2120 Tractor

John Deere

TECHNICAL MANUAL
2120 Tractor

TM4252 (01Dec70) English

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 Model 2120 Tractor
Serial No. 61020 L-up
Technical Manual
TM-4252 (Dec-70)
CONTENTS

SECTION 10 - GENERAL INFORMATION

Group 5 - Specifications
Group 10 - Pre-delivery, delivery and after-sales inspections
Group 15 - Lubrication and service
Group 20 - Engine and tractor tune-up and adjustment
Group 25 - Removal and installation of assemblies
SECTION 20 - ENGINE
Group 5 - General information, diagnosing malfunctions
Group 10 - Cylinder head, camshaft and balancer shafts
Group 15 - Cylinder block, liners, pistons and connecting rods
Group 20 - Crankshaft, crankshaft bearings and flywheel
Group 25 - Timing gear train
Group 30 - Oil pump, oil pressure regulating valve and oil filter
Group 35 - Engine cooling system
Group 40 - Speed control
SECTION 30 - FUEL SYSTEM
Group 5 - Diagnosing malfunctions
Group 10 - Fuel tank, transfer pump, fuel filters
Group 15 - ROTO-DIESEL injection pump
Group 20 - ROOSA-MASTER injection nozzles
-
Group 25 Cold weather starting aids
SECTION 40 - ELECTRICAL SYSTEM
Group 5 - Diagnosing malfunctions
Group 10 - Components and wiring diagrams

SECTION 50 - POWER TRAIN

Group 5 - Engine clutch and clutch linkage
Group 10 - HIGH-LOW shift unit
Group 15 - Transmission
Group 20 - Differential assembly
Group 25 - Final drives
Group 30 - Continuous-running power shaft
Group 35 - Independent power shaft
SECTION 60 - FRONT AXLE, STEERING AND BRAKES
Group 5 - Front axle
Group 10 - Steering
Group 15 - Brakes
SECTION 70 - HYDRAULIC SYSTEM
Group 5 - General information, diagnosing malfunctions, pressure tests
Group 10 - Oil reservoir, filter, valves and oil cooler
Group 15 - Hydraulic pump and transmission oil pump
Group 20 - Rockshaft
Group 25 - Selective control valves (spool type)
Group 30 - Selective control valve (poppet valve type)
Group 35 - Remote hydraulic cylinder
SECTION 80 - MISCELLANEOUS
Group 5 - Belt pulley
Group 10 - DE LUXE seat
Group 15 - Front and rear wheels
-
Group 20 Hydraulic hitch
Group 25 - Roll guard

Printed in Germany
 Model 2120 Tractor
2 TM-4252 (Dec-70)

INTRODUCTION

Use FOS Manuals for Reference Use Technical Manuals for Actual Service

This technical manual is part of a twin concept of Some features of this technical manual:
service:

• FOS Manuals — for reference • Table of contents at front of whole Manual.

• Technical Manuals — for actual service • Contents at front of each Section
The two kinds of manuals work as a team to give
• Specifications at end of each Group
you both the general background and technical
details of shop service.
• Special tools at end of each Group
This technical manual was planned and written for
Fundamentals of Service (FOS) Manuals cover you — a journeyman mechanic. Keep it in a
basic theory of operation, fundamentals of trouble permanent binder in the shop where it is handy.
shooting, general maintenance, and basic types of Refer to it whenever in doubt about correct service
failures and their causes. FOS Manuals are for procedures or specifications.
training new men and for reference by experienced
men. Using the technical manual as a guide will reduce
error and costly delay. It will also assure you the
Technical Manuals are concise service guides for a best in finished service work.
specific machine. Technical Manuals are on-the-job
guides containing only the vital information
needed by a journeyman mechanic.

When a serviceman should refer to a FOS

Manual for more information, a FOS
symbol like the one at the left is used in
the TM to indentify the reference.

Printed in Germany
Model 2120 Tractor General Information 10
TM-4252 (Dec-70) Specifications 5-1

Section 10
GENERAL INFORMATION

CONTENTS OF SECTION
GROUP 5 - SPECIFICATIONS GROUP 15 -LUBRICATION AND
PERIODIC SERVICE
Page Page

Serial numbers 5-2 Lubrication and periodic service .... 15-1

Model numbers 5-2

.....
Engine 5-2
Engine clutch
Electrical system
Transmission
HIGH-LOW shift unit
Differential and final drives
Differential lock
Powershafts
5-2
5-2
5-3
5-3
5-3
5-3
5-3
General information .....
GROUP 20 - ENGINE AND TRACTOR

.....
TUNE-UP AND ADJUSTMENT

Preliminary engine testing

Engine checks and adjustment
Performance test
20-1
20-1
20-2
20-3
Hydraulic system 5-3 Tractor adjustment 20-3
Hydraulic steering 5-3 Standard torques 20-5
Manual steering 5-3 Special tools 20-5
Hydraulic brakes 5-3
Handbrake 5-3
Capacities 5-3 GROUP 25 - REMOVAL AND INSTALLATION
Travel speeds 5-3 OF ASSEMBLIES
Front and rear wheels 5-3
Dimensions and weights 5-3 Separating between engine and
tractor front end 25-1
Removal and installation of
GROUP 10 - PREDELIVERY, DELIVERY engine 25-3
AND AFTER-SALES INSPEC¬ Removal and installation of
TIONS clutch housing 25-5
Removal and installation of
Predelivery inspection 10-1 final drives 25-7
Delivery inspection 10-4 Removal and installation of
After-sales inspection 10-4 rockshaft 25-8
Torques for hardware 25-9
Special tools 25-10

Printed in Germany
10 General Information Model 2120 Tractor
5-2 Specifications TM-4252 (Dec-70)

Group 5
SPECIFICATIONS
SERIAL NUMBERS

.....
Fast idle 2650 rpm

..............
The engine serial number is stamped into the name Slow idle 650 rpm

............
plate at the lower right of the front cylinder block.
Working speed range 1500 to 2500 rpm

.........
NOTE: If ordering engine parts, indicate all digits
of the serial number on the name plate. Flywheel horsepower 1at 2500 rpm
Net 67 HP (68 PS)
The name plate showing the tractor serial number Gross2 71 HP (72 PS)
is located on the right-hand side of the front
support. PTO horsepowerÿ 60 HP (61 PS)
(at 2500 rpm engine speed and
NOTE: If ordering tractor parts, (excluding engine 650 or 1210 rpm powershaft speed)
parts), indicate all digits of the serial number on
the name plate.
ENGINE CLUTCH

MODEL NUMBERS Dual dry disk clutch, foot operated.

The injection pump, injection nozzles, the Single dry disk clutch with torsion damper
generator (alternator), starter and the main (isolator), foot-operated (on tractors with
hydraulic pump have model numbers to facilitate independent PTO)

..........
identification of different makes of a given unit.

..........
ELECTRICAL SYSTEM

............
SPECIFICATIONS
Batteries 2 x 12 Volts, 55 Ah

...... .............
ENGINE

............
Starter 12 Volts, 4 HP (4 PS)

.......
Number of cylinder 4
Alternator 12 Volts, 28 A

.......
Cylinder liner bore 4.02 in. (102 mm)
Generator 12 Volts, 11 A
Stroke 4.33 in. (110 mm)
Battery terminal grounded negative
Displacement 219 cu.in. (3590 cm2)

1500 rpm

Firing order
..........
Compression ratio

Maximum torque at
16.7 : 1

170 ft.lbs. (23.5 mkg)

1-3-4-2
1) 1PS = 1ch = 0.736 KW; 1KW = 1,36 PS = 1.36
ch; 1PS = 0.986 HP; 1HP = 1.01 PS

2) Less water pump, fan, generator (alternator), air

cleaner and muffler.

Valve clearance (engine hot or cold) 3) With the engine run in (above 100 hours of
Intake valve 0.014 in. (0.35 mm) operation) and having reached operating
Outlet valve 0.018 in. (0.45 mm) temperature (engine and transmission);
measured by means of a dynamometer.
Permissible variation + 5%.

Printed in Germany
Model 2120 Tractor General Information 10
TM-4252 (Dec-70) Specifications 5-3

TRANSMISSION HYDRAULIC SYSTEM

........
Collar shift transmission with helical cut gears. Closed center, constant pressure system; also
includes rockshaft, power steering and selective

............
This transmission is available in three variations: control valves.
8 speed transmission with parking lock, without System pressure 2220 to 2280 psi
independent hand brake; (156 to 160 kg/cm '
8 speed transmission without parking lock and
with independent hand brake; Pump 4 or 8-piston pump
8 speed transmission without parking lock, with driven by the engine
blocked 8th gear and independent hand brake.
With this transmission 8 or 7 forward and 4 reverse POWER STEERING
speeds are available.
The steering system is a "closed center" type
incorporated by the hydraulic system and supplied
HIGH-LOW SHIFT UNIT with oil by the main hydraulic pump. It is
connected to the front wheels by means of a
Hydraulically controlled reduction gear which can steering linkage.
be shifted under load, with "wet" multiple disk
MANUAL STEERING
clutch and "wet" multiple disk brake. Allows
reduction of the individual gear speeds by 26%. The manual steering is a recirculating ball bearing,
worm and nut type. A number of steel balls
between ball nut and steering wheel shaft provide
DIFFERENTIAL AND FINAL DRIVES for positive engagement of steering wheel and
steering linkage.
Planetary reduction gear and differential with
spiral bevel gears.
HYDRAULIC BRAKES
The disk brakes run in an oil bath and are
DIFFERENTIAL LOCK
hydraulically controlled.
Hand or foot operated; spring-loaded out of
engagement. HANDBRAKE
Band-type locking brake acting on differential.
POWER SHAFTS
CAPACITIES Imp, us Liters
Continuous Running Power Shafts Gals. Gals.

The power shafts are independent of the Fuel tank . 16.25 19.5 73.8
Cooling system 2.5 3.0 11.4
transmission if the tractor is equipped with a dual
stage engine clutch. Engine crankcase
incl. filter 1.25 1.5 5.7
Independent Power Shafts
Transmission-hydraulic
Independent of transmission, can be engaged and system
disengaged under load. Dry system 7.9 9.5 36.0
The independent power shaft is engaged by a At service intervals . . 6.5 7.4 28.0
hydraulically operated disc clutch. Disengaging the Oil-bath air cleaner ... ÿ
0.22 0.26 1.0
clutch is achieved by operating the hydraulically
actuated band type brake. Belt pulley . 0.25 0.30 1.1

Power Shaft Speeds (in rpm) TRAVEL SPEEDS

Engine Speed 540 rpm 1000 rpm See Operator's Manual
in rpm shaft shaft
FRONT AND REAR WHEELS
650 169 315 For tire sizes, treads, inflation pressure and weights
2067 538 1000 see Operator's Manual.
2075 540 1004
2500 650 1210 DIMENSIONS AND WEIGHTS
2650 689 1283
See Operator's Manual.

Printed in Germany
Model 2120 Tractor General Information 10
TM-4252 (Dec-70) Predelivery, Delivery and After-Sales Inspections 10-1

Group 10
PREDELIVERY, DELIVERY AND
AFTER-SALES INSPECTIONS
PREDELIVERY INSPECTION
Every new JOHN DEERE Tractor leaves the every new tractor before it leaves the factory. The
factory in such a condition that it can be delivered reverse side of this tag is filled in by the factory
to the customer after a minimum of service. after the tractor has undergone a thorough
inspection prior to shipping.
To promote complete customer satisfaction,
proper predelivery service including mending of After completing the factory-recommended dealer
possible shipping damage and giving the finishing checks and services listed on the predelivery tag,
touches to the tractor, are of prime importance to remove the tag from the tractor and file it with the
the dealer. shop order for the job. The tag will then serve as a
basis for certifying that the unit has received the
A tag pointing out the factory-recommended proper predelivery service.
procedure for predelivery service is attached to

TEMPORARY TRACTOR STORAGE

Service Specifications Reference

Check radiator for coolant loss and Coolant level should be Operator's manual
antifreeze protection (gravity of anti¬ midway between radiator
freeze and rust inhibitor mixture) core and bottom edge of
filler neck

CAUTION: On tractors equipped with a

generator and shipped with dry-charged bat¬
teries or without batteries which are to be
started by means of a slave battery, do
not remove insulating tape on terminal
of cable to starter under any circumstan¬
ces. Also, do not remove — contrary to
—
earlier statements wire between ter¬
minals D+ of regulator and D+ of gen¬
erator. If this advice is disregarded, damage
to generator and regulator may result.
CAUTION: On tractors equipped with
an alternator, do not remove or discon¬
nect the bridge piece which connects
D+, DF and D-terminals.
Remove batteries. Store at room temperature
Reduce shipping pressure of tires Operator's manual
Cover tractor and tires for protection
and cleanliness

Printed in Germany
10 General Information Model 2120 Tractor
10-2 Predelivery, Delivery and After-Sales Inspections TM-4252 (Dec-70)

BEFORE DELIVERING TRACTOR

Service Specifications Reference

COOLING SYSTEM
Check radiator for coolant loss Coolant level should be Operator's manual
midway between radiator
core and bottom edge of
filler neck.
Check gravity of antifreeze and rust Operator's manual
inhibitor mixture

ELECTRICAL SYSTEM
CAUTION: On tractors equipped with Section 40, group 10
a generator which are to be started by
means of a slave battery, do not remove
insulating tape on terminal of cable to
starter under any circumstances. Also,
do not remove - contrary to earlier sta¬
tements - wire between terminals D+ of
regulator and D+ of generator. If this ad¬
vice is disregarded, damage to genera¬
tor and regulator may result.
If the batteries are to be installed in the
tractor, remove insulating tape on ter¬
minal of battery cable. This is to be done
if the tractor was shipped with dry- char¬
ged batteries or without batteries, on
tractors supplied with a generator.
CAUTION: If a tractor equipped with Section 40, group 10
alternator is to be started by means of
a slave battery,do not remove bridging
wire connecting alternator terminals D+,
DF and D- under any circumstances.
Removing this wire will result in imme¬
diate destruction of diodes.
If the batteries are to be installed in the Section 40, group 10
tractor, proceed as follows: Remove brid¬
ging wire from terminals D+, DF and
D- and connect wires to alternator.

Printed in Germany
Model 2120 Tractor General Information 10
TM-4252 (Dec-70) Predelivery, Delivery and After-Sales Inspections 10-3

BEFORE DELIVERING TRACTOR - Continued

Service Specifications Reference

Fill batteries with electrolyte, F®S

"Fundamentals of
charge batteries and install in tractor. Service, Electrical
a Systems" manual
undei "Batteries"
First connect positive (+) and then Section 40, group 10
negative (-) wire of each battery. Only
then start tractor engine.

TIRES AND WHEELS

Check tire inflation pressure Operator's manual
Retighten wheel bolts and ball nuts Section 80, group 15 and
Operator's manual

LUBRICATION
Check crankcase oil level Top mark on dip stick Operator's manual
Check transmission-hydraulic system Operator's manual
oil level
Lubricate all lubrication points Operator's manual
on the tractor

ENGINE
Check oil bath air cleaner Fill with oil to "Full" Operator's manual
Check dry type air cleaner Operator's manual
Fill fuel tank and start engine Capacity: 16.25 Imp. Operator's manual
(19.5 US) Gals = 73.8 lit.
Check lighting system, indicator lights Operator's manual
and instruments for proper operation
Check if speed control linkage moves Section 20, group 40
easily
Check engine idle speeds Section 20, group 40
Check injection timing Section 30, group 15

TESTING OPERATION
Check clutch pedal adjustment Approx. 1in. (25 mm) Section 50, group 5
clutch pedal free travel
Check operation of HIGH-LOW shift Section 50, group 10
Shift transmission through all speeds Operator's manual
Check differential lock operation Operator's manual
Check power shaft operation Operator's manual
Check 3-point hitch operation Operator's manual
Check hydraulic system operation Section 70, group 5
Check brake system Section 60, group 15

Printed in Germany
10 General Information Model 2120 Tractor
10-4 Predelivery, Delivery and After-Sales Inspections TM-4252 (Dec-70)

BEFORE DELIVERING TRACTOR - Continued

Service Specifications Reference

Check steering operation Section 60, group 10

Check seat adjustment Operator's manual
Check operation of remote hydraulic Section 7 0, group 5
cylinder (if equipped)

GENERAL INFORMATION

Tighten accessible nuts and attaching Section 10, group 20

screws
Attach roll guard Tighten nuts and bolts to Section 80, group 25
94 ft.lbs. (13 mkg)
Clean tractor and touch up paint

DELIVERY
A thorough discussion of the operation and service .
1 Adjusting the seat
of the tractor at the time of its delivery helps to
assure complete customer satisfaction. 2. Operation of control levers and instruments

Proper delivery should be an important phase of 3. Starting and shutting off the engine
the dealer's program. 4. The importance of the tractor break-in period
It is a well-known fact that many complaints have 5. Use of counterweights and proper inflation
arisen simply because the owner was not shown pressure as well as filling of tires with water and
how to operate and service his new tractor magnesium chloride, if required.
properly. Therefore, enough time should be devot¬
ed, at the customer's convenience, to introducing 6. Operating the complete hydraulic system
him to his new tractor and explaining to him how
to operate and service it. 7. Operating the power shaft and belt pulley (if
equipped)
Using the tractor operator's manual as a guide, be 8. The importance of the safety rules
sure that the owner understands the following
points properly. 9. The importance of lubrication and periodic
service

AFTER-SALES INSPECTION
In the interest of the purchaser and the dealer an minor difficulties from developing into serious
after-sales inspection should be carried out by the problems later on. It also will promote stronger
dealer after the first 100 hours of using a new John dealer-customer relations and give the customer an
Deere tractor. opportunity to ask questions that may have arisen
during the first few days of use.
The purpose of this inspection is to make sure that
the customer is receiving satisfactory performance Thereby the dealer has the further opportunity of
from his tractor. At the same time, the inspection promoting the possible sale of other new
should reveal whether or not the tractor is being equipment.
operated, lubricated and serviced properly.
The following inspection program is recom¬
Through this inspection a needless volume of mended:
service work can be eliminated by preventing

Printed in Germany
Model 2120 Tractor General Information 10
TM-4252 (Dec-70) Predelivery, Delivery and After-Sales Inspections 10-5

AFTER-SALES INSPECTION
Service Specifications Reference

COOLING SYSTEM
Check coolant level Coolant level should be Operator's manual
midway between radiator
core and bottom edge of
filler neck
Clean exterior of radiator
Check hose connections

FUEL SYSTEM
Check sediment bowls and elements Operator's manual
of fuel filter for water or sediment
and clean transfer pump screen
Check line connections

ELECTRICAL SYSTEM
Check gravity of battery electrolyte Gravity should be 1.260
at an electrolyte tempera¬
ture of 80°F (27°C)

Check electrolyte level of batteries To bottom of filler neck Operator's manual

in each cell
Check tension of fan belt 3/4 in. (19 mm) deflection Operator's manual and
with a 20 lbs (9 kg) force section 20, group 35
Start engine and check operation of Operator's manual
lights, indicator lamps and instruments

LUBRICATION
Check crankcase oil level Top mark on dip stick Operator's manual
Check transmission oil level Operator's manual
Check oil level of manual steering Add oil up to filler hole Operator's manual
gear housing
Check oil level of belt pulley housing Add oil up to filler hole Operator's manual

Lubricate clutch throw-out Operator's manual

bearing
Lubricate 3-point hitch Operator's manual

Printed in Germany
10 General Information Model 2120 Tractor
10-6 Predelivery, Delivery and After-Sales Inspections TM-4252 (Dec-70)

AFTER-SALES INSPECTION

Service Specifications Reference

ENGINE

Check oil level in oil-bath air Fill with oil to level mark Operator's manual
cleaner
Check dry-type air cleaner Operator's manual
Check valve clearance Intake valve: 0.014 in. Section 20, group 10
(0.35 mm)
Exhaust valve: 0.018 in.
(0.45 mm)
Check engine speed under load as well Section 20, group 40
as fast and slow idle speed
Check engine performance Section 10, group 20

GENERAL INFORMATION
Check clutch pedal adjustment Approx. 1in. (25 mm) Section 50, group 5
free travel
Check operation of HIGH-LOW shift unit Section 50, group 10
Shift transmission through all speeds Operator's manual
Check operation of power shaft Operator's manual
Check differential lock Operator's manual
Check operation of hydraulic system Section 70, group 5
Check steering system Section 60, group 10
Check brakes Section 60, group 15
Tighten accessible nuts and cap screws Section 10, group 20
Tighten roll guard attaching screws and 94 ft.lbs. (13 mkg) Section 80, group 25
nuts
Tighten accessible hydraulic lines
Visual inspection of tractor Damaged paint, loose
connections, proper posi¬
tioning of hoses and lines,
leaks, operation of all me¬
chanical parts

Printed in Germany
Model 2120 Tractor General Information 10
TM-4252 (Dec-70) Lubrication and Periodic Service 15-1

Group 15
LUBRICATION AND PERIODIC
SERVICE

For brands of oil and lubricants to be used as well as for lubricating and servicing the model 2120
tractor, see operator's manual.

Printed in Germany
Model 2120 Tractor General Information 10
TM-4252 (Dec-70) Engine and Tractor Tune-up 20-1

Group 20
ENGINE AND TRACTOR TUNE-UP
GENERAL INFORMATION

Before tuning up the engine, determine whether a doubt, the following preliminary tests will help to
tune-up will restore operating efficiency. If there is determine if the engine can be tuned up.

PRELIMINARY ENGINE TESTING

Service Specifications Reference

Checking air intake system by 14 to 25 in. (355-635 mm) "Fundamentals of Service,

means of vacuum gauge water head; engine running res Engine" manual under
at fast idle speed a "Diagnosis and Testing"

Check radiator for air bubbles

or oil film

Measure blow-by at crankcase 436 Imp.gals./h.

vent tube * 524 US.gals./h.
1982 liters/h.

Check compression which 300 psi (21 kg/cm2) "Fundamentals of Service,

should be at least res
Engine" manual under
(using special tool No. 19.58-90.578) a "Diagnosis and Testing"

Measure engine horsepower at Record measured perfor¬

powershaft (using a dynamometer) mance and compare with
performance measured after
carrying out "Engine
Tune-up"

* Measure with a standard gas gauge, placing hose over end of crankcase vent tube. The engine must be
tested at 2500 rpm, normal running temperature and should be run in (at least 100 hours). Measure
over a period of 5 minutes and multiply measured value by 12 (for hourly rate). Compare with values
quoted above.

There is no undue wear on piston rings and cylinder liners if the measured value is lower than that
quoted above. Should a further test be desired, carry out a compression test. If the "blow-by " reading
is more than that quoted above, the decline in performance is due to excessive wear and the engine
should be overhauled.

Printed in Germany
10 General Information Model 2120 Tractor
20-2 Engine and Tractor Tune-up TM-4252 (Dec-70)

ENGINE TUNE-UP-Continued

Service Specifications Reference

AIR INTAKE SYSTEM

Oil-bath air cleaner - clean oil Operator's manual and
F®S
cup and fill with fresh engine "Fundamentals of Service,
oil to "Full" mark _ bJ Engine" manual.
Dry-type air cleaner - clean filter F®S
Operator's manual and
element and dust unloading valve "Fundamentals of Service,
B Engine" manual
Check crankcase vent tube for
foreign particles (restriction)
Tighten cylinder head cap screws 110 ft.lbs. (15 mkg) Section 20, group 10
Check and adjust valve clearance Intake valve 0.014 in. Section 20, group 10
(0.35 mm)
Outlet valve 0.018 in.
(0.45 mm)
BATTERIES
Thoroughly clean wires, connec¬
tions and batteries
Tighten cable clamp screws
Liberally coat battery terminals
and cable connectors with
petroleum jelly
Check electrolyte level of battery Operator's manual
Check specific gravity of Operator's manual
electrolyte
GENERATOR (ALTERNATOR)
Check fan belt tension 3/4 in. (19 mm) deflection Section 20, group 35
with 20 lbs (9 kg) force
FUEL SYSTEM
Check fuel tank and lines for leaks
or restriction
Clean screen of fuel transfer Operator's manual
pump
Check first stage filter element Section 30, group 10
and replace, if necessary
Check injection timing and Section 30, group 15
adjust, if necessary
Bleed fuel system Section 30, group 15
Check engine speeds and Section 20, group 40
adjust speed control linkage,
if necessary

Printed in Germany
Model 2120 Tractor General Information 10
TM-4252 (Dec-70) Engine and Tractor Tune-up 20-3

ENGINE TUNE-UP - Continued

Service Specifications Reference

ENGINE LUBRICATION SYSTEM

Check engine oil pressure 50 to 60 psi (3.5 to Section 20, group 30
4.2 kg/cm2) at 2500 rpm
COOLING SYSTEM
Clean and flush cooling system ro_ | "Fundamentals of Ser¬
vice, Engine" manual
Check radiator hoses for damage
and leaks
Clear radiator core of restrictions

CHECKING ENGINE PERFORMANCE

After the engine has been tuned up as Compare measured performance in HP with output
explained above, determine powershaft measured before carrying out "Engine tune-up".
d horsepower by means of a dynamometer.
see "Fundamentals of Service, Engine"
manual.

TRACTOR TUNE-UP

After carrying out engine tune-up, make the following adjustments on the tractor:

Service Specifications Reference

ENGINE CLUTCH

Adjust clutch pedal free travel Approx. 1in. (25 mm) Section 50, group 5

FRONT WHEELS

Clean and lubricate front wheel Section 80, group 15

bearings

Adjust front wheel bearings Section 80, group 15

Check toe-in 1/8 to 1/4 in. (3 to 6.5 mm) Section 60, group 5

Check torque of front wheel 87 ft.lbs (12 mkg)

bolts

HYDRAULIC BRAKES

Bleed brake system Section 60, group 15

Printed in Germany
10 General Information Model 2120 Tractor
20-4 Engine and Tractor Tune-up TM-4252 (Dec-70)

TRACTOR TUNE-UP - Continued

Service Specifications Reference

HYDRAULIC SYSTEM

Check stand-by pressure of 156 to 160 kg/cm2 Section 70, group 5

hydraulic pump (2220 to 2280 psi)

Check rockshaft lift cycle time 1.8 sec. to 2.3 sec. Section 70, group 5
at 2500 rpm engine speed

Check time required for extending 2 sec. Section 70, group 5

or retracting remote cylinder at
2100 rpm engine speed

Check operating pressure of

HIGH-LOW shift unit:
on tractors without 95-105 psi Section 50, group 10
independent power shaft (6.7 to 7.3 kg/cm2)
on tractors with in¬ 140-160 psi Section 50, group 10
dependent power shaft (9.8 to 11.2 kg/cm2)

Check operating pressure of 140 to 160 psi Section 50, group 35

power shaft clutch and brake (9.8 to 11.2 kg/cm2)

TIRES

Check tire inflation pressure Operator's manual

TORQUES
Check all accessible cap screws Torque chart
and nuts of tractor for proper
torque

Printed in Germany
Model 2120 Tractor General Information 10
TM-4252 (Dec-70) Engine and Tractor Tune-up 20-5

STANDARD TORQUES

Recommended torques in ft. lbs. and mkg for UNC and UNF
cap screws

Head marking
(v_\) /~7\ ATX
/
(identifying
strength) J <- >
-'
\_v
;;->
fxÿv
or or or
6.8 (6. S)* 10.9 (10 K)** 12.9 (12 K)***

Thread-O.D. (in.) ft .lbs. mkg ft .lbs. mkg ft Jbs. mkg

1/4 7 1 10 1,5 14 2
5/16 14 2 20 3 30 4
3/8 21 3 35 5 50 7
7/16 35 5 55 8 80 11
1/2 55 8 85 12 130 18
9/16 75 10 130 18 185 26
5/8 105 15 170 23,5 250 34,5
3/4 185 25,5 300 41,5 420 58
7/8 160**** 22**** 445 61,5 670 92,5
1 250 34,5 670 92,5 1000 138.5

NOTE: A variation off 10% is permissible for all torques indicated in

this chart.

Torque figures indicated above and in the Specifications sections of this manual
are valid for non-greased or non-oiled threads and heads unless otherwise
specified. Therefore, do not grease or oil bolts or cap screws unless otherwise
specified in this manual.

* Regular bolts and cap screws

Tempered steel high strength bolts and cap screws
Tempered steel extra high strength bolts and cap screws
Bolts and screws 7/8 in. and larger are often formed hot rather than
cold, which accounts for the lower torque.

JD Parts Depot

19.58-90-578
19.58-90-260*
...........
Part No. if ordered through
Manufacturer

* Details see section 70, group 5

SPECIAL TOOLS

Description

Special adapter
Special tool . .
Use

Checking compression pressure

Checking oil pressure

Printed in Germany
Model 2120 Tractor Genera]Information 10
TM-4252 (Dec-70) Separating Assemblies 25-1

Group 25
SEPARATING ASSEMBLIES
SEPARATING BETWEEN ENGINE AND TRACTOR FRONT END

REMOVAL Remove support rod at top of radiator. Disconnect

fuel return line 4 at fuel tank.
For safety disconnect ground strap (cable) from
battery. Disconnect headlight wires at distributors 7.

Remove front end weights (if equipped). Drain coolant and disconnect upper and lower
water hoses at radiator.
Remove radiator and fuel tank caps. Remove
radiator side grilles and hood. Install radiator and Only on tractors without oil cooler: Disconnect
fuel tank caps. hydraulic oil line (see 8, fig. 1) at top and bottom
hose and remove.

Only on tractors equipped with oil cooler: Remove

hose elbow between hydraulic oil reservoir and oil
cooler at oil cooler end. Disconnect return oil line
at bottom of oil cooler.

NOTE: Plug lines and openings immediately with

plugs or caps to prevent loss of oil and entering of
dirt into the system.

Remove screws securing fan shroud to radiator and

slide over fan to the rear.

Remove screws securing radiator to front axle

support and lift out radiator to the left of tractor.

Close fuel shut-off valve at bottom of fuel tank.

Fig. 1— Separating between Tractor Front End and
Engine Disconnect fuel inlet line at fuel tank and fuel
transfer pump. Remove transfer pump and fuel
1 Air intake hose
2 Upper water hose inlet line.
3 Leak-off and vent line
4 Fuel return line
5 Leak-off and vent line
6 Cable of fuel gauge sending unit
7 Distributor
8 Hydraulic line (on tractors without oil cooler)

Disconnect air intake hose (see 1, fig. 1) at engine

intake manifold and air cleaner.

Disconnect leak-off and vent lines 3 and 5 at

hydraulic oil reservoir.

Printed in Germany
10 General Information Model 2120 Tractor
25-2 Separating Assemblies TM-4252 (Dec-70)

Ifl

I, 51531

Fig. 2 — Disconnecting Hydraulic Lines Fig. 3 — Attaching Points of Tractor Front End
1 Retainer 1 Attaching screws of front axle support
2 Cap screw 2 Hydraulic pump drive shaft
3 Return line to transmission case
4 Pipe clamps
5 Hydraulic pump inlet line Remove cap screws (see 1, fig. 3) of front support
6 Hydraulic pump pressure line and separate front end from engine. Take measures
to prevent front of tractor from tipping forwards.
Remove side frames. (Drain fuel tank if it contains too much fuel or
support front end of tractor).
Remove pipe clamps (see 4, fig. 2).

Unscrew cap screw 2 and remove retainer 1which INSTALLATION

supports the hydraulic pump inlet line 5 and return
line 3 of oil cooler (oil reservoir if not equipped Make sure woodruff key is installed in shaft of
with oil cooler). hydraulic pump.

On tractors not equipped with HIGH-LOW Move front of tractor towards engine.
transmission: Take care that the check valve
installed in hydraulic pump inlet line 5 is not lost Engage pump shaft in hydraulic pump drive shaft
when the inlet line is removed. and at the same time connect return line of oil
cooler (reservoir if not equipped with oil cooler).
Disconnect pressure line 6 at connector situated at Slide hydraulic pump inlet line into clutch housing
front of engine. and tighten both lines (see fig. 2). Tighten cap
screw (see 2, fig. 2) securing retainer 1 to the
Disconnect drag link at bell crank. specified torque.

Remove securing screw of hydraulic pump drive CAUTION: On tractors not equipped with
shaft. HIGH-LOW transmission: Ensure check valve is
inserted in hydraulic pump inlet line before it is
Securely support rear of tractor under clutch installed.
housing by placing assembly stand 19.58-90.619
under transmission case. Attach front end of tractor to engine, using cap
screws (see 1, fig. 3). Tighten cap screws to
Insert wooden blocks between front axle and front specified torque. Tighten hydraulic pump drive
support to prevent the latter from slipping shaft cap screw to specified torque.
sideways.
NOTE: Do not tighten securing screw of hydraulic
Suspend front of tractor to a suitable hoist or pump drive shaft until tractor front end is secured
to engine.
support with assembly stand 19.58-90.618.
Install fuel transfer pump and connect fuel lines.

Printed in Germany
Model 2120 Tractor General Information 10
TM-4252 (Dec-70) Separating Assemblies 25-3

Make sure transfer pump inlet line is behind and Connect air vent lines to hydraulic reservoir.
below fuel pressure line.
Connect hydraulic pump pressure line and install
Open fuel shut-off valve. line clamps (see fig. 1).

Connect cable to fuel gauge sending unit. Connect air intake pipe at manifold and air filter.

Connect headlight cables to junctions. Attach drag link to bell crank and tighten
castellated nut to specified torque.
Lift and slide radiator into location from the left
side of tractor. Slide fan shroud forward over Install hood and radiator side grilles.
radiator, insert and tighten set screws. Secure
radiator to front axle support. Install upper and Fill radiator with clear, soft water, adding an
lower water hoses. anti-freeze-rust inhibitor mixture (see operators
manual).
Only on tractors not equipped with oil cooler:
Connect oil line to oil reservoir and tighten both Connect ground strap to battery.
hose clamps (see fig. 1).
CAUTION: Always connect ground strap to
Only on tractors equipped with oil cooler: Connect negative(-)pole of battery.
hose elbow between hydraulic oil reservoir and oil
cooler at top of oil cooler and return line at Start engine and check fuel lines, hydraulic lines
bottom of oil cooler. and water hoses for leaks.

REMOVING AND INSTALLING ENGINE

NOTE: For most engine service operations the

engine need not be removed. However, if the
crankshaft has to be removed or in case of major
overhaul, remove engine.

REMOVAL
For safety disconnect ground strap (cable) from
battery.

Separate front of tractor from engine, as explained

previously.

On tractors equipped with power steering:

Disconnect power steering pressure line at steering
housing and hydraulic pump pressure line.

On tractors equipped with an alternator:

Disconnect cable between alternator and regulator Fig. 4 — Separating between Engine and Clutch
by removing plug at alternator. Immediately Housing, R.H. Side
connect terminals D+, D and DF with bridge piece 1 Engine attaching screws
supplied with the tractor. Disconnect terminal B+ 2 Flexible shaft of tractormeter
at alternator. 3 Oil pressure switch
4 Starter cable

On tractors equipped with a generator: Disconnect

cable to starter and generator indicator lamp at Disconnect all cables at starter (see fig. 4).
regulator. Disconnect oil pressure switch cable 3 and cable at
signal horn.

Disconnect flexible shaft of tractormeter 2 at clutch

housing and camshaft. If necessary, renew gasket.

Printed in Germany
10 General Information Model 2120 Tractor
25-4 Separating Assemblies TM-4252 (Dec-70)

On tractors equipped with starting fluid adapter: Lift engine out to the front by means of the hoist.
Disconnect starting fluid line at intake manifold.
CAUTION: Move engine properly in line with drive
On tractors equipped with Thermostart aid: Discon¬ shaft and hollow drive shaft until these shafts come
nect cable at heater of intake manifold. loose of the driven disks of the engine dual-stage
clutch, or free of driven disk and torsion damper if
Disconnect air vent line of hydraulic oil reservoir at tractor is equipped with a single-stage clutch.
cylinder head cover.

INSTALLATION

Align engine properly with drive shaft and hollow

drive shaft. Move engine towards rear of tractor.
Align splines of both shafts with internal splines of
driven disks (tractor with dual-stage clutch), or (if
equipped with a single-stage clutch) with splines of
driven disk and torsion damper. Align screw holes
of flywheel housing with holes in clutch housing.
Slide engine evenly towards clutch housing. Engage
two dowels of flywheel housing in bores of clutch
housing until engine is in full contact with clutch
housing.

CAUTION: Make sure flywheel housing is flush

against clutch housing before tightening cap screws
to specified torque.

Secure oil pan to clutch housing, tightening both

cap screws to the specified torque.

Fig. 5 — Separating between Engine and Clutch Attach dashboard to flywheel housing.
Housing, L.H. Side
Connect speed control rod and shut-off cable to
1 Engine attaching screws fuel injection pump.
2 Speed control rod
3 Shut-off cable
Insert flexible tube of coolant temperature gauge
Disconnect speed control rod 2 (fig. 5) and shut- in cylinder head and tighten retaining screw.
off cables 3 at fuel injection pump.
On tractors equipped with an alternator:
On tractors with muffler facing downwards: Disconnect bridge piece from terminals D+, D- and
Remove muffler. DF and connect harness plug to terminals. Connect
cable from starter to terminal B+ on alternator.
Screw retaining screw of flexible tube of coolant
temperature gauge out of cylinder head and On tractors equipped with a generator: Connect
withdraw from cylinder head. cables from starter and generator indicator lamp to
regulator.
Remove left dash panel as well as both batteries.
Connect cables to starter.
Remove cap screws attaching dashboard to
flywheel housing. Connect cables to signal horn and oil pressure
warning switch.
Attach JD 244-1 and 244-2 engine lifting eyes to
cylinder head and attach engine to a suitable hoist. Install both batteries.

Remove cap screws 1 (figs. 4 and 5) attaching

flywheel housing to clutch housing and both cap
screws securing oil pan to clutch housing.

Printed in Germany
Model 2120 Tractor General Information 10
TM-4252 (Dec-70) Separating Assemblies 25-5

CAUTION: Connect battery cable to positive poles On tractors equipped with muffler facing
of batteries. downward: Install muffler.

Lubricate rubber seal of tractormeter flexible shaft Secure oil reservoir bleed line to cylinder head
and attach shaft to clutch housing (see 2, fig. 4). cover.
Make sure driving tab of flexible shaft engages in
slot of camshaft. Do not tighten excessively to Attach front of tractor to engine.
avoid damage to the seal resulting in leakage.
CAUTION: Connect ground strap of batteries to
On tractors equipped with starting fluid adapter: negative (-) poles.
Connect starting fluid line to intake manifold.
NOTE: If engine has been overhauled, tune up
On tractors equipped with Thermostart aid: engines as explained in group 20.
Connect Thermostart aid wire to heater in intake
manifold.

REMOVAL AND INSTALLATION OF CLUTCH HOUSING

NOTE: Separating and attaching of engine and On tractors equipped with power steering:
clutch housing as well as of clutch housing and Disconnect power steering pressure line at
transmission case is explained below. Where the connectors.
tractor is to be separated depends on the individual
repair operation. If, e.g., repair work has to be Remove clamp (see 6, fig. 6) and hydraulic pump
carried out on the transmission, separation between pressure line 3.
the clutch housing and the transmission case will
be sufficient. Insert wooden blocks between front axle and front
support to prevent front support from tipping
sideways.
REMOVAL
Suspend tractor front end and engine to a suitable
Disconnect battery ground strap. hoist or support under the engine by means of
assembly stand 19.58-90.618. Similarly the rear of
Drain transmission oil. tractor should be suspended to a suitable hoist or
be supported under the transmission case by means
Separate engine from clutch housing as explained of assembly stand 19.58-90.619.
under "REMOVING ENGINE", the tractor front
end may remain attached to the engine. Roll engine and tractor front end away from clutch
housing.
Disconnect drag link at steering arm.
CAUTION: Move engine properly in line with drive
Disconnect hydraulic oil reservoir vent line (see 5, shaft until these shafts come loose of the driven
fig. 6) at connector on gear shift cover. disks of the engine dual-stage clutch, or on tractors
with single-stage clutch, free of driven disk and
Remove pipe clamps (see 4, fig. 2), screws 2 and torsion damper.
retainer 1 which secure suction line 5 of hydraulic
pump and return line 3 of oil cooler (oil reservoir
if not equipped with oil cooler) to front side of
clutch housing.

On tractors not equipped with HIGH-LOW

transmission and independent PTO: Take care not
to lose check valve installed in hydraulic pump
pressure line when latter is removed.

Printed in Germany
10 General Information Model 2120 Tractor
25-6 Separating Assemblies TM-4252 (Dec-70)

'A
L 45333

Fig. 6 — Separating between Clutch Housing and Fig. 7 — Removing Gear Shift Cover
Transmission Case, R.H. Side 3 Attaching screws
1 Shift cover
1 Wiring harness 4 Brake lines 2 Clutch housing 4 Cover
attaching points
2 Attaching screws 5 Hydraulic oil
3 Hydraulic pump reservoir vent line
pressure line 6 Line clamp
Remove cap screws 2 (figs. 6 and 7) securing clutch
housing to transmission case, and separate clutch
Disconnect brake line (see 4, fig. 6) at master
cylinder. housing from transmission case.

Remove transmission cover.

Discard seal rings provided between the two
housings.
Disconnect both harnesses to rear fenders at
On tractors with continuous-running PTO: Be sure
connectors. Disconnect cable at starter safety
ball and spring provided on some PTO shaft types
switch and cables at stop light switch.
do not get lost (see section 50, group 30).
On tractors equipped with HIGH-LOW transmis¬
sion: Remove screws (see 3, fig. 7). Disconnect
connecting rod from lever shaft and remove cover
INSTALLATION
4 complete with lever shaft and control arm. Install new seal rings in clutch housing front facing
transmission case.
On tractors equipped with independent PTO:
Before removing cover (see 4, fig. 7), move PTO Slide clutch housing against transmission case.
shift lever in engaged position. After cover 4 has
been removed, do not move PTO shift lever Slide PTO drive shaft into needle bearing sleeve of
otherwise lock balls and springs will drop out of front PTO shaft or, if front PTO is not provided,
cover. into needle bearing sleeve of bearing cover.

Remove screws attaching transmission shift cover On tractors with continuous-running PTO: Make
to clutch housing. Remove gear shift cover sure, spring and ball provided on some powershaft
complete with shift levers. types are installed in PTO drive shaft, bearing
housing or front powershaft. Align clutch housing
Remove transmission oil filter. with centerline of PTO drive shaft and slide against
transmission case. Mesh powershaft gears with
splines of hollow PTO drive shaft.

Printed in Germany
Model 2120 Tractor General Information 10
TM-4252 (Dec-70) Separating Assemblies 25-7

Make sure clutch housing is flush against transmis¬ On tractors not equipped with HIGH-LOW Shift
sion case before tightening cap screws to the unit: Ensure check valve is installed in feed line to
specified torque. hydraulic pump before connecting.

NOTE: Before inserting the third retaining screw in

clutch housing (see arrow, fig. 6) coat it with a film Connect hydraulic pump pressure line.
of oil-resistant sealant.
NOTE: If clutch housing has also been separated On tractors equipped with power steering: Con¬
from engine, assemble as explained under "Instal¬ nect power steering pressure line.
lation of Engine. "
As regards further installation operations reverse
Insert hydraulic pump inlet line (see 5, fig. 2) and removal procedure.
oil cooler return line 3* in bore of clutch housing
and secure by means of screw and retainer. Tighten CAUTION: Connect ground cable of batteries to
screw to correct torque. negative(-)poles.
* Oil reservoir when not equipped with oil cooler.
REMOVAL AND INSTALLATION OF FINAL DRIVES

REMOVAL

NOTE: The removal of both final drives is

explained below. If only one final drive is to be
removed, remove only one wheel, wiring harness
etc.

For safety disconnect ground strap at batteries.

Lift up rear of tractor by means of a suitable jack

or hoist and remove rear wheels.

CAUTION: Support transmission safely to prevent

tipping of tractor.

Disconnect both rear wiring harnesses at

connectors.

Remove rear fenders and roll-over guard. Fig. 8 — Removing Final Drive
1 Final drive housing
Disconnect cables at stop light switch located in 2 Pressure ring
3 Brake disk
left-hand rear axle housing. 4 Final drive shaft
5 Brake housing
Disconnect brake lines on both brake housings. Remove selective control valve(s).
On tractors equipped with selective control
valve(s): Disconnect hydraulic lines and remove
two screws securing the bracket* or hydraulic
manifold** onto the right-hand final drive
assembly.

Cover connections and exposed openings with

plastic plugs or caps to prevent particles of dirt
from entering the system.

* On earlier tractors
** On later tractors

Printed in Germany
 10 General Information Model 2120 Tractor
25-8 Separating Assemblies TM-4252 (Dec-70)

Attach final drive to hoist. Remove final drive On tractors with selective control valve(s): Attach
attaching screws. Separate final drive housing control valves with bracket* or manifold** onto
together with brake housing from transmission the right hand final drive housing. Connect
case, Withdraw housing evenly until final drive hydraulic lines.
shaft gear is no longer in mesh with planetary gears
of final drive. Connect brake lines and bleed brakes, as explained
in section 60, group 15.
CAUTION: Take care that the brake housing does
not fall down (DANGER OF ACCIDENTS).
Install rear fenders and roll-over guard. Tighten
hex. nuts to specified torque.
INSTALLATION
NOTE: If the brake disk and the "floating" facing Connect lines of wiring harnesses to connectors.
were removed, install bonded two-layer facing so
that the brass-interwoven upper layer faces the Connect cable to brake warning switch.
brake surface of the transmission case.
Install rear wheels and tighten to the specified
Position new gaskets between final drive housing torque.
and brake housing as well as between transmission
case and brake housing.
CAUTION: Tighten ground strap to negative (-)
Attach final drive to transmission case by means of poles of batteries.
a suitable hoist. Make sure final drive shaft gear
engages with planetary gears and that the dowels
are guided into their respective bores.
Tighten final drive attaching screws to the specified
torque.

REMOVAL AND INSTALLATION OF ROCKSHAFT

REMOVAL

IMPORTANT: Work on the hydraulic system

requires extreme care and cleanliness. Minute dirt
or foreign particles, scratches, nicks or burrs may
put the hydraulic system out of function. Before
removing the rockshaft, check hydraulic system for
leaks.
For safety, disconnect ground cable from batteries.

Remove transmission shield. Disconnect line 1(fig.

9) of starter safety switch.

Remove operator's seat. Disconnect both lift links

at lift arms.

Disconnect oil return line (see 2, fig. 9) of selective

control valve (if equipped) at elbow on rockshaft.

Disconnect lines of rear quick couplers (if

equipped) at selective control valves.

Free both rear wiring harnesses. L5153

Fig. 9 — Rockshaft, Installed

1 Line of safety starter switch
2 Oil return line

* On earlier tractors
** On later tractors

Printed in Germany
Model 2120 Tractor General Information 10
TM-4252 (Dec-70) Separating Assemblies 25-9

Move selector lever in position "L" (load control) Move selector lever in position "L" so that the
so that the control linkage roller slides along the control linkage with roller can be slid over the cam.
cam of the control arm when removing the
rockshaft. Lift rockshaft on transmission case, using a suitable
hoist.
Attach engine lifting eye No. JD 244-2 to top of
rockshaft housing. If equipped: connect oil return line 2 (fig. 9) of
selective control valve to rockshaft housing.
Remove rockshaft attaching screws (see arrows in
fig. 9). Lift rockshaft assembly off transmission Connect lines to quick couplers.
case by means of a hoist.
Tighten rockshaft attaching screws to the specified
Take care not to damage two rear harnesses. torque.

NOTE: After removing rockshaft, cover Connect cable of starter safety switch.
transmission case to prevent foreign particles from
falling into the transmission. Connect both rear wire harnesses to rockshaft.
Install transmission shield on transmission case.

INSTALLATION Attach lift links to lift arms. Install operator's seat.

Use a new gasket between transmission case and For adjustment of rockshaft see section 70, group
rockshaft. Make sure dowels in transmission case 20.
and seal ring of oil inlet passage are installed.
CAUTION: Tighten ground strap to negative (-)
poles of batteries.

Front support to engine, cap screws

Hydraulic pump drive shaft, cap screw

................
TORQUES FOR HARDWARE

............... 170 ft.lbs.

32 ft.lbs.
23,5 mkg

4.4 mkg

Drag link to bell crank or steering arm,

castellated nut*

...............
...............
55 ft.lbs. 7.7 mkg

.............
Clutch housing to engine, cap screws 170 ft.lbs. 23.5 mkg

Oil pan to clutch housing, cap screws 170 ft.lbs. 23.5 mkg

Clutch housing to transmission, cap screws 85 ft.lbs. 11.7 mkg

Securing bracket, hydraulic lines to

clutch housing, cap screw 32 ft.lbs. 4.5 mkg

Final drive housings to transmission case,

cap screws 85 ft.lbs. 11.7 mkg

Roll-over guard to final drive housings, .

securing bracket, cap screws 94 ft.lbs. 13 mkg

* NOTE: If cotter pin cannot be inserted when tightening to the specified torque, turn nut to next slot
and secure with cotter pin.

Printed in Germany
10 General Information Model 2120 Tractor
25-10 Separating Assemblies TM-4252 (Dec-70)

.........
TORQUES FOR HARDWARE (Continued)

..................
Eockshaft housing to transmission case, cap screws 85 ft.lbs. 11,7 mkg

Rear wheels to rear axle, ball nuts (on rear wheels with steel disks) . 195 ft.lbs. 27 mkg

Rear wheels to rear axle, wheel securing bolts

(on rear wheels with cast disks) 130 ft.lbs. 18 mkg

Wheel disk to hub (on tractors equipped

with rack-and-pinion axle), wheel
securing bolts 300 ft.lbs. 41.5 mkg

............
SPECIAL TOOLS

........
Part No. when ordering from

........ ............
JD Parts Depot

........
Manufacturer Description Use

..........................
........
L 48524 JD 244-1* Lifting eye, straight Removing and installing

..
assemblies

L 48525 JD 244-2* Lifting eye, bent Ditto

19.58-90.618 Assembly stand Separating tractor front

end and engine.
19.58-90.619 Assembly stand Ditto

* SERVICE TOOLS INC., 1901 INDIANA AVENUE, ILLINOIS 60616, USA

Printed in Germany
 Removal
Repair
Installation

Installation
Specifications
.
Model 2120 Tractor
TM-4252 (Dec-70)

General information
Diagnosing malfunctions

Adjusting valve clearance

Camshaft
Removal
Repair
Installation
Balancer shafts
Removal
Repair

Torques for hardware

Special tools

......
CONTENTS OF THIS SECTION
GROUP 5 - GENERAL INFORMATION, DIAG¬
NOSING MALFUNCTIONS

GROUP 10 - CYLINDER HEAD, CAMSHAFT

Cylinder head
AND BALANCER SHAFTS
General information

GROUP 15 - CYLINDER BLOCK, LINERS,

General information
Removal
Repair
Assembly
Installation
Specifications
Torques for hardware
Engine break-in
Tune-up data
Special tools

GROUP 20 - CRANKSHAFT, MAIN BEARINGS

Removal
Repair
Installation
AND FLYWHEEL
General information

Printed in Germany
Page

5-2
5-2

10-1
10-1
10-1
10-1
10-3
10-3
10-4
10-4
10-4
10-5
10-6
10-6
10-6
10-8
10-9
10-11
10-12

PISTONS AND CONNECTING RODS

15-1
15-1
15-1
15-4
15-4
15-7
15-8
15-9
15-9
15-9

20-1
20-1
20-1
20-4
Specifications
Torques for hardware
Special tools

GROUP 25 - TIMING GEAR TRAIN

General information
Removal
Repair
Installation
Specifications.
Torques for hardware
Special tools

GROUP 30 - OIL PUMP, OIL PRESSURE

Removal
Repair
Installation

Torques for hardware

Tune-up data
Special tools

GROUP 35 - COOLING SYSTEM

General information
Diagnosing malfunctions
Repair
Radiator
Adjusting fan belt
Water pump
Checking thermostat
Specifications
Torques for hardware
Special tools

GROUP 40 - SPEED CONTROL LINKAGE

General information
Removal and disassembly
Repair
Assembly and installation
Adjustment
Specifications
Engine
General Information, Diagnosing Malfunctions

Section 20
ENGINE

REGULATING VALVE AND OIL

FILTER
General information

Adjusting engine oil pressure

Specifications
30-1
30-2
30-2
30-4
30-4
30-5
30-6
30-6
30-6
20
5-1

20-6
20-7
20-7

25-1
25-1
25-2
25-3
25-5
25-6
25-6

35-1
35-2
35-2
35-2
35-2
35-2
35-4
35-5
35-5
35-5

40-1
40-1
40-3
40-3
40-4
40-5
20 Engine Model 2120 Tractor
5-2 General Information, Diagnosing Malfunctions TM-4252 (Dec-70)

Group 5
GENERAL INFORMATION,
DIAGNOSING MALFUNCTIONS
GENERAL INFORMATION
The tractor is equipped with a 4-cylinder vertical A camshaft supported in the cylinder block con¬
in-line, valve-in-head, 4-cycle Diesel engine with trols the valves and drives the fuel transfer pump.
direct fuel injection. The engine is our own design.
The "wet" cylinder liners can be replaced one at a The intake and outlet valves are supported in the
time. The pistons are of forged aluminium alloy cylinder head. The valve stems slide in bores in the
and cam-ground. Each piston has two single, cylinder head. The rocker arm shaft assembly is
cast-iron compression rings and one oil control fitted on top of the cylinder head.
ring. All ring grooves are above the piston pin. The
case-hardened piston pins are full floating and are The engine is supplied with lubricating oil by a gear
held in place by two snap rings each. pump. The lubricating oil passes through a
full-flow oil filter in the main oil circuit. To ensure
The crankshaft is a one-piece, heat-treated, steel engine lubrication, the oil filter is provided with a
forging. It is supported in five replaceable by-pass valve which opens when the filter element
two-piece main bearings machined to close toleran¬ is clogged.
ces.
The engine has a pressure cooling system consisting
The connecting rods are provided with a bronze of the radiator, water pump, multi-blade fan and
bushing and a two-piece, replaceable bearing cap thermostat.
each.

DIAGNOSING MALFUNCTIONS

ENGINE WILL NOT CRANK Water, dirt or air in fuel system

Dead batteries Fuel filter clogged

Bad battery connections Stuck shut-off knob

Defective main switch or starter safety switch Dirty or faulty fuel injectors

Starter solenoid defective Defective injection pump

Starter defective Defective fuel transfer pump

Shut-off valve at fuel tank closed

ENGINE HARD TO START OR WILL NOT
START Injection pump out of time

Loose or corroded battery connections

Low battery output ENGINE RUNS IRREGULARLY OR STALLS
FREQUENTLY
Excessive resistance in starter circuit
Coolant temperature too low
Too high viscosity crankcase oil
Insufficient fuel supply

Printed in Germany
Model 2120 Tractor 20
Engine
TM-4252 (Dec-70) General Information, Diagnosing Malfunctions 5-3

Injector tips defective or leaking LACK OF ENGINE POWER

Fuel filter or fuel lines clogged Air cleaner clogged or dirty

Defective fuel transfer pump Excessive resistance in air intake system

Incorrect engine timing Fuel filter clogged

Improper valve clearance Defective fuel transfer pump

Cylinder head gasket leaking Defective fuel injection pump

Worn or broken compression rings Defective fuel injectors

Valves stuck or burnt Improper crankcase oil

Excessive back pressure Engine overheated

Engine compression too low Engine clutch drags

Engine overheated Defective cylinder head gasket

Defective fuel injection pump Cams of camshaft worn

Improper valve clearance

ENGINE MISSES
Improper valve timing*
Water in fuel
Burnt, damaged or stuck valves*
Mixture of petrol (gasoline) and Diesel fuel
Worn valve springs*
Air in fuel system
Incorrect engine timing
Defective fuel injectors
Piston rings and cylinder liners excessively worn
Defective fuel injection pump
Engine compression too low*
Fuel injectors improperly installed
Improper coolant temperature
Leaking fuel injector seals

Engine overheated ENGINE OVERHEATS

Cams of camshaft worn Lack of coolant in cooling system
Worn valve springs Radiator core and/or side grille screens dirty
Worn or defective fuel transfer pump Loose or defective fan belt

Engine backfiring Defective thermostat

Incorrect engine timing Cooling system limed up

Engine compression too low Engine overloaded

Improper valve clearance Injection pump delivers too much fuel

Burnt, damaged or stuck valves Damaged cylinder head gasket

* Measure blow-by at crankcase vent tube or carry

out cylinder compression test. See section 10,
group 20.
Printed in Germany
20 Engine Model 2120 Tractor
5-4 General Information, Diagnosing Malfunctions TM-4252 (Dec-70)

Incorrect engine timing HIGH OIL PRESSURE

Defective water pump Stuck or improperly adjusted regulating valve

Too low crankcase oil level Stuck or damaged filter by-pass valve

Defective radiator cap

EXCESSIVE FUEL CONSUMPTION

HIGH OIL CONSUMPTION Engine overloaded

Oil control rings worn or broken Compression too low

Scored cylinder liners or pistons Leaks in fuel system

Excessive resistance in air intake system Air cleaner restricted or dirty

Oil passages restrict free oil flow Fuel injectors dirty or faulty

Worn valve guides or stems Injection pump defective (delivers too much fuel)

Too low viscosity crankcase oil Incorrect engine timing

Excessive oil pressure

BLACK OR GREY EXHAUST SMOKE
Piston ring grooves excessively worn
Excess fuel
Piston rings sticking in ring grooves
Engine overloaded
Insufficient piston ring tension
Air cleaner restricted or dirty
Piston ring gaps not staggered
Defective muffler (causing back-pressure)
Excessive main or connecting rod bearing clearance
Fuel injectors dirty or faulty
Crankcase oil level too high
Incorrect engine timing
External oil leaks

Front and rear crankshaft oil seal faulty WHITE EXHAUST SMOKE

Engine compression too low

LOW OIL PRESSURE
Defective fuel injectors
Low crankcase oil level
Incorrect engine timing
Leakage at internal oil passages
Thermostat defective
Defective oil pump

Excessive main and connecting rod bearing COOLANT IN CRANKCASE

clearance
Cylinder head gasket defective
Improper regulating valve adjustment
Cylinder head or block cracked
Improper crankcase oil

Defective oil pressure warning switch or indicator

lamp

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) General Information, Diagnosing Malfunctions 5-5

Cylinder liner seals leaking Bent push rods

Worn camshaft
ABNORMAL ENGINE NOISE
Worn rocker arm shaft
Incorrect engine timing
Insufficient engine lubrication
Worn main or connecting rod bearings

Excessive crankshaft end play DETONATION OR PRE-IGNITION

Loose main bearing caps Oil picked up by intake air stream (intake
manifold)
Foreign material in combustion chamber
Dirty or faulty fuel injectors
Worn piston pin bushings and pins
Improper engine timing
Scored pistons
Injector tip holes enlarged
Worn timing gears
Injector tips broken
Excessive valve clearance
Carbon build-up in compression chamber
Worn cam followers

NOTE: Overall and detailed information on engine troubles and repair see also "Fundamentals of
res
Service, Engines" manual.

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Cylinder Head, Camshaft, and Balancer Shafts 10-1

Group 10
CYLINDER HEAD, CAMSHAFT AND
BALANCER SHAFTS
GENERAL INFORMATION Disconnect both battery ground straps.

The intake and exhaust valves are set in the cylin¬

der head. The valve guides are integral with the
head. The valve seats are ground directly into the
cylinder head. Between each valve stem and the
rocker arm is a hardened stem cap.

