New Holland FORD 555A User manual

FORD
Service Manual
Tractor-Loader-Backhoe
555A, 5558 and 655A
Part 1 - Engine Systems
Part 2 - Fuel Systems
Part 3 - Electrical Systems
Part 4 - Clutches
Part 5 - Transmission Systems
Part 6 - Cab, Heating and Air Conditioning
Vol. 1
40055540A , ·
FORO
N:WHOLLAI\D
I
Reprinted I

FOREWORD
This manual provides information for the proper servicing and overhaul of the Ford Model 555A
& Band 655A Tractor-Loader-Backhoe and is an essential publication for all service personnel car-
rying out repairs and maintenance procedures.
The model 555Adesignates three cylinder engine units produced from January 1984through June
1985. The model 555B designates units produced from July 1985and later.
The model 655A designates four cylinder engine units produced from June 1985 and later.
Special service instructions are identified by tractor model number or applicable production date
code throughout the text.
The Manual isdivided into twelve PARTS, each sub-divided into Chapters. EachChapter contains
information on generaloperating principles, detailed inspection and overhaul and, where applicable,
trouble shooting, special tools and specifications.
The material contained in this Manual was correct at the time of printing, but Ford policy is one
of continuous improvement and the right to change prices, specifications, equipment or design
at anytime without notice is reserved. All data in this Manual is subject to production variations,
so overall dimensions and weights should be considered as approximate only and the illustrations
do not necessarily depict the unit to standard build specification.
Ford New Holland, Inc.
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CONTENTS
Part 1- Engine Systems . . . . . . . . . . . . . . . . . . Vol. 1
Part 2 - Fuel Systems . . . . . . . . . . . . . . . . . . . . . Vol. 1
Part 3 - Electrical Systems . . . . . . . . . . . . . . . . Vol. 1
Part 4 - Clutches . . . . . . . . . . . . . . . . . . . . . . . . . Vol. 1
Part 5 - Transmission Systems . . . . . . . . . . . . . Vol. 1
Part 6 - Cab, Heating and Air Conditioning... . Vol. 1
Part 7- Rear Axle & Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vol. 2
Part 8- Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vol. 2
Part 9 - Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vol. 2
Part 1O- Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vol. 2
Part 11- Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vol. 2
Part 12- Separating the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vol. 2
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PRODUCTION DATE CODES AND
SERIAL NUMBERS
A vehicle identification plate is located on the steering console on the left hand side. Whenever
effecting repairor overhaulof the FordTractor, the relevantinformation should benoted and used
when referring to service bulletins or ordering parts.
This plate is stamped with the following information:
• TRACTOR NUMBER - Serial number prefixed by • ENGINE- Engine production date code.
the letter 'A', 'B' or 'C'.
• MODEL - Production model code. • TRANSMISSION - Transmissionproduction date
code.
• UNIT - Production unit date code.
PRINTEDIN U.S.A.
• REARAXLE - Rearaxle production date code.
iii
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iv
MODEL NUMBER -CODE
H.P. Series Chassis Series Fuel Power Transmission
Type (Prod. Stage) Type Take-Off Type
I I I I
4x4
Ind. Design Stage No- Torque
H.P. Flat Deck 1 thru 7 Diesel PTO Converter
DF711F
KEYTO PRODUCTION DATE CODES
First Number First Letter Second Number Second Letter
YEAR MONTH DAY OF MONTH PRODUCTION SHIFT
4 - 1984 A-Jan. H-Aug. 01-32 A-Midnight
5 - 1985 8-Feb. J-Sept. 8-Day
6 - 1986 C-March K-Oct. C-Afternoon
7 - 1987 D-April L-Nov.
8 - 1988 E-May M-Dec.
9 - 1989 F-June
0 - 1990 G-July
Exampleof Production Unit Date Code 4 C 0 3 B
'-....,---'
\
Year of Final
Assembly (19841 Month of Year (Marchi Day of Month (Third) Shift Period
(Day)
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A SAFETY PRECAUTIONS A
Practically all servicework involvesthe needto drive the tractor. The Operator's Manual, supplied with each tractor,
contains detailed safety precautions relating to driving, operating and servicing that tractor. These precautions are
as applicable to the service technician as they are to the operator, and should be read, understood and practiced
by all personnel.
