Ford Series 1000-1600 Tractors OEM Service & Repair Manual

SHOP MANUAL SERIES 1000-1600 Tractor serial number and engine serial number are stamped on vehicle identification plate located on left side of clutch housing. INDEX (By Starling Paragraph) BRAKES Adjust 63 R&R and Overhaul 54 CLUTCH Adjust 46 Clutch Shaft 50 R&R and Overhaul 48 COOLING SYSTEM Radiator 41 Thermostat 40 Water pump 42 DIESEL FUEL SYSTEM Filters 27 Glow Plugs 39 Injection Pump 29, 30 Injection Pump Drive Gear 28 Nozzles 32 DIFFERENTIAL Adjustment 57 Overhaul 58 Removie and Reinstall 56 DIFFERENTIAL LOCK 59 ELECTRICAL SYSTEM Alternator 43 Regulator 44 Starter 45 ENGINE Cam Followers 24 Camshaft, Bearings and Tappets 24 Connecting Rods and Bearings 21 Connecting Rod and Piston Removal 17 Crankshaft and Bearings [ .22 Cylinder Head 7 Engine Removal 6 Injection Timing 29 ENGINE CONT. Main Bearings Oil Pressure Relief Valve ... Oil Pump Pistons and Cylinders Piston Pins Piston Rings Rocker Arms Timing Gear Cover Timing Gears Valves and Seats Valve Guides Valve Springs Valve Clearance Adjustment. Valve Timing FINAL DRIVE Overhaul Remove and Reinstall FRONT SYSTEM Axle Front Support Steering Gear Steering Knuckles Tie Rods and Toe in HYDRAULIC SYSTEM Adjustment Control Valve Lubrication Pump Lift Cover and Rockshaft POWER TAKE OFF TRANSMISSION Overhaul Remove and Reinstall 22 26 25 19 20 18 11 12 13 8 9 10 llA .14. 15, 16 .61,62 .... 60 .1 .4 .5 .3 .2 .69, 70, 71 . ..75, 76 66 .... 72,73 .... 78.79 65 .54 .51

CONDENSED SERVICE DATA (NOTE: ALL MEASUREMENTS ARE METRIC) GENERAL Engine Make Own No. of Cylinders 2 Bore, mm ^^ Stroke, mm 100 Displacement, cc 1272 Compression Ratio 21:1 Pistons Remove From Above Main Bearings, Number of 2 Cylinder Sleeves None Forward Speeds 9 Reverse Speeds ^ TUNE-UP Compression, Gage at Cranking Speed 2690 kPa Valve Tappet Gap, I&E, Cold 0.3 mm Engine Low Idle RPM 750-850 Engine High Idle RPM 2650-2700 Engine RPM at Rated Load • 2500 Engine RPM for 540 PTO RPM 1955 Injection Timing 21° BTDC Battery Terminal Grounded Negative SIZES-CLEARANCES-CAPACrriES Crankshaft Journal Diameter 67.95-67.97 mm Crankpin Diameter 59.95-59.97 mm Camshaft Journal Diameter: Front 20.00 20.01 mm Rear . ! . * ' . . 19.99-20.00 mm Piston Pin Diameter 32 mm Valve Stem Diameter, Intake 8 mm Valve Stem Diameter, Exhaust 8 mm Main Bearing Running Clearance 0.04-0.010 mm Rod Bearing Running Clearance 0.06-0.13 mm Crankshaft End Play 0.1-0.45 mm Piston Skirt Clearance 0.12-0.18 mm Cooling System, Quarts 5.3 Liters Crankcase, Quarts, Without Filter Change 4.7 Liters With Filter Change 5.0 Liters Hydraulic System 10 Liters Transmission and Final Drive 19.8 Liters Fuel Tank 22 Liters FRONT AXLE AND STEERING SYSTEM FRONT AXLE 1. Front axle is adjustable type shown in Fig. 1. The axle pivots on shaft (2) which rides in support bushings (16). Spindles (29) are supported by bushings (22) and thrust bearings (26). All bushings and bearings are renewable. Desired pivot shaft end play is 0.03-0.008 mm and should not exceed 0.15 mm. Thrust washers (18) are available in varying thicknesses to adjust pivot shaft end play. Desired radial clearance between pivot shaft and bushings is 0.1-0.2 mm and should not ekeeed 1.0 mm. TIE RODS AND TOE-IN 2. Tie rod and drag link ends are automotive type. Adjust toe-in to 0-12.7 mm by shortening or lengthening tie rod. Steering drag link can be adjusted if necessary, to permit a full turn in either direction. STEERING KNUCKLES 3. To remove steering knuckle, support front axle and remove wheel. Detach tie rod from right steering arm (2—Fig. 2) or tie rod and drag link from left steering arm (10). Remove steering arm bolts and steering arm. Remove key and shims and withdraw spindle from front axle. Spindle bushings are pre-sized and can be renewed after spindle is with- drawn. Upper and lower bushings are fig, t~Explod9d view of adiustable front axte assembly. 1. Cover 2. Pivot shaft 3. Front support 4. Hub cap 5. Gasket 6. Cotter pin 7. Nut 8. Washer 9. Roller bearing 10. Hub 11. Roller bearing 12. Oil seal 13. Washer 14. Snap ring 15. Axle center member 16. Bushings 17. "0" rings 18. Thrust washers 19. Shims 20. Spacer (washer) 21. "0" ring 22. Bushings 23. Axle extension 24. Grease fitting 25. Bearing race 26. Thrust bearing 27. Thrust washer 28. "0" ring 29. Spindle

