Same Solaris 30 40 50 workshop service repair manual
It is workshop manual for Same tractors. Models included:
30
40
50
language:english
number of pages: 430 (full digital version)
Main sections:
Introduction
Safety sections
1. TRANSMISSION ................................................................ 1
1.1 INTRODUCTION ......................................................1
1.2 DESCRIPTION..........................................................2
1.2.1 DRIVE TRANSMISSION..................................3
1.3 CLUTCH HOUSING .................................................4
1.4 GEARBOX AND SHUTTLE ASSEMBLY...................5
1.5 4WD RANGE GEARS ASSEMBLY...........................6
1.6 PINION AND DIFFERENTIAL ASSEMBLY ...............7
1.7 BRAKES AND REAR AXLE ASSEMBLY ..................8
1.8 REAR PTO AND MID PTO .......................................9
1.8.1 COMPONENTS...............................................9
1.8.2 MAIN COMPONENTS...................................10
2. FRONT AXLE.................................................................... 11
2.1 STEERING CYLINDER...........................................12
2.2 DIFFERENTIAL- PINION - FINAL DRIVE UNIT.......13
3. CONTROLS ...................................................................... 14
3.1 RIGHT-HAND SIDE VIEW ......................................14
3.2 LEFT-HAND SIDE VIEW.........................................15
3.3 TOP VIEW ..............................................................16
4. HYDRAULIC SYSTEM..................................................... 17
4.1 DESCRIPTION .......................................................17
4.2 HYDRAULIC DIAGRAM.........................................18
4.3 STEERING CIRCUIT ..............................................19
4.3.1 FUNCTION....................................................19
4.3.2 OPERATION..................................................19
4.3.3 GEAR PUMP.................................................20
4.3.4 POWER STEERING ......................................21
4.3.5 DIFFERENTIAL LOCK CONTROL
ASSEMBLY...................................................23
4.3.6 AUXILIARY SERVICES CONTROL VALVE
(4 WAYS).......................................................25
4.3.7 POWER LIFT CONTROL VALVE...................26
ENGINE HOOD ..................................................... 1
Removal...................................................................... 1
Refitting ...................................................................... 1
SAFETY ROLL BAR.............................................. 2
Removal...................................................................... 2
Refitting ...................................................................... 2
SILENCER............................................................. 3
Removal...................................................................... 3
Refitting ...................................................................... 4
RADIATOR ............................................................ 5
Removal...................................................................... 5
Refitting ...................................................................... 7
FRONT SUPPORT ................................................ 8
Removal...................................................................... 8
Refitting .................................................................... 10
WHEELS.............................................................. 11
FRONT WHEELS...........................................................11
Removal.................................................................... 11
Refitting .................................................................... 11
REAR WHEELS.............................................................12
Removal.................................................................... 12
Refitting .................................................................... 12
INSTRUMENT PANEL........................................ 13
Removal.................................................................... 13
Refitting .................................................................... 14
CONSOLE SHROUDS ........................................ 15
Removal.................................................................... 15
Refitting .................................................................... 16
POWER STEERING ............................................ 17
Removal.................................................................... 17
Refitting .................................................................... 18
FUEL TANK......................................................... 19
Removal.................................................................... 19
Refitting .................................................................... 20
PLATFORM......................................................... 21
Removal.................................................................... 21
Refitting .................................................................... 23
STARTER MOTOR.............................................. 24
Removal.................................................................... 24
Refitting .................................................................... 26
HYDRAULIC PUMP............................................ 27
Removal.................................................................... 27
Refitting .................................................................... 27
ALTERNATOR..................................................... 28
Removal.................................................................... 28
Refitting .................................................................... 29
Tensioning the drivebelt ........................................... 29
ENGINE ............................................................... 31
Separating the engine from the transmission........... 31
Reconnecting the engine to the transmission .......... 36
Removal.................................................................... 37
Refitting .................................................................... 41
CLUTCH ASSEMBLY ......................................... 42
PTO CLUTCH................................................................42
Removal and renewal of the PTO clutch plate ......... 42
Check PTO clutch plate wear................................... 42
