever 7. Control Valve
by carefully lifting and moving sideways thereby 3. Torsion Spring 8. Bracket
enabling the draft lever to disengage from the pivot 4. Control Valve Lever 9. Actuator
pin. 5. Snap Ring 10.Actuator Pin

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 HYDRAULIC SYSTEM

Figure 39 Figure 40
Removing the Adjustable Stop Eccentric Removing Draft Control Plunger
1. Eccentric 2. Torsion Spring 1. Draft Lever 2. Draft Control Link
3. Snap Rings 4. Pivot Pin 3. Draft Control Plunger 4. Lift Arms in Lower Position
5. Adjustable Stop Nut 6. Actuating Lever

9. Remove the actuator pin snap ring, the actuator the draft control main spring housing. Slide the
pin and actuator. Then compress the control valve housing, draft control main spring, seat and
spring and carefully slide the control valve face shims over the draft control main spring plunger.
off the bracket.
15. Place the lift arms in the lower position and pull
10. Mount the actuating linkage in a vice. Shown in the draft control plunger, draft control link and
Figure 39. draft lever assembly through the housing.

11. Remove the adjustable stop nut and lock washer

16. Straighten the lock washer tab and remove the
and, whilst applying pressure to the actuating
bolt and flat washer retaining each lift arm to the
lever, withdraw the eccentric. Relax the pressure
lift cross-shaft.
on the actuating levers and allow the torsion
spring to unwind. 17. Slide both arms from the lift the cross-shaft.

12. Remove the snap rings between the levers and (a) Remove the lift cross-shaft from the left hand
the bracket. side of teh lift cover. Slide the two bushing and
"O" ring off the left hand end of the shaft. Discard
13. Extract the lever pivot pin from the bracket then
the "O" ring.
remove and separate the two levers and the
torsion spring.
(b) Remove the two bushings and "O" ring from

14. Unscrew the yoke at the rear of the draft control the cross-shaft locating bore in the right hand
main spring. Remove the three bolts securing side of the lift cover. Discard the "O" ring.

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 HYDRAULIC SYSTEM

Figure 41 Figure 42
Control Levers and Quadrant Assembly Removing and Installing Control Lever Shafts
1. Quadrant 6. Spring and Rollers
2. Support 7. Retaining Nut 1. Position Lever
3. Friction Discs 8. Position Control Lever 2. Draft Control Roller
4. Spacer(s) 9. Draft Control Lever 3. Draft Control Shaft
5. Cup Washer 4. Position Control Shaft
5. Position Control Rollers

18. Remove the position control lever retaining nut,

spring, cup washers, position control lever and
friction disc as shown Figure 41.

19. Withdraw the two bolts securing the quadrant to

the support and remove quadrant, friction disc,
draft control lever and quadrant to support
spacer(s).

20. Remove the two bolts securing the support to

the lift cover and withdraw the support over the
control lever shafts. Discard the support gasket.

21. Withdraw the control lever shafts and rollers from

the centre of the lift cover. As shown Figure 42.
Figure 43
22. Separate the shafts then remove and discard the
Control Lever Shafts and Rollers
"O" ring from the position control lever shaft. 1. Position Control Lever Shaft 6. Cam
2. Position Lever 7. Snap Ring
23. Remove the snap ring from the draft control lever
3. Draft Control Lever 8. "O" Ring
shaft and remove the cam, the shaft key and the 4. Shaft Key 9. Washer
position control rollers, Figure 43. 5. Position Control Roller

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 HYDRAULIC SYSTEM

9. FLOW CONTROL VALVE PLATE AND LINKAGE

(WHERE FITTED) ON FARMTRAC TRACTORS

DESCRIPTION AND OPERATION FLOW CONTROL VALVE PLATE AND LINKAGE

OVERHAUL
The high capacity manually operated flow control valve
is located at the top right-hand side of the rear axle A. REMOVAL
centre housing, Figure 44. The valve controls the
Repairs which necessitate removal of the flow control
volume of oil flowing to the cylinder and/or auxiliary
valve plate can only be effected after the lift cover has
equipment and is featured on Farmtrac models only
been removed.
with a gear type hydraulic pump.
To remove the oil cooler valve on Farmtrac Tractors, it
Hydraulic oil flow is established by a rocking control
will first be necessary to remove the flow control valve
knob which moves through an angle of approximately
plate.
45° to a give a slow flow (S) in the forward position and
a fast flow (F) in the rearward position. The control 1. Drain the hydraulic oil from the rear axle centre
knob is attached to the end of a restrictor shaft. housing.

2. Remove the lift control assembly.

3. Remove the pressure relief valve from the bottom

right-hand side of the rear axle centre housing.

4. Slacken the four flow control valve plate retaining

bolts, Figure 44.

Disconnect the oil cooler feed tube from the flow

control valve plate presently pluged.

5. With draw the return feed pipe from the centre

housing top face.

6. Disconnect the override link spring from the

Figure 44
override link.
Flow Control Valve Plate Assembly
Farmtrac Tractors
7. Extract the flow control override adjuster and cam
1. Retaining Bolts
2. Cooler Valve Location follower assembly from the centre housing top
3. Restrictor face.
4. Outlet to Oil Cooler
5. Flow Control Valve Location 8. Disconnect the flow control override link from the
6. Flow Control Knob restrictor by removing the snap ring.

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 HYDRAULIC SYSTEM

9. Remove the oil exhaust tube clip and disconnect

the tube, Figure 45.
10. Withdraw the top flow control pipe from the centre
housing top face.
11. Slacken the relief valve baffle retaining bolt,
remove the 'C' clip and push the lower feed pipe
downwards a sufficient distance to facilitate
removal of the flow control valve plate.
12. Remove the four retaining bolts and withdraw the
flow control valve plate from the rear axle centre
housing.
Figure 45
DISASSEMBLY Flow Control Valve Plate Assembly Installed
With reference to Figure 46. with Engine Mounted Gear Type Pump
1. Flow Control Override Adjuster and Cam Follower
1. Remove the oil cooler valve plug and seal. Assembly
2. Withdraw the spring from the oil cooler valve 2. Override Link Return Spring 3. Restrictor
housing. 4. Snap Ring 5. Lower Feed Pipe
6. Oil Exhaust Tube 7. Clip
3. Extract the oil cooler valve spool. 8. Top Flow Control Pipe 9. Retrun Feed Pipe
4. Remove the flow control valve plug and seal. 10.Centre Housing Top Face

Figure 46
Flow Control Valve Plate Disassembled on Farmtrac Tractors (where fitted)
1. Oil cooler valve plug 6. Spring 11. Restrictor shaft
2. Oil cooler valve seal 7. Flow control valve plunger 12. Restrictor
3. Oil cooler valve spool 8. Flow control valve seal 13. Restrictor retainer pin and seal
4. Flow control valve knob 9. Flow control valve plug 14. Oil cooler valve spring
5. Roll pin 10. Flow control valve spring

J–32
 HYDRAULIC SYSTEM

5. Withdraw the spring from the flow control valve and the restrictor is colour coded on the shank.
housing.
Ensure the flow control valve plunger and the flow
6. Extract the flow control valve plunger. control valve housing have the same colour code.
The housing is colour coded in the area of the
7. Extract the roll pin and remove the flow control
plunger locating bore and the plunger is colour
knob and spring from the end of the restrictor
coded on the shank.
shaft.
INSTALLATION
8. Withdraw the restrictor pin and seal and extract
the restrictor and shaft from the rear of the plate. 1. The installation of the flow control valve plate
Remove and discard the shaft "O" ring seal. follows the removal procedure in reverse.

9. Remove and discard the plate gasket. NOTE: For the Farmtrac Tractors, if the lower
pressure tube is removed, fit new "O" rings
INSPECTION AND REPAIR and install the tube from beneath the center
housing.
1. Wash all parts in a suitable solvent and dry with
a clean lint free cloth or compressed air. 2. Adjust the flow control override adjuster.

2. Examine the valve for wear, burrs or scratches. 3. Fill the rear axle with the correct grade and
Any minor burrs or scratches may be removed quantity of oil.
with a fine abrasive; ensure such parts are
thoroughly washed before re-assembly.
10 HYDRAULIC PUMP - ENGINE
MOUNTED GEAR TYPE
3. Ensure the valve bores are not scratched as heavy
DESCRIPTION AND OPERATION
scoring will necessitate installation of a new flow
control valve plate. A cross section of the engine mounted gear type
hydraulic pump is shown in Figure 47.
4. Check the valve springs are not broken or
damaged. The pump is mounted on a machined face at the rear
left-hand side of the engine and is driven by the
5. Ensure all oil passages are free from obstruction.
camshaft, through helical gears, to give a ratio of
6. Check the valve move freely in their bores. engine to pump rev/min. of 1:1.067.

7. Renew the gasket, all "O" rings and seals. Hydraulic oil is supplied to the pump from the rear
axle centre housing through an external pipe which
RE-ASSEMBLY connects to an intake port in the pump cover.

1. The re-assembly of the flow control valve plate Before entering the pump, the oil first passes through
components follows the disassembly procedure a replaceable micronic filter which screws on to a
in reverse. On re-assembly observe the following threaded adaptor mounted in the cover.
requirement:
A set of spur gears, housed in the body of the pump,
Ensure the flow control valve restrictor and the supply oil to the hydraulic system circuit. The spur
flow control valve housing have the same colour gears are supported in aluminium bearings
code. The housing is colour coded on the internal incorporating steel bushes with porous bronze and
face in the area of the restrictor locating bore P.T.F.E. plus lead linings.

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 HYDRAULIC SYSTEM

Figure 47
Cross-Section of Engine Mounted Hydraulic Gear Type Pump
1. Cover 4. Circlip 7. Washer 10. External Gear 13. Driven Gear
2. Drive Gear 5. Plug 8. Idler Gear Shaft 11. Shaft Seal 14. Bearing
3. Through Bolt 6. Idler Gear 9. Housing 12. Body 15. Threaded Adaptor

OIL FLOW

With reference to Figure 48.

On entering the pump, the hydraulic oil fills the spaces

between the teeth of the revolving gears and is then
carried around, within the pump body, to a point where
the teeth of the two gears come into mesh. As the oil
can not pass back between the gears it is forced out
of the pump body toan outlet port in the pump cover.
The oil is then conducted through an external pipe to
the base of the rear axle centre housing and from there,
via internal passages, to the lift cover.
PRESSURE OIL SUCTION OIL
Figure 48
Oil Flow in Hydraulic Gear Type Pump
A. To Hydraulic Circuit B. From Reservoir
1. Driven Gear 2. Drive Gear

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 HYDRAULIC SYSTEM

Figure 49
Hydraulic Gear Type Pump - Exploded
1. Cover 10. Circlip
2. Stuffer Strip 11. Plug
3. Pressure Loading Ring 12. Lockwasher
4. Sealing Ring 13. External Gear
5. Threaded Adaptor 14. Housing
6. Bearing 15. Bearing
7. Idler Gear Assembly 16. Drive Gear
8. Key 17. Driven Gear
9. Locknut 18. Body

11. HYDRAULIC PUMP - ENGINE DISASSEMBLY

MOUNTED GEAR TYPE-OVERHAUL
With reference to Figure 49.
REMOVAL
1. Mark the housing body and cover to facilitate
1. Thoroughly clean the pump at the cover area
correct re-assembly.
before removal.
2. Unscrew the filter.
2. Unscrew and disconnect the pump outlet tube.

3. Remove the retaining bolts and lock washers, lift 3. Remove the circlip and large dished plug in the
the pump off the tractor and pull free from the external gear housing to expose the pump
inlet tube. Cap the exposed tubes. external drive gear.

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 HYDRAULIC SYSTEM

Figure 50 Figure 51
Removing External Gear Housing Plug Removing External Gear Retaining Nut
1. Plug 1. Pump Assembly 3. Soft Jaw Vice
2. External Gear Housing 2. Idler Gear 4. External Gear Retaining Nut
3. Pliers with Relieved Jaws

NOTE: To facilitate removal of the plug use a pair of the pump body, carefully noting their original
pliers with the jaw tops relieved as shown in positions.
Figure 50. 11. Remove the circlip from the end of the idler gear
4. Mount the pump in a soft-jawed vice gripping the shaft by inserting a thin rod through the access
idler gear, see Figure 51. hole in the housing, Figure 52.
5. Release the tab washer and unscrew the external 12. Remove the plug from the end of the idler gear
gear retaining nut. shaft by giving the housing a sharp tap on a
wooden block.
6. Remove the pump from the vice.
7. Remove the four through bolts securing the pump
cover and body to the external gear housing.
8. Use a soft faced mallet to separate the external
gear housing and rear cover from the body then
tap the end of the pump drive gear shaft to release
the external gear from the shaft taper.
IMPORTANT: When performing this operation great
care must be taken to avoid damage
to:
(i) The threads on the end of the pump drive
gear shaft, and
(ii) The shaft seal by allowing the key to foul the
seal. Figure 52
9. Remove the external drive gear and key. Removing Idler Gear Shaft Plug Retaining
Circlip
10. Withdraw the bearings and gear assembly from 1. Circlip 2. Screw Driver 3. Rod 4. Access Hole

J–36
 HYDRAULIC SYSTEM

Figure 53 Figure 54
Removing Idler Gear Shaft Plug Pump Bearing
1. Idler Gear Housing 3. Bleed Hole A. Pump Inlet B. Pump Outlet
2. Plug 4. Air Line 1. Relieved Radius
2. Recess on Face Adacent to Gears
3. Seal Bridge 4. Lubrication Scrolls

NOTE: If the plug fails to drop out of the housing, NOTE: It is normal for the gears to cut a light track
remove by directing compressed air into the on the inlet side of the body bore and,
bleed hole located on the pump to engine providing the depth of the track does not
mounting face, see Figure 53. exceed 0.004 in. (0.10 mm.), the body is re-
13. Remove the idler gear shaft, idler gear and two usale. Using an internal micrometer measure
washers. the body at the track position to access the
track depth, see Figure 55.
INSPECTION AND REPAIR
1. Wash all parts in a suitable solvent to remove
any foreign particles and dry with a clean, lint-
free cloth or compressed air.
2. Examine each bearing for wear on the face and
in the bore. Pay particular attention to the
condition of the lubricating scrolls and the seal
bridge, Figure 54. At the stage of major overhaul,
bearings should be renewed but light score
marking may be removed by polishing as follows:
(i) Place a sheet of "O" grade emery paper,
lubricated with parafin, on a truly flat surface, then
polish the bearing face using light rotary motion.
(ii) Outer diameter may be lightly polished to obtain
Figure 55
free movement in the body.
Gear Track Body
3. Inspect the pump body for external damage and A. Inlet Side C. Bore Diameter(Bearing Location)
cracks. Examine the bores for wear and damage. B. Outlet Side D. Depth of Gear Break

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 HYDRAULIC SYSTEM

Figure 56 Figure 57
Polishing Gear Faces Gear Pairing
1. Gear A. Journals paired within 0.0005 in.(0.013 mm.)
2. Emery Paper "O" Grade B. Gear widths paired within 0.0002 in.(0.005 mm.)
3. Scrap Bearing

Burrs at the edge of the gear track should be and pump face. Ensure the internal passages
removed with "O" grade emery paper. are clear.
4. Examine the gears for scored or worn side faces 6. Check the external gears and housing for damage,
or journals, damaged teeth, thread or key way wear or cracks. Ensure the idler gear runs freely
and surface cracks. Slight wear and scoring on on the shaft.
the journals may be erased by mounting between
7. New seals and "O" rings should be installed when
lathe centre and polishing with "O" grade emery
servicing the pump.
paper lubricated with paraffin. Lightly scored side
faces may be renovated by sandwiching emery In the event of components being unsuitable
paper between the gear face and a scrap bearing for further use the advisable action is to clean
and rotating the gear, Figure 56. out the hydraulic system and replace the
IMPORTANT: Whilst servicing the drive and driven complete pump unit. Worn components can,
gears, particular attention must be in an emergency be replaced but the following
paid to the following points: points must be noted.
(i) Gear widths of drive and driven gears must be Under working conditions, hydraulic pressure
within 0.0002 in. (0.005 mm.) of each other to within the pump loads the gears towards the
ensure satisfactory pump efficiency, Figure 57. inlet side of the body thereby cutting the
(ii) Journals must be within 0.0005 in. (0.013 mm.) running track. If the bearings or gear journals
of each other, Figure 57. wear, the gears move over thus deepening the
(iii) Gear faces must be flat. This feature may be track.
checked by blueing a bearing face and rotating If the running track is worn to or beyond the
against the gear. This check will also reveal any limit for re-use, the installation of new bearings
sharp edges of the teeth. will re-centre the gears and prevent the tips
5. Inspect the cover for damage or cracks, of the teeth bottoming in the track thereby
particularly adjacent to the ports, filter connection resulting in pump inefficiency.

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 HYDRAULIC SYSTEM

On re-assembly observe the following requirements:

Lubricate all parts with hydraulic oil.

Coat all seals and "O" rings with petroleum jelly

and ensure the pump sealing rings are correctly
positioned, Figure 58.

Pack the cavity between the lips of the shaft seal

with high melting point grease.

Ensure the idler gear shaft plug is installed with

the slotted face towards the shaft.

If the pump is not to be re-used immediately,

Figure 58 cap the ports.
Position of Sealing Rings and Relationship of
Bearings to inlet Side of Body INSTALLATION
A. Inlet B. Outlet
1. Stuffer Strip 1. Installation of the engine mounted gear type
2. (Relieved) Radius on Outlet Side of Pump hydraulic pump follows the removal procedure in
3. Pressure Loading Ring
reverse.
4. Outer Sealing Ring
IMPORTANT: Prior to installation on the tractor,
RE-ASSEMBLY introduce hydraulic oil into the suction

Re-assembly of the engine mounted gear type pump port and rotate the gears by hand. To

follows the disassembly procedure in reverse. effect an airtight seal, install a new "O"
ring seal in the pump and ensure the
IMPORTANT: If used bearings are to be refitted they end of the inlet tube is smooth to
should be installed in their original prevent damage to the seal on
positions. Inspection of the bearings assembly.
indicates two distinct features which
may be used to ensure correct location. 2. Pressure check the pump.

(i) A.Y. - Shaped recess in the bearing face. IMPORTANT: Run-in the pump progressively for 2-5
minutes at each of the following
(ii) Relieved radii on one side of the bearing. pressures: 1000 lbf/in2 (70 kgf/cm2).
1800 lbf/in2 (125 bar) and the relief
Assemble the bearings with the Y - shaped recesses
valve pressure crack-off pressure 2400
adjacent to the gear faces and the relieved radii facing
lbf.in2 (169.5 kgf/cm2).
the outlet side of the body, see Figures 56 and 58.

