MF40B Tractor, Loader & Backhoe

Massey Harris Massey Ferguson Service Manual MF40B Tractor, Loader & Backhoe Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF MASSEY HARRIS MASSEY FERGUSON OR IT S SUCCESSORS. MASSEY HARRIS MASSEY FERGUSON 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. MH-S-MF40B TLB

MF 408 TRACTOR/LOADER/BACKHOE SERVICE MANUAL Part 1 - Important Procedures and Data Part 2 - Part - Part 4 - Front Axle and Steering Engine Clutch Part 5 - Transmission I " Part 6 - Drive Axle and Brakes Part 7 - PTO Part 8 - Internal Hydraulics Part 9 - Electrical System Part 10 - Part 11 - Loader Backhoe Form No. 1448 788 M1 Printed in U.S.A.

IMPORTANT PROCEDURES AND DATA SAFETY PRECAUTIONS........................................................................... 2 ROLL OVER PROTECTIVE STRUCTURES (ROPS) and/or SAFETY FRAMES............................ SERVICE PROCEDURE RECOMMENDATIONS...................................................... 4 SPECIAL TOOLS................................................................................. 5 TIGHTENING TORQUE RECOMMENDATIONS (GENERAL GUIDE)..................................... 5 PRODUCT CROSS REFERENCE FOR SEALANTS AND METHOD OF APPLYING........................ 6 Liquid Locking Metal Sealants................................................................... 6 CONVERTING UNITS OF WEIGHTS AND MEASURES.................................. 10 Definition of Terms and Selection of Units............................ 10 "Rounding-Off'" Converted Units.... 14 Conversions Between Units.... 15 CONVERSION TABLES... 18 How to Use Conversion Tables... 18 Table 1 - Inches and Millimetres, Celsius and Fahrenheit... 19 Table 2 - Tightening Torques (ft.lbs to kg.m) - NOT "SI"............. 20 Table - Tightening Torques (kg.m to ft.lbs) - NOT "SI"... 20 Table 4 - Area (Square Inches to Square Centimetres)... 20 Table 5 - Area (Square Feet to Square Metres)... 21 Table 6 - Bending Moment or Torque (Inch Pounds to Newton Metres)...,.... 21 Table 7 - Bending Moment or Torque (Foot Pounds to Newton Metres)... 21 Table 8 - Bending Moment or Torque (Kilogram-force-metre to Newton Metre)... 22 Table 9 - Force (Pounds-force to Newtons)... 22 Table 10 - Length (Microinches to Micrometres)... 22 Table 11 - Length (Hundredths of an Inch to Millimetre)... 2 Table 12 - Length (Inches to Millimetres)... 2 Table 1 - Mass (Pounds to Kilograms)... 2 Table 14 - Power (Horsepower to Kilowatts)... 24 Table 15 - Pressure or Stress (Pounds Per Square Inch to Kilopascals)... 24 Table 16 - Volume or Capacity (Cubic Inches to Cubic Centimetres)... 24 Table 17 - Volume or Capacity (Cubic Inches to Litres)... 25 Table 18 - Volume or Capacity (Cubic Feet to Cubic Metres)... 25 Table 19 - Volume or Capacity (Cubic Yards to Cubic Metres)... 25 Table 20 - Volume or Capacity (U.S. Fluid Ounces to Cubic Centimetres)... 26 Table 21 - Volume or Capacity (U.S. Liquid Pints to Litres)... 26 Table 22 - Volume or Capacity (U.S. Liquid Quarts to Litres)... 26 Table 2 - Volume or Capacity (U.S. Liquid Gallons to Litres)... 27-1- IMPORTANT PROCEDURES AND DATA