The camshaft is driven at half engine speed by the

upper idler gear of the timing drives. It is suppor¬
ted by three pressure lubricated bores, integral with
the cylinder block.

The camshaft has an eccentric lobe to actuate the

fuel transfer pump and an axial, pressed-in lug to
drive the tractormeter.

Both balancer shafts are arranged in the lower half

of the cylinder block. They are driven at double Fig. 1 - Removal of Rocker Arm Shaft Assembly
engine speed in opposite direction to each other, 1 Rocker arm shaft 3 Cylinder head cap screws
revolving in three replaceable, pressure-lubricated 2 Push rods 4 Valve stem caps

bushings. The right-hand balancer shaft is driven by

the lower idler gear and the left by the oil pump When removing, identify parts to facilitate reinstal¬
gear. lation.
Do not turn crankshaft after removal of cylinder
head, before all liners are secured with screws and
DIAGNOSING MALFUNCTIONS washers.
For diagnosing malfunctions see group 5. REPAIR
NOTE: For comprehensive and detailed
repair instructions see "Fundamentals of DISASSEMBLY
Service, Engines" manual.

CYLINDER HEAD
REMOVAL
NOTE: It is not necessary to remove the engine in
order to work on the cylinder head, valves and
associated parts.

Immediately cover or plug holes of all removed or

exposed fuel pipes with plastic caps or plugs.
Remove injection nozzles (nozzle points are
protruding from cylinder head sealing face and Fig. 2 - Rocker Arm Shaft Assembly
might be damaged). 1 Rocker arm support 4 Rocker arm shaft
2 Springs 5 Plug
3 Rocker arms
Printed in Germany
20 Engine Model 2120 Tractor
10-2 Cylinder Head, Camshaft and Balancer Shafts TM-4252 (Dec-70)

Remove plug from one end of rocker arm shaft Injection Nozzle Bores
and slide all parts off the shaft (see fig. 2). Identify
parts for correct reinstallation. Remove carbon deposits from bores, using special
tool No. JDE 39. CAUTION: Always turn the tool
When several valves are being removed, identify clockwise as turning it counterclockwise will dull
each to facilitate replacement in its original posi¬ the tool.
tion.

Compress valve spring with commercial tool and re¬ ASSEMBLY

move both retainer locks from the spring cap. Re¬
lease spring and remove spring cap and spring. Pull Rocker Arm Shaft Assembly
valves out of the cylinder head.
Assemble the individual parts, according to fig. 3
finally placing the plug on the shaft end. Make Sure
INSPECTION rocker arms are installed in their original positions.

Check all parts for wear or damage.

Valve Seats

Measure diameter of valve guides. Replace valves, if

necessary and ream the cylinder head bores. Be¬
side standard sized valves, there are valves with
oversize stems available. Check if new valves move
freely in the cylinder head.

Reface valve seats in cylinder head with commer¬

cial tools, if necessary, observing specified measure¬
ments.

Replace valve stem caps, if necessary.

Valve Springs

Valve springs may have different free lengths,

however, they must have the same length when
compressed at the specified load. Check valve
spring tension. L 50098
Fig. 3 - Rocker Arm Shaft Assembly and Valves
Rocker Arm Shaft Assembly —Exploded View
1 Plug 9 Valve stem cap
Make sure that all oil bores in the rocker arm shaft, 2 Rocker arm shaft 10 Keepers
rocker arms and the adjusting screws are clear. 3 Special washers 11 Valve spring cap
Thoroughly clean cavities of rocker arm supports. 4 Spring 12 Valve spring
5 Rocker arm 13 Intake valve
This is especially important for the rear support 6 Adjusting screw 14 Exhaust valve
through which the oil passes to the rocker arm 7 Rocker arm support 15 Cam follower
8 Cap screw 16 Push rod
shaft. Check all rocker arms for excessive wear and
tear on points of rocker arm contact. Check spring
tension.

If a valve is replaced, the accompanying rocker arm IMPORTANT: Make sure that oil bore in rocker
and push rod should be replaced at the same time. arm shaft is at the side of the flywheel and facing
down when assembly is installed on cylinder head.

Lubricate all rocker arms liberally with oil and see

that they move freely.

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Cylinder Head, Camshaft and Balancer Shafts 10-3

Cylinder Head Gradually tighten cylinder head cap screws evenly,

following the sequence outlined in fig. 4 and final¬
Apply clean oil to valve stems and install the valves ly tighten to specified torque. Install push rods
in the same guide ports from which they were re¬ into their original bores according to the marks
moved. Move valves up and down several times to made on removal. Place a valve cap on each stem
ascertain that they slide freely and are properly and make certain that they turn freely.
seated.

When assembling observe the following: ROCKER ARM SHAFT ASSEMBLY

1. Always use new keepers.
2. When replacing valve springs, make sure that the
end contacting the cylinder head is properly
seated.
3. After the valves are installed, give the stems two
or three taps with a rubber or nylon hammer, so
that the parts will seat properly, resp. to ensure
the proper positioning of the keepers.

INSTALLATION

CYLINDER HEAD

Use a new cylinder head gasket, coated with a

uniform thin layer of "PERMATEX Type 3", Fig. 5 - Tightening Rocker Arm Shaft Assembly
"TEROSON - Atmosit", "COLLEX-Aviation'", or
"HERMETIC-Hermalex" on both sides and place it 1 Cap screws 2 Rocker arm shaft assembly
on the cylinder block.

CAUTION: Use hardened flat steel washers under Install rocker arm shaft assembly on cylinder head
all cylinder head cap screws. so that the lubrication holes are at the flywheel
end. Turn the rocker arm shaft so that these holes
are facing down. Tighten cap screws to specified
torque (see fig. 5).

ADJUSTING VALVE CLEARANCE

The valve clearance can be adjusted with the engine

cold or warm.

Turn crankshaft to the right (seen from the

radiator) until the No. 1 piston (front) reaches top
dead center (TDC) of its compression stroke;
CAUTION: not the exhaust stroke.

Fig. 4 - Correct Sequence for Tightening

Cylinder Head Cap Screws

Printed in Germany
20 Engine Model 2120 Tractor
10-4 Cylinder Head, Camshaft and Balancer Shafts TM-4252 (Dec-70)

Insert timing screw into the flywheel housing hole. CAMSHAFT

Rock the flywheel until screw slides into hole in
flywheel rim (flywheel will then be exactly in TDC REMOVAL
position).
To remove the camshaft and related parts it is not
Adjust clearance of the exhaust valves of cylinders necessary to remove the engine. However, the front
Nos. 1and 3, and the intake valves of cylinders Nos. of the tractor must be separated to get access to
1and 2. the front of engine (see section 10, group 25).

Disconnect both battery ground straps.

Remove cylinder head, timing gear housing and

fuel transfer pump.

Remove all push rods and cam followers and iden¬

tify them to facilitate replacement in their original
bores.

NOTE: Be careful that cams do not damage the

bearing surfaces in bores.

REPAIR
Measure each of the three bearing journals of the
Fig. 6 Adjusting Clearance of the Intake camshaft as well as the corresponding bores in two
Valve of Cylinder No. 1 opposing planes.
1 Feeler gauge 3 Adjusting screw of Measure thickness of thrust plate since this thrust
2 Adjusting screw of exhaust valve
intake valve plate determines camshaft end play.

Adjust the valve clearance, using a feeler gauge (see

fig. 6 and Specifications).

Pull timing screw out of flywheel bore,turn crank¬

shaft one complete revolution (=360°) and insert
timing screw again into flywheel bore.

Adjust clearance of exhaust valves of cylinders

Nos. 2 and 4 and inlet valves of cylinders Nos. 3
and 4 (see Specifications).

NOTE: After the engine has run for some time on

a specified load (see Specifications), tighten cylin¬
der head screws to specified torque. Check
clearance of all valves and readjust, if necessary.

40169
Fig. 7 - Pressing Gear on Camshaft
a Timing mark up

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Cylinder Head, Camshaft and Balancer Shafts 10-5

Replace gear of camshaft, if necessary. Position the

new gear on camshaft so that timing mark "a" (fig.
7) faces away from camshaft.

CAUTION: Support camshaft behind the front

bearing journal, when pressing on gear.

Press on gear until it is tight against the shoulder of

camshaft.

Replace tractormeter drive lug, if necessary.

Install new drive lug in camshaft so that its slot

faces away from the camshaft. Support camshaft at
rear journal.

ALWAYS replace cam followers when installing a

new camshaft.

INSTALLATION
Install camshaft, observing the following: Fig, 8 - Measuring Camshaft End Play

1. Coat camshaft with light, clean engine oil. Use special tool No. JD 254 to align timing mark
"b" on the camshaft gear (fig. 9) between centers
2. When installing, make sure that cam lobes do of crankshaft and camshaft by rotating the cam¬
not damage bearing bores in block. shaft.
3. Rotate camshaft until cap screws attaching
thrust plate can be installed and tighten them to
specified torque.

4. Check camshaft end play (a new camshaft and a

new thrust plate should add up to the proper
end play).

5. With crankshaft at TDC and piston No. 1

(front) on compression stroke, adjust camshaft
for valve timing.

Fig. 9 - Timing Camshaft Gear by means of

Special Tool No. JD 254
b Timing mark

Printed in Germany
20 Engine Model 2120 Tractor
10-6 Cylinder Head, Camshaft and Balancer Shafts TM-4252 (Dec-70)

6. With camshaft gear in this position, install upper REMOVAL OF RIGHT-HAND BALANCER
idler gear and tighten cap screw to specified SHAFT
torque.
Remove lower idler gear 4 (fig. 10) (see group 25).
Install cam followers, cylinder head, timing gear Remove both cap screws 7 and thrust plate 6. Pull
cover and fuel transfer pump. balancer shaft out of block.

Run engine for some time at a specified load (see

Specifications) and then retighten cylinder head REMOVAL OF LEFT-HAND BALANCER
cap screws to specified torque. Check valve SHAFT
clearance and readjust, if necessary.
If still necessary, remove lower idler gear 4 (fig.
10). Remove oil pump gear 3 (see group 25).
BALANCER SHAFTS Remove both cap screws 7 and thrust plate 6. Pull
REMOVAL balancer shaft out of cylinder block.

NOTE: It is not necessary to remove the engine, CAUTION: Take care when pulling out balancer
when removing the balancer shafts. However, the shaft that neither the journals nor bushings located
front end of tractor must be removed to obtain in cylinder head are damaged.
access to front of engine (see section 10, group
25).
REPAIR
Disconnect ground strap at negative pole of each
battery. Measure twice each of the balancer shaft journals
and bushing bores at right-angles to each other.
Drain engine oil and remove oil pan.
Measure thickness of each balancer shaft thrust
Remove timing gear cover. plate, this plate determining the end play of each
shaft.

REPLACING A BALANCER SHAFT GEAR

With the aid of a commercial press or puller,

remove gear from balancer shaft.

Set replacement gear onto shaft with the

installation mark (see "c", fig. 11) facing upward.
Press gear onto shaft until it is, within a tolerance
(see Specifications), flush with face of balancer
shaft. It is recommended that this tolerance be
checked as it affects the end play of the balancer
shaft.

spv *i* yv

Fig. 10 — Balancer Shafts, Installed

1 Crankshaft gear 5 Right-hand balancer
2 Left-hand balancer shaft shaft gear
3 Oil pump gear 6 Thrust plate
4 Lower idler gear 7 Cap screws

NOTE: To facilitate reassembly, mark on each

balancer shaft and thrust plate from which side of
the engine they have been removed (right or
left-hand).

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Cylinder Head, Camshaft and Balancer Shafts 10-7

JD247

Fig. 12 — Drift JD 249 to Remove and Install

Balancer Shaft Bushings

1 Bushings m Cam shaft bore

Fig. 11 — Pressing Gear on Balancer Shaft by means

of Special Tool No. JD 247 After driving in new bushings, secure as follows, with
the aid of special tool No. JD 255.
c Installation mark

REPLACING BALANCER SHAFT BUSHINGS JD 255

NOTE: The front and centre bushings can be

replaced with the engine in position. It is necessary
to separate engine and clutch housing, when
replacing the rear bushing.

Using driver JD 249, drive out old bushings from

cylinder block.

From the timing gear side, drive in new bushings

with the aid of driver JD 249, insuring that face of
bushings does not protrude over countersunk part
of cylinder block bores.
Fig. 13 — Securing a Balancer Shaft Bushing in
CAUTION: Install each bushing so that its oil bore Cylinder Block with the Aid of Special
"h" (fig. 14) is aligned with cylinder block oil bore Tool No. JD 255
"i" on cylinder head side and that the bushing
e, d Special Tool No. JD 25&
recess, in which ball "k" of special tool JD 258
engages, corresponds with oil channel "g".
NOTE: The half-round part "d" (figs. 13 and 14)
of special tool No. JD 255 is, with regard to ball
"k'\ unsymmetrical, fitting properly only in one
position into the bushing bore (see fig. 14).

Printed in Germany
20 Engine Model 2120 Tractor
10-8 Cylinder Head, Camshaft and Balancer Shafts TM-4252 (Dec-70)

INSTALLATION

Coat each shaft with light, clean engine oil and

from the timing gear side, guide shaft into cylinder
block bushings.

CAUTION: Take care when doing this that the

journals and bushings are not damaged.

Tighten thrust plate cap screws to the specified

torque (see Torques for Hardware).

40462

Fig. 14 — Securing a Balancer Shaft Bushing, Using

Special Tool No. JD 255 (Sectional View)
d Half-round part of special tool
e Top part of tool
f Pin of part "e"
g Oil channel
h Oil bore
i Oil channel
k Ball
1 Bushing

Remove both cap screws of special tool No. JD

255. Turn part "e" of tool so that pin "f" fitting in
oil channel "g" is directed towards the bushing and
set up on cylinder block as shown in figs. 13 and 40081
14. Insert part "d" of special tool in bushing "1" so
that its rounded surface has the same radial Fig. 15 — Measuring Balancer Shaft "End Play"
distance from the bushing. At the same time, ball
"k" should be vertically under pin "f" of part "e".
The ball then lies in the bushing recess. Place both As shown in fig. 15, check that actual end play
cap screws through part "e" as shown in fig. 13 does not exceed maximum distance quoted in the
and screw into part "d" evenly and finger tight so Specifications.
that both parts of the tool are parallel to each
other, making sure that the ball is still in its correct CAUTION: If the balancer shaft end play is too
position. Now tighten both cap screws gradually great, although the thrust plate is within tolerance,
and evenly until the rounded part "d" of tool lies check whether balancer shaft gear and end face of
against the bushing "1". In this way ball "i" has shaft are within the tolerance quoted in
made a small bulge in the wall of the bushing, Specifications.
pressing the material in the oil channel "g" so that
the bushing cannot move sideways or revolve. After installing one or both balancer shafts and be¬
fore installing idler gear, align marks on balancer
shaft gears with centre of crankshaft (see group 25
for details).

Printed in Germany
Model 2120 Tractor
TM-4252 (Dec-70)

CYLINDER HEAD

Valve stem dia. (standard)

Bore for valve stem

Valve stem oversizes, stem dia.

larger than standard by

Valve seat angle

Angle of valve faces

.
IMPORTANT! Make sure that the keyway of each
balancer shaft gear is vertical to the cylinder head.
If this is not the case, both shafts have been mixed
up and must be reinstalled in the opposite bores.

...............
.....................
Clearance between bore and valve stem

Concentricity tolerance of valve seat (max.)

Valve seat width

Valve length

Valve clearance
Intake valve

Exhaust valve

Printed in Germany
...................
Valve head dia., intake valve

..........................
Valve head dia., exhaust valve
New Parts

0.3715 to 0.3725 in
9.43 to 9.46 mm

0.3745 to 0.3755 in
9.51 to 9.53 mm

0.002 to 0.004 in
0.05 to 0.10 mm

0.003; 0.015; 0.030 in

0.076; 0.381; 0.762 mm

44.88 to 45.13 mm
45°
43.5°

0.057 to 0.073 in
1.45 to 1.85 mm

1.767 to 1.777 in

1.570 to 1.580 in
38.88 to 40.13 mm
5.144 to 5.169 in
130.66 to 131.29 mm

0.014 in
0.35 mm

0.018 in
0.45 mm
Engine
Cylinder Head, Camshaft and Balancer Shafts

Install all engine and tractor parts removed to

20
10-9

facilitate removal of balancer shafts (see removal).

SPECIFICATIONS

....................
Dimensions of Wear Tolerance

0.001 in
0.025 mm

0.006 in
0.152 mm

0.002 in
0.05 mm

0.005 in
0.13 mm
20 Engine Model 2120 Tractor
10-10 Cylinder Head, Camshaft and Balancer Shafts TM-4252 (Dec-70)

CYLINDER HEAD - Continued

Dimensions of Wear Tolerance
New Parts
Valve lift (clearance adjusted)

Intake valve 0.460 to 0.490 in 0.430 in

11.7 to 12.5 mm 10.9 mm

Exhaust valve 0.456 to 0.482 in 0.426 in

11.6 to 12.2 mm 10.8 mm

Rocker arm shaft dia 0.7869 to 0.7879 in 0.002 in

19.987 to 20.013 mm 0.05 mm

Rocker arm bore dia 0.790 to 0.792 in 0.002 in

20.066 to 20.117 mm 0.05 mm

Rocker arm shaft spring

Spring tension at a length of
1.813 in (46 mm) 4 to 6 lbs
1.8 to 2.7 kg

Valve springs
2 12& _n
Spring free length approx 54 mm

Spring tension at a length of 1.813 in (= 46 mm)

Valves closed 54 to 62 lbs
24.2 to 27.8 kg

Spring tension at a length of 1.359 in (= 34.5 mm)

Valves opened 133 to 153 lbs
60.5 to 69.5 kg

Retightening cylinder head cap screws — Run engine for half an hour at rated speed = 2500 rpm.
Loosen screws by 5° to 10° and tighten to the specified torque.

CAMSHAFT

Dia. of camshaft bearing journal

Dia. of camshaft bearing bores

................. 2.1997 to 2.2007 in
55.872 to 55.898 mm
0.001 in
0.025 mm

in cylinder block 2.2042 to 2.2052 in

55.987 to 56.012 mm

Clearance 0.0035 to 0.0055 in 0.007 in

0.09 to 0.14 mm 0.178 mm

End play 0.0025 to 0.0085 in 0.015 in

0.06 to 0.22 mm 0.381 mm
Thickness of thrust plate 0.156 to 0.158 in 0.005 in
3.96 to 4.01 mm 0.13 mm

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Cylinder Head, Camshaft and Balancer Shafts 10-11

BALANCER SHAFTS

......
...............
Diameter of balancer shaft bearing journals
Dimensions of new paxts

1.4995 to 1.5005 in.

Weax Tolerance

......
....
38.087 to 38.113 mm

Clearance .............
Diameter of bushing bores

.....
1.5020 to 1.5040 in.
38.150 to 38.201 mm
0.0015 to 0.0045 in.
0.04 to 0.12 mm
0.006 in.
0.15 mm

................
Diameter of cylinder block bores for bushings

Thickness of pressure plate

Press on gear flush with face of balancer shaft,

1.6245 to 1.6255 in.
41.262 to 41.288 mm

0.117 to 0.119 in.

2.97 to 3.02 mm

0.0005 in.
within a tolerance of -
- 0.013 mm
End play 0.002 to 0.008 in. 0.015 in.
0.05 to 0.2 mm 0.38 mm

..............
TORQUES FOR HARDWARE

..............
..............
Rocker arm shaft to cylinder head, cap screws

...................
35 ft.lbs. 4.8 mkg
Cylinder head to cylinder block, cap screws 110 ft.lbs. 15 mkg
Injection nozzles to cylinder head, cap screws 20 ft.lbs. 2.8 mkg
Fan to V-belt pulley of water pump 20 ft.lbs. 2.8 mkg

..........
Intake manifold, cap screws 35 ft.lbs. 4.8 mkg

..............
Exhaust manifold, cap screws 35 ft.lbs. 4.8 mkg

.............
Camshaft thrust plate to cylinder block, cap screws 35 ft.lbs. 4.8 mkg

.............
Upper idler gear to cylinder block, cap screws 65 ft.lbs. 9 mkg

.......
Timing gear cover to cylinder block, cap screws 35 ft.lbs. 4.8 mkg

Rocker arm cover to cylinder head, cap screws 2 ft.lbs. 0 28 mkg

Balancer shaft pressure plate to cylinder block, cap screws 35 ft.lbs. 4.8 mkg

Printed in Germany
20 Engine Model 2120 Tractor
10-12 Cylinder Head, Camshaft and Balancer Shafts TM-4252 (Dec-70)

SPECIAL TOOLS

JD Parts Depot

.....
..... ........ ........
Part numbers when ordering from

........ .........
Manufacturer Description Use

.............
L 48545 JDE 39* Cleaning tool Cleaning cylinder head nozzle

..... ........
bores

..... ........ .........

L 48542 JD 254* Feeler gauge Adjusting camshaft gear

L 48528 JD 249* Driver Removing and installing

balancer shaft bushings

L 48543 JD 255* Special tool Securing balancer shaft

bushings

* SERVICE TOOLS INC., 1901 INDIANA AVENUE, CHICAGO, ILLINOIS 60616, USA

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Cylinder Block, Liners, Pistons and Connecting Rods 15-1

Group 15
CYLINDER BLOCK, LINERS,
PISTONS AND CONNECTING RODS
GENERAL Secure cylinder liners before removing the pistons.
Carefully remove any carbon from cylinder liners.
The cylinder block is a one-piece casting com¬
prising cylinders and crankcase. Inside the cylinder Keep bearing inserts with their respective rods and
block are the bearings for the crankshaft, camshaft covers.
and balancer shafts. The cylinder block also con¬
tains bores for the cylinder liners, the valve tappets, Each connecting rod and piston should be installed
various oil channels, coolant passages etc. in their original bore. Therefore mark connecting
rod, piston and rod cover for identification.
The cylinder block is equipped with individual Observe the "FRONT" mark stamped into every
liners of the wet-sleeve, replaceable type. A rubber piston crown and connecting rod. After installa¬
ring packing of square section fits on a shoulder of tion, this mark should face the radiator side of the
the cylinder liner. Together with two O-rings cylinder block.
located in cylinder block grooves it forms the
lower seal of each liner against the cylinder block. Before removing the cylinder liners, while they are
The top of the liner is sealed by means of the still secured by washers and screws, measure the
cylinder head gasket. amount by which each liner protrudes above
the sealing surface of the block (see Specifications).
The pistons are forged aluminium alloy. The outer
surface of the pistons is camground. The piston
crown has a cut-out swirl cup with a truncated REPAIR
cone in the center. Every piston is equipped with
two compression rings and an oil control ring. NOTE: Complete and detailed repair
F©S
instructions see manual: "Fundamentals of
The connecting rods have a bronze bushing serving Service, Engines".
as bearing surface for the piston pins. The repla¬
ceable steel-backed bearing insert halves are alu¬ PISTONS
minium-lined and tin-plated.
Place pistons in a cleaning solvent to allow carbon
deposits to soak. Then clean, flush and dry pistons.
DIAGNOSING MALFUNCTIONS Do not use a steel brush to clean piston rings and
piston crown.
For diagnosing malfunctions, see group 5.

REMOVAL

Pistons, connecting rods and cylinder liners may be

removed even with the engine installed.

With the cylinder head removed, do not rotate

crankshaft until all cylinder liners have been
secured by means of screws and washers.

Printed in Germany
20 Engine Model 2120 Tractor
15-2 Cylinder Block, Liners, Pistons and Connecting Rods TM-4252 (Dec-70)

Check piston pin bushing and replace, if necessary.

NOTE: Always install a new bushing when in¬

stalling a new piston pin. Press in new bushing and
ream until the respective piston pin can be inserted
by "thumb-press fit".

CYLINDER BLOCK
I- v 151325
Remove all gaskets and scrape off any residual
Fig. 1— Checking Top Piston Groove for Wear deposits. Remove O-rings sealing liners from
1 Piston a Piston can be used again cylinder block grooves and discard.
2 Feeler gauge No. 19.58-90.281 b Discard piston and replace
Thoroughly clean the block outside and parti¬
Check piston ring grooves for wear as follows: cularly inside with cleaning solvent or by pressure
Clean piston ring grooves carefully. Using feeler steam cleaning. Make sure all passages and orifices
gauge 19.58-90.281 (see 2, fig. 1) check the groove are free from sludge, rust and grease and remove all
of the top compression ring (trapezoidal-shaped) scale or lime deposits.
for excessive wear. As long as there is a gap bet¬
ween the shoulder of the feeler gauge and the
OIL PASSAGES AND VALVE SEAT BUSHING
piston (see a, fig. 1) the piston can be used again. If
OF OIL PRESSURE REGULATING VALVE
shoulder of feeler gauge comes into contact with
the piston (see b, fig. 1), wear is excessive and the
Valve Seat Bushing of Oil Pressure Regulating
piston must be replaced. When checking the center
Valve
piston ring groove, insert a new piston ring.
Measure clearance between ring and groove at
several points around the ring, using a feeler gauge.

Using a micrometer, measure all piston diameters

at a 90° angle from piston pin. The pistons are cam
ground with the largest diameter at right angles to
the piston pin (see Specifications).
Check piston pins and replace them, if excessively
worn (see Specifications).
Always use new piston pins when installing new
pistons.

CONNECTING RODS AND BEARINGS

Replace connecting rod bearings and piston pin

bushings at every major engine overhaul.

Connecting rods and rod caps are only available as Fig. 2 — Driving in Valve Seat Bushing of Oil
matched sets. Connecting rod bearing insert halves Pressure Regulating Valve
are available in standard sizes and several under- 1 Valve seat bushing
sizes (see Specifications). 2 Special tool No. JD 248
3 Special tool (driver) No. 813

Insert bearing insert halves, install rod cap and

tighten rod screws to the specified torque. Measure
each bearing bore and its respective crankshaft
journal at several places. The difference between
the two measurements is the bearing clearance ("see
Specifications).

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Cylinder Block, Liners, Pistons and Connecting Rods 15-3

Check the bushing with sealing edge for lubricating A comparison of these measurements will show if,
oil pressure regulating valve located in the front and to what extent, the cylinder liner is worn
cylinder block for serviceability. If necessary, out-of-round or tapered.
remove unserviceable bushing from cylinder block
and drive in a new bushing until driver contacts If a cylinder liner is excessively worn (see Specifi¬
cylinder block, using special tools JD 248 and 813 cations), the piston, too, may be so worn that it
(see fig. 2). needs replacement.
CAUTION: Do not use other unsuitable tools. Deglazing Cylinder Liner Bores
Above all do not press tool against the slightly
protruding inner edge of the bushing since it is a NOTE: Remove cylinder liners and place in a
delicate sealing face. suitable clamping device or in an old cylinder block
for deglazing.
Dowel Pins, Plugs and Studs
For deglazing cylinder liners 15 to 35 micro-in.
Check these parts for tight fit or proper sealing in (0.0004 to 0.0009 mm), use 180 grit emery cloth
cylinder block, If necessary, replace by new parts. or honing stone.
Coat part to be inserted in cylinder block with a
suitable sealant resistant to oil and water. When deglazing, move the tool up and down 10 to
12 times and adapted to driving speed of tool,
Threaded Bushing for Dip Stick guide the latter so that a 45° criss-cross hone
pattern shown in fig. 3 is produced.
If the threaded bushing for the dip stick has to be
replaced, coat threaded end of new bushing with
an oil-resistant sealant. Thread into cylinder block
as indicated under Specifications. ÿ
'
Ipiir j:S
_
"1 .. .. •. . jrjK jsausTar isar acaea . ÿ

- -
-
jM i.jb k >: -£ ars: rsrs: -a: X
Fitting for Lubricating Oil Filter I eg

If fitting has to be replaced, press in new fitting so

that it is flush with the cylinder block. The
threaded end should face away from the cylinder
block.
fppl
CYLINDER LINERS
Measure each cylinder liner as explained below,
using a suitable gauge (see specifications):
1. Measure cylinder liner bores at upper piston ring
- end of stroke.
2. Measure cylinder liner bores at lower piston
ring - end of stroke.
3. Measure cylinder liner bores at right angles from
piston pin and at the end of stroke of the upper
piston ring. Fig. 3 — Deglazing (Removing Hardened Shining
Spots) a Cylinder Liner Bore, Using
4. Also measure cylinder liner bores at the end of Special Tool
stroke of the lower piston ring.

Printed in Germany
20 Engine Model 2120 Tractor
15-4 Cylinder Block, Liners, Pistons and Connecting Rods TM-4252 (Dec-70)

Clean cylinders thoroughly. Wipe out cylinder Coat exterior of piston and all piston rings with a
liners with a cloth until a clean white rag shows no film of clean engine oil. Insert piston rings, using a
discoloration when wiped through cylinder bore. commercial piston ring expander.

1. Install the expander ring in groove of oil control

ASSEMBLY ring so that its gap is over a piston pin bore.

CONNECTING RODS, PISTONS AND PISTON CAUTION: Make sure fixed end of guide wire is
RINGS inserted at least four threads in the expander ring
and is properly seated. The other, free end should
Make sure that the marks for identifying matched move freely inside the expander ring. Then install
pistons and connecting rods, applied prior to oil control ring in ring groove with the gap
Disassembly, do tally. opposite the expander gap.
Apply a coat of clean, thin engine oil to the piston 2. Install second compression ring in center groove
pin and insert in piston bore and through with "TOP" mark facing upward and with its gap
connecting rod bushing. A properly fitting piston shifted 120o from expander ring gap.
pin can be positioned by thumb pressure,
Installing Piston Rings 3. Then install upper compression ring with the
side marked with a dot facing upwards and with its
NOTE; New piston rings are furnished with the gap shifted 120° from the gap of the second com¬
correct end gap. This should not be altered. pression ring.

INSTALLATION
CYLINDER LINERS

Make sure cylinder block is completely clean and

that the O-rings are removed from cylinder block
Sis****' grooves.

Install cylinder liner WITHOUT the square-section

packing and secure by means of a washer and cap
screw.

401(53

Fig. 4 - Installing Piston Rings Fig. 5 — Upper Fit and Sealing Face of Cylinder
Piston pin 3 Compression rings Liner in Cylinder Block
Snap ring 4 Oil control ring
d Check dimension e Seating afe&

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Cylinder Block, Liners, Pistons and Connecting Rods 15-5

Measure dimension "d" (see Specifications) shown Install two new, dry O-rings in grooves of cylinder
in fig. 5 by which the sealing face of the cylinder block.
liner protrudes over the cylinder block sealing face.
Measure at several places around the circumference Before installing liner, make sure O-rings are
and compare measurements to make sure sealing properly seated in cylinder block grooves. If part
face of cylinder liner is parallel to sealing face of of an O-ring projects into bore for liner, the O-ring
cylinder block. could be pressed onto groove edge, thus getting
damaged without the serviceman noticing it.
If the protrusion of the cylinder liner sealing face
over the cylinder block sealing face is less than Coat packing and O-rings with a film of oil and
specified, remove liner and install one shim R immediately slide liner with shim into its bore in
46906 (for proper thickness see Specifications) cylinder block. Observe the mark applied during
between liner and cylinder block. disassembly to identify the liner and its
corresponding bore in the block. Work the liner
Re-install liner with shim but WITHOUT packing gently in by hand. Finally use a block of hardwood
in cylinder block. Again measure dimension "d" to drive the liner into its proper position by
(fig. 5) and record. Remove cylinder liner and tapping lightly with a hammer.
shim.

NOTE: Do not soak packings and O-rings in oil CAUTION: Do not yet compress packing.
before installing them as they would swell up and
could get damaged when installing the cylinder The cylinder liner will now protrude over the
liners. sealing surface of the block by slightly more than
dimension "d" (see fig. 5).
Carefully slide new, dry packing 1 (fig. 6) over
liner until it contacts liner shoulder. Be sure Measure protrusion and record. Subtract dimension
packing is not twisted or crimped. Also make sure "d" (with shim, but without packings) measured
inner flank of packing contacts liner face when above from amount of protrusion. The difference
packing is installed. indicates how much the liner packings will be
compressed. The minimum dimension is given
under "Specifications".

If this dimension is not attained, the check must be

repeated with another cylinder liner.

If the minimum dimension can still not be

attained, replace the cylinder block. Do not place
more than one shim between liner and cylinder
block under any circumstances.

PISTON WITH CONNECTING ROD

Retain all cylinder liners in the block, using large

washers and cap screws.

L 51 501 Coat pistons and cylinder liners with a film of thin

•V engine oil.
Fig. 6 — Lower Liner Sealing
1 Square-section packing 3 Cylinder liner
NOTE: Observe the identification marks which
2 O-rings 4 Cylinder block were applied to the pistons and connecting rods
during removal and insert them into the liners from
which they were removed.

Printed in Germany
20 Engine Model 2120 Tractor
15-6 Cylinder Block, Liners, Pistons and Connecting Rods TM-4252 (Dec-70)

Make sure that the mark "FRONT" which is

stamped into the head of each piston and into the
shaft of each connecting rod faces toward the
radiator before installing them.

Be sure piston rings and oil control ring are still in

the original position.

Apply a film of thin engine oil to bore of special

tool No. 19.58-90.616.

41743
Fig. 8 — Installing Connecting Rod Caps
Fig. 7 — Installing Piston, Using Special Tool 1 Connecting rod cap 4 Connecting rod
2 Slots 5 "FRONT" mark
19.58-90.616 3 Tangs

Position special tool No. JD 19.58-90.616 exactly Install the bearing cap with the large tang in the
in the middle of the cylinder bore. Insert rod fitting into the large slot in the cap. Install the
connecting rod and piston through this tool until cap screws, coated with a film of oil. First tighten
piston rings touch the tool. Then press or tap them alternately, and finally to specified torque.
piston downward until all piston rings are in the
cylinder liner. Remove the special tool. Rotate the crankshaft several revolutions to make
sure there is no binding of parts or unusual resi¬
Apply a film of clean, thin engine oil to the bearing stance.
inserts and crankshaft rod journals. Install bearing
inserts (if used bearings are reinstalled, observe the
identification marks applied during removal). Make Install oil pan and cylinder head. Fill crankcase
sure the small tangs on each half of the bearing with oil of proper viscosity. Fill cooling system
shell fit correctly into slots in the rod and cap. with clean soft water or with antifreeze solution
(see Operator's Manual).

Printed in Germany
Model 2120 Tractor
TM-4252 (Dec-70)

CYLINDER BLOCK

Camshaft bearing bores

................
.............
Bores for crankshaft bearings

.............
Dimension from center of dipstick bushing
nipple end to base of cylinder block

Lower bore for seating liners

CYLINDER LINERS

block at lower bore

Cylinder liner bore

.........
.................
Outer diameter of liner at lower bore

...................
Clearance between liner and cylinder
.

Max. permissible wear or taper

Protrusion over cylinder block sealing face

SPECIFICATIONS

(see dimension "d", fig. 5, cylinder liner installed

without packing)

Thickness of shim R 46906

of liner packing

Desired cylinder liner wall finish

PISTONS

at right angles from piston pin

.............
Minimum dimension for proper compression

.............
Piston dia. below oil control ring, measured

.............
Play between piston and cylinder liner,
measured below oil control ring

-
measured at open piston end

Piston diameter at open end,

.............
Play between piston and cylinder liner,

measured at right angles to piston pin

Printed in
Germany
....
.....
..
Dimensions of New Parts

2.2042 to 2.2052 in.

55.987 to 56.012 mm
3.3250 to 3.3260 in.
84.455 to 84.480 mm

6.0 in.
152.5 mm

4.3730 to 4.3750 in.

111.075 to 111.125 in.

4.3680 to 4.3720 in.

110.950 to 111.050 mm

0,0010 to 0.0070 in.

0.025 to 0.175 mm
4.0150 to 4.0164 in.
101.982 to 102.018 mm

0.000 to 0.004 in.

0.000 to 0.102 mm
0.004 in.
0.1 mm

0.0126 in.
0.32 mm
15 to 35 micro-inch
0.0004 to 0.0009 mm

4.0053 to 4.0065 in.

101.735 to 101.765 mm

0.0085 to 0.011 in.

0.217 to 0.283 mm

0.0011 to 0.0044 in.

0.027 to 0.113 mm

4.0121 to 4.0140 in.

101.905 to 101.955 mm
Engine
Cylinder Block, Liners, Pistons and Connecting Rods

0.13 mm
20
15-7

Wear Tolerance

0.005 in.

0.016 in.
0.406 mm

0.0094 in.
0.249 mm
20
15-8
Engine

Bore for piston pins

Length of piston pin

Little end bushing bore

..................
.........
Piston ring side clearance (centre ring)

PISTON PINS
Piston pin diameter ..................
..................
.............
Piston pin clearance in piston

...........
................
CONNECTING RODS AND BEARINGS
Connecting rod bearing clearance

............
.............
Piston pin clearance in little end

Connecting rod bearing bores

Connecting rod bearing undersizes,

smaller than standard sizes by . .

.
Cylinder Block, Liners, Pistons and Connecting Rods

...............
Connecting rod cap screws (dip in oil) ............
Rocker arm shaft to cylinder head, cap screws

Cylinder head to cylinder block, cap screws

Rocker arm cover to cylinder head, cap screws

Intake manifold, cap screws

Exhaust manifold, cap screws

...........
Oil pan to cylinder block and timing gear cover
Oil pan to clutch housing, cap screws

.........
Fan to V-belt pulley (securing plate) of waterpump
Injection nozzles to cylinder head, cap screws

Printed in Germany
Dimensions of New Parts

1.1880 to 1.1883 in.

30.175 to 30.182 mm
0.0035 to 0.0053 in.
0.09 to 0.13 mm

1.1875 to 1.1879 in.

30.163 to 30.173 mm
3,3410 to 3.3510 in.
84.861 to 85.115 mm
0.0003 to 0.0008 in.
0.007 to 0.020 mm

0.0012 to 0.0042 in.

0.030 to 0.106 mm
1.1886 to 1.1896 in.
30.190 to 30.215 mm
0.0007 to 0.0021 in.
0.017 to 0.053 mm
2.7502 to 2.7522 in.
69.855 to 69.905 mm

TORQUES FOR HARDWARE

............
0.002; 0.010;
0.020 and 0.030 in.
0.051; 0.254;
0.508 and 0.762 mm

........... 60 to 70 ft.lbs.
35 ft.lbs.
110 ft.lbs.
2 ft.lbs.
35 ft.lbs.
170 ft.lbs.

35 ft.lbs.
35 ft.lbs.
20 ft.lbs.
20 ft.lbs.
Model 2120 Tractor
TM-4252 (Dec-70)

Wear Tolerances

0.001 in.
0.025 mm
0.008 in.
0.2 mm

0.0005 in.
0.013 mm
0.005 in.
0.13 mm
0.0015 in.
0.038 mm

0.0062 in.
0.16 mm
0.002 in.
0.05 mm
0.0041 in.
0.104 mm
no wear
permissible

8.3 to 9.7 mkg

4,8 mkg
15 mkg
0.28 mkg
4.8 mkg
23.5 mkg
4.8 mkg
4.8 mkg
2.75 mkg
2.75 mkg
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Cylinder Block, Liners, Pistons and Connecting Rods 15-9

ENGINE BREAK-IN

On an overhauled engine proceed as follows to 5. Tighten cylinder head cap screws: first loosen
safeguard proper break-in of new parts. them by 5 to 10°, then tighten to the specified
torque. Check valve clearance and adjust, if
1. Operate engine for approx. 5 minutes at 1500 necessary.
rpm idle speed.
NOTE: Explain to the operator that the engine
2. Check engine oil pressure; with engine running should be operated under normal load during the
at 2500 rpm and oil of operating temperature, oil
pressure should be 50 to 60 psi (3.5 to 4.2
first 100 hours of operation. Light loads and
unnecessarily long idle operation should be
kg/cm2). avoided. Replace engine oil and filter after 100
hours of operation. For subsequent oil change and
3. Run engine for approx. 25 minutes at 2000 rpm proper oil viscosity see Operator's Manual.
and half load.

4. Run engine for approx. 30 minutes at 2500 rpm

and three quarter load.

NOTE: Use a dynamometer to put load on the

tractor. If a dynamometer is not available, use
another suitable device to put load on the tractor.

......
SPECIFICATIONS

Compression if driven through starter (engine,

starter and batteries must be in good condition), minimum 300 psi 21 kg/cm2

be no more than 50 psi (3.5 kg/cm2).

Engine oil pressure at 2500 rpm ...............

The most important single factor regarding engine compression is the pressure differential among the
individual cylinders. Pressure should be approx. identical in all cylinders; the pressure differential should

50 to 60 psi 3.5 to 4.2 kg/cm2

......
SPECIAL TOOLS
Part No. if ordered through

.......
JD Parts Service Manufacturer Description Use

L 48527 . . .

......
JD 248* Driver Driving in fitting of oil pressure
regulating valve

............
L 48521 . . 813* Driving pin . To be used in conjunction with JD 248
19.58-90.281 JDE 62* Feeler gauge Checking the first compression ring

........ .....
groove (trapezoidal shaped)
19.58-90.616 Piston ring
compressor Installing pistons
JD 970-M* Washers . Securing cylinder liners in block
19H 432 Cap screws ditto
Washers DIN 9021 ditto

* SERVICE TOOLS INC., 1901 INDIANA AVENUE, CHICAGO, ILLINOIS 60616, USA

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Crankshaft, Main Bearings and Flywheel 20-1

Group 20
CRANKSHAFT, MAIN BEARINGS
AND FLYWHEEL

GENERAL INFORMATION DISASSEMBLY

The crankshaft is a steel forging supported by Remove starting motor.

five, replaceable aluminium, steel-backed, tinplated,
main bearings. Remove engine clutch, flywheel and flywheel
housing. Place engine on assembly stand.
The rear main bearing has a flange on each side to
support the crankshaft thrust and to limit end Remove cylinder head (see group 10).
play.
Remove oil pan and oil pump (see group 30).
The crankshaft is drilled for pressure lubrication to
all bearings. Remove pistons and connecting rods (see group
15).
The flywheel ring gear engaged by the starter is
shrunk-fit to the front of the flywheel. The fly¬
wheel has a bore for setting top dead center if the NOTE: As a rule, pistons and connecting rods will
engine timing is to be adjusted. have to be removed. However, removal is not re¬
quired if only the crankshaft is to be lifted out of
the cylinder block.
DIAGNOSING MALFUNCTIONS
Remove timing gear cover and gears as well as
See group 5 for diagnosing malfunctions. cylinder block front plate (see group 25).

Remove oil slinger from front of crankshaft.

REMOVAL
Remove crankshaft.
For removal of engine, see section 10, group 25.
NOTE: It is recommended to check crankshaft end CHECKING FLYWHEEL AND HOUSING
play be means of a dial indicator prior to removal.
If end play is excessive, reduce play by installing a Inspect flywheel ring gear for serviceability and
new pilot bearing. tight fit on flywheel. Check if flywheel seat, dowel
bore and ball bearing are in proper condition.
Inspect flywheel friction face contacting driven disk
REPAIR for heat cracks and rough spots.
NOTE: Overall and detailed information on
RDS
repair see "Fundamentals of Service,
Engines" manual.

Printed in Germany
20 Engine Model 2120 Tractor
20-2 Crankshaft, Main Bearings and Flywheel TM-4252 (Dec-70)

If ring gear has to be replaced, heat gear evenly and CHECKING CRANKSHAFT
lift away from flywheel. Also heat new gear evenly
and install with chamfered edge of teeth facing Clean crankshaft thoroughly, especially oil passages
away from flywheel. from crankshaft bearings to connecting rod
bearings.
Check flywheel pilot bearing for wear and replace,
if necessary. Install new bearing, with sealed side Check all crankshaft journals thoroughly. Make
facing clutch, in flywheel bore so that it is flush sure bearing faces are not damaged or excessively
with crankshaft face of flywheel. Pack ball bearing worn. If scores are not deep, carefully dress jour¬
with heat-resistant grease. nals by means of fine emery cloth or polishing
cloth.
Check flywheel housing and tachometer drive shaft
for damage. Check tachometer drive seal for ser¬ CAUTION: Especially check both shoulders of
viceability. pilot bearing journal for scores or unevenness
which might damage the lateral thrust faces of the
Check oil seal ring of flywheel housing, especially pilot bearing.
sealing lip, for proper condition; replace, if neces¬
sary. Press unserviceable oil seal ring out of fly¬ Measure each journal at several places by means of
wheel housing, using a suitable tool. Support a micrometer to determine out-of-roundness
housing securely in bore area to avoid damage. and/or taper due to wear (see Specifications).
The flywheel end of the crankshaft has an axial bore
receiving a plug. This plug receives the thrust exerted
by the shaft. If the plug is worn or damaged, pull
out old plug and insert a new plug in crankshaft
bore.

. : ii !.! jii-J

Fig. 1 - Driving in Oil Seal Ring of Flywheel Cover,

Using Special Tool No. JDE 2
1 Driver No. JDE 2
2 Oil seal ring

Use a suitable tube section or similar tool, or, if

available, driver No. JDE 2 to drive in a new oil seal
ring. Drive oil seal ring into flywheel housing, with
sealing lip facing away from driver, until metal
cover of seal ring is flush with machined face of
housing.
Fig. 2 - Pressing Gear on Crankshaft
When driving or pressing in oil seal ring, support
flywheel housing squarely in bore area so it will 1 Block for supporting crankshaft under front throw
not be damaged.

Printed in Germany
 Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Crankshaft, Main Bearings and Flywheel 20-3

Check teeth for excessive wear and damage. NOTE: Make sure you use the proper undersize
Remove unserviceable gear by means of a commer¬ bearing. If undersize bearings are too tight and
cial puller. clearance is not within specifications, the journal
and bearing will be wiped clean of the oil film,
If a press is used for pressing on a new gear, resulting in premature wear.
support crankshaft under front throw as shown in
fig. 2.
MEASURING CRANKSHAFT END PLAY
Insert new Woodruff key in crankshaft keyway.
Press gear on crankshaft so that it is flush against
crankshaft shoulder. To facilitate installation, the
gear may be heated to 350° F (180° C).

INSPECTING CRANKSHAFT MAIN BEARINGS

If one main bearing half needs replacement, always

replace both halves. In such a case check con¬
dition of sliding surfaces and clearance of all
crankshaft bearings. Damage in a bearing may be
due to excessive wear of another bearing. If an
inspection shows that other bearings, though
heavily worn, are still within the wearing tolerance,
do not hesitate to replace these bearings. All crank¬
shaft bearings should be replaced at every major
engine overhaul.

If the bearing inserts are to be used again, it will be Fig. 3 - Measuring Crankshaft End Play with Dial
useful to mark them for proper reinstallation. Indicator
X Mounting bar
2 Dial indicator
Remove all bearing inserts from cylinder block and
bearing caps. Check all bearings for excessive wear,
Fasten dial indicator to cylinder block as shown in
scores, chipping in which case they have to be
fig. 3 or in a similar way and position on crank¬
replaced. Above all, thoroughly check lateral thrust
shaft face.
faces of pilot bearing. Wear of this bearing is also
indicated by increased crankshaft end play.
Move crankshaft back and forth, using a bar or
similar tool and measure amount of clearance on
Measure crankshaft bearing clearance: Bearing dial gauge (see Specifications).
clearance is the difference between bearing bore
and crankshaft diameter (see Specifications). If the
CAUTION: Do not apply too much pressure with
permissible maximum clearance is exceeded, install bar as this could damage new bearing inserts.
undersize bearings.

Printed in Germany
20 Engine Model 2120 Tractor
20-4 Crankshaft, Main Bearings and Flywheel TM-4252 (Dec-70)

CRANKSHAFT WEAR RING FOR REAR OIL ring on crankshaft until flat bar of driver 3
SEAL bottoms on pilot ring 4. When pressing on wear
ring, turn driver No. JD 251 repeatedly (to prevent
"cocking" of wear ring).

CAUTION: When assembling, be careful not to

nick or damage polished wear ring surface (sealing
face for oil seal ring in flywheel housing).

INSTALLATION
INSTALLING CRANKSHAFT AND BEARINGS

NOTE: New crankshaft bearings, except for the

pilot bearing, may be installed at random. Used
bearings should be installed at the same location
from which they were removed. Observe the marks
applied on removal.

Place bearing inserts in their bores in the cylinder

block, observing the marks applied during removal
of the crankshaft. Make sure tangs properly engage
slots of cylinder block and that oil hole of bearing
Fig. 4 - Removing Old Wear Ring-Pressing on New insert is aligned with oil bore of cylinder block.
Wear Ring, Using Special Tools No. JD 251
and JD 251-3 Coat all bearing inserts and crankshaft journals
with a film of oil. Carefully install crankshaft in
1 Wear ring cylinder block.
2 Dull chisel
3 Special tool No. JD 251
4 Pilot ring No. JD 251-3 Place bearing inserts in bearing caps, making sure
tangs are properly engaged. Coat bearing insert
surfaces with a film of oil. Replace all bearing caps
Removing Old Wear Ring according to the marks so that the tangs of both
bearing halves are on the same side (see fig. 5).
Score wear ring with a dull chisel at several places
of its circumference. This will stretch the material
so that the wear ring gets loose on the crankshaft
and can be removed without using force (see fig.
4).

CAUTION: Do not score wear ring too deeply as

crankshaft surface may be damaged.
Pressing on New Wear Ring

Position pilot ring 4 (fig. 4) - special tool No. JD

251-3- against center of rear crankshaft face. Slide
new wear ring (rounded edge of ring outward) over
pilot ring and start wear ring onto crankshaft by
hand. Avoid "cocking" or forcing the ring (use no
force).

Place special tool 3 (fig. 4) - No. JD 251 - (as

shown in fig. 4) over pilot ring until it contacts
wear ring. Tap JD 251 driver lightly to drive wear

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Crankshaft, Main Bearings and Flywheel 20-5

Fig. 6 - Installing Flywheel Housing

a Flywheel housing
5 Crankshaft
6 No. JD 251-4 Seal Protector
7 Oil seal ring
Fig. 5 - Installing Crankshaft Bearing Caps and
Inserts
Slide seal protector 6 (fig. 6) - special tool No. JD
1 Thrust face of pilot bearing
2 Tangs in slots
251-4 - on rear end of crankshaft. Coat seal pro¬
3 Bearing inserts tector and crankshaft wear ring with a film of clean
4 Bearing caps engine oil.

Install flywheel housing, sliding oil seal ring (as

Turn all cap screws into cylinder block, but tighten shown in fig. 6) over seal protector onto crankshaft
only finger-tight. Align pilot bearing halves before wear ring. When installing seal ring, make sure
tightening bearing cap screws: sealing lip of ring is not damaged or turned over.
Force crankshaft from radiator side to flywheel
side and then back from flywheel side to radiator INSTALLING FLYWHEEL
side. Tighten all cap screws to the specified torque.
Check crankshaft end play as explained under Make sure seats of flywheel and crankshaft are
"Measuring Crankshaft End Play" (see fig. 3). clean and show no burrs or unevenness.

NOTE: To facilitate installation of flywheel, screw

INSTALLING FLYWHEEL HOUSING two pilot pins into crankshaft.

Make sure sealing faces of cylinder block and Slide flywheel over dowel of crankshaft and press
flywheel are thoroughly clean and both dowels are onto crankshaft. Tighten cap screws crosswise to
provided on cylinder block side. the specified torque, taking several steps.

Coat both sides of new gasket with a film of oil (do FINAL INSTALLATION
not stick on) and place on cylinder block.
Slide oil slinger onto crankshaft, with the flanged
edge facing away from engine.

Printed in Germany
20 Engine Model 2120 Tractor
20-6 Crankshaft, Main Bearings and Flywheel TM-4252 (Dec-70)

Installation of front crankshaft seal ring, see group Install cylinder head (see group 10).
25.
Install engine (see section 10, group 25).
Install pistons and connecting rods (see group 15).
Fill crankcase with oil and fill cooling system with
Install oil pan and oil pump (see group 30). coolant (see Operator's Manual).

................
....
SPECIFICATIONS

Dimensions of New Parts Wear Tolerance

Crankshaft end play

....... 0.002 to 0.008 in.

0.051 to 0.203 mm
0.015 in,
0.381 mm

.....................
Dia. of crankshaft journals (standard size) 3.1235 to 3.1245 in.
79.337 to 79.362 mm

Dia. of connecting rod journals

(standard size) 2.7480 to 2.7490 in.
69.799 to 69.824 mm

Journal taper for each inch (25.4 mm) of journal length . 0.001 in.
0.025 mm

Journal out-of-roundness

........
..............
Crankshaft bearing bore (standard size) 3.1256 to 3,1276 in.
79.390 to 79.441 mm
. 0.003 in.
0.076 mm

0.002 in.
0.05 mm

................
Crankshaft bearing clearance 0.001 to 0.0041 in. 0.006 in.
0.028 to 0.104 mm 0.152 mm

...........
Connecting rod bearing bore,
installed (standard size) 2.7502 to 2.7522 in.
69.855 to 69.905 mm

Connecting rod bearing clearance 0.0012 to 0.0042 in. 0.062 in.

0.030 to 0.106 mm 0.16 mm

Crankshaft bearing undersizes, smaller

than standard by 0.002; 0.010;
0.020 and 0.030 in.

0.051; 0.254; 0.508

and 0.762 mm

Crankshaft bearing bores in cylinder block 3.3250 to 3.3260 in.

84.455 to 84.480 mm

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Crankshaft, Main Bearings and Flywheel 20-7

TORQUES FOR HARDWARE

Crankshaft bearing cap-to-cylinder block, cap screws 85 ft.lbs. 11.7 mkg

Flywheel housing-to-cylinder block, 1st stage .. . 22 ft.lbs 3.0 mkg

Flywheel housing-to-cylinder block, 2nd stage .. 35 ft.lbs 4.8 mkg

Flywheel-to-crankshaft, cap screws 85 ft.lbs 11.7 mkg

V-belt pulley on crankshaft, cap screw 85 ft.lbs 11.7 mkg

SPECIAL TOOLS
Part No. if ordered through
JD-Parts Depot Manufacturer Description Use

JDE 2* ... Driver . Installing oil seal ring in flywheel housing

L 48539 .... JD 251* . . . Driver Driving wear ring on crankshaft

L 48585 .... JD 251-3* . . Pilot ring .... Pilots JD 251 driver

L 48586 .... JD 251-4* . . Seal protector . . Protects oil seal ring during installation of fly¬
wheel housing

* SERVICE TOOLS INC., 1901 INDIANA AVENUE, CHICAGO, ILLINOIS 60616, USA

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Timing Gear Train 25-1

Group 25
TIMING GEAR TRAIN
GENERAL INFORMATION The crankshaft gear, camshaft gear and both
balancer shaft gears are pressed on and keyed to
their respective shafts. The oil pump gear is pressed
on its taper seat and secured to the shaft by a
retaining nut. The injection pump gear is secured
to the pump shaft with three cap screws. The
upper and lower idler gears with bronze bushings
rotate on stationary shafts pressed into the
cylinder block front plate.

The camshaft gear, injection pump gear and both

balancer shaft gears have timing marks which must
be aligned with the center of the crankshaft when
No. 1piston is at "top dead center" of its compres¬
sion stroke. With the other gears no timing is
required.

DIAGNOSING MALFUNCTIONS

See group 5 for diagnosing malfunctions.

REMOVAL
L 40463 A
Removal of the timing gear cover, the timing gears
Fig. 1— Timing Gear Train - Cover Removed or the cylinder block front plate does not require
removal of the engine. However, split the tractor
1 Crankshaft gear
2 Upper idler gear and remove front end to get access to the front of
3 Injection pump gear the engine (see section 10, group 25).
4 Camshaft drive gear
5 Right-hand balancer shaft gear
6 Lower idler gear If engine has to be removed, see section 10, group
7 Oil pump gear
8 Left-hand balancer shaft gear
25.

The helical timing gear train consists of gears 1to 8 Whenever engine has to be overhauled or crank¬
(fig. 1), the gear train being driven by crankshaft shaft has to be removed, also remove timing gear
gear 1. The upper idler gear 2 drives camshaft gear train as follows:
4 and injection pump gear 3 while lower idler gear
6 drives oil pump gear 7 and right-hand balancer 1. Remove timing gear cover.
shaft gear 5. The left-hand balancer shaft gear 8 is
driven by oil pump gear 7.
2. Back hex. nut off oil pump shaft and remove
cap screws of upper and lower idler gears.
Due to the number of teeth of these gears, cam¬
shaft and injection pump shaft rotate at half the
crankshaft speed, whereas both balancer shafts run
at double the crankshaft speed.

Printed in Germany
20 Engine Model 2120 Tractor
25-2 Timing Gear Train TM-4252 (Dec-70)

3. Remove upper and lower idler gear. Pull oil If there are signs of insufficient lubrication, make
pump gear off the tapered pump shaft, using a sure that oil passage of cylinder block for
commercial puller. DO NOT PRY GEAR OFF lubricating the upper idler gear as well as longitu¬
THE SHAFT BY MEANS OF MOUNTING BARS dinal and vertical oil bores of shaft are open.
ETC.
The lower idler gear is splash-lubricated.
4. Remove oil pump (see group 30).
FRONT PLATE AND TIMING GEAR COVER
5. Remove injection pump with gear (see section
30). Make sure front plate is not warped or otherwise
damaged which would jeopardize safe sealing
6. Remove camshaft and balancer shafts (see against cylinder block and timing gear.
group 10).
REPAIR Do not pry or press against timing gear cover with
excessive force. The cover is cast aluminium alloy
NOTE: Overall and detailed information which might be sprung or warped.
on repair see "Fundamentals of Service,
If timing cover seal ring leaks, especially if this is
Engines " manual.
indicated by oil spots on the timing cover, remove
seal ring from cover.
Inspection, repair and replacement of gear of
camshaft and balancer shafts see group 10, CAUTION: Support timing cover squarely to
prevent distortion.
crankshaft see group 20,

lube oil pump see group 30,

injection pump see section 30, group 15.

Prior to replacing the crankshaft gear, camshaft

gear or balancer shaft gears, remove the respective
shaft (see above groups).
CHECKING TIMING GEAR BACKLASH

As a matter of experience unusual gear train noise

indicates excessive backlash or damaged teeth.

Check backlash between individual gear pairs and

replace gears, if necessary (see Specifications).

IDLER GEARS

Measure I.D. of bushing in idler gear and O.D. of

shaft; clearance see Specifications. If bushing has
to be replaced, press in new bushing by means of
tool JD 252 so that it is flush with either side of 148ÿ37
gear.
Fig. 2 - Front Crankshaft Oil Seal in Timing Cover
and Oil Seal Driver
1 Special tool No, JD 250 and driving pin No. 815

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Timing Gear Train 25-3

Prior to installing new oil seal, coat outer surface 3. Install oil pump and oil pump gear (see group
of seal with an oil-resistant sealing compound. 30).
Press in oil seal until it bottoms in bore. The
spring-loaded lip of the seal should face the timing NOTE: Tighten hex. nut of pump shaft only after
gears. Use special tools No. 815 and JD 250. timing gears have been adjusted and lower idler
gear has been installed so that the gear pair can be
CAUTION: When installing oil seal, support timing blocked by means of a clean rag.
cover to prevent distortion.
4. Install fuel injection pump with gear (see section
30).
INSTALLATION
5. With the crankshaft set at TDC as indicated in
NOTE: If engine has been completely disassemb¬ item 2, align mark "b" stamped onto camshaft gear
led, install crankshaft before installing cylinder (see fig. 3) with line drawn through center of
block front plate. crankshaft and camshaft as shown in fig. 3, using
timing tool No. JD 254 and rotating the camshaft.
Coat front plate seal facing cylinder block with a
film of "PERMATEX Type 3", "TEROSON
Atmosit", "COLLEX Aviation" or "HERMETIC
HERMALEX".