J–39
 HYDRAULIC SYSTEM

HYDRAULIC SYSTEM
12. TROUBLE SHOOTING

A. TROUBLE SHOOTING 4. Attempt to lift in Position Control.

The most important factor to consider in hydraulic 5. Attempt to lift in Draft Control.
system trouble shooting is verification of the problem NOTE: If the problem occurs in Position Control but
by observing the system operation. not in Draft Control (or Vice-versa) on internal
To assist in the diagnosis of the fault, determine under linkage fault is indicated.
which of the following headings the problem may be The fault finding procedure charts follows a logical
classified: sequence of operations to facilitate fault diagnosis with
a) Failure to Lift. the minimum amount of work and duplication.

b) Slow Lift or Failure to Lift under Load FAULT FINDING PROCEDURE

c) Lift and No Drop NOTE: An Auxiliary Service Selector Valve must be

installed for diagnosis of certain hydraulic
d) Lift with Control Lever in Lower or Neutral but
system faults on Farmtrac tractors where it
Drops when Engine Stopped and Control Lever
is fitted.
in Lower.
1. Attach suitable weights or an implement to the
e) Implement Lift but Drops when Control Lever in
lift arms.
Neutral or Raise Position.
2. Start the engine and set at 1650 rev/min.
Appropriate fault finding procedures charts are provided
on the following pages, but before attempting to 3. Adjust the Flow Control Knob (where fitted) to
diagnose a fault in the hydraulic system, conduct give the maximum flow.
certain preliminary checks as follows: 4. Select Draft Control and move the lift control lever
1. Ensure the Auxiliary Services Selector valve is to the top of the quadrant.
pushed fully in. 5. Observe and diagnose the operation of the
2. Check external linkage is fee from obstruction. hydraulic system on the appropriate according
to the instructions shown in chart.
3. Ensure the hydraulic oil in the rear axle is of the
correct grade and quantity, see "Specification". NOTE: Removal of the transmission hand brake
Check the hydraulic oil filter has been changed aperture cover plate will facilitate observation
and no other failure has occured (e.g. of the internal components and may assist
Transmission, Dual Power, etc.) in the diagnosis of certain faults.

J–40
 HYDRAULIC SYSTEM

HYDRAULIC SYSTEM
TROUBLE SHOOTING
PROBLEM POSSIBLE CAUSES REMEDY
Failure to Lift Under All 1. Low oil level. 1. Fill system with correct grade and
Conditions 2. Flow control valve binding. quantity of oil.
2. Loosen or install new valve.
3. Hydraulic piston pump not primed. 3. Prime pump.
4. Hydraulic pump pressure low. 4. Adjust pump pressure.
5. Check valve damaged or worn. 5. Install new check valve ball and seat.
6. Draft control or position control 6. Install new parts and adjust linkage.
linkage damaged.
7. Unload valve or back pressure valve 7. Inspect and renew if necessary.
faulty.
8. Lift piston seals damaged. 8. Install new seals.
9. Unload valve plug worn. 9. Install large size plug.
10. Lift cylinder, lift cover castings 10. Renew defective parts.
cracked or porous.

Failure to Lift Under 1. Hydraulic pump pressure low. 1. Adjust pump pressure.
Load 2. Damaged "O" rings between lift 2. Install new "O" rings.
cylinder and lift cover or between
accessory cover and lift cover.
3. Damaged "O" rings on hydraulic 3. Install new "O" rings.
pump pipes.
4. Damaged lift cylinder safety valve. 4. Install new valve.
5. Faulty lift piston seals. 5. Install new seals.
6. Cracked, porous lift cylinder or lift 6. Renew defective parts.
cover casting.

Excessive Corrections 1. Worn or damaged check valve. 1. Install new ball and seat.
in The Raised or 2. Selector valve worn or damaged. 2. Install larger size spool.
Transport Position
3. Unload valve worn ball or seat plug. 3. Install larger size plug.
4. Lift cylinder safety valve damaged. 4. Install new valve.
5. Faulty lift piston seals. 5. Install new seals.
6. Control valve worn. 6. Install new (or larger) valve.

J–41
 HYDRAULIC SYSTEM

PROBLEM POSSIBLE CAUSES REMEDY

Excessive Corrections 7. Damaged "O" rings between lift 7. Install new "O" rings.
in The Raised or cylinder and lift cover or between
Transport Position accessory cover and lift cover.
8. Cracked porous lift cylinder or lift 8. Renew defective parts.
cover castings.

Occasional Failure To 1. Worn or loose selector valves. 1. Install new (or larger) valve.
Lift (Not due to 2. Unload valve sticking. 2. Install new valve or "O" ring.
Loadings) 3. Faulty back pressure valve. 3. Install new valve.
4. Control valve incorrectly adjusted. 4. Adjust valve.

J–42
 HYDRAULIC SYSTEM

a) FAILURE TO LIFT

Check : Pressure Relief Valve

or
Replace with Valve of Known
Correct Setting

Pressure Relief Valve Blows Pressure Relief Valve does

Not Blow

Check : Implement too Heavy, Pressure Relief Valve does

Seized Cross Shaft Not Blow
Seized Piston
Control Valve Stuck
Bent Control Valve Lever
or stop pin
Pressure Relief Valve Blows Pressure Relief Valve
Does Not Blow

Check : Piston Seals,

Lift Cylinder Wear or Cracking
Pressure Test
Lift Cylinder Safety Hydraulic Pump
Valve, "O" Ring
Seals

No Pressure Constant System Low Pressure but Higher

Back Pressure than System Back Pressure

Check : Pump Drive Check : Unload Valve, Check : Worn Pump,

Feed Pipes Control Valve Intake Filter,
and "O" Rings, Feathering Valve Feed Pipes and "O" Rings,
Intake Filter Internal Linkage Flow Control (where fitted)
Unload Valve Plug,
Feathering Valve Plug,
Lift Cylinder loose
Loose or Blown
"O" Rings

J–43
 HYDRAULIC SYSTEM

b) SLOW LIFT
OR
FAILURE TO LIFT UNDER LOAD

Check : Pressure Relief Valve

or
Replace with Valve of Known
Correct Setting

Pressure Relief Valve Blows Pressure Relief Valve does

Not Blow

Check : Implement too Heavy, Pull out Auxiliary Services

Blocked Oil Galleries Selector Valve
Control Valve not moving
fully in to Raise

Pressure Relief Valve Blows Pressure Relief Valve

Does Not Blow

Check : Piston Seals,

Lift Cylinder Wear
Pressure Test
Lift Cylinder Safety Hydraulic Pump
Valve, "O" Ring Seals

Constant System Back Pressure Low Pressure but Higher

than System Back Pressure

Check : Unload Valve, Check : Worn Pump,

Control Valve Intake Filter,
Feathering Valve Feed Pipes and "O" Rings,
Internal Linkage Flow Control
Unload Valve Plug,
Feathering Valve Plug,
Lift Cylinder
Loose or Blown
"O" Rings

J–44
 HYDRAULIC SYSTEM

c) LIFT AND NO DROP

Check : Draft Control

Main Spring Adjustment,
Control Valve Stuck in
Lift Position

d) LIFT WITH CONTROL LEVER IN LOWER OR

NEUTRAL BUT DROPS WHEN ENGINE STOPPED
AND CONTROL LEVER IN LOWER

Check : Unload Valve Stuck in Lift Position

Feathering Valve Stuck in Lift Position
Cooler Valve Stuck (where fitted)

e) IMPLEMENT LIFTS BUT DROPS

WHEN CONTROL LEVER IN NEUTRAL
OR RAISE POSITION

Fully Raise Implement,

Pull Out Auxiliary Services
Selector Valve and Stop Engine

Lift Arms Drop Lift Arms Hold

Check : Piston Seals, Check : Check Valve and Seat,

"O" Ring Seals. "O" - Ring Seals
Lift Cylinder Wear or Cracking, Unload Valve Plug,
Selector Valve Spool (Rear lands) Control Valve,
Unload Valve Plug Selector Valve
Spool (front lands)

J–45
 13. HYDRAULIC SYSTEM VALVES FUNCTION & OPERATION
OPERATION PRESSURE
VALVE FUNCTION
NEUTRAL LOWER RAISE SETTING

Pressure Limits the pressure at which oil Closed Closed May open if system Crack of 2400 psi.
Relief Valve is fed to the system so that the pressure is too high fully open or by
components are not over loaded. pass 2550-2650
psi.

Control Valve Causes the flow of oil in the circuit 1. Traps oil in lift 1. Allows oil to escape 1. Traps oil in lift
to give Raise, Neutral or Lower. Cylinder from lift cylinder Cylinder

HYDRAULIC SYSTEM
2. Keeps unload Valve 2. Keeps unload Valve 2. Directs oil to move None
J–46

in the dump position in the dump position unload valve to

Raise position.

3. Directs oil to move

the feathering valve
to the close position
depending on the
amount of control
valve movement.

Unload Valve Moved by spring and/or oil Allows oil from the As for 'neutral' Prevents oil from which None
pressure as governed by control pump to return to therefore builds up
valve. sump. pressure to open check
valve and enter lift
cylinder
 OPERATION PRESSURE
VALVE FUNCTION
NEUTRAL LOWER RAISE SETTING

Feathering Modulates the flow of hydraulic oil Open Open Fully or partially closed None
Valve to the lift cylinder depending on depending on amount
the size of the lift signal. of control valve
movement.

Check Valve A one-way valve which allow oil Closed Closed Open as system 71-93 psi.
to enter the lift cylinder, but will pressure increases.
not allow it to return.

HYDRAULIC SYSTEM
Lift Cylinder Protects high pressure side of May open intermittently Closed Closed 2750-2850 psi.
Safety Valve system from excessive pressure. when transporting with
J–47

a heavy implement.
 HYDRAULIC SYSTEM

14. SPECIFICATIONS

DESCRIPTION FARMTRAC-60

Rear Axle and Hydraulic Oil Grade EP-80 W 90

LIFT CYLINDER & PISTON

Lift Cylinder Diameter 2.9995 - 3.0010 in. (76.187 - 76.225 mm.)
Lift Piston Diameter 2.9977 - 2.9991 in. (76.137 - 76.162 mm.)
Lift Cylinder Safety Valve Opening Pressure 2750 - 2850 lb/sq. in. (193 - 200 kg/sq. cm.)
Check Valve Opening Pressure 71 - 93 lb/sq. in. (5.0 - 6.5 kg/sq. cm.)

PRESSURE RELIEF VALVE

Minimum Crack-off Pressure 2400 lb/sq. in. (169.5 kg/sq. cm.)
Fully Opening Pressure 2550-2650 lb/sq. in. (180 - 187 kg/sq. cm.)
Tightening Torque 30 - 35 lbf.ft. (4.15 - 4,85 kgm)

FLOW CONTROL VALVE LINKAGE

Actuating Follower shim Thickness 0.01 in. (0.254 mm.)

DRAFT CONTROL MAIN SPRING

Draft Control Spring Shim Thickness 0.015 in. (0.381 mm.)
0.020 in. (0.508 mm.)
0.025 in. (0.635 mm.)
HYDRAULIC PUMP - GEAR TYPE
Hydraulic Pump 4.5 GPM 17 litres/min. 2133 RPM (Pump rpm)
Hydraulic Pump 9.0 GPM 34 litres/min. 2133 RPM (Pump rpm)

J–48
 HYDRAULIC SYSTEM

HYDRAULIC SYSTEM

TORQUE SPECIFICATIONS UNITS FARMTRAC-60

Lift Cylinder Retaining Bolts lbf.ft 52
(kgf.m) (7.2)
Lift Cover Retaining Bolts lbf.ft 78
(kgf.m) (10,8)
Accessory Cover to Lift Cover Bolts lbf.ft 60
(kgf.m) (8.3)
Centre Bolt lbf.ft 13.5
(kgf.m) (1.9)
Control Valve Baffle Plate and Rear Plate lbf.ft 27
Retaining Bolts (kgf.m) (3.7)

Quadrant Assembly to Quadrant Support lbf.ft 27

Retaining Bolts (kgf.m) (3.7)

Quadrant Support to Lift Cover Housing lbf.ft 41

Retaining Bolts Control Valve Lever (kgf.m) (5.7)

Draft Control Spring Housing Bolts lbf.ft 14

(kgf.m) (5.5)
Check Valve Plug lbf.ft 50
(kgf.m) (6.9)
Flow Control Plate Retaining Bolts lbf.ft 41
(kgf.m) (5.7)
Hydraulic Gear Type Pump Through Bolts lbf.ft 37
(kgf.m) (5.1)
Lift Cylinder Safety Valve lbf.ft 50
(kgf.m) (6.9)
Engine Mounted Gear Pump to Engine lbf.ft 30
Retaining Bolts (kgf.m) (44.2)

Draft Control Adjuster Rod Lock Nut lbf.ft 9

(kgf.m) (1.2)
Position Control Adjuster Rod Lock Nut lbf.ft 9
(kgf.m) (1.2)
Eccentric Adjustable Stop Retainer Nut lbf.ft 27
(kgf.m) (3.7)

J–49
 SECTION - 'K'

STEERING SYSTEM
(RE-CIRCULATING BALL TYPE)

S.NO. CONTENTS PAGE

1. DESCRIPTION AND OPERATION K-3

2. STEERING GEAR ASSEMBLY-OVERHAUL K-4

3. RE-ASSEMBLY AND ADJUSTMENTS K-5

4. TROUBLE SHOOTING K-9

5. SPECIFICATIONS K - 11
STEERING SYSTEM

K–2
 STEERING SYSTEM

STEERING SYSTEM
(RE-CIRCULATING BALL TYPE)

1. DESCRIPTION AND OPERATION The motion of the main nut is transmitted to the rear
rocker shaft by means of a 'rack and pinion' action,
The steering gear shown in the Exploded View is of the nut being the rack and the rocker shaft gear the
the re-circulating ball type (Rane Make). Roller bearings pinion. The movement is transmitted from the rear to
to take the thrust are positioned at the upper and lower the forward rocker shaft by direct level gearing
ends of the worm. Pre-load, adustment for these engagement between the two.
bearings is provided by means of shims fitted between
the steerig outer column flange and the steering gear Each rocker shafts is each supported by two bushes,
main casing. The shaft (inner column) is centered at one on the steering arm side and the other at the gear
the top of the outer column housing by a rubber end. The gear end of the shaft has a groove machined
mounted bush. in it (with a circlip), in which is located an adjuster
which is screwed into the rocker shaft cover. This
A total of 62 Nos. (9/32 in. Dia) re-circulating balls are adjuster makes it possible to adjust the rocker shaft
located in the main nut assembly which consists of free play.
the main nut, the two transfer tubes and the transfer
tube retainer. The helical grooves in the main nut and At the end of the rocker shaft is attached a steering
worm correspond to form a guide for the ball bearings. arm which is located on a tapered spline. To each
steering arm is connected a drag link, which is
The transfer tubes are connected to the groove in the adjustable for length and the other end of the drag link
main nut in such a way to form two continuous is connected to the wheel spindle arm. The action of
passages in which the balls are circulated. As the the steering arm moves forward the left-hand steering
shaft is turned the ball bearings are directed by the arm moves forward the left-hand steering arm moves
motion of the worm around this passage and only the towards the rear. A connecting rod between the wheel
balls in the main nut groove are in contact with the spindle arms is unnecessary due to the direct gearing
worm. connection.

K–3
 STEERING SYSTEM

2. THE STEERING GEAR ASSEMBLY- 12. After dislodging all the main nut balls, remove
OVERHAULING the main nut from the inner column.

A. DISASSEMBLY 13. Remove oil seals from the box and cover plate
bosses by carefully levering at diametrically
1. Remove the steering wheel nut and washer opposite points.
securing the wheel and pull of the steering wheel
using a suitable puller. B. INSPECTION AND REPAIR

2. Disconnect the Drag Links at the Drop Arm ends. 1. Examine the steel balls and bearing tracks of
main nut an inner column for undue wear pitting.
3. Remove the steering gear from the tractor. If damages to either component in the form of
pitting or grooving is evident, it should be
4. Loosen the drop arm nuts and remove drop arm replaced.
using a puller. DO NOT HAMMER IT OUT.
2. Check for wear on the teeth portion of the main
5. Remove oil plug and drain out all oil. nut.

6. Loosen adjuster screw lock nuts. Remove cover 3. Check for damages on the serration and threads
plate bolts. Withdraw the cover plate with primary of the inner column.
rocker shaft by gently tapping on the shaft end
with a mallet. NOTE: The inner column and main nut assembly
should be replaced as a set only.
7. Mark the primary and secondary gears tooth
positions before removal to ease correct 4. Check primary and secondary rocker shafts for
reassembly. wear and damages at gear teeth, splines and
threads.
8. Remove secondary rocker shaft from the housing
by screwing in the adjuster screw. 5. Check the adjuster screw visually for any bend
and threads for damage and replace if necessary.
9. Fix up the sleeve and locknut on to the inner
column and tighten nut (hand tight) to keep the 6. Check for axial play of the adjuster screw.
sleeve pressed against outer column bush.
7. Check the bearing races for wear and pitting.
Remove the outer column bolts, detach the outer
column with inner column and main nut 8. Check fit of inner column upper bearing area in
assembly. Collect the shims. upper bush. If a slack fit is apparent the sleeve in
the outer tube assembly should be driven out
10. Unscrew the lock nut and remove inner column
and the bush renewed.
with main nut assembly. Take care to collect,
ball races and 22 Nos. of 3/8" steel balls. 9. Check fit of rocker shaft in main case bush and
cover plate bush. If a slack fit is apparent bushes
11. Remove the transfer tube retainer bolts from the
should be replaced.
main nut. Remove transfer tube. Carefully
dislodge the main nut balls by rotating the main 10. Check the wear on the transfer tubes especially
nut balls (62 Nos.) at the tip and ball entry points.

K–4
 STEERING SYSTEM

3. RE-ASSEMBLY AND ADJUSTMENTS

1. Remove the steering wheel nut and washer

securing the wheel and pull of the steering wheel
using a suitable puller.

2. Disconnect the Drag Links at the Drop Arm ends.

3. Remove the steering gear from the tractor.

4. Loosen the drop arm nuts and remove drop arm

using a puller. DO NOT HAMMER IT OUT.

5. Remove oil plug and drain out all oil.

6. Loosen adjuster screw lock nuts. Remove cover

plate bolts. Withdraw the cover plate with primary
rocker shaft by gently tapping on the shaft end
with a mallet.

7. Mark the primary and secondary gears tooth

positions before removal to ease correct
reassembly.

8. Remove secondary rocker shaft from the housing

by screwing in the adjuster screw.

9. Fix up the sleeve and locknut on to the inner

column and tighten nut (hand tight) to keep the
sleeve pressed against outer column bush.
Remove the outer column bolts, detach the outer
column with inner column and main nut
assembly. Collect the shims.

10. Unscrew the lock nut and remove inner column

with main nut assembly. Take care to collect,
ball races and 22 Nos. of 3/8" steel balls.

11. Remove the transfer tube retainer bolts from the

main nut. Remove transfer tube. Carefully
dislodge the main nut balls by rotating the main
nut balls (62 Nos.)

K–5
 STEERING SYSTEM

Press the wheel end rubber bush and inner brass bush
in outer column assembly.

