WH-S-2-135+
WW hhiitteeService Manual
2-135, 2-155 & 2-180Chassis & Engine
4-210 Chassis OnlyVolume 1 of 2
THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF WHITE OR IT’S SUCCESSORS. WHITE AND IT’S SUCCESSORS
ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.
TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.
Serv
ice
Man
ual
GENER~..!:A~L _____________ S_E_C_T_I_O_N_l
CONTENTS
INTRODUCTION ............................ 1-1
SAFETY INSTRUCTIONS ................... 1-2
MODELS 2-135 and 2-155 DIMENSIONS AND WEIGHTS
Dimensions ............................... 1-7 Weights ................................... 1-7
MODEL 2-180 DIMENSIONS AND WEIGHTS
Dimensions ............................... 1-8 Weights ................................... 1-8
TIRE SPECIFICATIONS Front and Rear Tire 2-135/2-155 .......... 1-9 Front and Rear Tire 2-180 .............. 1-10 Power Front Axle Tire
Recommendations ..................... 1-10
CAPACiTIES .............................. 1-11
TORQUE CHARTS Cap screws ............................. 1-12 Refrigerant Fittings...................... 1-12 Steel Hydraulic Fittings ................. 1-13 Pipe Plugs .............................. 1-13 Magnetic Drain Plugs ................... 1-13
This manual was prepared from the latest product information available at publication time. The Company reserves the right to make changes at any time without notice.
Printed in U.S.A. Form No. 432-927-1
SECTION 1 INTRODUCTION GENERAL
Fig. 1 - 2-135 Tractor
This Tractor Shop Manual has been provided for qualified service personnel engaged in servicing and overhauling 2-135, 2-155, and 2-180 Tractors. Use of this publication is not recommended for field operators since they usually do not have access to special tools and shop equipment essential for most service operations.
Service procedures outlined herein contain sufficient information to return all component parts of a tractor to new condition. In discussion of each component part, it is assumed that a complete overhaul is being performed; consequently, complete disassembly and reassembly are outlined. The mechanic is relied upon to decide how far disassembly must be carried when complete overhaul is not required.
Study unfamiliar service procedures thoroughly and have them well in mind before attempting disassembly. Specific data essential for proper overhaul, such as running clearances and torque values, have been provided in chart form as a ready reference for the experienced mechanic. Remember, the mark of a true craftsman is quality of workmanship.
Discussions in this manual are written to cover "standard" units and this should be taken into consideration if any "non-standard" unit deviation is encountered. Some illustrations are of a general nature and should not be taken as accurate in all details for every unit built.
1-1 Printed in U.S.A. Form No. 432-927-1
SECTION 2 ENGINE
Engine section of this manual pertains to models 2-135 and 2-155 tractors only. For model 2-180, refer to Caterpillar Engine Service Manual SEBR0540-01 available from your servicing Caterpillar dealer.
CONTENTS
INTRODUCTION Design Changes and
Improvements ........................... 2-1 Troubleshooting ........................... 2-2 Smoke Diagnosis Chart ................... 2-8 Specifications ........................... 2-10
ENGINE SERVICE General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-22 Serial Number .......................... 2-22 Engine Break-in ......................... 2-22 Oil Pressure Test ....................... 2-22 Compression Check ..................... 2-22 Engine Removal
(Tractor Not Split) .................... 2-23 Engine Installation
Tractor Not Split) ..................... 2-23 Engine Removal
(Tractor Split) ......................... 2-23 Engine Installation .
(Tractor Split) ......................... 2-25
LUBRICATION System Operation ....................... 2-26 Lubrication Recommendations ........... 2-26
CYLINDER HEAD AND VALVES Rocker Arm Assembly and Push Rods
Removal .............................. 2-28 Disassembly .................. : ........ 2-28 Assembly ............................. 2-28 Installation ............................ 2-28 Valve Clearance Adjustment ........... 2-28
Cylinder Head . Removal .............................. 2-28
Inspection ............................. 2-29 Valves
Disassembly ........................... 2-29 Inspection ............................. 2-29 Valve Guide Replacement ............. 2-29 Valve Stem Seals ..................... 2-29 Valve Seat Inserts ..................... 2-30 Valve Refacing ........................ 2-31 Cylinder Head Installation ............. 2-31
CAMSHAFT AND TIMING GEAR COVER Removal ................................ 2-33 Installation .............................. 2-34
Printed in U.S.A.