Refitting the PTO clutch plate .................................. 42
Adjustment of the clutch levers ................................ 43
PTO DRIVE SHAFT OIL SEAL......................................44
Renewal .................................................................... 44
CLUTCH RELEASE BEARINGS...................................45
Removal.................................................................... 45
Refitting .................................................................... 47
LIFT ..................................................................... 48
COMPLETE ASSEMBLY..............................................48
Removal.................................................................... 48
Refitting .................................................................... 49
POWER LIFT CONTROL VALVE..................................50
Removal.................................................................... 50
Refitting .................................................................... 51
Disassembly ............................................................. 52
Assembly .................................................................. 55
CYLINDER ....................................................................57
Disassembly ............................................................. 57
Assembly .................................................................. 58
LIFT ARM OIL SEAL.....................................................59
Removal.................................................................... 59
Refitting .................................................................... 61
BUSHES ........................................................................62
Renewal .................................................................... 62
INTERNAL LINKAGE....................................................63
Removal.................................................................... 63
Refitting .................................................................... 64
HYDRAULIC LEVER LIMIT.......................................... 65
Adjustment ................................................................65
LIFT CONTROL VALVE................................................ 66
Disassembly ..............................................................66
Assembly...................................................................67
AUXILIARY SERVICES CONTROL VALVE
(4 WAYS) ............................................................. 68
AUXILIARY SERVICES CONTROL VALVE................. 68
Removal ....................................................................68
Refitting .....................................................................68
CONTROL RODS ......................................................... 69
Disassembly ..............................................................69
Assembly...................................................................69
DOUBLE/ SINGLE ACTING CONVERTER.................. 70
Overhaul ....................................................................70
CLUTCH HOUSING............................................ 71
Separation from the transmission .............................71
Reconnection to the transmission ............................76
GEARBOX AND SHUTTLE ASSEMBLY............ 77
COMPLETE ASSEMBLY.............................................. 77
Removal ....................................................................77
Refitting .....................................................................78
Disassembly ..............................................................79
Assembly...................................................................81
INPUT SHAFT............................................................... 83
Disassembly ..............................................................83
Assembly...................................................................84
PRIMARY SHAFT......................................................... 85
Disassembly ..............................................................85
Assembly...................................................................85
SECONDARY SHAFT................................................... 86
Disassembly ..............................................................86
Assembly...................................................................89
GEAR SELECTOR FORKS........................................... 90
Check flatness...........................................................90
REAR AXLE AND BRAKES................................ 91
REAR AXLE .................................................................. 91
Removal ....................................................................91
Refitting .....................................................................92
Disassembly ..............................................................93
Assembly...................................................................95
BRAKE.......................................................................... 99
Renewal of the braking discs ....................................99
REAR PTO ........................................................ 101
Disassembly ............................................................101
Assembly.................................................................104
RANGE GEARBOX AND REAR DIFFERENTIAL
ASSEMBLY....................................................... 105
RANGE GEARBOX INPUT SHAFT ............................ 105
Disassembly ............................................................105
Assembly.................................................................106
DIFFERENTIAL........................................................... 107
Removal ................................................................. 107
Refitting .................................................................. 108
Disassembly ........................................................... 109
Assembly................................................................ 110
BEVEL GEAR PAIR .................................................... 111
Disassembly ........................................................... 111
Preparation for installation ..................................... 113
Adjustment of the differential preload .................... 114
Adjustment of the pinion position .......................... 115
Adjustment of the pinion and crown wheel............ 118
Final assembly........................................................ 119