Paragraphs 4-7 interchangeable. Install sufficient shims (19—Fig. 1) to fill gap between steering arm and spacer (20). FORD 10 12 Fig. 2-^Expioded view of steering linkage. 1. Key 2. Steering arm, R.H. 3. Tie rod end 4. Tie rod extension 5. Pitman arm 6. Drag link end 7. Drag link 8. Tie rod 9. Drag link end 10. Steering arm, L.H. 11. Key 12. Tie rod end FRONT SUPPORT 4. To remove front support, remove hood, drain cooling system, disconnect radiator hose and remove radiator. Detach drag link from pitman arm and place a support under clutch housing. Unscrew twelve screws securing front support to sides of engine, and roll front axle assembly away from tractor. Separate front support from front axle. STEERING GEAR 5. All models are equipped with recirculating ball nut steering gear shown in Fig. 3. To remove steering gear, remove pitman arm, steering wheel and instrument panel. Unbolt and remove steering gear. Remove capscrews securing right side cover (12) and remove cover along with pitman shaft and gear (16). Remove steering shaft housing (4) being careful not to lose shims (6). Remove steering shaft and gear (8). Inspect components and renew any which are damaged or excessively worn. Shaft and gear unit (8) is available as an assembly only. Shims (6) are used to adjust bearing preload. Install steering shaft and gear (8), bearings (7), original shims (6), gasket (5) and steering housing (4). Tighten steering housing (4) screws Fig. 3—Expioded view of steering gear. 1. Bearing 2. Steering column 3. Ground wire 4. Steering housing 5. Gasket 6. Shims 7. Bearings 8. Steering shaft & gear 9. Fill plug 10. Nut 11. Lockwasher 12. Side cover 13. Gasket 14. Bushing 15. Adjusting screw 16. Cross shaft 17. Body 18. Gasket 19. Breather 20. Dipstick 21. Bushing 22. Oil seal 23. Pitman arm 24. Lockwasher 25. Nut Fig. 4—Turn screw {IS) to adjust steering gear baciciash. and measure force necessary to turn steering shaft. Add or remove shims (6) as needed so 1-3 kg/cm is required to turn steering shaft. Reassemble and install steering gear by reversing disassembly procedure. Fill housing with SAE EP90 oil through plug (9) hole until oil reaches bottom of plug hole. Steering shaft free play should be 20-35 mm measured at outer circum- ference of steering wheel. To adjust free play, loosen locknut and turn adjusting screw (15—Fig. 4). Turn screw clockwise to decrease free play or counterclockwise to increase free play. ENGINE AND COMPONENTS R&R ENGINE WITH CLUTCH 6. To remove engine, remove battery and disconnect all wires interfering with engine removal. Remove hood and disconnect throttle rod. Disconnect fuel tank lines, loosen clamps and remove fuel tank. Remove front support and axle assembly as outlined in paragraph 4. Disconnect hydraulic pump lines and remove muffler and air cleaner. Attach a hoist to engine, unscrew clutch housing bolts and remove engine. Install by reversing removal procedure. CYLINDER HEAD 7. To remove cylinder head, remove hood panel and drain cooling system. Detach upper coolant hose, air inlet hose and exhaust pipe from head. Remove and cap injector lines. Remove rocker arm assemblies and push rods. Unscrew six cylinder head retaining nuts and lift off cylinder head assembly.

