New Holland Boomer 20 Boomer Tractor Service workshop Manual

SERVICE MANUAL Boomer 20 / Boomer 25 Download Service Manual TM

TM

Part number 48017684 English June 2016

© 2016 CNH Industrial America LLC. All Rights Reserved.

SERVICE MANUAL Boomer™ 20 Boomer™ 25

48017684 02/06/2016 EN

Link Product / Engine Product Boomer™ 20 Boomer™ 25

Market Product Europe Europe

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Engine S3L2 S3L2

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 48017684 02/06/2016

[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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[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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INTRODUCTION

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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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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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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 manufacturer, 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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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 instructions. 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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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-conditioning 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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SERVICE MANUAL Engine Boomer™ 20 Boomer™ 25

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Engine - Engine and crankcase

Engine - General specification Engine Model Type No. of cylinders Combustion type Valve mechanism Cylinder bore x stroke Total displacement Compression ratio Fuel used

S3L , S3L2 Water cooled, 4-stroke cycle diesel 3 Swirl chamber Overhead valve type 78 mm x 92 mm ( 3.07 in x 3.62 in) 1.3 l (79 in³) 22:1 JIS K2204, Diesel fuel or its equivalent (ASTM diesel fuel oil No. 2-D) 1-3-2 Counterclockwise as viewed from flywheel side 512 mm (20.2 in) 453 mm (17.8 in) 563 mm (22.2 in) Approximately 140 kg (309 lb)

Firing order Direction of rotation Length Width Height Dry weight Inspection point Maximum rotation speed (rated rotation speed used as reference) Minimum rotation speed

Nominal Standard Varies depending on specification of destination

Varies depending on specification of destination Compression ratio @ 290 RPM 29 bar (421 psi) or above Valve timing Intake - Open - Close Exhaust - Open - Close Rocker arm Rocker arm inside diameter Rocker shaft outside diameter

- Exhaust

Valve guide inside diameter - Intake - Exhaust

Remark

26 bar (377 psi) or less

When oil and water temperatures at 20 - 30 °C (68 - 86 °F) 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.

BTDC 15 ° ABDC 41 ° BBDC 54 ° ATDC 10 ° 18.9 mm (0.744 in) 18.9 mm (0.744 in)

Clearance between rocker arm and rocker shaft (oil clearance) Valve Valve stem outside diameter - Intake

Limit

18.910 - 18.930 mm (0.7445 - 0.7453 in) 18.880 - 18.930 mm (0.7433 - 0.7453 in) 0.012 - 0.050 mm (0.0005 - 0.0020 in)

6.6 mm (0.260 in)

6.565 - 6.580 mm (0.2585 - 0.2591 in)

6.6 mm (0.260 in)

6.530 - 6.550 mm (0.2571 - 0.2579 in)

6.6 mm (0.260 in) 6.6 mm (0.260 in)

6.600 - 6.615 mm (0.2598 - 0.2604 in) 6.600 - 6.615 mm (0.2598 - 0.2604 in)

Clearance between valve guide and valve stem 48017684 02/06/2016

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0.200 Replace rocker arm mm (0.00 79 in)

6.500 mm (0.25 59 in) 6.500 mm (0.25 59 in)

Engine - Engine and crankcase

Inspection point - Intake

Nominal

- Exhaust

Standard 0.020 - 0.050 mm (0.0008 - 0.0020 in) 0.050 - 0.085 mm (0.0020 - 0.0033 in)

Valve seat angle Valve sinkage

45 ° 0 mm (0.00 in)

0.25 - 0.75 mm (0.0098 - 0.0295 in)

Valve head width

1.6 mm (0.063 in)

1.30 - 1.80 mm (0.0512 - 0.0709 in)

Valve margin

1.5 mm (0.059 in)

1.35 - 1.65 mm (0.0531 - 0.0650 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)

Length @ 131 - 145 N (29 33 lb) Length @ 279 - 309 N (63 69 lb) Push rod runout Cylinder head distortion