Keep the top ball race on the outer tube housing in

position and arrange 11 Nos. of 3/8" Steel balls on the
top ball race. Insert the inner column into the outer
column and fix the sleeve with the lock nut at the wheel
end top to keep the inner and outer columns together
without the steel balls slipping out of position.

Insert the column assembly into the box for shimming

without the shims or gasket. Screw in the retaining
bolts and tighten to finger tight.

Measure the gap between the flange and box facing

with feeler gauge to determine the shim pack
thickness. Deduct 0.002" from the determined
thickness.

Ensure that the gasket seating surface in the casing

is clean. Place the new gasket on the box face after
applying a thin coat of shellac.

Assembly the column assembly with the shims in

between and tighten the bolts to 25 ft. Ibs. Temporarily
fit the steering wheel and check pre-load using a spring
balance at the steering wheel rim. Adjust the shims
as necessary to achieve the correct pre-load of the
inner column.

K–6
 STEERING SYSTEM

NOTE: Ensure that the steel balls move only with

hand pressure in the top and bottom bearing
races. To check this condition thrust a steel
poker in between the steel balls.

Check for axial play of the adjuster screw. If

play exists, remove circlip and adjust with
shims. (End float of O.05mm max, on adjuster
screw is permissible).

NOTE: Adjuster screw should not get jammed due to

excess shimming and should be free to rotate
by hand.

Assembly the secondary rocker shaft in position and

draw out the adjuster screw.

Set the column in straight ahead position (i.e. 2.2

revolutions approximately from anti-clockwise lock).

Insert the primary rocker shaft in the correct position

as marked before removal, so that it has the correct
engagement with secondary rocker shaft.

K–7
 STEERING SYSTEM

Apply grease on the cover plate face. Apply shellac

on the casing and place a naw gaskel in position,
assemble the cover plate.

Draw-out the primary and secondary rocker shaft

adjuster screws carefully.

Provide a thin coating of Holdtite on bolts and tighten

the cover plate bolts with spring washers to 25ft. Ibs.
torque.

Fix the drop arm and adjust the primary rocker shaft
to NIL back lash condition between main nut rack and
gear teeth by suitably adjusting the adjuster screw
and tighten the lock nut.

NOTE: Ensure that the adjustment is done with the

gear in straight ahead position onlyand
secondary rocker shaft fully drawn out. Always
adjust the primary rocker shaft first.

Adjust the secondary rocker shaft to NIL back lash

condition between primary and secondary gears in
similar manner.

Drive new oil seals in position into the box and cover
plate bosses.

Ensure that the steering assembly is filled up with the

correct grade of oil (SAE 90 - 750 ml. approx.)

Check the gear for smooth operation before assembling

on to the tractor.

K–8
 STEERING SYSTEM

4. TROUBLE SHOOTING
IMPORTANT: When ever effecting a repair the reason for the cause of the problem must be investigated and
corrected to avoid repeat failures.
PROBLEM POSSIBLE CAUSES REMEDY
Stiff or jerky steering 1. Incorrect adjustment of rocker shaft 1. Check and adjust.
action free play.
2. Incorrect adjustment of steering shaft 2. Check and adjust.
bearings.
3. Damaged or binding steering shaft 3. Inspect and repair.
bearings.
4. Damaged or binding worm and nut 4. Inspect and replace.
assembly or bearings.
5. Damaged or seized rocker shaft 5. Inspect and repair.
gears or busings.

Loose steering or 1. Excessive play in steering linkage 1. Inspect and replace.

steering wanders ball joints.
2. Incorrect adjustment of rocker shaft 2. Check and adjust.
free play.
3. Incorrect adjustment of steering shaft 3. Check and adjust.
bearings.
4. Excessive play in worm and nut 4. Inspect and replace.
assembly.

Steering Hard 1. Under inflation. 1. Inflate tyres to recommended

pressure.
2. Dry king pin bushes bearings. 2. Lubricate bearings & bushes.
3. Incorrect adjustment of kingpin. 3. Adjust as per recommendation
4. Ball joints dry. 4. Lubricate Ball joints
5. Lack of lubrication in steering gear. 5. Fill up with correct grade of oil to the
level.
6. Lack of lubrication in column bearing. 6. Grease-column bearings.
7. Incorrect adjustment of bearing race. 7. Adjust as per recommendation.
8. Pitted adjustable bearing race, ball 8. Replace ball races wherever
race ring or spherical ball race. necessary.
9. Ball Peg Shimming improper (tight). 9. Shim up as per recommandation.
10. Pitted inner column worm and nut. 10. Replace as a set.
11. Bent Steering linkages. 11. Replace linkages.

K–9
 STEERING SYSTEM

PROBLEM POSSIBLE CAUSES REMEDY

Steering Wobbling 1. Toe-in and Toe-out setting disturbed. 1. Correct as per recommendation.
2. Excess backlash in wheel bearings. 2. Correct as per recommendation.
3. Worn out kingpin and bushes. 3. Replace parts.
4. Worn out front axle mounting pin 4. Replace as per recommendation.
bushes.
5. Ball join worn out. 5. Replace.
6. Excess lift in the inner column 6. Adjust as per recommendation.
bearings.
7. Improper loose shimming of ball peg. 7. Correct as per recommendation.
8. Excess free play on steering gear. 8. Correct as per recommendation.
9. Loose fitment of drop arm and other 9. Tighten to recommended torque.
levers/linkages.
10. Worn out bearings. 10. Replace.

Tractor pulling to one 1. Under inflation on one side. 1. Inflate to correct pressure.
side 2. Uneven tread of front Right/Left tyres. 2. Replace as necessary.
3. Wheel bearings adjusted tight on one 3. Correct wheel bearings.
side.
4. Drag link length in correct. 4. Correct as per recommendation.
5. Misaligned front axle. 5. Check and correct.

K–10
 STEERING SYSTEM

5. SPECIFICATIONS

DESCRIPTION FARMTRAC-60

Type Recirculating Ball (Double transfer track)

Main Nut Balls 9/32" Dia - 62 Nos. (31 Nos. in each track)

Inner Column Bearing Balls 3/8" Dia - 11 Nos. each end

Inner Column Bearing Preload 2 to 4 in. lbs.

Overall Assembly condition in straight ahead position Zero back-lash at drop Arm end

Oil Grade EP90

Capacity 750ml. approx.

Final Ream Size of Rocker Shaft Bush after Pressing 28.57 mm. / 28.60 mm.

TORQUE LOADINGS

DESCRIPTION UNITS FARMTRAC-60

Steering Column to Housing Bolts lbf.ft 25 Ft. lbs.

(kgf.m) (3.4 Kgfm)

Side Cover Bolts lbf.ft 25 Ft. lbs.

(Rocker shaft cover plate retaining bolts) (kgf.m) (3.4 Kgm)

Steering wheel to steering shaft retaining nut lbf.ft 60-80

(kgf.m) (8.3-11.04)

Steering arm to rocker shaft retaining nut lbf.ft 115-126

(kgf.m) (15.9-17.3)

Drag link ball pin nut lbf.ft 35-45

(kgf.m) (4.8-6.2)

K–11
 SECTION - 'L'

STEERING SYSTEM (HYDROSTATIC)

S.NO. CONTENTS PAGE

POWER ASSISTED STEERING PUMP, RESERVOIR AND

PIPES

1. DESCRIPTION AND OPERATION L-3

2. POWER STEERING PUMP-OVERHAUL L-4

3. POWER STEERING PUMP-PRESSURE TESTING L-7

4. RESERVOIR FILTER AND HYDRAULIC PIPES L-8

HYDROSTATIC STEERING SYSTEM

1. DESCRIPTION AND OPERATION L-11

2. HYDROSTATIC STEERING-OVERHAUL L-13

3. HYDROSTATIC STEERING CYLINDER-OVERHAUL L-24

STEERING SYSTEM

L–2
 STEERING SYSTEM

STEERING SYSTEM (HYDROSTATIC)

POWER ASSISTED STEERING PUMP,
RESERVOIR AND PIPES

1. DESCRIPTION AND OPERATION Two spur gears, Figure 1, produce oil flow for the
operation of the power steering and are mounted in
The power steering pump is mounted on the left hand
specially designed bearing blocks which are a precision
side of the engine and is gear driven from the engine
fit in the pump housing.
timing gears, at crankshaft speed.

Figure 1
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 Block 9. Pump Gears
5. Pump Body 10.Filter Elements

L–3
 STEERING SYSTEM

The Pump driving gear and shaft are integral. The front
of the shaft protrudes through the pump front cover
plate and is suitably tapered to accept the external
drive gear. The external drive gear meshes with the
engine camshaft drive gear so that whenever the engine
is running the pump is in operation.

Rotation of the pump gears draws oil from the reservoir

mounted directly on the rear of the pump body. On
entering the pump, the oil fills the gear tooth spaces
and is carried around the housing, by the closely fitting
gears, to the point where the teeth in the two gears
come into mesh.

The oil is then thrust out from between the teeth and Figure 2
delivered through an outlet port in the pump body to Power Steering Pump Installation
the pump outlet elbow. The oil on return passes through 1. Pump Return Pipe
a paper element filter incorporated into the reservoir. 2. Reservoir Retaining Bolt
3. Pump Pressure Pipe
When the tractor steering gear is held in the full lock
position or the front wheels are agaisnt an obstacle, 4. Extract the two bolts retaining the pump front
the pressure in the system will increase as the pump flange in the timing gear casing.
continues to deliver oil. When the oil reaches sufficient
pressure, see "Specifications", the pressure relief valve 5. Remove the pump assembly from the tractor and
lifts from the seat and the pump oil flows through a drain the remaining oil from the reservoir.
drilling into the reservoir. The pressure relief valve is
DISASSEMBLY
located in the pump rear cover and is accessible after
removing the reservoir casing, Figure 2.
1. Remove the reservoir retaining bolt and pull of
NOTE: The steering should not be held in the full the reservoir casing. Discard the large "O" ring
lock position, or with the front wheels against seal and filter element.
an obstacle, for more than 30 seconds as
2. Straighten the tap on the lock washer locating
damage to the system can result.
the drive gear retaining nut.
2. POWER STEERING PUMP-OVERHAUL
3. Undo the nut and remove the washer. Use Puller,
REMOVAL EF-0501 to withdraw the drive gear.

1. Support a suitable clean container under the

4. Remove the key from the drive gear shaft.
pump and reservoir assembly.
5. Withdraw the pressure relief valve from the pump
2. Disconnect the pump pressure and return pipes
body.
and allow the oil to drain.

3. Plug the two disconnected pipes and ports to 6. Remove the four bolts and separate the front and
prevent the entry of dirt. rear end covers from the pump body.

L–4
 STEERING SYSTEM

Figure 3 Figure 4
Pump Gears and Blocks Removed Gear Track in Body
1. Bearing Blocks 2. Pump Gears 1. Inlet Side 2. Bore Diameter
3. Pump Body 3. Outlet Side 4. Depth of Gear Track

7. Noting their positions relative to the pump body 3. Inspect teh bearing blocks, Figure 5, for signs of
for re-assembly, remove the bearing blocks and seizure or scoring. Light scoring on the sides
pump gear, Figure 3. can be removed by careful lapping on a surface
plate using "O" grade emery paper and paraffin
8. Remove the snap ring retaining the drive shaft oil
(Kerosene), ensure such parts are thoroughly
seal in the front end cover and extract the oil
washed and dried prior to reassembly. Should
seal.
the wear be excessive install new bearing blocks.

INSPECTION AND REPAIR

1. Clean all parts in a suitable solvent and air dry.

Lightly oil machined surfaces.

2. Examine the pump body and gears for wear or

damage.

The wear track on the inlet side of the pump body

interior should be free from scoring and no deeper
than 0.0025 in. (0.065 mm.) Figure 4.

The pump gears should not be scored or pitted.

The pump body and gears are not supplied for Figure 5
service, if they are excessively worn a complete Pump Gears and Bearing Blocks
replacement pump must be installed. 1. Drive Gear 2. Bearing
3. Driven Gear 4. Bearing Block

L–5
 STEERING SYSTEM

Figure 6 Figure 4
Steering Pump Pressure Relief Valve Gear Track in Body
1. Valve Head 5. Valve Seat 1. Inlet Side 2. Bore Diameter
2. Shims 6. "O" Ring 3. Outlet Side 4. Depth of Gear Track
3. Pin 7. Valve
4. Seal 8. Spring

4. Use the soft jaws of a vice to grip the seat of the torque see "Specifications", and secure with the
pump pressure relief valve then unscrew the head lock washer tab.
and body. Check the components for wear or
swarf contamination, Figure 6. Pour a small quantity of clean oil into the pump
for initial lubrication and ensure the pump drive
RE-ASSEMBLY
gear can be turned by hand.

Re-assembly of the power steering pump follows the

Install a new oil filter element.
disassembly procedure in reverse. On re-assembly
observe the follwing requirement:
INSTALLATION

All rubber seals, "O" rings and the drive shaft

Installation of the power steering pump follows the
oil seal must be replced.
removal procedure in reverse. On installation observe
the following requirements:
Ensure correct installation of the bearing
blocks and seals, Figure 7.
Fill the power steering reservoir with the correct

Tighten the four through bolts evenly and to the grade and quantity of oil, see "Specifications".
correct torque, see "Specification".
Operate the steering from lock-to-lock several
Install a new lock washer under the pump drive times to expel any air from the system and re-
gear retaining nut. Tighten the nut to the correct check the oil level.

L–6
 STEERING SYSTEM

Figure 8 Figure 9
Pump Pressure Test Installation Pressure Relief Valve
1. Pressure Gauge, Tool No. EF-1400 1. Shims
2. Adaptor, Tool No. EF-1401 2. Spring
3. Output Elbow 3. Valve
4. Valve Seat

3. POWER STEERING (i) With a suitable container held under the

pump assembly, disconnect the return pipe.
PUMP-PRESSURE TESTING
(ii) Remove the reservoir casing and carefully
1. Disconnect the pump pressure pipe at the elbow.
drain the oil.
2. Connect Adaptor, Toll No. EF-1401 and Pressure
(iii) Extract the pressure relief valve, Figure 9.
Gauge, Tool No. EF-1400, to the output elbow,
Figure 8. (iv) Use the soft jaws of a vice to grip the seat of
the pressure relief valve then unscrew the
3. Start the engine and obtain a reading on the
gauge for the pump relief valve setting. Refer to head and body.

"Specifications" for the correct setting. (v) Carefully withdraw the pressure relief valve

WARNING: Operate the engine just long enough head, guide, seal and spring and add or
to obtain an accurate reading. subtract shims as required.
Prolonged operation will cause
NOTE: For every 0.01 in. (0.25 mm.) increase in
overheating and damage.
shim thickness, the pressure relief valve
4. If the setting is incorrect remove the relief valve setting is increased by 100 lbf/in2 (6.9 bar) (7.0
and adjust the shims as follows: kgf/cm2).

L–7
 STEERING SYSTEM

(vi) Re-assemble and replace the pressure relief

valve and reservoir. Re-check the pressure
setting.

5. When the adjustment is correct, remove the

pressure test equipment and re-install the pump
pressure pipe.

6. Fill the reservoir with the correct grade and

quantity of oil, see "Specifications". Turn the
steering from lock-to-lock several times with the
engine running to expel any air from the system
then re-check the oil level. Do not mix. oil grades.

4. RESERVOIR FILTER AND

Figure 10
HYDRAULIC PIPES
Hydrostatic Steering Oil Filter
TO RENEW FILTER ELEMENT 1. Filter
2. "O" Ring
1. Hold a suitable container under the pump
assembly then disconnect the pressure and return 8. Fill the reservoir with the correct grade and
pipes and allow the oil to drain. quantity of oil, see "Specifications".

2. Extract the reservoir retaining bolt, ease the 9. Operate the steering from lock-to-lock several
reservoir casing away from teh pump body and times with the engine running to expel any air
drain off any remaining oil. from teh system then re-check the oil level.

3. Discard the old filter element. HYDRAULIC PIPES

4. Clean the reservoir casing with a suitable solvent 1. Inspect the hydraulic pipes for leakage at
and dry with a lint-free cloth. connections. Replace oil seals (where fitted) and
tighten loose connections.
5. Inspect the large reservoir sealing ring and
retaining bolt sealing washer for damage and 2. Check the pipes for signs of tracture and re-new
replace if necessary. if necessary.

6. Install a new filter element and replace the 3. Examine flexible hoses for cracks or chafing and
reservoir. renew if required.

7. Re-connect the power steering pump pressure 4. Ensure the anti-vibrations clamps are correctly
and return pipes. installed as shown in Figure 10.

L–8
 STEERING SYSTEM

STEERING SYSTEM
(HYDROSTATIC STEERING)

1. DESCRIPTION AND OPERATION STEERING MOTOR CONTROL VALVE SECTION

With reference to Figure 1.
The Farmtrac-60 feature an hydraulic power assisted,
The control valve section directs the hydraulic oil to
hydrostatic steering system. The components are
and from the metering unit, to and from the front steering
serviced separately and consist of the steering column
cylinder and also regulates the pressure of the oil
shaft, steering motor, front steering cylinder, power
flowing to the front steering cylinder. The lower end of
steering pump and reservoir, and the hoses and tubes
the input shaft is bored to receive the top of the torsion
required to connect the system.
bar. The torsion bar is pinned to the input shaft, extends
through the spool and is linked with the drive link in
the emetering system.

The integral power steering pump and reservoir are

mounted on the rear of the engine front cover plate at
the left-hand side of the engine. The pump and reservoir
are connected to the steering motor by two oil tubes.

The steering wheel is secured to the steering column

shaft. The steering column upper shaft is joined to the
power steering motor input shaft by a coupling secured
with a pinch bolt. The power steering motor and
steering column assembly are mounted on a housing
bracket which is bolted at the transmission housing.

Figure 1
Steering Motor Control Valve Section
The hydrostatic steering motor uses a linear control
1. Drive Ring 6. Valve Housing
valve to control the direction of the steered wheels 2. Spacer 7. Spool
and a metering unit to control the rate of turn. In the 3. Input Shaft 8. Retainer Ring
event of pump failure the metering unit functions as an 4. Pin 9. Torsion Bar
hydraulic pump and the wheels can be turned manually. 5. Actuating Ball

L–9
 STEERING SYSTEM

PUMP METERING SYSTEM

With reference to Figure 2.

The metering system meters oil to the steering cylinder

and maintains the relationship between the steering
wheel and the front wheels. The metering system also
acts as a manually operated hydraulic pump in the
event of power steering pump failure.