OIL PAN, PUMP, COOLER AND FILTERS Pan Removal............................ 2-35 Pump and Idler Gear Removal .......... 2-35 Pump - Assembly and Disassembly ..... 2-35 Pump Installation ....................... 2-35 Pan Installation ......................... 2-35 Filter and Cooler Removal .............. 2-35 Filter and Cooler Installation ............ 2-36
CONNECTING RODS, PISTONS AND SLEEVES Piston and Rod Removal. ............... 2-37 Piston and Rod Disassembly ............ 2-37 Piston and Rod Assembly ............... 2-37 Piston and Rod Installation ............. 2-38 Sleeve Removal and Installation......... 2-38
CRANKSHAFT, FLYWHEEL AND BLOCK Flywheel Removal and Installation ...... 2-39 Crankshaft Removal and Installation .... 2-39 Pre-start Lubrication .................... 2-39
AIR SYSTEM General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-41 Pre-cleaner Screener .................... 2-41 Aspirated Pre-cleaner ................... 2-41 Air Cleaner ............................. 2-41 Restriction Indicator Light. .............. 2-41 Servicing ................................ 2-42 Manifolds ............................... 2-43 Pre-heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-43
TURBOCHARGER General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-44 Operation ............................... 2-44 Lubrication .............................. 2-45 Special Operating Instructions .......... 2-45 Inspection and Maintenance ............. 2-47 Axial End Play.......................... 2-48 Radial Bearing Check ................... 2-48 Overhaul - Disassembly................. 2-49 Inspection Requirements ................ 2-51 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-52 Mounting ............................... 2-55 Troubleshooting ......................... 2-56 Failure Analysis ......................... 2-61
Form No. 432-927-2
ENGINE SECTION 2 FUEL TANK AND FILTERS
General ................................. 2-71 Removal and Installation ................ 2-71 Bleeding Fuel System ................... 2-73 Servicing Fuel System .................. 2-74 Water Separator ......................... 2-74
FUEL INJECTORS General ................................. 2-75 Operation ............................... 2-75 Troubleshooting ......................... 2-75 Removal ................................ 2-75 Testing ................................. 2-75 Service .................................. 2-77 Installation .............................. 2-78
FUEL INJECTION PUMP General ................................. 2-79 Governor Adjustments ................... 2-79 Idle Speed .............................. 2-79 Removal ................................ 2-79 Installation .............................. 2-80 Checking Transfer Pump Pressure ...... 2-81 Service .................................. 2-81 Checking Advance Movement ........... 2-81
COOLING SYSTEM Operation ............................... 2-82 Coolant Heater .......................... 2-82 Radiator Removal and
Installation ............................ 2-82 Thermostat Replacment ................. 2-82 Water Pump Removal and
Installation ............................ 2-82 Water Pump Disassembly ............... 2-82 Water Pump Inspection ................. 2-83 Water Pump Assembly .................. 2-83
Printed in U.S.A. Form No. 432-927-2
ENGINE SECTION 2
ENGINE SERVICE
GENERAL
2-135/2-155 diesel engines are of six cylinder, four cycle, overhead valve design. They are equipped with aluminum pistons, precision shell-type connecting rod and main bearings, and replaceable, dry-type sleeves.
SERIAL NUMBERS
Engine serial number is stamped on plate on right side of engine near front (Fig. 2).
Fig. 2 - Engine Serial Number Location
NEW AND REBUILT ENGINE BREAK-IN
Refer to tractor Operator's Manual for recommended break-in procedure.
