service repair manual

1. © 2016 CNH Industrial America LLC. All Rights Reserved.
SERVICE MANUAL
BoomerTM
20 / BoomerTM
25
Compact Tractor
Part number 48017684
English
June 2016
SERVICE
MANUAL
BoomerTM
20
BoomerTM
25
Compact Tractor
Part number 48017684

2. SERVICE MANUAL
Boomer™ 20
Boomer™ 25
48017684 02/06/2016
EN

3. Link Product / Engine
Product Market Product Engine
Boomer™ 20 Europe S3L2
Boomer™ 25 Europe S3L2
48017684 02/06/2016

4. Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase ............................................................. 10.1
[10.304] Engine lubrication system.......................................................... 10.2
[10.400] Engine cooling system ............................................................. 10.3
Clutch ....................................................................................... 18
[18.110] Clutch and components ............................................................ 18.1
[18.112] Slip clutch or flywheel damper ..................................................... 18.2
Transmission.............................................................................. 21
[21.114] Mechanical transmission ........................................................... 21.1
Front axle system ....................................................................... 25
[25.100] Powered front axle ................................................................. 25.1
[25.102] Front bevel gear set and differential ............................................... 25.2
[25.108] Final drive hub, steering knuckles, and shafts ..................................... 25.3
[25.310] Final drives ......................................................................... 25.4
Rear axle system........................................................................ 27
[27.106] Rear bevel gear set and differential................................................ 27.1
[27.124] Final drive hub, steering knuckles, and shafts ..................................... 27.2
Hydrostatic drive......................................................................... 29
[29.100] Transmission and steering hydrostatic control ..................................... 29.1
[29.202] Hydrostatic transmission ........................................................... 29.2
[29.204] Reservoir, cooler, and lines ........................................................ 29.3
[29.218] Pump and motor components...................................................... 29.4
Power Take-Off (PTO)................................................................. 31
[31.101] Rear mechanical control ........................................................... 31.1
[31.104] Rear electro-hydraulic control...................................................... 31.2
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5. [31.110] One-speed rear Power Take-Off (PTO) ............................................ 31.3
[31.120] Central Power Take-Off (PTO) ..................................................... 31.4
Brakes and controls .................................................................... 33
[33.110] Parking brake or parking lock ...................................................... 33.1
[33.120] Mechanical service brakes ......................................................... 33.2
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems.................................................................. 35.1
[35.104] Fixed displacement pump.......................................................... 35.2
[35.114] Three-point hitch control valve ..................................................... 35.3
[35.116] Three-point hitch cylinder .......................................................... 35.4
[35.204] Remote control valves ............................................................. 35.5
[35.300] Reservoir, cooler, and filters........................................................ 35.6
[35.350] Safety and main relief valves ...................................................... 35.7
Hitches, drawbars, and implement couplings.................................. 37
[37.110] Rear three-point hitch .............................................................. 37.1
Steering..................................................................................... 41
[41.106] Tie rods............................................................................. 41.1
[41.200] Hydraulic control components...................................................... 41.2
[41.216] Cylinders ........................................................................... 41.3
Wheels...................................................................................... 44
[44.511] Front wheels........................................................................ 44.1
[44.520] Rear wheels........................................................................ 44.2
Electrical systems....................................................................... 55
[55.000] Electrical system ................................................................... 55.1
[55.010] Fuel injection system............................................................... 55.2
[55.011] Fuel tank system ................................................................... 55.3
[55.012] Engine cooling system ............................................................. 55.4
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6. [55.013] Engine oil system .................................................................. 55.5
[55.031] Parking brake electrical system .................................................... 55.6
[55.048] Rear Power Take-Off (PTO) control system ....................................... 55.7
[55.100] Harnesses and connectors......................................................... 55.8
[55.201] Engine starting system ............................................................. 55.9
[55.202] Cold start aid ..................................................................... 55.10
[55.302] Battery............................................................................ 55.11
[55.404] External lighting .................................................................. 55.12
[55.405] External lighting switches and relays ............................................ 55.13