CAUTION: Cut off protruding edge of gasket only

when timing cover has been tightened. Tighten
front plate attaching screws to the specified torque
(see Torques for Hardware).

INSTALLATION AND ADJUSTMENT OF

TIMING GEAR TRAIN
Align timing marks of camshaft, balancer shaft and
injection pump gears with center of crankshaft
after having installed them. Install and adjust
timing gears as follows:

1. Install camshaft and balancer shafts (see group

10).
2. Rotate crankshaft clockwise (seen from radia¬
tor) until piston No. 1 (radiator side) is imme¬ Fig. 3 - Timing Camshaft Gear by means of Timing
diately before TDC of its compression stroke. Tool No. JD 254
Insert timing screw in bore of flywheel housing and b Timing mark
flywheel when the latter is exactly in its TDC
position.
6. With the crankshaft set in TDC position as in¬
NOTE: With the engine disassembled, rotate dicated in item 2, align mark "c" (fig. 4) stamped
crankshaft so that piston No. 1 bearingjournal is in onto injection pump gear with line drawn through
its top position facing the cylinder head. In this center of crankshaft and pump shaft as shown in
position the keyway of the crankshaft gear faces fig. 4, using timing tool No. JD 254 and rotating
exactly upward (cylinder head side). the injection pump shaft. CAUTION: Use timing
mark indicating number of cylinders on respective
CAUTION: Do not rotate crankshaft after having engine.
adjusted TDC.

Printed in Germany
20 Engine Model 2120 Tractor
25-4 Timing Gear Train TM-4252 (Dec-70)

Make sure that the rear thrust washer 1 (fig. 5) is

installed.

If a new shaft is installed, first drive spring pin 6

(fig. 5) in shaft so that it protrudes from the front
face of the shaft by a specified dimension (see
Specifications). Install front thrust washer 5 and
cap screw 7, secure gears against rotation and
tighten screw to the specified torque (see
Torques for Hardware).

8. While the crankshaft is set in its TDC position

in accordance with paragraph 2, align both
balancer shaft gears with the aid of timing tool No.
JD 254. Rotating the balancer shafts, set the
balancer gear markings (see "d" and "e", fig. 6) so
Fig. 4 - Timing Injection Pump Gear, Using Timing that they are in alignment with the centre of the
Tool No. JD 254 crankshaft and balancer shaft (see fig. 6).
c Timing mark

7. After having timed the camshaft and injection

pump gear, carefully slide upper idler gear on shaft,
simultaneously engaging the gear in crankshaft,
camshaft and injection pump gears with a rotating
motion. Use special care not to rotate the pre¬
viously timed gears.

Fig. 6 — Timing Balancer Shaft Gear by means of

Timing Tool No. JD 254

d Timing mark on right-hand balancer shaft gear

e Timing mark on left-hand balancer shaft gear

9. After having timed the balancer shaft gears,

carefully slide the lower idler gear onto the shaft,
simultaneously engaging the gear in the crankshaft,
lubricating oil pump and right-hand balancer shaft
gears with a rotating motion. Take extra care not
L 48439 \ to rotate the previously timed gears. Make sure
that rear thrust washer 1(fig. 7) has been installed.

Fig. 5 - Upper Idler Gear and Support - Sectional

View

1 Rear thrust washer 5 Front thrust washer

2 Cylinder block front plate 6 Spring pin
3 Idler gear 7 Cap screw
4 Idler gear bushing 8 Shaft

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Timing Gear Train 25-5

Install front thrust washer 5 over the spring pin 6,

screwing the second cap screw 7 (see fig. 7) into
y - \
the shaft. Secure gears against rotation and tighten
screw to specified torque (see Torques for
Hardware).

After final installation of all shafts and gears,

SSs
0 X « W/////A// •
check timing of the individual gears as explained
above, using timing tool JD 254.
Then withdraw timing pin from flywheel and
flywheel housing and attach protective cover to
flywheel housing.

FINAL ASSEMBLY
Install oil slinger on crankshaft with flange facing
L 48440 away from engine.

Coat spring-loaded lip of timing cover oil seal with

Fig. 7 — Lower Idler Gear and Its Support a film of high-temperature grease. Slide timing
Sectional View cover over crankshaft. However, be careful not to
damage or turn over lip of oil seal. Install nuts and
1 Rear thrust washer 5 Front thrust washer screws of timing cover and tighten to the specified
2 Cylinder block front plate 6 Spring pin
3 Idler gear 7 Cap screws torque.
4 Idler gear bushing 8 Shaft
9 Special steel washer
Cut off protruding edge of gasket between front
If a new shaft is installed for the lower idler gear, plate and cylinder block or between front plate
drive spring pin 6 (fig. 7) in shaft so that it and timing cover so that it is flush with the oil pan
protrudes from front face of shaft by a specified sealing face.
value. Slide rear thrust washer 1 on shaft journal
and spring pin. Drive in shaft until thrust washer is Install all parts of oil pressure regulating valve (see
fully seated. Secure shaft with special steel washer group 30). Install all engine or tractor parts
9 and cap screw 7. Tighten screw to specified removed to facilitate removal of parts dealt with in
torque (see Torques for Hardware). this group.

SPECIFICATIONS

Timing gear backlash between

upper idler gear and crankshaft gear .........

..........
Dimensions of new parts

0.0027 to 0.0116 in.

0.069 to 0.295 mm
Wear tolerance

0.0166 in.
0.422 mm

upper idler gear and camshaft gear

upper idler gear and injection pump gear .......

..........
0.0028 to 0.0135 in.
0.071 to 0.343 mm

0.0028 to 0.0135 in.

0.071 to 0.343 mm
0.0185 in.
0.470 mm

0.0185 in.
0.470 mm

lower idler gear and crankshaft gear

lower idler gear and balancer shaft gear ...... 0.0027 to 0.0137 in.
0.069 to 0.348 mm

0.0018 to 0.0156 in.

0.046 to 0.396 mm
0.0187 in.
0.475 mm

0.0206 in.
0.523 mm

Printed in Germany
 20 Engine Model 2120 Tractor

..........
25-6 Timing Gear Train TM-4252 (Dec-70)

.......
Dimensions of new parts Wear tolerance

lower idler gear and oil pump gear 0.0016 to 0.0147 in. 0.0157 in.

................
0.041 to 0.374 mm 0.400 mm

oil pump gear and balancer shaft gear 0.0020 to 0.0140 in. 0.0190 in.

..............
0.051 to 0.356 mm 0.483 mm
Dia. of an idler gear shaft 1,7495 to 1,7505 in. 0.0010 in.
44,436 to 44,462 mm 0.025 mm
Dia. of idler gear bushing bore

End play of an idler gear

Hub width of an idler gear

...................
..................
1,7515 to 1,7535 in.
44,487 to 44,538 mm

0.001 to 0.007 in.

0.02 to 0.17 mm

0.865 to 0.867 in.

0.0010 in.
0.025 mm

0.015 in.
0.38 mm
0.002 in.
21,97 to 22,02 mm 0.05 mm
Width of shaft 0.868 to 0.872 in. 0.002 in.

...................
22.05 to 22.15 mm 0.05 mm
Spring pins protruding from shaft:

on lower idler gear by

on upper idler gear by ...................

TORQUES FOR HARDWARE
0.197 to 0.275 in.
5 to 7 mm

0.138 to 0.177 in.

3.5 to 4.5 mm

Front plate to cylinder block 25 ft.lbs 3.5 mkg

Drive gear on oil pump shaft,

hex. nut (staked)

Cap screw of upper idler gear

Cap screw of lower idler gear

.......
35 ft.lbs.

65 ft.lbs.

95 ft.lbs.
4.8 mkg

9 mkg

13 mkg

Timing gear cover to cylinder block

and front plate 35 ft.lbs. 4.8 mkg

SPECIAL TOOLS
Part No. if ordered from
JD Parts Depot Manufacturer Description Use
L 48540 . JD 252* . Driver . Driving in idler gear bushings
L 48529 . JD 250* . Special tool' . .. Driving crankshaft front oil seal in timing
gear cover
L 48522 . 815* . Driving pin ... To be used in conjunction with tools
JD 252 and JD 250
L 48542 . JD 254* . Timing tool ... Timing gears of timing train

* SERVICE TOOLS INC., 1901 INDIANA AVENUE, CHICAGO, ILLINOIS 60616, USA

Printed in Germany
 Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Engine Lubrication 30-1

Group 30

OIL PUMP, OIL PRESSURE

REGULATING VALVE AND OIL FILTER
GENERAL INFORMATION and to the main oil gallery of the cylinder block.
The pressure regulating valve is located at the front
LUBRICATION SYSTEM of the cylinder block. It is situated at the end of the
gallery branching off the cylinder bore leading to the
oil filter. It controls oil pressure before the oil enters
the filter and it provides constant pressure in the
main gallery and in the entire lubrication system.

The cone of the pressure regulating valve is pressed

by a spring onto the replaceable valve seat in the
cylinder block. This pressure spring is retained by
means of a plug turned into the timing gear cover.
The oil pressure can be adjusted by changing the
number of shims between spring and plug. If oil
pressure exceeds spring pressure, the cone is lifted
from its seat and part of the oil may return to the
oil pan via the timing case to maintain constant
pressure.

OIL FILTER

The lubricating oil filter is located on the right-

hand side of the cylinder block. As it is of the
full-flow type, oil for lubricating the points
connected with the main gallery flows through the
filter. The element is integral with the filter
housing and for this reason the entire filter must
L 48441 always be replaced. When the oil filter element no
longer permits sufficient oil flow, the pressure
relief valve opens, allowing oil to flow through
(unfiltered). Thus excessive pressure build-up is
Fig. 1 — Engine Lubrication System avoided and lubrication of the engine is main¬
1 OU pump 4 Oil pressure sending unit tained.
2 Oil pressure regulating valve 5 Main oil gallery
3 By-pass valve

DIAGNOSING MALFUNCTIONS
The engine has a pressure lubrication system. In
the main it consists of the gear pump, filter strainer For diagnosing malfunctions, see group 5.
in the suction pipe, full flow oil filter, adjustable
oil pressure regulating valve and the electrical oil
pressure warning switch in the flywheel housing.

OIL PUMP AND OIL PRESSURE REGULATING

VALVE
The pump draws the lubricating oil from the oil
pan through a strainer and a suction line and
pumps it through a pressure line to the oil Filter

Printed in Germany
20 Engine Model 2120 Tractor
30-2 Engine Lubrication TM-4252 (Dec-70)

REMOVAL
OIL PUMP Remove hex. nut which is secured by three center
punch marks. Pull pump gear off the tapered seat
Drain engine oil and remove oil pan. on the pump shaft.

Place a clean cloth between the teeth of the lower

idler gear and the teeth of the oil pump gear.

L 48442

Fig. 2 — Oil Pump Assembly

1 Pump housing 6 Groove pin 11 Cap screw
2 Shaft for driven gear 7 Gear on pump shaft 12 Spring washers
3 Bearing bushing for pump shaft 8 Hex. nut 13 Pressure pipe
4 Pump drive shaft 9 Pump cover with suction pipe and strainer 14 O-Ring
5 Pump gears 10 Cap screw (3 used) 15 Plug

REPAIR
NOTE: For overall and detailed infor¬ INSPECTION
RSS
mation on repair of the engine lubrication
system see Fundamentals of Service, Pump Housing and Shaft for Driven Gear
Engines" manual.
Check pump housing 1 (fig. 2) for distortion or
DISASSEMBLY OF THE OIL PUMP cracks. Especially check sealing surface to which
pump cover 9 attaches. Measure diameter of
Pull drive shaft with gear out of pump housing. bearing bushing 3. Replace bushing if worn, or if
not absolutely perfect. Drive in new bushing with
Remove driven gear from shaft. Support pump special tools No. JD 253 and 813 so that it is flush
housing by means of a pipe section and press shaft with inside face of housing.
of driven gear out of the housing.

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Engine Lubrication 30-3

Check shaft 2 for serviceability; determine wear by Oil Pressure Regulating Valve
measuring shaft diameter. Drive new shaft from
cover side into pump housing 1 so that the shaft
face is flush with sealing face of pump housing.

Pump Cover

Make sure that inner sealing face of pump cover 9

(fig. 2) is completely level, smooth and un¬
damaged. This is important since the cover is not
provided with any gaskets. The metal-to-metal
sealing is achieved by means of the precision-
machined sealing surfaces. For that reason these
surfaces should be absolutely perfect.

Replace O-ring on outlet side. Make sure suction

pipe is free of foreign matter and that the filter
strainer is not blocked or damaged.

Pump Drive Shaft Fig. 3 — Oil Pressure Regulating Valve, Removed

Measure diameter of bearing area of pump drive 1 Valve cone 4 Aluminium washer
2 Pressure spring 5 Plug
shaft 4 (fig. 2). 3 Shims

NOTE: The pump drive shaft is only available as an Turn plug 5 (fig. 3) out of timing gear housing and
assembly with the drive gear and the groove pin. remove with all parts shown above.

Pump Gears Check valve cone 1for excessive wear and damaged
sealing face.
Measure width of both pump gears 5 (fig. 2).
Check valve seat bushing in cylinder block for
Install drive shaft with gear and driven gear. damage, especially the slightly protruding edge
Measure clearance between gears and housing With (sealing face) of the bushing.
a feeler gauge. Excessive clearance can only be
corrected by replacing the components. Always
replace gears 5 in pairs.

With both gears installed, place an exact straight

edge on sealing face of housing and measure the
clearance between faces of both gears and the
straight edge with feeler gauge.

This dimension is equal to the end play of the gears

in the pump housing (see Specifications).

Fig. 4 — Driving in Valve Seat Bushing of Oil Pres¬

sure Regulating Valve
1 Bushing
2 Special tool No. JD 248
3 Special tool No. 813

Printed in Germany
 20 Engine Model 2120 Tractor
30-4 Engine Lubrication TM-4252 (Dec-70)

Drive in a new bushing, using special tools No. JD Install pump driving gear and tighten hex.nut to
248 and No. 813 until driver contacts cylinder the specified torque. Secure nut by applying three
block. center punch marks.
CAUTION: Do not use other unsuitable means for OIL PRESSURE REGULATING VALVE
this job and above all do not damage the slightly
protruding edge of the bushing as it is a sealing Install all parts shown in fig. 3. As a preliminary
surface. adjustment, place the number of shims 3 found on
disassembly between spring 2 and plug 5. Slide an
Check condition and tension of valve spring (see aluminium washer 4 on the plug and tighten plug
Specifications). to the specified torque.

Oil Filter If necessary, add or remove shims when checking

oil pressure (see Adjusting Engine Oil Pressure).
When in doubt regarding the effectiveness of the
oil filter installed because of unusually dirty oil,
replace oil filter. OIL FILTER
Install new oil filter (see Specifications)
Check that there is no foreign matter in the oil
galleries of the cylinder block.
After final installation, check oil filter connection
For replacing the oil filter fitting, see group 15. for leakage with engine running. If necessary,
retighten filter, but do not overtighten.
ASSEMBLY OF OIL PUMP
IMPORTANT: The full flow filter has a special
Install pump shaft 4 with driving gear 5 in pump by-pass valve (see fig. 1) to protect the engine
housing 1 as shown in fig. 2 and slide driven gear 5 when the filter element is blocked. Therefore, use
on shaft 2. Turn the pump shaft to make sure that only genuine John Deere filters.
shaft and both gears move absolutely free in the
housing.
ADJUSTING ENGINE OIL PRESSURE
Place a new O-ring 14 in oil outlet opening in
pump cover 9.

INSTALLATION
OIL PUMP

Insert pump housing with gears and shaft installed

through the bore of cylinder block front plate.
Insert pressure pipe, attached to the pump cover,
into the oil gallery of the cylinder block. Make sure
that all sealing faces and the faces of both pump
gears are perfectly clean. Place the pump cover on
the housing by pivoting the pressure pipe in the
cylinder block. Attach pump to cylinder block
front plate, using cap screws. However, do not
firmly tighten yet. Rotate pump shaft to make sure Fig. 5 — Checking Oil Pressure by Means of
that shaft and gears move freely. If necessary, ad¬ Pressure Gauge
just by lightly tapping the housing. Tighten the
1 Special adapter Nr. 19.58-90.267
four cap screws crosswise to the specified torque. of special tool No. 19.58-90.260
2 Pressure hose of special tool No. 19.58-90.260
3 Pressure gauge No. 19.58-90.268
of special tool No. 19.58-90.260

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Engine Lubrication 30-5

Adjust oil pressure as follows: Before checking the pressure, warm up engine to
allow the lubricating oil to reach normal operating
Check oil pressure by means of special tool temperature.
19.58-90.260. Connect pressure gauge instead of
oil pressure warning switch to flywheel housing At the rated engine speed the gauge should indicate
(see fig. 5). the specified oil pressure (see Tune-Up Data).

Operate starter: the oil pressure warning lamp on To increase oil pressure, place as many shims bet¬
the instrument panel will now light up. It will only ween plug and spring of oil pressure regulating
go out when the engine has started and a minimum valve as are required to attain the required pres¬
oil pressure has built up. sure.

CAUTION: If the warning light is still on when the CAUTION: However, do not use more than four
engine has run for 10 seconds, stop engine at once shims.
and check if shims have been installed between
spring and plug of oil pressure regulating valve and To reduce the oil pressure, remove part or all of
if the plug has been provided with an aluminium the shims located between plug and spring. Turn in
washer. plug with aluminium washer and measure pressure.
If pressure is still too high, add a second washer.

SPECIFICATIONS

.....................
Dimensions of new parts Wear tolerance
OIL PUMP

...................
Bore for the drive shaft in pump housing
(with bushing installed) 0.6315 bis 0.6335 in. 0.0030 in.
16.040 to 16.091 mm 0.08 mm

.................
Diameter of the idler shaft

.......
Diameter of drive shaft journal
0.4850 to 0.4856 in.
12.319 to 12.334 mm

0.6295 to 0.6305 in.

15.989 to 16.015 mm
0.0005 in.
0.013 mm

0.0010 in.
0.025 mm

Gear width ....................

.......
Radial clearance between gears and pump housing

...........
Axial clearance between gears and pump cover
0.0010 to 0.0040 in.
0.025 to 0.1 mm
1.4163 to 1.4183 in.
35.974 to 36.025 mm

0.001 to 0.006 in.

0.0050 in.
0.13 mm

0.0020 in.
0.05 mm
0.008 in.
0.025 to 0.15 mm 0.2 mm

OIL FILTER

Screw filter onto fitting by hand until the rubber gasket just touches the cylinder block without
compression. Then tighten filter another 1-1/2 turns for proper sealing.

Printed in Germany
20 Engine Model 2120 Tractor
30-6 Engine Lubrication TM-4252 (Dec-70)

OIL PRESSURE REGULATING VALVE

Spring of oil pressure regulating valve

Free length of spring approx. 4.7 in.
119 mm

Spring pressure at a length of 1.68 in. (42.5 mm) 13.5 to 16.5 lbs.
(6.1 to 7.5 kg)

TORQUES FOR HARDWARE

Oil pump assembly to cylinder block front plate 35 ft.lbs 4.8 mkg

Driving gear on oil pump shaft (nut secured by center

.............
......
punch marks) 35 ft.lbs 4.8 mkg

Oil pan to cylinder block and timing gear housing 35 ft.lbs 4.8 mkg
Oil pan to clutch housing, cap screws . 170 ft.lbs 23.5 mkg

Plug of oil pressure regulating valve in timing

gear housing 80 ft.lbs 11 mkg

TUNE-UP DATA

Oil pressure at 2500 rpm and normal operating temperature

of engine and lubricating oil 50to60psi 3.5 to 4.2 kg/cm2

SPECIAL TOOLS

L 48541 .....
Part No. if ordered from

.....
JD Parts Depot Manufacturer

JD 253* . . .
Description

Driver . .
Use

Driving in bearing bushing of lubricating

..... .........
oil pump
L 48527 JD 248* . . . Driver . . Driving in bushing of oil pressure regulating
valve
L 48521 813* . . . Driving pin Sliding on the above tools
19.58-90.260** Special tool Measuring oil pressure

* SERVICE TOOLS INC., 1901 INDIANA AVENUE, CHICAGO, ILLINOIS 60616, USA
** Details see section 70, group 5.

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Engine Cooling System 35-1

Group 35
ENGINE COOLING SYSTEM
GENERAL INFORMATION WATER PUMP

COOLING SYSTEM The coolant is circulated by means of a centrifu¬

gal-type pump which is mounted on the front of
The pressure cooling system includes mainly the the cylinder block. The pump is driven by the
radiator, the water pump, the multi-blade fan and V-belt which also drives the generator and the fan,
the thermostat. from the crankshaft. The pump shaft runs in a
pre-lubricated special bearing. The pump housing is
The pump sucks cooled water from the radiator sealed against the bearing with a seal ring. If this
and pumps it through a passage integral with the seal ring leaks, water escapes through a bore in the
pump housing to the cylinder block. After the pump housing (see "c", fig. 1).
coolant has passed the cylinder liners, it flows
through the cylinder head to the thermostat
housing where the thermostat is located. With the
engine hot, the thermostat is open and the coolant
returns to the radiator. If the engine has not yet
reached operating temperature, the thermostat
remains closed; the coolant flows from the mani¬
fold through a by-pass hose back into the water
pump (suction side). In this case it only circulates
through the engine and the pump. This way the
coolant temperature is automatically regulated by
the thermostat. For observing the coolant tempera¬
ture, a temperature gauge is provided on the dash¬
board.
RADIATOR

The radiator is of the conventional design with

cooling tubes through which the coolant passes and
with soldered exterior cores.

The filler neck of the radiator is provided with a

filler cap with built-in relief valve.

THERMOSTAT —
Fig. 1 Water Pump, Sectional View

The thermostat is located in a housing attached to 1 Pump shaft 8Cover

2 V-belt pulley 9Rubber cap
the cylinder head and is available in several types 3 Pump shaft bearing 10Ceramic washer
4 Seal ring 11Fan securing plate
to suit different operating conditions. These ther¬ 5 Pump housing bClearance
mostats open at varying temperatures of the 6 Impeller c Drainhole
7 Seal
coolant (see Specifications).

Printed in Germany
20 Engine Model 2120 Tractor
35-2 Engine Cooling System TM-4252 (Dec-70)

DIAGNOSING MALFUNCTIONS

ENGINE OVERHEATED

Causes see group 5.

WATER PUMP LEAKING

Seal ring or pump shaft worn

COOLANT TEMPERATURE BELOW NORMAL

Thermostat defective

Coolant temperature gauge defective.

ENGINE VIBRATING

Fan blades bent

Pump shaft worn

REPAIR Fig. 2 — Driving Out Ball Bearing With Pump

Shaft, Seal Ring and Impeller, Using
RADIATOR Special Tool No. JD 262
Radiator repairs should only be made in specialised 1Special Tool No. JD 262
repair shops. If radiator leaks and source of leak
cannot be determined visually, proceed as follows: Support pump housing under a press, allowing
sufficient clearance for impeller. Using special tool
Install radiator cap and plug top hose connection. No. JD 262, press bearing assembly together with
Attach pressure air hose to bottom radiator inlet. pump shaft, seal ring and impeller from pump
Submerge radiator in clean tank filled with clear housing (see fig. 2).
water. Put radiator under pressure (see Specifica¬
tions). Check radiator pressure cap, especially NOTE: Instead of the special tool No. JD 262 a
gasket and spring, if still usable. The seal must fit suitable tube section can be used which contacts
tightly and feel soft. Replace unserviceable radiator only the bushing-shaped race of the bearing.
cap.
Press pump shaft with special support bearing and
ADJUSTING FAN BELT seal ring out of impeller, using a press and a
suitable tool. Pull seal ring off the shaft.
For specified flex with a given amount of pull on
the fan belt, see Specifications. NOTE: Remove ceramic washer (see 10, fig. 1)
from the impeller bore, and also remove rubber cap
WATER PUMP 9.

Drain coolant and remove radiator. Remove fan,

V-belt pulley and water pump.

Disassembly of Water Pump

Remove rear cover 8 (fig. 1) and gasket 7. Discard

gasket.

Remove fan securing plate 11 with a standard

puller from the pump shaft.

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Engine Cooling System 35-3

20

Fig. 3 — Water Pump Assembly

3 Gasket 9 Stud 16 Hex. nut

2 Reai cover 10 Pump shaft with bearing 17 Cap screw (2 used)
3 Gasket 11 Elbow 18 Fan securing plate
4 Impeller 12 Pump housing 19 V*beit pulley
6 Rubber cap 13 Cap screw (2 used) 20 Fan belt
6 Ceramic washer 14 Cap screw 21 Fan
7 Special seal ring 15 Cap screw 22 Cap screw (4 used)
8 Adjusting strap 23 Repair set

Checking the Water Pump CAUTION: To do this, use special tool No. JD 262
or a suitable tube section that contacts only the
If coolant drains from bore "c" during operation bushing-shaped race of the bearing (see fig. 2).
(see fig. 1), this generally indicates a faulty seal
ring 4 (fig. 1). Install special seal 7 (fig. 3) in pump housing, open
side facing upward (see fig. 1).
Check all parts for wear and replace, if necessary.
Apart from the various spare parts (see fig. 3), a Install ceramic washer in rubber cap so that un¬
repair set is available (see 23, fig. 3), consisting of polished side of washer provided with a V-groove
ceramic washer 6, special seal ring 7, and pump faces the rubber cap. Make sure that all parts are
shaft 10 with bearing. dry and clean.

Check rubber cap 5 and replace, if necessary. Dip rubber cap and ceramic washer in oil and insert
in impeller bore (rubber cap should bottom on
Assembly of Water Pump bore). The ceramic washer should be flush with the
impeller face.
Place pump housing (open side first) on a press and
drive bearing assembly with pump shaft into pump
housing until bearing face is flush with the hub
face.

Printed in Germany
20 Engine Model 2120 Tractor
35-4 Engine Cooling System TM-4252 (Dec-70)

After installation in the impeller, the folded por¬ Attach pump cover to pump housing, using a new
tion of the rubber cap should equally surround the gasket, and tighten cap screws to the specified
ceramic washer. torque. Install water pump, placing a new gasket
between pump cover and cylinder block. Tighten
screws to the specified torque.

Install radiator.

INSPECTING THERMOSTAT

If the engine remains too cool (possibly due to the

thermostat not closing properly or leaking) or gets
too hot (due to the thermostat not opening), check
thermostat thoroughly. If no exterior damage or
defects can be found, place thermostat in hot
water of suitable temperature (see opening tempe¬
ratures, Specifications) and observe whether the
valve starts to open properly.

CAUTION: The opening value applies to normal

altitude. In higher altitudes this temperature is cor¬
respondingly lower. After the thermostat has
cooled off, the valve should close again. If neces¬
sary, check against a new thermostat. If in doubt,
do not hesitate to replace the thermostat.
Fig. 4 — PressingImpeller on Pump Shaft and
Checking Clearance from Housing Sealing
Face.
Place pump housing with shaft installed under a
press and support on pump shaft.

Press impeller on pump shaft until clearance "b"

(fig. 1), within a given tolerance, is flush with the
pump housing face (see Specifications).

Check this clearance by means of a perfect straight

edge (see fig. 4).

Place water pump under a press so that the thrust

from pressing on the fan securing plate 18 (fig. 3)
is received only by the pump shaft face.

Place fan securing plate on pump shaft with the

plate hub facing the press. Press on to shaft until
shaft face is flush with hub face (see fig. 1).

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Engine Cooling System 35-5

RADIATOR

Capacity of cooling system ..............

Relief valve of radiator filler cap opens
at a pressure of
SPECIFICATIONS

2.3 Imp. (2.75 US) gals

6.25 to 7.5 psi

10.5 lit.

0.44 to 0.53 kg/cm2

Radiator test pressure 7 psi 0.5 kg/cm2

THERMOSTAT

....
Thermostat for hot climate or permanent
full load operation opens at

.....
Thermostat for normal operation opens at

Thermostat for light operating conditions

opens at
180° F

194° F

205° F
82oC

90° C

96° C

WATER PUMP
Clearance between impeller and cover
(see fig. 1, dim. "b") . +0.005 in. +0.12 mm

FAN BELT
The fan belt should have 0.75 in. (19 mm) flex with 20 lbs (9 kg) pull midway between crankshaft and
generator or water pump (use a spring scale).

TORQUES FOR HARDWARE

.......
Flanged cover to thermostat housing 20 ft.lbs. 2.75 mkg
Cover to water pump housing 35 ft.lbs. 4.8 mkg

Fan to securing plate . . 20 ft.lbs. 2.75 mkg

........
SPECIAL TOOLS
Part number if ordered from

JD Parts Depot Manufacturer Description Use

L 48535 JD 262* . Special tool Installation and removal of pumpshaft bearing

* SERVICE TOOLS INC., 1901 INDIANA AVENUE, CHICAGO, ILLINOIS 60616, USA

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Speed Control Linkage 40-1

Group 40
SPEED CONTROL LINKAGE

GENERAL INFORMATION REMOVAL AND DISASSEMBLY

The desired speed is selected by means of the hand HAND THROTTLE ASSEMBLY
or foot throttle. The position of these levers con¬
trols — through the governor on the injection Remove right-hand cowl.
pump — the amount of fuel being injected into the
cylinders.

The hand throttle shaft is self-locking: two spring-

loaded friction disks keep the hand lever in the
position selected.

With engine running at slow idle speed, the stop 4

(fig. 1) of the hand throttle contacts the dash¬
board. When turning the hand throttle in a clock¬
wise direction to its stop, stop screw 2 contacts the
dashboard, and engine speed is increased to
maximum rpm.

The engine is stopped by means of a shut-off cable.

One end of the cable is connected to the injection
pump stop lever, the other to a knob in the dash¬
board.

CAUTION: Never stop engine by turning off the

fuel shut-off valve. Otherwise injection pump will
run dry and the internal parts will be damaged.

Fig. 1— Removing Hand Throttle Assembly

1 Hand throttle 10 Groove pin
2 Fast idle stop screw 24 Connecting rod
4 Slow idle stop screw 28 Spring pin
5 Groove pins

Printed in Germany
20 Engine Model 2120 Tractor
40-2 Speed Control Linkage TM-4252 (Dec-70)

NOTE: Numbers behind parts in the following text Drive groove pin 10 out of stop 12 and hand
refer to figs. 1and 2. throttle. Push down stop 12 and spring 7 and drive
both groove pins 5 out of hand throttle.
Disconnect rod 24 from arm 27 and speed control
arm 22. Lift hand throttle out of dashboard and remove all
parts located on throttle.
Drive out spring pin 28 securing arm 27 to hand
throttle 1and remove arm.

L453PS A

Fig. 2 — Parts of Hand Throttle Assembly

1 Hand throttle 8 Washer 15 Hex. nuts 22 Speed control arm
2 Fast idle stop screw 9 Bushing 16 Swivel 23 Retainer
3 Bushing 10 Groove pin 17 Speed control rod 24 Connecting rod
4 Slow idle stop screw 11 Jam nuts 18 Cotter pin 25 Clip
5 Groove pins 12 Stop 19 Washer 26 Spring pin
€ Friction disks 13 Upper disk 20 Shaft 27 Arm
7 Spring 14 Lower disk 21 Bushing (2 used) 28 Spring pin

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Speed Control Linkage 40-3

FOOT THROTTLE SHAFT WITH ARM 20 AND SPEED CONTROL

ROD 17 (Fig. 2)

NOTE: On tractors with foot throttle, the speed

control arm 12 (fig. 3) is connected by means of
spring pin 26.

On tractors without foot throttle, the speed

control arm 22 (fig. 2) is attached to the shaft with
arm 20 by means of the spring pin 26.

Disconnect linkage, remove lever and arm from

shaft and withdraw shaft from its two bushings on
left-hand side of tractor.

SHUT-OFF CABLE

Disconnect shut-off cable from injection pump and

dashboard. Remove shut-off cable.

Fig. 3 — Parts of Foot Throttle Assembly REPAIR

1 Foot throttle 9 Washer Inspect rods and levers of speed control linkage for
2 Cap screw 10 Cotter pin
3 Washer 11 Clevis cracks or distortion. Check linkage for binding,
4 Spacer 12 Speed control arm excessive play or any damage which could result in
5 Rod 13 Return spring
6 Jam nut 14 Speed control arm insufficient engine performance.
7 Yoke 15 Snap ring
8 Headed pin 26 Spring pin

ASSEMBLY AND INSTALLATION

Remove parts of foot throttle as shown in fig. 3.
For assembly and installation of speed control
linkage, reverse removal procedure as shown in fig.
1through 3.

Printed in Germany
20 Engine Model 2120 Tractor
40-4 Speed Control Linkage TM-4252 (Dec-70)

ADJUSTING SPEED CONTROL LINKAGE

L.45306

Fig. 4 — Speed Control Linkage

a Angle (welded onto dashboard) 6 Rod of foot throttle
1 Hand throttle 7 Foot throttle
2 Fast idle stop screw 12 Stop
4 Slow idle stop screw 17 Speed control rod

NOTE: Before adjusting engine speed, make sure master gauge. The respective engine speeds are
engine has reached its normal operating tempera¬ indicated in section 10, group 5.
ture. The engine speed at any one moment will be
shown on the tractor tachometer. For a more All speeds indicated apply to an engine not under
accurate examination it is recommanded to deter¬ load. The maximum permissible speed variation is
mine powershaft speeds by means of a commercial ±20 rpm.

Printed in Germany
Model 2120 Tractor Engine 20
TM-4252 (Dec-70) Speed Control Linkage 40-5

Make all speed adjustments in the order shown 5. Move hand throttle clockwise to the stop (fast
below. idle speed). The engine speed should now be 2650
rpm.

If this is not the case, adjust fast idle stop screw 2

(fig. 4) located in stop 12 (fig. 4) of dashboard
accordingly.

Adjusting Foot Throttle

6. Depress foot throttle until it contacts the foot-

rest. Engine speed should now be 2650 rpm.

If this is not the case, adjust effective length of

foot throttle rod 6 (fig. 4) accordingly.

Adjusting Shut-Off Cable

7. Completely push in shut-off knob and make

sure there is no gap between shut-off lever of pump
Fig. 5 — ROTO DIESEL Injection Pump, Installed and its stop. If shut-off lever is not in contact,
disconnect steel cable at injection pump and pull
1 Slow idle stop screw slightly rearward so there will be a gap between the
2 Fast idle stop screw
3 Pump throttle lever knob and the retainer fastened to the dashboard.

Push pump shut-off lever by hand against the stop

1. Disconnect speed control rod at injection and attach steel cable. To check, run engine until

.........
pump. hot. Pull out shut-off knob as far as possible and
make sure engine stops quickly.

.........
2. Move pump throttle lever 3 (fig. 5) against
pump stop screw 2 for fast idle.
SPECIFICATIONS

Now engine speed should be 2650 rpm. Low idle speed '650 rpm.

Fast idle speed 2650 rpm.

If this is not the case, adjust pump stop screw 2 for
fast idle and lead-seal screw.

3. Move pump throttle lever in slow idle position

against the stop screw. Engine speed should now be
650 rpm. If not, adjust pump stop screw 1for slow
idle accordingly.

Adjusting Hand Throttle

4. Make sure speed control rod is still disconnected

from pump throttle lever. Move speed control lever
first clockwise and then counterclockwise to the
stop. Now adjust speed control rod, if necessary, so
that it can easily be attached to the pump throttle
lever when the latter is in that position where the
engine just starts to pick up speed. Then increase
effective length of speed control rod by backing
off the rear hex. nut two full turns. In this posi¬
tion, tighten front hex. nut and attach speed con¬
trol rod to pump throttle lever.

Printed in Germany
TM-4252 (Dec-70)

GROUP 10

Fuel tank

Removal
Repair

.
Model 2120 Tractor

Installation

Repair
......
General information
Removal
Repair
Installation
.....
...
Fuel transfer pump
...
GROUP 5 - DIAGNOSING MALFUNCTIONS

Diagnosing malfunctions

.....
- FUEL TANK, TRANSFER
FUEL FILTERS

....
.....
......
General information
Diagnosing malfunctions

.......
ROTO-DIESEL fuel filter
General information
Repair
Dry-type air cleaner
General information

Oil-bath air cleaner

General information
Repair

GROUP 15

Removal
..

.........
.

- ROTO DIESEL INJECTION PUMP

General information

Disassembly
Repair
Installation and adjustment
Adjusting fuel delivery to
different altitudes
Torques for hardware

Printed in Germany
....
..
.
.
.
CONTENTS OF THIS SECTION

10-4

.......
PUMP,

..
5-2

10-1
10-1
10-1
10-1
10-1
10-2
10-2
10-2
10-2
10-2
10-3
10-3
. . 10-3
10-3
10-4
10-4

10-5
10-5
10-5

15-2
15-3
15-5
15-5
15-5

15-8
15-9
GROUP 25

Repair
—
.....
General information
Removal
Testing
Disassembly
Repair
...
.

Assembly (1st stage)

Adjustment
Assembly (2nd stage)
Installation
Tune-up data
Torques for hardware
Special tools
Fuel System
Diagnosing Malfunctions

FUEL SYSTEM
Section 30

GROUP 20 - ROOSA MASTER INJECTION

NOZZLES

COLD WEATHER STARTING

AIDS

Starting fluid adapter

General information
Repair
Thermostart aid ......
General information

Torques for hardware

.
.
.....
30
5-1

20-1
20-1
20-3
20-5
20-6
20-9
20-9
20-10
20-10
20-12
20-12
20-13

25-1
25-1
25-1
25-2
25-2
25-2
25-2
30 Fuel System Model 2120 Tractor
5-2 Diagnosing Malfunctions TM-4252 (Dec-70)

Group 5
DIAGNOSING MALFUNCTIONS
FUEL NOT REACHING INJECTION NOZZLES ENGINE IDLES POORLY

Fuel filters clogged Air leak in fuel system

Fuel line clogged or restricted Injection nozzles dirty or faulty
Fuel transfer pump pressure too low Incorrect timing
Air in fuel system Automatic advance or injection pump faulty or not
Fuel tank shut-off valve closed operating
Fuel return line restricted Fuel lines clogged or restricted
Water in fuel
Injection pump return line restricted
ENGINE STARTS HARD OR WON'T START Injection nozzle return line clogged

Water, dirt or air in fuel system

Fuel filters clogged ENGINE DOES NOT DEVELOP FULL POWER
Shut-off knob stuck
Fuel lines clogged or restricted Air cleaner restricted
Injection nozzles dirty or faulty Incorrect timing
Injection pump faulty Automatic advance of injection pump faulty or not
Fuel transfer pump faulty operating
Fuel tank shut-off valve closed Fuel filters clogged
Incorrect timing Injection nozzle return line clogged
Injection nozzles faulty or sticking
Injection pump return line restricted
ENGINE STARTS AND STOPS Injection pump housing is not full of fuel
Water in fuel
Water in fuel
Filters clogged
Air in fuel system ENGINE SMOKES BLACK OR GREY
Fuel lines clogged or restricted
Injection pump fuel return line damaged Injection nozzles faulty or sticking
Incorrect timing
Automatic advance of injection pump faulty or not
ERRATIC ENGINE OPERATION operating
Air cleaner element clogged or dirty
Filters clogged
Air in fuel system
Injection nozzles faulty or dirty ENGINE SMOKES BLUE OR WHITE
Fuel lines clogged or restricted
Incorrect timing Cranking speed too low
Water in fuel Incorrect timing
Injection pump fuel return line restricted Automatic advance of injection pump faulty or not
Injection nozzle return line clogged operating
Injection nozzles faulty or sticking
Excessive wear in liners and/or stuck piston rings
Engine does not get hot

Printed in Germany
Model 2120 Tractor Fuel System 30
TM-4252 (Dec-70) Fuel Tank, Transfer Pump, Fuel Filters 10-1

Group 10
FUEL TANK, TRANSFER
PUMP, FUEL FILTERS
FUEL TANK
GENERAL INFORMATION Disconnect rod (see 2, fig. 1) at1 fuel tank. Loosen
rod screws on radiator and swing rod away.
The fuel tank is located in front of the radiator, Remove cap screws 5 on both sides. Loosen both
between the front plate and the two side grille cap screws 9, slide stops backward and lift fuel
screens. The fuel gauge sending unit is attached to tank off tractor.
the right-hand side of the tank. The fuel shut-off
valve is located at the bottom of the tank. The fuel REPAIR
tank filler cap is vented for safety.
Inspect seal rings and other tank parts for
REMOVAL serviceability. When removing fuel gauge sending
unit, take care of the float.
Remove both radiator grilles and hood.
If filler cap is unserviceable, replace only with a
Disconnect line at fuel gauge sending unit (see 8,
genuine JOHN DEERE filler cap.
fig. 1).

Remove air cleaner and hydraulic oil reservoir 7. CAUTION: Cleaning and repairing a fuel tank is
very dangerous. Do not smoke or permit live sparks
Close fuel shut-off valve. or fire of any nature in the vicinity while cleaning
or repairing a tank.
Disconnect fuel inlet line as well as return line 1at
tank. When installing the sending unit, make sure float
can freely move up and down vertically.

NOTE: Description of fuel tank repair

operations see "Fundamentals of Service
- Engines" manual.
INSTALLATION
When installing the fuel tank, reverse removal
procedure. After filling the tank with fuel, bleed
the fuel system.

NOTE: After installing fuel tank and tightening the

four cap screws (see 5, fig. 1), press both fuel tank
$ stops against tank flange. Tank must then be flush
against front axle support. Hold stops in this
position and tighten cap screw 9.

Fig. 1— Installed Fuel Tank

1 Fuel return line 5 Cap crews
2 Rod 6 Radiator
3 Fueltank 7 Hydraulic oil reservoir
4 Front cover 8 Fuel gauge sending unit
9 Cap screws

Printed in Germany
30 Fuel System Model 2120 Tractor
10-2 Fuel Tank, Transfer Pump, Fuel Filters TM-4252 (Dec-70)

REPAIR
TRANSFER PUMP
GENERAL INFORMATION

The fuel transfer pump is a diaphragm-type pump

driven by the engine camshaft and attached to the
right-hand side of the engine.

The pump can be operated manually, e.g. for

bleeding the fuel system. Fuel is fed from the fuel
tank through a line. The pump transfers the fuel
through the dual filter to the injection pump.

DIAGNOSING MALFUNCTIONS

NO FUEL, OR ONLY A LITTLE, FLOWS

Pump primer lever on upper end of stroke

Leaking pump bowl seal ring

Plugged fuel screen inside pump fuel bowl

Clogged fuel inlet line

Fuel line loose or damaged

1 51 527
Loose cover screws on pump

If correction of the above troubles does not Fig. 2 — Fuel Transfer Pump - Exploded View
produce a satisfactory flow, the pump is defective
and must be replaced or overhauled. 1 Bail 10 Spring
2 Bowl 11 Retainer
3 Seal ring 12 Button-head screw (2 used)
REMOVAL 4 Screen 13 Machine screw (6 used)
5 Pump cover 14 Spring washer (6 used)
6 Diaphragm 15 Complete pump
Close fuel shut-off valve at tank. Disconnect fuel 7 Diaphragm spring 16 Cap screw (2 used)
lines. Remove both cap screws and take away 8 Pump body 17 Washer (2 used)
9 Rocker arm and 18 Gasket
complete transfer pump. Plug opening on cylinder bearing parts
block to protect it from foreign matter.
Disassemble transfer pump as shown in fig. 2.
When disassembling, mark pump cover 5 and pump
body 8 for easier reassembly.

Printed in Germany
Model 2120 Tractor Fuel System 30
TM-4252 (Dec-70) Fuel Tank, Transfer Pump, Fuel Filters 10-3

Test all parts for serviceability and replace, if

necessary.

Apart from various parts (see fig. 2) three repair

sets are available:

1. A repair set consisting of parts 3, 6, 7, 10 and 18

(see fig. 2).

2. A repair set for replacing the rocker arm and

u
bearing parts (see 9, fig. 2).

3. A repair set for overhauling the pump, consisting

of parts 1through 14 (see fig. 2), equivalent to the
complete pump 15.

Assemble transfer pump as shown in fig. 2,

observing the following:

1. Make sure diaphragm is engaged in rocker arm.

2. Before installing the pump cover, position Fig. 3 - ROTO-DIESEL Dual Stage Fuel Filter
diaphragm so that it is level by moving rocker arm. Sectional View
Hold lever in this position.
1 Fuel outlet 5 Seal ring 9 Seal ring
2 O-Rings 6 Filter element 10 Stud screw
3. Install pump cover and cover screws. However, 3 Filter cover 7 Seal ring 11 Drain plug
turn in screws so that they just contact the lock 4 Fuel inlet 8 Sediment bowl 12 O-ring (3 used)
washers. Operate rocker arm several times, then 13 Screen
release with a snap to make sure that diaphragm
will not be overstretched when in use. Tighten REPAIR
cover screws crosswise.
NOTE: For proper servicing of dual-stage fuel filter
INSTALLATION see Operator's Manual.
Using a new gasket, attach transfer pump to Replace filter elements or complete cartridges at
cylinder block. Connect lines and open fuel the specified service intervals (see Operator's
shut-off valve. Bleed fuel system. Manual).

If the cartridge of the 1st stage filter with element

FILTERS 6 (fig. 3) is replaced, clean screen 13 and sediment
bowl 8 carefully. New seal rings 5 and 7 will be
ROTO-DIESEL FUEL FILTER supplied with the cartridge. Replace O-rings 2 of
filter cover, if required. Check all other parts for
GENERAL INFORMATION serviceability and replace, if necessary. Before
installing a filter cartridge, tighten stud screw 10
The ROTO-DIESEL dual-stage fuel filter has a 1st fingertight. Check for leakage before starting
and 2nd stage which are connected in series. The operation.
1st stage is provided with a screen for removing
coarse dirt. Both filters have a paper cell filter Bleed fuel system.
element each to retain fine dirt. The fuel flow is
indicated by arrows in fig. 3.

Printed in Germany
30 Fuel System Model 2120 Tractor
10-4 Fuel Tank, Transfer Pump, Fuel Filters TM-4252 (Dec-70)

Dry-type Air Cleaner A restriction indicator 7 located in the outlet

manifold indicates the degree of pollution by
GENERAL INFORMATION means of a red warning signal (see Operator's
Manual).

R36
NOTE: For a detailed explanation of the
dry-type air cleaner see "Fundamentals of
Service — Engines" manual.
REPAIR

NOTE: For servicing and cleaning of dry-

type air cleaner see Operator's Manual and
"Fundamentals of Service — Engines"
manual.

Check air intake line, especially hoses between air

cleaner and intake manifold for proper condition
and tight connections.

CAUTION: Do not operate engine without filter

element or dust unloading valve.

INSPECTING THE AIR INTAKE SYSTEM

After the filter element has been cleaned, check

system for restrictions which could inhibit the free
flow of air. Use a commercial vacuum gauge with a
range of up to 40 in. (1000 mm) water head.
Fig. 4 — Dry-type Air Cleaner
1 Air cleaner housing 11 Hose clamps Proceed as follows:
2 Filter element 12 Hose section
3 Wing nut 13 Pipe
4 Filter cover 14 Hose section Remove starting aid adapter or plug from intake
5 Dust unloading valve 15 Cap screw (2 used) manifold and connect vacuum gauge.
6 Cap screw 16 Adapter
7 Restriction indicator 17 Plug
8 Connector 18 Intake manifold Operate engine at fast idle.
9 Cap screw (2 used) 19 Gasket
10 Air intake neck
If the air cleaner is not restricted, the gauge should
show a vacuum of approx. 14 in. (355 mm) water
Under the influence of the suction generated by head. However, it should not exceed 25 in. (635
the engine, the intake air flows through intake pipe mm). If this happens, the free flow of air is
10 (fig. 4) into the filter, past the fins of filter restricted. Find and remove the cause of
element 2. The filter element fins collect coarse restriction.
dirt which is then stored in dust unloading valve 5.
The intake air now passes through filter element 2
where fine dirt is retained, and is finally sucked in
by the engine.

Printed in Germany
Model 2120 Tractor Fuel System 30
TM-4252 (Dec-70) Fuel Tank, Transfer Pump, Fuel Filters 10-5

OIL-BATH AIR CLEANER Dusty air passes through the center tube into the
oil cup where most of the heavier particles are
GENERAL INFORMATION deposited, forming the sludge. The direction of the
air flow is then reversed, carrying along smaller
particles and oil droplets. Both are trapped in the
oil-saturated wire filtering element.
NOTE: For a detailed explanation of oil-
Qse-MJ bath air cleaner operation see "Funda¬
mentals of Service — Engines" manual.

CAUTION: Open oil-bath air cleaner only with the

engine stopped!

REPAIR

res NOTE: For servicing and cleaning of

oil-bath air cleaner see Operator's Manual
a nd ''Fundamentals of Serv ice — Engines''
manual.

Inspect air intake line, especially hose sections

between air cleaner and intake manifold for proper
condition and air-tight connections.

CAUTION: Do not operate engine with the air

cleaner oil cup loose or removed.

Fig. 5 — Oil-Bath Air Cleaner — Exploded View CHECKING AIR INTAKE SYSTEM
Oil bath air cleaner 8 Pipe See "Dry-type Air Cleaner".
Clamp 9 Hose section
Element 10 Intake manifold
Oil cup 11 Cap screw (2 used)
Cap screws <3 used) 12 Connector
Hose clamps 13 Plug
Hose bend 14 Gasket

The oil-bath air cleaner consists essentially of the

filter body with intake and outlet tubes, the
wiremesh filter element and the removable oil cup
with the oil bath.

Printed in Germany
Model 2120 Tractor Fuel System 30
TM-4252 (Dec-70) ROTO-DIESEL Fuel Injection Pump 15-1

Group 15
ROTO-DIESEL FUEL INJECTION PUMP

13 14

32 31 SO 29 26 27 26 25 24 23
22 21 20 19 IB 17 16 15 42

43658
Fig. 1— ROTO DIESEL Injection Pump — Sectional View

1 Connecting shaft 16 Cap screw 30 Governor cage

2 Drive hub 17 Sliding blades of displacement 31 Flyweights
3 Spring washer pump 32 Pump housing
4 Seal ting 18 Distributor channel 33 Leak-off connector
5 Governor housing 19 Radial bore (quantity depending 34 Shut-off lever
6 Seal on number of cylinders) 35 Governor spring
7 Metering valve 20 Pressure connectors* 36 Speed control lever
8 Metering valve chamber 21 Hollow screw 37 Adjusting screw for
9 Metering channel 22 Race upper idle speed
10 Pump head 23 Cam ring 38 Fuel inlet
11 Pump and distributor 24 Pump piston 39 Filter
rotor 25 Rear adjusting plate 40 Pressure regulating valve
12 Eccentric sleeve of 26 Front adjusting plate sleeve
displacement pump 27 Cam roller 41 Pressure regulating valve
13 Seal 28 Pump shaft piston
14 Rotor of displacement pump 29 Internal chamber of 42 Bleed spring
15 End plate pump housing 43 Automatic hydraulic
speed advance

* In contrast to the above illustration, the pressure connectors of fuel injection pumps installed in John
Deere engines are of the pressure valve type (see fig. 5).

Printed in Germany
30 Fuel System Model 2120 Tractor
15-2 ROTO-DIESEL Fuel Injection Pump TM-4252 (Dec-70)

GENERAL On the other end of the rotor, opposite the two

pump pistons, there is a displacement pump which
The ROTO-DIESEL fuel injection pump is a hori¬
zontally installed distributor pump with
delivers the Diesel fuel, sucked from the fuel filter,
mechanical governor and automatic hydraulic through the metering valve into inlet bore "a", (see
fig. 3) in the pump head, at a pressure which varies
speed advance. The moving parts of the pump are
simultaneously lubricated and cooled by the Diesel with engine speed.
fuel flowing through the pump. No lubricant is
required.

V///////K
Fig. 2 — Fuel Injection Pump Installed
1 Pump housing with f Governor housing
L 48460 J
mounting flange g Speed control lever Fig. 3 — Diagram of Fuel Distribution by Rotor
2 Pump head h Adjusting screw for
3 Fuel pressure lines slow idle speed Action
4 Pump cover i Timing hole cover
5 Fuel supply line k Hex. nuts for attaching Filling the rotor with the Inlet bore in pump head
6 Fuel inlet screen the pump fuel quantity adjusted to Inlet bore in Pump- and
7 Bleed and fuel return 1 Shut-off lever load requirements distributor rotor
line to tank m Bleed plug Fuel supply to cylinder, Outlet bore in pump head
9 Connector w Bleed line fitting adjusted to load require¬ Distributor bore in pump-
10 Hydraulic, automatic ments and distributor rotor
speed advance Pump and distributor Longitudinal bore in pump-
11 Speed control rod rotor and distributor rotor
12 Shut-off cable Pump piston
Pump head

Fuel Pump and Flow Regulation Filling Process (see I, (fig. 3): As rotor 1rotates,
the inlet bore "a" in pump head 3 aligns with the
The diesel fuel for injection is fed to the cylinders inlet bore "b" in the rotor. The fuel coming from
—
— regardless of their number by a single unit. Its the displacement pump reaches the pump piston
pump and distributor rotor is fitted with two chamber through bores "a" and "e" (the flow
opposed pistons controlled by a cam ring. The being regulated by the metering valve) and forces
distribution to the individual cylinders is done by the two pistons 2 apart.
the rotor in conjunction with the pump head (see
fig. 3). This design assures an equal quantity of fuel
being injected into each cylinder at any moment.

Printed in Germany
Model 2120 Tractor Fuel System 30
TM-4252 (Dec-70) ROTO-DIESEL Fuel Injection Pump 15-3

Pumping and Delivery Process (see II, fig. 3): Automatic Adjustment of the Injection Timing
During further rotation of the rotor 1 the inlet (Speed Advance)
bore "a" in the pump head 3 is closed and the
distributor bore "d" in the rotor eventually aligns To facilitate starting and to obtain the best
with one of the 4 outlet bores "c" in the pump possible engine performance over the entire speed
head. Meanwhile the two pump pistons 2 have range, the injection pump is fitted with an
reached the cam so that they move towards each automatic, hydraulically operated, speed advance,
other. The trapped, metered fuel is forced, under (see 10, fig. 2), It is pre-set at the factory.
high pressure, through the bores "e" and "d" in
the rotor and the outlet opening "c" in the pump The speed advance adjusts the timing of the injec¬
head, through the pressure valve and the connected tion in relation to engine speed and load. Due to
pressure line, to the fuel injection nozzle and into the varying pressure of the fuel fed from the dis¬
the appropriate cylinder. placement pump to the working pump piston, the
A pressure valve is located at each outlet in the cam ring rotates in the pump head. The power
pump head (as on in-line type injection pumps) required for rotating the cam is provided by a
where the pressure line leading to the injection piston at the base of the pump housing (see 10, fig.
nozzle is connected. After injection, the pressure 2). The piston is coupled to the cam ring by a bolt.
valve closes again and with its small relief piston A pre-stressed helical spring in the timing control
sucks a quantity of fuel from the pressure line. The operates contrary to the hydraulic movement of
resulting relief in the pressure line causes a quick the adjusting piston. When the engine is started,
and firm shutting of the nozzle needle thus this spring sets the cam for "retarded" injection;
preventing fuel from leaking into the combustion with increasing engine speed the cam ring is rotated
chamber. hydraulically toward "advance". The final position
of the cam ring is reached at a certain engine speed
The quantity of fuel which is needed at any given given by the setting of the adjusting screw. When
moment for each cylinder and combustion cycle is the engine is at a standstill, the spring returns the
regulated by a metering valve which is controlled, cam ring to its starting position.
over speed control rod 11 (fig. 2) and the control
lever "g", by the governor inside the injection
pump housing "f". REMOVAL

In the "engine shut-off" position the metering NOTES:

valve completely cuts the supply of fuel from the
displacement pump to the rotor (for further details Before removing, clean off any dirt from all oil
about speed control and engine shut-off, see section lines, the injection pump and its surrounding area.
20,group40). The unused fuel flows through the Each fuel pressure line must fit the injection pump
pressure regulating valve back to the suction side of and nozzle easily, without stress. Take care not to
the displacement pump. bend the lines when removing them as this may
At idling speed or under load, the transfer pump
reduce their working life. Remove all fuel pressure
lines before removing the injection pump.
feeds more fuel to the metering valve than is
needed for injection. CAUTION: Never pour cold water onto a warm
The excess fuel flows through the pressure regula¬ injection pump. This might cause corrosion of the
ting valve back to the suction side of the displace¬ moving parts of the pump. Never clean the pump
ment pump. A very small amount of this surplus with a steam cleaner.
fuel escapes through the top of the governor
housing "f" (fig. 2) and, together with any air
bubbles the fuel may contain, flows through the
bleed and return line 7 back into the fuel tank.
This ensures both a constant bleeding of all injec¬
tion pump fuel channels and a certain amount of
cooling.

Printed in Germany
30 Fuel System Model 2120 Tractor
15-4 ROTO-DIESEL Fuel Injection Pump TM-4252 (Dec-70)

The complete injection pump can be removed and

installed with the engine in the tractor.

In order to preserve the correct position for the

installation of the injection pump, do not change
the position of the timing gears after removing the
injection pump.

REMOVAL

1. Remove the hood (see Operator's Manual).

2. Turn the crankshaft clockwise, as seen from the
radiator, until No. 1 piston is just before the top
dead center (TDC) of its compression stroke.

CAUTION: Do not mistake exhaust stroke for Fig. 4 — Timing Marks of the ROTO DIESEL
compression stroke. Injection Pump for Adjusting the Injection
Timing
Put the adjusting screw through the bore in the
n Driven disk ol the rotor p Timing mark on snap ring
flywheel housing (see fig. 7) and into the flywheel o Snap ring in pump housing q Timing mark with Identifica¬
bore, as soon as the flywheel has reached the tion letters on driven disk
"TDC" position. In case the crankshaft was turned
beyond "TDC", it should be turned to the left at
least 1/4 of a revolution and then back to the IMPORTANT: When loosening the union nut of a
"TDC" position. This must be done to eliminate fuel pressure line, make sure to hold the injection
timing gear backlash. nozzle (see fig. 8).

3. Remove cover "i" (fig. 2) from the timing hole Plug all open connections on pump, injection
in the injection pump (the cover is lead-sealed and nozzles and fuel lines, preferably with plastic caps
fitted with a gasket). and plugs. Do not use fibrous material.

Make sure that the timing mark "p" (fig. 4) on the 6. Remove cover from mounting hole in timing
snap ring "o" is directly opposite the mark "q" on gear cover.
the driven disk "n" of the rotor; the mark "q" has
the identification letter "A". 7. Remove the three cap screws which secure the
injection pump drive gear to the pump shaft (take
CAUTION; There are other letters on the driven care of the spring washers!).
disk which have no significance. Remove the three hex. nuts "k" (fig. 2) and pull
the complete injection pump backward from the
4. Close the fuel shut-off valve at the tank. three studs.

5. Remove all fuel lines and disconnect speed con¬

trol rod as well as stop cable at injection pump.

Printed in Germany
Model 2120 Tractor Fuel System 30
TM-4252 (Dec-70) ROTO-DIESEL Fuel Injection Pump 15-5

DISASSEMBLY PRESSURE VALVE ASSEMBLY

FUEL INJECTION PUMP If leakage occurs at the connection of pressure

valve and fuel pressure line on pump head, remove
NOTE: Certain external parts which can be easily pressure valve from pump head and replace both
replaced are available as spare parts; (see parts list). copper ring gaskets.