1000-1600 Paragraphs 8-16 NOTE: One cylinder head retaining nut is iocated in air inlet passage. Cylinder heat warpage should not exceed 0.12 mm. Reverse removal procedure to install cylinder head. Note tightening sequence of cylinder head retaining nuts in Fig. 5. Later 1600 models are equipped with a long stud (L—Fig. 5) and spacer (S) in air inlet passage to prevent loosening of retaining nut. Tighten cylinder head nuts on all models to 147-151 Nm. Be sure rocker arm support holes are aligned with roll pins in cylinder head. VALVES AND SEATS 8. Valve seat and valve face angles are 45 degrees for intake and exhaust valves. All valves seat directly in head. Recommended valve seat width is 1.2-1.5 mm. Maximum allowable valve seat depth is 2.0 mm measured from cylinder head surface to valve head surface. Minimum allowable valve mar- gin is 1.0 mm. Valve stem diameter is 8 mm for all valves. VALVE GUIDES 9. Maximum allowable intake valve- to-guide clearance is 0.2 mm while maximum allowable exhaust valve-to- guide clearance is 0.25 mm. Replace- ment valve guides are not available from manufacturer. VALVE SPRINGS AND SEALS 10. Identical springs are used on all valves. Valve spring free length should Fig. 5—Use sequence sfiown above when tightening cyiinder head nuts. Long stud (L) and spacer (S) in air iniet passage are used on later 1600 modeis. be 48 mm. Valve spring tension should be 12-14 kg at 36 mm. Identical valve seals are used on all valves. ROCKER ARMS 11. Intake and exhaust rocker arms are interchangeable. Desired clearance between rocker arm and rocker shaft is 0.04 mm while maximum allowable clearance is 0.2 mm. Renew rocker shaft if diameter is less than 13.55 mm. Rocker arms, shafts and valves are lubricated by oil directed through push rods from valve tappets. When installing rocker shaft support stand on cylinder head, be sure hole in support stand is aligned with roll pin in cylinder head. VALVE CLEARANCE ADJUSTMENT 11 A. Valve clearance for all valves should be 0.3 mm. Set valve clearance with engine cold. R&R TIMING GEAR COVER 12. To remove timing gear cover, tilt hood forward, drain cooling system and remove radiator. Drain engine oil. Remove fan, fan belt, crankshaft pulley and pulley key. Disconnect oil lines to hydraulic oil pump. Unbolt and remove timing gear cover. Crankshaft front seal (8—Fig. 6) can now be renewed. After installing crankshaft pulley, tighten pulley bolt to 40-48 Nm. TIMING GEARS 13. Before removing any gears in the timing gear train, rocker arms should be removed to avoid possible damage to piston or valve train if either the camshaft or crankshaft should be turned independently of the other. The timing gear train consists of the crankshaft gear, camshaft gear, injection pump drive gear, oil pump gear and an idler gears which drives the camshaft and injection pump gears. Refer to paragraph 28 for injection pump drive gear service. Tachometer drive gears are located behind camshaft gear. 14. IDLER GEAR AND SHAFT. To remove idler gear and shaft, unscrew two retaining screws which secure assembly to front of cylinder block and loosen oil tube banjo bolts. Renew shaft and/or gear if bushing to shaft clearance is excessive or bushing is scored. Bushing (3—Fig. 6) and gear (2) are available as a unit assembly only. Shaft oil hole must be free of dirt or foreign material. Inspect gear and renew if damaged or excessively worn. Note that oil tubes leading to idler shaft direct oil to main oil gallery and must be properly attached to idler gear shaft (4—Fig. 6). Do not over-tighten banjo bolts. Timing marks between idler gear and camshaft gear and idler gear and crankshaft gear must be aligned when installing idler gear. Tighten idler gear retaining screws to 18-19 Nm. Backlash between idler gear and camshaft gear or between idler gear and crankshaft gear should be 0.1-0.3 mm. Renew gears which exceed backlash requirements. 15. CAMSHAFT AND TACHOME- TER GEARS. To remove camshaft gear, unscrew gear retaining nut. Tachometer drive gears are now acces- sible and may be removed. When reinstalling camshaft gear, align timing marks on idler gear and camshaft gear. Tighten camshaft gear retaining nut to 147-156 Nm. Backlash between idler gear and camshaft gear should be 0.1-0.3 mm. 16. CRANKSHAFT GEAR. The crankshaft is equipped with two keys to retain crankshaft pulley and crankshaft gear. Use a suitable puller to pull gear off crankshaft. Inspect gear, key and crankshaft. To reinstall gear, fully seat key in crankshaft keyway and install gear with timing mark out. Backlash between idler gear and crankshaft gear should be 0.1-0.3 mm. Fig. e—Expioded view of timing gear cover and idier gear. 1. Retainer plate 2. Idler gear 3. Bushing 4. Idler shaft 5. Alternator bracket 6. Timing gear cover 7. Timing pointer 8. Oil seal 9. Gasket 10. Inner plate 11. Gasket