OIL PRESSURE TEST
If low or erratic oil pressure is indicated by dash gauge, first check gauge reliability by installing a test gauge in main oil gallery on right side of block. With engine oil at normal operating temperature, oil pressure should be 15 psi (103 kPa) at idle speed and 30-40 psi (207-276 kPa) at 2200 rpm. If pressure is abnormal, remove and inspect relief valve assembly (Fig. 3). If pressure is normal, replace oil pressure gauge on dash.
2-22 Printed in U.S.A.
Fig. 3 - Piston Cooling Regulator Valve And Oil Pressure Regulator Valve
COMPRESSION CHECK
When checking engine compression, figure given in Specifications, 300-500 psi (2067-2412 kPa), is only an approximation. Compression will vary with differences in temperature, cranking speed, test equipment and altitude.
It is important, however, that compression variation among cylinders in not greater than 25 psi (172 kPa).
To check engine compression, WF-10018 Compression Test Kit is recommended. Kit includes WF-10018-1 Tester, and WF-10018-2 Adapter (Fig. 4).
Fig. 4 - Engine Compression Test Equipment
Form No. 432-927-2
OVER/UNDER TRANSMISSION SECTION 3
CONTENTS
General ................................... 3-1 DISASSEMBL Y
SPECIFICATIONS General ................................... 3-3 Dimensions ............................... 3-4 Torque Values ............................ 3-6 Design Improvements ..................... 3-6
Unit .................................. 3-20 Unit Subassemblies ................. 3-21 Housing Cover, Pump, and Valves .. 3-21 Oil Pump ........................... 3-22 Input Shaft and Support ............ 3-23 Output Shaft and Direct Clutch ..... 3-23
OPERATION Planetary Gear Carrier .............. 3-24
General ................................... 3-7 Overdrive Clutch Housing, Overdrive
Direct Drive ............................... 3-7 Clutch, and Sun Gear Shaft .. _ .... 3-24
Overdrive ................................. 3-8 Parts Inspection ..................... 3-26
Underdrive ................................ 3-9 ASSEMBLY
Lubrication ................................ 3-9 Unit Subassemblies ................. 3-27
Cooling ................................. 3-10 Overdrive Cutch Housing and Sun Gear Shaft .................... 3-27
TESTING AND TROUBLESHOOTING Planetary Gear Carrier . . . . . . . . . . . . .. 3-27 Checking Oil Circuit Pressures .......... 3-11 Output Shaft and Direct Clutch ..... 3-28 Direct Drive Clutch Circuit .............. 3-11 Input Shaft and Support ............ 3-29 Overdrive Clutch Circuit ................ 3-12 Oil Pump ........................... 3-29 -Clutch Fill Time ........................ 3-12 Housing Cover, Pump, and Valves .. 3-30 Lubrication Circuit ...................... 3-12 Countershaft ........................ 3-30 Troubleshooting ......................... 3-13 Unit ................................... 3-30
OVERHAUL General ................................. 3-15 Unit Removal ........................... 3-15 Unit Installation ......................... 3-15
Printed in U.S.A. Form No. 432-927-3
DRIVE TRAIN SECTION 4
CONTENTS
GENERAL Design Changes and
Improvements .......................... .4-1 Specifications ............................. 4-2
Countershaft ................. ' ......... 4-27 Bevel Pinion Shaft .................... 4-32 Reverse Idler Gear .................... 4-32
CLUTCH Park Lock Latch and Rod ............ 4-32 General (2-135/2-155) ..................... 4-7 Safety Start Switch ....................... 4-7 Clutch Pressure Deactivator
Transmission Assembly Park Lock Latch and Rod ............ 4-32 Reverse Idler Gear .................... 4-32
Switch .................................. 4-7 Bevel Pinion Shaft .................... 4-33 Linkage Adjustment ...................... .4-7 Removal .................................. 4-7
Countershaft ........................ " 4-33 Input Shaft ........................... 4-33
Installation ................................ 4-8 Shifter Mechanism .................... 4-33 PTO Drive Hub and Pilot Bearing
Disassembly ..................... , ...... .4-8 Assembly ............................... 4-8
Reconditioning Clutch Cover Assembly General ................................. 4-8 Disassembly ............................. 4-9 Assembly ............................. 4-11 Release Lever Adjustment ............. 4-11 General (2-180) ....................... 4-13 Operation ............................. 4-13 Linkage Adjustment ................... 4-14 Removal .............................. 4-14
