FORD FORDSON MAJOR Tractor Full Service Repair Manual

P Repair Manual r": i,r'y . ; ," \ :" f :,, ,I;,+;<:, , ; . b.+$ :.E. , ,-,, ,.: . , ., . , $ ,_. , FORDSON 1 POWER MAJOR SUPER M

THE NElU MANUFACTURED IN ENGLAND BY FORD MOTOR COMPANY LTD.

FOREWORD This manual is written to assist in the efficient repair of the New Fordson Major Tractor. Wherever possible, each operation is self-contained and sufficient detail is given to ensure that unnecessary dismantling will be avoided. Special tools have been developed to assist when carrying out the work and reference has been made to these tools in the appropriate places. The tools are numbered according to the Basic Part Number of the component in question. All necessary specifications, repair data and wear limits are quoted at the end of each section and will be of assistance when deciding if pans are suitable for further service. Whenever reference is made to the right- and left- hand side of the tractor, this is as viewed from the Driver's seat, facing forward. The tractor number is the same as the engine number which is stamped on the left-hand top face of the flywheel housing flange. This number is also stamped on a plate attached to the engine front bulkhead. Ford Policy is one of continuous imprmement and the right to change prices, specijicat~on and equipment at any time without notice is resmed.

CONTENTS 7 SECTION PAGE NO. Engine--Diesel ... ... ... ... ... ... 5 - Petrol - Vaporising Oil ... ... ... ... 35 - Lubrication System ... ... ... ... 59 ... Cooling System ... ... ... ... ... 68 Fuel System- Diesel ... ... ... ... ... 75 - Fuel Tanks and Fuel Supply Taps ... 99 -Petrol/Vaporising Oil ... ... ... 103 Separating the Tractor ... ... ... ... ... 115 ... ... Clutch ... ... ... ... ... ... 119 Front Transmission- Gearbox ... ... ... ... 129 Rear Transmission- Rear Axle ... ... ... ... 137 Hydraulic System ... ... ... ... ... ... I47 Front Axle ... ... ... ... ... ... ... 167 Steering Gear ... ... ... ... ... ... 173 Braking System . . ... ... ... ... ... 179 Wheels and Tyres ... ... ... ... ... ... 187 ... ... ... Electrical System ... ... ... 191 Power Take- off Equipment ... ... ... ... 231 Index ... ... ... ... ... ... ... ... 242 Supplement ... ... .. ... ... ... ... 245

COPYRIGHT IN GREAT BRITAIN, JANUARY 1954. ~epmductio in any manner, in whole or in parr, prohibircd without the express pcrrni.sion in wiring of Ford Moror Company Limited, 88 Regcnr Strccq London, W.,, England.

THE DIESEL ENGINE The 3.61 litre, four cylinder, direct injection type diesel engine fitted in the New Fordson Major Tractor has a bore diameter of 100 mm, and a stroke of 115 mm. 0verhead7valves are employed operated by push rods from a gear driven camshaft located in the right-hand side of the cylinder block. The compression ratio is 16 to 1. The valves are fitted vertically in the cylinder head, the inlet valve head being larger than the exhaust. The valve guides are replaceable. Aluminium alloy pistons are employed with a combustion chamber machined in the crowns and have three cornprcrsion rings and one oil ring above the piston pin and one oii control ring below the piston pin. T h e piston pins are fully floating and are retained in position by two circlips. Detachable wet cylinder liners are fitted, flange-mounted in the top face of the cylinder block and retained in position by the cylinder head. The crankshaft is supported in five large diameter main bearings. These bearings and the connecting rod big end bearings are of the detachable steel-backed lead-bronze type. Crankshaft end-float is controlled by detachable thrust washers fitted at each side of the centre main bearing. An enclosed camshaft type fuel injection pump is driven from the rear end of the auxiliary drive shaft and feeds multi-holed type injectors located at an angle in the top of the cylinder head. The engine speed is controlled by a pneumatic governor mouuted on the f~e injedon pump. An excess fuel device is fitted to assist cold starting. On current engines rotator type exhaust valves are fitted. A cap located over the end of the valve stem transmits pressure from the rocker lever to the spring retainer and valve spring. This anion allows the valve to remain free throughout its operating cycle. A decompressor, operating on all valves, was fitted to early type engines. On current engines this is optional equipment. Note - The operations described in the following pages are each complete in themselves and used in conjunction with the instructions from page 31 onwards give detailed information for a complete engine strip down and rebuild. These instructions have been prepared in orderthat the operations mqy be completed in the quickest time, involving the removal of the least number of component parts. A guide as to whether a part is fit for re-use or not is given in the form of wear limits tabulated at the end of the section. In the case of a complete overhaul of the engine, discretion must be exercised when re-fitting parts which, although within the limits, may be subject to arduous service when reassembled. THE ROCKER SHAFT ASSEMBLY To Remove 1 Undo the adaptor nut securing the ventilation pipe from the rocker cover to the inlet manifold. 2 Unscrew the two securing bolts and remove the rocker cover and gasket. 3 Release the retaining nut on the decompressor control (where fitted) and disengage the inner end of the control from the rocker shaft lever. 4 Release the tab washers on the five rocker shaft bolts. Gradually unscrew the bolts and lift off the rocker shaft, taking care not to dislodge the rotator caps from the exhaust valves if this type of valve assembly is fitted. (See Fig. 1.) 5 Lift out the push rods from their block locations, keeping them in their correct order and remove the rotator caps which should also be kept in their correct order. Note - I t is possible to change a push rod without removing the rocker shaft. This is done in the following manner: make sure that the valve in question is closed, slide the valve rocker sideways off the valve stem, until its ball end can be disengaged from the push rod cup. Fig. 1 Removing the Rocker Shaft