[55.408] Warning indicators, alarms, and instruments .................................... 55.14
Platform, cab, bodywork, and decals............................................. 90
[90.120] Mechanically-adjusted operator seat............................................... 90.1
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7. INTRODUCTION
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1

8. Contents
INTRODUCTION
Foreword ........................................................................................ 3
Foreword - Important notice regarding equipment servicing .................................... 4
International symbols ........................................................................... 5
Safety rules ..................................................................................... 6
Safety rules ..................................................................................... 7
Safety rules - Ecology and the environment .................................................... 8
Basic instructions hardware .................................................................... 9
Torque - Standard torque data for hydraulic connections ..................................... 10
Basic instructions - Shop and assembly ...................................................... 17
General specification - Tractors with Hydrostatic Transmission (HST) ....................... 19
General specification - Tractor with mechanical transmission ................................ 23
General specification ......................................................................... 26
Dimension .................................................................................... 27
Consumables ................................................................................. 30
Capacities ..................................................................................... 31
Product identification .......................................................................... 32
Product identification machine orientation .................................................... 34
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2

9. INTRODUCTION
Foreword
This repair manual provides the technical information needed to properly service the NEW HOLLAND models Boomer
20 and 25 tractors. Use this manual in conjunction with the operator's manual for complete operation, adjustment,
and maintenance information
On NEW HOLLAND equipment, left and right are determined by standing behind the unit, looking in the direction of
travel.
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10. INTRODUCTION
Foreword - Important notice regarding equipment servicing
All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or
local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manu-
facturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The manufacturer reserves the right to make improvements in design and changes in specifications at any time without
notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and
illustrative material herein are as accurate as known at time of publication but are subject to change without notice.
In case of questions, refer to your NEW HOLLAND Sales and Service Networks.
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4

11. INTRODUCTION
Safety rules
Personal safety
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury.
Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in-
structions. These precautions are intended for the personal safety of you and those working with you.
Read and understand all the safety messages in this manual before you operate or service the machine.
DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT
IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.
Information
NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about a step, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.
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12. INTRODUCTION
Safety rules - Ecology and the environment
Soil, air, and water quality is important for all industries and life in general. When legislation does not yet rule the
treatment of some of the substances that advanced technology requires, sound judgment should govern the use and
disposal of products of a chemical and petrochemical nature.
Familiarize yourself with the relative legislation applicable to your country, and make sure that you understand this
legislation. Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, anti-freeze,
cleaning agents, etc., with regard to the effect of these substances on man and nature and how to safely store, use,
and dispose of these substances.
Helpful hints
• Avoid the use of cans or other inappropriate pressurized fuel delivery systems to fill tanks. Such delivery systems
may cause considerable spillage.
• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of these products contain substances
that may be harmful to your health.
• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.
• Avoid spillage when you drain fluids such as used engine coolant mixtures, engine oil, hydraulic fluid, brake fluid,
etc. Do not mix drained brake fluids or fuels with lubricants. Store all drained fluids safely until you can dispose of
the fluids in a proper way that complies with all local legislation and available resources.
• Do not allow coolant mixtures to get into the soil. Collect and dispose of coolant mixtures properly.
• The air-conditioning system contains gases that should not be released into the atmosphere. Consult an air-condi-
tioning specialist or use a special extractor to recharge the system properly.
• Repair any leaks or defects in the engine cooling system or hydraulic system immediately.
• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.
• Protect hoses during welding. Penetrating weld splatter may burn a hole or weaken hoses, allowing the loss of oils,
coolant, etc.
Battery recycling
Batteries and electric accumulators contain several substances that can have a harmful
effect on the environment if the batteries are not properly recycled after use. Improper
disposal of batteries can contaminate the soil, groundwater, and waterways. NEW
HOLLAND strongly recommends that you return all used batteries to a NEW HOLLAND
dealer, who will dispose of the used batteries or recycle the used batteries properly. In
some countries, this is a legal requirement.