Prior to undertaking any maintenance, repair, overhaul, dismantling or re-assembly operations, whether within a
workshop facility or out "in the field," consideration should be given to factors that may have an effect upon safety,
not only upon the mechanic carrying out the work, but also upon bystanders.
PERSONAL CONSIDERATIONS
• The wrong clothes or carelessnessin dress can cause accidents. Check to see that you are suitably clothed.
Some jobs require special protective equipment.
• Skin Protection
Used engine oil may cause skin cancer. Follow work practices that minimize the amount of skin exposed and
the length of time used oil remains on the skin.
• Eye Protection
The smallest eyeinjury may causeloss of vision. Injury can be avoided by wearing eyeprotection when engaged
in chiselling, grinding, discing, welding, painting, etc.
• Breathing Protection
Fumes,dust and paint sprayareunpleasantand harmful. Thesecan beavoidedby wearing respiratoryprotection.
• Hearing Protection
Loud noisemay damageyour hearing and the greater the exposure the worse the damage. If you feel the noise
is excessive, wear ear protection.
• Hand Protection
It is advisable to use a protective cream before work to prevent irritation and skin contamination. After work
clean your hands with soap and water. Solvents such as white spirit, paraffin, etc., may harm the skin.
• Foot Protection
Substantial or protective footwear with reinforcedtoe-capswill protect your feet from falling objects. Additionally,
oil-resistant soles will help to avoid slipping.
• Special Clothing
For certain wor~ it may be necessary to wear flame or acid-resistant clothing.
• Avoid injury through incorrect handling of components. Make sure you are capable of lifting the object. If in
doubt get help.
EQUIPMENT CONSIDERATIONS
• Machine Guards
Before using any machine, be sure the machine guards are in position and serviceable. These guards not only
prevent body and clothing from coming in contact with the moving parts of the machine, but also ward off
objects that might fly off the machine and cause injury. •
• Lifting Appliances
Always ensure that lifting equipment, such as chains, slings, lifting brackets, hooks and eyes are thoroughly
checked before use. If in doubt, select stronger equipment than is necessary.
Never stand under a suspended load or a raised implement.
• Compressed Air
The pressurefrom a compressed air line is often as high as 100 psi (6.9 bar) 7 (kgf/cm 2). It is perfectly safe
if used correctly. Any misuse may cause injury.
PRINTED IN U.S.A. V
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Never use compressed air to blow dust, filing, dirt, etc., away from your work area unless the correct type of
nozzle is fitted.
Compressed air is not a cleaning agent, it will only move dust, etc., from one place to another. Look around
before using an air hose as bystanders may get grit into their eyes, ears or skin.
• Hand Tools
Many cuts, abrasions and injuries are caused by defective tools. Never use the wrong tool for the job, as this
generally leads either to some injury, or to a poor job.
Never use
- A hammer with a loose head or split handle.
- Spanners or wrenches with splayed or worn jaws.
- Spanners or files as hammers; or drills, clevis pins or bolts as punches.
For removing or replacing hardened pins use a copper or brass drift rather than a hammer.
For dismantling, overhaul and assembly of major and sub components, always use the Special Service Tools
recommended. They will reduce effort, labor and repair cost.
Always keep tools clean and in good working order.
• Electricity
Electricity has become so familiar in day to day usage, that it s potentially dangerous properties are often over-
looked. Misuse of electrical equipment can endanger life.
Before using any electrical equipment - particularly portable applicances - make a visual check to make sure
that the cable is not worn or frayed and that the plugs, sockets, etc., are intact. Make sure you know where
the nearest isolating switch for your equipment is located.