Paragraphs 17-23 FORD CONNECTING ROD AND PISTON UNITS 17. Connecting rod and piston units are removed from above after removing the cylinder head and oil pan. Be sure to remove top ridge from cylinder bores before attempting to withdraw assemblies. Connecting rods should be marked so assembly can be reinstalled in original cylinder. Assemble connecting rod and piston so "F" mark on rod will be towards engine front and slot (S—Fig. 7) in piston crown will be towards intake side of engine. Tighten connecting rod screws to 69-73 Nm. PISTON RINGS 18. Pistons are fitted with three compression rings and one oil control ring. Top compression ring is chrome plated while the two lower compression rings are cast iron. Oil control ring is a one-piece slotted two rail type. All rings have a straight face. Install rings so "R" mark is towards piston crown. Piston ring end gap should be 0.3-0.5 mm. Side clearance should be 0.3-0.9 mm for compression rings and 0.3-0.7 mm for oil ring. Piston ring sets are available in oversizes of 0.5 mm and 1.0 mm. PISTONS AND CYLINDERS 19. Engine is equipped with full skirt type pistons which are available in oversizes of 0.5 mm and 1.0 mm. Cylinders are not sleeved. Piston-to-cylinder clearance should be 0.12-0.18 mm. Maximum allowable cylinder taper is 0.2 mm. Cylinder must not be out-of-round more than 0.2 mm. PISTON PINS 20. Piston pin floats in connecting rod but is a light press fit in piston. Heat piston to 100*^ C. to remove piston pin. Piston pin diameter is 32 mm. Renew pin if worn more than 0.05 mm. Desired pin-to-rod clearance is 0.01 mm while maximum allowable clearance is 0.05 mm. Refer to paragraph 17 when assembling piston and connecting rod. CONNECTING RODS AND BEARINGS 21. Connecting rod bearings are available in standard size only. Con- necting rod is fractured at big end and rod and cap must mesh perfectly during assembly. Tighten connecting rod screws to 69-73 Nm. Refer to paragraph 17 when assembling piston and connecting rod. Connecting rod bearing clearance is 0.06-0.13 mm. Desired connecting rod side play is 0.1-0.3 mm and should not exceed 0.7 mm. CRANKSHAFT AND MAIN BEARINGS 22. Crankshaft is supported by two sleeve type main bearings; one in front cylinder block wall and one in flywheel cover. Both bearings are pressed into place. Crankshaft thrust is directed against thrust washers (12 and 17—Fig. 8) pinned to flywheel cover and front cylinder block wall. To remove crankshaft, remove engine as outlined in paragraph 6. Refer to appropriate paragraphs and remove clutch assembly, alternator, starter cylinder head, water pump, timing gears, injection pump, and front plate. Unscrew flywheel nut and remove flywheel. Note that it may be necessary to tap end of crankshaft to free Fig. l—Piston crown siot (S) must be towards intake side and (F) on rod must be towards engine front. Fig. B^Expioded view of cyiinder biock and crankshaft assembiy. 1. Oil slinger 2. Gear S. Bearing 4. Plug 5. Oil pan 6. Dowel pin (2) 7. Oil pressure sensor 8. Roll pin 9. "0" ring 10. Dowel pin (2) 11. Drain valve 12. Thrust washer 13. Keys 14. Crankshaft 15. Kev 16. RoU pin 17. Thrust washer 18. Bearing 19. Gasket 20. Plug 21. Flywheel cover 22. Oil seal 23. Dowel pin (2) 24. Flywheel 25. Roller bearing 26. Tab washer 27. Nut flywheel from crankshaft taper. Remove oil pan and oil pump. Remove piston and rod assemblies. Unscrew capscrews securing flywheel cover. Remove flywheel cover while supporting crankshaft as rear end of crankshaft will be unsupported after flywheel cover re- mo vial. Withdraw crankshaft from cylinder block. Inspect bearings, thrust washers and crankshaft. Crankshaft main bearing journal diameter is 67.95-67.97 mm. Main bearing clearance is 0.04-0.10 mm. Standard size main bearings only are available. Crankshaft main bearing journal out-of-round or taper should not exceed 0.05 mm. Crankshaft rod journal diameter is 59.95-59.97 mm. Connecting rod bearing-to-rod journal clearance is 0.06-0.13 mm. Standard size only connecting rod bearings are available. Be sure oil holes are aligned when installing main bearings. Crankshaft end play should be 0.1- 0.45 mm while maximum allowable end play is 0.7 mm. Thrust washers (12 and 17—Fig. 8) control end play. Install thrust washers so oil grooves are adjacent to crankshaft. Be sure thrust washer locating pin is 0.5 mm below thrust bearing face. Care should be used not to damage crankshaft main bearings and thrust washers when installing crankshaft. Be sure camshaft bearing "0" ring (9) is installed and coated with a sealant. Tighten flywheel cover screws in a diagonal pattern to 44-48 Nm. CRANKSHAFT REAR OIL SEAL 23. Crankshaft rear oil seal is located in flywheel cover (21—Fig. 8). For 24 H < 21 t9 20 22