As the spool moves up or down from the neutral

position, the oil flow to the return line is restricted and
causes the pump pressure to rise. Simultaneously,
the flow is directed to the metering rotor assembly
Figure 2 through the manifold and commutator. The oil flows
Steering Motor Metering System from the metering rotor assembly to one side of the
1. Spacer front steering cylinder whilst oil flows back into the
2. Drive Link
system from the opposing side of the cylinder.
3. Commutator
4. End Cover
Oil flow through the metering rotor assembly causes
5. Commutator Ring
6. Manifold the rotor to rotate. The rotor is keyed to the spool by
7. Rotor and Stator Assembly the drive link and rotation causes the spool to react
against a helix and move towards the neutral position.
The drive link is splined to, and truns the rotor of, the A feedback is thus provided so that as the steering
rotor and stator assembly. The torsion bar is the wheel is turned, the steering cylinder movement is
principal link between the input shaft and the metering measured and the spool is neutralised after the
system in the power steering mode of operation. cylinder has moved the required amount.

The lower end of the input shaft is splined to engage STEERING CYLINDER
the drive ring. The drive ring is externally splined to
engage and drive the spool. The drive ring splines are The double acting steering cylinder is transversely
wider than those on the input shaft to allow a pre- mounted on the front axle. The cylinder end of the
determined amount of free-play. This design provides assembly is bolted to an adjuster bar which forms an
a mechanical link between the shaft and spool for integral part of the front axle assembly and facilitates
manual steering in the event of pump failure and limits re-positioning of the cylinder when adjusting the track
the amount of twist on the torsion bar. setting. The rod end is attached to the left-hand spindle
arm which is connected by the track rod to the right-
A helical groove is machined in the side of the input hand spindle arm.
shaft and the actuating ball is held captive between
the helical groove and a pocket inside the spool. The cylinder incorporates a piston centrally mounted
on the piston rod. This arrangement enables the piston
When the steering wheel is turned the torsion bar twists to present surfaces of equal area to the operating oil
and moves the spool up or down to uncover oil ports and the resultant forces ensure similar right and left-
leading to the metering system. hand turning circles.

L–10
 STEERING SYSTEM

Figure 3 Figure 4
Hydrostatic Steering Pipes Steering Motor Removal
1. Flexible Hoses
2. Rigid Pipes

2. HYDROSTATIC STEERING 7. Remove the four bolts retaining the steering motor
SYSTEMOVERHAUL support bracket.

STEERING MOTOR 8. Slacken clamp bolt securing the steering column

to the motor and carefully withdraw the motor
REMOVAL
assembly from the left-hand side of the tractor,
1. Disconnect the battery ground cable at the Figure 5.
battery.

2. Clean the flexible steering hose to rigid pipe

connections, Figure 3.

3. With a suitable container positioned to store the

escaping steering oil, mark and separate the
flexible steering hoses from the rigid pipes. Cap
and seal the pipes, using suitable plugs.

4. Slacken the retainer bolts securing the pipes to

the side of the engine.

5. Unclip and separate the throttle connecting rod

from the pedal linkage.

6. Withdraw the four retaining screws and remove Figure 5

the loser steering column shroud by withdrawing Steering column to Motor Connection
main harness connector to gain access to the 1. Clamp Bolt
steering column to motor coupling. Figure 4. 2. Steering Column.
3. Steering Motor

L–11
 STEERING SYSTEM

SEAL REPLACEMENT INSTRUCTIONS 9. Assemble the new seal onto the steering unit
input shaft and down into the steering unit upper
NOTE: Follow the Instruction and do not
cover counter bore.
disasssemble the steering unit upper cover;
to replace the shaft, seal. DISASSEMBLY
1. Remove the dirt seal over the end of the steering Cleanliness in servicing the power steering system is
unit upper cover, if applicable. Discard this part. imperative. If it is necessary to disassemble any of
2. Remove the retaining ring do not discard, this the units, ensure a clean work bench or table is used.
part must be reinstalled during assembly Clean off external dirt before the unit is placed on the
procedure. work bench.
3. To remove the seal package parts from the When disassembled, parts should be cleaned only in
steering unit plug three of the four ports in the
clear-clean petroleum base solvent and blown dry with
steering unit and pressurize the other port with
clean air. Other solvents may cause deterioration of
air pressure to force the seal package out. Discard
rubber seals. Avoid wiping parts with cloth and never
these parts.
steam clean hydraulic steering assemblies.
NOTE: Clean the steering unit input shaft and upper
NOTE: The spool and housing, the commutator and
cover seal bore to remove particle of dirt, felt,
commutator ring and the rotor and stator are
lint, etc. with a clean, lint-free rag.
selectively fitted and must be serviced as
CAUTION: Excessive particle of felt or lint can cause follows:
the new seal package to leak.
If the spool or housing must be replaced, replace
4. Cover the end of the steering unit input shaft with the complete motor.
cellophane tape to protect the new seal when it
is assembled over the sharp edges of the input If the commutator or commutator ring must be
shaft. replaced, replace both as a matched set.

5. Lubricate the new seal using hydraulic oil and If the rotor or stator must be replaced, replace
install the new seal with lip side first, onto the the complete metering element.
steering unit input shaft. If the pin in the end cover or the end cover must
6. Remove the cellophane tape from the steering be replaced, replace the pin and end cover
unit input shaft. assembly.

7. Assemble the new washer, with small end first, Refer to Figure 6 for identification of parts during
onto the steering unit input shaft and push the disassembly and re-assembly.
new washer and the new seal, previously installed,
Plug the four port holes and clean the exterior of the
down into the steering unit uupper cover. Short
steering unit throughly. Then remove the plugs.
piece of metal tubing 15/16 minimum I.D. x 1-3/
16 maximum O.D. or a 7/ 8 deep well socket 1. To prevent possible distortion or damage to unit
may be used to push these parts into place. if placed directly in vice, the following procedure
should be used. Insert “O” ring tube fitting, with
8. Assemble the previously used retaining ring onto
the steering unit input shaft and down into the tube nut or fitting cap attached, into one of the
steering unit upper cover groove. Be sure the four threaded ports in the housing. Clamp the
rounded edge of the retaining ring is faced inward. fitting in a vice in a manner, which will locate the

L–12
 STEERING SYSTEM

Figure 6
Steering Motor
1. Thrust Washer 20. 'O' Ring (where fitted)
2. Snap Ring 21. Steel Ball (where fitted)
3. Shims 22. Housing
4. Valve Thrust Bearing 23. Valve Spool
5. Thrust Washer 24. Spool Ball Retainer Spring
6. Pin 25. Bolt
7. Dirt Seal 26. End Cover
8. Snap Ring 27. Washer
9. Input Shaft 28. Rotor Seal
10. Back-up Washer 29. Seal Retainer
11. Packing Seal 30. Commutator
12. Cover Screw 31. Commutator Ring
13. Upper Cover Assembly 32. Manifold
14. Seal 33. Metering Element Rotor
15. Drive Ring 34. Metering Element Stator
16. Spacer 35. Drive Link
17. Torsion Bar 36. Spacer
18. Steel Ball 37. Spacer
19. Plug (where fitted) 38. Spring Washer

L–13
 STEERING SYSTEM

Figure 7 Figure 8
Power Steering Motor Commutator Removal
1. Tube Fitting 1. Cummutator Ring 3. Metering Section
2. Vice 2. Manifold 4. Commutator

seven end cover bolts in an upright position. by a sliding and lifting motion. Care should be
Figure 7. used in the handling of this fragile component.

2. Unscrew the seven special bolts from the end 7. Remove the manifold from the rotor set by sliding
cover. and lifting motion.
NOTE: Special care should be used in the following 8. Remove the rotor set spacer and drive link as an
steps to insure protection of the gound and assembly by grasping the spacer and removing
lapped faces of the componenets. A void the assembly with a sliding and lifting motion.
scratching or nicking of finished surfaces. Figure 9.
3. Remove end cover by bumping it sideways with
a soft hammer to loosen it from the rotor seal
and seal retainer, and lift from unit.
CAUTION: The washer and commutator may adhere
to the end cover, and may be
removedwith the end cover. Do not
attempt to remove pin because pin is
press fit in the plate and is non
serviceable. Figure 8.
4. Remove the rotor seal and seal retainer by
bumping the sideways with a soft hammer to
loosen it from the housing and lift off the rotor
seal and seal retainer. Discard the rotor seal.
5. If the wear washer and commutator were not
Figure 9
removed with the end cover, remove these parts
Metering Element Removal
from the steering unit. 1. Metering Element
6. Remove the commutator ring from the manifold, 2. Spacer

L–14
 STEERING SYSTEM

Figure 7 Figure 8
Power Steering Motor Commutator Removal
1. Tube Fitting 1. Cummutator Ring 3. Metering Section
2. Vice 2. Manifold 4. Commutator

9. Separate drive link by sliding the rotor set on the motion, remove the input shaft, upper cover and
spacer, allowing the drive link teeth to clear the spool assembly from the housing.
spacer hole. Remove drive link and separate rotor
NOTE: A void applying side forces to the spool which
set from spacer.
would cause binding of the closely fitted
Use extreme caution to keep vanes and springs assembly. Never use excessive force to
from failing out. When handling the rotor set, remove the spool from the housing.
pressure should be applied to the rotor by gripping
13. Remove and discard seal.
the rotor set between the fingers and urging the
rotor into contact with the stator. Figure 10. 14. Remove the upper cover with shaft seal package

Carefully protect against damage to side faces. intact. Remove spacer item.

NOTE: The rotor and the stator must be kept in a 15. Remove shims from either upper cover cavity or
matched set. from face of thrust washer. Count and record the
number of shims to aid in reassembly of unit.
10. Reverse the steering unit in the vice to place the
input shaft in a vertical position. Using a prick or 16. Remove seal, retaining ring, using proper snap
centre punch, mark the upper cover flange in ring pliers. Discard seal. Remove and discard
relation to a similar mark placed on the port face backup washer. Remove and discard seal.
of the housing to facilitate reassembly. Figure
17. Remove the retaining ring, thrust washer, thrust
11.
bearing, thrust washer and spring washer from
11. Remove the four special cap screws by using a input shaft.
5/16-12 point socket.
NOTE: Retaining ring is twisted design. Do not
12. Grasp the input shaft and with a smooth upward straighten ring.

L–15
 STEERING SYSTEM

Figure 12 Figure 13
Steering Motor Input Shaft and Spool Torsion Bar and Spool
1. Spool 2. Input Shaft 1. Spool 2. Torsion Bar

18. Remove the needle roller by using a pin punch of the spool outside diameter and control edges.
0.125 in. (3 mm) max. diameter for a minimum The followng provedure is optional.
of 0.625 in. (16 mm) length. The input shaft should
23. Return to the housing which is mounted in the
be placed on a block of wood (to avoid shaft
vice. Remove the plug and roll pin assembly. A
damage) and the needle roller removed by
steel ball is captivated by the plug and roll pin
impact, using light hammer blows. Figure 12.
assembly. Care must be used to avoid the loss
19. Remove the torsion bar and spacer by inverting of the ball. Remove ball by shaking after housing
the spool assembly and allowing the parts to fall is removed from the vice. Discard “O” ring.
free. Do not remove needle roller from torsion bar.
This completes the disassembly of the steering
Figure 13.
unit.
20. Remove the drive ring by placing the end of the
spool on a table surface. Rotate the input shaft
to extremes of travel unitl the drive ring falls free.
Figure 14.
21. With the spool assembly in the same position
as the step above, rotate the input shaft in a
clockwise direction unitl the actuator ball
disengages from the helical groove in the input
shaft. Lift out input shaft.
CAUTION: The actuator ball may fall free and care
should be used to not lose it.
22. Do not remove the ball retainer spring unless
replacement is required. If necessary to remove
this spring, discard the retainer if moved.
A screwdriver may be used to assist in the prying Figure 14
of the spring over the shoulder of the spool. Care Drive Ring Removal
must be used to avoid scratching or nicking of 1. Spool 2. Drive Ring

L–16
 STEERING SYSTEM

INSPECTION AND REPLACEMENT

Visually inspect all parts and replace those parts which
are not in good condition. The followng finished surfaces
should be inspected for abnormal wear, scroing or
damage.
1. Housing bore and ends.
2. Valve spool outside diameter, Some burnishing
due to use may be observed.
3. Valve spool control edges.
4. Valve spool splines.
5. Input shaft seal area. Check for rust, pitting and
excessive wear. Light circumferential polishing
due to seal contact may be observed.
6. Input shaft helical groove. Note the contact Figure 15
pattern created by the actuator ball. Surface Metering Element
should be free from pits chipping or surface break 1. Rotor 2. Stator 3. Vane Spring 4. Vane
down.
assembly face down on the lapped face of
7. Thrust bearing and thrust washers. Inspect for the end cover and check for freedom of rotor
pitting of rolls and faces of thrust washers. rotation within the stator. The action of the
8. Drive link pin slot. Width of slot must not exceed spring loaded vanes may be observed during
0.001 in. difference at any point in its length. rotation. The vanes should move freely in their
9. Drive link teeth. slots, without bind, due to the forces of the
springs. Figure 15.
10. Torsion bar and needlle roller assembly.
Difference in diameter of needle roller should not Using a feeler gauge, check the rotor to the stator
0.001 in. clearance as shown in Figure 16. If there is more
than a 0.007 in. clearance, the rotor set must be
The following parts may show a polish pattern replaced.
due to the rotor action and the circular motion of
the commutator. The sides of these components
are ground and lapped and should be free from
nicks, burrs and scroing.
1. Spacer
2. Manifold
3. Rotor
4. Commutator and Commutator Ring
NOTE: Thickness difference between commutator
and commutator ring shall not exceed 0.002
in.
5. End cover and pin assembly.
NOTE: The rotor set requires special attention in
handling to avoid nicks and scratching. It is
recommended that the rotor, stator, vanes and Figure 16
springs be checked in the assembled Rotor to Stator Check
condition. To inspect the rotor set, place the 1. Rotor 2. Stator 3. Feeler Gauge

L–17
 STEERING SYSTEM

NOTE: This applies to rotor sets with and without

vanes.
Carefully lift the rotor set assembly from the end
cover and measure the thickness of the rotor and
stator. Thickness difference between the rotor and
stator shall not exceed 0.002 in. (0.05 mm).
The internal splines in the rotor should not allow
abnromal wear or damage.
ASSEMBLY PROCEDURE
IMPORTANT: Before starting assembly, clean all
parts wth clean petroleum base solvent
and air dry. Do not wipe dry with rages.
Be sure all dried paint chips have been
removed from edges of lapped
surfaces. Unless otherwise indicated, Figure 17
DO NOT oil parts before assembly. Steering Motor Upper Cover
1. Insert ball into its cavity in the housing. 1. Mandrel 2. Upper Cover

2. Install new “O” ring on plug and roll-pin assembly will be a gap of approximately 0.350 in. (8.89
and install in the housing. Tighten to the correct mm) between end of valve spool and thrust
torque, see “Specifications”. washer if the drive ring is assembled properly.
3. Re-clamp housing in the vice as shown in Figure 10. Insert the drive ring into the spool end by visually
11. aligning an internal space on the drive ring with a
4. Assemble thrust washer, thrust bearing, thrust tooth on the input shaft spline, and allow the drive
washer and retaining ring on input shaft. ring to drop to the limit of its travel. If the drive
ring does not engage the input shaft spline, a
5. If the retaining spring has been removed, install
slight rotation of the input shaft will allow the drive
a new retaining spring. The spring must fit tightly.
ring to become fully engaged. Remove torsion
6. Insert actuator ball into ball seat located inside
bar gauge. Figure 18.
spool.
7. Assemble wave spring washer over thrust washer
and thrust bearing. Insert the input shaft into the
spool, engaging the helix and ball with a counter-
clockwise motion. This operation is best done
while holding the Spool in a horizontal position.
8. Using the mid-section of the torsion bar as a
gauge, insert the gauge between the spool end
and the thrust washer. Figure 17. This will position
the spool in the necessary radial relationship with
the input shaft spline teeth for assembly of drive
ring.
9. Place the input shaft and spool assembly in a
vertical position, with the shaft end on the table
surface.
NOTE: Rotate the input shaft out of the valve spool Figure 18
until input shaft will no longer rotate. There Using Torsion Bar as a Gauge
1. Spool 2. Torsion Bar 3. Thrust Washer

L–18
 STEERING SYSTEM

Figure 19 Figure 20
Pressing Pin into Input Shaft Upper Cover Installation
1. Press Arbor 2. Input Shaft 1. Upper Cover 2. Hose Clamp

CAUTION: The steering will not function properly if Place shims on top of the thrust washer.
the correct relationship of spool, drive Coat seal with clean grease and place in upper
ring and input shaft is not achieved. cover counterbore. Assemble upper cover on to
11. Install spacer over torsion bar and pin assembly input shaft and rotate to align punch marks
and insert the assembly into the spool end. previously made during disassembly.
12. Align the cross-hole in the torsion bar with the NOTE: If a new upper cover is used then no angual
cross-hole in the input shaft and insert a 0.120 alignment is required. However, it is necessary
in. (3 mm) diameter pin punch to maintain to align the upper cover and housing.
alignment. 17. Install the upper cover screws finger tight. Use a
13. Insert the needle roller into cross-hole in input pilot ring, or a worm drive type hose clamp
shaft; and while retracting the pin punch, engage tightened around the upper cover flange and the
the pin in the torsion bar cross-hole. body pilot diameter, to achieve the required
14. Press the pin flush with the outside diameter of alignment, Figure 20. Tighten the screws to the
the input shaft, Figure 19. With a few light taps correct torque, see “Specifications”.
on the 0.12 in. (3 mm) diameter pin punch, drive NOTE: If any of the input shaft housing and spool
the pin approximately 0.03 in. (0.76 mm) below torsion bar or upper cover have been replaced,
the input shaft outside diameter. the following procedure for checking and shim
15. Assemble spacer over valve spool against spring adjustment must be used.
washer. If so constructed the inside lipend of 18. Conduct the shimming procedure as follows:
spacer must be toward the spring washer. Place After torquing the four screws revolve the unit in
assembly, spool end first, into housing. vise so that the input shaft is pointing downwards.
CAUTION: A void applying side forces to the spool In order to determine that the unit is shimmed
which would cause binding of the closely correctly, the drive link must be in its proper
fitted assembly. position, To do this, grasp the input shaft pull
16. If neither the input shaft or upper cover are down ward, and prevent rotation. Engage drive
replaced, the original shims may be reused. If link splines in spool and rotate to postion spool
the shims are damaged, replace with shims of essentially flush with end of housing. Remove
the same thickness. drive link and orient drive link slot to engage