GENERAL CONSIDERATIONS
• Solvents
Use only cleaning fluids and solvents that are known to be safe. Certain types of fluids can cause damage to
components such asseals,etc., and can causeskin irritation. Useonly solvents that are suitable for the cleaning
of components and parts, and that do not affect the personal safety of the user.
• Housekeeping
Many injuries result from tripping or slipping over, or on, objects or material left lying around by a carelessworker.
Prevent these accidents from occurring. If you notice a hazard, don't ignore it - remove it.
A clean, hazard-free place of work improves the surroundings and daily environment for everybody.
• Fire
Fire has no respect for persons or property. The destruction that a fire can cause is not always fully realized.
Everyone must be constantly on guard.
- Extinguish matches/cigars/cigarettes, etc., before throwing them away.
- Work cleanly, disposing of waste material into proper containers.
Locate the fire extinguishers and find out how to operate them.
Do not panic - warn those near and raise the alarm.
Do not allow or use an open flame near the tractor fuel tank, battery or component parts.
• First Aid
vi
In the type of work that mechanics are engaged in, dirt, grease, fine dusts, etc., all settle upon the skin and
clothing. If a cut, abrasion or burn is disregarded it may be found that a septic condition has formed within
a short time. What appearsat first to be trivial could become painful and injurious. It only takes a few minutes
to have a fresh cut dressed, but it will take longer if you neglect it. Make sure you know where the First Aid
box is located.
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• Cleanliness
Cleanlinessof the tractor hydraulic system is essential for optimum performance. When carrying out service
and repairs plug all hose ends and component connections to prevent dirt entry.
Cleanthe exterior of all components before carrying out any form of repair. Dirt and abrasive dust can reduce
the efficiency and working life of a component and lead to costly replacement. Useof a high pressurewasher
or steam cleaner is recommended.
OPERATIONAL CONSIDERATIONS
• Stop the engine, if at all possible, before performing any service.
• Placea warning sign on tractors which, due to service or overhaul, would be dangerous to start. Disconnect
the battery leads if leaving such a unit unattended.
• Do not attempt to start the enginewhile standing besidethe tractor or attempt to by-passthe neutralstart switch.
• Avoid prolonged running of the engine in a closed building or in an areawith inadequate ventilation as exhaust
fumes are highly toxic.
• Always turn the radiator capto the first stop to allow pressureinthe systemto dissipatewhen the coolant ishot.
• Neverwork beneath a tractor which is on soft ground. Always take the unit to an areawhich hasa hard working
surface - concrete for preference.
• If it is found necessaryto raisethe tractor for easeof servicing or repair, make surethat safe and stable supports
are installed beneath axle housings, casings, etc., before commencing work.
• Certainrepairor overhaulproceduresmay necessitate"separating the tractor," eitherat the engine/front transmis-
sion or front transmission/rear transmission locations. Theseoperations aresimplified by the useof the Tractor
Splitting Kit/Stands. Should this equipment not be available, then every consideration must be given to stabili-
ty, balance and weight of the components, especially if a cab is installed.
• Use footsteps or working platforms when servicing those areas of a tractor that are not within easy reach.
• Before looseningany hosesor tubes connecting implements to remote control valves, etc., switch off the engine,
remove all pressure in the lines by operating leversseveraltimes. This will remove the danger of personal injury
by oil pressure.
• Prior to pressuretesting, make sure all hoses and connectors not only of the tractor, but also those of the test
equipment, arein good condition and tightly sealed. Pressurereadingsmust betaken with the gaugesspecified.
The correct procedure should be rigidly observed to prevent damage to the system or the equipment, and to
eliminate the possibility of personal injury.
• When equipment or implements are required to be attached to the hydraulic linkage, either for testing purposes
or for transportation, then "position control" should be used.
• Always lower equipment to the ground when leaving the tractor.
• If high lift attachments are installed on a tractor beware of overhead power, electric or telephone cables when
traveling. Drop attachment near to ground level to increase stability and minimize risks.
• Do not park or attempt to service a tractor on an incline. If unavoidable, take extra care and block all wheels.