PTO Drive Hub and Pilot Bearing Disassembly ........................... 4-14 Assembly ............................. 4-14 Clutch Repair ......................... 4-14 Disassembly ........................... 4-14
BRAKES General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-34 Operation ............................... 4-34 Brake Disc Removal and
Installation ............................ 4-34 Pressure Plate and Piston
Removal and Disassembly ............. 4-34 Assembly and Installation ............. 4-38 Bleed Screw .......................... 4-38
Brake Valve Removal and Installation .............. 4-40 Disassembly ........................... 4-40 Assembly ............................. 4-40 Brake Pedal Linkage
Adjustment .......................... 4-40 Bleeding .............................. 4-40
Adjustment. ........................... 4-15 Assembly ............................. 4-16 Installation ............................ 4-16
REAR AXLES, CARRIERS AND PLANETARY Axle Carrier and Planetary
Removal .............................. 4-41
TRANSMISSION General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-17 Operation ............................... 4-17 Lubrication System ...................... 4-17 Operation ............................... 4-17 Checki ng System ....................... 4-21 Hydraulic Pump
Removal .............................. 4-21 Installation ............................ 4-21
Installation ............................ 4-41 Disassembly ........................... 4-41 Assembly ............................. 4-42
Differential Lock Operation ....................... 4-46 Removal .............................. 4-46 Installation ............................ 4-46 Disassembly ........................... 4-47 Assembly ............................. 4-47
Drive Gear Removal .................. 4-22 Drive Gear Installation ................ 4-22
Transmission Disassembly Preparation ........................... 4-23 Shifter Mechanisms ................... 4-23 Input Shaft ........................... 4-27
Printed in U,S.A. Form No. 432-927-4
SECTION 5 HYDRAULICS AND THREE-POINT HITCH
CONTENTS
SPECIFICATIONS General ................................... 5-1 Hydraulic Pump ........................... 5-1 Charge-lube Pump ........................ 5-1 Internal Cylinder (Hitch Cylinder) ......... 5-1 Remote Control Valve-Pressure Detent .... 5-1 Pressure Control Valve .................... 5-1 Torque Valves ............................ 5-1 Leakage Specifications .................... 5-2
Design Changes and Improvements ......... 5-2
GENERAL ................................... 5-4
TESTING AND TROUBLESHOOTING General ................................... 5-5 Bleeding System .......................... 5-5 Testing
Charge-lube Pump, Reservoir, Filter, and Cooler .................... 5-5
Hydraulic Pump ......................... 5-6 Pressure Control Valve .................. 5-6 Servo Valve ............................. 5-8 Steering Control Unit ................... 5-8 Brake Valve ............................. 5-9
Quick Check .............................. 5-9 Service Tools Required ................. 5-10 Material Required ....................... 5-10 Troubleshooting Guide .................. 5-11 Hydraulic Test Sequence ................ 5-15
CHARGE-LUBE PUMP AND INLET SCREEN Charge-lube Pump
General ..... . . . . . . . . . . . . . . . . . . . . . . . . .. 5-24 Removal .............................. 5-24 Installation ................. : .......... 5-25 Disassembly ........................... 5-25 Assembly ............................. 5-25
Inlet Screen Removal .............................. 5-26 Installation ............................ 5-26
HYDRAULIC FILTER General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-27 Filter Head
Removal .............................. 5-27 Installation ............................ 5-28
Cooler Bypass Valve Removal .............................. 5-28 Installation ............................ 5-28
Pressure Regulating Valve Removal ............................... 5-28 Installation ............................ 5-28
Printed in U.S.A.