PART 2 - FRONT AXLE AND STEERING Page TESTING AND TROUBLE-SHOOTING.............................................................. 2 Checking Pump Pressure........................................................................ 2 Filling and Removing Air From System.......................................................... 2 ENGINE DRIVEN STEERING PUMP... Removal/Installation............................................................................ Servicing... Refer to CS-18 STEERING CONTROL UNIT... 4 Removal/Installation............................................................................ 4 Servicing... Refer to CS-18 STEERING CYLINDERS... -................................... 5 WHEEL BEARINGS AND SEAL... 6 SPINDLE BUSHINGS AND SPINDLE... 8 STEERING AXLE... 9 AXLE SUPPORT CASTING... 10 Pivot Pin Bushings... 10 CS-18 2nd Issue ENGINE DRIVEN STEERING PUMP (Parker Hannifin) CS-21 1st Issue STEERING CONTROL UNIT This Part contains three separate sections, each beginning with Page 1 and Figure 1. Place CS sections at end of Part, in numerical order. A CAUTION: To avoid personal injury, use positive acting jacks, hoists and secure blocking when raising, lowering or supporting Tractor, Loader, Backhoe and components. Refer to Loader and Backhoe Parts in this manual for additional precautions. -1- MF 40B - FRONT AXLE AND STEERING

PART - ENGINE INTRODUCTION.... General Information.... Engine Serial Number.... SPECIFICATIONS.... General Specifications.... Tightening Torques.... Engine Overhaul Specifications.... Lubrication System Specifications... Fuel System Specifications.... Cooling System Specifications.... 2 2 2 6 7 7 CRANKSHAFT AND MAIN BEARINGS... 25 Crankshaft End-Play...................... 25 Checking Crankshaft End-Play... 25 Replacing Thrust Washers................. 25 Removing Crankshaft... 25 Inspecting Crankshaft...................... 26 Regrinding Crankshaft..................... 26 Installing Crankshaft...................... 26 Rear Crankshaft Oil Seal.................... 27 Replacing Oil Seal...................... 27 Installing Oil Seal Retainer... 28 ENGINE REMOVAL AND INSTALLATION.. Removing Engine Installing Engine. 8 8 10 CYLINDER HEAD. 12 Removing Cylindt!r Head.... 12 Disassembling Cylinder Head.... 12 Cylinder Head lnsp,!ction and Servicing.... 12 Valve Guides................. 14 Valves and Valve St!ats.... 14 Servicing Valves and Valve Seats.... 14 Installing Exhaust Valve Seat Inserts.... 14 Valve Springs........ 16 Tappets.... 16 Rocker Arm Shaft Assembly.... 16 Disassembling and Inspecting Rocker Arm Shaft Assembly............... 16 Reassembling Rocker Arm Shaft Assembly........................ 16 Reassembling Cylinder Head................. 16 Installing Cylinder Head.................... 17 Retorquing Cylinder Head... 17 Adjusting Valve Lash...................... 18 PISTONS AND CONNECTING RODS... 19 Removing Piston/Connecting Rod Assembly.......................... 19 Separating Piston from Connecting Rod... :.................... 19 Connecting Rods... 19 Connecting Rod Alignment................ 19 Pistons and Rings... 20 Pistons... 20 Piston Rings.... 21 Rejoining Piston to Connecting Rod.... 21 Installing Piston/Connecting Rod Assembly.... 21 CYLINDER BLOCK AND LINERS.... 2 Inspecting and Servicing Cylinder Block and Liners.... 2 Replacing Cylinder Liner.... 2 FLYWHEEL.... 29 Removing Flywheel and Transmission. Adapter Plate........................... 29 Replacing Ring Gear...................... 29 Installing Flywheel and Transmission Adapter Plate........................... 29 TIMING CASE AND DRIVE... '... 1 Timing Gear Case... 1 Replacing Front Crankshaft Oil Seal... 1 Installing Timing Gear Cover... 1 Removing Timing Gear Housing............. 2 Installing Timing Gear Housing... 2 Timing Gears........................... Timing Gear Backlash and End-Play... Removing Timing Gears.................. Replacing Idler Gear Bushings.............. 4 Installing Timing Gears and Retiming Engine....................... 4 Camshaft.............................. 5 Removing Camshaft..................... 5 Inspecting Camshaft Thrust Washer and Tappets... 5 Installing Camshaft... 5 Tachometer Drive... 5 Checking Valve Timing... 6 LUBRICATION SYSTEM... 7 Oil Pan... 7 Removing Oil Pan...................... 7 Installing Oil Pan... 7 Oil Pump... 7 Oil Pump Idler Gear Backlash and End-Play................... 7 Removing Oil Pump... 7 Disassembling Oil Pump.................. 7 Inspecting Oil Pump... 8 Reassembling Oil Pump.................. 8 Installing Oil Pump... 9 Replacing Oil Filter and Crankcase Oil........................... 9-1- MF 40B - ENGINE