L–19
 STEERING SYSTEM

Figure 21 Figure 22
Shimming on Final Assembly Spacer Installation
1. Drive Link 2. Straight Edge 1. Assembly Posts 2. Spacer
3. Feeler Gauge 4. Spool

torsion bar needle roller and insert drive link. 20. Assemble space plate over assembly posts and
Observe relationship of spool end to the body. The onto housing with plain side up.
valve spool must protrude [0.20 in. ± 0.0025 in.] from 21. Install rotor seat over assembly posts and onto
the adjacent counterbore surface. If within spac. no spacer plate.
additional shimming required. If not within 0.0025 in. NOTE: One of the seven holes in the rotor set may
add or remove shims until this requirement is satisfaied be smaller than the other six holes. Position
repeating assembling steps as outlined above. With this, hole, if applicable, over one of the
reference to Figure 21. assembly posts. Reference Figure 23.
The correct shimming must be checked on the vehicle
or on a suitable hydraulic test sand. The amount of
steering effort required to steer the vechicle when the
vehicle is at rest on dry payment must be equal within
two inch pounds. For example if twenty-one inch
pounds is required to steer to the right, not less than
thirteern or more than twenty-three inch ponds should
be required to steer to the left.
If a test stand is available to place a load between
cylinder ports in the same manner as on the vehicle,
a test stand should be used. Add shims to increase
steering efforts in a left turn, subtract shims to increase
steering effort in a right turn.
19. With the drive link installed as described above,
assemble two assembly posts into the housing
as shown Figure 22. These assembly posts can Figure 23
be made by simply cutting the heads off of two Metering Element Installation
bolts similar to the special bolts. 1. Rotor 2. Stator 3. Drive Link

L–20
 STEERING SYSTEM

Figure 24 Figure 25
Manifold Installation Commutator Ring
1. Assembly Posts 2. Manifold 1. Slot 2. Manifold

WARNING: All vane springs must be down in their 28. Install five of the special bolts finger tight. Remove
slots with no part of spring protruding out two assembly posts and assemble the other two
either side of metering element. special bolts finger tight.
22. Install manifold over assembly posts and onto WARNING: Finish tightening the seven special bolts
rotor set, make sure circular slot side of manifold according to the following procedure. Do
is up. With reference Figure 24. not over-tighten as irrepairable damage
will occur.
23. Install commutator ring over assembly posts and
onto manifold make sure slot side is down.
Reference Figure 25.
24. To allow for washer assemble commutator with
counterbore up into commutator ring with slotted
hole in commutator engaging nose of drive link.
Align commutator outside diameter concentric
with inside diameter of commutator ring. With
reference Figure 26.
25. Install rotor seal and seal retainer over rotor set
and down against housing.
26. Apply a small amount of clean grease to washer
and install over pin in the end cover the assembly.
Grease should hold washer to the end cover
assembly.
27. Assemble the end cover assembly with washer
attached, over assembly posts and onto the Figure 26
steering motor. Commutator Installation
1. Commutator Ring 2. Commutator

L–21
 STEERING SYSTEM

Figure 27 Figure 28
Steering Motor End Cover Bolt Tightening Steering Cylinder and Anchor
Sequence 1. Anchor
1. Torque all seven special bolts to 2-3 ft. lbs. in 2. Cylinder Assembly Retaining Nut
sequence as shown in Figure 27. 3. Feed Hose Support Bracket
2. Torque all seven special bolts to 15-19 ft.lbs. in 4. Rod End Assembly
sequence as shown in Figure 27.
NOTE: Rotate input shaft during step 2 to prevent INSTALLATION
binding. Installation of the steering motor assembly follows the
29. Relocate unit in a vice with the input shaft upwards. rmoval procedure in reverse. On installation observe
Cover end of input shaft with cellophane tape, to the following requirements:
protect new seal when it is assembled over sharp Tighten all nuts, bolts and connections to the
edges of input shaft. correct torques, see “Specifications”.
Purge the air from the system by starting the
30. Lubricate and install new seal with lip side first
engine and turning the front wheels from lock-to-
onto input shaft. lock several times. If necessary, add oil to the
31. Assemble new washer, with small end first, onto reservoir. Repeat until steering is normal and the
input shaft and push new washer and new seal oil level in the reservoir remains constant. For
down into upper cover. (A short piece of metal the correct grade and quantity of oil see
tubing. 15/16 in. minimum I.D. x 1-3/16 in. “Specifications.
maximum O.D. or a 7/8 in. deep well socket may HYDROSTATIC STEERING SYSTEM CYLINDER
be used to push these parts into place.) OVERHAUL

32. Assemble retaining ring into upper cover groove. REMOVAL AND DISSASSEMBl Y
Be sure rounded edge of retaining ring is faced 1. Disconnect the two oil feed pipes from the power
inward. cylinders. Cap the pipe ends.
2. Unscrew the ball stud nuts.
33. Assemble new dirt seal into upper cover
counterbore. 3. Remove the power cylinder assembly from the
tractor.
NOTE: If the unit is the be stored, plug the cylinder
4. Loosen the clamp retaining the ball end to the
ports and fill the inlet port with clean oil. Rotate piston rod and unscew the ball end assembly.
input shaft until oil appears at outlet port.
5. Remove the piston rod bush retaining snap ring
34. Plug the port holes to prevent entrance of dirt. and remove the scraper, outer seal, retainer and
This completes asseembly of the unit. inner seal. Figure 28.

L–22
 STEERING SYSTEM

NOTE: The power cylinder assembly cannot be further Operate the Steering several times with the engine
dismantled and if faulty, must be replaced as running to expel all air from the system then re-
a unit. check the oil level.
RE-ASSEMBlY AND INSTALLATION WARNING: All vane springs must be down in their
Re-assembly and installation follows the WARNING: Do not mix oil types any mixture or an
disassembly and removal procedures in reverse. unapproved oil, could deteriorate the
On installation observe the following seals. Enough fluid could then leak to
requirements. create a loss of power steering assists.
Do not allow fluid level to go below fill
Tighten all nuts to the correct torque, see
line on dipstick. Before adding new fluid,
“Specifications”.
completely drain old oil from the system.
Fill the power steering reservoir with the correct It may be necessary also that you flush
grade and quantity of oil, see “specifications”. the system with clean oil.

L–23
 SECTION - 'M'

FRONT AXLE
(Mechanical Steering)

S.NO. CONTENTS PAGE

1. DESCRIPTION M-3

2. ADJUSTMENTS M-3

3. FRONT WHEEL HUB & SPINDLE OVERHAUL (FT-60) M-4

4. FRONT WHEEL BEARING ADJUSTMENT M-5

5. FRONT AXLE & SUPPORT OVERHAUL (FT-60) M-5

6. END-FLOAT ADJUSTMENT PROCEDURE (FT-60) M-6

7. SPECIFICATIONS M-7
FRONT AXLE

M–2
 FRONT AXLE

FRONT AXLE
(Mechanical Steering)

1. DESCRIPTION AND OPERATION The wheel hub is supported on the wheel spindle by
two opposed taper roller bearings. A nut on the spindle
In Farmtrac-60, the front axle consists of an inverted
is used to retain the outer cone and roller assembly.
‘U’ section centre beam that is mounted centrally to
This nut provides means of an adjustment for the
the front axle support by an axle support pin. The front
bearing pre load. .
axle radius rod is not provided in Farmtrac-60. The
front axle is having the benefit of additional seals to 2. ADJUSTMENTS
make it water proof. The axle support pin ends have
A. FRONT TRACK ADJUSTMENT FARMTRAC-60
sleeves shrink fitted onto the two ends. The sleeves
run into support bushes. Both ends have grease The track of front axle for Farmtrac-60 is adjustable
pockets in front, closed by plugs. The inner ends of from 48 in. (122 cm.) to 76 in. (193 cm.). Refer to
the sleeve house ‘O’ rings for grease retention and as Figure 2 and the table given below for the track setting.
a seal against water ingress.
The axle section of Farmtrac 60 consists of an inverted
‘U’ section beam with a tube to accept the wheel spindle
welded to outer end. The centre axle assembly and
the axle sections are machined to provide a series of
holes that will allow the track of axle to be varied in 4
in. (10cm.) from 48 in. (122 cm.) to 72 in. (183 cm.)
The outer end of the axle sections accept the front
wheel spindles. These spindles are located by
bushings in the axle section and at the lower end a
thrust bearing is used to support the vertical thrust of
the spindle on the axle section. The spindle itself acts
as the king pin and hence the king pin inclination
remain constant in relation to the axle beam. The top Figure 1
of each wheel spindle has a key way to locate a Front Axle Extension (left-hand side)
steering arm, which is connected at the other end to 1. Securing Bolts
the relative steering gear steering arm by means of a 2. Centre Beam
drag link. 3. Axle Outer Section

M–3
 FRONT AXLE

number of turns required. Turn the steering half the

Track Setting Axle bolt locations Refer number of turns from either lock to give the mid point
in. (cm.) to Figure 2 of steering movement.
48 (122) A C Position the wheels in the straight ahead position.
52 (132) B D
Install the drag links into the steering gear arms without
56 (142) C E moving the steering gear from its determined mid point.
60 (152) D F
Adjust the length of the drag links to obtain the
64 (163) E G specified toe-in. Mark the steering spindle arms and
68 (173) F H axle section with a chisel to indicate the correct
72* (183) E G position.
76* (193) F H 3. FRONT WHEEL HUB AND SPINDLE
* With wheels reversed. OVERHAUL FARMTRAC-60
The overhauling procedure for front wheel and hub for
NOTE: The front wheel discs are off-set relative to Farmtrac-60 with the following changes.
the center line of the rim. If the front wheels
are reversed on the hubs the track settings
will be increased by approximately 8 in (20
cm).
B. TOE-IN ADJUSTMENT
The toe-in of the front wheels may be adjusted to within
the specified limits by adjusting the length of the drag
links. The correct toe-in is set during the production of
the tractor. The axle sections, and their respective
steering spindle arms are marked to identify the correct
position of the wheels, with the steering in the straight
ahead position.
If the new axle sections or steering spindle arms are
installed it will be necessary to realign the wheels and
Figure 2
mark the components for future reference. When the
Spindle and Hub Assembly
marking has been retained at one side of the tractor 1. Upper Dust Seal 2. Upper Seal Assembly
this mark is used as a reference to find the centre 3. Lower Seal Assembly 4. Spindle Seal
point of the steering. Adjust the length of the drag link 5. Double Lip Hub Seal 6. Bush
of the side to be marked and to bring the wheel toe- 7. Loctite 8. Lower Dust Seal
outer to within specifications. Mark the wheel spindle 9. Spindle Thrust Spacer
arm and axle sections with a chisel accordingly to
indicate the correct position.
1. The steering spindle has been provided with upper
Where it is not possible to use existing markings to and lower grease seals. An additional inner seal
determine the straight ahead position of the steering and thrust spacer are also provided on each
it will be necessary to find the centre point of steering spindle. Figure 2.
gear movement.
2. There is a double lip seal in place of the grease
Disconnect the drag links from the steering gear arms. retainer. An additional cup is provided in the hub
Turn the steering gear from lock to lock counting the in which the seal runs. Replacement of the cup

M–4
 FRONT AXLE

and seal will restore the assembly to 'as new' respective steering spindle arms.
condition.
4. Remove bolts and nuts retaining the axle sections
3. A layer of Locktite 577 is applied to the fillet corner to the centre axle assembly and remove the axle
prior to assembly of the spacer. When re- sections.
assembling, ensure that the spindle and spacer
5. Remove 4 mounting bolts of bracket assembly
surfaces are clean and dry prior to applying
trunnion and slide it out. Remove the front centre
Locktite 577.
axle assembly from the front axle support. The
4. FRONT WHEEL BEARING front axle support pin for Farmtrac-60 is different
ADJUSTMENT from that for Farmtrac-50/55, as discussed below.

1. After cleaning, pack the wheel hub and bearings a) The axle trunnion pins have sleeves shrink
with a suitable grease and install the wheel hub fitted onto both ends. The sleeves run in
on the wheel spindle. support bushes and house “O” rings at their
inner ends for grease retention and sealing
2. Install the front wheel outer bearing cone and as shown in Figure 3. Replacing the sleeve
roller assembly on the front wheel spindle. and bushes will restore the assembly to as
3. Install the hub retaining washer on the wheel ‘new’ position.
spindle, locating the tab with the key way in the b) Two grease nipples are provided, one on the
spindle. front axle support and other on the trunnion,
4. Install the wheel hub retaining nut. as shown in Figure 3. To enable the trunnion
pin to be effectively greased, a screw in plug
5. Tighten the bearing retaining nut to a torque of
is provided in the centre of end covers.
20-30 lbf.ft. (2.8-4.2 kgf.fm.).
Remove the plug before greasing and apply
6. Rotate the hub clockwise 3-6 revolutions. a high pressure grease gun to the grease
7. Further tighten the retaining nut to a torque of nipples until grease is expelled from the plug
45-55 lbf.ft. (6-7.6 kgf.m.). holes Reinstall the plugs after greasing.

8. Loosen the retaining nut by two slots. c) An additional thrust washer has been
provided towards the rear of the trunnion pin.
9. Tighten the nut, if necessary, to the nearest
position to allow insertion of a new retaining split B. INSPECTION AND REPAIR
pin. 1. Inspect the bush bracket assembly trunnion and
NOTE: Ensure that the wheel rotates freely without front axle support bush rear for excessive wear
any drag. or scoring. If necessary, remove the bushing and
inspect the bore in the bracket assembly and
5. FRONT AXLE AND SUPPORT front axle support for damage. Install new
OVERHAUL FARMTRAC-60 bushings using step plate adapter.

A. DISASSEMBLY 2. Examine front axle support pin sleeves for

excessive wear or scoring. If necessary, fit the
1. Remove the radiator as outlined earlier see
new sleeves. As sleeves are shrink fitted on the
“SEPARATING THE TRACTOR”
front axle support pin, heat the sleeves to 140-
2. Support the tractor at the front end with a suitable 150°C to shrink onto the axle pin.
jack or hoist.
3. Examine the front axle support for fractures. To
3. Remove drag link front end assembly retaining replace front axle support, remove the four bolts
nut and disconnect the drag links from their and nuts retaining the support to engine cylinder.

M–5
 FRONT AXLE

Figure 3
Axle Trunnion Pin Assembly
1. Thrust Washer 7. Plug
2. Plug 8. Grease Cavity
3. Grease Nipple 9. Trunnion Pin
4. "O" Ring 10.Bush
5. Sleeve 11. Shim
6. Grease Nipple 12.Thrust Washer

C. ASSEMBLY Remove 4 mounting bolts of bracket assy; trunnion

and slide it out. Add shims to achieve required end
1. Fit front axle support pin in the front axle support,
float of 0.002-0.010 in. Check end float initially at 50
install and tighten four mounting bolt of bracket
hours and then every 300 hours, adjust if required. For
assembly trunnion.
fitting the sleeves on front axle pins, heat the sleeves
2. Check the end float of front axle support pin with to a temperature of 140-150°C. For removal of sleeves,
feeler gauge. Add or remove shims to achieve heat the sleeves with welding torch and prime out by
required end float of 0.002 - 0.010 in. striking at ‘O’ ring grooves.
3. Install the axle extensions and retain them to NOTE: To ensure proper sealing maintenance of end
the centre axle assembly with bolts and nuts float is very essential.
and tighten to the specified torque.
Excessive end float will cause water/mud ingress.
4. Connect the drag links to their respective wheel
spindle arms. Remove plug screw from end covers to allow the grease
pressure to escape, refit plug screws use only
5. Remove the jack or hoist supporting the tractor.
“UNIVAX” ‘A’ Grease.
6. Install the radiator and associated sheet metal.
Greasing every 50 hours/weekly under normal
6. END FLOAT ADJUSTING conditions and daily in paddy operation is required
PROCEDURE FARMTRAC-60 after completion of days job work.

M–6
 FRONT AXLE

7. SPECIFICATIONS
DESCRIPTION FARMTRAC-60

Wheel Track Adjustment in 4 in. (10.06 cm.) steps 48 in. (122 cm.) to 76 in. (193 cm.)

Axle articulation 18°

Camber angle 2°

Castor angle 5°

King Pin inclination 9°

Toe-in 0 to 0.5 in. (0-13 mm)

Truning Radius (with brakes) 2.97 mt.

Truning Radius (without brakes) 3.28 mt.

SHIMS FT-60

Location Front axle support pin

Thickness 0.002 in. 0.005 in. 0.015 in.

(0.05 mm) (0.13 mm) (0.38 mm)

TORQUE SPECIFICATIONS UNITS FARMTRAC-60

Spindle Arm Clamping Bolt lbf.ft 45-50
(kgf.m) (6 - 7)
Axle Section Bolt lbf.ft 130 - 160
(kgf.m) (18 - 22)
Support Pin Bolts lbf.ft 140 - 160
(kgf.m) (19-22)
Radius Rod Foot Bolt lbf.ft -
(kgf.m) -
Radius Rod Ball Cap Bolts lbf.ft -
(kgf.m) -
Front Axle Support To Engine lbf.ft 180 - 220
(kgf.m) (24.9 - 30.4)
Drag Link Ball Pin Nuts lbf.ft 55 - 73
(kgf.m) (7.6 - 10.0)
Drag Link Adjusting Clamp Bolts lbf.ft 8 - 10
(kgf.m) (1.10 - 1.38)
Front Axle trunnion Bracket lbf.ft 55 - 75
(kgf.m) (7.6 - 10.0)

M–7
 SECTION - 'N'

FRONT AXLE
(Hydrostatic Steering)

S.NO. CONTENTS PAGE

1. DESCRIPTION N-3

2. ADJUSTMENTS N-4

3. FRONT WHEEL SPINDLE OVERHAUL (FT-60) N-6

4. FRONT WHEEL BEARING ADJUSTMENT N-8

5. FRONT AXLE & SUPPORT OVERHAUL (FT-60) N-8

6. END-FLOAT ADJUSTMENT PROCEDURE (FT-60) N-9

7. SPECIFICATIONS N - 10
FRONT AXLE

N–2
 FRONT AXLE

FRONT AXLE
(Hydrostatic Steering)

1. DESCRIPTION Outer axle sections, consisting of an inverted ‘U’

section with a tube welded to the outer end to accept
The three part front axle is an inverted ‘U’ section beam
the wheel spindle, are installed into the open ends of
which is mounted centrally to the front axle support.
The support is bolted to the front of the engine cylinder the cenre axle assembly.
block. The method of mounting consists of two support The centre axle assembly and the axle sections are
pins located on the same axis. The forward support machined to provide a series of holes that will allow
pin is attached to the mid-point of the centre axle beam. the track of the axle to be varied in 4 in. (10.2 cm)
The rear support pin is attached to the rear extension steps between 52 in. (122 cm) and 76 in. (193 cm).
of the centre axle and locates in a bushing in the front
axle support. The forward front axle support pin locates With reference to Figure 1.
in a bushing incorporated in a bracket bolted to the The left hand spindle arm is activated by the hydrostatic
front axle support. steering power cylinder and the movement is
The method of mounting restricts the axle assembly transmitted from the left-hand spindle to the right-hand
to a radial movement about the support pin axis. The spindle by means of a track rod, which is adjustable
radial movement is limited by the front axle support. to suit various track settings.

Figure 1
Front Axle Assembly

N–3
 FRONT AXLE

Figure 2 Figure 3
Toe-in Alignment marks Toe-in/Toe-out Measurement
1. Spindle Arm 2. Alignment Marks A. Dimension Between Wheel Rim Marks
3. Outer Axle Section

Toe-in/Toe-out of the front wheels may be adjusted by 4. Maintain the straight ahead position and move
setting the length of the track rod. The correct toe-in the tractor forward so the wheels rotate through
setting is made during production and the spindle arms 180° and the marks on the wheels face the rear
and axle sections are marked to identify the correct at wheel centre height.
position of the front wheels with the steering in the
5. Again measure and note the distance between
straight ahead position, Figure 2. the two marks, call this dimension B.