HYDRAULIC PUMP General ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-29 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-32 Overhaul
General ....... . . . . . . . . . . . . . . . . . . . . . . .. 5-33 Disassembly ........................... 5-34 Inspection ............................. 5-36 Assembly ............................. 5-39 Checking, Adjusting Preload of
Yoke Bearings ...................... 5-40 Checking, Adjusting Drive Shaft
Bearing Preload ..................... 5-40 Final Assembly ........................ 5-41
PRESSURE CONTROL VALVE General ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-45 Operation
Unloader Valve ........................ 5-45 High Pressure Relief Valve ............ 5-45 Priority Valve ......................... 5-46 Pressure Reducing and Low Pressure
Relief Valve ......................... 5-46 Servicing
General ............................... 5-47 Removal and Installation .............. 5-47 Adjustment. ........................... 5-47 Disassembly and Assemhly
Unloader Valve ...................... 5-47 High Pressure Relief Valve .......... 5-47 Priority Valve ....................... 5-47 Pressure Reducing and Low Pressure
Relief Valve....................... 5-48
SERVO VALVE General ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-49 Operation ............................... 5-49 Removal ................................ 5-52 Installation .............................. 5-52 Overhaul
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-52· Disassembly ........................... 5-52 Assembly ............................. 5-52
DRAFT CONTROL HYDRAULIC CYLINDER Cylinder Removal and Installation ....... 5-54 Cylinder and Piston ..................... 5-54 Cylinder Safety Valve
Overhaul .............................. 5-54 Adjustment ............................ 5-55
DRAFT CONTROL ACTUATING ASSEMBLY General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-56 Removal and Installation . . . . . . . . . . . . . . .. 5-56 Cross Shaft Installation ................. 5-56 Pivot Shaft
Removal... . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-56 Installation ............................ 5-56
Draft Control Spring ................... , 5-56
Form No. 432-927-5
POWER TAKE-OFF SECTION 6
CONTENTS
SPECiFiCATIONS ........................... 6-1 PTO ASSEMBLY
Removal .................................. 6-9
GENERAL ................................... 6-2 Installation ................................ 6-9 Single Speed ........................... 6-20
OPERATION ................................ 6-7 Disassembly ........................... 6-20 Dual Speed Units ......................... 6-7 Assembly ............................. 6-22
LUBRiCATION .............................. 6-7 Dual Speed ................... , ......... 6-23
Disassembly ........................... 6-23
PTO CLUTCH OPERATING TEST .......... 6-7 Assembly ............................. 6-25
REMOVING PTO AND DIFFERENTIAL LOCK VALVE ............................. 6-8
SHAFT REMOVAL AND INSTALLATION .... 6-8
DUAL SPEED UNITS ....................... 6-8
Printed in U.S.A. Form No. 432-927-6
SECTION 6
Pull bearing cones that are to be replaced from shafts. Pull needle roller bearing out of 1000 rpm output gear. Remove seals from output gear and rear bearing support.
Fig. 33 - Gears Removed From Rear Bearing Support
PTO ASSEMBLY
Press bearings onto drive gear (Fig. 34). Place "O"-rings in front grooves and sealing rings in rear grooves of drive gear. Apply Lubriplate to all rings.
Fig. 34 - Drive Shaft "0" -Ring, Sealing Ring & Bearing Cone Installation
Printed in U.S.A.
POWER TAKE-OFF
Fig. 35 - 1000 RPM Output Gear
Install bearings on 1000 rpm output gear (Fig. 35). Apply Permatex to outside of seal case. Press seal into output gear with spring side toward inside of tractor. Apply Lubriplate to seal lip. Install roller bearing into output gear.
Fig. 36 - Rear Support
Apply Permatex to outer circumference of seal case. Press seal into rear support with spring side toward inside of tractor (Fig. 36). Apply Lubriplate to seal lip. Press bearing races into rear support.
Position drive gear and 1000 rpm output gear in rear support. Exercise care to avoid breaking seal rings on driven gear or turning seal lip.