Mandatory battery recycling
NOTE: The following requirements are mandatory in Brazil.
Batteries are made of lead plates and a sulfuric acid solution. Because batteries contain heavy metals such as lead,
CONAMA Resolution 401/2008 requires you to return all used batteries to the battery dealer when you replace any
batteries. Do not dispose of batteries in your household garbage.
Points of sale are obliged to:
• Accept the return of your used batteries
• Store the returned batteries in a suitable location
• Send the returned batteries to the battery manufacturer for recycling
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13. SERVICE MANUAL
Engine
Boomer™ 20
Boomer™ 25
48017684 02/06/2016
10

14. Engine - Engine and crankcase
Engine - General specification
Engine Model S3L , S3L2
Type Water cooled, 4-stroke cycle diesel
No. of cylinders 3
Combustion type Swirl chamber
Valve mechanism Overhead valve type
Cylinder bore x stroke 78 mm x 92 mm ( 3.07 in x 3.62 in)
Total displacement 1.3 l (79 in³)
Compression ratio 22:1
Fuel used JIS K2204, Diesel fuel or its equivalent (ASTM diesel fuel oil
No. 2-D)
Firing order 1 - 3 - 2
Direction of rotation Counterclockwise as viewed from flywheel side
Length 512 mm (20.2 in)
Width 453 mm (17.8 in)
Height 563 mm (22.2 in)
Dry weight Approximately 140 kg (309 lb)
Inspection point Nominal Standard Limit Remark
Maximum rotation speed
(rated rotation speed used as
reference)
Varies depending on specification of
destination
Minimum rotation speed Varies depending on specification of
destination
Compression ratio @ 290 RPM 29 bar (421 psi) or above 26 bar
(377 psi)
or less
When oil and water
temperatures at 20 - 30 °C
(68 - 86 °F)
Valve timing
Intake
- Open BTDC 15 °
- Close ABDC 41 °
Exhaust
- Open BBDC 54 °
- Close ATDC 10 °
With 2 mm (0.079 in) clearance
on valve side, when cold.
Values are only for checking
valve timing and are different
from the actual ones.
Rocker arm
Rocker arm inside diameter 18.9 mm
(0.744 in)
18.910 - 18.930 mm
(0.7445 - 0.7453 in)
Rocker shaft outside diameter 18.9 mm
(0.744 in)
18.880 - 18.930 mm
(0.7433 - 0.7453 in)
Clearance between rocker arm
and rocker shaft (oil clearance)
0.012 - 0.050 mm
(0.0005 - 0.0020 in)
0.200
mm (0.00
79 in)
Replace rocker arm
Valve
Valve stem outside diameter
- Intake 6.6 mm
(0.260 in)
6.565 - 6.580 mm
(0.2585 - 0.2591 in)
6.500
mm (0.25
59 in)
- Exhaust 6.6 mm
(0.260 in)
6.530 - 6.550 mm
(0.2571 - 0.2579 in)
6.500
mm (0.25
59 in)
Valve guide inside diameter
- Intake 6.6 mm
(0.260 in)
6.600 - 6.615 mm
(0.2598 - 0.2604 in)
- Exhaust 6.6 mm
(0.260 in)
6.600 - 6.615 mm
