1110 & 1210 Compact Diesel

Transcription

1 Ford Service Manual 1110 & 1210 Compact Diesel Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF FORD OR IT S SUCCESSORS. FORD AND IT S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL. TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. FO-S-1110,1210

2 FORD 1110 AND 1210 TRACTORS Repair Manual -,' - " J FORD TRACTOR OPERATIONS FORD MOTOR COMPANY

3 PART 1 ENGINE SYSTEMS ENGINE AND LUBRICATION SYSTEM A.. B. DESCRIPTION AND OPERATION.... ENGINE - OVERHAUL.... CYLINDER HEAD, VALVES AND RELATED COMPONENTS.... ENGINE FRONT COVER, TIMING GEARS, AND OIL PUMP.... CONNECTING RODS, BEARINGS, PISTONS, RINGS AND CYLINDER BLOCK.... MAIN BEARINGS, CRANKSHAFT, CAMSHAFT AND FLYWHEEL COOLING SYSTEMS A. DESCRIPTION AND OPERATION B. COOLING SYSTEM - OVERHAUL Chapter 3 TROUBLE SHOOTING, SPECIFICATIONS AND SPECIAL TOOLS A. TROUBLE SHOOTING B. SPECIFICATIONS C. SPECIAL TOOLS SE 4300

4 ",.-~- """.. ;,.'. PART 2 FUEL SYSTEM DIESEL FUEL SYSTEM A. B. C. INJECTION PUMP-DESCRIPTION AND OPERATION.... INJECTION PUMP-REMOVAL AND INSTALLATION.... INJECTION PUMP-TIMING AND GOVERNOR ADJUSTMENTS ~.....'..:.'...'.;...:....'......:.":"'.. ~L'::,:~:"i:~'.,j ~# INJECTORS A. INJECTORS-DESCRIPTION AND OPERATION B. INJECTORS-REMOVAL AND INSTALLATION C. INJECTORS-OVERHAUL Chapter 3 TROUBLE SHOOTING, SPECIFICATIONS AND SPECIAL TOOLS A. TROUBLE SHOOTING B. SPECIFICATIONS C. SPECIAL TOOLS D. FUEL INJECTION PUMP SPECIFICATION STANDARDS... 27

5 PART 3 ELECTRICAL SYSTEMS WIRING, SWITCHES, GLOW PLUGS and INSTRUMENTATION A. WIRING, SWITCHES, GLOW PLUGS and INSTRUMENTATION - DESCRIPTION AND OPERATION... 1 B. WIRING, SWITCHES, GLOW PLUGS and INSTRUMENTATION. OVERHAUL... 5 BATTERY A. BATTERY-DESCRIPTION AND OPERATION...." B. BATTERY-MAINTENANCE AND TESTS Chapter 3 STARTING SYSTEMS A. B. C. D. E. F. STARTING SYSTEM-DESCRIPTION AND OPERATION.... STARTING MOTOR-OVERHAUL..... SAFETY START SWITCH-DESCRIPTION AND OPERATION.... SAFETY START SWiTCH-OVERHAUL.... KEY START SWITCH-DESCRIPTION AND OPERATION.... KEY START SWiTCH-OVERHAUL

6 Chapter 4 CHARGING SYSTEM A. CHARGING SYSTEM-DESCRIPTION AND OPERATION B. CHARGING SYSTEM-PRELIMINARY CHECK AND ELECTRICAL TESTS C. CHARGING SySTEM-OVERHAUL Chapter 5 SPECIFICATIONS A. SPECiFiCATIONS ii

7 CHAPTER PART 3 ELECTRICAL SYSTEMS WIRING, SWITCHES, GLOW PLUGS and INSTRUMENTATION A. WIRING, SWITCHES, GLOW PLUGS and INSTRUMENTATION - DESCRIPTION AND OPERATION.... B. WIRING, SWITCHES, GLOW PLUGS and INSTRUMENTATION. OVERHAUL... 5 ': 1,J A. WIRING, SWITCHES, GLOW PLUGS, and INSTRUMENTATION-DESCRIPTION AND OPERATION WIRING Thirteen wiring components are utilized in making up the wiring harness. Figure 1, shows the various components and their locations in the wire harness assembly. See Figure 2 for trouble shooting and tracing wiring components. SWITCHES KEY START SWITCH See Chapter 3, E. SAFETY START SWITCH See Chapter 3, C. LIGHT SWITCH The light switch, Figure 3 is a push-pull type switch. Full in position is off. Full out position energizes the headlights and tail lamp. The light switch also energizes the flasher switch when in the full out position. 1