• Escaping hydraulic/diesel fluid under pressure can penetrate the skin causing serious injury. Do not use your
hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Stop the engine and relieve
the pressurebefore connecting or disconnecting oil lines. Tighten all connections before starting the engine or
pressurizingthe lines. If fluid is injected into the skin, obtain medicalattention immediately or gangrenemay result.
PRINTED IN U.S.A. vii
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• Observe recommended precautions as indicated in this Repair Manual when dismantling the air conditioning
system as escaping refrigerant can cause frostbite.
• Priorto removingwheelsand tiresfrom a tractor, check to determinewhether additional ballast(liquid or weights)
has been added. Seek assistance and use suitable equipment to support the weight of the wheel assembly.
• When inflating tires beware of over inflation - constantly check the pressure. Overinflation can causetires to
burst and result in personal injury.
Safety precautions are very seldom the figment of someone's imagination. They are the result of sad experience,
where most likely someone has paid dearly through personal injury.
Heed these precautions and you will protect yourself accordingly. Disregard them and you may duplicate the sad
experience of others.
viii
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SERVICE TECHNIQUES
A. SERVICE SAFETY
Appropriate service methods and proper repair pro-
cedures are essentialfor the safe, reliable operation of
all motor vehicles aswell asthe personal safety of the
individual doing the work. This Shop Manual provides
general directions for accomplishing service and repair
work with tested, effective techniques. Following them
will help assure reliability.
There are numerous variations in procedures, techni-
ques, tools, and parts for servicing vehicles, aswell as
in the skill of the individual doing the work. This Manual
cannot possibly anticipate all such variations and pro-
vide adviceor cautions asto each. Accordingly, anyone
who departs from· the instructions provided in this
Manual must first establishthat hecompromisesneither
his personalsafety nor the vehicleintegrity by hischoice
of methods, tools or parts.
B. SERVICETECHNIQUES
Cleanthe exterior of all components before carrying out
any form of repair. Dirt and abrasive dust can reduce
the efficient working life of a component and lead to
costly replacement.
Time spent on the preparation and cleanlinessof work-
ing surfaces will pay dividends in making the job easier
and safer and will result in overhauled components be-
ing more reliable and efficient in operation.
Use cleaning fluids which are known to be safe. Cer-
tain types of fluid can cause damage to 'O' rings and
cause skin irritation. Use solvents that are suitable for
cleaningcomponents anddo not riskthe personalsafety
.of the user.
Replace 'O' rings, sealsor gaskets whenever they are
disturbed. Never mix new and old seals or 'O' rings,
regardlessof condition. Always lubricate new sealsand
'O' rings with hydraulic oil before installation.
When replacing component parts use the correct tool
for the job.
HOSES AND TUBES
Always replace hosesand tubes if the end connections
are damaged.
When installing a new hose loosely connect each end
PRINTED IN U.S.A.
and makesure the hose takes up the designed position
before tightening the connection. Clamps should be
tightened sufficiently to hold the hosewithout crushing
and to prevent chafing.
The hosesare the arteries of the unit, be sure they are
in good condition when carrying out repairs or
maintenance, otherwise the machine's output and pro-
ductivity will be affected.
After hose replacement to a moving component check
the hose does not foul by moving the component
through the complete range of travel.
Be sure any hose which has been installed is not kink-
ed or twisted.
Hoseconnections which aredamaged, dented, crush-
ed or leaking, restrict oil flow and the productivity of
the components being served.Connectors which show
signs of movement from the original swaged position
have failed, and will ultimately separate completely.
A hose with a chafed outer cover will allow water en-
try. Concealedcorrosion of the wire reinforcement will
subsequently occur along the hose length with resul-
tant hose failure.
Ballooning of the hose indicatesan internal leakagedue
to structural failure. This condition rapidly deteriorates
and total hose failure soon occurs.
Kinked, crushed,stretched or deformed hosesgenerally
suffer internal structural damagewhich can result in oil
restriction, a reduction in the speed of operation .and
ultimate hose failure.