1000-1600 access to rear oil seal, remove flywheel cover as outlined in paragraph 22. CAMSHAFT, BEARINGS AND TAPPETS 24. Camshaft rides in two ball bearings located in front and rear cylinder block walls. Refer to Fig. 9 for an exploded view of camshaft and tachometer drive assemblies. To remove camshaft, tappets and bearings, first remove crankshaft as outlined in paragraph 22. Remove "0" ring (9—Fig. 8) adjacent to rear camshaft bearing and withdraw bearing and camshaft. Tap- pets and front camshaft bearing can now be removed. Desired camshaft lobe height is 32.05 mm while minimum allowable lobe height is 31.65 mm. Maximum allowable camshaft runout measured at center of camshaft with ends supported in V-blocks is 0.2 mm. Be sure "0" ring (9—Fig. 8) is installed when assembling engine. Sea- lant should be used around "0" ring to prevent possible oil leakage. OIL PUMP 25. Engine oil pump is a gear type located in front cylinder block wall. Pump is driven by crankshaft timing gear. Pressurized oil from pump is directed by internal passages to relief valve adjacent to pump, to full flow oil filter, to front main bearing, then to banjo bolt and external line above pump. Oil flows through external line to idler gear shaft and from idler gear shaft by external line to banjo bolt above camshaft gear. Oil then flows through internal passages to rear main bearings and tappets. Oil is forced through tappets and up push rods to lubricate valve train. To remove oil pump, drain engine oil and remove oil pan. Remove timing gear cover as outlined in paragraph 12. Detach oil pickup from oil pump body and remove oil pump drive gear (8—Fig. 10). Unbolt oil pump cover (10) and remove oil pump. Pump may be disassembled after removing pump cover to-body screws. Clearance between oil pump body face and gear faces should be 0.07-0.14 mm with a maximum allowable clearance of 0.25 mm. Clearance between Fig. lO^Exploded view of oii pump and reiief valve. 1. Cap 2. Snap ring 3. Sprmg seat 4. Spring 5. Ball 6. Relief valve body 7. Nut 8. Gear 9. Key 10. Oil pump cover 11. Driven gear 12. Drive gear 13. Oil pump body 14. "0" ring 15. Oil pick up Paragraphs 24-27A gear teeth and pump should be 0.01- 0.03 mm. Tighten oil pump drive gear nut to 30 34 Nm. RELIEF VALVE 26. Relief valve for engine lubri- cating system is located adjacent to oil pump. Remove timing gear cover as outlined in paragraph 12 for access to relief valve. Refer to Fig. 10 for exploded view of relief valve. Later models have a cap (1) in end of valve housing. Early and late relief valve components are interchangeable. Relief valve should open when oil pressure exceeds 245-392 kPa. FUEL SYSTEM All models are equipped with a diesel fuel injection system. When servicing any unit associated with the fuel system, absolute cleanliness must be maintained. Of equal importance is the avoidance of nicks or burrs on any working parts. Probably the most important precaution that service personnel can impart to owners of diesel powered tractors is to urge them to use an approved fuel that is absolutely clean and free from foreign material. Extra precaution should be taken to make certain that no water enters the fuel storage tanks. FUEL FILTERS AND LINES 27. Fuel filter and valve assembly is located on fuel tank bottom. Fuel filter element should be removed and cleaned after every 100 hours of operation and renewed after every 200 hours. 27A. BLEEDING. To air bleed fuel system, open fuel valve and fuel filter bleed screw (B—Fig. 11). Allow fuel to flow until air bubbles disappear and fuel is clear. Close fuel filter bleed screw while fuel is flowing; open injection pump bleed screw (B—Fig. 12) Fig. H^View of fuel fiiter and air bleed screw (6). Fig. 9^ Expioded view of camshaft assembiy. 1. Nut 2. Gear 3. Washer 4. Tachometer gear 5. Spacer 6. Bearing 7. Key 8. Camshaft 9. Bearing 10. Tachometer drive assy. 11. Gasket 12. Inner plate 12 Fig. 12^View showing location of injection pump bleed screw (B).