(0.2598 - 0.2604 in)
Clearance between valve
guide and valve stem
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15. Engine - Engine and crankcase
Inspection point Nominal Standard Limit Remark
- Intake 0.020 - 0.050 mm
(0.0008 - 0.0020 in)
0.100
mm (0.00
39 in)
- Exhaust 0.050 - 0.085 mm
(0.0020 - 0.0033 in)
0.150
mm (0.00
59 in)
Replace valve and valve guide
Valve seat angle 45 °
Valve sinkage 0 mm
(0.00 in)
0.25 - 0.75 mm
(0.0098 - 0.0295 in)
1.50 mm
(0.0591
in)
Valve head width 1.6 mm
(0.063 in)
1.30 - 1.80 mm
(0.0512 - 0.0709 in)
2.50 mm
(0.0984
in)
Valve margin 1.5 mm
(0.059 in)
1.35 - 1.65 mm
(0.0531 - 0.0650 in)
0.50 mm
(0.0197
in)
Valve guide mounting length 10 mm
(0.39 in)
9.5 - 10.5 mm (0.374 -
0.413 in)
Valve spring
Free length 47 mm (1.85 in) 46 mm
(1.81 in)
Length @ 131 - 145 N (29 -
33 lb)
39.0 mm (1.535 in) -15 %
Length @ 279 - 309 N (63 -
69 lb)
30.1 mm (1.185 in) -15 %
Push rod runout 0.3 mm (0.012 in) Replace
Cylinder head distortion 0.05 mm (0.0020 in) 0.10 mm
(0.0039
in)
Cylinder
Cylinder block distortion (Deck) 0.05 mm (0.0020 in) or
less
0.10 mm
(0.0039
in)
Repair
Inside diameter 78 mm
(3.071 in)
78 mm (3.071 in) 78.2 mm
(3.079 in)
Repair to oversize or replace
Cylindericity 0.01 mm (0.0004 in) or
less
Piston
Outside diameter
- STD 78.00 mm
(3.0709
in)
77.93 - 77.95 mm (3.0681
- 3.0689 in)
77.80
mm (3.06
30 in)
- 0.25 mm (0.010 in) OS 78.25 mm
(3.0807
in)
78.18 - 78.20 mm (3.0780
- 3.0787 in)
78.05
mm (3.07
28 in)
- 0.50 mm (0.020 in) OS 78.50 mm
(3.0906
in)
78.43 - 78.45 mm (3.0878
- 3.0886 in)
78.30
mm (3.08
27 in)
Weight difference within an
engine
+ / - 5 g (0.18 oz) or less
Piston pin outside diameter 23 mm
(0.91 in)
22.994 - 23.000 mm
(0.9053 - 0.9055 in)
Clearance between piston pin
bore and piston pin
0.006 - 0.018 mm (0.0002
- 0.0007 in)
0.050
mm (0.00
20 in)
Clearance between piston and
cylinder
0.035 - 0.086 mm (0.0014
- 0.0034 in)
0.300
mm (0.01
18 in)
Repair to oversize or replace
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16. Engine - Engine and crankcase
Inspection point Nominal Standard Limit Remark
Piston ring
Clearance between the piston
ring and ring groove
- Top compression ring 0.09 - 0.11 mm (0.0035 -
0.0043 in)
0.30 mm
(0.0118
in)
Replace the rings until the limits
are reached, then replace the
piston.
- Intermediate ring 0.07 - 0.11 mm (0.0028 -
0.0043 in)
0.20 mm
(0.0079
in)
Replace the rings until the limits
are reached, then replace the
piston.
- Oil ring 0.03 - 0.07 mm (0.0012 -
0.0028 in)
0.20 mm
(0.0079
in)
Replace the rings until the limits
are reached, then replace the
piston.