8 PART 3 - ELECTRICAL SYSTEMS ALTERNATOR ALTERNATOR --~ ~ B UNIT (THERMOSWITCH) ENGINE rio MANOCONTACT ~ B a e o o ~~EY~ ~~~~ SWITCH \ I ~ STARTER S FLA~H~ FLASHER LAMP -~. I' }ill L B G G 6P COUPPLER SAFETY SWITCH R 4P COUPPLER BW R SA RS SIZE WIRECOLOR CODE W B R Y G WHITE BLACK RED YELLOW GREEN "CO, ~oo ~ ~'9'\c ~ " )1;'0'---- B FLASHER UNIT ~II ~~~======================================~ L Figure 1 Wiring Harnesses Model 1110 and Harness - Key Switch to Fuse Wire Harness - Key Switch to Instrument Connector Harness - Light Switch to Connector 2. Fuse Wire Harness 3. Main - Battery to Safety Start Switch, Key Switch and Starter Assy. 4. Key Switch to Glow Plug 5. Key Switch to Glow Plug Indicator Lamps

9 PART 4 CLUTCHES SINGLE CLUTCHES A. SINGLE CLUTCHES - DESCRIPTION AND OPERATION B. SINGLE CLUTCHES - ADJUSTMENT C. SINGLE CLUTCHES - OVERHAUL SERVICING CLUTCH ASSOCIATED COMPONENTS A. CLUTCH PILOT BEARING - DESCRIPTION AND OVERHAUL B. CLUTCH RELEASE BEARING - DESCRIPTION AND OVERHAUL C. CLUTCH LINKAGE COMPONENTS - OVERHAUL Chapter 3 TROUBLE SHOOTING AND SPECIFICATIONS A. TROUBLE SHOOTING B. SPECIFICATIONS

10 PART 5 TRANSMISSION SYSTEMS STANDARD 10 x 2 GEAR TRANSMISSION A. STANDARD 10 x 2 GEAR TRANSMISSION - DESCRIPTION AND OPERATION B. STANDARD 10 x 2 GEAR TRANSMISSION - OVERHAUL HYDROSTATIC TRANSMISSION A. HYDROSTATIC TRANSMISSION - DESCRIPTION AND OPERATION B. HYDRCSTATIC TRANSMISSION - OVERHAUL C. HYDROSTATIC TRANSMISSION - TROUBLE SHOOTING AND ADJUSTMENTS Chapter 3 HYDROSTATIC TRANSMISSION GEAR BOX A. HYDROSTATIC TRANSMISSION GEAR BOX - DESCRIPTION AND OPERATION B. HYDROSTATIC TRANSMISSION GEAR BOX -- OVERHAUL... 37

11 Chapter 4. HYDROSTATIC TRANSMISSION CONTROL LINKAGE Sectio.n A. HYDROSTATIC TRANSMISSION - CONTROL LINKAGE - OPERATION, OVERHAUL AND, ADJUSTMENTS Chapter 5 SPECIFICATIONS A. SPECIFICATIONS ii