2. ADJUSTMENTS NOTE: If dimension A is larger, then A-B gives the

toe-out.
TOE-IN MEASUREMENT
If dimension B is larger, then B-A gives the
If the toe-in alignment marks on the spindle arms and
toe-in.
axle sections are not visible, or replacement parts have
been installed” use the following procedure to determine To ensure accurate results, repeat the procedure three
the toe-in setting. times with three different marks equally spaced around
each wheel rim and determine the average dimesnion
1. On flat level ground slowly drive the tractor in a
for toe-in/toe-out. This method minimises any
straight line for at least 10 feet (3 meters). Stop inaccuracy due to wheel rim run-out.
the tractor and ensure the front wheels remain in
the straight ahead position. TOE-IN ADJUSTMENT

2. Mark the inboard rim of each front wheel towards 1. Set the front wheels in the straight ahead position
using the alignment marks on the spindle arms
the front at wheel centre height.
and axle sections. If these marks cannot be used,
3. Measure and note the distance between the two position the wheels as described in the
marks, call this dimesnion a, Figure 3. measurement section.

N–4
 FRONT AXLE

Figure 4 Figure 5
Right-Hand Axle Assembly Left-Hand Axle Assembly
1. Center sleeve 1. Track Rod Clamp Bolt
2. Center sleeve retaining bolts 2. Track Rod Tube
3. Tie Rod end clamp
4. Tie Rod end
5. Arm steering spindle (LH)

2. Slacken the trac rod clamp bolt. Figure 4. FRONT TRACK ADJUSTMENT

3. Remove the right-hand end of the track rod from NOTE: The track of the front axle is adjustable from
the spindle arm. Figure 5. 52 in. (132 cm) to 68 in. (173 cm). To obtain a
front wheel track setting of 72 in. (183 cm)
4. Turn the track rod end to alter the length of the and 76 in. (193 cm). It is necessary to adjust
track until the toe-in marks on both the spindle the axle setting to a track of 64 in. (163 cm)
arms and axle sections are aligned, when the and 68 in (173 cm). and reverse the disc of
right-hand end of the track rod and clamp bolt is the front wheels to give required increase. It
re-installed. is not recommended that the wheels are
reversed in 72 in. (183 cm) axle setting to
NOTE: If the alignment marks cannot be used, adjust obtain 80 in. (203 cm) wheel track as undue
the length of the track rod to obtain the correct strain can be placed on components under
toe-in. high load and shock conditions.

5. Tighten the track-rod clamp bolts to the correct 1. With the tractor on firm level ground, apply the
torque. handbrake and chock the rear wheels. Use a
suitable jack or hoist to raise the front wheels
6. Re-check the toe-in. clear of the ground.

7. If the alignment marks on the spindle arms and 2. Remove the bolts and nuts retaining the axle outer
axle sections are missing, or out of alignment, sections and move the axle sections to the
lightly grind off this area and strike new marks. required positions. Reinstall the axle section

N–5
 FRONT AXLE

Figure 6
Track Width Adjustment Holes

retaining bolts and nuts in the appropriate holes 6. Check and if necessary adjust, the “Toe-in
as indicated in Figure 6 and the table below: Alignment”.
7. Remove the jack and wheel chocks.
Track Setting 3. FRONT WHEEL SPINDLE
Axle bolt locations
in. (cm.) OVERHAUL FARMTRAC-60
52 (132) B D A. DISASSEMBLY
56 (143) C E 1. Use a suitable jack or hoist to support the front
60 (153) D F end of the tractor.
64 (163) E G 2. Remove the six wheel retaining nuts and remove
68 (173) F H the wheel and tyre assembly.
72* (183) E G 3. Unscrew the front hub grease retaining cap.
76* (193) F H 4. Remove the cotter pin locating the castellated
nut retaining the wheel hub.
* With wheels reversed.
5. Remove the nut and the hub retaining washer
3. Tighten the retaining bolts and nuts to the correct along with the hub & outer bearing.
torque, see “Specifications”. 6. Remove the inner bearing cone and roller
4. Position the front wheels straight ahead to align assembly from the wheel spindle. Remove the
the toe-in marks on both the spindle arms and grease retainer.
axle sections. 7. Remove the spindle bolt and nut retaining the
5. Remove the two clamp bolts on the track rod. steering spindle arm to the wheel spindle.
Align the track rod clamps with the nearest 8. Remove the steering spindle arm from the wheel
notches and install the two clamps bolts. spindle. If arm is tight on the spindle use Tool
NOTE: Ensure an equal number ot notches are Nos. EF 0800, EF 0501 and shaft protectors to
exposed at either end of the track rod tube. remove.

N–6
 FRONT AXLE

Figure 7 Figure 8
Installing Front Wheel Spindle Installing Front Wheel Inner Bearing

9. Extract the woodruff key from the spindle and the shroud is to the top, this is indicated on the
remove the dust seal. bearing by the Manufacturer’s reference stamped
10. Extract the wheel spindle and thrust bearing from on this face, and in some instances the word
the axle extension. ‘Top’.
B. INSPECTION AND REPAIR 2. Install the wheel spindle into the axle section
1. Clean components with a suitable solvent and housing, make sure that it rotates in the bushings
air dry. Lightly lubricate machined surfaces. freely.
2. Inspect roller bearing cones, rollers and cups for 3. Install a new wheel spindle dust seal with the
signs of excessive wear, or damage. Replace if groove in the periphery of the seal nearest the
necessary. Remove bearing cups from the wheel base Figure 7.
hub using Tool Nos. EF 0600 and EF 0601. Install 4. Install the woodruff key in the wheel spindle,
new cups in hub, make sure that they are seated
Install the spindle steering arm on the wheel
correctly against the shoulder.
spindle located by the woodruff key. Make sure
3. Inspect spindle bushings in the axle extension the arm to spindle bolt hole in the arm is in line
housing for wear or scoring. If necessary to with the recess in the wheel spindle. Install ‘the
replace remove the axle extension from the tractor
arm to spindle bolt, lock-washer and nut and
by removing the two retaining bolts and their
tighten to the specified torque.
associated nuts and lock washers. Remove the
bushings making sure that the bores are not 5. Install the wheel hub grease retainer on the wheel
damaged and install new bushings in the bore. spindle.

4. Inspect the spindle thrust bearing for correct 6. Install the front wheel inner bearing cone and
operation. Replace if necessary. roller assembly on the front wheel spindle, Figure
5. Inspect the wheel spindle bearing surfaces for 8.
scoring or excessive wear. 7. Pack the wheel hub with a suitable grease. Install
C. ASSEMBLY the wheel hub on the wheel spindle.
1. Pack the wheel spindle thrust bearing with grease 8. Install the front wheel outer bearing cone and
and install on the wheel spindle. Make sure that roller assembly on the front wheel spindle.

N–7
 FRONT AXLE

(c) A layer of Locktite 577 is applied to the fillet

corner prior to assembly of the spacer. When
re-assembling, ensure that the spindle and
spacer surfaces are clean and dry prior to
applying Locktite 577.
4. FRONT WHEEL BEARING
ADJUSTMENT
1. After cleaning, pack the wheel hub and bearings
with a suitable grease and install the wheel hub
on the wheel spindle.
2. Install the front wheel outer bearing cone and
roller assembly on the front wheel spindle.
3. Install the hub retaining washer on the wheel
Figure 9 spindle, locating the tab with the key way in the
Spindle and Hub Assembly spindle.
1. Upper Dust Seal 2. Upper Seal Assembly 4. Install the wheel hub retaining nut.
3. Lower Seal Assembly 4. Spindle Seal
5. Tighten the bearing retaining nut to a torque of
5. Double Lip Hub Seal 6. Bush
20-30 Ibf. ft. (2.8-4.2 kg.fm.).
7. Loctite 8. Lower Dust Seal
9. Spindle Thrust Spacer 6. Rotate the hub clockwise 3-6 revolutions.
7. Further tighten the retaining nut to a torque of
9. Install the hub retaining washer on the wheel
45-55 Ibf. ft. (6-7.6 kg.fm.).
spindle. Locating the tab with the key way in the
spindle. 8. Loosen the retaining nut by two slots.

10. Install the wheel hub retaining nut. 9. Tighten the nut, if necessary, to the nearest
position to allow insertion of a new retaining split
11. Install the wheel and tyre assembly on the hub
pin
and retain with the six nuts.
NOTE: Ensure that the wheel rotates freely without
12. Tighten the slotted retaining nut to a torque of 45
any drag.
to 55 Ibf. ft. (6 to 8 Kgfm.) and then slacken off 2
to 3 slots to give an end float of 0.002 - 0.010 in. 5. FRONT AXLE AND SUPPORT
(0.05 - 0.25 mm.). Install a new cotter pin to locate OVERHAUL FARMTRAC-60
the nut. Install the hub grease retaining cap. A. DISASSEMBLY
13. Remove the jack or hoist from the tractor and 1. Position the front wheels straight ahead.
tighten the wheel retaining nuts. 2. Raise the front of the tractor and position safety
NOTE: stands under the engine to hold the front wheels
(a) The steering spindle has been provided with upper just clear of the ground. Remove the front wheels.
and lower grease seals. An additional inner seal 3. Disconnect the power steering cylinder hose
and thrust spacer are also provided on each assemblies at the connector plate located at right
spindle. Figure 9. hand side and attached to the engine oil sump of
(b) There is a double lip seal in place of the grease the tractor.
retainer. An additional cup is provided in the hub 4. Remove the retaining nuts securing the steering
in which the seal runs. Replacement of the cup cylinder end to the track rod and centre axle
and seal will restore the assembly to ‘as new’ assembly and carefully withdraw the steering
condition. cylinder assembly.

N–8
 FRONT AXLE

Figure 10
Axle Trunnion Pin Assembly
1. Thrust Washer 7. Plug
2. Plug 8. Grease Cavity
3. Grease Nipple 9. Trunnion Pin
4. "O" Ring 10.Bush
5. Sleeve 11. Shim
6. Grease Nipple 12.Thrust Washer

5. Remove 4 mounting bolts of bracket assembly 4. Install the axle extensions and retain them to
trunnion and slide it out. Remove the front centre the centre axle assembly with bolts and nuts
axle assembly from the front axle support. and tighten to the specified torque.
B. INSPECTION AND REPAIR 5. Remove the jack or hoist supporting the tractor.
1. Inspect the bush bracket assembly trunnion and
6. Install the radiator and associated sheet metal.
front axle support bush rear for excessive wear
or scoring. If necessary, remove the bushing and 6. END FLOAT ADJUSTING
inspect the bore in the bracket assembly and PROCEDURE
front axle support for damage. Install new Remove 4 mounting bolts of bracket assy; trunnion
bushings using step plate adapter. and slide it out. Add shims to achieve required end
2. Examine the front axle support for fractures. To float of 0.002-0.010 in. Check end float initially at 50
replace front axle support, remove the four bolts hours and then every 300 hours, adjust if required.
and nuts retaining the support to engine cylinder.
NOTE: To ensure proper sealing maintenance of end
C. ASSEMBLY float is very essential.
1. Fit front axle support pin in the front axle install Excessive end float will cause water/mud ingress.
trunnion and tighten four mounting bolts against
Remove plug screw from end covers to allow the grease
the support.
pressure to escape, refit plug screws use only
2. Before assembly of plug trunnion fill sufficient
“UNIVAX” ‘A’ Grease.
grease in the trunnion pocket for effective
lubrication and plug the same. NOTE: All grease fittings and pivots should be
3. Check the end float of front axle support pin with lubricated daily when operating in wet land
feeler gauge. Add or remove shims to achieve conditions; under normal working conditions
required end float of 0.002 - 0.010 in. grease every 50 hrs/weekly.

N–9
 FRONT AXLE

7. SPECIFICATIONS
DESCRIPTION FARMTRAC-60

Wheel Track Adjustment in 4 in. (10.06 cm.) steps 52 in. (132 cm.) to 76 in. (193 cm.)

Axle articulation 18°

Camber angle 2°

Castor angle 5°

King Pin inclination 9°

Toe-in 0 to 0.5 in. (0-13 mm)

Truning Radius (with brakes) 2.97 mt.

Truning Radius (without brakes) 3.28 mt.

SHIMS FT-60

Location Front axle support pin

Thickness 0.002 in. 0.005 in. 0.015 in.

(0.05 mm) (0.13 mm) (0.38 mm)

TORQUE SPECIFICATIONS UNITS FARMTRAC-60

Spindle Arm Clamping Bolt lbf.ft 45-50
(kgf.m) (6 - 7)
Axle Section Bolt lbf.ft 130 - 160
(kgf.m) (18 - 22)
Support Pin Bolts lbf.ft 140 - 160
(kgf.m) (19-22)
Front Axle Support To Engine lbf.ft 180 - 220
(kgf.m) (24.9 - 30.4)
Drag Link Ball Pin Nuts lbf.ft 55 - 73
(kgf.m) (7.6 - 10.0)
Drag Link Adjusting Clamp Bolts lbf.ft 8 - 10
(kgf.m) (1.10 - 1.38)
Front Axle trunnion Bracket lbf.ft 55 - 75
(kgf.m) (7.6 - 10.0)

N–10
 SECTION - 'O'

FRONT AND REAR WHEELS

S.NO. CONTENTS PAGE

1. DESCRIPTION O-3

2. TYRE REPLACEMENT O-3

3. WHEEL WEIGHTS O-4

4. WATER BALLASTING O-4

5. INFLATION PRESSURE O-5

6. WHEEL TRACK SETTING O-5

FRONT AND REAR WHEELS

O–2
 FRONT AND REAR WHEELS

FRONT AND REAR WHEELS

1. DESCRIPTION 2. Place suitable wooden blocks ‘fore and aft’ the

wheels.
Farmtrac Tractor is provided with pneumatic tyres. The
front tyres are designed to give positive steering and 3. Loosen the mounting nuts of the wheel, which is
maximum life. Walls and shoulders are heavily to be removed, by approximately one turn each.
buttressed to withstand shock and resist damage. The 4. Lift the tractor on a jack near the wheel which is
rear tyres are provided with heavy traction bars, in “V” to be removed so that the wheel clears the
shape, providing maximum, pull at the draw bar. ground.
The front wheel rim and disc are of unit construction 5. Remove the wheel nuts and take off the wheel.
and mounted on the wheel hub with six bolts and nuts.
6. Remove the valve assembly from the valve body
Each wheel hub is supported on the steering knuckle
of the inner tube (for rear wheels only).
with two taper roller bearings.
7. Deflate the inner tube completely.
The rear wheel rim and disc are separate units and
are bolted together with six bolts and nuts. The wheel 8. Press the valve inside through the valve hole in
assembly is mounted on wheel shaft by eight bolts the rim.
and nuts. 9. Loosen both tyre beads from the rim with tyre
levers and heavy mallet.
The front and rear wheels have provision for fixing wheel
weights to get more traction and steering response in 10. With the wheel lying flat, stand on the tyre with
difficult field conditions. the feet about 15 inches apart, opposite the valve,
then force the bead down towards the centre of
2. TYRE REPLACEMENT
the rim.
A. TYRE REMOVAL
11. Insert two tyre levers, about 8 inches apart,
1. Park the tractor safely in the appropriate section between the tyre bead and the wheel rim near
of the workshop. the valve, then pry the bead over the wheel rim.

O–3
 FRONT AND REAR WHEELS

12. Leave one tyre lever in position, then follow around combined weight of 80 kgs. can be mounted on the
the wheel rim with the other tyre lever to remove front wheels.
the remainder of the bead. Remove the inner tube.
B. REAR WHEEL WEIGHTS
13. Turn the wheel over and block the rim up off the
floor. Pry the wheel rim out of the tyre, starting Each rear wheel can be provided with three plate type
with a small section and following around the weights fitted to the rear wheel disc. The plate type
wheel. weights are fitted to the wheel disc with three bolts
and nuts, stacking each other. Kit for one wheel of
B. TYRE INSTALLATION three plate type weights 150 kgs. This provides an
additional weight of 300 kgs. to the rear wheels.
1. Place the wheel rim on the floor in a flat position.
4. WATER BALLASTING
2. Inflate the inner tube until it is barely rounded
out, then install the tube in the tyre. Water may be used as an inexpensive but effective
ballast weight for the tractor wheels to improve traction
3. Coat the inside and outside of the tyre beads
under extreme working conditions in the field.
with a soap solution to protect the bead, then
pry one bead over the edge of rim. In the territories where temperature may fall below
freezing point, calcium chloride should be added to
4. Be sure the valve extends through the rim
the water in proportion of 2 Ibs. (1 kg.) to 5 Liter water
properly, then pry the other bead over the rim.
as protection against freezing.
5. Refit the valve assembly in the Valve body of the
The weight of the tractor at front or rear axle can also
inner tube.
be increased by filling the tyre tubes with water. The
6. Inflate the tyre to the pressure or fill the tyre with procedure is as follows:
water ballast as required.
PROCEDURE
7. Reinstall the wheel to the tractor.
1. Jack up the wheel and turn it until the valve is at
NOTE: It is essential that the tyres of rear wheels the 12 O’clock position. Remove the valve body
should be installed with the traction bars of the inner tube and allow the air to escape.
pointing towards the front of the tractor when
2. Using special water ballasting nozzle with water
seen at the top of the tyre.
under pressure or by flow under gravity from a
3. WHEEL WEIGHTS tank about ten feet above the ground, fill the tyre
inner tube with clean drinkable water.
In order to obtain sufficient traction for maximum,
performance in heavy draft operations and to counter 3. Run the water into the tube releasing the air from
balance heavy implements, cast iron wheel weights time to time by means of the air release valve on
are provided for the front and rear wheels (if required). the adaptor.

A. FRONT WHEEL WEIGHTS 4. When the tube has filled almost completely with
water remove the filling nozzle. Keep tube nozzle
Four holes are provided in the front wheel disc to enable at 11 O’clock position and allow the excess water
front wheel weights to be attached to the wheel. These to drain till it stops dripping from the nozzle.
weights are to be mounted on the inside concave
surface of the disc, using two bolts to retain each 5. Fit the air inflation valve to the tube and inflate
weight. Each weight in 20 kgs. (45 Ibs.) and a quantity the tyre to the normal air pressure as without
of two weights are fitted to each wheel. Thus a total water ballasting.