Piston ring end gap
- Top compression ring 0.15 - 0.30 mm (0.0059 -
0.0118 in)
1.50 mm
(0.0591
in)
Replace
- Intermediate ring 0.15 - 0.30 mm (0.0059 -
0.0118 in)
1.50 mm
(0.0591
in)
Replace
- Oil ring 0.20 - 0.40 mm (0.0079 -
0.0157 in)
1.50 mm
(0.0591
in)
Replace
Connecting rod
Bend and torsion (over a
100 mm (3.9 in) span
0.05 mm (0.0020 in) or
less
0.15 mm
(0.0059
in)
End play 0.10 - 0.35 mm (0.0039 -
0.0138 in)
0.50 mm
(0.0197
in)
Replace the connecting rod
Crankshaft
Crank journal outside diameter 52 mm
(2.05 in)
51.985 - 52.000 mm
(2.0467 - 2.0472 in)
Crank pin outside diameter 48 mm
(1.89 in)
47.950 - 47.965 mm
(1.8878 - 1.8884 in)
Crankshaft runout 0.025 mm (0.0010 in) or
less
0.050
mm (0.00
20 in)
Repair or replace
Main bearing oil clearance 0.030 - 0.077 mm (0.0012
- 0.0030 in)
0.100
mm (0.00
39 in)
Replace main bearing
Connecting rod bearings oil
clearance
0.025 - 0.072 mm (0.0010
- 0.0028 in)
0.150
mm (0.00
59 in)
Replace connecting rod
bearings
End play 0.050 - 0.175 mm (0.0020
- 0.0069 in)
0.500
mm (0.01
97 in)
Replace flanged No. 3 main
bearing
Timing gear backlash
Between crankshaft gear and
idler gear
0.04 - 0.12 mm (0.0016 -
0.0047 in)
0.30 mm
(0.0118
in)
Replace
Between idler gear and valve
camshaft gear
0.04 - 0.12 mm (0.0016 -
0.0047 in)
0.30 mm
(0.0118
in)
Replace
Between idler gear and pump
camshaft gear
0.04 - 0.12 mm (0.0016 -
0.0047 in)
0.30 mm
(0.0118
in)
Replace
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17. Engine - Engine and crankcase
Inspection point Nominal Standard Limit Remark
Between valve camshaft gear
and PTO gear
0.08 - 0.19 mm (0.0031 -
0.0075 in)
0.30 mm
(0.0118
in)
Replace
Between pump camshaft gear
and oil pump gear
0.07 - 0.20 mm (0.0028 -
0.0079 in)
0.30 mm
(0.0118
in)
Replace
Cam height 35.62 - 35.82 mm (1.4024
- 1.4102 in)
34.72
mm (1.36
69 in)
Replace
Flywheel flatness 0.15 mm (0.0059 in) or
less
0.50 mm
(0.0197
in)
Repair
Clearance between tappet and
cylinder block bore
0.15 mm
(0.0059
in)
Replace tappet
Clearance between camshaft
journal and bushing
0.05 - 0.125 mm (0.0020 -
0.0049 in)
0.15 mm
(0.0059
in)
Replace
Clearance between idler gear
bushing and idler shaft
0.02 - 0.07 mm (0.0008 -
0.0028 in)
0.20 mm
(0.0079
in)
Replace idler gear or idler shaft
Engine - Torque
Description Threads
Diameter x pitch
Torque
Cylinder head bolt M10 x 1.75 83 - 93 N·m (61 - 69 lb ft)
Rocker cover bolt M8 x 1.25 10 - 13 N·m (7 - 10 lb ft)
Rocker shaft bracket bolt M8 x 1.25 10 - 20 N·m (7 - 15 lb ft)
Rocker arm adjusting nut M8 x 1.25 18 - 22 N·m (13 - 16 lb ft)
Tachometer L joint union nut M22 x 1.5 17 - 23 N·m (13 - 17 lb ft)
Band type hose cramp - 3 - 4 N·m (2 - 3 lb ft)
Thrust plate M8 x 1.25 10 - 12 N·m (7 - 9 lb ft)
Main bearing cap bolt M10 x 1.25 49 - 54 N·m (36 - 40 lb ft)
Connecting rod cap nut M9 x 1.0 32 - 37 N·m (24 - 27 lb ft)
Flywheel bolt M12 x 1.25 127 - 137 N·m (94 - 101 lb ft)
Crankshaft pulley nut M18 x 1.5 147 - 196 N·m (108 - 145 lb ft)
Rear plate use mounting bolt
- For general use M12 x 1.25 54 - 74 N·m (40 - 55 lb ft)
- For tractor M12 x 1.25 83 - 103 N·m (61 - 76 lb ft)
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18. Engine - Engine and crankcase
Engine - Remove
WARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
Failure to comply could result in death or serious injury.