FUEL AND AIR SYSTEM... 40 Air Cleaner............................. 40 Servicing Outer Filter Element... 40 Servicing Inner Filter Element... 40 Fuel Lift Pump... 40 Removing and Disassembling Fuel Lift Pump... 40 Reassembling and Installing Fuel Lift Pump.... Replacing Fuel Filter Element.... Fuel Injection Pump Removing Injection Pump.... Installing Injection Pump.... Checking and Adjusting 40 41 41 42 42 Injection Pump Timing... _.... 42 Adjusting Fuel Shut-Off Control... 4 Adjusting Engine Speed... 4 Adjusting Throttle Linkage... 4 Fuel Injectors....... 44 Removing Injectors... 46 Testing Injectors... 46 Disasse inbling Injectors... 47 Cleaning and Inspecting Injectors... 48 Assembling Injectors... 50 Installing Injectors... 50 Fuel Lines and Connections... 50 Low Pressure Fuel Lines... 50 High Pressure Injection Lines... 50 Air-Bleeding Fuel System... 50 COOLING SYSTEM Water Pump.... Removing Water Pump.... Disassembling Water Pump.... Reassembling Water Pump.... Installing Water Pump.... Thermostat Replacing Thermostat Testing Thermostat.... Fan Belt Tension.... 52 52 52 52 5 54 54 54 54 54 TROUBLE-SHOOTING... 56 INTRODUCTION GENERAL INFORMATION This Part contains service information for PERKINS AD 4.20 Direct Injection Diesel Engine. Thoroughly clean and inspect all components during servicing. Always plug or otherwise cover open fuel and oil lines and fittings to prevent entry of dirt. Right and left-hand sides mentioned within text refers to engine as viewed from rear of flywheel. Direction of engine crankshaft rotation is viewed from crankshaft pulley end. ENGINE SERIAL NUMBER Engine Serial Number for AD4.20 Diesel Engine is located on left side of cylinder block towards rear. Fig. 1-Engine Serial Number Location Fig. 1. ALWAYS GIVE COMPLETE ENGINE SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. -2-

PART 4-CLUTCH SPECIFICATIONS OPERATION.... Dual Clutch.... Split Torque Clutch.... SEPARATING/REJOINING TRACTOR.... / Separating Tractor.... Rejoining Tractor.... SERVICING DUAL CLUTCH.... Removing Dual Clutch.... Disassembling Dual Clutch.... Inspecting Dual Clutch.... Reassembling Dual Clutch.... Installing Dual Clutch.... Adjusting Dual Clutch.... 2 4 6 6 6 7 8 9 10 SERVICING SPLIT TORQUE CLUTCH... 11 Removing Split Torque Clutch.... 11 Disassembling Split Torque Clutch.... 11 Inspecting Split Torque Clutch.... 11 Reassembling Split Torque Clutch.... 12 Installing Split Torque Clutch.... 12 Adjusting Split Torque Clutch.... 12 SERVICING BEARINGS AND RELEASE MECHANISM. 1 Pilot Bearing.... 1 Release Bearing. 1 Release Fork 1 ADJUSTING CLUTCH LINKAGE... TROUBLE-SHOOTING... 15 14-1- MF 408 - CLUTCH