4WD AND GROUND SPEED PTO OUTPUT SHAFT 120
Disassembly ........................................................... 120
Assembly................................................................ 121
PEDALS AND CONTROL LEVERS.................. 122
BRAKE PEDALS ........................................................ 122
Adjustment ............................................................. 122
PARKING BRAKE LEVER.......................................... 122
Adjustment ............................................................. 122
CLUTCH PEDAL ........................................................ 123
Adjustment ............................................................. 123
PTO SPEED SELECTOR LEVER............................... 123
Adjustment ............................................................. 123
PTO ENGAGEMENT LEVER...................................... 123
Adjustment ............................................................. 123
RANGE GEAR LEVER................................................ 123
Adjustment ............................................................. 123
MAIN GEAR LEVER ................................................... 124
Adjustment ............................................................. 124
FRONT AXLE.................................................... 125
COMPLETE AXLE ASSEMBLY................................. 125
Removal ................................................................. 125
Refitting .................................................................. 127
BEVEL GEAR PAIR .................................................... 128
Disassembly ........................................................... 128
Assembly................................................................ 133
FINAL DRIVE REDUCTION UNITS ........................... 139
Removal ................................................................. 139
Refitting .................................................................. 139
OUTPUT FLANGE...................................................... 141
Disassembly ........................................................... 141
Assembly................................................................ 143
STEERING JOINT ...................................................... 144
Disassembly ........................................................... 144
Preparation For Assembly...................................... 146
Final assembly........................................................ 148
STEERING CYLINDER............................................... 149
Disassembly ........................................................... 149
Assembly................................................................ 152
THE STRUCTURE OF THE UNIT ................................ 1
HOW TO CONSULT THE UNIT ................................... 2
1. INTRODUCTION ...................................................... 3
1.1 LIST OF WIRING LOOMS.................................................. 3
1.2 DEFINITION OF COMPONENTS AND SYMBOLS ............ 3
1.3 GENERAL RULES.............................................................. 4
1.3.1 MODIFICATION OF THE TRACTOR'S
ELECTRICAL/ELECTRONIC CIRCUITS.................. 4
1.3.2 MAIN WIRING FAULTS........................................... 4
1.3.3 REMOVAL, REFITTING AND DRYING OF
CONNECTORS AND WIRING................................. 5
1.4 DIAGNOSTIC INSTRUMENTS........................................... 6
1.5 WIRE COLOUR CODES .................................................... 6
2. INDICES ................................................................... 7
2.1 INDEX BY PART DESCRIPTION........................................ 7
2.2 INDEX BY PART CODE ..................................................... 9
2.3 INDEX BY CONNECTOR................................................. 11
3. COMPONENTS ..................................................... 13
3.1 COMPONENT TECHNICAL DATA................................... 13
3.2 PREHEATING SYSTEM................................................... 16
3.3 ENGINE STOP SYSTEM.................................................. 16
4. SYSTEMS ............................................................... 17
4.1 EARTHING POINTS .........................................................17
4.2 STARTING........................................................................18
4.3 FRONT AXLE DIFFERENTIAL LOCK ...............................19
4.4 LIGHTS-SWITCH UNIT-BRAKES.....................................20
4.5 INSTRUMENT PANEL......................................................21
5. LAYOUTS, ELECTRICAL WIRING DIAGRAMS,
CONNECTOR POSITIONS .................................... 23
FRONT WIRING (1/2) ................................................................23
FRONT WIRING (2/2) ................................................................24
CENTRAL WIRING (1/2) ............................................................31
CENTRAL WIRING (2/2) ............................................................32
REAR WIRING (1/2)...................................................................43
REAR WIRING (2/2)...................................................................44
INTRODUCTION........................................................... 1
How to use this manual.............................................. 2
GENERAL INFORMATION
Model identification and serial number location ........ 5
Component positions - naturally aspirated engine
(S4L/S4L2).................................................................. 6
Component positions - turbo engine
(S4L-T/S4L2-T) ........................................................... 7
Specifications ............................................................. 8
OVERHAUL INSTRUCTIONS
Determining when to overhaul the engine.................. 9
Compression pressure measurement ...................... 10
Troubleshooting........................................................ 11
Basic precautions for disassembly and assembly ... 19
DISASSEMBLY
Preparation for disassembly..................................... 21
Electrical system ...................................................... 22
Cooling system......................................................... 27
Fuel system .............................................................. 28
Lubrication system. .................................................. 30
Air inlet system and exhaust system........................ 31