ENGINE- DIESEL To Dismantle Note - Where a decompressor lever is not fitted the eccentric sleeves and keys refened to are also not fitted, and the build-up is similar to that used on the Petrol and Vaporising Oil engines with the exception of the rocker levers. 1 Stand the assembly on end with the decompressor lever uppkmost, push the rocker levers, springs, eccentric sleeves and support brackets downwards until the pin retaining the decompressor lever or the end plug is revealed. Remove the pin and withdraw the decompressor lever or end plug assembly. (See Fig. 3.) 2 Pull off the adjacent support bracket, then the two rockers, spacer spring and eccentric sleeve. This will disclose the eccentric sleeve key, which must be removed before the next support bracket can be pulled off the shaft. Remove the remaining parts in a similar sequence and extract the keys as they are revealed. 3 Finally, remove the front plug after removing the retaining pin. To Reassemble 1 Fit the front end plug and retaining pin to that end of the shaft which has the pin hole centrally drilled. 2 Fit the support brackets, keys, eccentric sleeves, rocker levers and spacer springs in their correct order as shown in Fig. 2. The front and rear brackets are interchangeable, as also are the intermediate brackets, which are identified by a tapped hole for the rocker cover bolt. Ensure that the support bracket bolt holes are to the right viewing the shaft from the front end, with each pair of rocker levers inclined towards each other at the valve end. Fig. 3 Decompressor Lever 3 Complete the assembly by pushing all the parts towards the front of the rocker shaft and fitting the decompressor lever and its retaining pin. To Replace 1 Fit the push rods in their original position and place the rotator caps on the exhaust valve stems if this type of valve assembly is fitted. Care should be taken to prevent these caps falling in the engine. Fig. 2 Rocker Shaft and Supports

ENGINE- DIESEL Fig. 4 Correct Sequence for Loosening Cylinder Head Bolts 2 Fit the rocker shaft to the cylinder head, entering the adjusting screw ball ends in the push rod cups and engage the decompressor control with the decompressor lever. 3 Fit and tighten down evenly the five rocker shaft support bracket bolts and lock with the tab washers. 4 Adjust the valve clearances initially to 0.015 in. for inlet valves and exhaust valves without rotators. Rotator type exhaust valves should be set to 0.012 in. Ensure that all locknuts are tightened. Note - Ensure that the decompressor control is pushed in and the locking nut screwed in before carrying out the valve adjustment. 5 Warm up the engine and if necessary readjust the valve clearance to 0.015 in. for inlet valves and exhaust valves without rotators and 0.012 m. for rotator type exhaust valves. 6 Fit the rocker cover and gasket and fighten down the two securing bolts which are fitted wlth folded copper sealing washers. 7 Fit the ventilation suction pipe between the rocker cover and the inlet manifold. CYLINDER HEAD ASSEMBLY AND GASKET T o Remove 1 Disconnect the negative cable from the battery terminal post. 2 Remove the radiator filler cap and drain the water from the cooling system through the two taps, one on the radiator and one on the left-hand side of the cylinder block. 3 Disconnect the radiator tie bar, remove the water outlet connection and lift out the thermostat. 4 Remove the temperature gauge connection from the front of the cylinder head. 5 Remove the rocker cover, gasket, rocker shaft and push rods as described on page 5. 6 Remove the injectors as described in the Fuel System Section. 7 Remove the inlet and exhaust manifolds as described on page 8. 8 Unscrew the seventeen bolts retaining the cylinder head to the cylinder block in the order shown in Fig. 4. 9 Lift off the cylinder head and remove the gasket and rocker shaft oil feed seal. Note - Current type cylinder head bolts are marked " 100 " on rhe head. To Replace 1 Thoroughly clean off all dirt, carbon, etc., from the cylinder block, cylinder head faces and the recess in the cylinder block for the rocker shaft oil feed seal. 2 Fit a new rocker shaft oil feed seal and screw the cylinder head locating studs (tool No. TTr/MD 6050) into opposite corners of the cylinder block face and locate the new cylinder head gasket in position. 3 Replace the cylinder head and screw in the seventeen bolts and tighten in the correct order, as shown in Fig. 5, to the correct torque shown in the specification. 4 Replace the inlet and exhaust manifolds as described on page 8. 5 Replace the injectors as described in the Fuel System Section. 6 Replace the rocker shaft, push rods, rocker cover and gasket, and adjust valve clearances as described on this page. 7 Replace the temperature gauge connection in the front of the cylinder head. 8 Refit the thermostat, water outlet connection and the radiator tie bar. 9 Refill the cooling system. 10 Reconnect the battery lead to the battery terminal post. Fig. 5 Correct Sequence for Tightening Cylinder Head Bolts