W0398A
WARNING
Avoid injury!
Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protec-
tive Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety
footwear.
Failure to comply could result in death or serious injury.
W0208A
WARNING
Hot liquid under pressure!
Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot.
Let the system cool. Turn the filler cap to the first notch and allow any pressure to escape, and then
remove the filler cap. Loosen the recovery tank cap slowly to allow any pressure to escape.
Failure to comply could result in death or serious injury.
W0296A
Engine removal
1. Open the hood and disconnect the negative (-) battery
terminal (1).
83115266 1
2. Open the drain cock (1) under the left hand side of the
radiator.
83118786 2
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19. Engine - Engine and crankcase
3. Drain the engine coolant into a clean container (2).
NOTE: Engine coolant capacity is 3.8 l (1 US gal)
83118785 3
4. Loosen the radiator cap (3) to accelerate draining all of
the fluid.
83118787 4
5. Loosen the hose clamp and disconnect the lower
coolant hose (1) located on the right hand side of the
engine.
83118788 5
6. Loosen the hose clamp (2) and disconnect the upper
coolant hose.
83118789 6
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20. Engine - Engine and crankcase
7. Remove the M8 x 16mm radiator retaining bracket bolts
(1).
83118790 7
8. Remove the radiator (1) in the direction of the arrow.
83118791 8
9. Disconnect the electrical connection (1) remove the clip
(2).
10. Remove the hood retaining nuts (3).
11. Remove the engine hood (4)
83118792 9
12. Disconnect the throttle cable (1) and the fuel line (2).
83118793 10
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21. Engine - Engine and crankcase
13. Disconnect the engine electrical connectors (1) lo-
cated under the left hand side of the instrument panel.
83118794 11
14. Remove the rubber cover (1), and the M8 nut. Dis-
connect the positive (+) battery cable from the starter
motor.
83118795 12
15. Disconnect the negative (-) ground cable by removing
bolt (1).
83118796 13
NOTICE: Insure that all necessary tubes, hoses and electrical connectors have been disconnected . It may also be
necessary to disconnect additional items due to other optional systems being installed on the tractor.
16. Remove the four M14 engine mount retaining nuts (1).
83118797 14
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22. Engine - Engine and crankcase
17. Use an overhead hoist (1) to lift the engine (2). Place
engine on a suitable stand.
83118798 15
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23. Engine - Engine and crankcase
Engine - Install
WARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
Failure to comply could result in death or serious injury.
W0398A
WARNING
Avoid injury!
Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protec-
tive Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety
footwear.
Failure to comply could result in death or serious injury.
W0208A
WARNING
Hot liquid under pressure!
Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot.
Let the system cool. Turn the filler cap to the first notch and allow any pressure to escape, and then
remove the filler cap. Loosen the recovery tank cap slowly to allow any pressure to escape.
Failure to comply could result in death or serious injury.
W0296A
1. Use an overhead hoist (1) to lift the engine (2).
2. Place the engine on the chassis mounts.
83118798 1
3. Install four M14 engine mount retaining nuts (1).
83118797 2
NOTICE: Ensure that all necessary tubes, hoses and electrical connectors have been connected . It may also be
necessary to connect additional items due to other optional systems being installed on the tractor.
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24. Engine - Engine and crankcase
4. Connect the negative (-) ground cable by installing bolt
(1).
83118796 3
5. Connect the positive (+) battery cable to the starter mo-
tor. Install the M8 nut and the rubber cover (2).
83118795 4
6. Connect the engine electrical connectors (1) located
under the left hand side of the instrument panel.
