DIESEL ENGINES
IMPORTANT: Whenever making a repair, the reason for the cause of the problem must be investigated and cor-rected to avoid repeat failures.
The following tables list problems and their possible causes with recommended corrective action.
GENERAL
PROBLEM POSSIBLE CAUSES CORRECTION
Fuel not reaching injection pump 1. Restricted fuel filters 2. Air in system 3. Fuel leakage
1. Check and flush the fuel filters clean.
2. Bleed the fuel filters.
3. Check the fuel lines and connectors for damage.
Fuel reaching nozzles but engine will not start
1. Check the cranking speed 2. Check the throttle control
rod travel
3. Check the pump timing 4. Check the fuel lines and
connectors for leakage 5. See injector
troubleshooting 6. Check the engine
compression Engine hard to start 1. Low cranking speed
2. Incorrect pump timing 3. Restricted fuel filters 4. Contaminated fuel 5. Low compression 6. Air in system
1. Check the cranking speed 2. Check the pump timing 3. Replace filters
4. Check for water in the fuel 5. Check the engine
compression
6. Check for air leaks on the suction side of the system Engine starts and stops 1. Fuel starvation
2. Contaminated fuel 3. Restricted air intake 4. Engine overheating 5. Air in system
1. Check and flush clean restricted fuel lines or fuel filters
2. Check for water in the fuel 3. Check for restrictions in the
air intake
4. Check cooling system 5. Check for air leaks on the
suction side of the system
PROBLEM POSSIBLE CAUSES CORRECTION
6. Faulty or sticking injector nozzles
7. Incorrect engine timing
1. Check the injector lines and connectors for leakage 2. Check and flush clean
restricted fuel lines or filters
3. Check the pump timing 4. Check for water in the fuel 5. Bleed the fuel system 6. See injector
troubleshooting
7. Check for faulty engine valves
Engine emits black smoke 1. Restricted air intake 2. Engine overheating 3. Incorrect timing 4. Faulty injectors 5. Low compression 6. Incorrect engine timing
1. Check for restricted air intake
2. Check cooling system 3. Check the pump timing 4. See injector
troubleshooting 5. Check the engine
compression
6. Check the engine valves Engine does not develop full
power or speed 3. Check and flush clean
restricted fuel lines and filters
4. Check for air leaks on the suction side of the system 5. Check pump timing 6. Check engine compression 7. Check for improper valve adjustment or faulty valves
ADJUSTMENTS FUEL INJECTION PUMP (OP NO 210)
PRIMING THE FUEL SYSTEM
NOTE: The fuel system should be primed whenever fuel system components are removed or discon-nected in order to expel any air in the system.
1. Make sure there is sufficient fuel in the tank and all connections are tight.
2. Operate key start switch to activate the electric fuel pump. An audible difference is detectable when the system is primed, and may take up to 5 minutes.
NOTE: The bleed screw in the filter head is on the in-take side and must be kept closed during priming Attempt to start the engine. If it does not start, con-tinue through Step 4.
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10 3. With the throttle in the maximum no-load speed
position, operate the starting motor to crank the engine. The fuel injection pump is self-venting and does not require bleeding.
IMPORTANT: Do not crank the starting motor con-tinuously for more than 60 seconds as doing so may cause starting motor failure.
4. If the engine fails to start after 60 seconds, repeat the priming procedure outlined above.
5. Run the engine and check for leaks.
NOTE: Turbocharged engines only - The high oper-ating speed of the turbocharger makes it essential that adequate lubrication is assured when the engine is started. Therefore, idle the engine at 1000 RPM for one minute before driving the tractor.
IDLE SPEED ADJUSTMENT
1. With the engine running and at normal tempera-ture, disconnect the throttle cable at the injection pump.
2. Loosen the locknut and adjust the idle speed stop screw (1) until the specified idle speed of 700–800 RPM is obtained. Tighten the locknut and reconnect the throttle cable.
3. Operate the throttle lever several times and check that the idle speed is correct. If excessive free play is felt in either the foot or hand throttle after adjustment, proceed to “Throttle Linkage Adjustments” in this section.