Inside diameter

- 0.25 mm (0.010 in) OS - 0.50 mm (0.020 in) OS Weight difference within an engine Piston pin outside diameter Clearance between piston pin bore and piston pin Clearance between piston and cylinder

30.1 mm (1.185 in)

-15 %

78 mm (3.071 in)

Replace 0.10 mm (0.0039 in) 0.10 mm Repair (0.0039 in) 78.2 mm Repair to oversize or replace (3.079 in)

0.01 mm (0.0004 in) or less

Cylindericity Piston Outside diameter - STD

39.0 mm (1.535 in)

0.05 mm (0.0020 in) or less 78 mm (3.071 in)

1.50 mm (0.0591 in) 2.50 mm (0.0984 in) 0.50 mm (0.0197 in)

46 mm (1.81 in) -15 %

0.3 mm (0.012 in) 0.05 mm (0.0020 in)

Cylinder Cylinder block distortion (Deck)

Limit Remark 0.100 Replace valve and valve guide mm (0.00 39 in) 0.150 mm (0.00 59 in)

78.00 mm (3.0709 in) 78.25 mm (3.0807 in) 78.50 mm (3.0906 in)

77.93 - 77.95 mm (3.0681 77.80 - 3.0689 in) mm (3.06 30 in) 78.18 - 78.20 mm (3.0780 78.05 - 3.0787 in) mm (3.07 28 in) 78.43 - 78.45 mm (3.0878 78.30 - 3.0886 in) mm (3.08 27 in) + / - 5 g (0.18 oz) or less

23 mm (0.91 in)

22.994 - 23.000 mm (0.9053 - 0.9055 in) 0.006 - 0.018 mm (0.0002 0.050 - 0.0007 in) mm (0.00 20 in) Repair to oversize or replace 0.035 - 0.086 mm (0.0014 0.300 - 0.0034 in) mm (0.01 18 in) 48017684 02/06/2016

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Engine - Engine and crankcase

Inspection point Piston ring Clearance between the piston ring and ring groove - Top compression ring

Nominal

Standard

0.09 - 0.11 mm (0.0035 0.0043 in)

- Intermediate ring

0.07 - 0.11 mm (0.0028 0.0043 in)

- Oil ring

0.03 - 0.07 mm (0.0012 0.0028 in)

Piston ring end gap - Top compression ring

0.15 - 0.30 mm (0.0059 0.0118 in)

- Intermediate ring

0.15 - 0.30 mm (0.0059 0.0118 in)

- Oil ring

0.20 - 0.40 mm (0.0079 0.0157 in)

Connecting rod Bend and torsion (over a 100 mm (3.9 in) span End play

Crankshaft Crank journal outside diameter 52 mm (2.05 in) Crank pin outside diameter 48 mm (1.89 in) Crankshaft runout

0.05 mm (0.0020 in) or less 0.10 - 0.35 mm (0.0039 0.0138 in)

Limit

Remark

0.30 mm (0.0118 in) 0.20 mm (0.0079 in) 0.20 mm (0.0079 in)

Replace the rings until the limits are reached, then replace the piston.

Replace the rings until the limits are reached, then replace the piston.

Replace the rings until the limits are reached, then replace the piston.

1.50 mm (0.0591 in) 1.50 mm (0.0591 in) 1.50 mm (0.0591 in)

Replace

0.15 mm (0.0059 in) 0.50 mm (0.0197 in)

51.985 - 52.000 mm (2.0467 - 2.0472 in) 47.950 - 47.965 mm (1.8878 - 1.8884 in) 0.025 mm (0.0010 in) or less

Replace Replace

Replace the connecting rod

0.050 mm (0.00 20 in) 0.030 - 0.077 mm (0.0012 0.100 - 0.0030 in) mm (0.00 39 in) 0.025 - 0.072 mm (0.0010 0.150 - 0.0028 in) mm (0.00 59 in) 0.050 - 0.175 mm (0.0020 0.500 - 0.0069 in) mm (0.01 97 in)