Fig. 11-Removing Retainer Pin Fig. 1-Removing Clutch Cover 4. Remove release lever fulcrum pins, Fig. 12, and torsion springs. 5. Loosen nuts on "T" bolts evenly until coil springs are fully extended and cover is free. 6. Remove "T" bolts. 7. Lift clutch cover off pressure springs, Fig. 1. 8. Remove: a. Coil springs and insulating washers. b. Belleville spring. c. Secondary pressure plate. d. Secondary (9") friction disc. e. False flywheel plate. f. Secondary clutch adjusting screws and lock nuts. 9. Drive lower pins out of release lever links, Fig. 14, and remove release lever and links. 10. Turn cover over and drive out retaining pins, Fig. 15. INSPECTING DUAL CLUTCH 1. Inspect all parts for wear or damage. Replace as needed. a. Flywheel friction face or clutch primary pressure plate may be resurfaced within reasonable limits, providing same amount of material is removed from clutch mounting surface on flywheel. Fig. 14-Removing Lower Pivot Pin b. Original distance between clutch mounting surface and friction face on flywheel is 1.7175-1.7225 inches. Check this dimension whenever new pressure plate or clutch assembly is installed. 2. Correct coil spring color code is violet. a. Compressing each coil spring to 1.820 inches should give a 14 ± 6.7 lbs. load. b. Free length of new spring should be 2.794 inches. c. Replace insulating washer each time a spring is replaced. Fig. 12-Removing Release Lever Fulcrum Pin Fig. 15-Clutch Cover Showing Retainer Pins Partly Removed 1. Retainer Pins -7- MF 408 - CLUTCH

PART 5 - TRANSMISSIONS SERVICE INFORMATION TESTING AND ADJUSTING INSTANT REVERSE TRANSMISSION (HYDRAULIC SHUTTLE)... REMOVING/INSTALLING TRANSMISSION ASSEMBLY.............................................. 6 Separating/Connecting Engine and Transmission................................................. 6 Separating/Connecting Transmission and Center Housing......................................... 9 REMOVING/INSTALLING TORQUE CONVERTER... 12 SERVICING 8-SPEED TRANSMISSION... *Refer to Separate Publication CS-17 SERVICING MANUAL SHUTILE TRANSMISSION - SERVICING MANUAL SHUTILE TRANSMISSION - WITHOUT PTO INPUT SHAFT....................... SERVICING INSTANT REVERSE (HYDRAULIC SHUTILE) AND TORQUE CONVERTER........................ WITH PTO... *Refer to Separate Publication CS-22.... *Refer to Separate Publication CS-45.... *Refer to Separate Publication CS-44 TROUBLE SYMPTOMS OF INSTANT REVERSE (HYDRAULIC SHUTILE)*Refer to Separate Publication CS-44 *IMPORT ANT: This reference is a separate componenr service publication which contains disassembly, inspection and reassembly instructions after transmission has been removed. These instructions are filed under this divider... and are identified by their CS number printed in the lower right-hand corner on each odd numbered page (beginning with a Page 1). SERVICE INFORMATION Many of the service procedures may be performed WITHOUT complete removal oftransmission assembly from Tractor. It will require good judgement by the serviceman as to necessity for complete removal of transmission while considering the extent of servicing to be performed. 1. The following information pertains to 8-Speed Transmissions: a. Although reference service publication CS-17 shows a regulating valve installed on input shaft retainer... this valve is not used in this Tractor application. Also the supply line shown routed through transmission case is not installed. The brake cross shaft shown through front of case member (beneath clutch release bearing) is not installed in this location for this Tractor model. However, these minor variations will not affect BASIC servicing. b. Main input shaft retainer and PTO input shaft (with their related seals and bearings) may be serviced by separating Tractor between engine and transmission... this "split" will also allow servicing engine clutch release bearing. c. Dual range planetary may be serviced by separating between transmission and center housing. If shift cover is removed after this "split"... -1 MF 408 - TRANSMISSIONS