Do not disassemble the ROTO DIESEL injection Remove any defective pressure valves as an assem¬
pump further than necessary for installing available bly. Tighten pressure valves and thus also fuel pres¬
parts, not even for cleaning. Therefore, it is ad¬ sure lines in the pump head to the specified torque.
visable to keep a replacement pump available.

INSTALLATION AND ADJUSTMENT

PRESSURE VALVES
INSTALLING THE INJECTION PUMP
NOTE: Pressure valves (see fig. 5) are only
available as an assembly. Therefore, disassemble a NOTES:
pressure valve only for cleaning.
The outlets for the connection of the fuel pressure
lines are marked on the pump head with letters
"V", "C7", "V" and "W" relating to cylinder No. 1,
3, 4 and 2 in firing order.

The timing gear housing is provided with a boss

(indicator) and an adjusting mark. A mark "O"
identifying the TDC is located on the circumferen¬
ce of the crankshaft pulley (see fig. 6).

Fig. 5 — Pressure Valve — Sectional View

1 Valve body 3 Valve piston
2 Pressure spring 4 Plug

Remove pressure valve assembly from injection

pump head.

Turn plug 4 (fig. 5) out of valve body 1. Remove

piston 3 and spring 2.

REPAIR

INJECTION PUMP

Proper checking of the injection pump, especially

as regards deliveries in various load ranges and the
L 30216
operation of the governor, is only possible if a
special test stand and the appropriate specifications Fig. 6 — Indicator on Timing Gear Housing and
are available. Therefore, do not attempt to Adjusting Marks on Crankshaft Pulley.
disassemble or repair injection pumps, but send
o Adjusting mark on crankshaft pulley
them to the dealer's specialized service shop.

Printed in Germany
30 Fuel System Model 2120 Tractor
15-6 ROTO-DIESEL Fnel Injection Pump TM-4252 (Dec-70)

Installing the Injection Pump with the Pump Drive 4. Set the injection timing accurately (by pivoting
Gear still in the Position of Removal (see "Remo¬ the pump housing) (see "Timing the injection
val"). pump"). Then tighten the mounting nuts to the
specified torque.
1. Remove cover "i" (see fig. 2) on the injection
pump. Turn the drive shaft of the injection pump 5. Install timing cover on injection pump hole and
until the adjusting mark "q" on the driven disk "n" tighten screws to the specified torque. Install
(see fig. 4) lines up with the mark "p" on snap ring mounting hole cover on timing gear cover and
"o" (see fig. 4). tighten securely.

IMPORTANT: The driven disk has several 6. Install and connect all fuel lines, the speed
adjusting marks identified by different letters. control linkage and the stop cable. Bleed the fuel
However, only the mark "q" identified by letter system (see below).
"A" (see fig. 4) is applicable.
Installing Injection Pump with Pump Drive Gear
2. Make sure that No. 1 piston is still on its com¬ Removed
pression stroke at TDC and that the pump gear has
the corresponding position (check the position of 1. Mount the injection pump and secure it with
the dowel against position of slot in hub of pump the three nuts (the position of the rotor is of no
drive shaft). significance).
Insert adjusting screw 1 (fig. 7) through flywheel 2. Mount the drive gear onto the pump shaft hub
housing and into flywheel bore. and make sure that the dowel fits into the groove
in the shaft hub. At the same time adjust the gear
to the injection timing (see section 20, group 25).
Tighten the cap screws to the specified torque.

NOTE: By adjusting the gear to the injection

timing, the rotor of the injection pump is also
turned into the correct position with regard to
injection timing.

3. Adjust (see below) and completely install fuel

injection pump (see items 4-6 above).

ADJUSTING FUEL INJECTION PUMP

NOTE: After having installed the injection pump,

accurately determine the injection timing. For
adjusting, use the marks on the snap ring in the
Fig. 7 — Using Timing Screw for Adjusting TDC
pump housing and on the driven disk of the rotor.
1 Timing Screw
Use the latter mark in conjunction with an iden¬
tification letter referring to No. 1 cylinder.
3. Fit a new gasket onto the pump housing and
slide the housing onto the three studs. Fit pump
shaft hub into drive gear and make sure that the
1. Only if required:
dowel fits into bore in pump shaft hub (can be
judged by means of the three screw holes). Insert —
Turn crankshaft — seen from radiator side clock¬
wise until No. 1 piston is just before top dead
pump housing into bore in cylinder block front
center of its compression stroke (TDC), i.e. both
plate. Screw the gear onto pump shaft and tighten
three cap screws to the specified torque. Finally
valves closed. CAUTION: Do not mistake exhaust
screw the three hex. nuts onto the studs and
stroke for compression stroke. Insert the adjusting
screw 1 (see fig. 7) through the flywheel housing
tighten only finger-tight.
and into flywheel bore as soon as flywheel

Printed in Germany
Model 2120 Tractor Fuel System 30
TM-4252 (Dec-70) ROTO-DIESEL Fuel Injection Pump 15-7

has reached the exact TDC position. If the crank¬ 5. Bleed fuel system and injection pump
shaft was turned beyond TDC, it must be turned thoroughly (see below).
back by at least 1/4 turn and then forward again to
the TDC position. This is necessary to eliminate
timing gear backlash. INSTALLING FUEL LINES, SPEED CONTROL
Remove cover from the pump housing timing hole. ROD AND STOP CABLE

After adjusting and checking the injection timing,

2. Loosen attaching nuts of injection pump and connect the speed control rod to the speed control
pivot pump housing first away from cylinder block lever and the stop cable to the shut-off lever.
as far as the slots allow. Then pivot it back again, Reinstall all fuel pressure lines and tighten to injec¬
but only far enough to place mark "A" on the tion pump head by means of pressure valves (see
driven disk "n" (see fig. 4) exactly opposite the fig. 5). Tighten pressure valves and thus lines to the
mark "p" on the snap ring "o". Re-tighten the specified torque.
three pump attaching nuts to the specified torque.
When tightening injector line nuts, use one hand
3. To check the adjustment of the injection timing and two wrenches, holding the injector pressure
remove timing screw and rotate crankshaft clock¬ screw (see fig. 8). Tighten union nuts just enough
wise two complete tums as seen from the radiator to prevent leaks with the engine running.
until No. 1 piston (radiator side) is near the TDC
of its compression stroke. Insert timing screw into
flywheel bore. Then check position of driven disk
in relation to snap ring (see item 2).
NOTE: When rotating the crankshaft, take care not
to turn it beyond TDC. However, if this should
happen, turn crankshaft in opposite direction by at
least 1/4 turn and then back to TDC. This
eliminates timing gear backlash.

If necessary, correct the timing by pivoting pump

housing in relation to cylinder block. Always pivot
pump housing first in opposite direction before
moving it back in direction for correct adjustment
to eliminate timing gear backlash (see item 2).

4. Re-install and secure cover on injection pump

timing hole. Tighten screws to specified torque. Fig. 8 — Proper Tightening of Injector Line Nut

Tighten hollow screw "w" (fig. 2) of fuel return

line at injection pump to the specified torque.

Printed in Germany
30 Fuel System Model 2120 Tractor
15-8 ROTO-DIESEL Fuel Injection Pump TM-4252 (Dec-70)

BLEEDING INJECTION PUMP AND FUEL CHECKING THE ENGINE SPEED

SYSTEM
After bleeding the fuel system, check the slow and
Always bleed the entire fuel system after installing the fast idle speed; for details see section 20, group
the injection pump. 40. If necessary, re-adjust the speed control device.

NOTE: A new or spare injection pump is not yet

filled with fuel. This is done by operating the ADJUSTING FUEL DELIVERY TO DIFFERENT
priming lever of the fuel transfer pump. ALTITUDES
Loosen the bleed plug on the front (first stage) At high altitudes a Diesel engine draws in less
fuel filter; operate the fuel pump by hand and oxygen than at sea level. If injected fuel quantities
pump fuel through the filter until a solid stream of remain the same as at sea level, the engine gets too
fuel without air bubbles is obtained. Tighten bleed much fuel with incomplete combustion resulting.
plug again. As a result the engine emits too much smoke.

NOTE: If the fuel pump does not deliver and no Stamp the percentage by which fuel delivery should
resistance is felt in the top position of the lever, be reduced into the name plate.
turn the crankshaft a little with the starter to find
a more suitable position for the camshaft.
EXAMPLE: DPA 34 42 410
Loosen bleed plug of 2nd stage filter. Bleed filter Code - 12%
and tighten bleed plug.
CAUTION: Fuel delivery may only be modified by
Loosen bleed plug "m" (fig. 2) on injection pump, a ROTO DIESEL dealer.
bleed and retighten to the specified torque.
The following chart shows the percentage by which
Loosen hollow screw "w" of the bleed and return fuel delivery should be reduced at a given altitude.
line 7 at the pump and after bleeding, re-tighten to
the specified torque.
Percentage at an altitude of
After bleeding, keep the hand lever of the fuel
pump in the lowest position.
0% 0 to 1500 ft. ( 0-450 m)
Loosen the union nut of the pressure line on at 3% 1500 to 2500 ft. (450-750 m)
least two injection nozzles by one turn and turli 6% 2500 to 3500 ft. (750-1050 m)
the crankshaft with the starter until sufficient fuel 9% 3500 to 4500 ft. (1050-1350 m)
without air issues from the connections. 12% 4500 to 5500 ft. (1350-1650 m)
CAUTION; Do not loosen the line more than one
turn. Tighten injector line nut just enough to
prevent leaks with the engine running. When tigh¬
tening the union nut, do not forget to hold the
injector pressure screw as explained above.

Printed in Germany
Model 2120 Tractor Fuel System 30
TM-4252 (Dec-70) ROTO-DIESEL Fuel Injection Pump 15-9

TORQUES FOR HARDWARE

Pump drive gear-to-pump shaft,

cap screws 18 ft.lbs. 2.5 mkg

Injection pump-to-cylinder block

front plate, hex. nuts 18 ft.lbs. 2.5 mkg

Bleed and fuel return line,

hollow screw 9.2 ft.lbs. 1.3 mkg

Fuel pressure lines,

pressure valve 21.5 ft.lbs. 3 mkg

Fuel supply line, connector 21 ft.lbs. 2.9 mkg

Adjusting screw for slow idle

speed, hex. nut 3.3 ft.lbs. 0.45 mkg

Timing hole cover on injection pump,

cap screws 2.5 ft.lbs. 0.35 mkg

Bleed plug 2.5 ft.lbs. 0.35 mkg

Printed in Germany
Model 2120 Tractor Fuel System 30
TM-4252 (Dec-70) ROOSA MASTER Fuel Injection Nozzles 20-1

Group 20
ROOSA MASTER FUEL
INJECTION NOZZLES
GENERAL INFORMATION NOTE: The numbers listed below refer to fig. 1,
unless reference is made to another figure.

The ROOSA MASTER fuel injection nozzle has

several orifices.
The nozzle (see 1, fig. 1) forms an integral unit
with nozzle body 4 from which it cannot be
separated. The injection nozzle is secured in the
cylinder head by three superimposed spring clamps
(see 28, fig. 2) which press on clamp 15, and a cap
screw 25; the contact pressure is limited by spacer
ring 26 and spacer washer 27. The nozzle is sealed
IIW-J
in the cylinder head at its lower end with a carbon
stop seal 2. The top end is sealed with plastic seals
5 and 24. Clamp 15 ensures correct position of the
complete injection nozzle in the cylinder head. The
leak-off line is connected by fuel leak-off boot 20,
which is fitted on the nozzle body and secured
with plastic ring 22 and knurled nut 21.
The Roosa Master injection nozzle works basically
in the same way as a normal spray type nozzle. Its
opening pressure is adjusted by the pressure ad¬
justing screw 14. Valve lift is adjusted by screw 12
located in pressure adjusting screw 14.

The carbon stop seal 2 prevents carbon from

collecting around the nozzle in the cylinder head.
The injection nozzles have five orifices of a
specified diameter (see Specifications).

REMOVAL
Fig. 1— ROOSA MASTER Injection Nozzle
Sectional View REMOVING ONE OR SEVERAL INJECTION
1Spray tip 11Ball washer NOZZLES
2 Carbon stop seal 12 Lift adjusting screw
3 Nozzle valve 13 Lock nut IMPOR TANT NOTES
4 Nozzle body 14 Pressure adjusting screw
5 Plastic seal 15 Location clamp
6 Connection for
injection line
16 Pipe union (male)
17 Nipple
Before removal, carefully remove all dirt from the
18 Fuel pressure line
cylinder head around injection nozzles and blow
7 Seal ring of nozzle
valve guide 19 Pipe union (female) off with compressed air in order to prevent any
8 Nozzle valve guide 20 Fuel leak-off boot dirt entering the cylinders or valve seats. Plug the
9 Adjustable pressure 21 Knurled nut
spring 22 Plastic ring bore in the cylinder head after injection nozzle has
10 Spring seat 23 Leak-off line been removed. Cap fuel line openings as soon as
24 Plastic seal they are removed.

Printed in Germany
30 Fuel System Model 2120 Tractor
20-2 ROOSA MASTER Fuel Injection Nozzles TM-4252 (Dec-70)

Fit protecting caps immediately over the nozzle tip

and the line connection to avoid damage to the
nozzle when handling it.

Do not bend the fuel pressure lines, as this may

affect their durability and breakdowns may occur.
When loosening the fuel pressure line, hold
pressure union of nozzle.

1. Remove hood (see Operator's Manual).

Fig. 3 — Removal of Injection Nozzle by Hand

4. Remove cap screw 25 (fig. 2) from cylinder head

and pull complete injection nozzle from cylinder
k 51503 head by hand (see fig. 3). Should this not be
possible because the nozzle is "set" in the cylinder
Fig. 2 — Injection Nozzle Installed head with carbon deposits, then use special puller
15 Locating clamp 25 Cap screw No. JDE 38 (see fig. 4).
19 Pipe union (female) 26 Spacer ring
20 Fuel leak-off boot 27 Spacer washer
21 Hex.nut 28 Spring clamps

2. Withdraw leak-off hoses from leak-off boots 20

(fig. 2) of injection nozzles to be removed. Turn
knurled nut 21 off boot 20. Remove boot and
withdraw knurled nut 21 with plastic ring 22 (see
fig. 1) from nozzle.

3. Unscrew union 19 (figs. 1and 2) from pressure

union 16, holding the latter firmly with a wrench.

t MM*

Fig. 4 — Removal of Injection Nozzle with

Special Puller No. JDE 38

Printed in Germany
Model 2X20 Tractor Fuel System 30
TM-4252 (Dec-70) ROOSA MASTER Fuel Injection Nozzles 20-3

CAUTION: Do not use screw drivers or similar EXTERNAL CLEANING OF AN INJECTION

tools for this as they might damage the injection NOZZLE
nozzle irreparably.
NOTE: Before testing an injection nozzle with a
As long as the carbon stop seal is in good con¬ nozzle tester, remove both sealing rings and
dition, no carbon deposits will form in the cylinder thoroughly clean the outside of the injection
head bore and the injection nozzle can therefore be nozzle.
removed without using a tool.

REMOVAL OF THE FUEL PRESSURE LINES

NOTES %ÿ ,

£g
j*;5v
.
° ; 'o- 6* *

» <» .,
r?
i, ;- <•
". '

Carefully clean fuel pressure lines, injection nozzles

v

and injection pump before removing lines to

prevent dirt entering the nozzles and pump
through the exposed openings. Plug the openings
immediately with caps or plugs. Each fuel pressure
line is fit to the injection pump and nozzles. Con¬
sequently, do not bend lines when removing them,
as this reduces their durability. Before removing
one or all fuel pressure lines, remove the two
clamps.

IMPORTANT: When loosening the pipe union of Fig. 5 — Removal of Carbon Stop Seal
the fuel pressure line, hold nozzle union firmly.
Remove carbon stop seal from the groove in the
TESTING nozzle body, using suitable pliers (see fig. 5). Pull
upper seal from the nozzle body and discard both
TESTING INJECTION NOZZLE IN ENGINE seals.

Allow the engine to run at high speed under no Place the injection nozzle in solvent or clean Diesel
load. Loosen the fuel pressure line at one of the fuel until the accumulated deposits are saturated.
injection nozzles (so that the fuel escapes at the Clean the body and tip in particular, up to the
line connection and is not forced through the groove for the carbon stop seal, with brass wire
nozzle). If there is no change in the engine's speed, brush No. 16488 provided with special injection
it is a sign that this particular nozzle is not in nozzle cleaning kit, using ample Diesel fuel or
order. Repeat test consecutively at each of the solvent. NEVER USE A STEEL WIRE BRUSH OR
remaining nozzles. A SCRAPER FOR THIS PURPOSE.

Remove faulty nozzle assembly and check CAUTION: When removing the sealing rings and
thoroughly by means of a nozzle tester. when cleaning the nozzle, take care not to damage
the Teflon coating of the nozzle body above the
groove for the sealing ring.

Printed in Germany
30 Fuel System Model 2120 Tractor
20-4 ROOSA MASTER Fuel Injection Nozzles TM-4252 (Dec-70)

TESTING INJECTION NOZZLE WITH NOZZLE Connect the injection nozzle to the tester as shown
TESTER in fig. 6 so that the axis of the injection nozzle
forms an angle of approx. 30° to the vertical, and
NOTES: the spray of fuel is directed downwards and all of
it is collected in the container underneath. Make
Testing the performance of a nozzle while the sure that all connections are leakproof to avoid
engine is running (see above) is just a rough test. false results when testing.
To obtain a true check of nozzle performance, use
a nozzle tester, such as - Robert Bosch, part. No. Close the gauge shut-off valve and flush (bleed) the
EFEP 60 A (see fig. 6) (or from Messrs. Bacharach, nozzle by operating test pump rapidly. Thus, the
see part No. 65-030 D). To connect a nozzle to the nozzle valve, too, will seat.
BOSCH tester, use special tool (fuel pressure line)
No. 19-58-90.577. For connection to the
SPRAY PATTERN TEST
BACHARACH nozzle tester use special tool
(connecting piece) No. 16492.
Close gauge shut-off valve and operate the pump
lever at 60 strokes per minute. If the injection
Use only carefully filtered Diesel fuel for testing
nozzle is working properly, the fuel should issue
the injection nozzles, since dirty fuel will severely
damage the precision parts of a nozzle. through all nozzle orifices in a fine, evenly shaped
spray cone. This spray cone is inclined from the
centerline of the nozzle body, but should be evenly
CAUTION: The nozzle tip must always point away distributed. For a better check, place a piece of
from the operator. The fuel issuing from an orifice paper or cardboard at a suitable distance below the
can penetrate clothes and skin and thus cause nozzle and check the appearance of the damp cir¬
severe infection. It is therefore advisable to direct cular spots made by the fuel. Deviations from the
the jet of atomised fuel into a transparent con¬ regular spray pattern or angle may be due to the
tainer (see fig. 6). complete or partial clogging of a nozzle orifice. In
this case the fuel issues in a jet rather than in a fine
spray.

CHATTER TEST

Make sure nozzle orifices are free. When working

pump of injection nozzle tester at 60 strokes per
minute (gauge shuLoff valve closed), a definite
characteristic "chatter" should be heard. If this is
not the case, the nozzle needle may be bent, or
tight in its guide because of the laquer deposits
which have accumulated. This can be corrected
only by disassembling the nozzle.

TESTING OPENING PRESSURE

NOTE: Absolute opening pressure is less important

than equal opening pressure of all nozzles. Max.
permissible variation see Specifications.

Fig. 6 — ROOSA MASTER Injection Nozzle Con¬

nected to BOSCH Tester

Printed in Germany
Model 2120 Tractor Fuel System 30
TM-4252 (Dec-70) ROOSA MASTER Fuel Injection Nozzles 20-5

Close gauge shut-off valve and actuate the pump FUEL PRESSURE LINES
several times to allow the nozzle needle to seat
properly. Open gauge shut-off valve. Pump the Defects cause irregular running of the engine or
pressure up to the point where the pressure gauge leaks. If in doubt, replace the line.
needle falls rapidly. This point (take reading) is the
nozzle valve opening pressure (minimum pressure DISASSEMBLY
see "Specifications").

If spray pattern, leakage test, and valve wear test

(see below) are good but the opening pressure test NOTE: Disassemble the injection nozzle only when
is unsatisfactory, adjust opening pressure as des¬ necessary, due to faulty operation or as a result of
cribed under "Adjustment". tests on the injection nozzle tester.

CHECKING VALVE SEAT It is not advisable to disassemble a Roosa Master

injection nozzle if the special tools for cleaning and
Connect the nozzle to tester in horizontal position. repair are not available.
Operate the pump lever rapidly to bleed the nozzle
and allow the needle to seat. Dry the tip of the Disassemble the nozzle only in a clean working
nozzle thoroughly. Now operate the pump lever area. Dirt is the worst enemy of injection nozzles.
slowly until the indicated pressure is approx. 2400
psi (= 169 kg/cm2). Keep watching the nozzle. For Place all parts of the injection nozzle immediately
10 seconds no drops should form on the nozzle tip, into a bowl of well-filtered Diesel fuel and leave
although a trace of moisture is permissible. Work there till required for assembly. Just before
the pump lever quickly several times in succession, assembling, rinse all nozzle parts in another pan of
to make the nozzle spray in the normal way. After clean Diesel fuel.
the last stroke of the pump, observe again. If the
nozzle is not quite leakproof, disassemble for CAUTION: Never use a steel wire brush for
servicing. cleaning the nozzle components. They must not be
scratched.
CHECKING VALVE STEM AND GUIDE WEAR

Connect injection nozzle to the nozzle tester with

the tip raised a little higher than its opposite end.
Cover the tip and pump the pressure to 1500 psi
(105 kg/cm2). Keep the pressure constant and
observe how much fuel leaks out of the nozzle
return end. After the first drop has formed, count
the drops for 30 seconds, there should be 4 to 8
drops.

NOTE: If all tests prove that the nozzle performs

properly, no further service is necessary and the
nozzle can be reinstalled (see under "Installation").
An injection nozzle which is not operating
properly must be disassembled for cleaning and/or
reconditioning, as far as possible.

Fig. 7 — Loosening LockNut, Using Holding

Fixture

Printed in Germany
30 Fuel System Model 2120 Tractor
20-6 ROOSA MASTER Fuel Injection Nozzles TM=4252 (Dec-70)

Place the injection nozzle in a vise, using holding

fixture No. 16475 which is supplied with the
special injection nozzle tool kit. Loosen lock nut
13 on the adjusting screws (see fig. 1).

Unscrew and remove spring pressure adjusting

screw 14 and lift adjusting screw 12 from nozzle
body 4. Unclamp nozzle and remove clamp 15.
Invert nozzle and catch in your cupped hand the
parts which will now fall out: ball washer 11,
upper spring seat 10, pressure spring 9 and lower
spring seat 10. If nozzle needle 3 also slips out,
hold it carefully by its stem (see fig. 8) and not by
the end with the nozzle needle seat. Do not bend
needle.

Fig. 9 — Removal of Nozzle Needle Using Special

Tool No. 16481

If the nozzle needle does not slide freely from the

nozzle body when the injection nozzle has been
turned over, use special tool No. 16481 as shown
in fig. 9. Should the needle no longer be in its
deepest position in the nozzle body, first push it
completely into the nozzle body with the aid of
the special tool (clamp holder) to avoid bending
the needle when the tool is applied. Turn the nut
clockwise, slide the tool as far as possible onto the
needle so that the gripping device gets a hold of it,
then turn the knurled nut to the left to secure the
Fig. 8 — Correct Handling of Nozzle Needle
nozzle needle. Remove the needle from the nozzle
body by carefully pulling the tool.
IMPORTANT: If several injection nozzles are
disassembled at the same time, make sure that the Completely unscrew stroke adjusting screw 12
nozzle needles and nozzle bodies are not mixed up. from spring pressure adjusting screw 14 with small
When assembling, the nozzle needle must be in¬ screw driver No.16504 which is provided with the
stalled into the same nozzle body from which it special nozzle tool kit.
was taken.
REPAIR

CLEANING INJECTION NOZZLE PARTS

Injection Nozzle Body

Carefully remove all carbon deposits from the
nozzle tip and the groove for the lower sealing ring
with solvent or clean Diesel fuel and brass wire
brush No. 16488 which is supplied with the special
nozzle tool kit. Never use a steel wire brush for this
purpose.

Printed in Germany
Model 2120 Tractor Fuel System 30
TM-4252 (Dec-70) ROOSA MASTER Fuel Injection Nozzles 20-7

Check the tip of the nozzle with magnifying glass Rinse the nozzle body and check nozzle tip for
No. 16487, supplied with the special nozzle tool damage and wear. If only one of the nozzle orifices
kit, for cracks, and check the nozzle orifices for is chipped or corroded, the spray pattern will be
chipped edges. affected. Replace complete injection nozzle.

Fig. 11 — Cleaning Nozzle Needle Seat in Nozzle

Body with Special Tool No. 16482

Fig. 10 — Cleaning Nozzle Orifices Insert special tool (scraper) No. 16482, supplied
with the tool kit up to the needle seat and rotate it
Clamp one of the 0.008 in. (= 0.20 mm) diameter several times in order to remove carbon deposits
nozzle cleaning needles No. 16484, supplied with which may stick near the seat.
the special tool kit, into clamping holder No.
16483, also supplied with the tool kit, allowing
only about 0.03 in (= 0.8 mm) to protrude.

CAUTION: If the needle protrudes further, it

might break off and get stuck in the nozzle orifice
from which it is very difficult to remove.

Remove, by grinding on emery stone No. 16490,

any burr which may have formed on the cleaning
needle when it was cut. Stoning the wire to provide
a flat surface is helpful for removing carbon
deposits from a clogged orifice.

Insert the cleaning needle into each of the nozzle D*0032

orifices and remove carbon deposits by turning the
holder.
Fig. 12 — Cleaning the Sac Hole in Nozzle Body
CAUTION: Each nozzle bore forms a different with Special Tool No. 16476
angle to the longitudinal axis of the nozzle. When
this cleaning needle moves freely through all ori¬ Insert tool with drill No. 16476, supplied with the
fices, repeat the process with wedge-shaped tool kit into the sac hole in the nozzle body, and
bevelled needle No. 16485 of 0.010 in. rotate the tool several times to remove any carbon
(=0,25 mm) diameter. Use magnifying glass No. deposits which may be adhering. Clean all nozzle
16487, Supplied with the tool kit, for this cleaning orifices as described above.
operation.

Printed in Germany
30 Fuel System Model 2120 Tractor
20-8 ROOSA MASTER Fuel Injection Nozzles TM-4252 (Dec-70)

Nozzle Needle and Seat

Fig. 14 — Polishing Valve Guide Area

Fig, 13 — Cleaning Nozzle Valve Tip with Brass 2. Insert needle into the body. When the long part
Wire Brush No. 16488 of the needle slides through the nozzle valve guide,
it might rub a little. However, this will not affect
In order to remove the carbon deposits from the the correct operation of the nozzle. Hold the
nozzle valve tip and its vicinity, clean the nozzle needle with special tool No. 16481 (see fig. 9) and
valve tip with brass wire brush No. 16488 (see fig. rotate it in the nozzle body by turning the tool by
13) supplied with the tool kit. Rub off varnish hand. After every three or four turns raise the tool
deposits with felt pad No. 16544, using plenty of and the needle a little (see fig. 14). This lapping
solvent or Diesel fuel. may be completed after 10 to 20 turns.

CAUTION: Do not clamp the nozzle needle into a CAUTION: Never use a motor driven chuck for
motor driven device, this operation.

Examine the surface of the needle where it fits into 3. Before reassembly, wash the nozzle needle and
the nozzle body for scratches which would cause body thoroughly in Diesel fuel.
sticking. This part of the needle is usually polished
on one side during operation. Visible marks are Seat leakage may be caused by several factors such
normal. If an injection nozzle produces spotty as: dirt, carbon deposits or a resinous laquer-like
chatter while it is being tested or if there is coating in the seat area; stoppage in the movement
evidence that the needle is sticking in its guide and of the needle because it is bent or is sticking in the
if there is too little fuel leakage while testing the guide.
wear of the needle stem (see above), the nozzle
can be corrected by polishing the valve guide area If it is evident that the leakage from the nozzle is
as follows: not due to the above defects, examine the surface
of the needle for fine scratches or damage. If
1. Apply a small quantity of No. 16489 special evident, they may be removed by using No. 16489
polishing paste, supplied with the injection nozzle special polishing compound provided in the tool
tool kit, to that part only of the nozzle needle kit. Apply a small amount of No. 16489 special
coming into contact with nozzle valve guide 8. Do paste to the tip (seat) of the nozzle needle and
not use any other compound for this purpose. insert the needle into the body. Fix special tool
No. 16481 to the needle (see fig. 9) and lap the
needle by hand with a rotary movement of the
tool. A very slight polishing (three to five turns by
hand) is enough to lap the seat surface.

Printed in Germany
Model 2120 Tractor Fuel System 30
TM-4252 (Dec-70) ROOSA MASTER Fuel Injection Nozzles 20-9

CAUTION: Too much lapping will cause an Screw lift adjusting screw 12 into spring pressure
undesirable extension of the effective sealing adjusting screw 14 until slotted end of screw is
surface between nozzle and body. This prevents roughly flush with hex. head of spring pressure
the normal "chattering" and results in uneven adjusting screw. Screw lock nut 13 completely
spraying. onto spring pressure adjusting screw 14. Hold both
screws in such a way that the pointed end of the
lift adjusting screw faces upward and insert in
VALVE ADJUSTING MECHANISM succession, as per fig. 1, ball washer 11, upper
spring seat 10, pressure spring 9 and lower spring
Make sure the stroke adjusting screw 12 is not seat 10. Tilt nozzle body, as shown in fig. 15
bent. A bent or otherwise damaged adjusting screw (CAUTION: Do not allow the needle to slide out),
must be replaced with a new part. Also check that and screw the adjusting screw 14, together with the
spring pressure adjusting screw 14 is still usable. internal parts completely into the body (normally
Replace if necessary. Check if the remaining 10 complete turns). Use care not to dislodge the
components - both spring seats 10, pressure spring spring seats and spring.
9, ball washer 11, lock nut 13 and clamp 15 - are
still usable; if necessary, replace them.
ADJUSTMENT
ASSEMBLY PREPARATIONS

STEP 1 Clamp the injection nozzle in a vise, using tool No.

16475 provided with the nozzle tool kit and loosen
Slip locating clamp 15 over nozzle body with bent lock nut 13 on the adjusting screw (see fig. 7).
ends down. Rinse the needle in well-filtered Diesel
fuel and insert it into the body.
Loosen lift adjusting screw 12 by at least two turns
CAUTION: Use greatest care when handling (counterclockwise).
needle.
Connect the injection nozzle to the tester (as
shown in fig. 6) so that its centerline forms an
angle of approx. 30° with the vertical. Make sure
that the connections do no leak.

Close gauge shut-off valve and operate the pump

several times quickly, thus flushing the nozzle
thoroughly (bleeding). This will seat the needle.

CAUTION: The nozzle tip must always face away

from the person operating the tester. The fuel
issuing from an orifice can penetrate clothes and
skin, causing serious infection. It is, therefore,
advisable to direct the spray into a transparent
container (see fig. 6).

ADJUSTING OPENING PRESSURE

3ÿ0175
NOTE: When setting nozzle opening pressure, it is
Fig. 15 — Assembly of Injection Nozzle desirable to adjust opening pressure toward the
high rather than the low limit.

Repeat measuring process to obtain proper result.

Printed in Germany
30 Fuel System Model 2120 Tractor
20-10 ROOSA MASTER Fuel Injection Nozzles TM-4252 (Dec-70)

Open the gauge shut-off valve on the tester, and, ASSEMBLY

while operating the pump, turn pressure adjusting
screw 14 in or out until correct pressure is ob¬ STEP 2
tained (see Specifications).
IMPORTANT: Each time an injection nozzle is
To increase pressure, turn the spring pressure removed from the cylinder head, replace carbon
adjusting screw in. If less pressure is required, turn stop seal 2 (fig. 1), with a new one, otherwise car¬
it out. Close shut-off valve of tester and operate bon deposits may settle in the cylinder head bore,
pump lever several times quickly, thus opening and making it considerably more difficult to extract
closing the nozzle needle repeatedly. Open the the injection nozzle.
shut-off valve again and check the opening
pressure; correct if necessary.

ADJUSTING VALVE LIFT

Carefully insert lift adjusting screw 12 into spring

pressure adjusting screw 14 until screw 12 bottoms
on needle 3. Test bottoming as follows: Raise
pump pressure above opening pressure. There
should be no valve action. Turn adjusting screw 12
counter-clockwise by 1/2 turn for proper valve lift.
(see Specifications). Tighten lock nut 13, while
holding spring pressure adjusting screw 14 in
position. Then recheck the opening pressure and
correct, if necessary.

NOTE: If the nozzle does not produce the L 51504

characteristic chatter sound, after carrying out the
cleaning and repair operations, the value parts may Fig. 16 — Installing Carbon Stop Seal and Sealing
not be properly aligned. Washer
2 Carbon stop seal a Pilot tool No. 16477
5 Top plastic seal b Nozzle cap
To correct this, screw spring pressure adjusting 24 Sealing washer
screw 14 in and out several times. Then reset
needle lift as described above. Slide top plastic seal 5 followed by sealing washer
24 onto nozzle body (see fig. 16). Place No. 16477
Repeat check on the "chatter sound". pilot tool provided with special nozzle tool kit, on
tip of nozzle and slide new carbon seal 2 over
Remove nozzle from tester, clamp it in a vise, with nozzle body until it fits properly into the groove.
No. 16475 special tool (see fig. 7) and tighten lock
nut 13 to the specified torque. Install torque NOTE: If a No. 16477 pilot tool is not available, a
wrench adapter No. 16478, provided with special nozzle cap (fitted to every new nozzle) will do,
tool kit, in torque wrench and use for this while the carbon stop seal is being fitted.
operation. When tightening lock nut 13, hold
spring pressure adjusting screw 14. To prevent
damage, protect the nozzle with a cap. INSTALLATION

INSTALLING ONE OR SEVERAL INJECTION

NOZZLES

NOTE: If the injection nozzle cannot be removed

by hand from the cylinder head, it is likely that
carbon deposits have formed in the cylinder head
bore. To clean, remove the cylinder head (see
section 20). Remove oil carbon from cylinder head
bore with special tool No. JDE 39.

Printed in Germany
Model 2120 Tractor Fuel System 30
TM-4252 (Dec-70) ROOSA MASTER Fuel Injection Nozzles 20-11

CAUTION: Always turn the tool clockwise INSTALLING THE FUEL PRESSURE LINES
through the bore even when pulling back,
otherwise tool will get dull. NOTE: When installing one or all fuel pressure
lines, reverse removal procedure (see "Removal").
Then blow out bore with compressed air.
Blow compressed air through new lines before
installation. Insure that each line fits easily to the
Make sure that the sealing surface of the cylinder pump body and the appropriate injection nozzle. If
head, on which the seal washer 24 will be resting, is it does not, adjust the line very carefully. Tighten
smooth and free of damage or dirt which could pipe union on each pressure line with one hand,
prevent proper sealing. Dirt and roughness could using two wrenches. Hold male union with a
cause distortion to nozzle when the attaching wrench, see fig. 17. Do not tighten more than
screw is tightened, making the valve stick. necessary to stop fuel leaks.

CAUTION: Before installing the injection nozzle,

make sure nozzle is clean and free from oil or
grease. Do not grease or oil the nozzles.

Remove plug from cylinder head bore and insert

nozzle into the cylinder head with a twisting
motion. Fit the forked end of clamp 15 over the
nozzle connecting piece and place spacer washer 27
and spacer ring 26 (see fig. 2) on the cylinder head.
Slide washer and three spring clips over cap screw
25 and screw the cap screw into the cylinder head,
(see fig. 2), but only finger tight. Connect the fuel
pressure line and lightly tighten union for bleeding;
tighten cap screw 25 to the specified torque.

When all injection nozzles are installed, slide

Fig. 17 — Tightening Pressure Lines
knurled nuts 21 and seal washers 22 (see fig. 1)
over nozzle bodies. Screw T-boots 20 into knurled
Bleeding the Fuel System (see also Operator's
nuts and tighten. Connect leak-off hoses to boots
(see figs. 1and 2). Manual): Set the hand throttle to medium speed.
Turn crankshaft with starter until fuel lines to the
injection nozzles are bled.

Only when air bubbles stop issuing from the loose

line connections, and not before, tighten pipe
union on each pressure line as described above.

Start up engine and check for leaks.

Printed in Germany
30 Fuel System

Opening pressure

..
20-12 ROOSA MASTER Fuel Injection Nozzles

Number of nozzle tip orifices

Diameter of nozzle tip orifice

Sac hole diameter

Opening pressure of a new or reconditioned

nozzle with a new spring

Opening pressure of a used nozzle which is

to be checked, minimum

Opening pressure to be adjusted on a

reconditioned nozzle (adjust to higher value)
SPECIFICATIONS

....................
.........
Max. opening pressure difference between cylinders

Nozzle Valve Lift

Turning valve lift adjusting screw (based

on zero valve lift) 1/2 turn counterclockwise
corresponds to a valve lift of

Spray Pattern Test

Lock nuts of adjusting screws

for Leakage
.........
2950-3050 psi

2750 psi

2750-2850 psi
5

0.012 in.

0.042 in.

100 psi

0.009 in.

With the gauge shut-off valve closed, work pump lever at 60 strokes per minute

Chatter Test
Model 2120 Tractor
TM-4252 (Dec-70)

206-214

7
0.25 mm

1.067 mm

kg/cmÿ

193 kg/cm2

193-200 kg/cmÿ
kg/cmÿ

0.229 mm

If the nozzle tester pump is worked at 60 strokes per minute, with the shut-off valve closed, a charac¬
teristic chatter should be heard.

Checking Nozzle Valve Seat

Operate pump lever slowly until gauge indicates a pressure of 2400 psi (169 kg/cm2). Observe nozzle: no
drop should form on the nozzle tip within 10 seconds.

Checking Valve Stem and Guide Wear (Fuel Leakage)

Pump the pressure to 1500 psi (105 kg/cmÿ) and maintain. Count drops for 30 seconds after first drop
has formed at rear end of nozzle; there should be from 4 to 8 drops.

..................
.............
TORQUES FOR HARDWARE

Injection nozzle to cylinder head, cap screw

Printed in Germany
70-75 in.lbs.

20 ft.lbs.
80-85 cmkg

2.8 mkg
Model 2120 Tractor Fuel System 30
TM-4252 (Dec-70) ROOSA MASTER Fuel Injection Nozzles 20-13

SPECIAL TOOLS
Part No. if ordered from
JD Parts Depot Manufacturer Description Use

65-030 D** ... BACHARACH nozzle tester Testing injection nozzles

EFEP 60 A BOSCH nozzle tester Testing injection nozzles
1958-90.577 . Pressure line Injection nozzle to BOSCH
tester
L 48544 JDE 38* Sliding hammer puller Removing nozzles
L 48545 JD 39* Cleaning tool Cleaning cylinder head bores
for nozzles
L 48546 16494* 1set of tools Servicing nozzles
L 48554 16487* Magnifying glass Checking nozzle parts
L 48555 16475* Special holding fixture Clamping complete nozzle
in a vise
L 48556 16484* 5 nozzle cleaning wires Cleaning nozzles
(0.008 in. = 0.20 mm dia.)
L 48557 16485* 5 nozzle cleaning wires Cleaning nozzles
(0.01 in. = 0.25 mm dia.)
L 48568 16476* 2 Sac hole drills Cleaning nozzle sac hole bore
L 48569 16482* Scraper Cleaning nozzle valve seat
L 48570 16490* Honing stone Flattening nozzle valves
16544* Felt cleaning pad (not available
individually) Cleaning nozzle valves
L 48571 16483* Pin vise Holding nozzle cleaning wires
L 48572 16504* Screwdriver Adjusting needle stroke
L 48573 16488* Brass wire brush Cleaning nozzle parts
L 48574 16481* Valve retractor Pulling nozzle valve
L 48576 16478* Special adapter for torque wrench Tightening lock nuts of
adjusting screws
L 48577 16492* Connector Injection nozzle to
BACHARACH tester
L 48578 16489* 1can of special polishing compound Lapping nozzle valve in
nozzle body
L 48531 16477*
JD 258* Pilot tool Installing carbon stop seal
16493* Tool kit case (not available
individually) Tool storage

* SERVICE TOOLS INC., 1901 INDIANA AVENUE, CHICAGO, ILLINOIS 60616, USA
** BACHARACH INDUSTRIAL INSTRUMENT CO., 200 NO. BRADDOCK Ave., PITTSBURGH 8,
PA., USA

Printed in Germany
Model 2120 Tractor Fuel System 30
TM-4252 (Dec-70) Cold Weather Starting Aids 25-1

Group 25
COLD WEATHER STARTING
AIDS
STARTING FLUID ADAPTER To facilitate engine starting in cold weather, the
tractor can be equipped with an adapter for in¬
jecting starting fluid (from a pressure can).
GENERAL INFORMATION
When starting the engine, this adapter is used for
injecting a volatile starting fluid from pressure can
13 (fig. 1) into the intake manifold and thus into
the combustion chamber of the cylinders.

To use the starting aid, unscrew adapter cap 12 and

press the head of the spray can into the bore of
adapter 10 of the pressure line.

CAUTION: Do not run engine if cap 12 is not in

position.

REPAIR
Take off right-hand cowl; remove all starting aid
parts as shown in fig. 1.

Check all parts for serviceability.

When cleaning the spray nozzle 5, make sure that

the bore is not enlarged or damaged.

Install all starting aid components as shown in fig.

CtHUlMt
'®MN DII** 1. Install nozzle holder 4 so that the spray nozzle 5
ÿar»No fiu'O points upward (see fig. 1). An arrow stamped into
one of the hexagonal faces of the nozzle holder
will indicate the position.
Fig. 1— Parts of Starting Fluid Adapter NOTE: Threads on spray nozzle and nozzle holder
1 Pressure line 8 Connector are self-sealing; use no sealing compound or seal.
2 Hollow screw 9 Seal ring
3 Seal rings 10 Adapter
4 Nozzle holder 11 Seal
5 Spray nozzle 12 Cap
6 Hose section 13 Pressure can with
7 Hex. nut spray fluid

Printed in Germany
30 Fuel System Model 2120 Tractor
25-2 Cold Weather Starting Aids TMÿ4252 (Dec-70)

THERMOSTART AID This is how the "Thermostart" device works: Fuel

from the leak-off line is fed to the fuel reservoir 1
(fig. 2), located above the cylinder head. This reser¬
voir is constantly kept full; surplus fuel returns to
GENERAL INFORMATION
the fuel tank. To operate, push switch 21. Current
then flows through leads 19 and 18 to a filament
inside the burner 17, located in the intake mani¬
fold. As the filament heats up, a heat-sensitive
valve (also installed in the burner) opens, allowing
fuel to enter the burner through fuel line 15.

—1 The hot filament ignites the fuel which heats the

air in the intake manifold, thus providing the
engine with preheated intake air for easy starting.

REPAIR
Remove hood and cowl side panel.

Remove parts of Thermostart aid as shown in fig.

2.

When removing push button switch 21, disconnect

ground cable from negative (-) pole of batteries.
23

15 22
Check all parts for serviceability and replace, if
21 necessary.

Install all parts as shown in fig. 2. When installing

Thermostart burner 17, coat threads of burner
with a suitable sealant and tighten burner to the
specified torque.

CAUTION: Before operating Thermostart aid for

the first time after installation, make sure fuel
Fig. 2 — "Thermostart" - Exploded View reservoir is filled to prevent damage to the Ther¬
1 Fuelreservoir 14 Hollow screw mostart aid.
2 Hollow screw 15 Fuel line to burner
3 Sealing washers 16 Hose nipple
4 Cover 17 Burner TORQUES FOR HARDWARE
5 Gasket 18 Wire from push
6 Hose connections button switch to
7 Fuel hose to reservoir burner Thermostart burner
8 Clamp
9 Cap screw
10 Fuel return hose
19

20
Wire from main switch
to push button switch
Wire clamp
in intake manifold . 14.5 ft.lbs 2 mkg
to tank 21 Push button switch
11 Hex. nut 22 Button-head screw
12 Bracket 23 Washer
13 Cap screw

Printed in Germany
 Model 2120 Tractor Electrical System 40
TM-4252 (Dec-70) Diagnosing Malfunctions 5-1

Section 40
ELECTRICAL SYSTEM
CONTENTS OF THIS SECTION
GROUP 5 - DIAGNOSING MALFUNCTIONS Page
Page
Controls and instruments 10-5
Batteries
Alternator
Tests and diagnosis on
tractor
Generator
Controls
Starter
.
5-1
5-2

5-2
5-3
5-4
5-4
lights ....
Cables and wires
Wiring diagrams
Electrical system without turn-signal

General information on repair

Checking main switch
.... 10-13
10-5
10-6

10-13

10-14

......
Checking circuit fuses 10-15
Head lights 5-4 Checking engine oil pressure
Cigar lighter 5-4 warning switch 10-15
Checking fuel gauge sending unit . . . 10-15
GROUP 10 - COMPONENTS AND WIRING Checking stop light switch 10-15
DIAGRAMS Checking starter safety switch .... 10-16
Checking head lights, turn and parking
Important notes 10-1 .... 10-16
lights, stop lights and tail lights
Batteries 10-1 Adjusting starter safety switch .... 10-16
Starter 10-2 Adjusting head lights 10-16
Alternator 10-2 Specifications 10-16
Generator 10-4 Torques for hardware 10-20
Regulator .. 10-4
Alternator (generator) indicator light . 10-5
Group 5
DIAGNOSING
1
MALFUNCTIONS
BATTERIES BATTERIES USE TOO MUCH WATER

LOW OUTPUT Defective regulator

Terminals loose or corroded; cables defective Battery case cracked

Low electrolyte level BATTERIES ARE NOT CHARGED

Low gravity of electrolyte Terminals loose or corroded

Defective regulator Fan belt slack or damaged

Defective alternator (generator) Sulfated or worn batteries

Printed in Germany
40 Electrical System Model 2120 Tractor
5-2 Diagnosing Malfunctions TM-4252 (Dec-70)

ALTERNATOR

TESTS AND DIAGNOSIS ON TRACTOR

Almost every trouble in the alternator will be revealed by the alternator indicator light or by battery
behaviour. Therefore, locate cause of trouble as follows:
NOTE: AI = Alternator indicator light, TL ~
Test lamp, 2 Watt

Trouble indicated with

main switch turned ob Test Cause

1. Alternator indicator light TL between alternator terminals B+ Bulb blown or test lamp circuit to D+
does not light with the and D+ lights clearly of alternator interrupted
engine shut off
TL between alternator terminals B+ Positive diode in alternator shorted.
and D+ does not light up Disconnect charging wire B+ immediately
TL between D+ and ground lights or switch off main switch, otherwise
clearly; AI fails batteries will be discharged.
TL between D-t- and ground glows;
AI glows, too:
Withdraw regulator plug, ammeter
between B+ and DF indicates an
exciting current of 0 amp Brushes worn, slip rings corroded, rotor
windings have an open circuit
exciting current of 2-3 amps Regulator or wires between alternator
and regulator open-circuited

2. Alternator indicator light Pull out regulator plug with the

lights clearly with the engine engine shut off:
running or shut off AI stays on Alternator wire D+ grounded
AI fades out:
Insert regulator plug and
connect ammeter between
alternator terminals B+ and D+:
less than 2-3 amps Regulator defective (open circuit)
Circuit between alternator diodes and brush
holder interrupted
more than 2-3 amps Wire DF or rotor field windings grounded

3. With the engine shut off, With the engine running, TL between
alternator indicator light B+ and D+:
lights clearly, but grows faded out: Excessive resistance in charging circuit
dark or glows when the or current flow to alternator indicator light
engine is running glowing:
Regulator defective (battery overcharged
or alternator defective (insufficient
battery charge)
With the engine shut off,
connect new regulator
TL with the engine running:
faded out: Removed regulator defective
glowing: Alternator defective

Printed in Germany
Model 2120 Tractor Electrical System 40
TM-4252 (Dec-70) Diagnosing Malfunctions 5-3

ALTERNATOR DOES NOT CHARGE GENERATOR

Alternator-fan belt slipping GENERATOR DOES NOT CHARGE

Open circuit or excessive resistance in charging Generator-fan belt slipping

circuit
Regulator or generator connections loose or
Worn or defective brushes corroded or wires chafed through (grounded);
battery cable loose or corroded
Regulator operating improperly
Worn or defective brushes
Open circuit in rotor field windings
Brushes stuck in holder (do not bear fully)
LOW OR IRREGULAR CHARGING SYSTEM
OUTPUT Regulator not operating

Fan belt slipping Armature and/or field windings defective

Open circuit or excessive resistance in charging LOW OR IRREGULAR CHARGING SYSTEM
circuit OUTPUT

Brushes insufficiently supported; worn or defective Fan belt slipping

brushes
Regulator or generator connections loose or
Defective regulator corroded or wires chafed through (grounded)

Shorted or defective rectifier diodes Brushes insufficiently supported; worn or defective

brushes
Rotor windings shorted or grounded
Defective regulator
Stator windings open, shorted or grounded
Grounded or shorted windings or open armature or
EXCESSIVE CHARGING SYSTEM VOLTAGE field windings

Alternator or regulator terminals loose EXCESSIVE CHARGING SYSTEM VOLTAGE

Regulator operating improperly Connections or wires between regulator and

generator loose or corroded or wires chafed
NOISY ALTERNATOR through

Defective or heavily worn fan belt Regulator operating improperly

Fan belt or pulley not aligned NOISY GENERATOR

Pulley loose Defective or heavily worn fan belt

Worn bearings Generator (pulley) not aligned

Shorted rectifier diodes Pulley loose

Worn bearings

Printed in Germany
40 Electrical System Model 2120 Tractor
5-4 Diagnosing Malfunctions TM-4252 (Dec-70)

CONTROLS STARTER

GENERATOR (ALTERNATOR) INDICATOR SLUGGISH STARTER OPERATION

LIGHT
Low battery output
Tractors equipped with alternator
Terminals loose or corroded; cable defective
Diagnosing Malfunctions see "Alternator"
Starter defective
Tractors equipped with generator
Excessive engine drag
Glows dim or flickers on and off Crankcase oil too heavy
Excessive resistance in generator DOES NOT OPERATE
Generator defective Starter safety switch not closed
FUEL GAUGE Batteries discharged
Always shows "empty " Terminals loose or corroded; cables or wires
damaged
Open circuit
Starter defective
Poor ground connection between dashboard and
fuel gauge Main switch defective
Wire between sending unit and fuel gauge grounded Start safety switch improperly adjusted or defective
Float leaking SOLENOID SWITCH "CHATTERS"
Sending unit and/or fuel gauge defective Low battery output
Always shows "full" Terminals loose or corroded; cables or wires
Excessive resistance in wire between sending unit defective
and fuel gauge or defective wire
HEAD LIGHTS
Poor ground contact on sending unit
DIM LIGHT
Sending unit and/or fuel gauge defective Poor contact at cable connections or poor ground
ENGINE OIL PRESSURE INDICATOR LIGHT contact on head lights

Does not light up Low battery output

Bulb blown Main switch defective

Excessive resistance or ground circuit in wire CIGAR LIGHTER

Indicator lamp damaged DOES NOT OPERATE

Oil pressure warning switch defective Circuit breaker has interrupted circuit

Does not fade out Lighter filament or sleeve defective

Low engine oil pressure Defective wire

Indicator lamp damaged NOTE: For overall and detailed

information on inspection and repair of the
Wire to oil pressure warning switch grounded electrical system and its components e.g.
starter, generator and batteries, see
Oil pressure warning switch defective "Fundamentals of Service — Electrical Systems"
manual.

Printed in Germany
Model 2120 Tractor Electrical System 40
TM-4252 (Dec-70) Components and Wiring Diagrams 10-1

Group 10
COMPONENTS AND
WIRING DIAGRAMS
TRACTORS EQUIPPED WITH
IMPORTANT NOTES A GENERATOR

TRACTORS EQUIPPED WITH AN 1. When starting the engine by means of a slave

ALTERNATOR battery and thereafter, make sure battery clamp
of cable to starter is properly insulated. Damage
1. CAUTION: With the engine running, do not to generator and regulator can be avoided only
disconnect battery terminals or wires between by following this recommendation.
regulator, alternator and battery. Interrupting
the circuit for even less than a second will 2. Never start engine by means of a slave battery
immediately destroy the rectifier diodes in the when wires between regulator and generator are
alternator. disconnected.

2. With the engine running, do not short or ground

(even momentarily) alternator and regulator BATTERIES
terminals.
The tractor is equipped with two 12-volt batteries
3. If the tractor is to be operated without battery connected in parallel. They are located in front of
(using a slave battery for starting), remove plug the cowl and are accessible through a hinged door.
at alternator and connect terminals D+, DF and
D- together with bridge piece supplied with the The negative pole of the left-hand battery is
tractor. The alternator will then generate no grounded by means of the ground strap attached to
electricity. the cowl. The negative pole of the right-hand
battery is connected to the negative pole of the
4. Connect batteries or battery chargers in the left-hand battery by means of a ground cable.
proper polarity. If they are improperly
connected, the rectifier diodes will be The positive pole of the left-hand battery is
immediately destroyed. connected to the positive pole of the right-hand
battery by means of a cable.
5. Before carrying out electric welding jobs on the
tractor, disconnect plug and terminal B+ at The battery cable to the starter is connected to the
alternator. Connect terminals D+, DF and D- positive pole of the right-hand battery.
together with bridge piece supplied with the
tractor. Connect ground terminal of welding The cable to the main switch is connected to the
apparatus directly to the part being welded. positive pole of the left-hand battery.

NOTE: For detailed battery description

res and service see "Fundamentals of Service
— Electrical Systems" manual.

Printed in Germany
40 Electrical System Model 2120 Tractor
10-2 Components and Wiring Diagrams TM-4252 (Dec-70)

When installing the starter, first slide cable 3 (fig.

STARTER 1) over starter connecting pin, then wire 4.
Connect wire 5 from starter button (see wiring
GENERAL INFORMATION diagram).

The BOSCH 12-Volt helical-spline sliding gear

starter is located on the right side of the tractor. It
is seated in a flywheel bore and is attached by
ALTERNATOR
means of a stud screw and a cap screw. GENERAL INFORMATION
A solenoid moves the pinion forward. When the
engine starts, the pinion is pulled back by a coil
spring installed in the solenoid.

NOTE: For a detailed explanation of

starter design and operation see "Funda¬
mentals of Service — Electrical Systems "
manual.

Fig. 2 — Alternator Installed

The BOSCH 14-Volt alternator is a 12-pole self-

induced synchronous generator. The current coil is
located in the stator, and the exciting coil in the
rotor. The exciting current is supplied by the
rectifier (terminal D+) through the regulator, two
brushes and slip rings to the exciting coil in the
rotor.

The alternator is driven by the fan belt off the

Fig. 1— Starter Installed
crankshaft. The rotor is supported by two pre-lubri-
1 Hex.nut 4 Wire to generator* or cated bearings.
2 Cap screw regulator**
3 Starter cable of batteries 5 Wire from starter button
The alternator generates alternating current which
is then transformed into direct current by the
* On tractors equipped with alternator
On tractors equipped with generator
rectifier diodes 4 (see fig. 3).
**
REPAIR The alternating windings are Y-connected. The coil
ends U, V and W (see fig. 3) are connected to the
Disconnect ground strap and cable at negative pole rectifier diodes. The current flows through the
of each battery. Then disconnect wires 4 and 5 (see diode and terminal B+ directly to the positive pole
fig. 1) as well as cable 3 at starter. Remove cap of the battery. Due to this arrangement the main
screw 2 and hex.nut 1and remove starter. current no longer flows through the regulator.

Alternating current is generated in each stator coil

NOTE: For a detailed explanationÿ of 3 of the alternator. During one revolution of the
F©S
starter repair operations see "Fundamentals rotor, voltage in the stator coil rises from 0 to the
a of Service — Electrical Systems" manual. positive maximum, drops to 0, rises to the negative
Necessary specifications are indicated at maximum and again drops to 0. Then the process is
the end of this group. repeated.

Printed in Germany
Model 2120 Tractor Electrical System 40
TM-4252 (Dec-70) Components and Wiring Diagrams 10-3

7 REPAIR

With the engine shut off, disconnect plug at alter¬

nator. Disccmnect terminal B+ at alternator.

Remove alternator attaching screws and lift out

alternator.

CAUTION: Replace alternator bearings and

brushes after every 2000 hours of operation. The
D+ DF D- life of the brushes is adjusted to that of the
bearings so that the alternator will fail when the
bearings have to be replaced. Therefore always
D+/61 DF D- replace bearings together with brushes. If bearings
are not replaced, the rotor will run unevenly,
rubbing against the alternator stator. This will
result in severe damage to the alternator.

Replacing brushes

Remove brush holder plate with brushes from rear

of alternator. Unsolder brushes and replace. Make
sure solder (use only colophony tin solder) does
not flow into copper strands (minimum length of
brushes see Specifications).

Check if brushes can be moved easily after

installation.
Replacing ball bearings

Loosen attaching screws in drive bearing and pull

rotor together with drive bearing carefully out of
stator. Push rotor out of drive bearing, using a
press and suitable support. Remove ball bearing
from drive bearing and press in new bearing with
L49379 closed side facing downward. Attach holder plate.
Fig. 3 — Wiring Diagram of an Alternator with Push bearing facing slip ring from rotor, using a
Regulator
press, or pull off by means of an extractor. Press
1 Alternator on new bearing.
2 Exciting coil (rotor)
3 Current coil (stator)
4 Rectifier Press drive bearing with ball bearing on rotor, using
5 Alternator indicator light
a press. Make sure that support is clean so that no
6 Single unit, 2- terminal regulator
7 Regulator terminals dirt can enter the bearing.
8 Battery

As the stator coils are Y-connected, a three-phase

or alternating current is generated. The individual
phases are shifted by 120°.

NOTE: For a detailed explanation of alter¬

F©S
nator design and operation see "Fundamen¬
a tals of Service — Electrical Systems" manual.

Printed in Germany
40 Electrical System Model 2120 Tractor
10-4 Components and Wiring Diagrams TM-4252 (Dec-70)

NOTE: For detailed explanation of alter¬ IMPORTANT: If the generator fails to function
FSS
nator repair operations see "Fundamentals properly and is removed for inspection, the
of Service— Electrical Systems" manual as regulator should also be removed and tested. When
well as "Repair Instructions" of manu¬ installing a new or reconditioned generator, have
facturer. Necessary specifications are indicated at the regulator checked, too. Failing to do so may
the end of this group. cause damage to the new or reconditioned
generator.
When installing the alternator, reverse removal
procedure. NOTE: For detailed explanation of
generator repair operations see "Funda¬
For checking and adjusting fan belt tension see —
mentals of Service Electrical Systems"
section 20, group 35. manual. Necessary specifications are
indicated at the end of this group.

When installing the generator, reverse removal

GENERATOR procedure. Make sure that wires and cables are not
mixed up (see Wiring Diagrams).
GENERAL INFORMATION
For checking and adjusting fan belt tension see
section 20, group 35.