Free-moving, unsupported hoses must never be allow-
edto touch eachother or relatedworking surfaces.This
causes chafing which reduces hose life.
BEARINGS
Bearingswhich are considered suitable for further ser-
vice should becleanedin asuitablesolvent and immers-
ed in clean lubricating oil until required.
Installation of a bearing can be classified in two ways:
pressfit on rotating parts such asshafts and gears,and
push fit into static locations such as reduction gear
housings.Where possible,alwaysinstallthe bearingon-
to the rotating component first.
ix

Usethe correct tools or a pressto install a bearing or
bushing. In the absenceof the correct tools or press,
heat the bearingsand/or casing in hot oil to assistthe
installation of the bearing.
When bearings or bushings are removed always care-
fully check that the bearing is free from discoloration
and signs of over-heating. Also check for mechanical
damage such as excessiveclearance, nicks and scuff-
ing. If in doubt replace the bearings or bushings.
Bearings should never be removed unless absolutely
necessary. Always use the recommended puller to
reduce the risk of bearing or related component
damage.
The reliability and durablity of a unit depends on the
effective operation of the many types of bearings and
bushings which are incorporated in the complete
assembly.
These bearingsand bushings aresubjected, in normal
operation, to high working loads and adverse condi-
tions.
X
Figure 1
Loader Lift Cylinder "Safety Bar"
Installed in Raised Position
Besure, during normal routine servicing, maintenance
or repairthat bearingsaregiven the right attention and
are installed with care.
PRESSURE TESTING
Prior to pressuretesting be sure all hosesare in good
condition and all connections tight. Pressurereadings
must betakenwith gaugesof specifiedpressureratings.
The correctprocedureshouldberigidly observedto pre-
vent damage to the system or the equipment and to
eliminate the possibility of personal injury.
A WARNING: Servicetheenginecompart-
ment with the loader bucket on the
ground in the dumpedposition or in the
raisedposition with theloaderlift cylinder
"SAFETY BAR" installed (seeFigure 1).
Never work under or around a raised
loader without the "SAFETY BAR
INSTALLED."
Figure 2
Loader Lift Cylinder "Safety Bar"
Installed in Storage Position

PART 1
ENGINE SYSTEMS
Chapter 1
ENGINES
Section Page
A. DIESELENGINE- DESCRIPTIONAND OPERATION . . . . . . . . . . .. . . . . 1
B. DIESELENGINE- OVERHAUL. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . 3
Chapter 2
COOLING SYSTEM
Section Page
A. COOLINGSYSTEM - DESCRIPTIONAND OPERATION............. 37
B. COOLINGSYSTEM - OVERHAUL. . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . .. 37
Chapter 3
TROUBLE SHOOTING, SPECIFICATIONS AND
SPECIAL TOOLS
Section Page
A. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 43
B. SPECIFICATIONS .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. . 47
C. SPECIALTOOLS . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . .. . . . . . 55
PRINTEDIN U.S.A.

PART 1
ENGINE SYSTEMS
Chapter 1
ENGINES
Section
A. DIESEL ENGINE - DESCRIPTION AND OPERATION ............... . Page
1
B. DIESEL ENGINE - OVERHAUL ................................... · 3
A. DIESEL ENGINE -
DESCRIPTION AND OPERATION
This chapter describes the overhaul and repair of the
3 and 4 cylinder Ford tractor direct injection diesel
engines used in the 555A and B and 655A TLB model
tractors.
The engines are of similiar design and service pro-
cedures are basically the same except as noted.
The major difference between the two engines is that
the 3 cylinder engine, Figure1, isequippedwith a rotary
type fuel injection pump and has a four main bearing
crankshaft. The 4 cylinder engine, Figure 2, is equip-
Figure 1
3-Cylinder Diesel Engine with Rotary Type
Fuel Injection Pump
PRINTED IN U.S.A.
ped with a·in-line fuel injection pump, afive main bear-
ing crankshaft and a dynamic engine balancer.