12 CHAPTER 1 B. STANDARD 10 x 2 GEAR TRANSMISSION - OVERHAUL REMOVAL 1. Drain the oil from the transmission. 2. Separate the transmission from the engine and rear axle assembly. See "SEPARATING THE TRACTOR" - Part Remove the input shaft from the front, Figure If required, remove the oil seal, bearings, collar and drive gear from the input shaft, Figure 7. DISASSEMBLY 1. Slide each of the main gear shift rails rearward out of the transmission case while carefully sliding the shift fork off of the rail, Figure 5. I CAUTION: Hold a shop towel over the top of the shift fork to restrain the detent ball when the rail is removed from the fork. The detent ball will be expelled with considerable force when it is released. S'16863~ Figure 6 Input Shaft - Removal 1. Input Shaft Assembly 3. Driven Gear 2. Snap Ring 4. Collar S ?~""""," ~ --\ ~ \: ~J Figure 5 Main Gear Shift Rail - 1. Main Gear Shift Rails 2. Shift Forks 3. Detent Balls and Springs Removal S Figure 7 Input Shaft Assembly 1. Input Shaft 5. Drive Gear 2. Seal 6. Collar 3. Bearing 7. Bearing 4. Collar 9

13 PART 6 - POWER TAKE-OFF FRONT WHEEL DRIVE If front wheel drive, also install the FWD idier gear, needle bearings and snap rings, Figure Install the rear PTa countershaft gear, cclla'r and rear bearing, Figure Assemble the PTa output shaft, Figure 9. S Figure 7 Front PTO Countershaft - Assembly (FWD) 1. Front Countershaft 2. Snap Ring 3. Bearings 4. Snap Ring 5. Snap Ring 6. Needle Bearing 7. Spacer 8. Front Wheel Drive Idler Gear 9. Needle Bearing 10. Clip 11. Snap Ring Figure 8 Rear PTO Countershaft - 1. Bearing 2. Spacer 3. Gear 4. Snap Ring 5. Bearing 6. Countershaft 7. Sliding Coupler 8. Needle Bearing Assembly 4. Install the forward countershaft through the front of the housing. 5. Position the sliding coupler in the housing, Figure Position the needle bearing inside the front countershaft, Figure Install the countershaft forward bearing on the shaft and secure with snap ring, Figure Insert the shaft into the housing engaging the sliding coupler and front countershaft from the needle bearing rear. Figure 9 PTO Output Shaft - 1. Output Shaft 2. Oil Seal 3. Shims 4. Bearing 5. Spacer 6. Gear 7. Spacer 8. Bearing 9. Spacer 10. Washer wi Locking Tab 11. Nut Assembly 4

14 PART 6 POWER TAKE OFF MID-MOUNT POWER TAKE-OFF A. MID-MOUNT POWER TAKE-OFF - DESCRIPTION AND OPERATION.... B. MID MOUNT POWER TAKE-OFF - OVERHAUL A. MID-MOUNT POWER TAKE-OFF - DESCRIPTION AND OPERATION The mid-mount power take-off is available on the Models 1110 and 1210 tractors equipped with hydrostatic drive transmission, as a factory installed option. The mid-mount power take-off shaft, Figure 12, drives at 1000 rpm, while the rear power take-off shaft drives at 540 rpm. Both power take-off shafts are engaged simultaneously with a single lever located on the left side of the operator's seat. {;. "'~) The mid-mount PTO gear box assembly, Figure 13, is installed by removing a plate located on the underside of the rear axle center housing. The gear box bolts to the underside of the center housing, Figure 14, and is gear driven by an idler gear located on the front wheel drive shaft, if so equipped, or on the countershaft if a two-wheel drive model, Figure 15. In the engaged position, the sliding coupler (8), Figure 12, on the rear PTO countershaft completes the power flow to the rear shaft and mid-mount PTO shaft. Figure 12 Mid-Mount Power Take-Off - Model 1110 and 1210 (FWD) 1. Rear PTO Output Shaft 2. Mid-Mount PTO Output Shaft 3. Transmission Drive Shaft 4. Differential Pinion Shaft 5. Front PTO Countershaft 6. Front Wheel Drive Shaft 7. Rear PTO Countershaft 8. PTO Sliding Coupler

15 ,f""h,,, ~ 'v PART 7 DIFFERENTIAL - REAR AXLE AND BRAKES DIFFERENTIAL - REAR AXLE AND BRAKES A. DIFFERENTIAL - REAR AXLE AND BRAKES - DESCRIPTION AND OPERATION... 1 B. DIFFERENTIAL - REAR AXLE AND BRAKES - OVERHAUL... 3 SPECIFICATIONS A. SPECIFICATIONS