Repair or replace

Timing gear backlash Between crankshaft gear and idler gear

0.04 - 0.12 mm (0.0016 0.0047 in)

Replace

Between idler gear and valve camshaft gear

0.04 - 0.12 mm (0.0016 0.0047 in)

Between idler gear and pump camshaft gear

0.04 - 0.12 mm (0.0016 0.0047 in)

Main bearing oil clearance Connecting rod bearings oil clearance End play

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0.30 mm (0.0118 in) 0.30 mm (0.0118 in) 0.30 mm (0.0118 in)

Replace main bearing Replace connecting rod bearings Replace flanged No. 3 main bearing

Replace Replace

Engine - Engine and crankcase

Inspection point Between valve camshaft gear and PTO gear Between pump camshaft gear and oil pump gear Cam height Flywheel flatness Clearance between tappet and cylinder block bore Clearance between camshaft journal and bushing Clearance between idler gear bushing and idler shaft

Nominal

Standard 0.08 - 0.19 mm (0.0031 0.0075 in)

Limit 0.30 mm (0.0118 in) 0.07 - 0.20 mm (0.0028 - 0.30 mm (0.0118 0.0079 in) in) 35.62 - 35.82 mm (1.4024 34.72 mm (1.36 - 1.4102 in) 69 in) 0.50 mm 0.15 mm (0.0059 in) or (0.0197 less in) 0.15 mm (0.0059 in) 0.05 - 0.125 mm (0.0020 - 0.15 mm (0.0059 0.0049 in) in) 0.02 - 0.07 mm (0.0008 - 0.20 mm (0.0079 0.0028 in) in)

Remark Replace Replace Replace Repair Replace tappet Replace Replace idler gear or idler shaft

Engine - Torque Description Cylinder head bolt Rocker cover bolt Rocker shaft bracket bolt Rocker arm adjusting nut Tachometer L joint union nut Band type hose cramp Thrust plate Main bearing cap bolt Connecting rod cap nut Flywheel bolt Crankshaft pulley nut Rear plate use mounting bolt - For general use - For tractor

Threads Diameter x pitch M10 x 1.75 M8 x 1.25 M8 x 1.25 M8 x 1.25 M22 x 1.5 M8 x 1.25 M10 x 1.25 M9 x 1.0 M12 x 1.25 M18 x 1.5

83 - 93 N·m (61 - 69 lb ft) 10 - 13 N·m (7 - 10 lb ft) 10 - 20 N·m (7 - 15 lb ft) 18 - 22 N·m (13 - 16 lb ft) 17 - 23 N·m (13 - 17 lb ft) 3 - 4 N·m (2 - 3 lb ft) 10 - 12 N·m (7 - 9 lb ft) 49 - 54 N·m (36 - 40 lb ft) 32 - 37 N·m (24 - 27 lb ft) 127 - 137 N·m (94 - 101 lb ft) 147 - 196 N·m (108 - 145 lb ft)

M12 x 1.25 M12 x 1.25

54 - 74 N·m (40 - 55 lb ft) 83 - 103 N·m (61 - 76 lb ft)

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Torque

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 Protective 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

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2. Open the drain cock (1) under the left hand side of the radiator.

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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)

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4. Loosen the radiator cap (3) to accelerate draining all of the fluid.

5. Loosen the hose clamp and disconnect the lower coolant hose (1) located on the right hand side of the engine.

6. Loosen the hose clamp (2) and disconnect the upper coolant hose.

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Engine - Engine and crankcase

7. Remove the M8 x 16mm radiator retaining bracket bolts (1).

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8. Remove the radiator (1) in the direction of the arrow.

9. Disconnect the electrical connection (1) remove the clip (2).

10. Remove the hood retaining nuts (3).

11. Remove the engine hood (4)

12. Disconnect the throttle cable (1) and the fuel line (2).

83118793

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10

Engine - Engine and crankcase

13. Disconnect the engine electrical connectors (1) located under the left hand side of the instrument panel.

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14. Remove the rubber cover (1), and the M8 nut. Disconnect the positive (+) battery cable from the starter motor.