Paragraphs 28-31 and allow fuel to flow until air bubbles disappear, then close bleed screw. Loosen high pressure fuel lines at injectors, open throttle and crank engine until fuel escapes from loosened fuel line connections. Tighten fuel line compression nuts. INJECTION PUMP DRIVE GEAR 28. To remove injection pump drive gear, remove timing cover as outlined in paragraph 12. Note alignment marks (A—Fig. 14) on drive gear (P) and coupling (C) and remove pump drive gear from coupling. Be sure marks (A) are aligned when installing gear on coupling. If a new gear is installed, refer to paragraph 29 for injection pump timing. Tighten gear retaining screws to 40-49 Nm. INJECTION PUMP 29. PUMP TIMING. Fuel injection should occur at 21 *» BTDC. Timing gear cover must be removed as outlined in Fig. IS—Expioded view of injection pump gear drive. 1. Gear 2. Coupling 4. Gasket 3. Inner plate 5. Injection pump paragraph 12 to check or adjust injection timing. If original pump drive gear (1—Fig. 13) and coupling (2) are installed, pump timing is correct if marks (M—Fig. 14) on pump drive gear (P) and idler gear (I) are aligned and marks (A) on pump coupling (C) and pump drive gear (P) are aligned. See Fig. 4. If pump drive gear or coupling has been renewed, spill timing procedure must be used. Remove injection pump delivery valve (8—Fig. 15) for number one cylinder and install a spill tube. Position pump drive gear (1—Fig. 13) on coupling (2) but do not install screws. Align marks (M—Fig. 14) on pump drive gear (P) and idler gear (I). Rotate injection pump drive shaft so drive shaft mark (D) is nearest elon- gated hole (E). Install injection pump gear screws finger tight. Rotate injec- 2 3 Fig. 15—Exploded view of fuel delivery valve. Remove No. 1 fuel deiivery vaive to spiii time engine. FORD tion pump coupling until fuel just ceases to flow and tighten pump gear screws to 3948 Nm. Mark pump gear and coupling for future reference as shown at (A). 30. REMOVE AND REINSTALL. To remove injection pump, disconnect fuel lines and throttle rod and remove timing cover as outlined in paragraph 12. Unscrew coupling (2—Fig. 13) nut and remove coupling and pump gear as a unit. Unscrew pump mounting nuts and remove pump. To install pump, reverse removal procedure. Tighten pump mounting nuts to 44-48 Nm. Tighten coupling nut to 39-48 Nm. Refer to previous paragraph for pump timing procedure. Bleed fuel lines and pump as outlined in paragraph 27A. THROTTLE LINKAGE ADJUSTMENT 31. To check and adjust governed speed, start and run engine until normal temperature is reached. Back out high speed stop screw (W—Fig. 16) and detach foot throttle rod from bell crank (B). Adjust high idle speed screw (S—Fig. 16A) to obtain 2650-2700 rpm high idle speed. Turn high speed stop screw (W—Fig. 16) in so screw contacts throttle arm stop when hand throttle is in full throttle position. If stop screw (W) will not contact stop when screwed in or if screw prevents full throttle 1. Holder retainers 2. Lockwasher 3. Screw 4. Delivery valve holder 5. Spring 6. Gasket 7. Delivery valve 8. Plunger Fig. ISA--Adjust high idie speed screw (S) to obtain 2650-2700 rpm high idie speed. Fig. 4—Diagram of injection pump gear and coupiing timing marks. See text. Fig. 16'-Refer to text for throttie iinkage adjustment.