REGULATOR
GENERAL INFORMATION
Tractors equipped with Alternator

A single unit, 2-terminal regulator is used for

regulating the alternator voltage. The 2-terminal
regulator limits the alternator voltage to approx.
14 Volts. No current regulation is required as the
alternator current curve rises to its maximum value
and then flattens out at maximum alternator
speed.
Fig. 4 — Generator and Regulator, Installed
The regulator is located in the tractor dashboard.
1 Generator 2 Regulator
To remove the regulator, detach right-hand side
panel of cowl.
The Bosch 12-volt generator is V-belt driven by the
crankshaft. The armature is supported by two pre- CAUTION: Disconnect cable plug only with the
lubricated bearings. The generator is completely engine shut-off.
enclosed. The carbon brushes can be reached only
after removing the rear bearing cover. 1 NOTE: For a detailed explanation of alter¬
F0S
nator-regulator design and operation see
F0S
NOTE: For a detailed explanation of "Fundamentals of Service— Electrical
generator design and operation see "Funda¬ Systems" manual.
mentals of Service— Electrical Systems"
manual. Tractors equipped with Generator

REPAIR The regulator is rubber-mounted above the

generator (see fig. 4).
Disconnect generator wires. Remove cap screws
and spacer. Take out generator. IMPORTANT: Do not replace the regulator
without having the generator carefully checked by
a specialist. Always have regulator and generator
inspected together; both parts rely on and
influence each other.

Printed in Germany
Model 2120 Tractor Electrical System 40
TM-4252 (Dec-70) Components and Wiring Diagrams 10-5

When installing the regulator, be absolutely sure Most of the controls and instruments are located in
not to mix up wires (see wiring diagrams). the dashboard (see fig. 5).

NOTE: For a detailed explanation of Other controls are located as follows: Engine oil
generator-regulator design and operation pressure warning switch in the flywheel housing,
see "Fundamentals of Service — Electrical fuel gauge sending unit in the fuel tank, start safety
Systems " manual. switch in the rockshaft housing and the stop light
switch in the left-hand brake line.
GENERATOR
(ALTERNATOR) CABLES AND WIRES
INDICATOR LIGHT The components of the electrical system are
The generator (alternator) indicator light is located connected by cables and wires which are partly
in the dashboard (see 4, fig. 5). When switching on arranged in harnesses, as shown in the wiring
the main switch, this light goes on. It fades out as diagram:
soon as the engine is running.
Wiring Connects the following Components of
If all components of the electrical system, Harness the Wiring System
including the indicator light, are functioning
properly and the indicator light fades out, the "A" Dashboard — Engine
batteries are being charged by the generator (alter¬
nator). However, if the indicator light stays or goes "B" Dashboard — Stop light switch, start safety
on when the engine is running, this indicates a fault switch, connectors, right and left-hand
which should be remedied immediately (see group 5).
Connector, right-hand — Turn and parking
light, right-hand, 7-terminal socket
CONTROLS AND D" Main switch — Fuse box
INSTRUMENTS "E" Connector, left-hand — Turn and parking
light, left-hand, stop and turn light, and
tail light, left-hand
"F" Generator (Alternator) — Regulator
"G" Flasher — Turn light switch and turn light
indicator lights
"H" Wire distributor — Head light, right-hand
"J" Wire distributor — Head light, left-hand
"K" 7-terminal socket — Stop and turn light,
and tail light, right-hand
Flashing warning light switch — Turn light
switch and fuse box

GROUND STRAP AND GROUND CABLE

A ground cable connects the negative pole of the

right-hand battery to the negative pole of the
left-hand battery. A ground strap connects the
Dashboard, Controls and Instruments negative pole of the left-hand battery to the cowl.
3 Engine oil pressure light 11 Horn button
4 Generator (Alternator) 12 Socket for handlamp
indicator light 13 Cigar lighter
5 Full-beam indicator light 16 Starter button
6 Fuse box 17 Main switch
* On tractors equipped with flashing warning
7 Tractor turn signal indicator 25 Fuel gauge
light 35 Tractormeter lights.
8 Coolant temperature gauge 41 Flashing warning light
9 Trailer turn signal switch*
indicator lights
10 Turn signal light switch

* On tractors equipped with flashing warning lights.

Printed in Germany
40 Electrical System Model 2120 Tractor
10-6 Components and Wiring Diagrams TM-4252 (Dec-70)

WIRING DIAGRAM
The individual components of the wiring system are identified by the following numbers:
1 Head lights 12 Socket (for handlamp) 27 Rear work light
2 Turn-signal and parking lights 13 Cigar lighter 28 Connector, right-hand
3 Engine oil pressure indicator 14 Start safety switch 29 7-terminal socket
light 15 Starter button 32 Stop light switch
4 Generator (alternator) indicator 17 Main switch 33 Stop and turn light, and
light 18 Flasher tail light, righthand
5 Full-beam indicator light 19 Horn 34 Stop and turn light, and tail
6 Fuse box 20 Engine oil pressure light, left-hand
7 Tractor turn-signal warning switch 35 Tractormeter with lamp
indicator light 21 Regulator 36 Connector, left-hand
8 Coolant temperature gauge 22 Alternator 37 Wire distributor
with lamp 22a Generator 38 Wire distributor
9 Trailer turn-signal indicator 23 Starter 39 Therm ostart button
lights 24 Fuel gauge sending unit 40 Burner of Therm ostart aid
10 Turn-light switch 25 Fuel gauge with lamp 41 Flashing warning light switch*
11 Hom button 26 Batteries
Cables and wires have different colours to facilitate identification. Each component and wire in the
wiring diagram is identified by a number. From these numbers which are indicated below it is possible to
establish the colour, size and purpose of each wire or cable.
Cable or wire from to
No. mm2 Colour Component No. Terminal Component No. Terminal
No. No.
11 11
42 Ground strap L.H. battery 26 Dashboard
*5 >1
43 25 black R.H. battery 26 11 11
L.H. battery 26
44 25 black L.H. battery 26 R.H. battery 26
45 25 black R.H. battery 26 Starter 23 30
46 2.5 black Starter 23 50 Starter button 16
47 2.5 black Starter button 16 Start safety
switch 14
48 6 red Starter 23 30 Alternator 22
or Regulator** 21 B+
51 1 green Generator 22 DF Regulator 21 DF
or 1.5 light blue** or 22a**
52 1 brown Generator 22 D- Regulator 21 D-
or 1.5** or 22a**
53 1 light blue Generator 22 D+ Regulator 21 D+
or 6 red** or 22a**
55 1 green Oil pressure Oil pressure
warning switch 20 indicator light 3
57 1 blue/white Fuel gauge Fuel gauge 25 G
sending unit 24
59 1 light blue Regulator 21 D+ or Generator (alternator)
61** indicator light 4
60 6 red Battery, L.H. 26 »_!_>> Main switch 17 30
62 1 black/yellow Hom button 11 Signal hom 19
63 1 brown Horn 19 6 Ground
64 1 grey Coolant temperature Fuse box 6 58
gauge lamp 8 (fuse 6)
On tractors equipped with flashing warning lights ** On tractors equipped with generator
*
Printed in Germany
Model 2120 Tractor Electrical System 40
TM-4252 (Dec-70) Components and Wiring Diagrams 10-7

Cables and wires from 1 to

No. mm2 Colour Component No. Terminal Component No. Terminal
No. No.

65 1 white Wire distributor 37 Fuse box

(fuse 8) 6 56a
66 1 yellow Wire distributor 38 Fuse box (fuse 7) 6 56b
67 1 white Headlight, L.H. 1 56a Wire distributor 37
68 1 white Full-beam indi¬ Fuse box
cator light 5 (fuse 8) 6 56a
69 1 yellow Headlight, L.H. 1 56b Wire distributor 38
70 1 grey / Fuse box
black (fuse 4) 6 58 Connector 36
71 1 grey / Fuse box
black (fuse 4) 6 58 Connector 28
72 1 grey / Fuse box
red (fuse 5) 6 58 Connector 28
73 1 black Stop light switch 32 Fuse box (fuse 3) 6 15
74 black Flasher 18 49 Fuse box (fuse 2) 6 15
74* 1 green/yellow Flasher 18 49 Warning light switch 41 49
75 1 black Fuel gauge 25 Fuse box
(fuse 2) 6 15
76 1 red Socket Fuse box
(hand lamp) 12 (fuse 1) 6 30
77 1 red Horn button 11 Socket 12
78 1 red Fuse box
(fuse 1) 6 30 Cigar lighter 13
79 1 white Main switch 17 56a Fuse box
(fuse 8) 6 56a
80 1 yellow Main switch 17 56b Fuse box
(fuse 7) 6 56b
81 1 grey Main switch 17 58 Fuse box
(fuse 5) 6 58
82 1 black Main switch 17 15 Fuse box
(fuse 2) 6 15
83 1 red Main switch 17 30 Fuse box
(fuse 1) 6 30
84 1 black Main switch 17 15 Generator (alter¬
nator) indicator
light 4
85 2.5 black Main switch 17 15 Start safety switch 14
86 1 brown Full-beam
indicator light 5 Fuel gauge 25
87 1 white Full-beam
indicator light 5 Fuse box (fuse 8) 6 56a
88 1 brown Fuel gauge 25 Ground Turn signal light
switch 10 Ground
89 1 black Turn signal light
switch 10 54 F Stop light switch 32
89* 1 light blue/ Turn signal light
white switch 10 R Connector 28
ractors equipped with flashing warning lights
Printed in Germany
40 Electrical System Model 2120 Tractor
10-8 Components and Wiring Diagrams TM-4252 (Dec-70)

51
52
53
65
-66
57
62
-121

-46
55

24- 48- 121

40I
35 3 55
50 3-46-1
22 23 20

45—,
"•J
42 o-
26
43
44

o-
26
-60

48 59

45 48
r»F
23
69-1

L 51550

Fig. 6 — Wiring Diagram on Tractors without Flashing Warning Lights

Printed in Germany
Model 2120 Tractor Electrical System 40
TM-4252 (Dec-70) Components and Wiring Diagrams 10-9

27

-33
109
r|- "1 K
108
107
52-
-112—
-113 , 1<g
i.x=-
53-
65-
— -103—1
59 -104
57- I05-1
62- -28
121 111 1 72 71 29
92
110
46
55-

57
121
25 39
75

•94-
100 r95 -93-
86
-92-
87 68 89 =9a
35 -120
97

96
117 •88"

LS18
-85
-79 78
55
r82>
—
' 84-
>30 17 •80J

60-

59
46
-0" 47- 47-

7,9 80 82 8,3 iB

-6
-87— 72 ( 71
—'
66
65 I 70 73 73-
-68- -78
64- 32
9&J
114
111
90

6 6 6
* -36
-101- -34
L 51550 .116 -1 - 102

Printed in Germany
40 Electrical System Model 2120 Tractor
10-10 Components and Wiring Diagrams TM-4252 (Dec-70)

56 op—~118-
56 bL119— |

37 52
53
r67- 65
66
69 57
62
121

53 46
52
57
121
48
24-
•45 ÿÿ

| 46
62 '"SOP
50p
— -
22
23 20

4?

— -1 J 26
43 44

o-
26
-60

48

45

53 46

23
-| 56 bl

L 51551

Fig. 7 — Wiring Diagram on Tractors Equipped with Flashing Warning Lights

Printed in Germany
Model 2120 Tractor Electrical System 40
TM-4252 (Dec-70) Components and Wiring Diagrams 10-11

27

109 129-o

—108-c
1ÿ2 123

T L •112-
104
-113-
65 -128
•106
57
129 108
28 107 106
46 105
55 109
121 128
39-
2?B
125 V/bQ03i
-104XJÿ|X
-75- 120 110

160 89-
86 cm en

87
35

--
f96-
'G l_
117 88-/

120

84
64
030 17
78
85
60
47-
Dr
79 8
84

87- 125.
126
32
64- -123

114

36

Eri
-102-
-115
L 51 551 -116-
-101- 34
-127-

Printed in Germany
40 Electrical System Model 2120 Tractor
10-12 Components and Wiring Diagrams TM-4252 (Dec-70)

Cables and wires from to

No. mm2 Colour Component No. Terminal Component No. Terminal
No. No.

90 1 black/red Turn-light switch 10 L 54 Connector 36

90* 1 black/white Wire 92 Connector 36
91 1 black/red Turn- light switch 10 L 54 Connector 28
91* 1 black/white Flashing warning
light switch 41 L Turn-light switch 10
92 1 black/green Turn-light switch 10 R 54 Connector 28
92* 1 black/white Turn-light switch 10 L Wire 90
93 1 light blue/ Turn light switch 10 R Connector 28
white
93* 1 black/white Wire 92 Connector 28
94 1 black/white Tum-light switch 10 L Connector 36
94*1 black/green Flashing warning
light switch 41 R Turn-light switch 10 R
95 1 black/green Turn-light switch 10 49a Flasher 18 49a
white
96 1 black/ Flasher 18 C Turn-light
yellow indicator light 7 CI
97 1 black Flasher 18 C 2 Tum-light
indicator light 9 CII
98 1 black/white Flasher 18 C3 Tum-light in¬
dicator light 9 cm
99 1 green Engine oil pres¬ Fuse box
sure indicator light 3 (fuse 2) 6 15
100 1 grey Tractormeter Fuel gauge
(lamp) 35 (lamp) 25
101 1 grey /black Connector 36 Tail light, L.H. 34
102 1 black/red Connector 36 Stop and turn-
signal light, L.H. or
stop light, L.H.* 34
103 1 black/green or Connector 28 Socket 29 R
light blue/white*

104 1 grey/black Connector 28 Socket 29 58 L

105 1 black/red Connector 28 Socket 29 L or 54*
106 1 grey/red Connector 28 Socket 29 58 R
107 1 grey/red Socket 29 58R Tail light, R.H. 33
108 1 black/green Socket 29 R Stop and turn-
signal light, R.H. 33
108* 1 black/ green Socket 29 54 Stop light, R.H. 33
109 1 grey/red Socket 29 58L Rear work light 27
110 1 brown Socket 29 31 Ground
111 1 grey Fuse box (fuse 6) 6 58 Connector 28
112 1 grey Connector 28 Parking light, R.H. 2
113 1 light blue/ Connector 28 Turn signal light, 2
white R.H.
114 1 grey Fuse box (fuse 6) 6 58 Connector 36

* On tractors equipped with flashing warning lights (see wiring diagram, fig. 7)

Printed in Germany
Model 2120 Tractor Electrical System 40
TM-4252 (Dec-70) Components and Wiring Diagrams 10-13

C ables and wires from to

No. mm2 Colour Component No. Terminal Component No. Terminal
No. No.

115 1 grey Connector 36 Parking light, L.H. 2

116 1 black/white Connector 36 Turn-signal light,
L.H. 2
117 1 grey Coolant tempera¬ Tractormeter
ture gauge lamp 8 (lamp) 35
118 1 white Wire distributor 37 Head light, R.H. 1 56a
119 1 yellow Wire distributor 38 Head light, R.H. 1 56b
120 1 black Main switch 17 15 Button of Ther-
mostart aid 39
121 1 black Button of Burner of
Therm ostart aid 39 Thermostart aid 40
122* 1 red Fuse box (fuse 1) 6 30 Flashing warning
light switch 41 30
123* 1 black Fuse box (fuse 2) 6 15 Flashing warning
light switch 41 15
124* 1 brown Flashing warning Ground
light switch 41 31
125* 1 black/red Stop light switch 32 Connector 28
126* 1 black/red Stop light switch 32 Connector 36
127* 1 blach/ white Turn light 34 Connector 36
128* 1 black/white Socket 29 Connector 28
129* 1 black/white Turn light 33 Socket 29 R

ELECTRICAL SYSTEM WITHOUT TURN-SIGNAL LIGHTS

On tractors without turn-signal lights, wires No. 88 2 Turn signal lights**, R.H. and L.H.
to 94 (see fig. 6, wiring diagram) are not connected 7 Turn-signal indicator light
to the turn light switch, but to a terminal plate. In 9 Turn-signal indicator lights for trailer
addition, the following parts shown in the wiring 10 Turn-signal switch
diagram are not provided: 18 Flasher
wire 74 as well as wires 95 to 98.

REPAIR
GENERAL INFORMATION and screws during major inspection. Accidental
grounding can be largely reduced by using plastic
Various faults may occur in the electrical system. insulated cables and holding groups of cables in
Apart from the occasional burning out of a bulb cable clamps.
and blowing of fuses, bad connections and
accidental grounding of wires may be the cause of CAUTION: Before removing parts of the electrical
difficulties. system, check whether the fault is caused by loose
connections or bad ground connections.
Connections or terminal screws can become loose;
it is, therefore, advisable to check all connections

* On tractors equipped with flashing warning lights

(see wiring diagram, fig. 7)
** Parking lights are provided, but no turn-signal lights

Printed in Germany
40 Electrical System Model 2120 Tractor
10-14 Components and Wiring Diagrams TM-4252 (Dec-70)

MAIN SWITCH

When checking the main switch, ensure that the connected circuits are in good condition (see wiring
diagram).

NOTE: The switch key can be removed only in positions "0" and "1".

Switch Key Position (see fig. 8) Equipment Receiving Current

Key in position "O", pulled out No current, except for horn, socket for handlamp, cigar
lighter and flashing warning lights (if equipped)

Key in position "O", pressed in Horn, socket for handlamp, cigar lighter, flashing warning
lights (if equipped), fuel gauge, engine oil pressure indicator
light and generator (alternator) indicator light, start safety
switch and button, turn-light switch, flasher, tractor and
trailer turn lights, tractor and trailer turn-signal indicator
lights, stop light switch and stop lights

Key turned clockwise to position As in position "O", key pressed in; in addition: coolant
"1 (first notch) temperature gauge (lamp), fuel gauge (lamp), tractormeter
(lamp); both parking lights, both tail lights of tractor and
trailer; rear work light

Key turned clockwise to position Horn, socket, cigar lighter, flashing warning lights (if
"1" (first notch) and removed equipped), coolant temperature gauge (lamp), fuel gauge
(lamp), tractormeter (lamp), both parking lights, both tail
lights of tractor and trailer, rear work light

Key turned clockwise to position As in position "O", key pressed in; in addition: temperature
"2" (second notch) gauge (lamp), fuel gauge (lamp), tractormeter (lamp); both
parking lights, both tail lights of tractor and trailer; dimmed
headlights; rear work light

Key turned clockwise to position As in position "2", the only difference: headlights switched
"3" (third notch) to full beam, and full-beam indicator light on

NOTE: If switch terminals are faulty (e.g. lights are weak or flicker on and off), install a new main
switch.

Printed in Germany
Model 2120 Tractor Electrical System 40
TM-4252 (Dec-70) Components and Wiring Diagrams 10-15

FUSES Fuses of 8 ampere are used for all these circuits. If

fuses keep blowing in one circuit, check where the
circuit is overloaded (usually through faulty wires
causing short circuit to ground).

Quick Check: Disconnect suspected wire at both

ends; connect new length of wire to both
terminals, install fuse, switch on circuit, and watch
fuse for a few minutes. If it lasts, install the new
cable which should have at least the same cross
section as the original one (s. details of wiring
diagram), using the necessary insulation and cable
holders. Remove possible corrosion from fuse box
contacts or replace fuse box.

Fuses with corroded ends should be replaced.

ENGINE OIL PRESSURE WARNING SWITCH

If the engine oil pressure indicator light does not

light up although oil pressure is present and bulb is
in order, a faulty pressure switch may be the cause
(spring worn or broken, faulty contacts). Check
circuit by installing a new warning switch. If this
proves that the old switch was defective, replace it.

Fig. 8 — Fuse Box with Fuses, Main Switch and CAUTION: The thread is conical and seals itself;
Starter Button Installed no sealant needed.
16 Starter button 17 Main switch
FUEL GAUGE SENDING UNIT
The fuses 1 to 8 shown in fig. 8 refer to the
following circuits: The main operating parts of the sending unit are
subject to wear. As a defective or improperly
operating fuel gauge may be due to other causes
1 Horn, socket for handlamp, cigar lighter and
than a faulty sending unit, it is recommended to
flashing warning lights (if equipped)
check the circuit by installing a new or properly
operating sending unit. Replace sending unit, if
2 Engine oil pressure indicator light, flasher and
fuel gauge defective.

3 Stop light switch STOP LIGHT SWITCH

4 Left tail light of tractor and trailer and rear In neutral position, i.e. if the foot brake is not
work light being operated, the stop light switch is open and
the circuit interrupted. When depressing the brake
5 Right tail light of tractor and trailer pedal, the switch closes the circuit and the stop
lights light up. If lights do not light up, the switch
6 Parking and turn lights, lamps of coolant may be defective.
temperature gauge, fuel gauge and tractormeter

7 Dimmed headlights

8 Headlights, full beam and blue indicator light

Printed in Germany
40 Electrical System Model 2120 Tractor
10-16 Components and Wiring Diagrams TM-4252 (Dec-70)

Quick Check: Bridge both switch terminals with a ground connection. The trouble may also be due to
piece of wire to close the circuit. If switch is weak spring contacts exerting insufficient pressure
faulty, both stop lights of the tractor and of the on light bulbs. Re-bend contacts, if necessary.
trailer (if hitched), should light up. If the lights fail Corroded contacts in bulb sockets or on bulbs can
to light up, the fault must be traced elsewhere. also cause lighting trouble. Clean connections.

START SAFETY SWITCH

ADJUSTMENT
If the starter does not work although the key is
pressed in and the range shift lever is in neutral or START SAFETY SWITCH
park position, check the start safety switch by
installing a new switch and check circuit. Ensure Adjust start safety switch by installing as many
that the switch is set correctly (see "Adjustment"). shims between rockshaft housing and switch as
needed to make contact on starter when the range
NOTE: The start safety switch can be checked in shift lever is in neutral position, but not if it is in
the same manner as the stop light switch (see range Ior II.
above).
CAUTION: Do not overtighten switch when
installing it in the rockshaft housing. For
HEAD LIGHTS, PARK AND TURN SIGNAL maximum torque see Specifications.
LIGHTS, STOP AND TURN SIGNAL LIGHTS
AND TAIL LIGHTS HEAD LIGHTS
Apart from bulbs blowing, faults on these lights are For adjusting the head lights, use a commercial
normally caused by bad connections. This applies head light testing device. Test each head light
especially to ground connections. individually. Make the required corrections by
turning the head light in its pivoting mounting.
Check ground connections as follows:
Connect a length of wire to a bare metal area of
the light housing and to bare spot on the tractor
frame. Bulb should light brighter if cause was poor

SPECIFICATIONS
STARTER

ELECTRICAL TEST

NOTE: The test period should be as short as possible; batteries installed in the test stand should be well
charged and function properly (battery capacity: 135 Ah). Test starter at room temperature (approx.
20°C = 68°F). On a defective starter the electrical test values differ considerably from specifications
given on the next page! If in doubt, check field and armature windings for breaks, ground or winding
short-circuits.

Printed in Germany
Model 2120 Tractor
TM-4252 (Dec-70)

.
No-load test (including solenoid)

Volts

11,5

Load test (including solenoid)

Volts

Minumum voltage of solenoid

..........
Min.
Ampere

90

Min.
Ampere

775

...........
CHECKING STARTER SPECIFICATIONS
Max.
Ampere

no

Max.
Ampere

805

Minimum dia. of commutator (when re-turning: CAUTION!

..........
Centerings of armature shaft are out of center)

Commutator out-of-roundness, max

Out-of-roundness of stack of armature plates, max

(see dimension "c", fig. 9)

.......
.....................
Undercutting insulation after re-turning
commutator by approx. (then finish-turn)

.......
Brush pressure (check by means of a spring scale)

Gear backlash

Ring gear clearance (see dimension "a", fig. 9)

Pinion protruding from housing by

Gap between pinion face and ring gear with

................
starter disengaged; not adjustable (see
dimension "b", fig. 9)

(see dimension "d", fig. 10)

Armature end play

Armature braking torque

Overrunning torque

Printed in Germany
..................
Adjusting dimension for solenoid, drawn in
Min. Speed

6000 rpm

Min. Speed

1300 rpm
Electrical System

Max. Speed

8000 rpm

Max. Speed

1600 rpm

1.555 in.
0.0012 in.

0.002 in.

0.02 to 0.03 in.

2.2 to 2.9 lbs.

0.0138 to 0.0236 in.

1.98 to 2.03 in.

1.89 to 1.91 in.

0.1 to 0.12 in.

1.039 to 1.055 in.

0.004 to 0.012 in.

4.0 to 6.6 in.lbs.

1.0 to 2.8 in.lbs.

....
40
Components and Wiring Diagrams 10-17

8 Volts

39.5 mm
0.03 mm

0.05 mm

0.5 to 0.8 mm

1.0 to 1.3 kg

0.35 to 0.6 mm

50.5 to 51.5 mm

48.0 to 48.5 mm

2.5 to 3.0 mm

26.4 to 26.8 mm

0.1 to 0.3 mm

4.5 to 7.5 cmkg

1.2 to 3.2 cmkg

40 Electrical System Model 2120 Tractor
10-18 Components and Wiring Diagrams TM-4252 (Dec-70)

Fig. 9 — Ring Gear and Pinion Clearance, Pinion Fig. 10 — Adjusting Measurement of Solenoid
Protrusion d Adjusting measurement (When retracted)
a Ring gear clearance
b Pinion clearance
c Pinion protrusion

ALTERNATOR

GENERAL INFORMATION FOR INSPECTION AND REPAIR

Observe the following recommendations closely before starting inspection:

1. The wires between alternator and regulator and/or test stand must be properly connected. Do not
make provisional connections. If a provisionally connected cable comes loose during the test, peak
voltages will be generated in the alternator which may destroy the diodes.

2. Use only D.C. voltages of up to 24 Volts maximum for testing the diodes. Higher voltages will destroy
them.

3. Check high-voltage windings for opens or grounds only after diodes have been disconnected.

4. With the alternator running, do not disconnect battery cable as peak voltages will destroy the diodes.

5. Operate the alternator only by means of the fan belt pulley.

6. To facilitate current flow to the exciting coil, be sure to connect an indicator lamp between terminals
B+ and D+. This lamp should have a capacity of 2 watt. It will be most suitable to connect the
indicator lamp to a battery post and to alternator terminal D+. The indicator lamp should now light
up.

TESTING ALTERNATOR OUTPUT

Connect battery.

Connect voltmeter to alternator terminal B+ and to ground.

Connect resistor pile.

Adjust alternator speed to specified rpm and increase load to value specified in the following chart.

Printed in Germany
Model 2120 Tractor Electrical System 40
TM-4252 (Dec-70) Components and Wiring Diagrams 10-19

Watch indicator lamp closely; it should completely fade out in any case.

Connect voltmeter to terminal D+. Voltage differential between terminals B+ and D+ should not exceed
0.5 volt.

Adjusting Maximum Resistance

Load Speed * Ohms+ 10%
Amps. RPM Stator* * Rotor

10 1500
18 2500 0,4 4,0
28 6000

* Warm alternator (60° C = 140°F) with regulator

** Between phase leads

TESTING ALTERNATOR IF SPECIFIED OUTPUT IS NOT ACHIEVED

NOTE: Since diodes can only be checked for shorts (with the alternator assembled), the indicator lamp
should not light up during the following tests.

1. Testing exciting diodes

Connect positive (+) test prong to terminal D+ and negative (-) test prong to a connecting point
(solder point or screw),

2. Testing positive diodes

Connect positive (+) test prong to terminal B+ and negative (-) test prong to a connecting point
(solder point or screw)

3. Testing negative diodes

Connect positive (+) test prong to phase connecting point or terminal "W" and negative test prong to
terminal D-.

NOTE: If indicator lamp does not light up during tests 1 to 3, one or more diodes of the tested group
will be defective due to a short circuit.

4. Testing exciting coil in rotor

Connect test prongs to terminals DF and D-. When turning the rotor slowly, the indicator lamp should
light darker than when placing test prongs directly on rotor. If lamp lights brightly or does not light at
all or if it lights intermittently, the exciting coil or the brushes will be defective.

....................
CHECKING ALTERNATOR SPECIFICATIONS

Minimum length of brushes 0.55 in. 14 mm

.............
Brush spring pressure 0.66 to 0.88 lbs. 0.3 to 0.4 kg

Minimum diameter of slip rings 1.24 in. 31.5 mm

Out-of-roundness of slip rings (maximum) 0.0012 in. 0.03 mm

Printed in Germany
40

.
Electrical System
10-20 Components and Wiring Diagrams

No-load speed at rated voltage

1250 to 1450 rpm

CHECKING GENERATOR SPECIFICATIONS

...............
TESTING ALTERNATOR SPECIFICATIONS (CONT.)
Out-of-roundness of rotor, maximum
..........
Isolation gap to alternator housing, minimum
GENERATOR
ELECTRICAL TEST
NOTES: When testing generator and regulator, check

generator voltage as this would damage the exciting coil.

Speed when testing output

cold

1700 to
1900 rpm

commutator by approx. (then finish-turn)

Armature end play

.......
Out-of-roundness of stack of armature plates, max
Undercutting insulation after re-turning

Brush pressure (check by means of a spring scale)

hot

..........
Minimum dia. of commutator (when re-turning: CAUTION!
Centerings of armature shaft are out of center)
Commutator out-of-roundness, max

..........
TORQUES FOR HARDWARE
Start safety switch inrockshaft housing, max
Pulley to generator

Printed in Germany
1850 to
2000 rpm
0.002 in.
0.12 in.

7.5 Amperes

1.22 in.
0.0012 in.
0.002 in.

0.02 to 0.03 in.

1.0 to 1.3 lbs.
0.004 to 0.012 in.

35 ft.lbs.
29 ft.lbs.
Model 2120 Tractor
TM-4252 (Dec-70)

0.05 mm

for proper connection and polarity of regulator.

3.5 Ohms
+ 10 %
3 mm

When testing generator without regulator, no-load speed at rated voltage and output speed (cold and hot)
can be measured. To do so, first connect terminal "DF" directly to terminal "D- " (thus only regulator
failure can be eliminated when testing). Make sure output speed is not exceeded considerably at
When putting the generator to an endurance test, it is recommended to use the regulator, too. This will
avoid a voltage surge. Do not test the generator in an endurance test at double output speed without
using the regulator. When generator failure is evident, always check the regulator.

1. Operate generator as a motor for a short time. To do this, separate generator from drive motor of test
bench. Connect battery directly to terminal "D+". The generator should now run as a motor in its
normal direction of rotation.

2. No-load speed at rated voltage (see chart)

Connect voltmeter to terminal "D+" and ground (using an insulated ground wire) to "D-". Increase
speed slowly. With no-load speed at rated voltage, the generator voltage should be reached ("cold").

Speed when testing output "cold";

Ambient temperature should be
approx. 68° F (20° C).

3. Adjusting load
Speed when testing output "warm";
Housing temperature should be
approx. 140°F (60°C).

Adjusting load always corresponds to 2/3 of maximum amperage. When testing output, increase ohm
value of resistor installed in test bench until load amperage is obtained (see chart). Record relative
speed and compare to actual speed.

Load amperage Resistance

31 mm
0.03 mm
0.05 mm

0.5 to 0.8 mm
0.45 to 0.6 kg
0.1 to 0.3 mm

4.8 mkg
4 mkg
Model 2120 Tractor
TM-4252 (Dec-70)

GROUP 5 - ENGINE CLUTCHES AND CLUTCH

LINKAGE

Diagnosing malfunctions
Clutch linkage
Genera] information
Repair
Installation
Adjustment

Removal
Disassembly
Repair
Assembly
Adjustment
Installation
Adjusting externally

Assembly
......
Installation
Adjustment
Specifications
Torques for hardware
Special tools

General information

Repair
Assembly
Installation
Specifications
Torques for hardware
Special tools
.
Engine dual-stage clutch
General information

Engine single-stage clutch

General information
Removal
Disassembly
Repair .

.......
GROUP 10 - HIGH-LOW SHIFT UNIT

Checking operating pressure

Diagnosing malfunctions
Removal .
Disassembly
.
.

...

GROUP 15 - COLLAR-SHIFT TRANSMISSION

General information
Diagnosing malfunctions
Shifter mechanism ..
Transmission shafts and gears
Specifications
Torques for hardware

Printed in Germany
..
.....
..

.
CONTENTS OF THIS SECTION

.....
•

.5-14
Page

5-2
5-3
5-3
5-3
5-5
5-5
5-7
5-7
5-8
5-8
5-9
5-9
5-10
5-11
5-11
5-12
5-12
5-13
5-13
5-13

5-15
5-15
5-16
5-17
5-17

10-1
10-4
10-4
10-6
10-7
10-9
10-11
10-12
10-12
10-15
10-15

15-1
15-3
15-3
15-6
15-14
15-14
GROUP 20 - DIFFERENTIAL ASSEMBLY

General information
Diagnosing malfunctions
Repair
Adjustment
Installation
Specifications
Torques for hardware

GROUP 25 - FINAL DRIVES

General information
Diagnosing malfunctions
Repair
Adjustment
Specifications
Torques for hardware

GROUP 30
......
- CONTINUOUS-RUNNING PTO
SHAFTS
General information
Single, rear 540 rpm PTO shaft
Removal
Repair
Installation
Mid PTO shaft
Removal
Repair
Installation
Dual rear 540 and 1000 rpm PTO
shaft
Removal
Repair
Installation
Rear 540 rpm and front 1000 rpm
PTO shafts
Specifications

GROUP 35 - INDEPENDENT PTO SHAFTS

General information
Operation
Checking operating pressure
Diagnosing malfunctions
Rear PTO assembly
PTO clutch
PTO brake

......
.....
Control valve assembly
Specifications .
.
Power Train
Engine Clutches and Clutch Linkage

POWER TRAIN

......
....
Section 50

.....
.
50
5-1

Page

20-1
20-1
20-2
20-3
20-4
20-4
20-4

25-1
25-1
25-2
25-3
25-3
25-3

30-1
30-1
30-1
30-3
30-4
30-4
30-4
30-5
30-5

30-6
30-6
30-8
30-8

30-8
30-10

35-1
35-3
35-5
35-6
35-7
35-8
35-10
35-10
35-12
50 Power Train Model 2120 Tractor
5-2 Engine Clutches and Clutch Linkage TM-4252 (Dec-70)

Group 5
ENGINE CLUTCHES AND CLUTCH
LINKAGE
DIAGNOSING MALFUNCTIONS CLUTCH NOISE (when engaged)

CLUTCH SLIPS Splines of drive shaft(s) or hub(s) of driven disk(s)

worn
Worn or burned clutch facings
Clutch disk loose at hub rivets
Oil or grease on clutch facings
Torsion damper defective
Insufficient clutch pedal free travel
Flywheel loose on crankshaft flange
Release levers out of adjustment
CLUTCH DRAG
Operator riding clutch pedal
Clutch shaft splines and/or clutch disk hub
CLUTCH GRABS OR CHATTERS distorted or rough

Facings loose, gummed, worn or glazed, clutch Clutch disk hub tight on clutch shaft
disk(s) bent or warped
Clutch disk facings loo.se or oil- soaked
Clutch disk(s) loose at hub (loose rivets or
insufficiently pre-stressed springs) Clutch disk(s) warped or bent

Clutch disk hub tight on shaft (does not slide High spots on clutch disk(s)
freely)
Defective diaphragm spring
Tight or binding clutch fork shaft
Clutch parts worn
Cracked or broken pressure plate(s)
Excessive clutch pedal free travel
Pressure plates sticking
Excessive clutch face run-out (flywheel not seated
Defective diaphragm spring properly)

Excessive transmission backlash CLUTCH PEDAL PULSATION

Clutch throw-out bearing damaged, dirty, worn or Broken or missing clutch pedal return spring
improperly lubricated
Clutch release levers out of adjustment
Clutch release levers out of adjustment
Flywheel not seated properly

Distorted crankshaft flywheel flange

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Engine Clutches and Clutch Linkage 5-3

CLUTCH LINKAGE
GENERAL INFORMATION
When depressing the clutch pedal (see 1, fig. 1),
motion is transmitted through clutch rod 8/10,
clutch shaft 16 and clutch fork 18 to the throw-
out bearing carrier and bearing 19. The latter will
be pressed against the clutch release levers, thus
disengaging the clutch.

Power is transmitted from the clutch pedal 1to the

yoke rod 8/10 through pedal arm 3 which is
attached to the clutch pedal by means of cap screw
6. The cap screw is seated in a slotted hole in the
pedal arm. On machines equipped with a dual
clutch this design allows two pedal positions. When
cap screw contacts rear of slot, only the front
(engine) clutch can be engaged or disengaged (see Fig. 1— Clutch Linkage, Exploded View
"Adjustment" and Operator's Manual). On 1 Clutch pedal 12 Cotter pin
machines equipped with single clutch only, the 2 Return spring 13 Bushing
clutch pedal can be adjusted to suit operator's 3 Arm 14 Bearing pin
4 Washer 15 Spring pins
height by means of slotted hole in the pedal arm 5 Snap ring 16 Clutch shaft
(see "Adjustment"). 6 Cap screw 17 Bushing
7 Toothed lock washer 18 Fork
8 Yoke 19 Throw-out bearing with carrier
9 Lock nut 20 Return spring
REPAIR 10 Clutch rod 21 Sleeve for throw-out
11 Clevis pin bearing carrier
CLUTCH LINKAGE (fig. 1)
Throw-out bearing, carrier and bushing
Separate tractor between engine and clutch
housing (see section 10, group 25). CAUTION: Do not soak throw-out bearing in
solvent as it is packed with grease. Wipe clean with
Remove clutch linkage parts. cloth dampened in solvent. The bearing can be
filled with grease externally (see Operator's
Check bushing (see 17, fig. 1) of clutch shaft 16 in Manual). Do not oil the throw-out bearing.
left-hand bore of clutch housing for wear or
damage. If necessary, drive in new bushing so that Check throw-out bearing for evidence of overheat¬
it is flush with face of clutch housing. ing (blue discoloration of surface). If bearing has
been overheated or runs rough, it must be replaced
Check clutch shaft 16, bearing pin 14 and bushing complete with carrier (throw-out bearing and
13 of clutch pedal 1 for wear or damage. If carrier are only supplied assembled). Inspect
necessary, drive new bearing pin into clutch bearing carrier for excessive wear in bore and on
housing so that its face protrudes from the housing lugs. Also check for pitting, cracks or other
by a specified dimension (see Specifications). damage. Make sure bearing carrier slides freely on
the sleeve. If necessary, replace the complete
assembly (throw-out bearing and carrier).

Printed in Germany
50 Power Train Model 2120 Tractor
5-4 Engine Clutches and Clutch Linkage TM-4252 (Dec-70)

26 28 22

22Z

L 50 969

Fig. 2 — Drive Shaft and Hollow PTO Drive Shaft Installed

(Tractor without High-Low Unit Shown)
21 Sleeve 24 Oil seal 27 PTO drive gear
22 Needle bearing 25 Guide 28 Hollow PTO drive shaft
23 Oil seal 26 Drive shaft

Inspect carrier sleeve 21 for wear or damage and Only on tractors without HIGH-LOW unit
replace, if necessary. Drive new sleeve into clutch
housing so that its face protrudes from the housing If it is necessary to renew oil seal (see 23, fig. 2)
by a specified dimension (see Specifications). located in clutch housing, remove both drive shafts
(26 and 28). Remove complete transmission oil
Check clutch fork 18 for wear, cracks or other pump followed by needle bearing 22 and
damage and replace, if necessary. unserviceable oil seal.

CLUTCH HOUSING Fill space between lips of new oil seal with multi¬
purpose grease. Press oil seal into bore of clutch
If there is oil in the clutch compartment of the housing with sealing lip facing driver so that face of
clutch housing which is not due to oil leakage seal is a specified distance from clutch housing face
through the rear crankshaft seal, inspect oil seal (see Specifications).
(see 23, fig. 2) located between clutch housing and
hollow PTO drive shaft 28. Check needle bearing for excessive wear, roughness
or damage. Press new needle bearing into clutch
If necessary, separate tractor between transmission housing bore so that its face is flush with shoulder
and clutch housing. of bore.

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Engine Clutches and Clutch Linkage 5-5

Only on tractors with HIGH-LOW unit on both shaft ends for excessive wear or damage.
Check drive shaft for distortion. Inspect guide
If it is necessary to renew oil seal located in clutch bearing seat on shaft and replace shaft, if
housing, remove complete HIGH-LOW unit (see unserviceable.
group 10). Remove thrust washer, bushing and
unserviceable oil seal from clutch housing. Only on tractors with HIGH-LOW unit

Fill space between lips of new oil seal with multi¬ The drive shaft is part of the HIGH-LOW unit.
purpose grease. Press seal into bore of clutch Therefore it is necessary to remove and disassemble
housing with sealing lip facing driver so that face of the HIGH-LOW unit when the drive shaft is
seal is a specified distance from clutch housing face checked.
(see Specifications).
See group 10 for details.
Check HIGH-LOW unit bushing for wear and
replace, if necessary. Press new bushing into clutch
housing so that the lubrication holes in bushing INSTALLATION
corresponds with those in the clutch housing. Coat
bore of bushing with a film of oil. For installation of clutch linkage, reverse removal
procedure.
HOLLOW PTO DRIVE SHAFT
When installing, observe the following details:
Only on tractors without HIGH-LOW unit
Coat sliding face of sleeve, bore and both faces of
Check hollow PTO drive shaft (see 28, fig. 2) for bearing carrier which contact clutch fork, using
excessive wear, scores or damage on bearing surface MOLYKOTE BR 2 grease. Fill grease compartment
for needle bearing and roller bearing, on sliding of bearing carrier with multi-purpose grease.
surface for oil seal, on splines for clutch disk and
torsion damper as well as on slots for woodruff key Install two spring pins (see 15, fig. 1) flush with
and oil pump gear. Check seat of gear 27 on shaft. clutch fork and secure with wire.
Replace shaft if unserviceable.
When installing drive shafts, take care not to
Only on tractors with HIGH-LOW unit damage oil seals.

The hollow PTO drive shaft is part of the

HIGH-LOW unit. Therefore, when checking this ADJUSTMENT
shaft it is necessary to remove and disassemble the
HIGH-LOW unit. Normal adjustment of clutch pedal on tractors
equipped with dual-stage clutch
See group 10 for details.
With this adjustment, both (engine and PTO)
DRIVE SHAFT clutches are operated one after the other. Adjust as
follows: Loosen cap screw (see 6, fig. 3) and move
Only on tractors without HIGH-LOW unit clutch pedal to the rear until cap screw 6 contacts
front of slot in pedal arm 3. Then tighten screw.
Check drive shaft for excessive wear, scores or
damage on sliding surface for oil seal. Check splines

Printed in Germany
50 Power Train Model 2120 Tractor
5-6 Engine Clutches and Clutch Linkage TM-4252 (Dec-70)

Adjusting clutch pedal for operation of engine Reinstall clevis pin through yoke 8 and arm 3,
clutch only on tractors with dual-stage clutch securing with cotter pins. Tighten lock nut 9.

Loosen cap screw (see 6, fig. 3) and move clutch

pedal forward until cap screw contacts rear of slot
in pedal arm. Then tighten cap screw.

Fig. 4 — Adjusting Clutch Pedal and Free Travel

on Tractors Equipped with Single-Stage
Clutch
Fig. 3 — Adjusting Clutch Pedal, Pedal Arm and 1 Clutch pedal 9 Lock nut
3 Clutch arm b Stop bracket
Free Travel on Tractors Equipped with 6 Cap screw e Free travel
Dual- Stage Clutch 8 Yoke

1 Clutch pedal 8 Yoke

3 Pedal arm 9 Lock nut Adjustment for tall operators: In this case loosen
6 Cap screw e Free travel cap screw 6 and push clutch pedal (see 1, fig. 4)
forward until cap screw contacts rear of slot in arm
Adjusting clutch pedal free travel on tractors 3. Tighten cap screw.
equipped with dual-stage clutch
Remove clevis pin from yoke 8 and arm 3. Loosen
Remove clevis pin from yoke (see 8, fig. 3) and lock nut 9. Thread yoke on clutch rod until clutch
arm 3. Loosen lock nut 9. Thread yoke 8 on clutch pedal shows specified free travel, measured from
rod until clutch pedal shows specified free travel foot rest (see "e", fig. 4 and Specifications).
(see "e", fig. 3 and Specifications). Remove stop bracket "b" when making this
adjustment thus ensuring that the engine clutch
Reinstall clevis pin through yoke 8 and arm 3 and can be fully disengaged. In this case the foot rest
secure with cotter pin. Tighten lock nut 9. acts as a stop, ensuring that no damage occurs to
the clutch linkage.
Adjusting clutch pedal and free travel on tractors
equipped with single-stage clutch. Reinstall clevis pin through yoke 8 and arm 3 and
secure with cotter pins. Tighten lock nut 9.
Normal Adjustment: Loosen cap screw 6 (fig. 4)
and move clutch pedal to the rear until cap screw On both clutch types
contacts front end of slot in arm. Tighten cap
screw. CAUTION: If clutch pedal free travel is less than
specified minimum (see Specifications), do not
Remove clevis pin from yoke 8 and arm 3. Loosen start engine until correct free travel has been set.
lock nut 9. Thread yoke on clutch rod until clutch
pedal shows specified free travel (see "e", fig. 4).
Make sure clutch is completely disengaged before
clutch pedal comes against stop bracket "b".

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Engine Clutches and Clutch Linkage 5-7

ENGINE DUAL-STAGE CLUTCH

L 51 508
wvww
Fig. 5 — Engine Dual-Stage Clutch, Sectional View
1 Drive shaft 3 Sleeve 6 Rear driven disk 8 Front pressure plate
2 Hollow PTO 4 Clutch throw-out bearing and carrier (PTO chitch) 9 Front driven disk (engine clutch)
drive shaft 5 Release lever (3 used) 7 Rear pressure plate 10 Pilot bearing
11 Cap screw (6 used)

GENERAL INFORMATION (see 9, fig. 5) is splined to drive shaft 1and the rear
disk 6 is splined to hollow PTO drive shaft 2.
The dual-stage clutch combines the functions of Driven disk 9 transfers power to the transmission
two single-disk clutches. The dual-stage clutch has whereas driven disk 6 transmits power to the PTO
two driven disks of different sizes. The front disk shafts.

Printed in Germany
50 Power Train Model 2120 Tractor
5-8 Engine Clutches and Clutch Linkage TM-4252 (Dec-70)

REMOVAL Back hex.nuts (see 18, fig. 6) off operating bolts

16 and remove spacers 17.
Separate tractor between engine and clutch
housing, see section 10, group 25. Remove both snap rings 12 from each release lever
10 and unhook loop spring 11 from pivot pin 13.
Remove cap screws (see 11, fig. 5) and lift out Drive spring pins 14 out of release levers 10 and
clutch assembly, taking care of engine clutch disk 9 pivot pins 13. Push pivot pins out of base plate 7
which comes free. and release levers. Remove release levers and base
plate, taking care not to lose release pins 8.
CAUTION: Prevent oil or grease from getting on
the engine clutch disk 9. Remove gear driven disk 6 (PTO clutch), rear
pressure plate 5, diaphragm spring 4, front pressure
DISASSEMBLY plate 3 and operating bolts 16.

NOTE: The clutch assembly is balanced. There¬

fore, mark the individual parts before disassembly
to facilitate proper reassembly.

as
L51291

Fig. 6 — Exploded View of Engine Dual-Stage Clutch

1 Clutch assembly 6 Rear pressure plate 9 Bushing (6 used) 14 Spring pin (3 used)
2 Front driven disk 6 Rear driven disk <PTO clutch) 10 Release lever (3 used) 15 Cap screw (6 used)
(engine clutch) 7 Base plate 11 Loop spring (3 used) 16 Operating bolt (3 used)
3 Front pressure plate 8 Release pin (3 used) 12 Snap ring (G used) 17 Spacer (3 used)
4 Diaphragm spring 13 Pivot pin (3 used) 18 Hex.nut (6 used)

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Engine Clutches and Clutch Linkage 5-9

REPAIR ASSEMBLY

DRIVEN DISKS When assembling, observe the following:

Check all rivets and facings on driven disks for Coat the indicated faces and bores of the following
serviceability. Facings should be smooth, even and parts with MOLYKOTE BR 2 grease:
free of grease and oil, nor should they be glazed.
The sides of the three lugs of front pressure plate
If any rivets or facings are loose or if facings are (see 3, fig. 6) and rear pressure plate 5, the sides of
excessively worn (see Specifications), replace the three longidutinal flywheel grooves, the bores
defective disk. Check each disk for distortion. of base plate 7 for seating the three release pins 8
Inspect disk splines for wear and damage. and the three operating bolts 16 as well as the
bores of the six bushings 9, the faces of diaphragm
PRESSURE PLATES AND BASE PLATE spring 4 which contact front and rear pressure
plates, surfaces of three release pins 8 and bearing
Check friction faces of pressure plates and base surfaces of the three pivot pins 13.
plate for wear and flatness by means of a feeler
gauge and a true square (see Specifications for wear The clutch assembly is balanced. Therefore, when
tolerance). Replace pressure plates or base plate if reassembling observe the marks made during
scored or otherwise damaged. disassembly.

FLYWHEEL AND PILOT BEARING Install front driven disk (see 2, fig. 6) in flywheel
with long part of hub facing toward flywheel.
See section 20, group 20 for checking and repair of Align with pilot bearing by means of centering tool
flywheel and pilot bearing. No. 19.58-90.486.

DIAPHRAGM SPRING To facilitate assembly, the heads of the three

operating bolts should be flush against front
Check diaphragm spring for heat cracks or pressure plate. For this purpose, place a suitable
distortion. Do not hesitate to renew spring if spacer between each operating bolt and flywheel.
operation is doubtful.
Place diaphragm spring 4 with cupped face on
RELEASE PINS AND OPERATING BOLTS front pressure plate 3.

Check release pins and operating bolts for wear on When placing rear pressure plate 5 on diaphragm
contact faces. Check threads of operating bolts for spring, move diaphragm spring so that it aligns
wear. properly with pressure plate, if required.

RELEASE LEVERS Position rear driven disk 6 on rear pressure plate 5

with long hub end facing away from flywheel.
Check contact faces of release levers for wear and
pitting. When base plate 7 and release pins 8 have been
installed, align front driven disk 2 and rear driven
LOOP SPRINGS disk 6 with pilot bearing in flywheel by means of
centering tool No. 19.58-90.486 (see fig. 7). This
Inspect loop springs for rusty spots, fatigue and applies especially to rear driven disk 6, which, if
distortion. Replace, if necessary. misaligned, will impede assembly of engine to
clutch housing.

Printed in Germany
50 Power Train Model 2120 Tractor
5-10 Engine Clutches and Clutch Linkage TM-4252 (Dec-70)

.V/

Fig. 7 — Driven Disks Aligned with Pilot Bearing

of Flywheel
c Centering tool No. 19.58-90.486 6 Rear driven disk
e Spacer 7 Base plate

After having properly tightened clutch assembly to

flywheel (for specified torque see Torques for
Hardware), withdraw centering tool.

Thread second hex.nut (see 18, fig. 6) on each Fig. 8 — Dimension for Adjusting Engine Dual-
operating bolt and tighten only after release levers Stage Clutch
have been adjusted.
a Distance between clutch release 1 Release pin
levers and hub face of rear 2 Release lever
ADJUSTMENT driven disk

Whenever the clutch has been disassembled or a NOTE: Be sure all three release levers are evenly
new front driven disk or flywheel has been adjusted.
installed, do not forget to adjust the release levers.
The clutch release levers can be adjusted by means
of a separate flywheel or the flywheel attached to
the engine. The adjusting dimension "a" shown in
figure 8 and under "Specifications" applies only if
both driven disks are new.

Measure distance "a" between pressure face of

each release lever and hub face of rear driven disk
by means of a depth gauge (see 2, fig. 8). See
"Specifications" for adjusting dimensions.

Fig. 9 — Determining Clearance "a" with Depth

Gauge
d Depth gauge e Spacer

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Engine Clutches and Clutch Linkage 5-11

If assembly or adjustment is not made with engine ADJUSTING ENGINE DUAL-STAGE CLUTCH
flywheel installed, place a suitable spacer (see "e" EXTERNALLY
figs. 7 and 9) between each release lever and base
plate. Disconnect linkage of clutch pedal

INSTALLATION
Install flywheel (if necessary). Tighten attaching
screws crosswise to the specified torque.

Fig. 11 Adjusting Engine Dual-stage Clutch

Externally
1 Release pin 4 Operating bolt
2 Release lever 5 Throw-out bearing
3 Hex.nuts

Fig. 10 — Installing Engine Dual-Stage Clutch Loosen two hex.nuts (see 3, fig. 11) of each
1 Clutch assembly 3 Centering tool operating bolt 4 until release lever 2 contacts
2 Front driven disk relative release pin 1.

Insert centering tool No. 19.58-90.486 (see 3, fig. NOTE: Rotate flywheel so that hex.nuts of each
10) in clutch assembly. Slide front clutch disk 2 on operating bolt consecutively become accessible
tool with long hub end facing away from clutch through opening of clutch housing.
assembly.
Tighten inner nut 3 of an operating bolt 2-1/2
Align lugs of pressure plates with slots of flywheel. turns. Attach linkage of clutch pedal and adjust so
Install clutch assembly in flywheel. Insert pilot of that throw-out bearing 3 contacts adjusted release
centering tool in pilot bearing of flywheel. Attach lever 2.
clutch assembly to flywheel. Tighten cap screws
crosswise to the specified torque (see Adjust remaining two release levers with the aid of
Specifications). operating bolt hex.nuts so that they just touch
throw-out bearing. Then tighten lock nuts of each
Re-install all parts of engine and/or tractor operating bolt.
removed or separated to facilitate removal of parts
explained in this group (see section 10, group 25). Adjust clutch pedal free travel.

Printed in Germany
50 Power Train Model 2120 Tractor
5-12 Engine Clutches and Clutch Linkage TM-4252 (Dec-70)

ENGINE SINGLE-STAGE CLUTCH

(Tractors with Independent PTO)

Fig. 12 — Engine Single-Stage Clutch, Sectional View

1 Drive shaft 4 Throw-out bearing and carrier 7 Hex.socket screw (6 used) 10 Pilot bearing
2 Hollow PTO drive shaft 5 Release lever (3 used) 8 Pressure plate 11 Cap screw (6 used)
3 Sleeve 6 Torsion damper 9 Clutch disk

The engine single-stage clutch is a single dry-disk The clutch disk (see 9, fig. 12) is splined to the
type. It consists essentially of the pressure plate drive shaft 1and torsion damper 6 is splined to the
assembly complete with diaphragm spring, and a hollow drive shaft.
torsion damper (see 6, fig. 12) secured to the base
plate.

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Engine Clutches and Clutch Linkage 5-13

The clutch disk transfers power to the transmission Remove cap screws (see 11, fig. 12) which secure
whereas the torsion damper transfers power to the the clutch assembly to the flywheel. Lift out
PTO shaft. clutch assembly, taking care of clutch disk 9 which
comes free.
REMOVAL
CAUTION: Prevent oil or grease from getting on
Separate tractor between engine and clutch the engine clutch disk.
housing, see section 10, group 25.

10 14 15

l 50360

Fig. 13 — Engine Single-Stage Clutch, Exploded View

1 Clutch disk 7 Torsion damper 12 Pivot pin (3 used) 18 Clutch fork
2 Operating bolt (3 used) 8 Hex.socket screw (6 used) 13 Snap ring (6 used) 19 Bushing
3 Pressure plate 9 Release lever (3 used) 14 Washer (3 used) 20 Spring pin (2 used)
4 Diaphragm spring 10 Loop spring (3 used) 15 Hex.nut (6 used) 21 Clutch shaft
5 Base plate 11 Spring pin (3 used) 16 Return spring 22 Bushing for pivot pin
6 Cap screw (6 used) 17 Throw-out bearing with carrier (6 used)

DISASSEMBLY REPAIR

Back hex.nuts (see 15, fig. 13) off operating bolts CLUTCH DISK
2 and remove washers 14. Remove both snap rings
13 from each release lever 9. Unhook loop springs Check all rivets and facings on clutch disk (see 1,
10 from pivot pins 12. Drive spring pins 11 out of fig. 13) for serviceability. Facings should be
release levers 9 and pivot pins 12. Push pivot pins smooth, even and free of grease and oil, nor should
12 out of base plate 5 and release levers 9. Remove they be glazed.
release levers.
If any rivets or facings are loose or if facings are
Take out base plate complete with torsion damper excessively worn (see Specifications), replace
7 and separate by removing the six hex. socket clutch disk.
screws 8.
Check clutch disk for distortion.
Remove diaphragm spring and operating bolts 2
from pressure plate 3. Inspect clutch disk splines for wear and damage.

Printed in Germany
50 Power Train Model 2120 Tractor
5-14 Engine Clutches and Clutch Linkage TM-4252 (Dec-70)

PRESSURE PLATE AND FLYWHEEL PILOT BEARING

Check friction face of pressure plate (see 3, fig. 13) Check flywheel pilot bearing for roughness and
and flywheel for wear and flatness by means of a excessive wear. Make sure bearing is seated
feeler gauge and a true square (see Specifications correctly in flywheel bore. See section 20, group
for wear tolerance). Replace if scored or otherwise 20 for renewal of pilot bearing.
damaged.
ASSEMBLY
DIAPHRAGM SPRING
NOTE: The clutch assembly is balanced.
Check diaphragm spring 4 for heat cracks or distor¬ Therefore, when reassembling observe the marks
tion. Do not hesitate to renew, if operation is made during disassembly.
doubtful.
Coat the indicated faces and bores of the following
OPERATING BOLTS parts with MOLYKOTE BR 2 grease: The sides of
the three lugs of front pressure plate 3 (fig. 13) and
Check operating bolts 2 for wear on contact faces the corresponding three grooves in the flywheel,
and proper condition of threads. the bores of base plate 5 for seating operating bolts
2, the faces of diaphragm spring 4 which contact
pressure plate 3 and base plate 5, the surface of
RELEASE LEVERS pivot pins 12 and the bores of bushings 22.
Check contact faces of release levers 9 for wear and Insert the three operating bolts (see 2, fig. 13) in
pitting. bores of pressure plate (from friction side). Place
pressure plate on work bench.
PIVOT PINS AND BUSHINGS
Place diaphragm spring 4 (in alignment) on
Check pivot pins 12 and bushings 22 for wear or pressure plate with cupped face toward pressure
scoring. Replace if necessary. plate.

LOOP SPRINGS Secure torsion damper (see 7, fig. 13) to base plate
5, tightening hex. socket screws 8 to specified
Inspect loop springs 10 for rusty spots, fatigue and torque (see Torques for Hardware).
distortion. Replace if necessary.
Guide pre-assembled base plate over the three
TORSION DAMPER operating bolts 2 and place on diaphragm spring 4.
If necessary, shift diaphragm spring so that it is
Check ail rivets on the torsion damper. Replace, if properly seated around the shoulder of the base
any rivets are loose. Check torsion damper splines plate.
for wear or damage. Check damper springs for
serviceability. Place the three release levers 9 over the three
operating bolts 2. Push pivot pins 12 into bushings
22 located in base plate 5 and into release levers 9.
Make sure bore in each pivot pin (for installing
spring pin 11) is in line with bore in release levers.
Drive in spring pins flush with release levers.