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THROTTLE LINKAGE ADJUSTMENTS (OP NO 10 220)
NOTE: If the throttle cables have been removed from the tractor, it is necessary to install and adjust the hand throttle cable prior to the installation of the foot throttle cable. The following procedures assume that the fuel injection pump idle and maximum no-load speeds are correctly adjusted.
1. Loosen the locknut at the ball stud connector (1), on the throttle cable at the fuel injection pump.
Retract the retaining sleeve and disconnect the cable from the pump throttle lever.
2. Remove the access cover below the hand throttle and verify the the cable locknut (2) is tight against the throttle lever assembly.
3. Set the hand throttle lever in the idle position by placing against the rubber boot at the rear of the lever slot (3).
4. Adjust the ball stud connector at the pump end of the throttle cable so that it fits on the ball stud of the pump throttle lever when the lever is in low idle position. Tighten the locknut against the re-taining sleeve at the pump end.
5. Remove the rubber boot from the lever slot.
Move the hand throttle lever to the maximum speed position. Check that the lever stops as the pump throttle lever touches the maximum speed stop screw. Adjust the hand lever stop as re-quired. Replace the rubber boot.
6. Check the adjustment of the foot throttle by pressing the pedal against the stop bolt (4). Ad-justment is correct when the pedal is firmly against the stop bolt and the pump throttle lever gently touches the maximum speed stop screw.
Adjust the pedal stop bolt as required.
1 2
4 3
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FUEL TANK REMOVAL, (Op No 10 216)
NOTE: Prior to removing the fuel tank from the trac-tor, first determine the quantity of fuel left in the tank.
It will be necessary to drain the tank of fuel.
1. Disconnect the battery, earth lead first, or at the isolator switch where fitted.
14 2. With the tank drained of fuel disconnect the fuel
line to the lift pump. Plug the exposed pipes to prevent contamination.
3. Loosen and remove the tank to frame attaching bolts and lower the tank to the ground
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FUEL FILTER/SEDIMENT SEPARATOR (OP NO 10 206)
Removal
1. Drain the filter and sediment separator of fuel, by removing the bowl drain screw (3).
2. Disconnect and remove the fuel lines from the head of the filter/sediment separator assembly and plug the exposed openings to prevent con-tamination.
3. Remove the retaining bolts, then remove the as-sembly from the tractor.
16 Disassembly
1. Remove the center retaining bolts and separate the filter components.
2. Using clean fuel, wash out the filter bowl and the glass bowl on the sediment separator.
Reassembly
Reassembly of the fuel filter/sediment separator fol-lows the disassembly procedure in reverse. On reas-sembly, observe the following requirements:
3. Install a new filter element and sealing rings, be sure the sealing rings are correctly positioned.
4. Tighten the center retaining bolts.
Installation
Installation of the fuel filter/sediment separator as-sembly follows the removal procedure in reverse. On installation, observe the following requirements:
5. Tighten the retaining bolts.
6. Assemble the fuel pipes to the connectors in the head and tighten the nuts until the stop is reached (metal to metal contact).
7. Bleed the fuel system as previously described.
SECTION 10 – FUEL Air Cleaners
CONTENT
Section Description Page
10 202 Specifications . . . 13 Tightening Torques . . . 13 Description and Operation. . . 14 Fault Finding . . . 15 Overhaul . . . 15
SPECIFICATIONS AIR CLEANER
Type. . . Dry, Dual Element
Change Interval. . . 600 hours (or more frequently when operating in adverse conditions)
TORQUE VALUES
DESCRIPTION ft. lbs. N·m kgf/m Air Cleaner Retaining Bolts
Air Cleaner Hose Clamps
Air Cleaner Restriction Indicator Switch
40 1.8 9
55 2.5 12
5.6 0.25
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DESCRIPTION AND OPERATION
The tractors feature a dry element type air cleaner lo-cated beneath the engine top hood panel.
Air enters the cleaner in a circular direction and cen-trifugal force results in heavier particles being thrown to the outside of the container and collecting in the bottom of the cleaner. The lighter particles are col-lected on the (outer) primary element.