ENGINE- DIESEL THE INLET AND EXHAUST MANIFOLDS To Remove 1 Lift off the vertical type exhaust pipe. If the horizontal type is fitted, disconnect the pipe at the manifold. 2 Unscrew the clips at either end of the rubber hose between the air cleaner and the inlet manifold and remove the hose. 3 Disconnect the throttle control rod. 4 Disconnect, at the manifold end, the two suction pipes from the pneumatic governor. Also disconnect and remove the ventilation suction pipe between the rocker cover and the inlet manifold. 5 Unscrew the manifold to head bolts and lift away the manifolds. i o Replace 1 Fit the manifolds using new gaskets, and screw in the retaining bolts evenly, making sure that the clamping washers are correctly positioned in their recesses. 2 Connect the pneumaticgovernor suction pipes, making sure that the bleed pipe (i.e. the outer pipe on the governor casing) is fitted to the upper connection on the inlet manifold, and refit the ventilation suction pipe between the rocker cover and the inlet manifold. NOTE - THE ENGINE MUST NOT BE RUN WITH THE GOVERNOR PIPES DISCONNECTED, AS UNDER THESE CONDITIONS THE GOVERNOR IS INOPERATIVE, AND SERIOUS DAMAGE MAY RESULT. 3 Reconnect the throttle control rod. 4 Refit the rubber hose between the inlet manifold and the air cleaner. 5 Replace the horizontaltype exhaust pipe with two bolts and a nut, or if vertical type, replace in adaptor. VALVES, GUIDES AND SPRINGS The valves are mounted vertically in the cylinder head and operated from the camshaft by conventional type push rods and rocker arms. The diameter of the inlet valve head is greater than that of the exhaust valve to improve engine breathing. On current engines rotator type exhaust valves are fitted and the operation of these is described overleaf. The inlet valve on aU engines remains the same. Oil seals are fitted to the stems of aU valves with the exception of the rotator type exhaust valves. To Renew a Valve Spring (without removing the cylinder head) 1 Remove the rocker cover and rocker shaft assembly, push rods and rotator caps (if fitted), as described on page 5. 2 Turn the piston on the cylinder beneath the valve affected, to the top of its stroke. 3 Refit a rocker shaft support bolt adjacent to the affected valve, slide the block of the valve spring compressor (toolNo. TTr/D 6513) under the bolt head and tighten down the bolt. Pull down the cam handle to compress the valve and extract the collets. (See Fig. 6.) 4 Release the cam handle and remove the spring retainer, valve spring and rubber sealing ring. 5 Fit a new valve spring with the close-coiled end to the cylinder head and replace the spring retainer. Compress the valve spring and fit a new rubber sealing ring into the lower groove of the valve stem where applicable and locate the collets. 6 Remove the tool and replace the push rods, rotator caps, rocker shaft assembly and rocker cover, as described on page 6. 7 Readjust the valve clearances to the figure specfied. Fig. 6 Valve Spring Compressor

OIL FlLLER CAP ROCKER ARM ADJUSTER INJECTOR LEAK- OFF PIPE VALVE COLLET V A L V E SPRING RETAINER VALVE SPRING INJECTOR PIPE THERMOSTAT VALVE GUIDE STOP CONTROL LEVER PISTON RlNG WATER PUMP GENERATOR HAND PRIMER CONNECTING ROD LINER SEALING RlNG FUEL INJECTOR PUMP TIMING GEARS CR PUMP DRIVE COUPLING OIL FILTER OIL SCREEN \---OIL PRESSURE RELIEF VALVE AUXILIARY DRIVE SHAFT \L FRONT MOUNTING PLATE PUMP .a Fig. 7 Sectioned View of Diesel Engine

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FORD FORDSON MAJOR Tractor Full Service Repair Manual

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