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Engine Clutches and Clutch Linkage 5-15

Place loop springs 10 on release levers 9. Press Remove centering tool.

springs (to obtain necessary tension) downward
and push over the end of pivot pins 12. Finally ADJUSTMENT
secure springs in position with two snap rings 13.
NOTE: The engine clutch can be adjusted in
Slide washer 14 over each operating bolt 2, thread conjunction with its flywheel only.
hex. nut 15 on each bolt and tighten. Do not install
second hex. nut (lock nut) until adjustment of Whenever the clutch has been disassembled or a
release levers has been completed. new clutch disk or flywheel has been installed, do
not forget to adjust the release levers.
INSTALLATION
Measure clearance between pressure face of each
Install flywheel (if necessary). Tighten attaching release lever (see 2, fig. 15) and torsion damper
screws crosswise to the specified torque. hub splines by means of a depth gauge as shown in
fig. 15 (see "Specifications" for adjustment dimen¬
Insert centering tool No, 19.58-90.486 (see 1, fig. sions).
14) in clutch assembly. Slide clutch disk 2 on tool
with long hub end facing away from clutch
assembly.

Fig. 15 — Adjusting
Gauge
Release Levers with Depth

2 3 1 Depth gauge 3 Adjusting nut

Fig. 14 — Installing Engine Single-Stage Clutch

2 Release lever

1 Centering tool 3 Clutch assembly If measured clearance is larger than that quoted in
2 Clutch disk Specifications, slacken hex. nut 3 accordingly. If
the clearance is less, the nut must be tightened
Align lugs of pressure plate with slots of flywheel. until the correct clearance has been obtained.
Install clutch assembly in flywheel. Insert pilot of When adjustment is completed, tighten lock nuts.
centering tool in pilot bearing of flywheel.
IMPORTANT: To safeguard proper operation of
Attach clutch assembly to flywheel. Tighten cap engine clutch, difference in height of release levers
screws crosswise, gradually (with this the should not exceed specified measurement (see
diaphragm spring is tightened) to the specified Specifications).
torque (see Torques for Hardware).
Reassemble tractor between clutch housing and
engine, see section 10, group 25.

Printed in Germany
50
5-16

.
Power Train
Engine Clutches and Clutch Linkage

CLUTCH LINKAGE

..........
......
.....
...
Dia, of hollow PTO drive shaft
seat for roller bearing

.....................
Dia. of drive shaft seat for pilot bearing

Dia. of needle bearing bore of

clutch housing

.........
........
Dia. of clutch pedal bearing pin

Inner dia. of clutch pedal bushing

(installed)

housing face .......

....... .......
.........
...........
Clearance between bushing face and clutch

........
Dia. of clutch shaft in clutch housing
SPECIFICATIONS

Clearance between oil seal face and clutch housing face

clutch housing by

............
Bearing pin of clutch pedal protrudes from
.

Inner dia. of clutch shaft bushing (installed)

ENGINE DUAL-STAGE CLUTCH

...........
............
Thickness of a new engine clutch disk

Thickness of a new PTO clutch disk

Maximum permissible wear or roughness of

pressure plate, base plate and flywheel .

Printed in Germany
.
Dimensions of New Parts

1.9651 to 1.9657 in.

49.913 to 49.929 mm

0.5895 to 0.5901 in,

14.973 to 14.989 mm

2,1245 to 2,1255 in.

53.962 to 53.988 mm
1.3 in.
33.3 mm

2.5 in.
63.5 mm

0.9975 to 0.9985 in.

25.336 to 25.362 mm

1.0030 to 1.0075 in,

25.48 to 25.59 mm

2.8 in.
71.5 mm

1.122 to 1.128 in.

28.50 to 28.66 mm

1.128 to 1.132 in.

28.65 to 28.75 mm

0.366 to 0.390 in.

9.3 to 9.9 mm

0.303 to 0.327 in.

7.7 to 8.3 mm
Model 2120 Tractor
TM-1252 (Dec-70)

Wear Tolerance

0.238 in.
6.3 mm

0.185 in.
4.7 mm

0.006 in.
0.15 mm
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Engine Clutches and Clutch Linkage 5-17

Dimensions of New Parts Wear Tolerance

Adjustments
Clearance of clutch levers from hub
face of rear clutch disk 1.466 to 1.474 in.
37 to 37.6 mm

Clutch pedal free travel approx. 1in. approx. 0.5 in.

25 mm 13 mm

ENGINE SINGLE-STAGE CLUTCH

Thickness of a new clutch disk .. 0.366 to 0.390 in. 0.238 in.

9.3 to 9.9 mm 6.3 mm

Maximum permissible wear or roughness of

pressure plate and flywheel 0.006 in.
0.15 mm

Adjustments

hub splines (see fig. 15) ..................

Clearance between release levers and torsion damper

Maximum permissible difference in height

1.791to 1.811 in.
45.5 to 46.0 mm

of release levers

Clutch pedal free travel ....

TORQUES FOR HARDWARE
0.01 in.
0.25 mm
approx. 1in.
25 mm
approx. 0.5 in.
13 mm

ENGINE DUAL-STAGE CLUTCH

Flywheel to crankshaft, cap screws

Clutch assembly to flywheel, cap screws ........... 85 ft.lbs.

33 to 40 ft.lbs.
11.7 mkg
4.5 to 5.5 mkg

...........
ENGINE SINGLE-STAGE CLUTCH

......
Flywheel to crankshaft, cap screws 85 ft.lbs. 11.7 mkg

Clutch assembly to flywheel, cap screws 33 to 40 ft.lbs. 4.5 to 5.5 mkg

Torsion damper to base plate, hex.socket screws 14 to 20 ft.lbs. 2.0 to 2.5 mkg

........
SPECIAL TOOLS
Part No. if ordered from
JD Parts Depot Manufacturer Description Ubc

19.58-90.486 Centering tool Installing engine clutch

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) HIGH-LOW Shift Unit 10-1

Group 10
HIGH-LOW SHIFT UNIT
GENERAL INFORMATION

i/;

Fig. 1— HIGH-LOW Shift Assembly, Sectional View

1 Transmission input shaft 9 HIGH-LOW housing 18 Planet gear (3 used)
2 Oil inlet from control valve to HIGH clutch 10 LOW brake piston 19 Backing plate
3 Oil inlet from control valve to LOW brake 11 Planet pinion carrier 20 Drive gear for 1000 rpm PTO
4 Oil manifold 12 Planet sun gear (tractors with dual PTO)
5 Hollow gear shaft (for driving transmission 13 HIGH clutch for normal travel speed 21 Driven gear for 1000 rpm PTO
oil pump and PTO shaft) 14 HIGH clutch drum 22 Driven gear for 540 rpm PTO
6 Transmission oil pump 15 HIGH clutch piston (tractors with continuous
7 HIGH-LOW cover 16 Hollow drive shaft (integral with running PTO)
8 LOW brake HIGH-LOW housing 9) 23 Front plate of transmission case
17 Drive shaft

Printed in Germany
50 Power Train Model 2120 Tractor
10-2 HIGH-LOW Shift Unit TM-4252 (Dec-70)

The HIGH-LOW shift unit (see fig. 1) is a hydraulic The return oil from the oil cooler serves to
gear reduction unit which can be shifted under lubricate the HIGH-LOW shift unit.
load. This unit allows the operator to shift to a
lower range in any transmission gear while "on the
go" and without declutching. CONTROL VALVE ASSEMBLY

Shifting from HIGH to LOW decreases the travel

speed by 26% and boosts torque to the tractor rear
axle by 35% (LOW brake see item 8, fig. 1).
Shifting back to HIGH deactivates the reduction
part of the HIGH-LOW unit and the tractor
resumes the speed selected by the transmission.

The HIGH-LOW shift unit is located in front of the

transmission and contained in the clutch housing.
It consists essentially of a control valve assembly
located in the transmission shift cover, a HIGH
hydraulic clutch for normal travel speed, a LOW
hydraulic brake for reduced travel speed (both of
the multiple-disk type) and a planetary assembly
(see fig. 1).

OIL SUPPLY

Pressure oil to operate the HIGH-LOW shift unit is

supplied by the transmission oil pump located
directly behind the HIGH-LOW shift unit (see item
6, fig. 1). L 48468

Oil from the transmission oil pump passes through

transmission oil filter to the control valve unit in
Fig. 2 — Operation of HIGH-LOW Control Valve
Assembly
the transmission shift cover.
1 Pressure regulating valve
2 To oil manifold and HIGH clutch
A pressure regulating valve located in the control 3 Control valve
valve unit (see item 1, fig. 2) maintains the oil 4 To oil manifold and LOW brake
5 Passage for pressure oil from
pressure required for clutch or brake pack transmission oil pump
operation (see Specifications). As little oil only is 6 Passage for oil flowing to main hydraulic pump
required for operating the disk packs, the main oil 7 Pressure oil (100 psi = 7 kg/ cm2)*
8 Pressure oil (50 psi = 3,5 kg/cm2)
stream flows past the pressure regulating valve 1, 9 Pressure-free oil
through by-pass 6 to the relief valve in the right-
hand side of the clutch housing. The control valve assembly in the transmission
shift cover (see fig. 2) contains a control valve 3
This relief valve senses pressure to and from the and a pressure regulating valve 1.
main hydraulic pump, preventing the build-up of
excessive pressure due to restriction (see section The control valve 3 is a spool-type valve shifted by
70).
the HIGH-LOW control lever. It directs oil to
engage the HIGH clutch and the LOW brake and
returns oil from the opposite unit. The valve has
two detented positions, HIGH and LOW. There is
no neutral position.

* Oil pressure on tractors equipped with indepen¬

dent PTO = 150 psi (10.5 kg/cm2)

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) HIGH-LOW Shift Unit 10-3

The pressure regulating valve 1 is adjustable by With control lever in LOW position, pressure oil
shims to maintain the oil pressure required for from the control valve causes the piston 10 to
HIGH clutch or LOW brake engagement (see engage the LOW brake disks and plates, forming a
Specifications). solid unit. Thus rotation of planet pinion carrier 11
will be prevented.

HYDRAULIC FUNCTION OF HIGH-LOW UNIT Now the pinions function as countershafts, trans¬
mitting power from the clutch shaft gear to the
Power flow in HIGH drive planet sun gear. The different gear ratios cause the
reduction in speed for LOW drive. The sun gear
At the input end, drive shaft 17 (fig. 1) is driven at transmits power over the input shaft 1to the trans¬
engine speed by the engine clutch disk (the shaft is mission.
splined to the disk). The HIGH clutch hub is
welded to the drive shaft. The bronze disks (3 Both the clutch and brake packs are disengaged by
used) are splined to the hub and the separator spring washers acting on the piston. Any time one
plates (4 used) are tanged to the HIGH clutch pack is engaged, the other one is disengaged.
drum 14.
PTO power flow
With control lever in HIGH position, pressure oil
from the control valve causes the piston 15 to Engine power is transmitted through the rear
engage the HIGH clutch disks and plates, forming a driven disk of PTO clutch* or torsion damper** of
solid unit. engine clutch, splined to the hollow drive shaft (see
16, fig. 1) and thus to HIGH-LOW housing 9
Now the planet pinion carrier, attached to the welded to the hollow drive shaft. From here power
HIGH clutch drum, rotates with the clutch shaft. is transferred through HIGH-LOW housing cover 7,
attached to HIGH-LOW housing to the hollow gear
Since the larger planet pinion gear is in mesh with shaft which is splined to the HIGH-LOW housing
the clutch shaft gear, it is locked to the planet cover. The hollow gear shaft is provided with the
pinion carrier. Therefore, the rotating force of the PTO drive gear (540 rpm) for continuous-running
carrier is transmitted to the planet sun gear or independent PTO, The shaft and gear are
through the smaller planet pinion gear while the machined as an integral assembly. On tractors
planet pinions are stationary. equipped with dual speed continuous-running PTO
the gear is keyed to the hollow shaft (see 20, fig. 1)
The power flow continues from the planet sun gear and drives the 1000 rpm PTO. The shaft also drives
through the transmission input shaft 1 onto the the large transmission oil pump gear (see fig. 1).
transmission.

Power flow in LOW drive

The hub of LOW brake 8 (fig. 1) is splined to the

shaft of clutch oil manifold 4. The LOW brake
disks (4 used) are splined to the hub and the
separator plates (4 used) are tanged to the planet
pinion carrier.

* Tractors equipped with engine dual-clutch

(Tractors with continuous-running PTO)
Tractors equipped with engine single-stage
** clutch
(Tractors with independent PTO)

Printed in Germany
50 Power Train Model 2120 Tractor
10-4 HIGH-LOW Shift Unit TM-4252 (Dec-70)

CHECKING OPERATING PRESSURE DIAGNOSING MALFUNCTIONS

If adjusting pressure does not correct trouble, carry

out the following checks:

CHECKING FOR CLOGGED TRANSMISSION

OIL FILTER

A clogged filter is very difficult to detect from the

outside. When the filter is almost clogged, the oil
flow to the HIGH-LOW pressure regulating valve
and the main hydraulic pump charging circuit will
be very small. Since only a small volume is required
to operate the HIGH-LOW disk packs, there will be
hardly an indication of disk pack slippage. As the
hydraulic system has an auxiliary oil reservoir,
operation of most hydraulic units will appear
regular.

The function of the tractor hydraulic system that

Fig. 3 — Checking Operating Pressure at Pressure will be most affected by this reduced oil flow is
that of transmission and HIGH-LOW unit
Regulating Valve
lubrication. Prolonged operation with a clogged
1 Low pressure gauge No. filter element could cause a HIGH-LOW unit
19.58-90.268 failure due to lack of lubrication.
2 High pressure hose of special tool
No. 19.58-90.260
3 Special adapter 19.58-90.266
4 Plug
CHECKING TRANSMISSION PUMP OUTPUT

Operate rockshaft or selective control valve lever

Remove plug on right side of transmission shift continuously with remote cylinder connected.
cover and connect gauge No. 19.58-90.268 Since each of these two units requires a specified
(measuring range from 0 to 355 psi = 0 to 25 oil quantity for normal operation, and since this
kg/cm2) with the aid of pressure hose assembly volume of oil is returned to the transmission case,
and adapter No. 19.58-90.266 of special tool No. rockshaft or remote cylinder operation will be
19.58-90.260 (see fig. 3). affected by the transmission oil pump output.
Move range shift lever in park position or apply If transmission oil pump output is low, rockshaft
hand brake and move gear shift lever in neutral or remote cylinder will operate very slowly when
position. Run engine at specified speed (see Speci¬ the auxiliary hydraulic oil reservoir of tractor is
fications). empty.
Actuate HIGH-LOW control lever to warm oil to
normal operating temperature and observe gauge
(operating pressure see Specifications).

If operating pressure is not within specified range,

remove plug 4 (fig. 3) of pressure regulating valve
in control valve assembly. Adjust to proper
operating pressure by adding or removing shims
located between plug and valve spring.

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) HIGH-LOW Shift Unit 10-5

A broken transmission filter relief valve spring CHECKING OPERATION OF INDEPENDENT

could also cause the low flow in the system. PTO (if equipped)

However, if rockshaft or remote cylinder operate On tractors equipped with independent PTO, con¬
properly, all the components in the main hydraulic nect a manometer No. 19.58-90.260 of special tool
pump charge circuit can be considered in good No. 19.58-90-260 to pressure oil channel of PTO
condition and the problem is in the HIGH-LOW clutch and one to pressure oil channel of PTO
circuit. brake (see group 35). Connect a further mano¬
meter No. 19.58-90.268 to pressure regulating
Check for a broken pressure regulating valve spring
valve (see fig. 3).
or a sticking pressure regulating valve.
Start engine. Fully engage and disengage PTO by
means of control lever. The manometer connected
CHECKING OPERATION OF HIGH-LOW SHIFT to pressure channel of pressure regulating valve and
UNIT one of the two manometers connected to PTO
pressure oil channels (depending on position of
Operate tractor in both HIGH and LOW ranges, PTO control lever) should show a pressure of
carefully observing both operations. Use the brakes 140-160 psi (9.8-11.2 kg/cm2).
to simulate a load condition on the tractor. Low
oil pressure in the HIGH-LOW control valve When this pressure is not reached, slowly move
assembly will be indicated by equal disk pack slip¬ PTO control lever until both manometers con¬
page in both ranges. If operation is normal in one nected to PTO pressure oil channels show no pres¬
range and not in the other, a mechanical failure in sure. Now oil flow to PTO clutch and brake is
the HIGH-LOW shift unit is probably the cause. interrupted and the pressure regulating valve
isolated. The operating pressure at pressure regu¬
Always check operating pressure before disas¬ lating valve should now read 140-160 psi (9.8-11.2
sembling the HIGH-LOW shift unit. kg/cm2).
NOTE: Speed of shifting on HIGH-LOW unit is not If, with the PTO engaged or disengaged, the
adjustable. However, the unit should shift instantly operating pressure is too low but not with isolated
when the control lever is moved. The correct pres¬ pressure regulating valve, a leak in the PTO oil
sure adjustment assures oil for fast engagement of system will be the cause (see group 35).
HIGH-LOW disk packs.
If operating pressure is too low both with engaged
or disengaged PTO and with isolated pressure regu¬
lating valve, the fault will not be found at the inde¬
pendent PTO.

Printed in Germany
50 Power Train Model 2120 Tractoi
10-6 HIGH-LOW Shift Unit TM-4252 (Dec-70)

REMOVAL Remove lube oil line 3 to LOW disk brake and lube
oil line 5 to HIGH disk clutch from clutch housing.
Separate tractor between transmission case and
clutch housing, see section 10, group 25. NOTE: Take care of 0-rings located at the end of
each oil line.
Pull transmission input shaft (see 8, fig. 4) out of
HIGH-LOW housing. If installed, remove both independent PTO oil
lines.
Remove retainer holding oil lines. On tractors
equipped with independent PTO, remove PTO oil If installed, remove front PTO shaft (see group 30).
distributor secured to oil manifold and housing of
oil transmission pump complete with retainer and Remove cap screws attaching oil manifold and
two short pressure lines leading to disk packs of transmission oil pump to clutch housing. Remove
HIGH-LOW shift unit. oil manifold with hollow gear shaft and transmis¬
sion oil pump as shown in fig. 5.

Fig. 5 - Removing Oil Manifold with Transmission

Oil Pump

Fig. 4 — Removing Oil Lines

Pull HIGH-LOW shift assembly out of clutch
housing, taking care of thrust washer located
1 Pressure lines to disk packs
2 Pressure line to main hydraulic pump between HIGH-LOW housing and clutch housing.
3 Lube oil line to LOW disk brake
4 Pressure line from transmission oil filter to HIGH-LOW control
valve assembly and PTO clutch control valve assembly
(if independent PTO is equipped)
5 Lube oil line to HIGH disk clutch
6 Pressure line of transmission oil pump
7 Suction line of transmission oil pump
8 Transmission input shaft

Remove suction line 7 (fig. 4) and pressure line 6

of transmission oil pump.

Remove both pressure lines 1* to disk packs of

HIGH-LOW shift assembly through top of clutch
housing. Remove pressure lines 2 and 4.

* Not on tractors equipped with independent PTO

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) HIGH-LOW Shift Unit 10-7

DISASSEMBLY CAUTION: Make sure special tool is centered over

spring washer pack. After snap ring is removed,
Remove cover from HIGH-LOW housing and pull release pressure slowly and keep fingers away.
HIGH-LOW shift assembly out of housing, taking
care of the thrust washer located between housing Remove spring washers and annular piston.
and clutch drum.
The planet pinions rotate in a carrier on shafts (see
Remove three short cap screws (see 26, fig. 7) and 45, fig. 7) and are supported by two sets of needle
three long cap screws 25 from cover plate 27. bearings 42 which are separated by spacer 44.
Remove cover plate as well as planet pinion carrier.
Prior to removal, rotate planet pinions until "V"
Store disks in installation sequence. marks match the "V" marks on sun gear. Then
identify planet pinions and sun gear so that marks
on pinions exactly match the SAME marks on sun
gear when reassembling.

NOTE: Identification is necessary only if old

planet pinions are to be installed again.

To remove planet pinions, pull bearing pins slightly

out of planet pinion carrier by means of a 1/4 in.
cap screw and remove detent ball at end of each
bearing pin. Be careful not to lose the balls.

Pull bearing pins completely out of carrier and

remove planet pinions, needle bearings, spacers and
thrust washers.

NOTE: Be careful not to lose the needle bearings.

There are 44 needles in each planet pinion or a
total of 132 needles for the pinion set.
Fig. 6 — Removing Annular Piston of HIGH Disk
Clutch
Remove sun gear and thrust washer from planet
a Special tool No. 19.58-90,617 pinion carrier.
1 Annular piston
2 Snap ring
3 Spring washers

To facilitate removal of annular piston (see 1, fig.

6) from planet pinion carrier or HIGH clutch
drum, first remove snap ring 2 retaining spring
washers 3 in planet pinion carrier or clutch drum.

Position special tool No. 19.58-90.617 (see item

"a", fig. 6) on spring washers and press washers
down so that the snap ring can be removed.

Printed in Germany
50 Power Train Model 2120 Tractor
10-8 HIGH-LOW Shift Unit TM-4252 (Dec-70)

Fig. 7 — HIGH-LOW Shift Assembly, Exploded View

1 Sealing rings 22 Roller bearing 43 Planet pinion (3 used)

2 Transmission input shaft 23 Cap screw (6 used) 44 Spacer (3 used)
3 Oil tube 24 HIGH-LOW housing cover 45 Planet pinion bearing pin (3 used)
4 Sealing ring 25 Cap screw (3 used) 46 Bushing
5 Retainer 26 Cap screw (3 used) 47 Drive shaft
6 Sealing rings 27 Cover plate of disk brake 48 Drum of disk clutch
7 Cap screw (3 used) 28 Bronze disks 49 Bushing
8 Cap screw (2 used) 29 Separator plates 50 Thrust washer
9 Oil manifold with bushing 30 Brake hub 51 Bushing
10 Thrust washer 31 Snap rings 52 Oil seal ring
11 Hollow gear shaft 32 Spring washers 53 Dowel
12 Roller bearing 33 Sealing rings 54 HIGH-LOW housing and hollow drive shaft
13 Cap screw 34 Annular piston 55 Thrust washer
14 Transmission oil pump housing 35 O-rings 56 Bushing
15 Bearing pin 36 Planet pinion carrier 57 Oil seal ring
16 Pump drive gear 37 Bushing 58 Pilot bearing (flywheel)
17 Pump driven gear 38 Dowels 59 Woodruff key only on tractors
18 Cap screw (4 used) 39 Thrust washers 60 Drive gear for equipped with
19 Transmission oil pump cover 40 Sun gear 1000 rpm PTO dual continuous-
20 Dowel (4 used) 41 Thrust washers (6 used) 61 Snap ring running PTO
21 Dowel (2 used) 42 Bearing needles (44 used per pinion)

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) HIGH-LOW Shift Unit 10-9

REPAIR Check control arm 7 and shaft for wear or damage

and replace, if necessary.
CONTROL VALVE ASSEMBLY
NOTE: Numbers behind parts in the following text To remove valve spool 12, pull off rubber boot and
refer to fig. 8. snap ring of gear shift lever (R.H. lever). Withdraw
gear shift lever with retaining ring from transmis¬
sion shift cover.

Remove control valve plate 20 on bottom of trans¬

mission shift cover; also remove bearing needle 18
(on tractors not equipped with independent PTO).

Remove spring 16 and ball 17 from transmission

9 shift cover.

Push valve spool 12 and plug 11 out of transmis¬

sion shift cover. Inspect valve spool for scores or
burrs and replace, if necessary.

Remove plug 23 of pressure regulating valve,

29 special shims 25, spring 26 and valve body 27 from
cover bore.

Check detent spring 16 and pressure regulating

spring 26 for damaged or broken coils. Check
spring resilience (see Specifications).
24
26
Only on tractors not equipped with independent
28 PTO: When installing parts, start with detent ball
25 17. Then insert detent spring 16 in bore and com¬
o
23 20 press until bearing needle 18 for securing spring 16
can be inserted.
22
Only on tractors equipped with independent PTO :
When installing parts, first insert detent spring 16
and detent ball 17 into transmission shift cover and
press into bore by means of a suitable tool.
L 48490
Fig. 8 —Transmission Shift Cover and Control Insert valve spool 12, with pointed end first, in
Valve Assembly, Exploded View bore of transmission shift cover. Install all other
1 Control valve shaft parts in sequence shown in fig. 8.
2 O-ring
3 Special screw <6 used)
4 Cap screw HIGH-LOW SHIFT UNIT
5 Washer
6 Cover
7 Control valve arm NOTE: Numbers behind parts in the following text
8 Retaining ring
9 Washer refer to fig. 7. For repair of transmission oil pump
10 Gasket see section 70, group 15.
11 Plug
12 Control valve spool
13 O-ring Check transmission oil pump cover 19 for wear and
14 Plug (pressure test)
15 Plug* damage, especially sliding face of gears 16 and 17
16 Detent spring
17 Detent ball
of transmission oil pump. Replace cover, if neces¬
18 Bearing needle* sary.
19 O-ring
20 Control valve plate
21 Cap screw (2 used) Check annular piston 34 of disk brake and clutch
22 Gasket
23 Plug of pressure regulating valve for wear or damage. Replace seal rings 33 and 35.
24 O-ring
25 Special shim (use as required)
26 Pressure regulating valve spring
27 Valve body
28 O-ring
29 Transmission shift cover

* Not provided on tractors equipped with independent PTO

Printed in Germany
50 Power Train Model 2120 Tractor
10-10 HIGH-LOW Shift Unit TM-4252 (Dec-70)

Check spring washers 32 for damage or flattening: Inspect oil manifold 9 and its bushing for damage.
place each washer on a flat support with cupped Replace complete oil manifold, if necessary.
side down and measure height of washer (see Speci¬
fications). Check HIGH-LOW housing and hollow drive shaft
54 (forming an integral unit) for damage. Check oil
Check disks 28 and separator plates 29 for wear. seal ring 52 and bushing 51 for serviceability. Press
Make sure grooved pattern of disk facings is not in new oil seal ring with numbered side facing
worn or rubbed off. Otherwise replace disk. Check driver.
disk splines for broken teeth. For thickness of an
individual disk as well as total stacked height of a If necessary, remove unserviceable bushing 51 from
new disk pack see Specifications. HIGH-LOW housing. Press in new bushing by
means of driver No. 19.58-90.613 and drift No.
Check planet pinion carrier 26 for cracks or other 815 until drift is flush against HIGH-LOW housing.
damage and replace, if necessary.

Inspect brake hub 30, gear and hub of drive shaft CLUTCH HOUSING
47, sun gear 40 and planet pinions 43 for chipped
or worn teeth. Replace parts, if necessary. Check oil seal ring (see 57, fig. 7) and bushing 56
of clutch housing for serviceability. Press new oil
NOTE: If one or two planet pinions must be seal ring in clutch housing bore so that its sealing
replaced, install a complete set (3) of pinions as lip faces driving tool and ring is within clutch
they are matched and are available only as a com¬ housing face by a specified dimension (see Specifi¬
plete set. cations).

Check bearing needles 42 supporting planet pinions Remove unserviceable bushing 56 and install new
for worn spots. A total of 132 bearing needles are bushing by means of driving tool No. 19.58-90.273
used. in clutch housing so that lube oil bores of bushing
match housing bores. Coat bore of bushing with a
Check transmission input shaft 2 for wear and film of oil.
damage and replace, if necessary. Replace sealing
rings 1,4 and 6 on input shaft. When replacing
sealing ring 4, first remove retaining ring 5 from
input shaft.

Now, if necessary, pull oil tube 3 out of input

shaft. Press new oil tube in retaining ring 5. Slide
sealing ring 4 on retaining ring and push oil tube
with retaining ring and sealing ring in transmission
input shaft.

Examine drive shaft 47 for wear or damage. If

bushing 46 is damaged, remove it from shaft and
press in new bushing with open ends of oil grooves
facing outward. Replace sealing rings 1 on drive
shaft.
Fig. 9 — Installing Hydraulic Pump Pressure Line
Adapter
1 Adapter 3 Washer
2 Cap screw

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) HIGH-LOW Shift Unit 10-11

Check adapter (see 1, fig. 9) for pressure line to Insert a thrust washer 41 on each side of planet
main hydraulic pump, situated at the rear and to pinion. Then install bearing pin 45 with threaded
the right in the clutch housing. end facing forward. As a first step, push in pin
sufficiently to allow access to detent ball bore.
If necessary, remove unserviceable adapter and Install ball in bore and push in pin completely so
replace as follows: Remove master cylinder. Drive that it is flush with front face of planet pinion
adapter inwards out of clutch housing. Slide new carrier. Install remaining two pinions in the same
adapter onto cap screw and washer (see 2 and 3, way.
fig. 9). Place against bore in clutch housing. Screw
on hex. nut and tighten, so forcing adapter into IMPORTANT: Make sure "V" mark on each planet
location in clutch housing (see fig. 9). pinion matches corresponding "V" mark on sun
gear.

ASSEMBLY Install drive shaft 47 in planet pinion carrier with

gear first and mesh gear of shaft with planet
NOTE: Numbers behind parts in the following text pinions.
refer to fig. 7.
Slide a steel plate 29 on clutch hub welded to drive
When assembling, principally reverse disassembly shaft 47. First slide a bronze disk, then a steel plate
procedure. Observe the following: etc. on shaft, totaling four steel plates and three
When installing annular pistons, make sure sealing bronze disks.
rings are not inverted or damaged when pistons are
pressed into clutch drum or planet pinion carrier. Slide second thrust washer 39 on drive shaft. Place
clutch drum 48 with spring washers 32 and annular
Install spring washers of disk brake as follows: piston 34 on front side of planet pinion carrier 36.
Place a spring washer 32 on piston with cupped
side facing away from piston. Then place second Slide brake hub 30 over spring washers 32 of disk
spring washer on first washer with cupped side brake. First install a steel plate 29 on brake hub,
facing outward. Install third washer with cupped then follow with a bronze disk, a steel plate etc.,
side facing second washer etc. (see fig. 1). totaling four steel plates and four bronze disks.

Compress spring washers as shown in fig. 6 until Install cover plate 27 and tighten screws to the
snap ring 31 can be inserted in groove, using a press specified torque.
and special tool No. 19.58-90.617. CAUTION: Be
careful when compressing washers. Insert disk clutch, disk brake and planetary gear in
HIGH-LOW housing 54, making sure thrust washer
Install a spacer and 44 bearing needles into each 50 is installed between HIGH-LOW housing and
planet gear. clutch drum. Attach HIGH-LOW cover 24 to
housing 54 and tighten cap screws to the specified
Install planet pinions 43 as follows: Insert planet torque.
pinions with bearing needles in planet pinion
carrier with large gear facing front of carrier and
"V" mark of each pinion matching one of the
three "V" marks on the sun gear.

NOTE: If old pinions are to be installed again,

observe marks made before removal. When
reinstalling planet pinions, they should mesh sun
gear as before removal, i.e. "V" mark of each
planet pinion should match SAME "V" mark on
sun gear as before removal.

Printed in Germany
50

fig. 5)

.
Power Train
10-12 HIGH-LOW Shift Unit

INSTALLATION
Install HIGH-LOW shift assembly in clutch
housing, making sure thrust washer (see 55, fig. 7)
is installed in clutch housing.

If equipped, install front PTO (see group 30).

Install oil manifold and transmission oil pump (see

NOTE: Make sure thrust washer is installed

between hollow gear shaft and oil manifold.

Tighten four cap screws attaching transmission oil

pump cover to clutch housing as well as oil mani¬
fold and transmission oil pump attaching screws to
the specified torque.

Insert transmission input shaft in HIGH-LOW shift

unit through bore of oil manifold. Be careful not
to damage sealing rings of transmission input shaft.

Install lube oil lines (see 3 and 5, fig. 4) of disk

packs, taking care of the O-rings.

On tractors equipped with independent PTO:

Install both PTO oil lines and oil distributor to oil
manifold of HIGH-LOW shift unit and housing of

Dia. of hollow gear shaft

bearing seat

TRANSMISSION INPUT SHAFT

DRIVE SHAFT
..............
I.D. of oil manifold bushing

.....
..........
O.D. of shaft in planet pinion carrier bushing

...............
O.D. of shaft in drive shaft bushing

..................
I.D. of bushing in gear end

Dia. of bushing bore

Printed in Germany
Model 2120 Tractor
TM-4252 (Dec-70)

transmission oil pump. Tighten hex. nut securing

oil distributor to bracket on oil manifold to speci¬
fied torque (see Specifications). Before tightening
cap screws and nuts, install the two short pressure
lines leading to disk packs of HIGH-LOW shift unit
between oil distributor and oil manifold. Enter
both oil lines into oil distributor.

Enter both pressure lines (see 1*, fig. 4) of

HIGH-LOW disk packs in bores of oil manifold.
Install pressure line 4 from transmission oil filter
and pressure line 2 leading to hydraulic pump.
Slide retainer over oil lines and secure on oil mani¬
fold. Install suction and pressure lines of transmis¬
sion oil pump.

Join tractor between clutch housing and transmis¬

sion case as explained in section 10, group 25.

Check operating pressure of HIGH-LOW shift unit

as explained previously and adjust pressure regu¬
lating valve of control valve assembly, if necessary.

* Only

SPECIFICATIONS
installed on
independent PTO
tractors not equipped with

Dimensions of New Parts

1.3750 to 1.3760 in.

1.9651 to 1.9657 in.

1.1235 to 1.1245 in.

0.9330 to 0.9340 in.

0.9360 to 0.9390 in.

1.0620 to 1.0630 in.

34.925 to 34.951 mm

49.913 to 49.929 mm

28.537 to 28.563 mm

23.698 to 23.724 mm

23.774 to 23.852 mm

26.975 to 27.000 mm
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) HIGH-LOW Shift Unit 10-13

..........
............ Dimensions of New Parts

................
Dia. of shaft in clutch drum bushing 1.3580 to 1.3590 in. 34.493 to 34.519 mm

Dia. of shaft at oil seal location 1.1240 to 1.1260 in. 28.555 to 28.605 mm

Dia. of pilot bearing seat 0.5895 to 0.5901 in. 14.973 to 14.989 mm

CLUTCH DRUM

I.D. of bushing .....................

.................. 1.3620 to 1.3650 in. 34.595 to 34.671 mm
Dia. of bushing bore

............
Dia. of drum hub in HIGH-LOW
housing bushing
1.4995 to 1.5005 in.

2.0610 to 2.0630 in.

38.087 to 38.113 mm

52.349 to 52.400 mm

.....................
..................
HIGH-LOW HOUSING AND HOLLOW DRIVE SHAFT

...................
I.D. of bushing 2.0675 to 2.0695 in. 52.515 to 52.565 mm

Dia. of bushing bore 2.1870 to 2.1880 in. 55.550 to 55.575 mm

oil seal location.....................

Dia. of oil seal bore

.......
Dia. of housing at clutch housing

Dia. of housing in clutch housing bushing

1.6230 to 1.6250 in.

1.6240 to 1.6260 in.

2.6860 to 2.6880 in.

41.235 to 41.275 mm

41.255 to 41.305 mm

68.225 to 68.275 mm

PLANETARY GEAR

..........
...........
...........
I.D. of planet pinion carrier bushing 1.1275 to 1.1295 in. 28.639 to 28.689 mm

Dia. of planet carrier bushing bore 1.3120 to 1.3130 in. 33.325 to 33.351 mm

......................
Dia. of planet carrier bearing bore

............
Dia. of bearing pin bores of
1.1250 to 1.1260 in. 28.575 to 28.601 mm

...............
planet carrier 0.6606 to 0.6616 in. 16.779 to 16.805 mm

..................
Dia. of planet pinion bearing pin 0.6602 to 0.6606 in. 16.771 6o 16.779 mm

................
Dia. of planet pinion bore 0.8797 to 0.8803 in. 22.344 to 22.360 mm

....................
Width of a planet pinion 1.217 to 1.223 in. 30.92 to 31.08 mm

I.D. of bearing needle spacer 0.669 to 0.679 in. 16.99 to 17.25 mm

........................
Thickness of a spacer

Width of sun gear (between

butting faces)
0.084 to 0.090 in.

0.615 to 0.625 in.

2.13 to 2.29 mm

15.62 to 15.88 mm

Printed in Germany
50 Power Train
10-14 HIGH-LOW Shift Unit

THRUST WASHERS

pinion and planet pinion carrier

manifold and hollow drive shaft

Total stacked height of brake

plate pack (4 bronze disks
and 4 separator plates)

SPRINGS

Control valve detent spring

I.D. of clutch housing bushing

Dia. of bushing bore

..
...............
Thickness of a thrust washer between planet

...........
Total width of thrust washer between oil

Thickness of remaining thrust washers

DISK CLUTCH AND BRAKE

Thickness of a separator plate

Thickness of a clutch disk

...............
.................
......................
Height of a spring washer

Total stacked height of clutch

disk pack(3 bronze disks and
4 separator plates)

...................
...........
.........
Resilience at a length of 0.7 in. (17.5 mm)

Pressure regulating valve spring

Resilience at a length of 2.5 in. (63.5 mm)

CLUTCH HOUSING

.............
....................
Clearance between clutch housing front face
and oil seal front face

OPERATING PRESSURE

Adjusting pressure of pressure regulating

valve (Engine speed — 2100 rpm)
On tractors without independent PTO

On tractors equipped with independent PTO

Printed in Germany
0.036 in.

0.13 to 0.18 in.

0.056 to 0.068 in.

0.060 to 0.077 in.

0.033 to 0.037 in.

0.139 in.

0.281 to 0.397 in.

0.375 to 0.458 in.

13 to 16 lbs.

26.5 to 32.3 lbs

2.6910 to 2.6950 in.

2.811 to 2.813 in.

............
........
1.3 in.

95 to 105 psi

150 to 160 psi

Model 2120 Tractor
TM-4252 (Dec-70)

Dimensions of New Parts

0.88 mm

3.92 to 4.05 mm

1.42 to 1.73 mm

1.52 to 1.96 mm

0.84 to 0.94 mm

3.53 mm

8.14 to 10.08 mm

9.53 to 11.63 mm

6 to 7.3 kg

12 to 14.7 kg

68.350 to 68.450 mm

71.40 to 71.44 mm

33.5 mm

6.7 to 7.3 kg/cm2

9.8 to 11.2 kg/cm2

Model 2120 Tractor
TM-4252 (Dec-70)

cap screws .... .............

......
.......
.....
Cover plate to planet pinion carrier or to
clutch drum, cap screws

.............
....

........
HIGH-LOW cover to HIGH-LOW housing,

..........
Transmission oil pump cover to
clutch housing, cap screws
.

..............
Oil manifold and pump housing to
pump cover, cap screws

......................
.......
Oil distributor to oil manifold bracket,
hex. nut (tractors with independent PTO)

Clutch housing to transmission case,

cap screws

JD Parts Depot

19.58 - 90.260*
19.58 - 90.617
19.58-90.613
19.58 - 90.273
L 48522. . . 815**

*
**
....... .......
Part No. if ordered from

....... .......
Manufacturer

For details see section 70, group 5

23 ft.lbs.

Special tool
Special tool
Driver
Driver
.... Drift .
TORQUES FOR HARDWARE

SPECIAL TOOLS

Description

.......
Use
23 ft.lbs.

35 ft.lbs.

35 ft.lbs.

20 ft.lbs.

85 ft.lbs.
Power Train

Checking oil pressure

2.8 mkg
50
HIGH-LOW Shift Unit 10-15

3.2 mkg

3.2 mkg

4.8 mkg

4.8 mkg

11.7 mkg

Installing and removing spring washers

Driving in HIGH-LOW housing bushing
Driving in clutch housing bushing
ditto

SERVICE TOOLS INC., 1901 INDIANA AVENUE, CHICAGO, ILLINOIS 60616, USA

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Collar-Shift Transmission 15-1

Group 15
COLLAR-SHIR
TRANSMISSION
GENERAL INFORMATION DIFFERENTIAL DRIVE SHAFT

The collar-shift transmission is available in three The differential drive shaft is supported on two
versions: taper roller bearings below the drive shaft in the
8-speed transmission without parking lock, transmission case. Four gears are provided on the
with blocked 8th gear and independent secon¬ shaft. They are positively engaged to the
dary brake (hand brake) differential drive shaft by means of shift collars
8-speed transmission without parking lock, and sleeves. Power is transmitted to the differential
with independent secondary brake (hand assembly through the bevel pinion of the
brake) and differential drive shaft.
8-speed transmission with parking lock, with¬
out independent secondary brake. COUNTERSHAFT
The transmission has helical gears. Its two shift The countershaft is located to the left and below
levers are installed on top of the clutch housing. the transmission drive shaft. It carries the range
pinions for range Iand for reverse. Input power is
The range shift lever operates range Iand II and transmitted through the transmission drive gear
the reverse speeds. The gear shift lever selects four located between transmission input shaft and trans¬
speeds in each range except for the transmission mission drive shaft to the countershaft.
version with blocked 8th gear which has only three
speeds in range II. Thus the collar-shift transmis¬ GEAR SHIFT CONTROLS
sion provides a choice of 7 or 8 forward speeds and
four reverse speeds. The parking lock (if equipped) Transmission gears are selected manually by two
can also be engaged by means of the range shift levers. The range shift lever (left-hand lever) is used
lever. to select low (range I), high (range II) and reverse
ranges. If the tractor is not equipped with an inde¬
The gearshift mechanism is contained in the front pendent second brake (hand brake), the range shift
compartment of the transmission case. The trans¬ lever is also used to engage the parking lock.
mission case also serves as main oil reservoir for the
transmission as well as for the hydraulic system. A The gear shift lever (right-hand lever) is used to
transmission oil pump forces oil under pressure select 1st, 2nd, 3rd and 4th gears when range shift
through horizontal and vertical bores in the trans¬ lever is in low position (I). It is used to select 5th,
mission shafts to lubricate the gear train. In addi¬ 6th, 7th and 8th gears unless 8th gear is blocked
tion, there is an oil cup reservoir which gravity- (depending on transmission type; see above) when
feeds oil to the differential drive shaft when the range shift lever is in high position (II). When range
tractor is being towed. shift lever is in reverse position, the four reverse
gears can be selected.
The transmission gears are carried on three shafts:
the transmission drive shaft, the differential drive A starter safety switch is provided to protect the
shaft and the countershaft (see fig. 1). operator. Therefore, the range shift lever must be
moved in neutral or in park position before the
TRANSMISSION DRIVE SHAFT engine can be started.
The transmission drive shaft is located in the upper
half of the transmission compartment. The four
gears are integral with the shaft. The gears transmit
power at various speeds through the countershaft to
the differential drive shaft if range Ior reverse is
engaged or directly to the differential drive shaft if
range IIis engaged.

Printed in Germany
50 Power Train Model 2120 Tractor
15-2 Collar-Shift Transmission TM-4252 (Dec-70)

PARKING THE TRACTOR CAUTION: When towing tractor, do not exceed

maximum permissible speed of tractor.
Only on tractors provided with parking lock
TOWING TRACTOR FOR STARTING
Move the gear shift lever into any gear position.
Then move the range shift lever to park (P) On tractors not equipped with HIGH-LOW shift
position. In this position the transmission is unit
blocked and acts as a brake directly on the rear
axle. When towing the tractor for starting, do not tow it
at a speed greater than normal for the gear in
CAUTION: The parking lock can be engaged only which the tractor is being towed. Tow the tractor
after the gear shift lever has been moved into any for starting only in 6th, 7th, or 8th gear.
gear position. Engaging of a gear is not sufficient,
particularly on tractors equipped with a Only on tractors equipped with HIGH-LOW shift
HIGH-LOW shift unit. With the engine shut off, unit
clutch disks are disengaged, disconnecting drive It is not possible to tow or push a tractor equipped
between engine and rear axle. with HIGH-LOW shift unit for starting. To do so
Only on tractors with independent second brake would damage the transmission.
(hand brake) GROUND SPEEDS
Apply hand brake.
For information on tractor ground speeds, con¬
TOWING THE TRACTOR sidering the various tire sizes, see Operator's
Manual.
When towing the tractor, move both shift levers in
neutral position.

Erjl 1-5
II R 2-6

L50099
5- 6. 8. 7.'
—
Fig. 1 Collar-shift Transmission Assembly
1 Transmission input shaft 8 Driven gear for 2nd and 6th gear 15 Shift collar for high (II) range and parking lock
2 Drive gear of transmission drive shaft 9 Driven gear for 4th and 8th speed 16 Shift collar for low (I) and reverse ranges
3 Drive gear for 3rd and 7th speed 10 Driven gear for 3rd and 7th speed 17 Transmission drive shaft
4 Drive gear for 4th and 8th speed 11 Countershaft drive gear 18 Shift collar for 1st, 2nd, 5th and 6th speeds
5 Drive gear for 2nd and 6th speed 12 Reverse range pinion 19 Shift collar for 3rd, 4th, 7th and 8th speeds
6 Drive gear for 1st and 5th speed 13 Low (I) range gear 20 Differential drive shaft
7 Driven gear for 1st and 5th gear 14 Countershaft

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Collar-Shift Transmission 15-3

POWER FLOW SHIFTING MECHANISM

Power flow in the individual speeds is shown in the

following chart in conjunction with fig. 1. Drive
gears and driven gears in the following chart have
the same numbers as in fig. 1. The numbers are
indicated in the sequence of power flow. 1

Speed Power Flow (see fig. 1)

Forward
1 1. 2, 11, 13, 4, 6, 7, 20,
2 1, 2, 11, 13, 4, 5, 8, 20,
3 1, 2, 11, 13, 4, 3, 10, 20,
4 1, 2, 11, 13, 4, 9, 20
5 1, 2, 6, 7, 20
6 1, 2, 5, 8, 20
7 1, 2, 3, 10, 20
8 1, 2, 4, 9, 20

Reverse
1 1, 2, 11, 12, 10, 3, 6, 7, 20
2 1, 2, 11, 12, 10, 3, 5, 8, 20
3 1, 2, 11, 12, 10, 20
4 1, 2, 11. 12, 10, 3, 4, 9, 20

DIAGNOSING MALFUNCTIONS
NOISY SHIFTING

Improper shifting or declutching

Details see Operator's Manual

Parts of shifting mechnism worn or broken

Replace parts

Engine clutch slips Fig. 2 — Shifting Mechanism for 8-Speed Trans¬

Adjust clutch pedal (see group 5) mission with Parking Lock
Pin of starter safety switch
Gears still rotate when clutch pedal is depressed Caps
Transmission brake not installed or defective Spring pins
Detent springs
Detent and lock balls
EXCESSIVE OPERATING NOISE Shifter fork of range II and parking lock
Shifter forks for 3rd and 7th, 4th and 8th speed
Transmission parts worn or damaged Shifter forks for 1st and 5th, 2nd and 6th speed
Shifter shaft for 1st and 5th, 2nd and 6th speed
Overhaul transmission 9 Shifter shaft for 3rd and 7th, 4th and 8th speed
10 Shifter fork of range 1and reverse range
11 Shifter shaft of range IIand parking lock
Little transmission oil 12 Shifter shaft of range Iand reverse range
Add oil of proper viscosity and 13 Lock pin
quality (see Operator's Manual) 14
15 Spring
ÿ1
Lock balls
I
not provided on tractors with 8-speed
transmission, without parking lock

Transmission oil pump defective

Check pump and repair (see section 70,
group 15)

Printed in Germany
50 Power Train Model 2120 Tractor
15-4 Collar-Shift Transmission TM-4252 fDec-70)

CAUTION: When removing, do not turn shifter

shafts as spring-loaded detent balls may slip into
the set screw holes in the shifter shafts, causing
them to be locked in their guides.
Move both range shifter shafts 10 and 11 (figs. 2
and 3) in neutral position. Then pull shifter shaft
10 out of transmission case bore.

CAUTION: Do not lose two lock balls 4 and detent

ball 4 or spring 3 of shifter shaft 10.

Only on 8-speed transmission with parking

lock.'Before removing shifter shaft 11 (fig. 2),
move shifter shaft 9 for 3rd and 7th, 4th and 8th
speed so that a gear is engaged (for releasing lock
pin 13).

Then, on all transmission types, pull shifter shaft

11 of range IIout of bore in transmission case.

CAUTION: Do not lose lock ball 4 and spring 3 of

this shifter shaft.

On tractors provided with parking lock unhook

tension spring 15 (fig. 2) of range shifter shaft 11
from its pawl, if necessary.

Remove shifter forks of range Iand reverse range

L3O201
as well as that of range II.

NOTE: The shift collar of range II can only be

removed when the front transmission shield has
Fig. 3 — Shift Mechanism for 8-Speed Transmission been detached (see below).
with Blocked 8th. Gear
Pull inner shifter shaft 9 (fig. 2) sufficiently out of
a Pin of starter safety switch transmission case so that, on tractors provided with
1 Caps
2 Spring pins parking lock, the three lock balls 14 can be removed
3 Detent springs from the shifter shaft. Then pull shifter shaft com¬
4 Detent and lock balls
5 Shifter fork of range II
pletely out of bore.
6 Shifter fork for 3rd* 7th and 4th speed
7 Shifter fork for 1st, 6th, 2nd and 6th speed CAUTION: Do not lose lock balls 4 located
8 Shifter shaft for 1st, 5th, 2nd and 6th speed
9 Shifter shaft for 3rd, 7th and 4th speed
between both shifter shafts as well as detent ball 4
10 Shifter fork of range Iand reverse range and spring 3 of shifter shaft 9.
11 Shifter shaft of range II
12 Shifter shaft of range Iand reverse range
13 Lock pin Remove the two lock balls 14 arranged between
the two shifter shafts (on tractors provided with
REPAIR parking lock).

Separate tractor between clutch housing and trans¬ Withdraw outer shifter shaft 8 from transmission
mission case, see section 10, group 25. case, taking care of detent ball 4 and spring 3.
Remove rockshaft, see section 10, group 25. Remove shifter forks from shifter collars.
Remove pin "a" (figs. 2 and 3) of starter safety
switch from shifter fork of range Iand reverse
range.
Remove self-locking set screws attaching shifter
forks to shifter shafts.

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Collar-Shift Transmission 15-5

Checking shifter shafts

7-©
Make sure shifter shafts are not distorted. Check
faces around pawls and bores of shifter shafts for
wear; also check sliding faces of shafts and shaft
bearing bores of transmission case.

Checking interlock pin, balls and springs

22 NOTE: The interlock pin is not provided on

8-speed transmission without parking lock.

Check if springs are still in proper condition (rusty

spots, resilience). If necessary, replace spring.
20
23
\--10
Check ball surfaces for flat spots which could
prevent them from rolling freely. Check interlock
24 pin for serviceability.

l50 202
25 NOTE: If the interlock pin has to be replaced,
drive spring pin 2 (fig. 2) out of transmission case,
using a suitable spring pin. Then pull spring pin
used as tool sufficiently out of case to withdraw
interlock pin. When a new interlock pin is installed,
coat new cap with a film of oil-resistant sealant and
drive into bore of transmission case.
Fig. 4 — Exploded View of Shifter Mechanism For installation of shifter mechanism reverse
removal sequence, observing figs. 2 through 4.
1 Shift cover
2 Boot
3 Snap ring Install rockshaft unit, see section 10, group 25.
4 Retaining ring
5 Cap screw
6 Shift lever Attach transmission case to clutch housing, see
7 Knob section 10, group 25.
8 Self-locking set screws
9 Shifter fork for 1st and 5th, 2nd and 6th speed
10 Shifter fork for 3rd and 7th, 4th and 8th speed Check operation of transmission by shifting
11 Shifter fork of range IIand parking lock through all ranges and speeds.
12 Shifter fork of range Iand reverse range
13 Pin of starter safety switch
14 Caps
15 Spring pins
16 Detent springs
17 Lock and detent balls
18 Shifter shaft of range Iand reverse range
19 Shifter shaft of range IIand parking lock
20 Shifter shaft for 3rd and 7th, 4th and 8th speed
21 Shifter shaft for 1st and 5th, 2nd and 6th speed
22 Gasket
23 Lock balls (only on tractors with parking lock)
24 Lock pin (not provided on tractors with 8-speed transmission,
but without parking lock)
25 Tension spring (only on tractors with parking lock)

Checking shifter forks

Examine shifter forks for excessive wear or distor¬
tion. Replace, if necessary.

Printed in Germany
50 Power Train Model 2120 Tractor
15-6 Collar-Shift Transmission TM-4252 (Dec-70)

TRANSMISSION SHAFTS AND GEARS

REMOVAL Pry front bearing support carefully off the dowels

in the transmission case. As bearing support with
Separate tractor between clutch housing and trans¬ countershaft, and transmission drive shaft gear is
mission case, see section 10, group 25. pulled forward, the snap ring 1, the gears, the
shifter collar, sleeve and the thrust washers will
Remove rockshaft, see section 10, group 25. slide off the countershaft. Place hand unter these
parts and lift them out of the transmission case.
Remove transmission shifter mechanism.
Removing the Transmission Drive Shaft
On tractors equipped with continuous-running
PTO: Remove PTO drive gears from front of trans¬ Remove front bearing support assembly with the
mission case. countershaft and the transmission drive gear (see
above). Slide the shifter collar for range II off the
On tractors equipped with independent PTO: drive shaft.
Remove PTO clutch and brake of the independent
PTO (see group 35).

Remove transmission oil cup and rear lube line of

transmission.
Removing the Countershaft

'+3A33
Fig. 6 — Transmission Drive Shaft Quill
1 Quill 2 Oil line

Straighten out the corners of the lock plates and

Fig. 5 — Removing Countershaft remove the screws. Remove the drive shaft quill 1
(fig. 6) and the shims, and detach front oil line 2
1 Snap ring 4 Thrust washer from differential drive shaft.
2 Low range (I) pinion 5 Reverse range pinion
3 Shift collar
Tap transmission drive shaft forward to free front
bearing cup from case and rear bearing cone from
Remove cap screws securing front bearing support cup.
to transmission case.

Lift snap ring 1 (fig. 5) out of the groove at the

end of the countershaft and push it back. Push
back pinion 2, sleeve and collar 3. Rotate thrust
washer 4 until splines in washer index with
countershaft splines. Then push the thrust washer
back.

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Collar-Shift Transmission 15-7

Move transmission drive shaft forward, lift the rear Then unlock the central locking thrust washer
end of the shaft and lift the shaft diagonally out of which is secured by a lock plate. To unlock, press
the transmission case. the secohd (large) gear forward and slide the lock
plate forward to disengage it from the locking
Removing the Differential Drive Shaft thrust washer. Hold the lock plate in position and
rotate the thrust washer until its splines index with
Block up the transmission case and remove both the shaft splines. Then slide the thrust washer for¬
final drives, see section 10, group 25. ward on the shaft.

Remove differential assembly, see group 20. Now unlock the rear locking thrust washer in the
Remove countershaft and transmission drive shaft same way as the front thrust washer.
(see previous page).
Pull the drive shaft carefully toward the rear until
it can be lifted out of the differential compart¬
ment. As the shaft is pulled back, the gears, the
shifter collar sleeves, the shifter collars and the
locking thrust washers slide off the shaft. Place one
hand under these parts and slide them off the
shaft.

Should one of the locking thrust washers become

locked while the shaft is pulled off, unlock it again
as described above.

Fig. 7 — Removing Differential Drive Shaft

1Locking thrust washers

Remove hex. nut from the differential drive shaft.

Tap differential drive shaft to the rear until a
resistance is felt. Remove bearing cone, shims and
spacer. Unlock the three locking thrust washers
(see 1, fig. 7) as follows: Press front shifter collar
forward until front locking thrust washer is free to
be rotated. Hold shifter collar m this position and
rotate the thrust washer with a screwdriver to align
the washer lugs with the shaft splines. Slide the
thrust washer forward on shaft.

Printed in Germany
50 Power Train Model 2120 Tractor
15-8 Collar-Shift Transmission TM-4252 (Dec-70)

REPAIR

Differential drive shaft

s
L 51 292 A

Fig. 8 — Exploded View of Differential Drive Shaft

1 Ring gear and differential shaft 7 Collars 13 Driven gear for third and seventh speed
2 Taper roller bearing cone 8 Sleeves 14 Spacer
3 Taper roller bearing cup 9 Driven gear for second and sixth speed 15 Shims (use as required)
4 Shims (2 used) 10 Locking thrust washer with outer tangs 16 Taper roller bearing cup
5 Driven gear for first and fifth speed 11 Locking washer 17 Taper roller bearing cone
6 Locking thrust washers 12 Driven gear for fourth and eighth speed 18 Hex. nut

Check gears, shifter collars and sleeves of differen¬ NOTE: If transmission case, taper roller bearings of
tial drive shaft for damage. differential drive shaft, the shaft itself and the
differential ring gear have been replaced, check and
Examine taper roller bearing cones for wear or adjust, if necessary, preload of differential drive
damage. Replace, if necessary. Make sure splines of shaft bearings as explained below and cone point
shaft are free of burrs and are not excessively adjustment, see group 20.
worn.

IMPORTANT: If differential drive shaft has to be

replaced, also replace differential ring gear as
explained in group 20. These parts are a matched
set and are therefore available only as an assembly.

Printed in Germany
Model 2120 Tractor Power Train50
TM-4252 (Dec-70) Co liar- Shift Transmission 15-9

Transmission drive shaft

43 437

Fig. 9 — Exploded View of Transmission Drive Shaft

1 Taper roller bearing cup 7 Bearing cup 12 Cap screw
2 Taper roller bearing cone 8 Shims 13 Cap screw
3 Transmission drive shaft 9 Tab washers 14 Quill (transmission with parking lock)
4 Needle bearing 10 Cap screw 15 Quill (transmission without parking lock)
5 Dowel pin 11 Range IIshifter collar 16 Range II shifter collar (transmission
6 Bearing cone (transmission with parking lock) without parking lock)

Examine transmission drive shaft, expecially its Check taper roller bearings of shaft, needle bearing,
gears, for damage and excessive wear. quill, shifter collar of range II, tab washers, and
shims for serviceability. Replace parts, if necessary.

Countershaft
Inspect countershaft gears as well as shifter collar
and sleeve for proper condition. Replace parts, if
necessary.

Examine front bearing support assembly with

countershaft and transmission drive gear as well as
splines of countershaft and its gear for damage.
Check taper roller bearings of countershaft as well
as needle bearing for serviceability. Replace
damaged parts.

Only on tractors equipped with independent PTO:

If necessary, remove piston from PTO brake
assembly (see 29, fig. 11) out of front bearing sup¬
port and check for serviceability. Replace parts, if
necessary. Replace O-rings 28 and 30. ÿ/*>//

If the front bearing support, the countershaft, the

transmission drive gear or the ball bearings have to
be replaced, remove the snap rings (see 1, fig. 10) Fig. 10 — Pressing Countershaft and Transmission
securing bearings to support and shafts. Press both Drive Gear from Bearing Support
shafts out of the bearing support or the bearings as
shown in fig. 10. 1 Snap rings

Printed in Germany
50 Power Train Model 2120 Tractor
15-10 Collar-Shift Transmission TM-4252 (Dec-70)

21 22 23
13 14_1fi

14
12 24 13 19

l 51518

Fig. 11— Exploded View of Countershaft

1 Needle bearing 12 Hollow dowels 24 Front bearing support
2 Snap ring 13 Washers (tractors without
3 Snap rings 14 Cap screws independent PTO)
4 Thrust washers 15 Lock tab 25 Countershaft
5 Low range (1) pinion 16 Cap screw 26 Transmission drive gear
6 Shifter collar sleeve 17 Snap ring 27 Front bearing support
7 Thrust washer 18 Snap ring (tractors with independent PTO)
8 Shift collar 19 Ballbearing 28 O-ring
9 Reverse range pinion 20 Cap screw 29 PTO brake piston
10 Spring (2 used) 21 Ballbearing (tractors with independent PTO)
11 Friction pin (2 used) 22 Snap ring 30 O-ring
23 Snap ring 31 Plug

NOTE: The transmission drive gear must be Inspect the oil cup for damage. If replacement
removed before the countershaft can be removed. becomes necessary, replace complete oil cup as
well as O-ring located on bottom of ball seat bore.
Press the ball bearings and countershaft or drive
gear into the bearing support until the snap rings Remove oil sump cover at the bottom of the trans¬
will fit in their proper grooves. mission case. Clean reservoir at bottom of case and
replace cover.
Ball bearing (see 19, fig. 11) can be pressed into
the bore only from the outside of the bearing Transmission case
support 24. Therefore, install bearing first — then
the countershaft. Carefully clean transmission case and check for
cracks or other damage.
Check the friction pins 11 and springs 10 (fig. 11)
for damage and wear. Check resilience of springs Check oil dipstick and tube for damage and
(see Specifications). replace, if necessary. If tube has been damaged,
press in new tube so that face of tube protrudes by
Transmission Lubrication System a specified dimension from top machined surface
of transmission case (see Specifications).
Inspect all lubricating oil lines for damage or bent
condition, make sure the oil lines are not plugged,
especially the small oil bores along the bottom of
the oil line above the transmission drive shaft, and
the small bore facing the differential.