1000-1600 opening, turn throttle rod turnbuckle (T) to shorten or lengthen throttle rod. Turn low idle speed stop (I—Fig. 17) to obtain low idle speed of 750-850 rpm. Attach foot throttle rod to bellcrank (B—Fig. 16) and adjust turnbuckle (FT) so foot throttle does not affect low or high speed settings. INJECTION NOZZLES CAUTION: Fuel leaves injection nozzles with sufficient force to penetrate sicin. Care must be used when testing injection nozzies. 32. TESTING AND LOCATING A FAULTY NOZZLE. If engine is missing and fuel system is suspected as being the cause of trouble, system can be checked by loosening one and then the other injector line connection while engine is running at slow idle speed. If engine operation is not materially affected when injector line is loosened, that cylinder is missing. Remove and test (or install a new or reconditioned unit) as outlined in appropriate follow- ing paragraphs. 33. REMOVE AND REINSTALL. Before removing an injector, carefully clean all dirt and other foreign material from lines, injector and cylinder head. Detach injector leak-off line and disconnect injector line from pump and injector. Cap all lines and openings. Unscrew injector from cylinder head. Fig. 17—Low idie speed shouid be 750-850 rpm and is adjusted by turning screw (/). When installing injector, make sure machined seating surface in cylinder head is clean and free from carbon buildup. Use a new copper washer underneath injector nozzle and tighten injector to 59-68 Nm. 34. TESTING. Testing and adjusting injector requires special test equip- ment. Only clean, approved testing oil should be used in tester tank. Nozzle should be tested for opening pressure and leakage. Before conducting test, operate tester lever until fuel flows, then attach injector to tester. Close valve to tester gage and pump tester lever a few quick strokes to be sure nozzle valve is operating and not stuck thereby requir- ing overhaul. 35. OPENING PRESSURE. Open tester valve and operate tester lever slowly while observing gage reading. Opening pressure should be 11760 kPa. Opening pressure is adjusted by adding or deleting shims (7—Fig. 18) which are 0.1 mm thick. Installation or removal of one shims will raise or lower opening pressure approximately 980 kPa. 36. LEAKAGE. To check injector for leakage, operate tester until pressure reading is 9800 kPa. If external leakage is evident, especially at nozzle tip, injector must be disassembled and overhauled. 37. SPRAY PATTERN. Spray pattern should be well atomized and slightly conical, emerging in a straight axis from nozzle tip. If pattern is wet, ragged or intermittent, nozzle must be overhauled or renewed. 38. OVERHAUL. Hard or sharp tools, emery cloth, grinding compound or other than approved solvents or lap- ping compounds must never be used. An approved nozzle cleaning kit is available through a number of special- ized sources. Wipe all dirt and loose carbon from exterior of nozzle and holder assembly. Refer to Fig. 18 for an exploded view of injector. 10 Fig. 18—Expioded view of fuei injector unit. 1. Ga^et 2. Nut 3. Nozzle body 4. Nozzle plate 5. Pressure pin 6. Spring 7. Shim 8. Injector body 9. Fitting 10. Nut Paragraphs 32-38 Secure nozzle nut (2) in a soft jawed vise or holding fixture and remove nozzle body (3). Place all parts in cleajf calibrating oil or diesel fuel as they ig^ removed. Be sure parts are not mixed if more than one injector is being serviced. Clean exterior surfaces with a bras4 wire brush and soak in an approved carbon solvent, if necessary, to loosen hard carbon deposits. Rinse parts in clean diesel fuel or calibrating oil immediately after cleaning to neutralize solvent and prevent etching polished surfaces. Clean nozzle spray hole from inside using a pointed hardwood stick or wood splinter as shown in Fig. 19. Scrape carbon from pressure chamber using hooked scraper as shown in Fig. 20, Clean valve seat using brass scraper as shown in Fig. 21, then polish seat using Fig. 19—Use a pointed hardwood Mtick to dean spray hoie as shown. Fig. 20—Use hooked scraper to c/Mfi from pressure chamber. Fig. 21 —dean vaive seat U9lng frrttf scraper as shown.