The inner (secondary) element is located within the outer element. The element protects the engine from the finer dust particles that may have passed through the outer element.
17 A vacuum indicator switch is mounted in the air
cleaner outlet tube and illuminates a warning light on the instrument console when the air cleaner requires servicing.
If the air cleaner restriction warning light illuminates when the engine is running, stop the engine and ser-vice the air cleaner.
18 IMPORTANT: The safety element must be replaced
if damaged or clogged with dust, or if, after cleaning or installing a new outer element, the warning light re-mains on when the engine is running.
If the warning light remains on after installation of both inner and outer elements, check the switch for faulty operation by replacing with a switch known to function correctly.
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FAULT FINDING
PROBLEM POSSIBLE CAUSES REMEDY
Air Cleaner Warning Light 1. Clogged Air Cleaner 1. Clean or renew
illuminates outer element
Air Cleaner Warning Light 2. Vacuum Switch Faulty 2. Replace switch with illuminates, after filter service a new one
Air Cleaner Warning Light 3. Aspirator tube not 3. Clear Aspirator tube, illuminates, before service working, debris in check muffler, clean
intervals. filter body element and refit.
OVERHAUL REMOVAL
1. Remove the engine side panels and lift off the pre-cleaner assembly.
2. Loosen the outlet hose clamp.
3. Remove the attaching bolts and withdraw the air cleaner assembly.
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20 DISASSEMBLY
1. Remove the wing nut and extract the outer el-ement.
2. With the outer element removed extract the inner element.
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INSPECTION AND REPAIR
1. Clean and examine the outer canister. Repair any damaged seams.
2. Check the condition and fit of the rubber dust col-lector.
3. If dust is present inside the outer element, it must be replaced. If satisfactory, clean the element.
4. Wearing safety goggles and using compressed air not exceeding 2 bar (29 psi) clean the ement. Insert the air line nozzle inside the el-ement and blow the dust from the inside to the outside. Blow loose particles from the outside of the element by holding the nozzle at least 150 mm (5.9in) from the element.
5. If undamaged, wash the element every 300 hours or after five dry cleanings, whichever oc-curs first, using the following procedure:
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IMPORTANT: Never use fuel oil, solvent, or water hotter than the hand can stand, otherwise the el-ement may be damaged.
A Seal the small hole at the closed end of the filter with a strip of adhesive tape and place the filter, open end up, in a deep flat-bot-tomed container or tub. Add a small amount of non-sudsing washing powder (automatic washing machine type) to the inside of the filter element. Add warm water35° C (100° F) to the inside of the element until the level in the container is just below the open end of the element. Allow the element to soak for at least 15 minutes (but never more than 24 hours) in the cleaning solution.
B After soaking, gently agitate the element, being careful not to allow dirty cleaning sol-ution from the container to splash into the in-side of the element.
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C Rinse the element in clean cold water, allow-ing water to flow from the inside through the element until the water comes through clear.
If using a hose do not use a pressured flow, a slow trickle is sufficient. Make sure water is allowed to flow through the entire element.
24 D Remove the adhesive tape and shake
ex-cess water from the filter element and allow to dry naturally. The element will need 24-48 hours to dry thoroughly. Install a new ement at this stage, retaining the washed el-ement for the next service.
IMPORTANT: Do not attempt to dry the element with compressed air or install before thoroughly dry as it may rupture. It is recommended that a new element is installed at this service and the washed element al-lowed to dry and retained for installation at the next service.
6. When dry, check the element for damage by in-serting a lamp into the middle of the element and observing the element surface. An even, fine pattern of light indicates the element is clean, un-damaged and suitable for further service.
7. Every 600 hours the element must be replaced.
INSTALLATION
Installation of the dry type air cleaner is the removal procedure in reverse, on installation observe the fol-lowing requirements:
1. Tighten the retaining bolts.
2. Tighten the outlet hose clamp.
REASSEMBLY
Reassembly of the dry type air cleaner is the disas-sembly procedure in reverse.
On reassembly, make sure the outer element sealing ring is secure.