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Collar-Shift Transmission 15-11

INSTALLATION Inch differential drive shaft forward and install

gear 6 for second and sixth speed, with the teeth
Differential drive shaft for the collar facing toward the rear. Then install
the center locking thrust washer with both internal
1. Cone Point Adjustment and external tangs and the lock plate with the
tangs facing toward the rear.
Adjust cone point by installing shims between
transmission case and rear taper roller bearing cup Move differential drive shaft further forward and
of differential drive shaft. slide gear 4 for fourth and eigth speed onto the
shaft, with the teeth for the collar facing forward.
If the rear bearing cup of the differential drive Then install the third locking thrust washer 1 and
shaft and the two shims were removed, install two collar 2, with sleeve, making sure that tangs for
shims of 0.01 in. (0.25 mm) each between case and securing the locking thrust washer face forward,
bearing cup to adjust cone point.
Install gear 3 for third and seventh speed with the
hub into the bore in the transmission case (tangs
2. Installing the Differential Drive Shaft for collar facing towards the rear). Move differen¬
tial drive shaft forward until the rear bearing cone
3 is seated in bearing cup. At the same time slide
the differential drive shaft into gear 3.

Slide gear 7 and the rear locking thrust washer

back until the washer fits the appropriate groove
cut in shaft. Using a screw driver, rotate the
locking thrust washer until the washer splines lock
with the shaft splines. Then mesh the locking tangs
of the collar sleeve with the thrust washer splines.

Push gear 6 and the center locking thrust washer

back until the washer fits into the proper groove
cut in the shaft. Rotate this thrust washer in the
same way as the rear locking thrust washer and
slide the lock plate over the center locking thrust
washer to prevent rotation.
Fig. 12 — Differential Drive Shaft Installed
Slide back gear 4 and the front locking thrust
1 Locking thrust washers 5 Collar washer. Mesh washer with the front collar sleeve in
2 Collar 6 Gear for 2nd and 0th speed the same way as the rear locking thrust washer.
3 Gear for 3rd and 7th speed 7 Gear for 1st and 5th speed
4 Gear for 4th and 8th speed
(if not locked) Slide spacer 14 (fig. 8) on the differential drive
shaft with the smooth side facing toward the gear.
Before proceeding further, make preload adjust¬
Insert the differential drive shaft with the rear ments explained on the next page.
bearing assembled from the differential side and
slide shaft forward about half its length into the
transmission compartment. First, install gear 7 (fig.
12) for the first and fifth speed with the teeth for
collar facing forward. Then slide one of the two
locking thrust washers 1with internal lugs onto the
shaft. Install collar 5 and sleeve, with tangs for
securing the locking thrust washers facing forward.

Printed in Germany
50 Power Train Model 2120 Tractor
15-12 Collar-Shift Transmission TM-4252 (Dec-70)

3. Adjusting Preload of Differential Drive Shaft dimension. By installing the remaining shims,
Bearings specified preload of differential drive shaft bearings
will be obtained.
The differential drive shaft should have a specified
preload corresponding to a specified rolling drag Install determined thickness of shims as well as
torque (see Specifications). Preload or rolling drag bearing cone. Thread on hex. nut and tighten to
torque is adjusted by means of shims 15 (fig. 8) the specified torque. Stake hex. nut to secure it.
between spacer 14 and front bearing cone 17 of
differential drive shaft. Adjust preload and rolling NOTE: Remove differential drive shaft before
drag torque as follows: checking and adjusting the differential assembly
bearing preload (see group 20). Take care not to
Since preload cannot be measured, first set end damage or lose the shim pack needed for preload¬
play. Therefore, add shims 15 between bearing ing the differential drive shaft bearings.
cone 17 (fig. 8) and spacer 14 until measurable end
play is obtained. For correct preload adjustment of Install the differential assembly as explained in
differential drive shaft, end play should not exceed group 20. Be sure to check bearing preload and
a specified dimension (see Specifications). Install differential backlash at this time. Adjust if neces¬
bearing cone on shaft and secure by means of hex. sary.
nut. Tighten hex. nut to the specified torque (see
Torques for Hardware). Install final drives, see section 10, group 25.

Installing transmission drive shaft

Insert transmission drive shaft diagonally in front

bore of transmission case. Level shaft, install rear
bearing cone of transmission drive in bearing cup.
Install front bearing cup.

Adjusting Transmission Drive Shaft End Play

Adjust transmission drive shaft end play (see

Specifications) by placing shims between front
bearing quill 1 (fig. 14) and transmission case.

Install quill with shim pack. Tighten quill screws to

the specified torque (see Specifications). Rotate
shaft to make sure it does not bind and that taper
roller bearings are properly seated.

Measure and record end play as shown in fig. 14.

Remove shims from or add to shim pack located
under bearing cap to obtain the specified end play
(see Specifications). After having tightened quill
screws to the specified torque, again check end
Fig. 13 — Measuring Differential Drive Shaft End play.
Play
1 Differential drive shaft 2 Dial indicator

Attach a dial indicator to front of transmission

case as shown in fig. 13 and place the feeler rod
against shaft. Move differential drive shaft to and
fro and read off shaft end play.

Record end play shown on dial indicator. Again

remove nut and bearing cone from shaft. Slide all
shims off shaft. Add a specified dimension to
recorded end play (see Specifications) and remove
thickness of shims corresponding to the calculated

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Collar-Shift Transmission 15-13

Using a screw driver, rotate locking thrust washer 7

until tangs on shifter collar sleeve engage with
locking washer. Slide low range pinion 5 and rear
thrust washer 4 further and snap second ring 3 in
groove of shaft.

Secure the transmission front cover to the trans¬

mission case.

On tractors equipped with independent PTO, make

sure that the piston (see 29, fig. 11) of the PTO
brake is installed in the front transmission cover.

CAUTION: If necessary rotate the snap ring until

lock plate 15 (fig. 11) is seated in its gap.

f Install transmission oil cup and rear oil lines.

Tighten oil cup attaching screws to the specified
torque (see Specifications).
Fig. 14 — Measuring Transmission Drive Shaft End
Play
To safeguard proper lubrication of final drives,
1 Quill 3 Dial indicator
2 Transmission drive shaft
lube oil lines should protrude into final drives or
should be flush with inner edge of final drive
Install front oil line for lubricating differential housing. Thus oil will be supplied directly to final
drive shaft. drives. Bend lines manually, if required.

Slide collar for high range (II) on front splines of Makre sure lines do not interfere with shafts. Also
the transmission drive shaft with the annular be sure nozzle-type oil line ends properly engage
groove for the shifter fork facing away from shaft. shaft bore.

Installing the Countershaft On tractors equipped with continuous-running

PTO: Install PTO gears at transmission front face.
NOTE: Before installing the countershaft, make
sure that the shifter collar for high range (II) is On tractors equipped with independent PTO:
installed. Install PTO brake and PTO clutch (see group 35).
Install shifter mechanism.
Install springs 10 (fig. 11), and friction pins 11
into the two bores in the front of the transmission FINAL ASSEMBLY OF TRACTOR
case, with the grooved thrust surface of the
friction pins facing the gear. Install rockshaft housing on transmission case, see
section 10, group 25.
With countershaft and transmission drive gear
assembled to bearing support, position support on Join tractor between transmission case and clutch
front of transmission. Insert countershaft through housing, see section 10, group 25.
bore in transmission case and install snap ring 3
(fig. 11), thrust washer 4 and reverse range pinion
9 with teeth for collar facing toward rear of trans¬
mission. Then slide locking thrust washer 7 on
shaft; next install shifter sleeve 6, with tangs facing
forward, and shifter collar 8. Move countershaft
further toward rear of transmission and slide low
range pinion 5, with its teeth facing toward the
front, the rear thrust washer 4 and the second snap
ring 3 on countershaft.

Printed in Germany
50 Power Train Model 2120 Tractor
15-14 Collar-Shift Transmission TM-4252 (Dec-70)

...............
SPECIFICATIONS

TRANSMISSION CASE
Distance between front of oil dipstick tube and
machined top face of transmission case 7.78 in. 197.5 mm

DIFFERENTIAL DRIVE SHAFT

............
....
..........
To adjust cone point, install two shims between
transmission case and rear bearing cup of
differential drive shaft, total thickness 0.02 in. 0.5 mm

of differential drive shaft ................

Preload of taper roller bearings
.......
Max. permissible end play of differential drive

.........
..........
shaft before adjusting taper roller bearing preload

........
Dimension to be added to measured end play

....
Rolling drag torque with proper preload
0.002 in.

0.006 in.
. 0.006 in.
5 to 15 in.lbs.
0.05 mm

0.15 mm
0.15 mm
5.7 to 17.2 cmkg
Backlash between ring gear and differential
drive shaft pinion 0.012 in. 0.30 mm
NOTE: The backlash of 0.012 in. (0.30 mm) should be adjusted as accurately as possible. At no point of
the ring gear's circumference should the backlash be less than 0.008 in. (0.20 mm) or more than 0.016

.............
in. (0.40 mm).

...........
TRANSMISSION DRIVE SHAFT

............
.

......
End play 0.004 bis 0.006 in. 0.10 bis 0.15 mm

COUNTERSHAFT
Spring of friction pin,
spring length, unstressed . 1-87 in. approx. 47.5 mm

................
resilience at a spring length of 1.51 in. (38.5 mm) . .... 63 to 77 lbs. 28.5 to 35 kg

...................
........
......
Clutch housing to transmission case

............
...
Final drives to transmission case
TORQUES FOR HARDWARE

. 85 ft.lbs.
85 ft.lbs.
11.7 mkg
11.7 mkg

.......
......
Rockshaft housing to transmission case

....................
..... .....
Hex. nut of differential drive shaft ..
Quill of transmission drive shaft, cap screws
. 85 ft.lbs.
160 ft.lbs.
35 ft.lbs.
11.7 mkg
22 mkg
4.8 mkg

cap screws

.............
...
..............
Front bearing support to transmission case,

Transmission oil cup to transmission case,

35 ft.lbs. 4.8 mkg

...
cap screws 20 ft.lbs. 2.8 mkg
Rear lube oil line, cap screw 20 ft.lbs. 2.8 mkg

cap screws

................
........
ft.lbs.

...
Differential housing cover to differential housing,
...
Differential bearing housing to transmission
case, cap screws
35

35 ft.lbs.
4.8 mkg

4.8 mkg

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Differential 20-1

Group 20
DIFFERENTIAL

Fig. 1— Differential Assembly

1 Cap screw (10 used) 7 Cap screw (8 used) 13 Ring gear
2 Bearing housing, l.h. 8 Differential housing cover 14 Differential housing
3 Shims 9 Bevel gears 15 Rivet (8 used)
4 Bearing cup 10 Bevel pinions 16 Bearing cone
5 Bearing cone 11 Bevel pinion shafts 17 Bearing cup
6 Brake disk and hub (only on 12 Differential drive shaft 18 Bearing housing, r.h.
tractors with handbrake)

GENERAL INFORMATION DIAGNOSING MALFUNCTIONS

The differential rotates on two adjustable taper OIL LEAKAGE
roller bearings. It is equipped with four bevel
pinions, two bevel gears and two bevel pinion Too much or improper oil (see operator's manual)
shafts. The ring gear is in mesh with the differential
drive shaft bevel gear. Loose transmission oil drain plug

The backlash of this bevel gear is adjusted by Transmission case broken

shims. These shims also serve for adjusting the
preload of the differential taper roller bearings. A Damaged seals
differential lock is located at the left-hand side of
the differential. Screws not tightened to the specified torque

Printed in Germany
50 Power Train Model 2120 Tractor
20-2 Differential TM-4252 (Dec-70)

EXCESSIVE NOISE Hold yoke 14 in place and drive shaft out toward
rear of tractor.
(Continuous)
Before shaft is fully driven out, remove plug 11
Worn bearings and Woodruff key 8. Discard O-ring 6.

Damaged or worn bevel gears or pinions Check splines of differential lock collar and of
differential housing cover for excessive wear and
Loss of lubricant damage. Check yoke and shaft for damage and
replace, if necessary.
(Under Load)
Check spring for worn or broken windings and
Differential drive shaft bevel gear and ring gear replace, if necessary.
adjustment too tight.
DIFFERENTIAL
(Under No Load)
Remove transmission oil cup and rear oil line.
Worn bearings
Remove rockshaft control arm and cam from trans¬
Differential drive shaft bevel gear and ring gear mission case.
adjustment too loose.
NOTE: If the tractor is equipped with a hand
REPAIR brake, remove this brake as described in section 60,
group 15.
Remove rockshaft housing and both final drive
Lift up on differential assembly to relieve weight
assemblies, see section 10, group 25. on bearing quills and remove cap screws securing
bearing quills to transmission case. Remove
DIFFERENTIAL LOCK
differential from transmission case.

Remove differential housing cover from differen¬

tial housing.

I50 21 1

Fig. 2 — Differential Lock Assembly L 43449

1 Hand lever 8 Woodruff key
2 Pedal 9 Shaft Fig. 3 — Removing Bevel Gears and Bevel Pinions.
3 Cap screw 10 Spring
4 Cap screw 11 Plug 1Bevel pinion shafts 4 Differential housing cover
5 Lock washer 12 Shoes 2 Bevel pinions 5 Ring gear
6 O-Ring 13 Collar 3 Bevel gears (2 used) 6 Differential housing
7 Key 14 Yoke

Remove cap screws 3 and 4 (fig. 2), remove pedal

and drive lever off the shaft. Remove key 7 from
shaft.

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Differential 20-3

Remove bevel gears 3 (fig. 3) and bevel pinion NOTE: To obtain accurate preload adjustment,
shafts 1 with bevel pinions 2 from the differential differential end play must not exceed specified
housing. dimension (see Specifications).

Examine the thrust and bearing surfaces of both Record end play shown on the dial indicator and
bevel gears. If the bevel gears are worn or damaged, add a specified value (see Specifications) to the
the bores in the differential housing and cover may recorded end play. Then remove enough shims
also be damaged. from the shim pack on the right bearing housing to
equal the calculated measurement. Install the
Check bevel pinions and bevel pinion shafts for remaining shims to obtain the correct bearing
excessive wear. If these parts are damaged or preload.
excessively worn, also replace parts they are in
mesh with, or they are sliding on. ADJUSTING BACKLASH OF DIFFERENTIAL

Check ring gear for wear or damage. If the ring gear After adjusting the preload, mount the dial
is no longer serviceable, separate from differential indicator as shown in fig. 4 and check the backlash
housing by removing rivets and replace. between the differential drive shaft pinion and the
ring gear at several points.
IMPORTANT! If the ring gear is replaced, also
replace the differential drive shaft. These parts are
furnished as matched sets and are not available
individually for replacement.

The number of teeth of the differential drive shaft

pinion and of the ring gear can be determined from
without. These figures are stamped into the trans¬
mission case, to the left of the rockshaft housing.

Check taper roller bearings if still serviceable.

NOTE: On tractors equipped with hand-brake,

push the brake hub and disk 6 on the splines of the
bearing cover, before pressing the roller bearing
cone on the differential housing cover 8 (fig. 1).

Coat bevel gears, bevel pinions and bevel pinion

shafts with transmission oil, before installing them. Fig. 4 — Measuring Backlash
Install differential housing cover on differential
housing and tighten screws to specified torque. Adjust backlash by transferring differential bearing
housing shims from one side of the case to the
other.
ADJUSTMENT
CAUTION! The total thickness of the shims must
PRELOAD ADJUSTMENT OF DIFFERENTIAL be maintained so that the correct preload of the
BEARINGS roller bearings is not altered.

Install both bearing housings. Place a number of To increase backlash, move shims from left to
shims 3 behind the right-hand housing 14 (fig. 1). right. To decrease backlash, move shims from right
Check the end play of the differential assembly to left. See Specifications for correct backlash
with a dial indicator. If necessary, add more shims measurement.
under right-hand bearing housing until measurable
end play is obtained.

Printed in Germany
50 Power Train Model 2120 Tractor
20-4 Differential TM-4252 (Dec-70)

INSTALLATION Install hand brake (if equipped), see section 60,

group 15.
With bearing preload and gear backlash properly
adjusted, tighten the differential bearing housing Install both final drive assemblies, see section 10,
cap screws to specified torque. group 25.

jimTP
NOTE: u/!. ,
I,- „
When installing
ÿ
/•« t- i i u
lock, „
use new
Install rockshaft control arm and cam.
differential
O-ring. Install rockshaft housing, see section 10, group 25.

...............
...............
SPECIFICATIONS
Dimensions of new parts

.................
Dia. of bevel pinion bore
Dia. of bevel pinion shaft

............
O.D. of bevel gear hub
0.8585 to 0.8615 in.
0.8545 to 0.8555 in.
2.0467 to 2.0477 in.
21.804 to 21.884 mm
21.704 to 21.730 mm
51.986 to 52.012 mm

.................
Bore dia. of differential housing, or differential
housing cover for bevel gear hub

........................
O.D. of a bearing housing
2.0497 to 2.0517 in.
5.035 to 5.039 in.
52.063 to 52.113 mm
127.89 to 127.99 mm

....................
Bearing bore dia. of l.h. housing for
bearing cup 3.810 to 3.812 in. 96.77 to 96.82 mm

....................
Bearing bore dia. of r.h. housing
for bearing cup 4.3282 to 4.3302 in. 109.94 to 109.99 mm

....................
Bearing seat dia. of differential housing cover
for bearing cone 2.2510 to 2.2526 in. 57.176 to 57.216 mm

..................
Bearing seat dia. of differential housing
for bearing cone 2.6885 to 2.6901 in. 68.288 to 68.328 mm

..............
Max. differential end play before preload

................
adjustment of taper roller bearing
Value to be added to differential end play
Taper roller bearing preload
Backlash between ring gear and differential
0.002 in.
0.003 in.
0.002 to 0.005 in.
0.05 mm
0.076 mm
0.05 to 0.13 mm

drive shaft pinion 0.012 in. 0.30 mm

NOTE: The backlash of 0.012 in. (0.30 mm) should be adjusted as accurately as possible. At no point of
the ring gear's circumference should the backlash be less than 0.008 in. (0.20 mm) or more than 0.016
in. (0.40 mm).

TORQUES FOR HARDWARE

Differential housing cover to differential housing, cap screws . . . . 35 ft.lbs. 4.8 mkg
Differential bearing housing to transmission
case, cap screws
.......
............. 35 ft.lbs. 4.8 mkg

.........
Cap screw of rear lube oil line and transmission oil cup 20 ft.lbs. 2.8 mkg
Final drives to transmission case, cap screws 85 ft.lbs. 11.7 mkg
Rockshaft housing to transmission case, cap screws 85 ft.lbs. 11.7 mkg

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Final Drives 25-1

Group 25
FINAL DRIVES

_
: ;

Fig. 1— Final Drive Assembly, Sectional View

1 Differential 4 Brake housing with ring gear 7 Flanged axle
2 Brake disk 5 Planet pinion carrier 8 Final drive housing
3 Brake pressure ring 6 Final drive shaft (sun pinion) 9 Planet pinion (3 used)
10 Ring gear

GENERAL INFORMATION UNUSUAL RUNNING NOISE

Each final drive unit contains a rear axle mounted Ring gear, gear (sun pinion) of final drive shaft or
on two taper roller bearings with oil seals and a planet pinions worn or damaged.
planetary gear system which provides the final
speed reduction. Worn planet pinion bearing rollers.

DIAGNOSING MALFUNCTIONS Worn or rough bearing surfaces of the rear axle

taper roller bearings.
LOSS OF LUBRICANT
Insufficient or improper type of lubricant used (see
Too much or improper lubricant used (see operator's manual).
operator's manual).
REMOVAL
Worn or damaged oil seals.
For removal of final drives see section 10, group
25.

Printed in Germany
50 Power Train Model 2120 Tractor
25-2 Final Drives TM-4252 (Dec.-70)

5 W— 6

I51560

Fig. 2 — Final Drive Assembly - Exploded View

1 Flanged axle* 13 Oil seal 25 Planet pinion carrier
2 Oil seal 14 Taper roller bearing cup 26 Snap ring
3 Oil seal cup 15 Taper roller bearing cone 27 Spacer (3 used)
4 Taper roller bearing cone 16 Dowel pin (3 used) 28 Brake housing with ring gear
5 Taper roller bearing cup 17 Thrust washers (6 used) 29 Dowel pin (3 used)
6 Grease nipple 18 Bearing rollers (120 used) 30 Dowel pin (2 used)
7 Plug 19 Planet pinion (3 used) 31 Wheel bolt* (8 used)
8 O-ring 20 Planet pinion shaft (3 used) 32 Ball nut* (8 used)
9 Cap screw (12 used) 21 Final drive shaft 33 Flanged axle**
10 Bleed screw 22 Lock plate 34 Rack-and-pinion axle
11 Rear axle housing 23 Cap screw 35 Dust cap
12 Gaskets 24 Washer

REPAIR

Be sure to remove lock plate 22 (fig. 2) before Be careful not to lose any of the 40 bearing rollers
attempting to remove cap screws 23. 18 located in each planet pinion. If some of them
have to be replaced, always replace all rollers.
Push brake housing with ring gear off dowel pins
and remove. When the ring gear of the brake housing is worn or
damaged, replace housing with ring gear.

Do not heat taper roller cones beyond 300° F

( 150° C) when installing.

* For rear wheels with steel disks

** For rear wheels with cast disks

Printed in Germany
2120 Tractor
TM-4252 (Dec.-70)

10, group 25.

ADJUSTMENT

Width of a planet pinion

Thickness of a thrust washer

Thickness of a spacer

planet pinion shafts

O. D. of planet pinion shaft

.
First measure the drag torque with the planet
carrier assembled in place, but with end play in
bearings (see fig. 3). Provide sufficient end play so
as not to exceed a certain drag torque. Then
tighten the cap screws 23 until final drag torque on
rear axle is obtained (for adjusting values see Speci¬
fications).

INSTALLATION

Slide final drive shaft in differential assembly.

Install assembled final drive as explained in section

............
............
..............
Dia. of rear axle at outer bearing

..................
Dia. of rear axle at inner bearing

Dia. of a planet pinion bore

..................
Rear axle drag torque with end play
in bearings, max

Rear axle drag torque with

preloaded bearings

Final drives to transmission case,

cap screws

Printed in Germany
........
Dia. of planet pinion bearing rollers
(measured at center)

....................
....................
..............
Dia. of planet pinion carrier bores for
SPECIFICATIONS

TORQUES FOR HARDWARE

L47197

2.235 to 2.245 in,

0.2498 to 0.2500 in.

0.04 in.

0.449 to 0.469 in.

1.350 to 1.352 in,

1.3491 to 1.3496 in.

48 in.lbs.

96 to 144 in.lbs.

85 ft.lbs.
Power Train
Final Drives

Fig. 3 — Adjusting the Rear Axle Taper Roller

Bearings

Dimensions of new parts

2.6885 to 2.6895 in.

2.4385 to 2.4395 in.

1.8501 to 1.8515 in.

68.287 to 68.313 mm

61.938 to 61.964 mm

46.992 to 47.028mm
50
25-3

56.77 to 57.03 mm

6.344 to 6.349 mm

1.00 mm

11.41 to 11.91 mm

34.29 to 34.34 mm

34.267 to 34.280 mm

55 cm/kg

110 to 165 cm/kg

11,7 mkg
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Continuous-Running PTO Shafts 30-1

Group 30
CONTINUOUS-RUNNING
PTO SHAFTS
GENERAL INFORMATION

The PTO shafts located in the lower part of the The dual PTO shaft can be converted from 540 to
transmission case are independent of the 1000 rpm and vice versa by exchanging the stub
transmission. They can operate only if the PTO shaft. In addition, the tractor may be equipped
clutch of the engine dual-stage clutch is engaged with a mid 1000 rpm PTO shaft.
(see group 5).
For operating the PTO shafts see operator's
The tractor may be equipped with a single rear 540 manual.
rpm or a dual rear 540 and 1000 rpm PTO shaft.

SINGLE REAR 540 RPM PTO SHAFT

L 5031 1 A

Fig. 1— Single Rear 540 rpm PTO Shaft

1 Rear quill 3 oil seal 5 PTO drive shaft 7 Front quill
2 PTO shaft 4 Shifter collar 6 PTO gear

REMOVAL

Before starting work on the PTO shaft, drain trans- shifter mechanism from dropping into the
mission oil. transmission case when removing PTO shaft.

REMOVING PTO SHAFT

Operate PTO shifter mechanism to disengage PTO

shaft. This will prevent the collar of the PTO

Printed in Germany
50 Power Train Model 2120 Tractor
30-2 Continuous-Running PTO Shafts TM-4252 (Dec-70)

REMOVING PTO SHIFTER MECHANISM

Remove rockshaft, see section 10, group 25.

NOTE: Prior to removing the PTO shifter

mechanism, the transmission countershaft and the
range shifter shafts must be removed, see group 15.

Fig. 2 — Removing Single Rear PTO Shaft

1 Rear quill 2 PTO shaft

Remove cap screws attaching quill 1 (fig. 2) to

transmission case. Pull PTO shaft 2 with quill 1out
of transmission case.

REMOVING PTO DRIVE SHAFT AND GEAR

Fig. 3 — Removing PTO Shifter Mechanism
Separate tractor between transmission case and 1 Shifter arm 3 Shifter collar
2 Shifter
clutch housing, see section 10, group 25.

Remove snap ring and push PTO gear off PTO Remove PTO shifter shaft lock on left side of
drive shaft. transmission case.

Re-install PTO shaft 2 (figs. 1 and 2), if removed. Remove PTO drive shaft from transmission (if still
Operate shifter mechanism of rear PTO shaft to installed) and remove shifter collar.
prevent shift collar from dropping into trans¬
mission case when removing PTO drive shaft. Remove parts of shifter mechanism.

Pull PTO drive shaft forward out of transmission

case.

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Continuous- Running PTO Shafts 30-3

L 51578

Fig. 4 — Exploded View of Single Rear PTO Shaft

1 PTO drive shaft 6 Thrust washer 11 PTO shaft 14 Oil seal
2 Bushing 7 Needle bearing 12 Bushing (seated 15 Ballbearing
3 Snap rings 8 Gasket in transmission case) 16 Snap ring
4 Gear 9 Lock plate (4 used) 13 Rear quill 17 Cap screw (3 used)
5 Front quill 10 Hex.nut (4 used) 18 Gasket

REPAIR Use new oil seal and drive into quill bore until
flush, with sealing lip facing driver.
REPAIR OF PTO SHAFT
Press PTO shaft with ball bearing into quill and
Check PTO shaft and quill bearing for wear or install snap ring in groove of quill.
damage. To replace PTO shaft or ball bearing,
remove snap ring of quill. Push PTO shaft and
bearing out of quill. Remove both snap rings of
PTO shaft and press bearing off shaft. Press new
bearing on shaft so that snap rings in front and
behind ball bearing fit into grooves of PTO shaft.

Check quill for damage.

Printed in Germany
50 Power Train Model 2120 Tractor
30-4 Continuous-Running PTO Shafts TM-4252 (Dec-70)

REPAIR OF PTO DRIVE SHAFT AND GEAR INSTALLING PTO SHAFT

Check PTO gear and drive shaft for wear or Install PTO shaft with ball bearing and quill in
damage. Check bushing in bore of PTO drive shaft transmission case. Attach quill to transmission
and PTO drive shaft bushing seated in transmission case.
case for wear. Replace, if necessary.
INSTALLING PTO DRIVE SHAFT AND GEAR
Inspect needle bearing and thrust washer of front
quill and replace, if necessary. Slide PTO drive shaft, with splined end in front,
into transmission case and introduce in shifter
REPAIR OF PTO SHIFTER MECHANISM collar. Slide gear onto drive shaft, with long hub
end facing transmission case, and install snap ring.
Check shifter shaft, shifter and splines of shifter
collar for wear and replace parts, if necessary. Attach front PTO quill to clutch housing (if
removed) and attach clutch housing to trans¬
Check detent spring for serviceability. mission case (see section 10, group 25). Tighten
screws to the specified torque.
INSTALLATION Fill transmission case with proper oil (see
operator's manual).
INSTALLING PTO SHIFTER MECHANISM

When installing, reverse removal procedure.

MID PTO SHAFT

REMOVAL When removing shifter fork, make sure detent ball
and spring do not get lost.
Drain transmission case.

Separate tractor between transmission case and REMOVING PTO SHAFT

clutch housing, see section 10, group 25.
Drive PTO shaft out of quill, using slight taps.
REMOVING PTO SHAFT SHIFTER Remove quill.
MECHANISM

Drive spring pin 11 (fig. 5) out of coupling 10 and

control lever shaft. Withdraw control lever from
clutch housing. Drive inner spring pin 8 out of
shifter fork and shifter shaft 9. Withdraw shifter
shaft and coupling from shifter fork.

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Continuous-Running PTO Shafts 30-5

L 50314

Fig. 5 — Exploded View of Mid PTO Shaft

1 PTO shaft 5 Needle bearing 9 Shifter shaft 13 Control lever
2 Shifter collar 6 Quill 10 Coupling 14 Dowel pins
3 Needle bearing 7 Oil seal 11 Spring pin 15 Shifter fork
4 Ball bearing 8 Spring pins 12 O-ring 16 Detent spring
17 Detent ball

REPAIR Check driven gear (1000 rpm) at front of trans¬

mission for wear or chipped teeth. Inspect bushings
REPAIR OF PTO SHAFT of gear for wear and replace gear, if necessary.
Check splines of PTO shaft and teeth of drive gear
INSTALLATION
for wear or damage. Inspect ball bearing on PTO
shaft and needle bearing in bore of PTO shaft for
When installing PTO shaft and shifter mechanism,
damage and replace, if necessary. Check needle
reverse removal procedure.
bearing of quill for wear or rough spots. Check oil
seal of quill for damage and replace, if necessary. When installing quill, use a new oil seal and when
installing PTO control lever, use a new O-ring.
REPAIR OF PTO SHIFTER MECHANISM
Attach clutch housing to transmission case and
Check shifter collar, shifter fork and control lever tighten screws to the specified torque (see section
for wear or damage and replace, if necessary. 10, group 25).
Check detent spring for serviceability.
Fill transmission case with proper oil (see
operator's manual).

Printed in Germany
50 Power Train Model 2120 Tractor
30-6 Continuous-Running PTO Shafts TM-4252 (Dec-70)

DUAL REAR 540 RPM AND 1000 RPM PTO SHAFT

50313A

Fig. 6 — Dual Rear 540 rpm and 1000 rpm PTO Shaft,
Shown with Mid 1000 rpm PTO Shaft
1 Stub shaft for 1000 rpm 4 Oil seal 7 Shifter collar
2 Stub shaft for 540 rpm 5 PTO pilot 8 PTO driven shaft
3 Quill 6 PTO shaft 9 540 rpm gear
10 1000 rpm gear

NOTE: This PTO shaft can be combined with a Remove oil seal 3 (fig. 7) from bore of trans¬
mid 1000 rpm PTO shaft (see fig. 6). mission case.

For details on mid PTO shaft see page 4. CAUTION: Take care not to damage bore when
removing oil seal. When assembling, install new oil
For rear PTO shifter mechanism see "Single rear seal.
540 rpm PTO shaft" (page 1).

REMOVAL

Before starting work on the PTO shaft, drain trans¬

mission case.

REMOVING PTO SHAFT

Operate rear PTO shifter mechanism to disengage

PTO shaft. This will prevent the collar of the
shifter mechanism from dropping into transmission
case when removing PTO shaft.

Remove cap screws attaching rear quill to transmis¬

sion case. Pull quill out of transmission case.

Fig. 7 — Removing PTO Shaft Pilot

1 PTO shaft pilot 4 Snap ring
2 Ball bearing 5 Special washer
3 Oil seal

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Continuous-Running PTO Shafts 30-7

Remove snap ring 4 (fig. 7). Pull PTO shaft pilot Push PTO shaft gears off PTO drive shaft.
out of transmission case. Remove PTO shaft.
Re-install PTO shaft and PTO shaft pilot or rear
CAUTION: When removing PTO shaft, make sure PTO shaft assembly (if removed). Operate PTO
thrust washer 16 (fig. 8) located between PTO shifter mechanism to engage PTO shaft. This will
shaft and PTO drive shaft does not drop into prevent collar of shifter mechanism from dropping
transmission case. into transmission case when removing PTO drive
shaft.
REMOVING PTO DRIVE SHAFT AND GEARS Pull PTO drive shaft forward out of transmission
case.
Separate tractor between transmission case and
clutch housing, see section 10, group 25.

L 50315A

Fig. 8 — Exploded View of Dual Rear 540 and 1000 rpm PTO Shaft
1 PTO drive shaft 12 Hex.nut (4 used) 21 Snap ring
2 Thrust washers 13 Lock plate (4 used) 22 Oil seal
3 Drive screw (4 used) 14 Bushing 23 PTO shaft pilot
4 Gear (540 rpm) 16 Bushing (seated in 24 O-ring
5 Gear (1000 rpm) transmission case) 25 PTO stub shaft
6 Spring 16 Thrust washer (540 or 1000 rpm)
7 Ball 17 PTO shaft 26 Cap screw (4 used)
8 Drive screw 18 Snap ring 27 Rear quill
9 Needle bearing 19 Ball bearing 28 Cap screw (3 used)
10 Front quill 20 Special washer 29 Bushing of PTO shaft
11 Gasket gears (4 used)

Printed in Germany
50 Power Train Model 2120 Tractor
30-8 Continuous-Running PTO Shafts TM-4252 (Dec-70)

REPAIR INSTALLATION

REPAIRING PTO SHAFT INSTALLING PTO SHAFT

Check PTO shaft, PTO shaft pilot, stub shaft and When installing the PTO shaft, reverse removal
rear quill for damage. Replace, if necessary. procedure.

Check ball bearing of PTO shaft pilot for damage. Make sure thrust washer 16 (fig. 8) is installed
If required, remove snap ring and drive ball bearing between PTO drive shaft 1and PTO shaft 17.
off pilot. Press new bearing onto pilot until snap
ring fits in groove. NOTE: When installing PTO stub shaft, use a new
O-ring.

REPAIRING PTO DRIVE SHAFT AND GEARS INSTALLING PTO DRIVE SHAFT
Check PTO shaft gears and drive shaft for wear or Slide PTO drive shaft into transmission case, with
damage. Inspect bushing in bore of PTO drive shaft splined end first, and insert in shifter collar. Slide
for wear and replace, if necessary.
large 540 rpm PTO gear with long hub end facing
transmission case as well as small 1000 rpm gear
Check bushing of PTO drive shaft in front trans¬ with long hub end facing away from transmission
mission case for wear and replace, if necessary. case onto drive shaft.

Check spring of PTO drive shaft for damaged or Attach front PTO quill to clutch housing (if
broken coils and replace, if necessary. removed). If tractor is equipped with mid PTO
shaft, install shaft (see page 5).

Attach clutch housing to transmission case and

tighten screws to the specified torque (see section
10, group 25).

Fill transmission case with proper oil (see

operator's manual).

REAR 540 RPM AND MID 1000 PTO SHAFTS

This PTO shaft is a combination of the "Single CAUTION: Contrary to the single rear PTO shaft,
Rear PTO Shaft" (see page 1), the "Dual Rear 540 on the above shaft a thrust washer 20 is located
and 1000 rpm PTO Shaft" (see page 6) and the between PTO shaft 21 (fig. 10) and PTO drive
"Mid PTO Shaft" (see page 4). shaft 18,
When removing PTO shaft 21, take care that thrust
washer 20 does not drop into transmission case.

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Continuous- Running PTO Shafts 30-9

Fig. 9 — Rear 540 rpm and Mid 1000 rpm PTO Shafts
1 PTO shaft 4 shifter collar 7 1000 rpm gear 10 Front quill
2 Quill 5 PTO drive shaft 8 Oil seal 11 Shifter collar
3 Oil seal 6 540 rpm gear 9 Mid PTO shaft

Fig. 10 — Exploded View of Rear 540 rpm and Mid 1000 rpm PTO Shafts
1 Thrust washer 7 Drive screw 13 Front quill 19 Bushing 25 Oil seal
2 540 rpm gear 8 Needle bearing 14 Oil seal 20 Thrust washer 26 Gasket
3 Bushings 9 Shifter collar 15 Seal ring 21 Rear PTO shaft 27 Rear quill
(4 used) 10 Mid PTO shaft 16 Lock plate (4 used) 22 Snap rings 28 Cap screw (3 used)
4 1000 rpm gear 11 Ball bearing 17 Hex.nut (4 used) 23 Snap ring 29 Drive screw (2 used)
5 Spring 12 Needle bearing 18 PTO drive shaft 24 Ball bearing 30 Bushing
6 Ball

Printed in Germany
50 Power Train Model 2120 Tractor
30-10 Continuous-Running PTO Shafts TM-4252 (Dec-70)

SPECIFICATIONS

for needle bearing ...................

SINGLE REAR 540 RPM PTO SHAFT

.................
Dia. of PTO drive shaft seat
Dimensions of New Parts

0.9979 to 0.9989 in. 25.351 to 25.367 mm

...................
Dia. of front quill bore for
seating needle bearing 1.3115 to 1.3125 in. 33.312 to 33.338 mm

..............
Inner dia. of bushing seated in
transmission case 1.3760 to 1.3790 in. 34.949 to 35.029 mm

...................
Dia. of PTO drive shaft
bearing journal for bushing 1.3730 to 1.3740 in. 34.874 to 34.900 mm

....................
Dia. of PTO drive shaft bore
for seating bushing 0.8120 to 0.8130 in. 20.625 to 20.651 mm

PTO drive shaft

...............
Inner dia. of bushing in

.........
0.7515 to 0.7545 in. 19.086 to 19.166 mm

..........
Dia. of PTO shaft journal 0.7495 to 0.7505 in. 19.037 to 19.063 mm

Dia. of PTO shaft seat for ball bearing 1.3779 to 1.3785 in. 34.998 to 35.014 mm

........
Dia. of ball bearing seat in rear quill 2.8343 to 2.8353 in. 71.991 to 72.017 mm

............
MID PTO SHAFT

..........
Dia. of PTO shaft seat for ball bearing . 1.7716 to 1.7722 in. 44.958 to 45.014 mm

Dia. of ball bearing seat in quill 3.3464 to 3.3474 in. 84.998 to 85.024 mm

for needle bearing ...................

Dia. of quill bore for needle bearing

.....................
Dia. of mid PTO shaft seat

Dia. of mid PTO shaft bore for

needle bearing
2.1245 to 2.1255 in.

1.7494 to 1.7500 in.

1.3115 to 1.3125 in.

53.962 to 53.988 mm

44.434 to 44.450 mm

33.312 to 33.338 mm

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Continuous- Running PTO Shafts 30-11

...................
DUAL REAR 540 AND 1000 RPM PTO SHAFT

Dia. of PTO drive shaft seat

for needle bearing

.......
Dimensions of New Parts

0.9979 to 0.9989 in. 25.351 to 25.367 mm

transmission case ............

Dia. of front quill bore for needle bearing

................
Inner dia. of bushing seated in
1.3115 to 1.3125 in.

1.3760 to 1.3790 in.

33.312 to 33.338 mm

34.949 to 35.029 mm

....................
Dia. of PTO drive shaft
bearing seat for bushing 1.3730 to 1.3740 in. 34.874 to 34.900 mm

...................
Dia. of PTO drive shaft bore for
seating bushing 0.8120 to 0.8130 in. 20.625 to 20.651 mm

in PTO drive shaft

...............
Inner dia. of bushing seated

......
0.7515 to 0.7545 in. 19.086 to 19.166 mm

.............
Dia. of PTO shaft journal 0.7495 to 0.7505 in. 19.037 to 19.063 mm

.........
Dia. of ball bearing seat of PTO shaft pilot 2.1653 to 2.1659 in. 54.998 to 55.014 mm

Dia. of PTO gear bushing bore 1.3760 to 1.3790 in. 34.949 to 35.029 mm

Dia. of PTO drive shaft bushing seats 1.3730 to 1.3740 in. 34.874 to 34.900 mm

REAR 540 RPM AND MID 1000 RPM PTO SHAFTS

This PTO shaft is a combination of the "Single Rear 540 rpm PTO Shaft", the "Dual Rear 540 and 1000
rpm PTO Shaft" and the "Mid PTO Shaft". Specifications see above PTO shafts.

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Independent PTO Shafts 35-1

Group 35
INDEPENDENT PTO SHAFTS
GENERAL INFORMATION

The tractor can be equipped with a single, When disengaging the PTO, oil pressure is relieved
independent, rear 540 rpm PTO shaft or with a from the PTO multiple-disk clutch. The PTO shaft
dual, independent, rear 540/1000 rpm PTO. is then immediately brought to a standstill by the
Conversion from 540 rpm to 1000 rpm is made by hydraulically operated brake band.
exchanging the stub shaft engaged in a reduction
gear at the rear of the transmission case. The number of PTO clutch disks varies for the
single, rear 540 rpm PTO and the dual, rear 540
Tractors with a dual, rear PTO can also be and 1000 rpm PTO. The differences are as follows:
equipped with a mid 1000 rpm PTO.
Single, rear 540 rpm PTO
In this case two selector levers are located on the
10 internally splined disk plates
left-hand side of the tractor, making it possible to
10 externally splined separator plates
engage or disengage the mid or rear PTO
mechanically when independent operation of one
Dual, rear 540 and 1000 rpm PTO
of the shafts is required. Then the PTO is hydrau-
lically operated, being engaged or disengaged by
6 internally splined disk plates
means of the control lever located on the clutch
6 externally splined separator plates
housing.
The clutch drums for the single, rear PTO and the
For this reason, the rear PTO also has a shifter dual, rear PTO vary in width (see Specifications).
collar (see 2, fig. 3), whereas on machines without
a mid PTO only a connecting sleeve is installed (see
2, fig- 2).
The PTO gear train is located in the lower portion
of the transmission case.

When engaging the PTO by means of the lever

located on the clutch housing, oil pressure is
relieved from the PTO brake and immediately
engages the PTO multi-disk clutch.

Printed in Germany
50 Power Train Model 2120 Tractor
35-2 Independent PTO Shafts TM-4252 (Dec-70)

wmm

L 50321

Fig. 1— Hydraulic Circuit Flow Diagram of Independent PTO

1 PTO clutch piston 11 Oil flow to manifold and 16 Pressure oil passage to PTO brake
2 Disk hub HIGH disk clutch 17 Pressure oil passage to PTO clutch
3 Clutch drum 12 Oil flow to manifold and 18 Oil passage from transmission oil pump
4 PTO clutch shaft LOW disk brake 19 Port for checking regulating valve
5 Front transmission cover 13 Spool of HIGH-LOW control valve pressure
6 Passage for oil flowing to 14 PTO clutch valve actuator 20 Brake band
hydraulic pump (engaged position) 21 Brake piston
7 Pressure regulating valve 15 Oil passage to transmission 22 Pressure oil (approx. 142 psi - 10 kg/cm2)
8 Oil passage to transmission case case (return oil from PTO 23 Intermediate pressure oil
(return oil from PTO clutch) brake) (approx. 71 psi = 5 kg/cm2)
9 Oil orifice 24 Pressure-free oil
10 Spool of PTO control valve

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Independent PTO Shafts 35-3

OPERATION
HYDRAULIC FUNCTION Oil flowing through passage 16 to the PTO brake
gets behind brake piston 21, which operates brake
When the PTO control lever is moved forward, band 20 with the aid of a brake arm. The brake
spool 10 (fig. 1) with the aid of a lever, a spring and band stops shaft 4 and PTO shaft through a hub
actuator 14, is pushed into housing of gear shift splined and thus positively engaged onto shaft 4 of
lever. PTO clutch.

By this means pressure oil passage 18 is connected When the PTO is engaged again, pressure oil from
to pressure oil passage 17 leading to the PTO behind the piston is drained and a tension spring
clutch. At the same time oil flows under pressure releases the brake band (see fig. 1).
into the passage behind spool 10 until it is
completely closed (see fig. 1). During the engaging
operation, pressure oil from behind the spool The control lever and spool are locked in both end
drains off through metering bore 9 thus positions, ("engaged" and "disengaged"), by means
counteracting the engaging movement until the of two detent balls and springs.
PTO clutch is completely engaged. In this way an
abrupt engagement of the PTO is prevented and a The oil pressure required for operating the PTO
smooth engagement guaranteed. clutch and brake is maintained by a pressure
regulating valve located in the transmission shift
To disengage the PTO, the spool is moved in the cover. This valve is similar to that installed on
opposite direction. First pressure oil passage 17 is tractors equipped with HIGH-LOW unit (see group
closed and return oil passage 8 opened so that oil 10).
from the PTO clutch can flow into the transmis¬
sion case. Afterwards the spool opens pressure oil
passage 16 and at the same time pressure oil
passage 17 is opened fully so that pressure oil can
flow from there to the PTO brake.

Printed in Germany
50 Power Train Model 2120 Tractor
35-4 Independent PTO Shafts TM-4252 (Dec-7 j)

l50207

Fig. 2 — Independent, Single, Rear 540 rpm PTO Shaft — Sectional View
1 PTO shaft for 540 rpm 4 PTO brake 7 Drive gear 9 Pressure spring
2 Connecting sleeve 5 Clutch drum 8 Disk pack 10 Disk hub
3 PTO clutch shaft 6 Piston of multiple disk-clutch

L 50320

Fig. 3 — Independent, Dual, Rear 540 rpm PTO and Front 1000 rpm PTO — Sectional View
1 PTO shaft with gear 5 Clutch drum 9 Pressure spring 13 Double gear
2 Shifter collar 6 Piston of multiple-disk clutch 10 Disk hub 14 1000 rpm stub shaft
3 PTO clutch shaft 7 Drive gear 11 Shifter collar 15 540 rpm stub shaft
4 PTO brake 8 Disk pack (front PTO) 16 Gear
12 Countershaft

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Independent PTO Shafts 35-5

OPERATION

Power is transmitted from the hollow gear shaft of

the transmission oil pump to gear 7 (figs. 2 and 3),
which is positively engaged to clutch drum 5 by
means of a spring washer.

When the clutch disk assembly 8 is compressed

through oil pressure by means of piston 6, power is
transmitted from clutch drum 5 through disk
assembly 8 to hub 10 and thus to shaft 3 (see figs.
2 and 3).

If the 540 rpm stub shaft 15 (fig. 3) is installed,

power flows from gear of powershaft end 1
through double gear 13 and gear 16 of counter¬
shaft into the stub shaft.
Fig. 4 — Connecting Points for Checking Operating
If the 1000 rpm stub shaft 14 is installed, power Pressure
flows from gear of power shaft end 1directly into 1 Plug (checking operating pressure of PTO brake)
the stub shaft which is splined to the powershaft 2 Plug (checking operating pressure of PTO clutch)
end (see fig. 3). Meanwhile, double gear 13 and
gear 16 of the countershaft are running idle. When the pressure reading is less than specified or
the PTO shaft turns with the control lever in the
disengaged position, do not place PTO shaft under
TESTING OIL PRESSURE load until the fault has been rectified.
Testingoperating pressure of PTO clutch and brake Testing operation of spool in control valve
assembly
Remove plug 1 (fig. 4) when checking the
operating pressure of PTO brake. Remove plug 2 Remove plugs 1 and 2 (fig. 4) and connect two
when checking the operating pressure of the PTO pressure gauges.
clutch.
Start engine again and run at 2100 rpm. Observe
Connect gauge No. 19.58-90.268 (range 0-355 psi both pressure gauges.
= 0-25 kg/cm2) with the aid of pressure hose
assembly and adapter No. 19.58-90.266 of special When the PTO control lever is moved slowly from
tool No. 19.58-90.260. When testing operating engaged to disengaged position, one gauge must
pressure of PTO brake, a special elbow is required. read zero before the other gauge shows any
pressure.
Start engine and run at 2100 rpm. Warm up oil to
normal running temperature by actuating PTO No pressure overlap should be experienced when
control lever, engaging and disengaging the PTO. shifting the lever slowly between the engaged and
The operating pressure in both final positions of disengaged positions.
the control lever should be the same. See
Specifications for correct operating pressure.

Printed in Germany
50 Power Train Model 2120 Tractor
35-6 Independent PTO Shafts TM-4252 (Dec-70)

DIAGNOSING MALFUNCTIONS Control valve defective

TOO LITTLE OR NO OIL PRESSURE PTO selector levers (if equipped) disengaged

Transmission ofl pump defective (see section 70, Engine clutch pressure plate defective
group 15)
PTO countershaft damaged
Pressure regulating valve incorrectly adjusted (see
section 50, group 10) PTO WILL NOT STOP
Clogged transmission oil filter Control valve spool defective
Broken pressure regulating valve spring
Clutch pack defective - will not release
Transmission filter relief valve defective
PTO brake worn or defective
PTO control valve assembly damaged
PTO IS NOISY
OIL PRESSURE OVERLAPS
Bearings failed or worn
Control valve spool and/or control valve housing
lands damaged
Countershaft worn or damaged
PTO FAILS TO OPERATE
Insufficient delivery of transmission oil pump
Transmission oil pump defective
Engine slow idle below specified rpm
Clutch facings worn or burned

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Independent PTO Shafts 35-7

REAR PTO SHAFT ASSEMBLY

REMOVAL Remove countershaft 12 (fig. 3) and gear 13 of
countershaft assembly.
REMOVAL ON TRACTORS EQUIPPED WITH
SINGLE, REAR 540 RPM PTO SHAFT INSPECTION AND REPAIR
Drain transmission oil. Remove complete rockshaft Remove oil seal from rear bearing cover and
assembly (see section 10, group 25). When
discard. Drive new seal into housing so that sealing
removing the rear PTO shaft, press connecting lip faces driving tool and the oil seal bottoms
sleeve 2 (fig. 2) against PTO clutch shaft 3 by shoulder of cover. Coat sealing lip with grease.
means of a long, thin screwdriver to prevent the
sleeve from falling into the transmission case. Check ball bearings and roller bearings (if
Remove attaching screws from rear bearing cover equipped) for serviceability.
and take bearing cover together with PTO shaft out
of the transmission case. Check countershaft 12 (fig. 3) for scores or wear.
REMOVAL ON TRACTORS EQUIPPED WITH Check bearing needles of gear 13 and spacer.
DUAL REAR 540 AND 1000 RPM PTO SHAFT Always replace a complete set (24) of needles if
any have to be replaced.
Drain transmission oil and remove rear bearing
cover complete with PTO stub shaft. Check PTO shaft bushing in transmission case.
Remove gear 16 (fig. 3).
ASSEMBLY
Remove rear PTO shaft 1as follows:
When installing, reverse removal sequence.
On tractors not equipped with a mid-PTO: Before
pulling out PTO shaft 1 (fig. 3), remove rockshaft When assembling the countershaft 12 (fig. 3), make
assembly and with the aid of a long, thin screw¬ sure that the thrust washer, all needle bearings and
driver hold connecting sleeve onto the PTO clutch spacer of double gear 13 are installed (see fig. 3).
shaft 3.

On tractors equipped with a mid-PTO: Shift rear

PTO selector lever, located on side of transmission
case, to the rear in the disengaged position before
pulling rear PTO shaft out of transmission case.
Doing this keeps connecting sleeve 2 (fig. 3) on
shaft 3 so that it cannot fall into the transmission
case.

Printed in Germany
50 Power Train Model 2120 Tractor
35-8 Independent PTO Shafts TM-4252 (Dec-70)

PTO-CLUTCH

Fig. 5 — PTO Clutch, Exploded View

1 Sealing ring <2 used) 6 Packing 11 Snap ring 15 Plate
2 Woodruff key 7 Sealing ring 12 Clutch hub 16 Snap ring
3 Clutch drum 8 Piston 13 Separator plate (externally 17 Thrust washer
4 Clutch gear 9 Pressure spring splined) (6 or 10 used) 18 Snap ring
5 Snap ring 10 Retainer 14 Clutch disk (internally splined)
(6 or 10 used)

REMOVAL On tractors equipped with mid-PTO, shift rear PTO

selector lever, located on side of transmission case
Separate tractor between transmission case and forward, to the engaged position. This will prevent
clutch housing, as explained in section 10, group the disconnect collar from falling into the
25. transmission case when removing the PTO drive
shaft and clutch assembly. Pull disk clutch
CAUTION: Before removing shift lever assembly, assembly together with shaft out of transmission
place shift lever forward in the engaged position. case.
Remove shift lever complete with cover. When
removed, do not move shift lever otherwise detent On tractors not equipped with mid-PTO, remove
balls and springs will fall out. front snap ring 18 (fig. 5) from clutch shaft. Push
disk clutch off shaft, at the same time pushing
Install rear PTO shaft (if removed). against the shaft so that it stays in the transmission
case, so preventing the connecting sleeve from
Remove clutch assembly as follows: sliding off the rear PTO shaft.

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec~70) Independent PTO Shafts 35-9

DISASSEMBLY NOTE: On tractors equipped with HIGH-LOW

unit, install gear with offset toward large end of
Remove snap ring 16 (fig. 5) from the clutch drum. drum and on machines not equipped with HIGH-
Take out clutch hub 12 with plate 15 and clutch LOW unit towards small end of drum,
pack, lining up the external splines of clutch disks
and plate with the splines in the clutch drum. To Check spring 9 (fig. 5) for damaged or broken
facilitate reassembling, make a note of the number coils. Check resilience of spring (see Specifi¬
of clutch disks and separator plates. cations).

Compress pressure spring 9 and remove snap ring ASSEMBLY

11 from clutch drum. Remove retainer 10, spring 9
and piston 8. Remove and discard packing 6. When assembling, reverse disassembly procedure,
watching the following points:
INSPECTION AND REPAIR
Install new packing 6 in clutch drum 3 (fig. 5).
Check all parts of clutch disk assembly for wear
and damage, watching the following points: Install retainer 10 so that the fins face away from
piston.
Check clutch hub 12 (fig. 5) for worn or damaged
splines. Install the correct number of clutch disks 14 and
separator plates 13 alternately on hub 12 so that a
Check the internally splined disks 14 and exter¬ separator plate is on the piston side and a clutch
nally splined separator plates 13 for wear, making disk on the side of plate 15.
sure that the grooved pattern of the disk facings is
not worn or rubbed off. If so, renew disks. Check
the internal splines for damage. For thickness of a INSTALLATION
clutch disk, see Specifications.
When installing, reverse removal procedure.
Check piston 8 and clutch drum 3 for cracks or
any other damage, and replace if necessary. Check NOTE: If the PTO drive shaft was removed on
piston sealing ring 7 and both clutch drum sealing machines not equipped with mid-PTO, ensure that
rings 1for serviceability. connecting sleeve 2 (fig. 2) is installed on the rear
PTO shaft. If this is not the case, insert a screw¬
Check bushings of clutch drum and bushing of driver or similar tool through the square opening of
PTO clutch shaft seated in transmission case. the transmission case and push the connecting
sleeve on the PTO shaft.
If clutch drum gear 4 has to be replaced, heat new
gear in an oil bath to 360°F (180°C) before
pressing on.

Printed in Germany
50 Power Train Model 2120 Tractor
35-10 Independent PTO Shafts TM-4252 (Dec-70)

PTO SHAR BRAKE CONTROL VALVE

REMOVAL ASSEMBLY
Separate tractor between transmission case and Before removing control lever assembly, push
clutch housing and remove PTO clutch. control lever forward into engaged position.
Remove control lever complete with cover.
4
Do not move control lever after assembly has been
removed, otherwise detent balls and springs will
fall out.

Remove transmission shift cover.

Remove plug 14 (fig. 7) and actuator 22 complete

with spring 18, shims 17 and spool 21 from trans¬
L 50 324 mission shift cover. Then remove special pin 20
complete with washer 19, second spring 18, shims
Fig. 6 — PTO Shaft Brake - Exploded View 17 and retaining ring 16.

1 Brake hub 5 Spring pin 8 Lever

2 Snap ring 6 Tension spring 9 Clevis pin
DISASSEMBLY
3 Washer 7 Guide pin 10 Cotter pin
4 Brake band Remove retaining rings 16 (fig. 7) of spool 21 and
special pin 20.
Disconnect tension spring 6 (fig. 6). Drive guide
pin 7 out of front transmission cover, and pull out CAUTION: Do not mix up springs 18 and shims 17
of lever 8 and brake band 4. Remove brake band of special pin and spool.
with lever 8.
INSPECTION AND REPAIR
NOTE: When removing brake piston 21 (fig. 1), it
is necessary to remove the front transmission Check spool 21 (fig. 7) and transmission shift cover
cover, see section 50, group 15. 6 for damaged lands.

REPAIR Check resilience of springs 18 (see Specifications).

Check all parts for wear and damage. Test spring ASSEMBLY
resilience (see Specifications).
Assemble special pin and spool of control valve
assembly as follows and check resilience of springs :
INSTALLATION
1. Install washer 19 (fig. 7), spring 18, three shims
BRAKE BAND 17 and retaining ring 16 onto special pin 20. Place
special pin (small end first) on spring scales. Press
Remove snap ring 2 (fig. 6) out of groove of guide down with your finger on spring of special pin. The
pin and drive pin (groove first) into front transmis¬ spring should break free from headed end of
sion cover until it is flush with outside edge of special pin at a determined load (see Specifi¬
cover. Guide lever 8 and brake band 4 through cations).
bore of transmission cover 1. Install brake band
around the hub and push lever 8 and the lugs of
brake band 4 onto guide pin 7. Replace snap ring
in pin groove.

Reconnect spring 6.

Printed in Germany
Model 2120 Tractor Power Train 50
TM-4252 (Dec-70) Independent PTO Shafts 35-11

17
—
16
®

21
20
19

L 50325

Fig. 7 — Control Valve Assembly and Pressure Regulating Valve, Exploded View
1 Plug 9 Plug (3 used) 16 Retaining rings 24 O-ring (2 used)
2 O-ring 10 O-ring (3 used) 17 Shims (6 used) 25 O-ring (2 used)
3 Shim (use as required) 11 Dowel pin (2 used) 18 Springs 26 Plate
4 Spring 12 Plug (on machines without 19 Washer 27 Cap screw (4 used)
5 Pressure regulating valve HIGH-LOW unit) 20 Special pin 28 Cap screw
6 Treansmission shift cover 13 Spring pin (on machines without 21 Spool 29 Washer
7 Plug HIGH-LOW unit) 22 Actuator 30 Gasket
8 Cap screw (6 used) 14 Cap 23 Control lever arm
15 Plug

If necessary, add or deduct shims until correct ADJUSTING INTERLOCK MECHANISM OF PTO
spring tension is obtained. CONTROL LEVER

CAUTION: There should always be a minimum of Coat both cap screws with sealing compound and
one washer. screw flush into transmission cover, that is until
springs are fully compressed. After that unscrew
2. Install three shims 17 (fig. 7), spring 18, both cap screws two turns.
actuator 22 and retaining ring 16 on spool 21.
MID-PTO SHAFT AND SHIFTER MECHANISM
Place spool end on scales and press with fingers on
actuator. If actuator does not break free from snap See group 30 for details regarding mid-PTO and
ring end of spool at the required load, add or PTO shaft shifter mechanism.
deduct washers until correct tension is obtained
(see Specifications).