Cylinder head and valve mechanism........................ 32
Timing gears and flywheel........................................ 36
Cylinder block, crankshaft, pistons and oil pan ....... 41
INSPECTION
Cylinder head and valve mechanism........................ 47
Timing gears and flywheel........................................ 55
Cylinder block, crankshaft, pistons and oil pan ....... 59
ASSEMBLY
Cylinder block, crankshaft, pistons and oil pan ....... 68
Timing gears and flywheel........................................ 77
Cylinder head and valve mechanism........................ 84
Air inlet system and exhaust system........................ 89
Fuel system .............................................................. 90
Lubrication system ................................................... 92
Cooling system......................................................... 93
Electrical system ...................................................... 95
ELECTRICAL SYSTEM
General ..................................................................... 97
Starter ..................................................................... 101
Alternator ................................................................ 109
Key shutoff system................................................. 115
Automatic glow plug system .................................. 117
COOLING SYSTEM
General ................................................................... 120
Inspection ............................................................... 121
LUBRICATION SYSTEM
General ................................................................... 125
Inspection ............................................................... 126
FUEL SYSTEM
General ................................................................... 129
Fuel injection nozzle ............................................... 130
Fuel injection pump ................................................ 133
Governor................................................................. 140
Fuel pump............................................................... 143
Fuel filter ................................................................. 143
AIR INLET SYSTEM AND EXHAUST SYSTEM
General ................................................................... 146
Inspection ............................................................... 147
MAINTENANCE
Lubrications a maintenance chart .......................... 149
Engine oil and oil filter ............................................ 150
Valve clearance....................................................... 152
Fuel injection timing................................................ 154
Fuel filter ................................................................. 157
Fuel system priming ............................................... 159
Fuel injection nozzle ............................................... 160
Fan belt................................................................... 161
SERVICE DATA
Specifications ......................................................... 163
Tightening torques.................................................. 167
Sealants .................................................................. 169
Special tools ........................................................... 170
30
40
50
language:english
number of pages: 430 (full digital version)
Main sections:
Introduction
Safety sections
1. TRANSMISSION ................................................................ 1
1.1 INTRODUCTION ......................................................1
1.2 DESCRIPTION..........................................................2
1.2.1 DRIVE TRANSMISSION..................................3
1.3 CLUTCH HOUSING .................................................4
1.4 GEARBOX AND SHUTTLE ASSEMBLY...................5
1.5 4WD RANGE GEARS ASSEMBLY...........................6
1.6 PINION AND DIFFERENTIAL ASSEMBLY ...............7
1.7 BRAKES AND REAR AXLE ASSEMBLY ..................8
1.8 REAR PTO AND MID PTO .......................................9
1.8.1 COMPONENTS...............................................9
1.8.2 MAIN COMPONENTS...................................10
2. FRONT AXLE.................................................................... 11
2.1 STEERING CYLINDER...........................................12
2.2 DIFFERENTIAL- PINION - FINAL DRIVE UNIT.......13
3. CONTROLS ...................................................................... 14
3.1 RIGHT-HAND SIDE VIEW ......................................14
3.2 LEFT-HAND SIDE VIEW.........................................15
3.3 TOP VIEW ..............................................................16
4. HYDRAULIC SYSTEM..................................................... 17
4.1 DESCRIPTION .......................................................17
4.2 HYDRAULIC DIAGRAM.........................................18
4.3 STEERING CIRCUIT ..............................................19
4.3.1 FUNCTION....................................................19
4.3.2 OPERATION..................................................19
4.3.3 GEAR PUMP.................................................20
4.3.4 POWER STEERING ......................................21
4.3.5 DIFFERENTIAL LOCK CONTROL
ASSEMBLY...................................................23
4.3.6 AUXILIARY SERVICES CONTROL VALVE
(4 WAYS).......................................................25
4.3.7 POWER LIFT CONTROL VALVE...................26
ENGINE HOOD ..................................................... 1
Removal...................................................................... 1
Refitting ...................................................................... 1
SAFETY ROLL BAR.............................................. 2
Removal...................................................................... 2
Refitting ...................................................................... 2
SILENCER............................................................. 3
Removal...................................................................... 3
Refitting ...................................................................... 4
RADIATOR ............................................................ 5
Removal...................................................................... 5
Refitting ...................................................................... 7
FRONT SUPPORT ................................................ 8