Paragraphs 39-42 wood polishing stick and mutton tallow as in Fig. 22. Back flush nozzle using reverse flusher adapter. Reclean all parts by rinsing thoroughly in clean diesel fuel or calibrating oil and assemble while parts are immersed in cleaning fluid. Make sure adjusting shim pack is intact. GLOW PLUGS 39. Each cylinder is equipped with a glow plug located on lower right side of cylinder head. Glow plugs are wired in parallel and controlled by key switch. To remove glow plugs, disconnect wir- ing, detach strap connecting glow plugs and unscrew glow plugs. COOLING SYSTEM RADIATOR PRESSURE CAP AND THERMOSTAT 40. A 90 kPa (13 psi) radiator pressure cap is used. The thermostat is located under the coolant outlet elbow on front of cylinder head. Standard thermostat opening temperature is 71** C. Thermostat should be fully opened at 85^ C. RADIATOR 41. To remove radiator, tilt hood forward and drain cooling system. Detach coolant hoses, unbolt lower mounts and support bracket and remove radiator. Cooling system capacity is 5.3 liters. WATER PUMP 42. To remove water pump, remove radiator as outlined in paragraph 41 and detach fan from water pump. Loosen alternator retaining bolts and remove fan belt. Unbolt and remove water pump. Using a suitable puller, pull pump pulley (2—Fig. 23) off shaft (3). Remove rear plate (10) and bearing retaining screw (4). Press shaft and bearing (3), seal (8) and impeller (9) out of housing (6). To reassemble water pump, press pump pulley (2) on shaft (3). Press shaft and bearing (3) into housing (6) so bearing groove is aligned with bearing FORD retaining screw (4) hole. Coat housing side of seal (8) with sealer and install seal in housing. Lubricate impeller side of seal (8) with oil and press impeller Fig. 23—Expioded view of water pump. 1. Fan 2. PuUey 3. Shaft & bearing 4. Bearing retaining screw 5. Locknut 6. Housing 7. Gasket 8. Seal 9. Impeller 10. Rear plate 11. Thermostat Fig. 24—Aiternator and voltage regulator schematic for modeis prior to serial number U101421. 1 2 3 Fig. 25—Expioded view of aiternator used on modeis prior to seriai number U101421. 1. Spring 2. Brush 3. Brush holder 4. Diode assy. 5. Frame 6. Stator 7. CoUar 8. Key 9. Rotor 10. Slip rings 11. Retainer 12. Bearing 13. Front frame 14. Bearing 15. Retainer 13 Fig. 22—Poiish seat using polishing stick and mutton taliow. 10

1000-1600 Fig, 26—Exploded view of alternator used on modeis after seriai number U101420. 1. Spacer 2. Front frame 3. Packing 4. Retainer 5. Bearing 6. Bearing retainer 7. Key 8. Rotor 9. Stator 10. Frame 11. Brush assy. 12. Cover 13. Diode assy. (9) on shaft (3) so clearance between impeller fins and housing is one mm. Install gasket and rear plate (10). ELECTRICAL SYSTEM Fig. 27—Adjust voltage regulator on models prior to seriai number U101421 as outlined in text. ALTERNATOR AND REGULATOR 43. ALTERNATOR. Models 1000 and 1600 are equipped with a 12 volt alternator. Current output is 10 amperes for alternator number 185046020, 35 amperes for alternator number 185046070 and 20 amperes for alternator number 185046071. CAUTION: Alternator output wire is connected directly with positive battery terminai and is "hot" at aii times Paragraphs 43-45 battery is connected. Use caution when disconnecting or connecting terminais so output wire is not grounded. 44. REGULATOR. On models prior to serial number U101421, voltage regulator unit contains a voltage regu- lating relay and an indicator lamp control relay. Output voltage is regu- lated at 13.5-14.2 volts. Refer to Fig. 24 for alternator and regulator schematic. To adjust voltage regulator on models prior to serial number U101421, refer to Fig. 27 and adjust voltage regulator relay yoke gap (Y) to 0.7 mm, core gap (C) to 1.3 mm and point gap (P) to 0.3 mm. Install regulator and reconnect all wires. Connect a voltmeter and ammeter as shown in Fig. 28. Run engine at approximately 2000 rpm and turn screw (S—Fig. 27) to obtain 13.5-14.0 volts. Ammeter should indicate 10 amperes or less after voltage adjustment. To adjust indicator lamp relay on models prior to serial number U101421, refer to Fig. 29 and adjust yoke gap (Y) to 1.1 mm, core (C) gap to 1.2 mm and point gap (P) to 1.0-1.3 mm. Install regulator and reconnect all wires. Connect a voltmeter and ammeter as shown in Fig. 30. Start engine. Turn adjusting screw (S—Fig. 29) so that as engine rpm is increased, indicator lamp relay closes at 3-4 volts and one ampere. Voltage regulator on models after serial number U101420 should regulate voltage between 13.8 and 14.8 volts. Closing voltage for regulator relay is 4.2-5.2 volts measured between "N" terminal of regulator and ground. STARTER MOTOR 45. The starter motor is on left side of engine and starter solenoid is Fig. 28—View showing connection of ammeter (A) and voitmeter (V) for regu- iator testing. Fig. 29—Adjust indicator lamp relay as outlined in text. 11

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Ford Series 1000-1600 Tractors OEM Service & Repair Manual

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