6-25 Form No. 432-927-6
SECTION 7 STEERING AND FRONT AXLE
CONTENTS
GENERAL Design Changes and
Improvements ........................... 7-1 Specifications
General ................................. 7-2 Special Torques ......................... 7-3
Troubleshooting And Testing Preliminary Checks ..................... 7-4 Steering System
Inspection ............................. 7-4 Troubleshooting Chart .................. 7-7
STEERING CONTROL UNIT Description ................................ 7-8 Operation
Neutral .................................. 7-8 Left and Right Turn .................... 7-8 Manual Turning ......................... 7-9
Removal SIN 272-595 to 300-927 ......... 7-9 Installation SIN 272-595 to 300-927 ..... 7-10 Removal SIN 300-928 Up............... 7-11 Installation SIN 300-928 Up ............. 7-11 General ................................. 7-16 Disassembly ............................. 7-16 Parts Inspection ......................... 7-20 Assembly ............................... 7-21
STEERING COLUMN Description and Operation ............. . Troubleshooting ........................ . Removal and Installation ............... . Disassembly
Early Model .......................... . Intermediate Model ................... . Late Model ............. ' ............. .
Parts Inspection ........................ . Assembly
Early Model .......................... . Intermediate Model ................... . Late Model .......................... .
2WD POWER STEERING CYLINDER -Model 2-135/2-155
Removal ............................... . Installation ............................. . Disassembly ............................ . Parts Inspection ........................ . Assembly .............................. .
2WD POWER STEERING CYLINDER -Model 2-180
Removal & Disassembly ................ . Inspection .............................. . Assembly .............................. .
Printed in U.S.A.
7-23 7-23 7-24
7-24 7-25 7-26 7-30
7-30 7-30 7-30
7-31 7-32 7-33 7-34 7-34
7-35 7-35 7-35
2WD FRONT END ASSEMBLY Front Tire Toe-in Adjustment ........... 7-36 Front Wheel Tread Width
Adjustment ............................ 7-36 Models 2-135/2-155
Removal .............................. 7-37 Installation ............................ 7-38 Disassembly
Pitman Shaft and Steering Sector Arm ....................... 7-38
Steering Knuckle and Wheel Hub ............................... 7-38
Parts Inspection ......................... 7-38 Assembly .
Front Axle Carrier .................... 7-38 Steering Knuckle and Wheel
Hub ................................. 7-39 Model 2-180
Removal & Disassembly ............... 7-41 Assembly & Installation ............... 7-41
PFA POWER STEERING CYLINDER Description and
Operation ............................. 7-44 Removal ................................ 7-44 Installation .............................. 7-44 Disassembly ............................ , 7-45 Parts Inspection ......................... 7-46 Assembly ....................... , ....... 7-46
4PFA TRANSFER CASE Description and
Operation ............................. 7-47 Lubrication .............................. 7-47 Removal and Disassembly ............... 7-48 Parts Inspection ......................... 7-49 Assembly and Installation ............... 7-49
PFA FRONT END ASSEMBLY Axle, Carrier and Pivot
Replacement .......................... 7-53 Troubleshooting
Drive Shaft ........................... 7-53 Axle Differential ....................... 7-54 Axle Planetary ........................ 7-55
PFA DRIVE SHAFT Removal and Disassembly ............... 7-58 Parts Inspection ......................... 7-58 Assembly and Installation ............... 7-58
PFA FRONT AXLE Planetary Wheel End
Disassembly .......................... , 7-61 Planetary Wheel End
Assembly ............................ , 7-62 Pivot and Spindle
Disassembly .......................... , 7-66
Form No. 432-927-7
STEERING AND FRONT AXLE SECTION 7
Pivot and Spindle Assembly ............................. 7-66
Constant Velocity Joint ................. 7-68 Cover Seal............................ 7-68
Differential .............................. 7-70 Pinion Shaft Seal ..................... 7-70
Disassembly ............................. 7-70 Pinion Shaft Bearing
Adjustment .......................... 7-71 Differential Case ........................ 7-73
Ring Gear and Pinion Tooth Contact ............................. 7-74