The three and four cylinder diesel engines have a com-
pression ratio of 16.3 to 1. The three cylinder engines
use headland type pistons, Figure3. The four cylinder
engines use conventional type pistons. The headland
type piston is a three ring piston having two compres-
sion rings and one oil control ring ail located above the
piston pin. The specialdesign"L" shapedtop compres-
sion ring is located at the top of the piston and provides
atight sealduring the combustion stroke thereby reduc-
ing blow-by. As combustion dissipates,the ring releases
its cylinder wall tension and rides almost friction free
on a thin film of oil thus reducing power loss and
cylinder wall wear.
Figure 2
4-Cylinder Diesel Engine with In-Line Type
Fuel Injection Pump
1

------------ PART 1 - ENGINE SYSTEMS------------
Figure 3
Headland Type Piston (3 Cyl.)
1. "L" Shape 3. Oil Control Ring
Compression Ring 4. Expander
2. Second
Compression Ring
The four cylinder engine piston hasthree compression
rings and one oil control ring, all located above the
piston pin.
The crankshaftissupported in the cylinder block by four
main bearings for the 3-cylinder engine and five main
bearingsfor the 4-cylinderengine.Crankshaftendthrust
issuppressedby a thrust bearinglocated on the second
main bearings of the 3-cylinder engine and the center
(third) main bearing of the 4-cylinder engine.
Front and rearcrankshaft oil sealing iseffected by one
piece, single lip type seals.
The crankshaft rear main bearing carrier block is
sealed by two rubber type side sealsand a gasket po-
sitioned between the block and the engine rear adap-
tor plate.
The crankshaft driven dynamic balancer, installed on
the 4-cylinder engines, counteracts out-of-balance
forces and thereby reduces engine vibration. The
balancer-housing isbolted to the bottom of the cylinder
block and containstwo meshinggearswhich aredriven
and timed from a gear machined on the crankshaft.
2
The enginesfeature crossflow cylinder headswith the
inlet and exhaust manifolds on opposite sides of the
head. The combustion chamber isformed in the crown
of the piston.
The cylinder head assembly incorporates the valves,
valve springs and spring retainers. Valve guides are an
integral part of the cylinder headwith replaceablevalve
seats pressed into the valve ports.
LUBRICATION SYSTEM
Lubrication of the engine is maintained by a rotor type
oil pump mounted at the baseof the engine block. The
oil pump isdriven from the camshaft anddraws oil from
the engine sump through a wire mesh screen.
A spring loaded relief valve in the pump body limits the
pressure in the system by directing excessoil back to
the intake side of the pump.
Oil passesfrom the pump to an external, throw-away,
spin on type filter incorporating areliefvalvewhich per-
mits oil to be bypassed if filter blockage occurs, and
so assuresengine lubrication at all times.
Oil flows from the filter to the main oil gallery which
runs the length of the cylinder block and intersects the
camshaft follower chambers.
The maingalleryalsosuppliesoil to the crankshaft main
bearingsand to the connecting rodjournals via drillings
in the crankshaft. Drilledpassagesfrom eachmainbear-
ing direct oil to the camshaft bearings.
The camshaft drive gearbushing ispressurelubricated
through a drilled passagefrom the front main bearing.
The gearhassmalloil passagesmachinedon both sides
which allow the oil to escape.
The timing gears are lubricated by oil from the cam
follower chamber and the pressurelubricated camshaft
drive gear bushing.
On the 4-cylinder engines, the dynamic balancer is
lubricated through a drilled passagefrom the cylinder
block intermediate thrust bearing web to the balancer
housing. Oil flows through the balancerhousing to the
drilled balancer gear shafts and onto the bushings in
the balancer gears.
Cylinder walls, pistons and piston pins are splash
lubricated by the connecting rods and rotating
crankshaft.