83118794 5
7. Connect the throttle cable (1) and the fuel line (2).
83118793 6
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25. Engine - Engine and crankcase
8. Install the engine hood (2), install the mounting nuts (3).
9. Connect the electrical connection (4), install the clip (5).
83118792 7
10. Install the radiator (1) in the direction of the arrow.
83118791 8
11. Install the M8 x 16mm radiator retaining bracket bolts
(1).
83118790 9
12. Install the lower coolant hose (1), and tighten the
clamp (2).
83118788 10
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26. Engine - Engine and crankcase
13. Install the upper coolant hose (3). Tighten the hose
clamp (4).
83118789 11
14. Close the drain cock under the left hand side of the
radiator (1).
83118786 12
15. Fill the coolant to the proper level, use Ethylene Glycol
coolant concentrate.
NOTE: Engine coolant capacity is 3.8 l (1 US gal)
16. Connect the negative (-) battery terminal (1).
83115266 13
17. Install the radiator cap (1) and run the engine until
the thermostat opens, ensuring that all of the air is
displaced.
83118787 14
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27. Clutch - Clutch and components
Clutch and components - Dynamic description
NHIL16CT00305FA 1
(1) Clutch cover (4) Release bearing (7) Clutch release lever (10) Flywheel
(2) Clutch disc (5) Release bearing hub (8) Clutch lever shaft (11) Diaphragm boss
(3) Diaphragm spring (6) Clutch main shaft (9) Pressure plate
The clutch assembly bolts to the flywheel and the clutch main shaft (6) connects to the diaphragm boss (11) in the
clutch assembly with splines. The pressure plate will compress the clutch by the force of the diaphragm spring (3).
When the engine is running, the flywheel, clutch assembly, clutch disc and clutch main shaft rotate together. When the
operator depresses clutch pedal, the clutch lever (7) pushes the release bearing hub (5) toward the flywheel. Then,
the release bearing (4) installed to the end of the release bearing hub pushes the center of the diaphragm spring (3)
of the clutch assembly. As a result, the edge of the diaphragm is separated from the pressure plate (9) which is then
separated from the clutch disc (2).As the clutch disc in between the flywheel and pressure plate loses contact, the
clutch disc and diaphragm stop but the flywheel and clutch cover continue to turn. Therefore, the rotating force of the
flywheel is not transferred to the clutch main shaft, resulting in the interruption of power from the engine.
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29. Clutch - Clutch and components
Clutch and components - Exploded view
NHIL16CT00311FA 1
(1) Main shaft (5) Bolt, M12 x 1.75 x
35, Qty:5
(9) Bolt / washer, M10
x 1.25 x 35, Qty:2
(13) Lock washer,
Qty:2
(17) Bolt / washer, M8
x 1.25 x 25, Qty:6
(2) Release bearing (6) Lock washer,
Qty:7
(10) Clutch lever shaft (14) Bolt, M8 x 1.25 x
25, Qty:1
(18) Clutch cover
assembly
(3) Release bearing
hub
(7) Bolt, M12 x 1.25 x
110, Qty:2
(11) Clutch housing (15) Clutch shift lever (19) Pin
(4) Bushing (8) Nut, M10 x 1.25,
Qty:1
(12) Cotter pin (16) Lock bolt, M12 x
1.25, Qty:1
(20) Clutch disc
assembly
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30. Clutch - Clutch and components
Clutch control mechanism - Detailed view
NHIL16CT00312FA 1
(1) Clutch pedal (Mechanical
transmission)
(4) Cotter pin (7) Pedal pad (Rubber)
(2) Pin (5) Clutch rod assembly (8) Clutch pedal
(3) Washer (6) Return spring (9) Spring pin
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31. Clutch - Clutch and components
Clutch and components - Disassemble the clutch
WARNING
Avoid injury!
Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protec-
tive Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety
footwear.
Failure to comply could result in death or serious injury.