O–4
 FRONT AND REAR WHEELS

5. INFLATION PRESSURE Disc/Rim Position Track Width

Too high inflation pressure or too low pressure will
reduce tyre life. It is important to use the recommended
inflation pressure.
52 in.
Inflation pressures lower than the minimum
recommended for any particular size are most
undesirable, and if it is necessary to drop the pressure
to extract the tractor from a particularly sticky patch,
the tyre should be re-inflated immediately afterwards.
Under-inflation causes excessive flexing, as a
consequence of which the cord structure in the side- 56 in.
wall area is weakened. The result may be a series of
breaks and separation in the cord fabric, with side
wall cracks.
Over inflation likewise should be avoided. If additional
pressure is required for operation on hard surfaces
(such as haulage work) it should not exceed the 60 in.
maximum pressure recommended for the particular
size of the tyre involved.
The recommended inflation pressure is given bellow:

Pressure
Size Field work Road work 64 in.
Front 6.00-16 20 p.s.i. 32 p.s.i.
2
(1.4 Kg/cm ) (2.29 Kg/cm2)
Rear 13.6-.28 12 p.s.i. 14 p.s.i.
2
(0.8 Kg/cm ) (1.0 Kg/cm2)

NOTE: Inflation pressures should be checked daily 68 in.

to obtain optimum performance from tyres.
This check must be made when the tyres are
cold, i.e, before the tractor is put into
operation.
6. WHEEL TRACK SETTING
The front and rear wheels are of adjustable wheel track 72 in.
for row crop cultivation. For the rear wheels, this has
been made possible by off setting the wheel rim lugs
relative to the wheel rim, and by making the disc of
dish shape.
NOTE: For track setting of Front wheels refer “Front
Axle”. 76 in.
REAR WHEEL TRACKS
Rear wheels track setting are achieved by locating
the lugs of the rim inside or outside the rim discs;
also by offsetting the rims and reversing the discs as
shown in figure 1. When off setting the rim it is vital to
ensure that tyre tread is not reversed.

O–5
 SECTION - 'P'

SEPARATING THE TRACTOR

S.NO. CONTENTS PAGE

1. TO SEPARATE THE ENGINE AND FRONT AXLE FROM THE

TRANSMISSION AND REAR AXLE ASSEMBLY P-3

2. TO RECONNECT THE ENGINE AND FRONT AXLE ASSEMBLY TO THE

TRANSMISSION AND REAR AXLE ASSEMBLY P-4

3. TO SEPARATE THE REAR AXLE ASSEMBLY FROM THE

TRANSMISSION AND ENGINE ASSEMBLY P-4

4. TO RECONNECT THE REAR AXLE ASSEMBLY TO THE

TRANSMISSION AND ENGINE ASSEMBLY P-5

5. TO SEPARATE THE FRONT AXLE ASSEMBLY FROM THE

ENGINE, TRANSMISSION AND REAR AXLE ASSEMBLY P-5

6. TO RECONNECT THE FRONT AXLE ASSEMBLY TO THE ENGINE,

TRANSMISSION AND REAR AXLE ASSEMBLY P-6

7. SPECIFICATIONS P-7
SEPARATING THE TRACTOR

P–2
 SEPARATING THE TRACTOR

SEPARATING THE TRACTOR

1. TO SEPARATE THE ENGINE AND assembly support struts by removing the

FRONT AXLE ASSEMBLY FROM THE respective nuts, bolts and washers.
TRANSMISSION AND REAR AXLE 10. Remove the two nuts, bolts and washers
ASSEMBLY supporting the front end of the fuel tank.

1. Disconnect the battery leads at the battery 11. Remove the two nuts, bolts and washers which
terminals. secure the battery support bracket to the rear
hood panel assembly.
2. Remove the vertical exhaust muffler.
12. Disconnect the lead between the starter (ignition)
3. Disconnect the wiring harness from the two
switch and the starter motor at the motor.
support clips situated under the centre of the
hood assembly. 13. Remove the three bolts and spring washers
securing the starter motor assembly and lift the
4. Remove the screws securing the hood (LH & RH
starter away from the engine.
panels) assembly. Lift the hood clear of the
tractor. 14. Remove the spring clip from the horizontal throttle
rod and disconnect the rod from underneath the
5. Disconnect the hour meter drive cable from the
fuel tank.
drive shaft adaptor and remove the engine oil filter.
15. Disconnect the fuel shut-off cable, at the arm on
6. Remove the six screws retaining the left hand
the fuel injection pump.
front and rear steering gear covers, where
applicable. 16. Disconnect the fuel leak-off tube, by loosening
the screw clamp.
7. Remove the remaining three screws securing the
right-hand front and rear steering gear covers, 17. Disconnect the wiring to the dynamo (at the
where applicable. dynamo terminals)/alternator terminals (where
fitted) the engine oil pressure pipe, the front lights
NOTE: To assist in the removal of the steering gear
(snap connector positioned in front of the radiator)
covers, it is advisable to turn the front wheels
the temperature gauge at the sender assembly
to the full lock position.
terminal and the horn.
8. Remove the two lock nuts securing the left hand
18. Disconnect the wiring at the terminals on the
and right-hand steering drag link, to the respective
regulator.
steering gear arm. Force the tapered pin from
the tapered bore in the arm using a suitable 19. Turn the fuel tap to the ‘off’ position and disconnect
separator. Remove the left hand and right hand the fuel tank to fuel filter pipe at the fuel tap.
radius rod rear securing bolts and caps swing 20. Loosen the hydraulic outlet pipe securing nut at
the radius rod outwards. In case of Farmtrac-60, the pump and slide it back ‘off’ the pump.
radius rods are not present. 21. Remove the four bolts and spring washers
9. Disconnect the centre and left-hand rear hood securing the engine drive hydraulic pump.

P–3
 SEPARATING THE TRACTOR

22. Place a suitable support under the transmission for FT-50/55.

housing, install lifting tackle on the engine, and, 12. Position the tapered pin of the left-hand and right-
using a moveable overhead hoist or floor crane, hand steering drag link in the tapered bore of the
take the weight to the engine. steering gear arm and secure with the lock nut.
23. Insert wooden wedges between the front centre Tighten to the specified torque (see
axle and front axle support. Specifications.)
24. Remove the eight bolts retaining the engine to 13. Reconnect the horizontal throttle control rod, to
the transmission housing and withdraw the the relay cross-shaft situated on the right hand
engine, radiator and front axle as an assembly, side underneath the fuel tank.
moving the assembly forward until clear of the
14. Install the two nuts, bolts and spring washers
transmission housing.
securing the battery support bracket to the rear
2. TO RECONNECT THE ENGINE AND hood panel assembly.
FRONT AXLE ASSEMBLY TO THE 15. Install the two nuts, bolts and washers that
TRANSMISSION AND REAR AXLE support the front end of the fuel tank.
ASSEMBLY 16. Position the left-hand and centre rear hood
1. Move the engine, radiator and front axle assembly assembly support struts and install the respective
towards the transmission housing. Accurate nuts bolts and washers.
alignment of the clutch driven plate is important. 17. Connect the wiring leads to the respective
If removed, the clutch should be correctly aligned terminals on the starter switch.
before installation. 18. Install the hydraulic pump (if removed) and tighten
2. Install the eight bolts retaining the engine the four retaining bolts. Connect the inlet and
assembly to the transmission housing. Two of outlet pipes.
these bolts are located at the bottom of engine 19. Position the right-hand and left-hand steering gear
assembly and secure the engine mounting plate covers and install the retaining screws.
to the transmission housing. Tighten the bolts to 20. Reconnect the battery leads.
the specified torque (See Torque Specifications).
21. Position the hood assembly and install the four
3. Remove the wooden wedges inserted between retaining screws.
the front centre axle and front axle support.
22. Support the wiring harness with the two clips
4. Remove the lifting tackle and supports.
situated under the centre of the hood assembly.
5. Reconnect the wiring to the dynamo, the oil
23. Install the vertical muffler.
pressure pipe and temperature gauge sender, the
24. Turn the fuel tap to the ‘on’ position and bleed
horn and the front lights.
the fuel system at the fuel filters and injection
6. Reconnect the wiring to the regulator terminals.
pump.
7. Reconnect the engine shut-off cable, to the arm
25. Bleed the hydraulic pump.
on the fuel injection pump. Allow approximately
1/4 in. (6.35 mm.) free movement of the cable at 3. TO SEPARATE THE REAR AXLE
the control panel. ASSEMBLY FROM THE
8. Position the starter motor and secure with the TRANSMISSION AND ENGINE
three bolts and spring washers. ASSEMBLY
9. Reconnect the fuel tank to filter pipe at the fuel 1. Disconnect the battery leads from the battery
tank tap. terminals.
10. Reconnect the hour meter drive cable to oil pump 2. Drain the oil from the rear axle centre housing.
drive gear location on the left hand side of the 3. Disconnect the rear light wiring at the connector
engine. underneath the right hand platform.
11. Position the left-hand and right-hand radius rods 4. Release the two brake pedal return springs
and install the securing caps and tighten the bolts connected to the underside of the right-hand
to the specified torque (see torque Specifications), platform.

P–4
 SEPARATING THE TRACTOR

5. Unscrew the three fender to platform screws on 6. Connect the rear light wiring at the connector
both sides of the tractor. located underneath the right-hand platform.
6. Remove the four bolts in each of the left and right- 7. Refill the rear axle centre housing with the correct
hand platform and remove the platforms from the quantity and grade of lubricant (check
rear axle centre housing. specifications).
7. Remove the cotter pin and clevis from the clutch 8. Connect the battery leads and remove the jacks
release arm and disconnect the clutch operating and stands supporting the rear axle and
rod. transmission.
8. Remove the inlet and outlet pipe work for the
5. TO SEPARATE THE FRONT AXLE
engine driven hydraulic pump.
ASSEMBLY FROM THE ENGINE,
9. Install a suitable jack or stands underneath the
engine and transmission assembly and support
TRANSMISSION AND REAR AXLE
the rear axle assembly on a moveable overhead ASSEMBLY
hoist or floor crane. 1. Disconnect the battery leads at the terminals.
10. Remove the ten bolts securing the rear axle to 2. Remove the vertical exhaust muffler.
the transmission and separate the two
3. Disconnect the wiring harness from the two
assemblies by withdrawing the rear axle.
support clips situated under the left-hand hood
4. TO RECONNECT THE REAR AXLE assembly.
ASSEMBLY TO THE TRANSMISSION 4. Remove the four screws securing the hood
AND ENGINE ASSEMBLY assembly. Lift the hood clear of the tractor.
NOTE: When reconnecting the rear axle to the 5. Remove the front grille from the radiator shell.
transmission and engine assembly take care
6. Drain the radiator of coolant.
to align the splines of the transmission output
shaft with those of the drive shaft coupling 7. Disconnect the front lamp wires at the
located on the drive pinion. The P.T.O. coupling connections in front of the radiator. Un clip the
should be in the disengaged position. wire from the radiator, and feed the wire back
between the radiator and the radiator shell.
1. Install a new transmission to rear axle gasket
Disconnect the wires at the horn terminals.
and locate the ten bolts which secure the
transmission to the rear axle housing. Reconnect 8. Loosen the radiator hose clamps and disconnect
the two assemblies and tighten the bolts to the the hoses from the radiator. Loosen the air cleaner
torque specified in the Torque Specifications. hose clamps.
2. Install the pipe work for the engine, drive hydraulic 9. Insert the wooden wedges between the front axle
pump, having check ‘0’ rings and replaced if support to prevent movement between the
damaged. radiator, front axle support, etc., and the front
3. Align the clutch operating rod clevis with the axle assembly. Remove the bolt and nuts
clutch release arm and install the cotter pin and retaining the radiator to the radiator shell support.
clevis pin. 10. Remove the two lock nuts securing the left hand
4. Install the left-and right-hand platform with four and right-hand front drag link ball pin to the
bolts at each side and secure the platform to respective steering gear arm. Force the tapered
fender screws, three at each side. The right-hand pin from the tapered bore in the arm using a
platform should be checked for maximum parking suitable separator.
brake ratchet engagement. 11. Remove the left-hand, right-hand radius rod front
5. Connect the two brake pedal return springs to securing nut and bolt. In case of Farmtrac-60 no
the underside of the right-hand platform. radius rod present.

P–5
 SEPARATING THE TRACTOR

13. Support the engine. Transmission, and rear axle 5. Install the bolts and nuts retaining the radiator
assembly. Use a hoist to support the front axle shell to the radiator shell support.
and radiator assembly.
6. Remove the wooden wedges from between the
14. Remove the four front axle support to engine bolts
front axle and the front axle support.
and nuts. Separate the front axle and radiator as
an assembly from the engine, etc.
7. Connect the radiator hoses to the radiator,
6. TO RECONNECT THE FRONT AXLE position and tighten the hose clamps. Position
ASSEMBLY TO THE ENGINE, and tighten the air cleaner hose clamps.
TRANSMISSION AND REAR AXLE
8. Pass the front lamp wire between the radiator
ASSEMBLY
and the radiator shell. Retain the wire in position
1. Move the front axle and radiator assembly into by the clips at the side of the radiator.
position at the front of the engine, transmission
and rear axle assembly. Install the four front axle 9. Reconnect the front lamp wire to the front lamps
support to engine bolts and nuts and tighten to by means of the connectors. Reconnect the wire
the specified torque. to the horn.

2. Remove the support and hoist from the tractor.

10. Refill the radiator with coolant to the correct level.
3. Position the radius rod forks on the front axle
and install the foot securing bolts and nuts in 11. Install the front axle in to the radiator shell.
each radius rod. Tighten to the specified torque
for FT - 50/55. 12. Position the hood on the tractor and retain with
the four screws, nuts, etc.
4. With the steering gear and the front wheels in
the straight ahead position, and, the toe-in marks 13. Retain the wiring harness under the left hand hood
(where applicable) on the spindle arms and front with the two support clips.
axle aligned, connect the left hand and right-hand
drag link front ball pin into the respective steering 14. Install the vertical exhaust muffler.
arms. Install the ball pin lock nuts and tighten to
the specified torque. 15. Connect the battery leads at the terminals.

P–6
 SEPARATING THE TRACTOR

Engine to Front Transmission Transmission to Rear Axle

Location 1 Transmission Engine Coupling (Top Bolts 2 Nos.)

Location 2 Transmission Engine Coupling (Side Bolts 2 Nos.)
Location 3 Transmission Engine Coupling (Bottom Bolts 2 Nos.)
Location 4 Transmission Engine Coupling (Bottom Bolts 2 Nos.)

TIGHTNING TORQUES

DESCRIPTION UNITS FARMTRAC-60

Location No. 1 - Transmission to Engine lbf.ft 200-240
Coupling - Top Bolts 2 Nos. (kgf.m) (28-33)
Location No. 2 - Transmission to Engine lbf.ft 140-170
Coupling 2 Nos. Bolts (kgf.m) (19-23)
Location No. 3 - Transmission to Engine lbf.ft 117-148
Coupling - 2 Nos. Bolts (kgf.m) (16-20)
Location No. 4 - Transmission to Engine lbf.ft 42-56
Coupling - 2 Nos. Bolts (kgf.m) (6-7.7)
Location No. 5 - Transmission to Rear Axle lbf.ft 105-115
Coupling - 4 Nos. Bolts (kgf.m) (14.5-16)
Location No. 6 - Transmission to Rear Axle lbf.ft 76-84
Coupling - 6 Nos. Bolts (kgf.m) (10.4-11.6)
Radius Rod Cap Nut lbf.ft 44-45
(kgf.m) (6-7.6)
Hydraulic Pump Mounting Bolts lbf.ft 25-35
(kgf.m) (3.4-4.8)
Front Axle Support to Engine lbf.ft 280
(kgf.m) (38)
Drag link Ball Pin Nuts lbf.ft 65
(kgf.m) (9)

P–7
 SECTION - 'Q'

REMOTE CONTROL VALVES

S.NO. CONTENTS PAGE

1. DESCRIPTION AND OPERATION Q-3

2. CONVERSION FROM "DETENTED" TO "NON-DETENTED TYPE Q-6

3. REMOTE CONTROL VALVES-OVERHAUL Q-8

4. PRESSURE TESTING Q - 12

5. TROUBLE SHOOTING Q - 14

6. SPECIFICATIONS Q - 16
REMOTE CONTROL VALVES

Q–2
 REMOTE CONTROL VALVES

REMOTE CONTROL VALVES

1. DESCRIPTION AND OPERATION The Remote Control Valves also feature a “Quick-Drop”
facility which allows the return oil from single acting
The FT-60 Remote control Valves where fitted on
cylinders to return direct to sump thus bypassing any
Farmtrac Tractors for the operation of hydraulic
hydraulic system back pressure. This feature provides
equipment fitted to implements and attachments. The
quicker retraction of gravity return single acting
valves are double spool and all parts are serviceable
cylinders. The “quick-drop” valve maintains an oil flow
except the spools and valve body which are matched
to the tractor hydraulic return circuit while the oil from
in manufacture.
the single acting cylinder is returned to sump.
The valves are fitted on the top of the hydraulic lift
cover in place of the accessory cover and are supplied This “quick-drop” facility is only provided on the inboard
with oil from the tractor hydraulic system. (left-hand) spool of double spool valves. The “quick-
drop” valve replaces the float valve on previous single
After passing through the flow control valve, hydraulic spool valves and the by-pass valve on previous double
oil circulates through the remote control valve prior to
spool valves.
reaching the main tractor hydraulic lift control valve.
Thus the remote control valves are independent of the NOTE: When using the remote control valves with
tractor hydraulic lift system over which they take double acting cyllinders the “quick-drop” valve
priority of flow. However, this flow is regulated by the (or float and by-pass valves on previous control
flow control valve. valves) must be closed.

NOTE: To enable the flow control to control the remote At a specific pressure, just below the main tractor
valve output the tractor hydraulic system hydraulic system relief valve pressure setting, the
quadrant lever must be kept below the point detent regulating valve opens. This pressurised oil acts
at which the flow control override is operated. on the face of the spool detent which is forced back
against the detent spring. With the detent lifted from
The valve assemblies do not contain relief valves as
protection from excessive pressure is provided by the the groove of the valve spool, the spool centring springs
tractor hydraulic system relief valve. return the spool to the neutral position. A small passage
through the detent valve allows the high pressure oil
The Remote Control Valves are fitted with detents which to drain from the detent valve to the oil return circuit
hold the control valve spool in the forward or rearward
and permits the detent valve to re-seat.
position until released by the increase in pressure when
the remote cylinder reaches the end of the stroke. DOUBLE SPOOL CONTROL VALVE

For applications requiring small incremental The double spool control valve contains two spools for
adjustment of the hydraulic cylinder travel, easier the independent control of two hydraulic circuits. The
control can be achieved using a “non-detented” control valve spools are similar in design and operation to the
valve. Refer to Point-2 for the conversion of detented single spool control valve, being of an open centre
valves to “non-detented” type. design.