PFA TIRE COMBINATION Ratios ................................... 7-76
Printed in U.S.A. Form No. 432-927-7
ELECTRICAL SECTION 8
CONTENTS
GENERAL Design Changes and Improvements ....... 8-1
SPECIFICATIONS Starti ng Motor ............................ 8-2 Alternator
2-135/2-155 ............................. 8-2 2-180 ................................... 8-2
Tractor Fuses and Circuit Breakers .................................. 8-2 Lights ..................................... 8-3 Sending Units ............................. 8-3 Batteries .................................. 8-4
Wiring Diagrams ............................ 8-5
BATTERIES Safety Instructions . . . . . . . . . . . . . . . . . . . . .. 8-15 Troubleshooting ......................... 8-15 Battery Replacement .................... 8-16 Battery Condition Check List ........... 8-17 Electrolyte Level ........................ 8-17 Testing Specific Gravity
of Electrolyte ......................... 8-17 Booster Battery or Charger
8-19 Connections ......................... . Activating Dry Charged Batteries
Safety Guidelines ..................... 8-19 Battery Activation . . . . . . . . . . . . . . . . . . . .. 8-19
BATTERY STORAGE Off-Season Storage ................... 8-19 Limited Use Storage .................. 8-19
SWITCHES, SENDERS AND WIRES Light Switch ............................ 8-20 Key Switch .............................. 8-20 Engine Oil Pressure Sender ............. 8-21 Hydraulic Oil Temperature
Switch ................................ 8-21 Coolant Temperature Sender ............ 8-21 Fuel Tank Sender ....................... 8-22 Transmission Lube Pressure
Switch ................................ 8-22 Air Restrictor Indicator
Switch ................................ 8-22 Wiring .................................. 8-23 Solenoids ............................... 8-23 Warning Lights .......................... 8-23 Gauges ................................. 8-23 Circuits ................................. 8-24
STARTING MOTOR Description .............................. 8-25 Operation ............................... 8-25 Tests and Adjustments
Printed in U.S.A.
No-Load Test ......................... 8-27 Interpreting Test Results .............. 8-27 Brush Holder Bench Check ........... 8-27 Armature Bench Check ............... 8-28 Field Winding Bench Check .......... 8-29
Troubleshooting ......................... 8-29 Disassembly
Parts Inspection ....................... 8-31 Bushing ............................... 8-34
Assembly General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-35 Checking Drive Gear
Clearance ........................... 8-35 Final Testing .......................... 8-35
ALTERNATOR (2-135/2-155) Description .............................. 8-36 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-37 Tests ................................... 8-38
Battery Installation, Charging and Testing Precautions ............ 8-38
Preliminary Inspection ................. 8-38 Test Equipment and
Installation .......................... 8-38 Battery Voltage and Isolation
Diode ............................... 8-39 Excitation Circuit ..................... 8-40 Open Isolation Diode ................. 8-40 Voltage Regulator Setting ............. 8-41 Field Currant Draw ................... 8-42 Output and System Test .............. 8-43 Bench Test ........................... 8-44
Disassembly ............................. 8-45 Parts Inspection and Testing
Housings .............................. 8-46 Isolation Diode ........................ 8-46 Brush Assembly ....................... 8-46 Rectifier Diodes ....................... 8-47 Stator Assembly ...................... 8-47 Rotor Assembly ....................... 8-48
Assembly ............................ '" 8-48 Installation .............................. 8-50
ALTERNATOR (2-180) Description .............................. 8-52 Operation ............ : .................. 8-52 Maintenance ............................ 8-54 Testing
On Vehicle ............................ 8-54 Bench ................................ 8-55 Static . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-56
Disassembly ............................. 8-57 Assembly ............................... 8-60
TACHOURMETER ......................... 8-64
Form No. 432-927-8
CAB SECTION 9 CONTENTS
GENERAL Design Changes and Improvements ....... 9-1
SPECIFICATIONS Air Conditioning System