W0208A
Prior operation:
Engine - Remove (10.001)
1. Install a 380003436 (1) into the center hole of the clutch
assembly (2).
2. Remove the six M8 x 1.25 x 25 mounting bolts (3) from
the clutch assembly (2).
3. Remove the clutch assembly (2).
NHIL16CT00275AA 1
NOTICE: During assembly torque these bolts to 24 - 29.4 N·m (18 - 0.0 lb ft).
4. Remove the clutch cover (1) and the clutch disc (2).
NHIL16CT00274AA 2
NOTICE: Replace the clutch disc at assembly with a new one .
• Engine side (1)
• Transmission side (2)
• Clutch (3)
NOTICE: Make sure that the boss of the clutch disc with
the short end is facing the engine at assembly.
NHIL16CT00260AA 3
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32. Clutch - Clutch and components
NOTICE: When installing the clutch disc to the flywheel
housing, fit the clutch disc to clutch aligning 380003436 tool
(A) and insert it to the center hole of the flywheel housing
(B). Make sure that the longer boss section of the clutch
disc (C) is facing the clutch housing.
NHIL16CT00276AA 4
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33. Clutch - Clutch and components
Clutch and components - Remove release fork and release bearing
1. Remove the clutch release fork mounting bolt (1).
2. Remove the clutch lever (2), by pulling in the direction
of the arrow.
3. Remove the clutch release fork (3).
NHIL16CT00279AA 1
4. Remove the clutch release bearing (1) and the release
hub (2) together.
NHIL16CT00278AA 2
• When installing the clutch bearing (1) to the hub as-
sembly, make sure to install it in the correct orienta-
tion.
• Make sure that the bearing number (2) is on the hub
side (A).
• When installing the bushing, make sure to use a
03-555-4 and be careful not to deform its edge.
• Lubricate the bearing and check the bearing for ease
of rotation.
NHIL16CT00280AA 3
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34. Clutch - Clutch and components
NHIL16CT00281AA 4
NHIL16CT00282AA 5
(1) Clutch disc (4) Clutch release fork
(2) Clutch cover (5) Release bearing
(3) Clutch lever (6) Release hub
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35. Clutch - Clutch and components
Clutch and components - Install the release fork and release bearing
1. Insert the fork pin (1) into the clutch lever shaft as
shown in the figure and assemble it with the release
fork (2).
NHIL16CT00283AA 1
2. Apply LOCTITE® 242® adhesive to the mounting bolt (1)
when installing the release fork (2).
NOTICE: Torque the M12X1.25 release fork bolt (1) to
42 N·m (31 lb ft).
NHIL16CT00285AA 2
3. Install the release bearing (1) onto the clutch release
hub (2).
NOTICE: Check the release bearing for damage before
installing it. Replace it if necessary.
4. Apply grease to the inner groove (3) of the clutch re-
lease hub (2).
NOTICE: Application of too much grease can contaminate
the clutch discs, which shortens the discs usable life. Re-
move any excess grease on or around the release hub
groove.
NHIL16CT00284AA 3
5. Install the release hub (1), and the release fork (2).
NHIL16CT00287AA 4
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36. Clutch - Clutch and components
Clutch and components - Assemble the clutch
WARNING
Avoid injury!
Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protec-
tive Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety
footwear.
Failure to comply could result in death or serious injury.
W0208A
NOTICE: Make sure that the boss of the clutch disc with
the short end is facing the engine at assembly.
NOTICE: When installing the clutch disc to the flywheel
housing, fit the clutch disc to clutch aligning 380003436 tool
(A) and insert it to the center hole of the flywheel housing
(B). Make sure that the longer boss section of the clutch
disc (C) is facing the clutch housing.
NHIL16CT00276AA 1
• Engine side (1)
• Transmission side (2)
• Clutch (3)
NHIL16CT00260AA 2
1. Join the clutch cover (1) and the clutch disc (2).
NHIL16CT00274AA 3
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