----------------CHAPTER 1----------------
An intermittent flow of oil isdirectedto the valverocker
arm shaft assemblyvia a drilled passagein the cylinder
block locatedvertically abovethe No. 1camshaft bear-
ing. This drilling alignswith a correspondinghole in the
cylinderhead.As the camshaftturns, holesin the cam-
shaft andcamshaftbearingalignanda regulatedstream
of oil is directed to the cylinder head and on up the
rocker arm shaft support bolt to the rocker shaft. The
oil flows from the shaft through drilled holes in each
rockerarm bushingto lubricate both endsof the arms.
Excessoil flows down the push rods and assists in
lubricating the cam followers before draining back into
the sump through cored openings in the block.
B. DIESEL ENGINE -OVERHAUL
CYLINDER HEAD, VALVES AND
RELATED PARTS
REMOVAL
Reference, Figure 4
Figure 4
4-Cylinder Engine with Rocker Arm Cover
Removed
1. Intake Manifold 6. Exhaust Manifold
2. Injection Tubes 7. Rocker Shaft
3. Leak-Off Tubes
4. Fuel Filter
5. Rocker Shaft
Assembly
PRINTEDIN U.S.A.
Retaining Bolts
8. Tab Washer
9. Alternator
10. Cold Start Tube
NOTE: The cylinder head can be removed with the
engine installed in the tractor.
1. Disconnect the battery.
2. Removethe vertical muffler
3. Drain the radiator and cylinder block
4. Shut off the heaterhosetapsthen disconnectand
plug the heater hose openings.
5. Remove the radiator top hose.
6. Shut off the main fuel tank tap.
7. Remove the hood panel assembly.
8. Disconnect the air inlet hose •at the intake
manifold.
9. Remove the vertical type exhaust pipe and
bracket.
10. Bendthe lock tabsbackand removethe bolts, ex-
haust manifold and gasket.
11. Disconnectthe cold startfuel linesat the fuel tank
and thermostart unit. See Part 2, Chapter 1.
12. Removethe injection linesfrom the fuel injection
pump and injectors. Cap the exposed openings
in the pump, injectors and line ends.
13. Disconnect the fuel lines and remove the fuel
filters from the inlet manifolds.
14. Remove the bolts and lockwashers and remove
the inlet manifold and gasket.
15. Removethe rocker cover bolts, rockerarm cover
and gasket from the cylinder heads.
16. Removethe fuel injector leak-off line. Cleanthe
area surrounding the fuel injectors then remove
the retaining nuts and carefullywithdraw the fuel
injectors and sealing washers from the head,
Figure 5.
17. Checkthe push rodsfor straightness by rotating
the rods with the valvesclosed and identify any
bent rods. 3

------------ PART 1 - ENGINE SYSTEMS------------
Figure5
Fuel Injector Removed
1. Dust Caps 3. Dust Seal Washer
2. Injector 4. Injector Seal Washer
18. Loosenthe rockershaft retainingbolts, which also
serveascylinder headbolts, evenlyand alternate-
ly. Remove the rocker shaft assembly.
NOTE:leave the bolts in the rocker shaft sup-
port during removal as they retain the supports
on the shaft.
19. Removethe push rods and place in a numbered
rackfor easeof assemblyin their originalposition.
20. Removethe remainingcylinder bolts andwashers
working inward from the endsto the center of the
head.
21. Lift the cylinderheadfrom the block. If necessary,
leverthe headoff the block at the pads provided,
taking care not to damage the cylinder head or
block surfaces, Figure 6.
DISASSEMBLY
THERMOSTAT:
4
1. Remove the coolant outlet connection and the
thermostat and gasket, Figure 7.
Figure 6
Cylinder Head Removal
Figure7
Coolant Outlet and Thermostat Removal
1. Cylinder Head 4. Coolant Outlet
2. Gasket Connection
3. Thermostat
CYLINDER HEAD:
2. Cleanthe headand removecarbon depositsfrom
around the valve heads.

----------------CHAPTER 1----------------
3. Usingavalvespringcompressor,Figure8, remove
the retainer locks, spring retainers/rotators,
springs and sealsfrom eachvalve, Figures9 and
10.