PART 6 - DRIVE AXLE AND BRAKES SPECIFICATIONS.................................................................................. 2 DRIVE AXLE IDENTIFICATION... 2 REAR WHEELS.................................................................................... ROPS (ROLL-OVER PROTECTIVE STRUCTURE)....................................................... AXLE HOUSING.............................................................................. 4 Differential Lock Adjustment...................................................................... 5 Brake Adjustment................................................................................ 5 Brake Disc Access............................................................................... 5 Axle Planetary.................................... Refer to CS-47 Differential Lock............................. Refer to CS-47 Brakes........................... Refer to CS-47 DRIVE PINION REMOVAL... DRIVE PINION INSTALLATION Servicing....... 6.... 8... Refer to CS-5 DIFFERENTIAL ASSEMBLY - REMOVAL OR INSTALLATION... 9 Service and Bearing Pre-Load... Refer to CS-5 CENTER HOUSING... 10 CS-47... Axle Planetary, Differential Lock and Brakes - Oil Immersed CS-5... Drive Pinion, Differential and Bearing Pre-Load NOTE: This Part Contains sections of material, all beginning with Page 1 and Figure 1. A CAUTION: To avoid personal injury, use positive acting jacks, hoists and secure blocking when raising, lowering or supporting Tractor, Loader, Backhoe and components. -1- MF 40B - TDL DRIVE AXLE AND BRAKES

PART 7 - POWER.TAKE-OFF. PTO SHAFT AND SEAL...,... 1 Servicing... 1 GROUND SPEED PTO GEARS...................................................................... Drive Gear..................................................................................... Driven Gear.................................................................................... NO PTO WITH FERGUSON HYDRAULIC PUMP...................................................... 4 INDEPENDENT PTO............................................................................... 5 Testing... 5 Trouble Shooting... 6 Pressure Regulating Valve.................................................................. 7 Clutch Pack... 7 Removal and Installation...................................................................... 7 Servicing... Refer to CS-54 HYDRAULIC PUMP AND PUMP DRIVE... Refer to Part 8, CS-26 CS-54 INDEPENDENT PTO CLUTCH PACK SERVICE This Part contains two separate sections, each beginning with Page 1 and Figure 1. h, CAUTION: PTO shaft cover and PTO shield must be replaced when servicing is completed, ~ to avoid possible injury from rotating shaft. PTO SHAFT AND SEAL SERVICING 1. Drain center housing. 2. Remove pto shield, beam bracket, 1, and retainer plate, 2, Fig. 1.. Remove pto seal retainer,, Fig. 1. 4. Withdraw pto shaft, Fig. 2. 5. Install pto shaft front bearing, Fig., when required. Left axle housing and differential are removed to reach bearing. 6. Fig. 4, remove 0-ring, 1, from seal retainer, 2. Remove snap ring,, and press bearing, 4, from shaft. 7. Fig. 5, in seal retainer, 1, seal shield, 2, is pressed to seat with inside protruding toward seal. Fig. 1 Fig. 2-1- MF 408 - TDL/PTO

PART 8 INTERNAL HYDRAULICS (-POINT LINKAGE) SERVICE INFORMATION... 2 Special Tools and Test Fittings................................................................... 2 -Point Linkage................................................................................. 2 Hydraulic Lift Cover........................................................................... 2 -Point Linkage Controls...................................................................... 2 Ferguson Hydraulic Pump..................................................................... 2 Auxiliary Hydraulics - IPTO..................................................................... 4 TROUBLE-SHOOTING............................................................................. 5 "Quick" Service Checks......................................................................... 5 Trouble Symptoms.............................................................................. 8 ADJUSTMENTS................................................................................... 9 Lift Cover Adjustments - Prior to Installation... *Refer to Publication CS-41 "Final" Adjustments - Lift Covers WITHOUT Mounted Dashpot... 9 HYDRAULIC LIFT COVER... 1 Removal/Installation............................................................................ 1 Servicing Lift Cover WITHOUT Mounted Dashpot... *Refer to Publication CS-41 FERGUSON HYDRAULIC PUMP... 14 Removal/Installation... 14 Servicing Ferguson Pump WITH Mounted Servo-Valve... *Refer to Publication CS-4 AUXILIARY HYDRAULICS - IPTO.................................................................. 16 Removal/Installation of Pump and Drive Train... 16 Servicing Pump and Drive Train... *Refer to Publication CS-26 *IMPORTANT This Part contains separate Component Service Publications (referred to as CS-_) with instructions that pertain to bench servicing of assemblies... AFTER they have been removed. These publications may be found under this same divider tab... immediately following this Part and are identified by the reference publication number printed in the lower right-hand corner of each odd numbered page. The service procedures within this Part pertain to the -Point Linkage and Auxiliary Hydraulic Pump (/PTO) ONLY... and their related components. To obtain instructions for other systems (i.e.: Steering, Independent Power Take-Off, etc.) refer to the appropriate Part (within this Manual) that pertains to the system. -1- MF 408 AND 50C - INTERNAL HYDRAULICS