16 CHAPTER Remove the snap ring. Straighten the lockwasher and remove the two locknuts. Remove the pinion and bearings. FOUR WHEEL DRIVE Figure I ~ 4! J> _S-1!487l Figure 10 Pinion Removal - Front Wheel Drive 1. Pinion Shaft 2. Snap Ring 3. Front Wheel Drive Gear 4. Lock Washer 5. Lock Nuts Figure 11 Differential Disassembly 1. Bearing 2. Locking Tab 3. Ring Gear 4. Side Gear 5. Thrust Washer 6. Pinion Gear 7. Pinion Shaft 8. Roll Pin 9. Case 10. Bearing INSPECTION DIFFERENTIAL GEAR ASSEMBLY 1. Inspect the gears for excessive wear or damage. Remove the snap ring. Remove the front wheel drive gear and key. Straighten the lockwasher and remove the two locknuts. Remove the pinion and bearings. DISASSEMBLY 1. Straighten the lock tabs and remove the ring gear bolts, Figure Remove the pinion shaft, pinions, thrust washers and side gears. 2. Inspect and measure the thickness of thrust washers for excessive wear. See "Specifications" Inspect the differential pinion shaft and pinion gears for excessive wear. See "Specifications" Inspect the pinion gear and ring gear tooth wear pattern. See "Specifications" Inspect bearings for excessive wear or binding when rotated by hand. ASSEMBLY NOTE: When the drive pinion, ring gear, bearing or other components are reused, reassemble using the 5

17 PART 8 HYDRAULIC SYSTEM HYDRAULIC SYSTEM CIRCUITS A. HYDRAULIC SYSTEM CIRCUITS - DESCRIPTION AND OPERATION... 1 B. HYDRAULIC SYSTEM CIRCUITS - OVERHAUL C. ADJUSTMENTS HYDRAULIC PUMP AND FILTER A. HYDRAULIC PUMP AND FILTER - DESCRIPTION AND OPERATION B. HYDRAULIC PUMP AND FILTER - OVERHAUL Chapter 3 TROUBLE SHOOTING, PRESSURE TESTING, SPECIFICATIONS AND SPECIAL TOOLS A. TROUBLE SHOOTING B. PRESSURE TESTING C. SPECIFICATIONS D. SPECIAL TOOLS

18 PART 9 STEERING SYSTEM STEERING SYSTEM MODEL 1110 AND 1210 A. STEERING SYSTEM - DESCRIPTION AND OPERATION B. STEERING SYSTEM - OVERHAUL TROUBLE SHOOTING AND SPECIFICATIONS (') A. TROUBLE SHOOTING B. SPECIFICATIONS o

19 PART 10 FRONT AXLE FRONT AXLE - TWO WHEEL DRIVE A. FRONT AXLE, 2WD - DESCRIPTION AND OPERATION... 1 B. FRONT AXLE, 2WD - OVERHAUL... 3 FRONT AXLE - FOUR WHEEL DRIVE A. FRONT AXLE, 4WD - DESCRIPTION AND OPERATION... 7 B. FRONT AXLE, 4WD - OVERHAUL... 8 Chapter 3 TROUBLESHOOTING AND SPECI FICATIONS A. TROUBLESHOOTING B. SPECiFiCATIONS... 20

20 ':"':P'A t AT';"11 WHEELS AND TIRES WHEELS AND TIRES A. WHEELS AND TIRES u

21 PART 12 SEPARATING THE TRACTOR SEPARATING THE TRACTOR A. FRONT AXLE - Removal and Installation B. SEPARATING THE TRACTOR - Between the Engine and Transmission... 5 C. TRANSMISSION - Removal and Installation (10 x 2 Gear Transmission) D. TRANSMISSION - Removal and Installation (Hydrostatic Transmission) E. REAR AXLE CENTER HOUSING - Removal and Installation F. REAR AXLE HOUSING - Removal and Installation SPECIFICATIONS A. SPECIFICATIONS... "