General ................................. 9-2 Hoses .................................... 9-2 Condenser .............................. 9-2 Evaporator .............................. 9-2 Air Filters ............................... 9-3 Circuit Breakers ......................... 9-3 Expansion Valve ........................ 9-3 Receiver-Drier ........................... 9-3 Clutch .................................. 9...;3 Controls ................................ 9-4 Compressor ............................. 9-4 Torque Valves .......................... 9-5 Refrigerant Fittings ...................... 9-5 Service Tools ........................... 9-6 Centigrade to Fahrenheit Chart ......... 9-7 Temperature - Pressure Relation Chart
Fahrenheit ............................ 9-8 Centigrade ............................ 9-9
Cab Removal Series I and II ........................ 9-10 Series III .............................. 9-11
Cab Installation Series I and II ........................ 9-12 Series III .............................. 9-12
Cab Glass and Molding Specifications ......................... 9-20
Seat Suspension SIN 272 595 - 293 408 ............... 9-22 SIN 293 409 - Up .................... 9-22
Heater ...................... .'........... 9-25 Windshield Wiper ....................... 9-25 Air Conditioning System ................ 9-28
Description ............................ 9-28 R-12 Refrigerant ...................... 9-29 Compressor ........................... 9-29 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-30 Receiver-Drier ......................... 9-30 Expansion Valve ..•................... 9-30 Evaporator ............................ 9-31 Cab Controls ......................... 9-31 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-32
Safety Precautions . . . . . . . . . . . . . . . . . . . . .. 9-33 Tests and Adjustments
Preliminary Visual Check .............. 9-34 Test Equipment .............•......... 9-34 Accuracy of Manifold Gauges and
Thermometer. . . . . . . . . . . . . . . . . . . . . . .. 9-35 Connecting Manifold Gauges .......... 9-35 Checking Temperature -
Pressure Relationship ............... 9-36 Testing for Leaks ..................... 9-36
Printed in U.S.A.
Leak Detectors........................ 9-36 Discharging System ..................... 9-39 Flushing System ........................ 9-39 Purging System ......................... 9-41 Evacuating System ...................... 9-41 Evacuating Wet or Contaminated
System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-42 Charging System ........................ 9-43 Tests and Adjustments - Individual Components
Compressor ........................... 9-44 Expansion Valve ...................... 9-44 Receiver-Drier ......................... 9-47 Clutch Belt ........................... 9-47 Warning Light ......................... 9-47
Evaporator and Condenser Core Repairs ............................... 9-48
Hose Replacement . . . . . . . . . . . . . . . . . . . . .. 9-48 Troubleshooting ......................... 9-50 Correcting Malfunctions ................. 9-56 Air Compressor (Tecumseh or York)
Description ............................ 9-61 Service Valves ........................ 9-62 Tests and Adjustments ................ 9-62 Changing Oil ......................... 9-64 Checking for Leaks ................... 9-65 Noise Complaints ..................... 9-65
Removal ................................ 9-66 Installation .............................. 9-66 Disassembly
Magnetic Clutch ...................... 9-67 Cylinder Head and Valve Plate ........ 9-67 Seal Assembly ........................ 9-67 Parts Inspection ....................... 9-68
Assembly Seal Assembly ........................ 9-69 Clutch ................................ 9-69 Valve Plate and Cylinder Head ........ 9-70
Air Compressor (Sankyo) Description ............................ 9-72 Tests and Adjustments ................ 9-73 Checking Oil Level ................... 9-73 Troubleshooting ....................... 9-75
Removal ................................ 9-76 Installation .............................. 9-76 Disassembly
Clutch ................................. 9-79 Shaft Seals ........................... 9-80 Cylinder Head and Valve Plate ........ 9-80
Parts Inspection ......................... 9-81 Assembly
Cylinder Head and Valve Plate ........ 9-81 Clutch ..................... , .......... 9-82
Form No. 432-927-9
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