Removal...................................................................... 8
Refitting .................................................................... 10
WHEELS.............................................................. 11
FRONT WHEELS...........................................................11
Removal.................................................................... 11
Refitting .................................................................... 11
REAR WHEELS.............................................................12
Removal.................................................................... 12
Refitting .................................................................... 12
INSTRUMENT PANEL........................................ 13
Removal.................................................................... 13
Refitting .................................................................... 14
CONSOLE SHROUDS ........................................ 15
Removal.................................................................... 15
Refitting .................................................................... 16
POWER STEERING ............................................ 17
Removal.................................................................... 17
Refitting .................................................................... 18
FUEL TANK......................................................... 19
Removal.................................................................... 19
Refitting .................................................................... 20
PLATFORM......................................................... 21
Removal.................................................................... 21
Refitting .................................................................... 23
STARTER MOTOR.............................................. 24
Removal.................................................................... 24
Refitting .................................................................... 26
HYDRAULIC PUMP............................................ 27
Removal.................................................................... 27
Refitting .................................................................... 27
ALTERNATOR..................................................... 28
Removal.................................................................... 28
Refitting .................................................................... 29
Tensioning the drivebelt ........................................... 29
ENGINE ............................................................... 31
Separating the engine from the transmission........... 31
Reconnecting the engine to the transmission .......... 36
Removal.................................................................... 37
Refitting .................................................................... 41
CLUTCH ASSEMBLY ......................................... 42
PTO CLUTCH................................................................42
Removal and renewal of the PTO clutch plate ......... 42
Check PTO clutch plate wear................................... 42
Refitting the PTO clutch plate .................................. 42
Adjustment of the clutch levers ................................ 43
PTO DRIVE SHAFT OIL SEAL......................................44
Renewal .................................................................... 44
CLUTCH RELEASE BEARINGS...................................45
Removal.................................................................... 45
Refitting .................................................................... 47
LIFT ..................................................................... 48
COMPLETE ASSEMBLY..............................................48
Removal.................................................................... 48
Refitting .................................................................... 49
POWER LIFT CONTROL VALVE..................................50
Removal.................................................................... 50
Refitting .................................................................... 51
Disassembly ............................................................. 52
Assembly .................................................................. 55
CYLINDER ....................................................................57
Disassembly ............................................................. 57
Assembly .................................................................. 58
LIFT ARM OIL SEAL.....................................................59
Removal.................................................................... 59
Refitting .................................................................... 61
BUSHES ........................................................................62
Renewal .................................................................... 62
INTERNAL LINKAGE....................................................63
Removal.................................................................... 63
Refitting .................................................................... 64
HYDRAULIC LEVER LIMIT.......................................... 65
Adjustment ................................................................65
LIFT CONTROL VALVE................................................ 66
Disassembly ..............................................................66
Assembly...................................................................67
AUXILIARY SERVICES CONTROL VALVE
(4 WAYS) ............................................................. 68
AUXILIARY SERVICES CONTROL VALVE................. 68
Removal ....................................................................68
Refitting .....................................................................68
CONTROL RODS ......................................................... 69
Disassembly ..............................................................69
Assembly...................................................................69
DOUBLE/ SINGLE ACTING CONVERTER.................. 70
Overhaul ....................................................................70
CLUTCH HOUSING............................................ 71
Separation from the transmission .............................71
Reconnection to the transmission ............................76
GEARBOX AND SHUTTLE ASSEMBLY............ 77