Q–3
 REMOTE CONTROL VALVES

Figure 1
Double Spool Control Valve - Both Spools in Neutral Position
PRESSURISED OIL TRAPPED OIL RETURN OIL
1. Right Hand Spool 4. 'Quick Drop' Valve
2. Left Hand Spool 5. Check Valves
3. Detent Regulating Valve 6. Float Valve
The valve spools are identified as left and right-hand If the pressure in this oil supply exceeds the setting of
with the remote control valve fitted to the tractor. With the detent regulating valve, the valve opens and
both spools in the neutral position, Figure 1, oil flow pressurised oil is directed to both valve spool detents.
The detents are lifted from the holding positions and
from the tractor hydraulic pump passes through the
the spools return to the neutral positons by the action
open centres of both spools and returns to the tractor of the centring springs.
hydraulic system without restriction. The left-hand If both valve spools are operated simultaneously,
spool (shown as the lower spool on Figure 1) features hydraulic oil will flow initially to the circuit with the
a quick drop valve for the control of single acting least pressure required to operate. The pressure will
cylinders. only increase and release the detents when both
The operation of this valve spool and the quick drop cylinders have reached the limit of their travel.
valve is identical to that of the single spool control The right-hand spool (shown as the upper spool in
Figure 1) features a “Float” Valve in place of the “quick-
valve. The left-hand spools Lift and Drop Ports are
drop” valve. Opening the “float” valve with the control
marked ‘A’ and ‘B’ respectively. The single detent spool in the lower position permits an implement,
regulating valve senses the pressure in the common controlled by a double acting cylinder, to float or follow
oil supply to both spool valves. the ground contour.

Q–4
 REMOTE CONTROL VALVES

Figure 2
Double Spool Control Valve - Right Hand Spool in Lower Position with Float Valve Slightly Open
PRESSURISED OIL TRAPPED OIL RETURN OIL
1. Right Hand Spool 4. 'Quick Drop' Valve
2. Left Hand Spool 5. Check Valves
3. Detent Regulating Valve 6. Float Valve
Implement down pressure may be varied by adjustment the return circuit by the valve spool land.
of the float valve between the fully open and fully closed Therefore the cylinder connected to the right-hand
positons. spool will be exposed to the return circuit back pressure.
If one single acting cylinder is to be operated by the This back pressure may cause slow retraction if the
double spool control valve, control valve, it is preferable cylinder is lightly loaded.
to connect it to the left-hand spool with the quick drop
Moving the spool outwards to the raise position directs
facility.
pump oil through the check valve to the lift port ‘C’.
If two single acting cylinders are connected to the
For normal operation of double acting cylinders the
double spool control valve, one must be connected to
float valve must be screwed in. Opening the float valve
the right-hand spool lift port ‘C’, whilst the drop port
and placing the control spool in the lower position
‘D’ is plugged. The float valve must be opened to allow
connects both lift port ‘C’ and drop port ‘D’ to the return
the pump flow to circulate to the return circuit with the
circuit, Figure 2. The piston of the double acting cylinder
spool in the lower position.
can move freely and transfer oil from one end of the
Return oil from the single acting cylinder is directed to cylinder to the other.

Q–5
 REMOTE CONTROL VALVES

Hose Installation
Right-Hand Spool of Left-Hand Spool of
Cylinder Float 'Quick-Drop
Double-Spool Valves Double-Spool Valves
Application(s) Valve Valve
Lift Port Drop Port Lift Port Drop Port
Two Double-Acting Closed Closed Lift-Hose Drop Hose Lift-Hose Drop Hose
One Double-Acting
Closed Open Lift-Hose Drop Hose Lift-Hose Plug
One Single-Acting
Two Single-Acting Open Open Lift-Hose Plug Lift-Hose Plug
Open = Screwed fully out Closed = Screwed fully in

Figure 3 Figure 4
Remote Control Valve Double Spool Remote Control Valve Installation
1. By-pass Valve 4. Lift Port 1. Levers
2. Float Valve 5. Right-Hand Spool 2. Drop Port
3. Drop Port 6. Left-Hand Spool 3. Lift Port

The oil flow from the pump passes across the drop 2. REMOTE CONTROL VALVES
port ‘D’ to the return circuit. Screwing the float valve
in, restricts the oil flow around the end of the float REMOVAL
valve and pressurises the oil at drop port ‘D’.
1. Clean the area around the remote control valve
This action causes implement down pressure which housing, Figure 4, and disconnect the remote
can be increased by screwing the float valve in further hoses from the control valve.
to cause a greater restriction to the pump flow.

NOTE: When a quick-drop remote control valve is 2. Remove the four valve retaining bolts and lift the
installed, the valve marked thus * has the valve from the tractor. Remove the valve-to-cover
quick-drop feature. Figure 3. ‘O’ ring seals.

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 REMOTE CONTROL VALVES

Figure 5 Figure 6
Spool Detent Installation Spool Detent Components
1. Detent Retainer 1. Detent Spring
2. Retaining Snap Ring 2. Detent Retainer
3. Right Hand Spool Detent 3. Retaining Snap Ring
4. Detent
5. Detent Ball
6. Remote Control Valve Body

REMOVAL OF DETENTS NOTE: Ensure that the ‘O’ ring seals are in good
1. Remove the detent retaining snap ring from the condition and correctly seated.
base of the remote control valve, Figure 5, and 5. Refer to Figure 4 for the correct installation of
withdraw the retainer, spring and detent, Figure the FT-60 remote control valve levers. Ensure the
6.
2. Discard the detent ball and spring. Install the
detent and retainer only and secure with the snap
ring.
INSTALLATION
1. Thoroughly clean the underside of the remote
control valve and the valve mounting surface.
2. Install new lubricated ‘O’ ring seals in the correct
locations, Figure 7.
WARNING: Use grease sparingly as excess grease
will displace the ‘O’ ring seals as the
retaining bolts are tightened.
3. Position the control valve on the mounting
surface, position the lever brakets and spindles,
install the retaining bolts and tighten to the
specified torque, see “Specifications”, Figure 7
4. Re-connect the remote hoses to the control valve. Valve-to-Cover 'O' Ring Seal Installation

Q–7
 REMOTE CONTROL VALVES

Figure 8 Figure 9
Remote Control Valve Linkage Spool Detent Components
1. Control Levers 1. Detent Spring
2. Remote Control Valve 2. Detent Retainer
3. Retaining Snap Ring
4. Detent
5. Detent Ball
6. Remote Control Valve Body

operator is aware that the Outer lever (right-hand) 1. Extract the spool retaining snap ring, Figure 10,
control lever operates the right hand spool and and remove the centring spring cap.
the Inner lever (left-hand) lever operates the left- Disassemble the control handles from the spools.
hand spool.
6. Refer to Figure 8 for the correct Installation of
Remote Control Valve Linkage. Ensure the correct
operation of the control levers.
3. REMOTE CONTROL VALVES
OVERHAUL
REMOVAL
1. Clean the area around the remote control valve
housing, Figure 4, and disconnect the remote
hoses from the control valve.
2. Remove the four valve retaining bolts and lift the
valve from the tractor. Remove the valve-to-cover
‘O’ ring.
DETENT ASSEMBLY Figure 10
Spool Installation
1. Remove the detent retaining snap ring from the
1. Left-Hand Spool Spring Cap
base of the remote control valve and withdraw
2. Retaining Snap Ring
the retainer, spring detent and ball, Figure 9.
3. Control Valve Body
VALVE SPOOL 4. Right-Hand Spool Spring Cap

Q–8
 REMOTE CONTROL VALVES

Figure 11 Figure 12
Withdrawing Control Valve Spool Control Valve Spool Components
1. Spool Centering Spring
2. Washer
3. Retaining Bolt
4. Retaining Snap Ring
5. Spring Cap
6. Spring Cups
7. Valve Spool
8. Control Valve Body

2. Gently tap the spool on the handle end and

withdraw the spool from the centring spring end,
Figure 11.

NOTE: For double spool valves, identify the spools

relative to the bores as the spools and bores
are matched fit.

3. Remove the centring spring retaining screw and

separate the washers, spring cups and spring,
Figure 12.

Figure 13
CHECK VALVE Check Valve Components
1. Control Valve Body
2. Check Valve Spring
3. Retaining Set Screw
1. Remove the check valve retaining set screw and
4. Check Valve Plug
withdraw the plug, spring and ball, Figure 13. 5. Check Valve Ball

Q–9
 REMOTE CONTROL VALVES

Figure 14 Figure 15
"Quick-Drop" Valve Components Detent Regulating Valve Components
1. Control Valve Body 1. Detent Regulating Valve Sleeve
2. "Quick-Drop" Valve Retaining Sleeve 2. Poppet 5. Spring
3. "Quick-Drop" Valve Spot 3. Set Screw 6. Ball
4. Retaining Plug 7. Control Valve Body

"QUICK-DROP" VALVE

1. Unscrew the “quick drop” valve retaining sleeve

from the remote control valve Figure 14.

NOTE: The “quick drop” valve retaining sleevs has a

left-hand thread.

2. Separate the “qucik drop” valve spool from the

retaining sleeve.

DETENT REGULATING VALVE

1. Unscrew the plug retaining the detent regulating

valve and withdraw the valve assembly from the Figure 16
remote control valve body. Float Valve
1. Control Valve Body
NOTE: The detent regulating valve is not screwed into
2. Float Valve
the body. If difficulty in removing the valve is
experienced use stiff wire or hexagon key to FLOAT VALVE (DOUBLE SPOOL VALVES)
‘hook’ the valve out.
1. Use a pin punch to remove the retaining roll pin.
2. Remove the set screw from the end of the
regulating valve and separate the spring, poppet, 2. Unscrew the float valve assembly from the
and ball from the valve sleeve, Figure 15. remote control valve body, Figure 16.

Q–10
 REMOTE CONTROL VALVES

INSPECTION AND REPAIR screw. As an initial setting screw the set screw
in until flush with the end of the valve sleeve. Then
VALVE SPOOL AND VALVE BODY
screw in a further 4 turns. The final adjustment is
1. Inspect the spool and spool bore for pitting and outlined in “Pressure Testing”.
deep scoring. If inspection reveals defects, a new
DETENT ASSEMBLY
control valve assembly must be installed. Check
that the spool moves freely in the spool bore. 1. Inspect the detent components for wear or
2. Check the centring spring, spring caps and damage. Check the small hole in the detent is
washers for cracks and distortion. If the centring free from obstruction.
spring fails to return the spool to the neutral FLOAT VALVE (DOUBLE SPOOL VALVES)
position install a new spring.
1. Install a new float valve assembly if this item is
3. Remove the control handle/lever pivot from the suspect.
rear of the control valve and install new ‘O’ ring
RE-ASSEMBLY
seals.
VALVE SPOOL
CHECK VALVE
1. Install a new ‘O’ ring seal in the valve spool bore
1. Inspect the check valve ball and ball seat for
at the opposite end to the centring spring
pitting and deep scoring. Install a new ball if
location.
necessary. Damage to the ball seat necessitates
the installation of a new remote control valve 2. Lubricate the valve spool and insert into the valve
assembly. body from the centring spring end. Be very careful
not to damage the ‘O’ ring seal.
2. Inspect the plug and spring for wear and replace
if necessary. Install a new ‘O’ ring seal on the 3. Push the spool beyond the ‘O’ ring seal location
plug. at the centring spring end and install the second
NOTE: A suspect check valve may be tested by using ‘O’ ring seal. Slide the spool back to a central
the remote control valve to operate a loaded position.
single-acting cylinder (e.g. a tipping trailer). 4. Re-assembly the spool centring spring, spring
Raise the load, move the remote control lever caps and washer to the valve spool. Tighten the
to neutral and stop the tractor engine. When spring retaining screw to the specified torque.
the control lever is now moved to the raise
5. Install the centring spring cap and secure with
position the load must not drop.
the snap ring.
1. Replace the ‘O’ ring seals on the “quick drop”
CHECK VALVE
valve spool.
1. Install the check valve ball, spring and plug into
DETENT REGULATING VALVE
the check valve bore of the control valve body.
1. Inspect the valve ball and ball seat in the valve
2. Install the retaining set screw and adjust so the
sleeve for pitting and scoring. Replace the
end of the set screw is flush with the valve body.
components if damaged, replacement of the valve
sleeve necessitates the replacement of the detent "QUICK-DROP" VALVE
regulating valve assembly.
1. Install the quick drop valve assembly into the
2. Install a new ‘O’ ring seal on the valve sleeve. control valve body and tighten the left-hand thread
Install the valve ball, poppet and spring into the retainer to the specified torque, see
valve sleeve and retain in position with the set “Specifications” .

Q–11
 REMOTE CONTROL VALVES

DETENT REGULATING VALVE

1. Install the detent regulating valve into the bore in

the rear of the control valve body.

2. If the detent regulating valve has been

disassembled, re-set according to the procedure
(pressure testing).

DETENT ASSEMBLY

1. Coat the detent ball with light grease and position

on the detent. Install the detent into the bore in
the base of the control valve.
Figure 17
2. Install the spring and retainer, securing with the Pressure Testing Detent Regulating Valve
snap ring.

NOTE: If the valve is to be converted to a non-

detented type, delete the detent ball and
spring. 4. Reconnect the remote hoses to the control valve.

FLOAT VALVE (DOUBLE SPOOL VALVES) NOTE: Ensure the ‘O’ ring seals are sound and
squarely seated.
1. Install the float valve into the bore at the front left-
hand side of the control valve body. 5. Ensure the correct operation of the control linkage.

IMPORTANT: Do not exceed the specified torque 4. PRESSURE TESTING & TROUBLE
when screwing the float valve to the in SHOOTING
position.
PRESSURE TESTING DETENT REGULATING VALVE
2. Re-install the retaining roll pin.
After servicing the detent regulating valve or if the control
INSTAllATION levers and spool are returning to neutral prematurely,
the detent regulating valve should be tested as follows:
1. Thoroughly clean the underside of the remote
control valve and the valve mounting surface. 1. Remove the dust cap from the “lift” coupling and
install hose connector. For a double spool control
2. Install new lightly lubricated ‘O’ ring seals in the
valve either “lift” coupling can be utilised.
correct locations.
2. Figure 17 Shows Pressure Testing Detent
3. Position the control valve on the mounting surface
Regulating Valve.
with the lever bracket and spindles then install
the retaining bolts and tighten to the specified 3. Remove the rear axle oil filler opening and secure
torque. the hose in the filler opening. Open the load valve.

Q–12
 REMOTE CONTROL VALVES

TEST PROCEDURE 6. If the pressure reading is not within the specified

1. Ensure the load valve is fully open. range, remove the screwed plug from the rear of
the remote control valve body and withdraw the
2. Start the tractor engine and set the engine speed
detent regulating valve.
to 1700 rev/min.

3. Warm the hydraulic oil to 50°C (122°F) by

operating the tractor hydraulic system. 7. Hold the detent valve assembly in a suitable fixture
then turn the adjusting set screw in, to increase
4. Move the remote control lever, of the spool to
the pressure setting, or out, to reduce the
which the test equipment is attached, to the raise
pressure setting.
position.

5. Gradually close the load valve and observe the

pressure gauge reading which should steadily 8. Re-assemble the detent regulating valve and re-
rise until the detent regulating valve opens, at check the pressure setting.
which point the needle will fluctuate and the
handle return to the neutral position. Note the
gauge reading immediately prior to the needle NOTE: The tractor hydraulic system relief valve should
fluctuation and compare with the specified also be checked to ensure the pressure setting
pressure. is above the detent regulating valve setting.

Q–13
 REMOTE CONTROL VALVES

5. TROUBLE SHOOTING
PROBLEM POSSIBLE CAUSES REMEDY
Loss of pressure at all ports 1. Tractor hydraulic system pressure 1. Check Tractor hydraulic system
low pressure
2. Damaged or worn spool bores 2. Replace remote control valve
assembly
3. Porous casting 3. Replace remote control valve
assembly
4. Leaking ‘O’ ring seal between valve 4. Replace ‘O’ ring seals
assembly and top cover
5. Detent regulating valve incorrectly 5. Adjust detent regulating valve
set

Slow Operation 1. Flow control in SLOW 1. Adjust flow control

2. Low oil level 2. Check oil level
3. Hydraulic System Suction Filter 3. Check and renew
4. Fault in tractor hydraulic pump 4. Check tractor hydraulic system

Loss of pressure at drop 1. Float valve or quick drop valve 1. Screw in float or quick drop valves
port only turned out in single acting position
2. Float valve or quick drop valve ‘O’ 2. Replace- ‘O’ ring seals
ring seals leaking
3. Worn spool or bores 3. Replace remote control valve
assembly
4. Porous casting 4. Replace remote control valve
assembly

Loss of pressure at at lift 1. Worn spool or bores 1. Replace remote control valve
port only assembly
2. Porous casting 2. Replace remote control valve
assembly

Cylinder retracts with 1. Worn spool or bore 1. Replace remote control valve
control valve in neutral 2. Equipment specification requires 2. Install a proprietary external lock
zero spool leakage valve in the cylinder hose.

Q–14
 REMOTE CONTROL VALVES

PROBLEM POSSIBLE CAUSES REMEDY

Initial hesitation when 1. Check valve ball worn or scored 1. Replace check valve ball
resuming lift cycle 2. Check valve ball seat worn 2. Replace remote control valve
assembly
3. Check valve spring distorted 3. Replace check valve spring

Tractor hydraulic system 1. Centring springs damaged or 1. Overhaul centring springs

system relief valve blows at retaining screw loosened
end of cycle (Detented 2. Detent regulating valve set too high 2. Adjust
type)
3. Detent jammed 3. Overhaul detent
4. Valve spool seized 4. a) Check for misplaced or
oversize ‘O’ rings
b) Check retaing bolt torques
c) Replace remote control valve.

Spool returns to neutral 1. Detent regulating valve set too low 1. Adjust
before cylinder reaches 2. Detent regulating valve ball or seat 2. Replace ball or regulating valve
end of travel 3. Spool worn at detent location 3. Replace remote control valve

Q–15
 REMOTE CONTROL VALVES

6. SPECIFICATIONS
DESCRIPTION FARMTRAC-60

Detent Regulating Valve Pressure 2000 - 2100 lbf/in.2

(140 - 147 kgf/cm2)

Spool Valve Leakage With the spool in neutral and the hydraulic oil at
a temperature of 50°C (122°F) and pressure of
1000 lbf/in2 (120 Kgf/cm2) the leakage past the
spool must not exceed:

15 c.c. per minute at the Lift Port

80 c.c. per minute at the Drop Port

TORQUE SPECIFICATIONS UNITS FARMTRAC-60

Spool Centring Spring Retaining Bolt lbf.ft 5-8
(kgf.m) (0.7 - 1.1)

Quick Drop Valve (Left Hand Thread) lbf.ft 7-9

(kgf.m) (1.0 - 1.2)

Float Valve - Maximum "in" Position Torque lbf.ft 4

(kgf.m) (0.5)

Remote Control Valve Retaining Bolts lbf.ft 35 - 47

(kgf.m) (4.8 - 6.5)

Control Lever Retaining Nut lbf.ft 15 - 21

(kgf.m) (3.1 - 2.9)

SPECIAL TOOLS

TOOL NO. DESCRIPTION

EF - 1400 Pressure Gauge
EF - 1401 Tee Adaptor including pipe & connections

Q–16