PART 9 - ELECTRICAL SYSTEM SPECIFICATIONS.................................................................................. 2 BATIERY... Activating Dry Battery........................................................................... Servicing Battery................................................................................ Charging and Cleaning........................................................................ Checking State of Charge...................................................................... Testing Battery................................................................................. 4 Specific Gravity Cell Comparison Test.......................................................... 4 Load Test.................................................................................... 4 Full Charge Hydrometer Test................................................................... 4. ALTERNATOR.................................................................................... 5 Service Information... :.... Alternator Precautions....... Alternator Operation.... Alternator Trouble-Shooting.... Undercharged Battery.... Overcharged Battery.... Alternator Overhaul.... Alternator Disassembly........................................................................ 8 Bearing Replacement and Lubrication.......................................................... 9 Alternator Reassembly........................................................................ 10 Alternator Component Testing and Servicing...................................................... 11 Rotor Checks................................................................................. 11 Slip Ring Servicing.... 11 Stator Checks.... 12 Brush Holder and Regulator Check.... 12 Diode Trio Check... 1 Rectifier Bridge Check.... 1 ST ARTER MOTOR...,... :.... 14 Trouble-Shooting Starter Circuit.... 14 Starter Circuit Inspection.... 14 Starter Motor No-Load Test.................................................................... 14 Starter Motor Overhaul.... Starter Motor Disassembly.... Field Frame Assembly.... Solenoid Assembly.... Starter Motor Cleaning and Lubrication.... Starter Motor Reassembly.... Starter Motor Component Testing and Servicing.... Brushes and Brush Holders Inspection.... Armature Checks and Servicing.... Field Coil Checks.... Solenoid Checks.... Pinion Clearance.... WIRING DIAGRAMS.... 5 5 5 5 5 7 8 16 16 17 18 19 19 19 19 19 20 20 21 22-1- MF 408 ELECTRICAL SYSTEM

MF LOADERS AND BACKHOES SAFETY PRECAUTIONS 2 SERVICE INFORMATION....................................................................... 2 LOADERS HYDRAULIC SYSTEM INFORMATION - MF 2A. MF 4A AND MF 00A LOADERS... System Flow..................................................................................... 4 Component Location and Operating Characteristics................................................. 5 TROUBLE-SHOOTING...... 1 Trouble Symptoms............................................................................... 1 TESTS AND ADJUSTMENTS... 16. Checking and Adjusting System Main Pressure.................................................... 16 Testing and Adjusting Circuit Reliefs (Within Valve)... 17 Testing for Valve Spool Leakage and Checking Spool Travel......................................... 18 Testing "Load Checks"........................................................................... 18 Testing for Internal Cylinder Leakage... 19 Checking Pump Efficiency (GPM)... 19 HYDRAULIC PUMP SERVICING..................................................................... 21 Information... 21 Disassembly... 21 Inspection....................................................................................... 22 Reassembly..................................................................................... 22 "Breaking-In" New or Rebuilt Pump... 22 CONTROL VALVE SERVICING... 2 Information...................................................................................... 2 Disassembly...,............... 25 Inspection....................................................................................... 26 Reassembly..................................................................................... 28 DOUBLE-ACTING CYLINDERS... 29 Service Information.............................................................................. 29 Service Procedures............................................................................... 29 Oil FILTERS....................................................................................... 7 Suction Filter - MF 2A and MF 4A Loaders..................................................... 7 Suction Filter - MF 00A Loader................................................................. 7 Return Filter... 9 BACKHOES (See "Contents" page for Backhoes following Loader section) Form No. 1448 976 M Printed In U.S.A. -1- MF - LOADERS