Figure 8
Valve Removal
1. Valve Spring 3. Valve Spring
Compressor 4. Cylinder Head
2. Retainer Locks
Figure 9
Intake Valve Assembly Components
1. Intake Valve Spring 3. Intake Valve Seal
Retainer Lock 4. Intake Valve Spring
2. Intake Valve Spring 5. Intake Valve
Retainer
PRINTEDIN U.S.A.
Figure 10
Exhaust Valve Assembly
1. Spring Retainer 3. ExhaustValve
Locks 4. Spring Retainer
2. Seal 5. Spring
4. Removethe valvesand placein a numberedrack
together with the valve rotators (where fitted).
ROCKER SHAFT ASSEMBLY:
5. Remove the cylinder head bolts which pass
through the rocker shaft supports and slide the
rocker shaft components from the shaft, Figure
11.
Figure 11
Rocker Shaft Disassembled
1. Spring 4. Rocker Arm
2. Retaining Bolt 5. Shaft
3. Shaft Support 6. Spacer
5

------------ PART 1 - ENGINE SYSTEMS-------------
INSPECTION AND REPAIR
CYLINDER HEAD:
6
1. Scrape all gasket surfaces clean then wash the
cylinderheadinasuitablesolventandthoroughly
dry with a lint free cloth or compressed air.
2. Inspect the cylinder head for damage and, if
necessary, remove nicks and burrs from the
gasketfacesusingasuitableabrasive.Besureall
traces of abrasive material are removed after
repair.
3. Usea straight edgeto check the flatness of the
cylinder head in all directions, Figure 12. For
flatness requirement see "Specifications" -
Chapter 3.
Figure 12
Measuring Cylinder Head Flatness
1. Straight Edge 2. FeelerGauge
NOTE:If the cylinder head exceeds the flatness
specification it may be skimmed providing the
depth from the lower face of the valve insert to
the cylinder head face is not less than 0.064-in.
(1.63 mm).
4. After skimming the head, check whether any
cylinderheadboltsarebottoming bymountingthe
cylinder headon the block without a gasketand
without anyof the pistonsat T.D.C. Installallthe
boltsfinger tight and besurethe rockershaft sup-
ports and flat washers are fitted with the long
bolts. If a 0.010 in. (0.25 mm) feeler gauge can
beinsertedunderthe bolt headthen the bolts are
bottoming andthe cylinder block thread must be
increasedin depth. Use a ½ in. x 13 UNC-2A
thread tap.
VALVE SEATS:
5. Examinethe valveseatinsertsand refaceif pitted
but replace if damaged. If necessary, install an
oversizeinsertby machiningthe seatcounterbore
in the cylinder head, see "Specifications" -
Chapter 3. The insert must be chilled in dry-ice
prior to installation.
NOTE: Valveseat inserts of0.010 in. (0.25 mm)
and 0.020 in. (0.5 mm) oversizeon diameter are
sometimes installed in cylinder heads in produc-
tion. Heads fitted with oversize inserts are
SOTO S020 .
stamped OS or OS on the exhaust manifold
side in line with the valve seat concerned.
Whenreplacing exhaust valveseatinsertsbe sure
the replacement inserts areof the correct type as
the size and material specification variesfor dif-
ferent engine types.
6. Check the width of the valve seat inserts and, if
necessary,reface by grinding to the dimensions
shown in Figure 13.
7. Grind the seat to:
pintake 0.080"-0.102" (2.032-2.590mm).
exhaust 0.84"-0.106" (2.133-2.692mm).
Loweror raisetheseatby removingmaterialfrom
the seat using the following stones.
To lower the seatusea30degreestone. To raise
the seat use a 60 degree stone.
NOTE:Refacing of the valveseat should always
be coordinated with refacing of the valve to be
sure of a compression tight fit.
VALVES:
8. Examinethe valve face and, if pitted, replaceor
reface by grinding to the dimension shown in
Figure 14. Before refacing the valve, be surethe
valvestemisnot bentor worn andcheckthe valve
seatrun-out, measuredat right-anglesto theseat,