COMPLETE ASSEMBLY.............................................. 77
Removal ....................................................................77
Refitting .....................................................................78
Disassembly ..............................................................79
Assembly...................................................................81
INPUT SHAFT............................................................... 83
Disassembly ..............................................................83
Assembly...................................................................84
PRIMARY SHAFT......................................................... 85
Disassembly ..............................................................85
Assembly...................................................................85
SECONDARY SHAFT................................................... 86
Disassembly ..............................................................86
Assembly...................................................................89
GEAR SELECTOR FORKS........................................... 90
Check flatness...........................................................90
REAR AXLE AND BRAKES................................ 91
REAR AXLE .................................................................. 91
Removal ....................................................................91
Refitting .....................................................................92
Disassembly ..............................................................93
Assembly...................................................................95
BRAKE.......................................................................... 99
Renewal of the braking discs ....................................99
REAR PTO ........................................................ 101
Disassembly ............................................................101
Assembly.................................................................104
RANGE GEARBOX AND REAR DIFFERENTIAL
ASSEMBLY....................................................... 105
RANGE GEARBOX INPUT SHAFT ............................ 105
Disassembly ............................................................105
Assembly.................................................................106
DIFFERENTIAL........................................................... 107
Removal ................................................................. 107
Refitting .................................................................. 108
Disassembly ........................................................... 109
Assembly................................................................ 110
BEVEL GEAR PAIR .................................................... 111
Disassembly ........................................................... 111
Preparation for installation ..................................... 113
Adjustment of the differential preload .................... 114
Adjustment of the pinion position .......................... 115
Adjustment of the pinion and crown wheel............ 118
Final assembly........................................................ 119
4WD AND GROUND SPEED PTO OUTPUT SHAFT 120
Disassembly ........................................................... 120
Assembly................................................................ 121
PEDALS AND CONTROL LEVERS.................. 122
BRAKE PEDALS ........................................................ 122
Adjustment ............................................................. 122
PARKING BRAKE LEVER.......................................... 122
Adjustment ............................................................. 122
CLUTCH PEDAL ........................................................ 123
Adjustment ............................................................. 123
PTO SPEED SELECTOR LEVER............................... 123
Adjustment ............................................................. 123
PTO ENGAGEMENT LEVER...................................... 123
Adjustment ............................................................. 123
RANGE GEAR LEVER................................................ 123
Adjustment ............................................................. 123
MAIN GEAR LEVER ................................................... 124
Adjustment ............................................................. 124
FRONT AXLE.................................................... 125
COMPLETE AXLE ASSEMBLY................................. 125
Removal ................................................................. 125
Refitting .................................................................. 127
BEVEL GEAR PAIR .................................................... 128
Disassembly ........................................................... 128
Assembly................................................................ 133
FINAL DRIVE REDUCTION UNITS ........................... 139
Removal ................................................................. 139
Refitting .................................................................. 139
OUTPUT FLANGE...................................................... 141
Disassembly ........................................................... 141
Assembly................................................................ 143
STEERING JOINT ...................................................... 144
Disassembly ........................................................... 144
Preparation For Assembly...................................... 146
Final assembly........................................................ 148
STEERING CYLINDER............................................... 149
Disassembly ........................................................... 149
Assembly................................................................ 152
THE STRUCTURE OF THE UNIT ................................ 1
HOW TO CONSULT THE UNIT ................................... 2
1. INTRODUCTION ...................................................... 3
1.1 LIST OF WIRING LOOMS.................................................. 3
1.2 DEFINITION OF COMPONENTS AND SYMBOLS ............ 3
1.3 GENERAL RULES.............................................................. 4
1.3.1 MODIFICATION OF THE TRACTOR'S
ELECTRICAL/ELECTRONIC CIRCUITS.................. 4
1.3.2 MAIN WIRING FAULTS........................................... 4