15. Disconnect the negative (-) ground cable by removing bolt (1).

83118796

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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

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Engine - Engine and crankcase

17. Use an overhead hoist (1) to lift the engine (2). Place engine on a suitable stand.

83118798

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15

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 Protective 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.

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83118797

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3. Install four M14 engine mount retaining nuts (1).

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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Engine - Engine and crankcase

4. Connect the negative (-) ground cable by installing bolt (1).

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5. Connect the positive (+) battery cable to the starter motor. Install the M8 nut and the rubber cover (2).

6. Connect the engine electrical connectors (1) located under the left hand side of the instrument panel.

7. Connect the throttle cable (1) and the fuel line (2).

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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).

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10. Install the radiator (1) in the direction of the arrow.

11. Install the M8 x 16mm radiator retaining bracket bolts (1).

12. Install the lower coolant hose (1), and tighten the clamp (2).

83118788

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Engine - Engine and crankcase

13. Install the upper coolant hose (3). Tighten the hose clamp (4).

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14. Close the drain cock under the left hand side of the radiator (1).

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).

17. Install the radiator cap (1) and run the engine until the thermostat opens, ensuring that all of the air is displaced.

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Clutch - Clutch and components

Clutch and components - Dynamic description

NHIL16CT00305FA

(1) Clutch cover (2) Clutch disc (3) Diaphragm spring

(4) Release bearing (5) Release bearing hub (6) Clutch main shaft

1

(7) Clutch release lever (8) Clutch lever shaft (9) Pressure plate

(10) Flywheel (11) Diaphragm boss

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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Clutch - Clutch and components

Clutch and components - Exploded view

NHIL16CT00311FA

(1) Main shaft (2) Release bearing (3) Release bearing hub (4) Bushing

(5) Bolt, M12 x 1.75 x 35, Qty:5 (6) Lock washer, Qty:7 (7) Bolt, M12 x 1.25 x 110, Qty:2 (8) Nut, M10 x 1.25, Qty:1

1

(9) Bolt / washer, M10 (13) Lock washer, x 1.25 x 35, Qty:2 Qty:2 (10) Clutch lever shaft (14) Bolt, M8 x 1.25 x 25, Qty:1 (11) Clutch housing (15) Clutch shift lever (12) Cotter pin

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(17) Bolt / washer, M8 x 1.25 x 25, Qty:6 (18) Clutch cover assembly (19) Pin

(16) Lock bolt, M12 x (20) Clutch disc 1.25, Qty:1 assembly

Clutch - Clutch and components

Clutch control mechanism - Detailed view

NHIL16CT00312FA

(1) Clutch pedal (Mechanical transmission) (2) Pin (3) Washer

1

(4) Cotter pin

(7) Pedal pad (Rubber)

(5) Clutch rod assembly (6) Return spring

(8) Clutch pedal (9) Spring pin

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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 Protective 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

NHIL16CT00274AA

2

NHIL16CT00260AA

3

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).

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.

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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

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4

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

NHIL16CT00278AA

2

NHIL16CT00280AA

3

4. Remove the clutch release bearing (1) and the release hub (2) together.

• When installing the clutch bearing (1) to the hub assembly, make sure to install it in the correct orientation.

• 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.

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Clutch - Clutch and components

(1) Clutch disc (2) Clutch cover (3) Clutch lever

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NHIL16CT00281AA

4

NHIL16CT00282AA

5

(4) Clutch release fork (5) Release bearing (6) Release hub

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

NHIL16CT00285AA

2

NHIL16CT00284AA

3

NHIL16CT00287AA

4

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).

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 release hub (2).

NOTICE: Application of too much grease can contaminate the clutch discs, which shortens the discs usable life. Remove any excess grease on or around the release hub groove.

5. Install the release hub (1), and the release fork (2).

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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 Protective 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

NHIL16CT00260AA

2

NHIL16CT00274AA

3

• Engine side (1) • Transmission side (2) • Clutch (3)

1. Join the clutch cover (1) and the clutch disc (2).

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