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