1.3.3 REMOVAL, REFITTING AND DRYING OF
CONNECTORS AND WIRING................................. 5
1.4 DIAGNOSTIC INSTRUMENTS........................................... 6
1.5 WIRE COLOUR CODES .................................................... 6
2. INDICES ................................................................... 7
2.1 INDEX BY PART DESCRIPTION........................................ 7
2.2 INDEX BY PART CODE ..................................................... 9
2.3 INDEX BY CONNECTOR................................................. 11
3. COMPONENTS ..................................................... 13
3.1 COMPONENT TECHNICAL DATA................................... 13
3.2 PREHEATING SYSTEM................................................... 16
3.3 ENGINE STOP SYSTEM.................................................. 16
4. SYSTEMS ............................................................... 17
4.1 EARTHING POINTS .........................................................17
4.2 STARTING........................................................................18
4.3 FRONT AXLE DIFFERENTIAL LOCK ...............................19
4.4 LIGHTS-SWITCH UNIT-BRAKES.....................................20
4.5 INSTRUMENT PANEL......................................................21
5. LAYOUTS, ELECTRICAL WIRING DIAGRAMS,
CONNECTOR POSITIONS .................................... 23
FRONT WIRING (1/2) ................................................................23
FRONT WIRING (2/2) ................................................................24
CENTRAL WIRING (1/2) ............................................................31
CENTRAL WIRING (2/2) ............................................................32
REAR WIRING (1/2)...................................................................43
REAR WIRING (2/2)...................................................................44
INTRODUCTION........................................................... 1
How to use this manual.............................................. 2
GENERAL INFORMATION
Model identification and serial number location ........ 5
Component positions - naturally aspirated engine
(S4L/S4L2).................................................................. 6
Component positions - turbo engine
(S4L-T/S4L2-T) ........................................................... 7
Specifications ............................................................. 8
OVERHAUL INSTRUCTIONS
Determining when to overhaul the engine.................. 9
Compression pressure measurement ...................... 10
Troubleshooting........................................................ 11
Basic precautions for disassembly and assembly ... 19
DISASSEMBLY
Preparation for disassembly..................................... 21
Electrical system ...................................................... 22
Cooling system......................................................... 27
Fuel system .............................................................. 28
Lubrication system. .................................................. 30
Air inlet system and exhaust system........................ 31
Cylinder head and valve mechanism........................ 32
Timing gears and flywheel........................................ 36
Cylinder block, crankshaft, pistons and oil pan ....... 41
INSPECTION
Cylinder head and valve mechanism........................ 47
Timing gears and flywheel........................................ 55
Cylinder block, crankshaft, pistons and oil pan ....... 59
ASSEMBLY
Cylinder block, crankshaft, pistons and oil pan ....... 68
Timing gears and flywheel........................................ 77
Cylinder head and valve mechanism........................ 84
Air inlet system and exhaust system........................ 89
Fuel system .............................................................. 90
Lubrication system ................................................... 92
Cooling system......................................................... 93
Electrical system ...................................................... 95
ELECTRICAL SYSTEM
General ..................................................................... 97
Starter ..................................................................... 101
Alternator ................................................................ 109
Key shutoff system................................................. 115
Automatic glow plug system .................................. 117
COOLING SYSTEM
General ................................................................... 120
Inspection ............................................................... 121
LUBRICATION SYSTEM
General ................................................................... 125
Inspection ............................................................... 126
FUEL SYSTEM
General ................................................................... 129
Fuel injection nozzle ............................................... 130
Fuel injection pump ................................................ 133
Governor................................................................. 140
Fuel pump............................................................... 143
Fuel filter ................................................................. 143
AIR INLET SYSTEM AND EXHAUST SYSTEM
General ................................................................... 146
Inspection ............................................................... 147
MAINTENANCE
Lubrications a maintenance chart .......................... 149
Engine oil and oil filter ............................................ 150
Valve clearance....................................................... 152
Fuel injection timing................................................ 154
Fuel filter ................................................................. 157
Fuel system priming ............................................... 159
Fuel injection nozzle ............................................... 160
Fan belt................................................................... 161
SERVICE DATA
Specifications ......................................................... 163
Tightening torques.................................................. 167
Sealants .................................................................. 169
Special tools ........................................................... 170