Printed in Germany
50 Power Train Model 2120 Tractor
35-12 Independent PTO Shafts TM-4252 (Dec-70)

.......
SPECIFICATIONS

.......
CONTROL VALVE ASSEMBLY Dimensions of new parts

.....
Clutch and brake oil pressure at 2100 engine rpm 140 to 160 psi 9.8 to 11.2 kg/cm2

Pressure regulating valve adjustment at 2100 rpm 140 to 160 psi 9.8 to 11.2 kg/cm2

(approx. 3 washers).....................
Spring load of special pin spring (approx. 3 washers)

Spring load of valve spool spring

Control valve assembly spring

Free length
6.9 to 7.1 lbs.

12.5 to 13.5 lbs.

1.91 in.
2.7 to 3.7 kg

5.7 to 6.1 kg

48.5 mm
....

.....
Resilience at a spring length of 1.33 in. (33.8 mm) 20 to 24.5 mm 9 to 11 kg

Detent springs of control lever

Free length 0.62 in. 15.8 mm

...........
Resilience at a spring length of 0.43 in. (10.9 mm) 4.5 to 5.5 lbs. 2.0 to 2.5 kg

.........
PTO COUNTERSHAFT ASSEMBLY

Thickness of countershaft gear thrust washer 0.0900 in. 2.25 mm

..................
Thickness of countershaft gear spacer 0.8680 to 0.8720 in. 22.05 to 22.15 mm

.... 0.3660 to 0.3670 in.

................
Thickness of countershaft needle bearing spacer 9.30 to 9.40 mm

..............
O.D. of countershaft 1.4580 to 1.4586 in. 37.033 to 37.049 mm

...............
I.D. of countershaft gear 1.8972 to 1.8982 in. 48.189 to 48.215 mm

................
Width of countershaft gear 2.8799 to 2.8800 in. 72.89 to 73.15 mm

Free height of drive gear spring washer 0.19 in. 4.8 mm

O.D. of a needle bearing 0.2186 to 0.2188 in. 5.552 to 5.558 mm

Total number of countershaft gear needle bearings 48

at bearing area .....................

POWERSHAFT AND DRIVE SHAFT

.................
O.D. of PTO shaft and drive shaft

I.D. of PTO shaft bushings

(in transmission case)
1.3720 to 1.3740 in.

1.3760 to 1.3790 in.

34.874 to 34.900 mm

34.949 to 35.029 mm

Printed in Germany
Model 2120 Tractor
TM-4252 (Dec-70)

Diameter of bores for bushings in

transmission case

I.D. of bushing located in drive shaft

Diameter of PTO shaft journal

PTO CLUTCH ASSEMBLY

on dual, rear PTO

on single, rear PTO

.
I.D. of clutch drum for installing piston

PTO BRAKE

O.D. of brake drum

.........
.....
Thickness of brake band with lining
Operating lever return spring
Free length .
SPECIFICATIONS (Cont.)

Thickness of externally splined separator plates

Thickness of internally splined clutch disks

Thickness of clutch hub thrust washer

O.D. of piston

I.D. of piston

Width of piston . .
Width of clutch drum
;
.

........
Diameter of bearing seat on clutch drum hub . . . . .
I.D. of bushings located in hub of clutch drum
Pressure spring of disk clutch piston
Free length

..........
Resilience at a spring length of 3.38 in. (85.8 mm)

Printed in Germany
...
.

. . . ..

Resilience at a spring length of 1.79 in. (45.5 mm)

.

.
0.7515 to 0.7545 in.

0.7495 to 0.7505 in.

0.0580 to 0.0620 in.

. . . . . 4.850 to 4.860 in.

2.2490 to 2.2510 in.

. . 3.573 to 3.593 in.

. . 4.203 to 4.223 in.

. ...
2,2440 to 2.2460 in.

1.4270 to 1.4280 in.

117 to 143 lbs.

2.3570 to 2.3670 in.

0.1420 to 0.1580 in.

1.03 in.
4.2 to 5.2 lbs.
Power Train 50
Independent PTO Shafts 35-13

Dimensions of new parts

1.4995 to 1.5005 in. 38.087 to 38.113 mm

19.086 to 19.166 mm

19.037 to 19.063 mm

2.3 mm
1.5 to 1.6 mm

1.47 to 1.57 mm

123.32 to 123.45 mm

57.125 to 57.175 mm

18.59 to 18.85 mm

90.75 to 91.25 mm
106.75 to 107.25 mm

4.8745 to 4.8755 in. 123.812 to 123.838 mm

56.995 to 57.045 mm
36.246 to 36.272 mm

98.5 mm
54 to 66 kg

59.87 to 60.13 mm
3.60 to 4.00 mm

51.6 mm
1.9 to 2.4 kg
Model 2120 Tractor
TM-4252 (Dec-70)

GROUP 5 - FRONT AXLE

General information
Removal
Repair
Installation and adjustment
Specifications
Torques for hardware

GROUP 10 - STEERING SYSTEM

Power Steering
General information
Operation
Checking steering system
Diagnosing malfunctions
Removal
Repair
Assembly
Installation and adjustment
Manual Steering
General information
Removal
Repair
Assembly
Adjustment
Installation
Specifications
Torques for hardware
Special tools

Printed in Germany
. Page

5-3
5-3
5-3
5-5
5-5
5-6

10-2
10-2
10-3
10-4
10-4
10-5
10-8
10-9

10-11
10-13
10-13
10-13
10-14
10-14
10-15
10-16
10-16
Front Axle, Steering System and Brakes

FRONT AXLE, STEERING

SYSTEM AND BRAKES
CONTENTS OF THIS SECTION

GROUP 15 - BRAKES

Hydraulic brakes
Diagnosing malfunctions
General information
Removing brake valve
and cylinder
Repair of brake valve
and cylinder
Installing brake valve
and cylinder
Adjustment and bleeding
Removing pressure rings
and brake disks
Repair of pressure rings
and brake disks
Installing pressure rings
and brake disks
Hand brake

Adjustment
....
General information
Removal
Repair
Installation

.......
Front Axle

Section 60

Parts for hydraulic trailer brake

Operation
Repair
Bleeding
Testing
Specifications
60
5-1

Page

15-1
15-1

15-1

15-3

15-3
15-3

15-5

15-5

15-5

15-6
15-7
15-7
15-7
15-7

15- 8
15-10
15-10
15-10
15-11
60 Front Axle, Steering System and Brakes Model 2120 Tractor
5-2 Front Axle TM-4252 (Dec-70)

Group 5
FRONT AXLE

Fig. 1— Parts of Front Axle Assembly (Standard Version)

1 Axle center 14 Drag link 27 Hex. nut
2 Bushing 15 Dust seal 28 Hex. nut
3 Bushings (2 used)* 16 Hex. nut 29 Seal ring
4 Special cap screw 17 Tie rod assembly 30 Bushings
5 Washers 18 Hex, nut 31 Axle knee
6 Tube 19 Tube 32 Thrust bearing
7 Shim (use as required) 20 Cap screw 33 Washer
8 Castellated nut 21 Tube 34 Seal ring
9 Snap ring 22 Clamp 35 Knuckle and spindle
10 Shim (use as required) 23 Cap screw assembly
11 Special washers 24 Outer tie rod end 36 Woodruff key
12 Castellated nuts 25 Cap screw 37 Cap screws
13 Bell crank 26 Steering arm

* Later units have two needle bearings installed in place of the two bushings

Printed in Germany
Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Front Axle 5-3

GENERAL INFORMATION Only on earlier units: Check bushing 2 and

bushings 3 for wear. Press new bushings 3 into axle
The tractor is equipped with an adjustable front center so that front face of each bushing is flush
axle (standard or heavy-duty). The rotation of the with bottom of chamfer in bore. Align grease hole
steering wheel is transmitted to the front axle and of upper bushing with grease bore in axle center.
thus to the front wheels through a steering linkage
consisting of a drag link, a bell crank, the tie rods Only on later units: Check bushing 2 and both bell
and the steering arms. crank needle bearings for wear. Press new needle
bearings into axle center so that the front, in¬
scribed, side of each sleeve faces towards installation
REMOVAL tool and is flush with bottom of chamfer in bore.
Attach a suitable hoist to the front end support. If required, press new bushing 2 in eye of axle
Disconnect drag link 14 (fig. 2) at bell crank 13. center so that its face is flush with bottom of
Support the front axle, using a jack. chamfer in bore and with grease holes aligned.

If necessary, press new spindle bushings 30 (fig. 1

or 3) in axle knees so that their front faces are
flush with bottom of chamfer in bore.

If tube 6 is excessively worn or damaged, install

new tube in front bearing bore of axle center so
that it is flush with rear face of axle.

Assemble front axle, observing the following:

When installing bell crank 13 (fig. 1 or 3), adjust

end play by adding or removing shims 10 so that
bell crank is free to turn easily. However, do not
exceed specified end play (see Specifications).
I50238 Slide thrust bearings 32 on spindles so that the
Fig. 2 Removal of Front Axle Assembly numbered side faces away from knuckle.
(Standard Axle Shown)
On tractors equipped with a standard front axle:
4 Special cap screw 14 Drag link Adjust end play of spindles by means of steering
12 Castellated nuts 26 Steering arm
13 Bell crank arm 26 (fig. 1) so that spindles are free to turn
easily. However, do not exceed the specified end
Remove special cap screw 4 (fig. 2) and slotted nut play (see Specifications). Tighten cap screws 25 to
8 (fig, 1 or 3) together with shims 10. Slide the specified torque (see Torques for Hardware).
complete front axle rearward while tube 6 comes
free of front support and axle comes free of front On tractors equipped with a heavy-duty axle:
support bearing pin. Pull out complete front axle Adjust end play of spindles by means of shims 28
from under tractor. (fig. 3) so that spindles are free to turn easily.
However, do not exceed the specified end play (see
Specifications). Tighten cap screws to the specified
REPAIR torque. Using a suitable hammer, strike several
blows on boss of steering arm 26 and tighten cap
Disassemble complete front axle and check parts screws to the same torque (see Torques for
for cracks, wear or damage. Repair or replace, if Hardware).
necessary.
Check seal rings 29 and 34 (fig. 1 or' 3) for
serviceability.
Inspect thrust bearings 32 for pitting and scoring
and replace, if necessary.

Printed in Germany
60 Front Axle, Steering System and Brakes Model 2120 Tractor
5-4 Front Axle TM-4252 (Dec-70)

25 20
22
23
26
24

28
29 -m

30

30

34

l 51561
35

Fig. 3 — Parts of Front Axle Assembly (Heavy-Duty Version)

1 Axle center 13 Bell crank 25 Cap screw
2 Bushing 14 Drag link 26 Steering arm
3 Bushing (2 used) 15 Hex. nut 27 Washer
4
*
Special cap screw 16 Hex. nuts 28 Shim (use as required)
5 Washers 17 Tie rod assembly 29 Seal ring
6 Tube 18 Hex. nut 30 Bushings
7 Shim, (use as required) 19 Tube 31 Axle knee
R Castellated nut 20 Cap screw 32 Thrust bearing
9 Snap ring 21 Tube 33 Cap screws
10 Shim (use as required) 22 Clamp 34 Seal ring
11 Special washers 23 Cap screw 35 Knuckle and spindle assembly
12 Castellated nuts 24 Outer tie rod end

* Later units have two needle bearings installed in place of the two bushings

Printed in Germany
Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Front Axle 5-5

Tighten screws attaching axle knees 31 to axle CHECKING AND ADJUSTING TOE-IN
center 1to the specified torque.
Checking
Tighten castellated nuts 12 (fig. 2) for attaching tie
rods to steering arm 26 or to bell crank 13 to the With front wheels in straight-ahead position, center
specified torque. bell crank. Measure tread at center line of rim at
front and rear of front wheels. Front wheel toe-in
is correct if measurement at front center line is by
INSTALLATION AND ADJUSTMENT a certain amount less than at rear (see
Specifications).

Adjustment

Remove cap screw 23 (fig. 1 or 3) of each tie rod

and loosen cap screw 20 sufficiently. Turn tube 21
an equal amount clockwise or counterclockwise on
both tie rods to obtain proper toe-in (see
Specifications). Install cap screw 23, making sure it
is placed in same notch in tie rod end 24 from
which it was removed. Tighten cap screws 23 and
20 to the specified torque.

Secure drag link 14 (fig. 2) to bell crank 13 and

tighten castellated nut 12 to the specified torque.

Turn front wheels from full left to full right.

Fig. 4 — Axle Center Installed On tractors with manual steering the stops on
knuckles should contact the stops on knees when
1 Axle center 6 Tube the wheels are turned full left or right. If necessary,
3 Bushings* 7 Shims
4 Special cap screw 8 Castellated nut
adjust tie rods so stops on axle knuckles contact
5 Washer stops on axle knees equally on both sides (see
Group 10).
Position front axle assembly for installation. Slide
axle center 1 (fig. 4) upon its rear support, On tractors with power steering the stops should
simultaneously inserting tube 6 of front axle in not contact when the wheels are turned full
bore of front support. left or right. If necessary, adjust tie rods so there
is an equal amount of clearance between stops of
Slide a number of shims 7 on special cap screw 4 knuckles and knees on both sides (see Group 10).
(see fig. 4). Install screw 4 and tighten castellated
nut 8 to the specified torque. Then check for
specified end play. If required, adjust for proper
end play by adding or removing shims 7. For
maximum permissible end play see Specifications.

* Later units have two needle bearings installed

in place of the two bushings.

Printed in Germany
60 Front Axle, Steering System and Brakes Model 2120 Tractor
5-6 Front Axle TM-4252 (Dec-70)

.....
.................
Inner dia. of bushing pressed into axle center
SPECIFICATIONS
Dimensions of New Parts

1.5777 to 1.5827 in. 40,077 to 40.197 mm

Inner dia. of bushing pressed
into front end support

......
..................
Dia. of bore in axle center for seating tube
1.2500 to 1.2550 in.

1.2405 to 1.2425 in.

31.754 to 31.874 mm

31.509 to 31.559 mm
Dia. of bearing tube

...........
.............
Dia. of bore in front end support
for seating front axle bearing pin
1.2440 to 1.2450 in.

1.5696 to 1.5705 in.

31.597 to 31.623 mm

39.853 to 39.903 mm

Dia. of front axle bearing pin

........
.................
Inner dia. of bushing pressed into axle center for
seating bell crank (only on earlier units)
1.5720 to 1.5730 in.

1.2500 to 1.2550 in.

39.927 to 39.953 mm

31.754 to 31.874 mm

Dia. of bell crank pin

..............
with standard front axle

............
Thrust bearing seat of knuckle, dia.
1.2490 to 1.2495 in.

1.3735 to 1.3741 in.

31.725 to 31.738 mm

34.886 to 34.902 mm

..............
with heavy-duty front axle

with standard front axle

............
Dia. of front axle knee bore for knuckle bushings
1.4985 to 1.4991 in.

1.4990 to 1.5010 in.

38.062 to 38.078 mm

38.075 to 38.125 mm

..............
with heavy-duty front axle 1.6240 to 1.6260 in. 41.245 to 41.295 mm

............
Inner dia. of knuckle bushing pressed into front
axle knee

........
....
with standard front axle 1.3755 to 1.3795 in. 34.938 to 35.038 mm

with heavy-duty front axle 1.5005 to 1.5045 in. 38.114 to 38.214 mm

Maximum permissible end play of bell crank 0.004 in. 0.10 mm

in front axle knee

.........
Maximum permissible end play of knuckles

.....................
Maximum permissible end play of front axle

Front wheel toe-in

0.03 in.

0 to 0.015 in.

0.125 to 0.25 in.

0.76 mm

0 to 0.4 mm

3 to 6.5 mm

...............
Axle knees-to-axle center, cap screws
TORQUES FOR HARDWARE

300 ft.lbs. 41.5 mkg

....................
Steering arm-to-knuckle, cap screws
(with standard front axle) 85 ft.lbs. 12 mkg

Steering arm-to-knuckle, cap screws

(with heavy-duty front axle) 170 ft.lbs. 23.5 mkg

Printed in Germany
 Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Front Axle 5-7

Tie rods-to-bell crank and steering arm,

castellated nuts* ..........
TORQUES FOR HARDWARE (Cont'd)

.......... 55 ft.lbs. 7.7 mkg

Drag link-to-bell crank and steering arm of

steering shaft, castellated nuts*

..........
..........
55 ft.lbs. 7.7 mkg

.........
Clamps of tie rods, cap screws 54 ft.lbs. 7.5 mkg
Inner clamping screws of tie rods 32 ft.lbs. 4.5 mkg

Axle center-to-front support, castellated nut* ... 220 ft.lbs. 30,5 mkg

NOTE: If cotter pin cannot be inserted in castellated nut with the specified torque, turn nut to next
slot and secure with cotter pin.

Printed in Germany
Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Steering System 10-1

Group 10
STEERING SYSTEM
POWER STEERING

Fig. 1— Oil Flow in Steering Valve Housing at

Right-hand Turn
1 Steering valve body 13 Operating sleeves
2 Steering valves 14 Steering piston rod
3 Steering valve sleeves 15 Piston
4 Spacers 16 Return passage to trans¬
5 Shims mission sump
6 Special washers 17 Pressure oil passage
7 Steering wheel shaft 16 Piston rod guide
S Needle thrust bearing 19 Connecting rod
9 Special washers 20 Pin
10 Snap rings 21 Steering housing
11 Springs 22 Adjuster
12 Shims 23 Pressure oil
-
24 Pressure free oil

Printed in Germany
60 Front Axle, Steering System and Brakes Model 2120 Tractor
10-2 Steering System TM-4252 (Dec-70)

INFORMATION When steering wheel rotation is stopped, piston 15

will continue to move up very slightly, thus
Power steering consists essentially of the power releasing lower valve sleeve 3 and allowing this
steering valve assembly, the steering linkage and valve to seat (neutral position). If steering wheel
the pressure control valve, located at the right side rotation is continued to the end of its range of
of the transmission case. travel, the piston 15 will bottom in upper part of
cylinder, holding the steering wheel shaft up, thus
Oil is supplied to the power steering by the main not allowing the lower valve 2 to go in neutral
hydraulic pump. Power steering is given first position. The valve remains open. However, as
priority on tractor hydraulic oil by the pressure there is no piston movement, there is no oil flow
control valve (see section 70, group 10). The and the main hydraulic pump goes out of stroke.
steering operates on the closed-enter system.
The return oil flow through the steering valve
housing provides lubrication for the valve housing
OPERATION components and for the parts located in the
steering and yoke shaft compartment in the clutch
NOTE: Numbers behind parts in the following text housing. The return oil flows through an overflow
refer to fig. 1if not otherwise indicated. passage in the steering and yoke shaft compart-
ment to the sump. The overflow is on the top
Pressure oil from the main hydraulic pump is surface of the compartment; the oil level is,
supplied to the steering valve body through drilled therefore, always above the components located in
passage 17 in the steering valve assembly housing. the compartment. Proper lubrication is thus
When valves 2 are in neutral position (steering ensured.
wheel motion stopped), the valves are held on their
seats by hydraulic pressure and pressure of springs
11 so there is no oil flow to either side of the OIL FLOW AT LEFT-HAND TURN
steering piston 15. (Hence the term "closed
center" system). Left-hand rotation of the steering wheel causes the
steering wheel shaft to thread out of the piston
A mechanical force from the steering linkage can rod. The special washers 9, the thrust bearings 8
move the steering piston, but a resultant hydraulic and the operating sleeves 13 move upward together
force will counteract any piston movement beyond with the steering wheel shaft. The upward sleeve
0.004 in. (= 0.1 mm). movement lifts the upper valve 2 off its seat,
allowing pressure oil to flow to the top side of
piston 15. This pushes the piston downward,
OIL FLOW AT RIGHT-HAND TURN (Fig. 1) causing the tractor to turn left. Oil below piston 15
is forced to return to the sump through the passage
Right-hand rotation of the steering wheel causes in the steering valve housing, the lower valve sleeve
the steering wheel shaft 7 to thread into the piston 3 to return passage 16.
rod 14. The special washers 9, secured to the
steering wheel shaft, move downward, taking along A slight downward motion of piston 15 will permit
the lower operating valve sleeves 13 and special valve 2 to return to neutral position after steering
washers 6. These washers push down the lower wheel rotation is stopped. When turning the
valve sleeve 3, lifting valve 2 off its seat. This steering wheel to its end of travel range, piston 15
allows pressure oil to flow to the bottom side of will bottom on piston rod guide 18 and upper
piston 15, pushing the piston upward. This motion, steering valve 2 remains open. But with no piston
transferred to the front wheels through the steering movement there will be no oil flow and the main
linkage, causes the tractor to turn right. hydraulic pump will go out of stroke.
Oil above the piston is forced to return to the
sump through upper valve sleeve 3, drilled passage
in housing 1and passage 16.

Printed in Germany
Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Steering System 10-3

MANUAL STEERING Check for front wheel steering drift when tractor is
moving, when it is standing still and with its front
Manual steering is possible when engine is not wheels jacked up. Drift is usually caused by
running or when there is a malfunction in the steering valve or O-ring leakage in the circuit of
hydraulic system. The steering wheel shaft and the steering direction affected.
piston rod provide sufficient mechanical advantage
to steer the tractor. Steering valve leakage can be caused by a worn or
distorted seat or dirt on valve seat, or improper
Turning the steering wheel will actuate the special adjustment of valve body shims "b" (see figs. 4 and
washers, valve sleeves and steering valves the same 5).
as for a power turn. The vertical thrust is taken up
by the needle bearings and valve bodies rather than NOTE: The number and thickness of shims "6"
the special washers and operating sleeves. (fig. 4) and thus the clearance between special
washers "c" and valve sleeves "d" has been
As the steering wheel shaft continues to turn, the determined at the factory. Do not attempt to
piston rod will move causing the piston to push oil readjust. When removing and disassembling valve
out of the steering cylinder, allowing the front body assemblies 19 and 19a, be extremely careful
wheels to turn. The mechanical stops are the same not to change the shim pack adjustment or to mix
as in power steering operation. up the other components of the valve body
assemblies.
CHECKING THE STEERING SYSTEM A large volume of oil leakage past seal 7 in adjuster
nut 9 indicates a restricted or blocked return oil
NOTE: Numbers behind parts in the following text passage. This can be caused by improper
refer to fig. 4 unless otherwise indicated. installation of the thrust washers 15 and 17 of the
lower thrust bearing. If the large chamfer of thrust
Should trouble on the power steering occur, always washer 17 does not face the lower valve body 19a
check main hydraulic pump and pressure control (fig. 3), the return passage will be restricted.
valve first for proper operation, as described in
section 70, group 5. If main hydraulic pump and The return oil passage in the clutch housing may be
pressure control valve operate properly, use testing blocked by improper installation of gasket 27
procedure as follows. between steering housing and clutch housing.
Shut off engine. Jack up front wheels and steer CAUTION: The gasket used on the manual steering
manually. Turn steering wheel left and right to will block this passage.
steering limits. There should be no binding and no
extreme hard spots in steering. If hard turning
exists, check the mechanical linkage.

Start engine and steer in both directions to the

travel limits. Steering effort and response should
be the same in both directions. Slow steering or
excessive steering effort in one direction may
indicate faulty operation of the valve body
assembly (19 or 19a, fig. 3) that controls pressure
oil for that steering direction. Steering trouble in
both directions indicates a fault in both valve body
assemblies 19 and 19a.

Printed in Germany
60 Front Axle, Steering System and Brakes Model 2120 Tractor
10-4 Steering System TMM252 (Dec-70)

DIAGNOSING MALFUNCTIONS REMOVAL

SLUGGISH STEERING Remove power steering unit as follows:

O-ring of steering piston or O-rings of piston rod Pull off steering wheel by means of a puller.
guide leaking. Remove drain plug 8 (fig. 2) and drain oil. Remove
transmission shield 1.
O-rings of valve body assemblies defective.
Disconnect pressure line 6 at elbow on steering
Internal leakage in valve body assemblies due to valve housing.
wear of parts
Replace both valve body assemblies

Transmission oil filter clogged

Replace filter element

Steering valves do not bottom on their seats (thus

leaking)
Factory-adjusted shim packs have been mixed
up

Excessive steering wheel play

Adjust pre-load of steering wheel shaft

INSUFFICIENT STEERING OPERATION

Insufficient oil supply to steering valve housing

assembly
Transmission oil pump operates improperly or
does not operate at all (clutch disengaged)

Priority in oil supply is given to other hydraulic

units of tractor
Adjust pressure control valve of power steering
unit

Transmission oil filter clogged

Replace filter element
Fig. 2 — Steering Valve Housing Assembly,
Hydraulic pump does not operate or has been shut Installed
off by means of the pump shut-off screw (if 1 Transmission shield 5 Cap screws (2 used)
equipped) 2 Shift cover (on tractors 6 Pressure line
with HIGH-LOW unit 7 Bearing cover of steering shaft
Repair hydraulic pump or back off shut-off and/or independent 8 Drain plug
screw PTO) 9 Lock plate
3 Linkage of HIGH-LOW 10 Pin
control lever 11 Cap screw
SLUGGISH STEERING IN ONE DIRECTION 4 Cap screws (4 used) R Mark (only with mechanical
steering)
Steering valve leaking due to contamination,
deformation or valve seat wear

Replace relevant direction steering valve body

assembly

CHATTER OF STEERING VALVE HOUSING

COMPONENTS

O-rings of valve body assemblies defective

Printed in Germany
Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Steering System 10-5

On tractors with HIGH-LOW unit, disconnect Turn yoke of steering shaft in position shown in
HIGH-LOW control linkage 3 (fig. 2) at lever of figure 2 and remove cap screw 11and lock plate 9.
shift cover 2. Pull pin 10 out of steering shaft yoke and linkage
by means of a cap screw (3/8 in. thread).
On tractors with HIGH-LOW unit and/or inde¬
pendent PTO, remove shift cover 2. Install steering wheel on steering wheel shaft and
turn left and right to the stop so pressing oil out of
CAUTION: Before removing shift cover, place steering cylinder, collecting oil in a suitable
control lever of independent PTO in forward container.
(engaged) position. After removal of complete shift
cover, do not move control lever otherwise detent Remove steering valve housing assembly.
ball and springs will fall out.
Remove steering linkage. CAUTION: When pulling
Remove cap screw securing foot throttle to clutch out steering shaft, make sure oil seal of clutch
housing and place foot throttle on running board. housing is not damaged.

Remove bearing cover 7 of steering shaft.

Remove one side of dash panel. Remove both

hex.nuts of attaching screws 5 (fig. 2) and four
screws 4 securing valve housing assembly.

REPAIR

19a
15 17

Fig. 3 — Steering Wheel Shaft and Valve Housing Assemblies

12 Snap rings 16 Thrust bearing 19 Upper valve body with spacer,
13 Special washers 17 Thrust washers shims and steering valve
14 Shims 18 Upper and lower 19a Lower valve body with spacer,
15 Thrust washers operating sleeve shims and steering valve
c Special washers

Printed in Germany
60 Front Axle, Steering System and Brakes Model 2120 Tractor
10-6 Steering System TM-4252 (Dec-70)

22
20

26
e— d ÿ-23
,o
24
25

27
&— b
30
--d
Q

20

34
O
-- 32

33

-17
(ry) -16
<S>-15

©>-29
&-28
©>—37
— 21
38

44 47

53
48
LSI 537
39
40 52

Fig. 4 — Parts of Steering Valve Housing Assembly and Steering Linkage

a Spacers 11 Spacer 25 O-ring 39 Cap screws (6 used)
b Shims (as required) 12 Snap rings 26 Hex.nut (2 used) 40 Seal ring
c Special washers 13 Special washers 27 Gasket 41 Steering shaft and yoke cover
d Steering valve sleeves 14 Steel shims (as required) 28 Back-up rings 42 Bushing
1 Steering wheel emblem 15 Special thrust washers 29 O-rings 43 Gasket
2 O-rings 16 Thrust bearing 30 Steering piston 44 Steering shaft pin
3 Hex.nut 17 Special thrust washers 31 Back-up rings 45 Cap screw
4 Special lock washer 18 Operating sleeves 32 O-ring 46 Retaining plate
5 Steering wheel 19 Upper valve body assembly 33 Steering piston rod 47 Steering and yoke shaft
6 Jam nut 19a Lower valve body assembly 34 Pin 48 Oil seal
7 Oil seal 20 O-rings 35 O-ring 49 Steering shaft arm
8 Elbow 21 Steering wheel shaft 36 Back-up ring 50 Special washer
9 Steering wheel shaft adjuster 22 Steering valve housing 37 Piston rod guide 51 Cap screw
10 Bushing 23 Cap screw (2 used) 38 Steering connecting rod 52 Castellated nut
24 Cap screw (4 used) 53 Drag link

Printed in Germany
Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Steering System 10-7

STEERING VALVE HOUSING ASSEMBLY Screw piston 30 off piston rod 33 by means of a
(Fig. 4) pronged wrench. Press pin 34 of connecting rod 38
out of piston rod 33 and lift connecting rod out of
Disassembly piston rod.

Remove jam nut 6. Inspection

Turn steering wheel shaft adjuster 9 out of steering Inspect oil seal 7 (fig. 4) in adjuster 9 for damage
valve housing, using a pronged wrench. Pull spacer or wear. If necessary, remove bushing 10 and drive
11 out of steering valve housing. in new bushing so that its face is flush with bottom
of chamfer in top side of the adjuster. Drive new
Turn steering wheel shaft 21 clockwise until piston oil seal 7 to bottom of adjuster 9 with sealing lips
contacts upper end of cylinder. Hold connecting facing inward.
rod 38 and turn steering wheel shaft 21 counter¬
clockwise until it is completely free of piston rod Inspect spacer 11, thrust washers 15 and 17 as well
33. as thrust bearing 16 for wear or damage and
replace, if necessary.
Remove piston, piston rod, connecting rod and rod
guide from steering valve housing. Examine valve sleeves "d" and special washers "c"
of both valve body assemblies 19 and 19a for
Pull steering wheel shaft with the two valve body distortion or wear.
assemblies, the thrust washers and thrust bearings
carefully out of steering valve housing. IMPORTANT: If replacement is necessary, replace
complete valve body assembly.
Remove the following parts in the order indicated
below from the steering wheel shaft (see figs. 3 to Check operating sleeves 18 for wear and damage.
5): first snap ring 12, first special washer 13,
second snap ring 12, second special washer 13, Inspect steering wheel shaft 21 for damage. Check
shims 14, upper thrust washer 15, upper thrust acme thread of steering wheel shaft for wear or
bearing 16 and upper thrust washer 17; upper valve scores. Replace if necessary.
body assembly 19 (including spacer "a", shims "b"
and special washer "c") with upper valve sleeve 18, Inspect steering piston 30 for damage or wear and
lower valve body assembly 19a (including spacer replace, if necessary.
"a", shims "b" and special washer "c") with lower
sleeve 18; lower thrust washer 17, lower thrust Replace back-up rings 31 and O-rings 32 on steering
bearing 16 and lower thrust washer 15. piston.
CAUTION: The upper valve body assembly 19, as Examine piston rod 33 for damage, especially its
well as lower valve body assembly 19a are inside thread; replace if necessary.
assembled individually, at the factory, being
accurately adjusted by means of shims "b". There¬
fore, special care should be taken to keep spacer
"a", shims "b" and special washer "c" of upper
valve body assembly 19 apart from corresponding
components of the lower valve body assembly 19a.
If any parts of the two valve body assemblies are
mixed up, malfunction of the steering system
could result.

Printed in Germany
60 Front Axle, Steering System and Brakes Model 2120 Tractor
10-8 Steering System TM-4252 (Dec-70)

Inspect piston rod guide 37 for damage or wear, NOTE: Before installing parts located between
especially in area of piston rod hole. Replace if lower thrust bearing 16 and lower snap ring 12 (see
necessary, figs. 3 and 5) in steering valve housing, determine
proper number of shims 14 (between lower special
Check connecting rod 38 for wear or damage and washer 13 and upper thrust washer 15).
replace, if necessary.
Slide parts on steering wheel shaft to determine
Thoroughly clean steering valve housing 22, number of shims required.
especially inside. Make sure that all oil bores are
perfectly clean. Use compressed air to clean and Slide parts on steering wheel shaft in the following
dry housing. Inspect housing for damage or cracks. order:

STEERING LINKAGE (Fig. 4) 1. Slide lower thrust washer 15, thrust bearing 16
and lower thrust washer 17 over steering wheel
Inspection shaft.

Check steering shaft 47 for damage and replace, if IMPORTANT: Install thrust washer 17 so large
necessary. Examine oil seal 48 on steering shaft 46 chamfered surface will face away from thrust
(located on left side of clutch housing) and replace, bearing.
if necessary. Install new oil seal, with lips facing
inside, flush with bottom of chamfer in bore. Use 2. Install lower operating sleeve 18 and lower valve
tool No. JD 252. body 19a with shims "b", spacer "a" and lower
special washer "c".
Check cover 41 for damage and replace, if
necessary. Inspect bushing 42 of cover and bushing NOTE: The body of lower valve assembly 19a,
located opposite for seating the steering shaft in apartfrom the steering valve bore, is provided with
the clutch housing and replace, if necessary. two other bores serving as return oil passages.
However, the body of upper valve assembly 19
Drive in new bushing so its face is flush with does not have these through bores (see figs. 1 and
chamfer in cover bore, using No. JD 252 driver. 3). Do not mix up valve bodies when installing
parts.
Check remaining steering linkage for serviceability.
3. Place upper special washer "c", upper operating
sleeve 18, upper spacer "a" and shims "b" on
ASSEMBLY shaft. Then install upper valve body.

IMPORTANT: Replace all O-rings and backup CAUTION: The upper valve body assembly 19, as
rings prior to assembly. Before installing, dip all well as lower valve body assembly 19a are
internal parts of steering valve housing in oil. assembled individually at the factory, being
accurately adjusted by means of shims "b".
Insert connecting rod 38 (fig. 4) (small end first) in Therefore, special care should be taken to keep
piston rod 33 and secure with pin 34. Pin should spacer "a", shims "b" and special washer "c" of
be flush with outside face of piston rod. upper valve body assembly 19 apart from the
corresponding components of the lower valve body
Thread piston 30 onto piston rod 33 so dowel assembly. If any parts of the two valve body
holes in piston face top of power steering valve. assemblies are mixed up, malfunction of the
Tighten to specified torque (see Specifications). steering system could result.
Install O-ring 32 in groove of piston 30. Position
one back-up ring 31 on either side of the O-ring. 4. Slide on upper thrust bearing 16 with thrust
washers 15 and 17,

Printed in Germany
Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Steering System 10-9

IMPORTANT: Slide thrust washer 17 on steering Carefully install pre-assembled steering wheel shaft
wheel shaft so that its large chamfer faces the in steering valve housing and screw shaft into
upper valve body. piston rod. Insert spacer 11 in steering valve
housing.

Insert O-ring 2 in groove of adjuster 9 pre-

1416 17 17 15 assembled with oil seal 7 and bushing 10. Coat lip
of oil seal ring 7 with grease. When sliding adjuster
9 on steering wheel shaft, protect sealing against
damage by means of a suitable sleeve etc.

Screw adjuster into steering valve housing 8 by

means of a pronged wrench and tighten to the
specified torque (see "Torques for hardware").
13 15 19 19a 16 Turn jam nut 6 on adjuster 9 and tighten to the
specified torque, holding the adjuster with the
pronged wrench.
l49426 A

Fig. 5 — Determining Thickness of Shim Pack bet¬ INSTALLATION AND ADJUSTMENT

ween Thrust Washer and Special Washer
For installation, reverse sequence of removal.
a Spacers 16 Thrust bearings
b Shims 17 Thrust washers
12 Snap ring 19 Upper valve body assy. Install new gasket between steering valve housing
13 Special washer 19a Lower valve body assy. and clutch housing. Tighten screws of steering
14 Shims 21 Steering wheel shaft
15 Thrust washers
valve housing assembly to the specified torque (see
"Torques for hardware").
5. Position some shims 14 (figs. 3 to 5) on thrust
washer 15. Then place one of the two special Tighten cap screw of steering shaft lock plate (see
washers 13 on the shims with the recess facing 11, fig. 2)to the specified torque (see "Torques for
downward. Adjust total thickness of shims so that hardware").
snap ring 12 just fits into groove of steering wheel
shaft 21. At this moment it is not necessary that Install steering shaft bearing cover before
the snap ring is fully seated in its groove. However, tightening cap screw of steering arm. Use a new
at any rate make sure that the snap ring really fits gasket between bearing cover and clutch housing.
in the groove.
NOTE: Install cap screw provided with seal ring 40
Add as many shims 14 as are required to obtain the (fig. 4) in bottom bore of bearing cover.
specified pre-load (see Specifications).
Tighten steering arm cap screw to specified torque
Insert lower snap ring 12 in its groove. Install (see "Torques for hardware"). Tap the steering arm
second special washer 13 on steering wheel shaft with a hammer and re-tighten screw to the
with the recess facing downward and fit upper snap specified torque.
ring 12.

If required, insert one O-ring (fig. 4) and one

back-up ring 28 each in bore of piston rod guide 37
and in bore of steering valve housing 22. Install
O-ring 35 and back-up ring 36 in groove of guide
37.
Slide guide 37 over piston rod 33 and insert piston
rod with piston, guide and connecting rod in
steering valve housing.

Printed in Germany
60 Front Axle, Steering System and Brakes Model 2120 Tractor
10-10 Steering System TM-4252 (Dec-70)

Install all tractor parts which had to be detached With steering wheel centered and front wheels in
for removal of the steering unit and connect all straight-ahead position, drag link should fit into
connections which had been separated (see steering arm. If required, adjust tie rods.
"Removal").
Tighten castellated nuts of drag link to the
CHECKING FRONT WHEEL STEERING specified torque (see "Torques for hardware").
TRAVEL
NOTE: First turn steering wheel fully to the
Install steering wheel and turn from stop to stop, right-hand stop and then likewise to the left. When
counting number of turns. Turn steering wheel doing this, the cast-on stop on spindle knuckle of
back half this number of turns. Pull steering wheel inner wheel should not come into contact with
and re-position so that a spoke points toward back stop on relative axle knee. If necessary, adjust
of tractor. tie-rods and front wheel toe-in.

Tighten steering wheel hex. nut to the specified

torque. Bend two tabs of lock plate upward and
one tab downward.

Printed in Germany
Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Steering System 10-11

MANUAL STEERING

L 45340

Fig. 6 — Sectional View of Steering System

1 Bairel bearing 4 Steering wheel shaft 8 Steering shaft
2 Oil seal ring 5 Ball nut 9 Steering arm
3 Steering housing € Ball guides 10 Drag link
7 Yoke

GENERAL INFORMATION balls from their helical path when they reach the
end of the ball nut, thus returning the balls to the
The manual steering (see fig. 6) is of the recirculat¬ helical path in the ball nut at the start of a circuit.
ing ball bearing, worm and nut type. The ball nut 5
is threaded over the worm portion of the shaft. The steering motion is transmitted by the steering
wheel shaft and the ball nut to the steering shaft
The bore of the nut has helical grooves correspond¬ 11 which is connected to the steering linkage
ing to grooves in the shaft worm. These grooves leading to the front wheels.
within the ball nut are filled with steel balls,
making up two separate circuits of recirculating The steering wheel shaft is supported on the upper
balls. To complete each circuit and to keep the end by two barrel-type bearings 1. An adjuster
balls from running out at the ends, the ball nut is threaded into the steering housing controls the
provided with ball guides 6. Each guide deflects the preload on the barrel bearings.

Printed in Germany
60 Front Axle, Steering System and Brakes Model 2120 Tractor
10-12 Steering System TM-4252 (Dec-70)

O/ ÿ20

32 31

Or
34 l<®

L 49430 A

Fig. 7 — Parts of Steering Housing Assembly and Steering Linkage

1 Steering wheel 14 Lock washer (9 used) 28 Tooth washer
2 Steering wheel emblem 15 Cap screw (2 used) 29 Oil seal ring
3 O-ring 16 Lock washer (2 used) 30 Steering shaft arm
4 Hex. nut 17 Steering wheel shaft and ball nut 31 Cap screw
5 Lock plate 18 Barrel bearing 32 Washer
6 Adjusting nut 19 Thrust washer halves 33 Steering shaft cover
7 Oil seal rings 20 Retainer 34 Bushing
8 Sleeve for adjusting 21 Yoke 35 Gasket
preload of barrel bearing 22 Flange 36 Cap screw (6 used)
9 Steering housing 23 Cap screw (2 used) 37 Seal ring
10 Gasket 24 Steering shaft 38 Drag link
11 Plug 25 Pin 39 Castellated nut
12 O-ring 26 Lock plate 40 Cottar pin
13 Cap screw (4 used) 27 Cap screw 41 Hex. nut (2 used)

Printed in Germany
Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Steering System 10-13

REMOVAL Inspect bearing cover 33 for damage and replace, if

necessary. Check bushing 34 of bearing cover and
For removal of manual steering see section on opposite steering shaft bushing in clutch housing
removal of power steering. Removal operations are and replace, if necessary. Drive in new bushing so
identical or similar. that its face is flush with chamfer of bearing bore,
using driving tool No. JD 252.
REPAIR
Check remaining steering linkage for serviceability.
STEERING HOUSING ASSEMBLY (Fig. 7)
Disassembly ASSEMBLY

Remove adjusting nut 6 and screw sleeve 8 out of When attaching yoke 4 (fig. 8) to ball nut, make
housing by means of a pronged wrench. sure that closed side of yoke faces ball tracks of
ball nut (see fig. 8);
Pull up on steering wheel shaft and remove upper
barrel bearing, retainer and both thrust washers. Tighten screws 1attaching flange to ball nut and to
Slide lower barrel bearing off steering wheel shaft. yoke, to the specified torque.

Pull steering wheel shaft, ball nut and yoke

downward out of steering housing. Separate yoke
from ball nut.

Inspection

Check adjuster sleeve 8 and its oil seal ring 7 for

serviceability. If necessary, press new seal ring in
sleeve so that its sealing lip faces the driver (metal
side bottoms in bore).

Check steering housing 9 for cracks or other

damage. Check oil seal 7 in steering housing. If
necessary, install a new oil seal 7 with its sealing lip
facing the driver (metal face bottoming in bore).

Inspect barrel bearing 18; bearing rollers should be

smooth, polished and free to turn.

Check both thrust washer halves 19 for damage

and replace, if necessary.

Check steering wheel shaft and ball nut 17 for Fig. 8 — Ball Nut and Yoke Assembled
damage. Inspect shaft worm for wear or breakage. 1 Cap sciews
Check if ball nut moves freely. If necessary, replace 2 Flange
steering wheel shaft and ball nut as an assembly. 3 Steeling wheel shaft and ball nut
4 Yoke

STEERING LINKAGE (Fig. 7)

Inspection

Check steering wheel shaft 24 for damage and

replace, if necessary. Remove oil seal ring 29 of
steering shaft from clutch housing, if necessary.
Install a new seal ring, using No. JD 252 driver,
with lips facing bottom of bore and opposite side
flush with lower chamfered edge of bore.

Printed in Germany
60 Front Axle, Steering System and Brakes Model 2120 Tractor
10-14 Steering System TM-4252 (Dec-70)

Turn steering wheel shaft counterclockwise out of INSTALLATION

ball nut, as far as possible.
For installation, reverse removal procedure.
Install steering wheel shaft assembly (take care of
steering housing oil seal) so that tracks of ball nut Use new gasket between steering gear housing and
face front side of steering housing. Pack one of the clutch housing.
two barrel bearings with grease and install on
steering wheel shaft with bearing cone facing CAUTION: Make sure large tab of gasket is located
upward. Insert both thrust washer halves and under left rear corner of steering gear housing (if
secure by means of retainer. installed).

Push steering wheel shaft into housing until barrel Tighten attaching screws of steering gear housing
bearing is seated on ridge in housing. Pack bearings to the specified torque (see "Torques for
and thrust washers liberally with grease. Then slide hardware").
second barrel bearing on steering wheel shaft so
that cone bottoms on thrust washers (position Tighten cap screw of steering shaft lock plate to
opposite that of first barrel bearing). the specified torque (see "Torques for hardware").

Make sure that all parts are well greased and screw NOTE: Make sure side marked "R" of yoke is on
adjuster sleeve in steering gear housing. the right-hand side (see fig. 2).

ADJUSTMENT Install bearing cover of steering shaft before

tightening cap screw of steering shaft arm. Use a
new gasket between bearing cover and clutch
housing.

NOTE: Install cap screw with seal ring 37 (fig. 7)

in lowest bore of bearing cover.

Tighten cap screw of steering shaft arm to the

specified torque (see 'Torques for hardware").
Strike arm with a hammer and retighten screw to
above torque.

Install all tractor parts which had to be removed to

facilitate removal of steering unit and remake all
connections (see Removal).

Fill up with oil (see Operator's Manual).

CHECKING FRONT WHEEL STEERING

TRAVEL

Install steering wheel. Turn steering wheel from

left stop to right stop, counting number of turns
Fig. 9 — Adjusting Preload of Barrel Bearings needed to turn the wheel from stop to stop. Turn
1 Adjuster 2 Yoke 3 Spring scale wheel back half the number of turns obtained
above. Remove steering wheel and reposition so
Turn ball nut so that it is at the bottom of the that a spoke points toward back of tractor, seen in
steering wheel shaft worm. Hook spring scale into the direction of forward travel.
bore of yoke as shown in fig. 9 and tighten adjuster
1 (fig. 9) until a specified force is required to move
the yoke (see Specifications).

Tighten adjusting nut to specified torque. Hold

adjuster while tightening.

Printed in Germany
Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Steering System 10-15

Attach steering wheel, tightening hex. nut to Tighten castellated nuts on drag link to specified
specified torque. Bend up two tabs of lock plate; torque (see "Torques for hardware").
bend down the other tab.
NOTE: First turn steering wheel fully to the
With tractor front wheels in straight-ahead right-hand stop and then likewise to the left. When
position and steering gear centered, drag link doing this, the cast-on stop on spindle knuckle of
should just fit into hole in steering shaft arm. If the relative inner wheel should contact the stop on
this is not the case, adjust tie rods to suit. relative axle knee. If necessary, adjust tie-rods and
front wheel toe-in.

SPECIFICATIONS

..........
MANUAL STEERING AND POWER STEERING

.........
....
Inner dia. of bearing cover and clutch
Dimensions of new parts

...............
housing bushing (bushing installed) 1.7514 to 1,7550 in. 44.485 to 44.545 mm

Dia. of steering shaft journals 1.7495 to 1.7505 in. 44.437 to 44.463 mm

........
Dia. of bearing cover bore 1.8640 to 1.8654 in. 47.345 to 47.381 mm

..........
POWER STEERING

Dia. of steering wheel shaft bearing seat 0.8740 to 0.8760 in. 22.200 to 22.250 mm

Preload in steering wheel shaft bearings 0.001 to 0.003 in. 0.02 to 0.08 mm
MANUAL STEERING

.....
steering shaft housing .......
Dia. of steering wheel shaft
bearing seat
....
......................
Dia. of barrel bearing bore in
. 2.1895 to 2.1905 in.

0.8730 to 0.8760 in.

55.613 to 55.639 mm

22.172 to 22.252 mm

Preload of barrel bearings, determined with

a spring scale at end of yoke 15 to 17 lbs 6.8 to 7.7 kg

Printed in Germany
60
10-16 Steering System

MANUAL STEERING AND POWER STEERING

Steering shaft bearing cover-to-clutch

housing, cap screws

Steering piston-to-piston rod

Adjuster in steering valve housing

Hex. nut on adjuster

MANUAL STEERING

Flange-to-ball nut and yoke, cap screws

Adjusting nut on sleeve

*
.
Front Axle, Steering System and Brakes

Steering gear housing assembly-to-clutch

housing, cap screws

Lock plate-to-steering shaft, cap screw

TORQUES FOR HARDWARE

...............
...........
...........
Steering shaft arm-to-steering shaft, cap screw

Steering wheel-to-steering wheel shaft, hex. nut

Drag link-to-steering shaft arm and

bell crank, castellated nuts*

POWER STEERING

...................
...............
nut to next slot and secure with cotter pin.

L 48540

**
Part No. if ordered from
JD Parts Depot

.... JD 252** ........ .....

Manufacturer
SPECIAL TOOLS

Description

Driving tool
36 ft.lbs.

8 ft.lbs.

36 ft.lbs.

170 ft.lbs.

50 ft.lbs.

55 ft.lbs.

250 ft.lbs.

50 ft.lbs.

30 ft.lbs.

85 ft.lbs.

75 ft.lbs.
Model 2120 Tractor
TM-4252 (Dec-70)

Use
5 mkg

1.1 mkg

5 mkg

23.5 mkg
7 mkg

7.7 mkg

34 mkg

7 mkg

4.3 mkg

11.7 mkg

10.5 mkg

NOTE: If cotter pin can not be inserted in castellated nut when tightening to the specified torque, turn

Driving in oil seal ring of steering shaft

in clutch housing and driving bushings
in bearing cover and clutch housing

SERVICE TOOLS INC., 1901 INDIANA AVENUE, CHICAGO, ILLINOIS 60616, USA

Printed in Germany
Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Brakes 15-1

Group 15
BRAKES
HYDRAULIC BRAKES
DIAGNOSING MALFUNCTIONS The operation of hydraulic brakes is
explained in the manual "Fundamentals of
EXCESSIVE PEDAL LEAK-DOWN Service — Hydraulics ".

Brakes not adjusted. BRAKE VALVE

O-rings of brake valve pistons leaking. AND CYLINDER
Leakage past pressure ring packings in brake REMOVAL
housings and/or leaking brake oil lines.
Disconnect brake lines 3 (fig. 1) at valve and
Equalizing valves of brake valve and cylinder and immediately plug lines and fittings. Remove both
reservoir check valves defective. cap screws 2 attaching brake valve and cylinder to
clutch housing, and lift off brake valve and cylin¬
NOTE: Isolate difficulty in either a defective reser¬ der. Discard gasket installed between brake valve
voir check valve or equalizing valve as follows: and clutch housing. Remove one of the snap rings 1
and remove pin and brake pedal.
1. Isolate brake valve and parts in brake housings
and check for pedal leak-down. If leak-down stops,
difficulty is in individual brake assembly in brake
housings.

2. If after brake valve isolation difficulty con¬

tinues, depress brake pedals separately, then simul¬
taneously. If leak-down occurs in each case, defec¬
tive reservoir check valves are indicated. If leak-
down occurs on individual and not simultaneous
pedal operation, faulty equalizing valves are
indicated.

EXCESSIVE BRAKE CHATTER

Improper or contaminated oil in hydraulic system.

GENERAL INFORMATION
3
—
........
Fig. 1 Brake Valve and Cylinder, Installed
i51515

1 Snap ring (2 used)

The brake pedals allow simultaneous (acting on 2 Cap screws
both wheels) or individual (steering brakes acting 3 Brake lines
on individual wheels) operation of the hydraulic
brakes. Couple brake pedals by means of a latch
for simultaneous operation.

The brake valve reservoir is filled with return oil

from the transmission oil pump lube circuit.
Hydraulic braking is assured as long as there is suf¬
ficient oil in the hydraulic reservoir.

Printed in Germany
60 Front Axle, Steering System and Brakes Model 2120 Tractor
15-2 Brakes TM-4252 (Dec-70)

36

19 1 50339

Fig. 2 — Parts of Brake Valve and Cylinder

1 Brake valve and cylinder housing 15 Spring (2 used) 29 Cap screws
2 Gasket 16 O-ring (2 used) 30 Plate
3 Plug 17 Seal ring <2 used) 31 Left-hand brake pedal
4 O-ring 18 Retainer 32 Right-hand brake pedal
5 Seat of check valves (2 used) 19 Balls 33 Bushings
6 O-ring (2 used) 20 Springs 34 Latch
7 Check valve (2 used) 21 Valve seats for balls 35 Leaf spring
8 Spring (2 used) 22 O-rings 36 Spring pin
9 Plug 23 Adapter 37 Cap screw
10 Plug (2 used) 24 O-rings 38 Hex. nut
11 O-rlng (2 used) 25 Left-hand brake line 39 Brake pedal shaft
12 Spring (2 used) 26 Right-hand brake line 40 Snap rings
13 Ball (2 used) 27 Elbows 41 Cap screw
14 Brake piston (2 used) 28 Pipe clamps 42 Cap screw

Printed in Germany
Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Brakes 15-3

REPAIR Pre-assemble check valves (spring 8, valve 7, valve

seat 5) and install in brake valve and cylinder.

Coat brake pistons 14 with transmission oil and

slide into bores of brake valve housing (small
diameter first).

NOTE: When assembling, always use fresh oil seal

rings and O-rings.

INSTALLATION
Using a new gasket, attach brake valve assembly to
clutch housing, connect brake lines. Run engine for
about 2 minutes at 2100 rpm with the clutch
engaged to allow the transmission lubrication
Fig. 3 — Removing Balls, Valve Seats, Springs and system to fill brake valve reservoir.
Retainers of Brake Valve and Cylinder
NOTE: If it is not desirable to run tractor engine at
1 Valve seat 4 Ball
2 Spring 6 Retainer
this time, screw out plug 3 (fig 2) and fill brake
3 Adapter valve reservoir manually with transmission oil.

Screw adapter elbow 3 (fig. 3) and elbow out of ADJUSTMENT AND BLEEDING
valve seats 1 and remove balls 4 and springs 2
which are now relw released. Screw valve seats 1 BLEEDING AIR FROM BRAKE SYSTEM
out of brake valve and cylinder and remove
retainers 5. Withdraw pistons and springs from Attach a plastic bleed tube to the brake bleed
brake valve and cylinder. screw located on top of brake housing and insert
other end of tube in transmission filler hole. Turn
Remove plugs on top of brake valve as well as out bleed screw by a 3/4 turn, slowly depress brake
check valves. pedal on brake being bled and then allow it to
return slowly. Continue operating pedal until oil in
Turn out both plugs 10 (fig. 2) on bottom of brake tube is free of air bubbles.
valve and remove springs and balls of equalizing
valves. CAUTION: Never allow brake pedal to return
sharply before brakes are completely adjusted. By
Check all parts for wear, scoring, cracks or other permitting brake valve piston to release quickly,
damage and replace, if necessary. damage may occur to valve as piston travel is not
yet closely adjusted.
Check tension of springs.
Close bleed screw securely while brake pedal is
Inspect check valves 7 (fig. 2) for wear or damage, depressed. Remove plastic bleed tube and repeat
especially in area contacting brake pistons when bleeding operation on other brake. Then adjust
brake pedals are released. brakes.

If pedal bushings 33 (fig. 2) have to be replaced,

press in new bushings so that they are flush with
outside edge of pedals.

Printed in Germany
60 Front Axle, Steering System and Brakes Model 2120 Tractor
15-4 Brakes TM-4252 (Dec-70)

ADJUSTING BRAKE PEDALS In this position turn out stop screw by 1/3 turn.

IMPORTANT: This adjustment must be made any When adjusting the right-hand brake pedal, apply a
time the brake valve is disassembled. Failure to specified force to the left-hand brake pedal (see
adjust pedal stop screws will allow the brake Specifications).
pistons to knock against the reservoir check valves,
causing damage or undue wear on valve parts. When adjusting the left-hand brake pedal, apply a
force to the right-hand brake pedal.
Make this adjustment after the brake system has
been bled. When the loaded brake pedal starts to settle, turn
out stop screw of pedal to be adjusted by another
1/3 turn. The loaded brake pedal should now stop
settling. If it does not, this indicates a leak (see
"Diagnosing Malfunctions").

When both brake pedals have been adjusted, align

them by turning the stop screw on the higher pedal
in or out.

CHECKING BRAKE PEDAL ADJUSTMENT

Apply a specified force (see Specifications) to each

brake pedal for one minute. The loaded pedal
should not settle by more than the specified value
151516 (see Specifications).

Fig. 4 — Adjusting Brake Pedals NOTE: Do not check both brake pedals simul¬
taneously, but each separately.
1 Stop screw of right-hand brake pedal
2 Stop screw of left-hand brake pedal

Adjust stop screw (1 or 2, fig. 4) of brake pedal to

be adjusted so that brake piston is fully extended
from the housing and the brake pedal arm is just
touching the piston.

Printed in Germany
Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Brakes 15-5

PRESSURE RINGS Discard packings of pressure rings and replace.

AND BRAKE DISKS INSTALLATION

REMOVAL Install the "floating" facing made up of two

bonded layers in transmission case so that the thick
Removal of final drives see section 10, group 25. layer interwoven with brass faces the transmission
brake face.

Slide brake disk on final drive shaft.

Fig. 5 — Removing Brake Disk and Inner Facing

i Final drive shaft 3 Facing Fig. 6 — Installing Pressure Ring with Packings
2 Brake disk
1 Packings
2 Pressure ring with facing

Remove final drive shaft and brake disk.

Install pressure ring in annular bore of brake
Lift pressure ring with the two packings from the housing, aligning pressure ring with dowels.
brake housing.
Make sure pressure ring is seated on bottom of
bore and that the packings have not been damaged
REPAIR or turned over during installation.
Check inner facings 3 (fig. 5) as well as internal
Install final drives as explained in section 10, group
splines of brake disks 2 for excessive wear. If
necessary, replace brake disks or inner facings.
25. Bleed brake system (see above).

Check facing on pressure rings for excessive wear

and inspect pressure rings for scoring or other
damage. Replace pressure rings, if necessary.

Printed in Germany
60 Front Axle, Steering System and Brakes Model 2120 Tractor
15-6 Brakes TM-4252 (Dec-70)

HAND BRAKE

GENERAL INFORMATION hand brake lever to the brake band. The hand
brake acts through the differential and the final
The main components of the hand brake are the drives on the rear axle, and thus on the rear
brake disk which is splined to the differential wheels of the tractor. The brake disks and the
housing, the brake band engaging the brake disk, brake band are partly submerged in transmission
the hand brake lever with toothed quadrant, and oil and are thus sufficiently cooled.
the components transmitting the movement of the

44420A

Fig. 7 — Parts of Hand Brake

1 Toothed quadrant 10 Woodruff key 19 Special rivet (12 used) 28 Lower anchor pin
2 Hand brake lever 11 Woodruff key 20 Pin 29 Cotter pin (2 used)
3 Latch 12 Lever 21 Toggle 31 Brake disk
4 Release rod 13 Cap screw 22 Brake band adjusting screw 32 Brake band support screw
5 Pressure spring 14 Lock plate 23 Tension spring 33 O-ring
6 Push button 15 Link 24 Toggle 34 Hex. nut
7 Hex. nut 16 Pin (2 used) 25 Anchor 35 Facings (4 used)
8 Brake shaft 17 Brake band arm 26 Pin
9 O-ring 18 Brake band assembly 27 Upper anchor pin

Printed in Germany
Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Brakes 15-7

REMOVAL ADJUSTMENT

Drain transmission oil and remove rockshaft (see After having installed all hand brake parts, tighten
section 10, group 25). brake band adjusting screw 22 (fig. 7) until brake
band fully contacts brake disk. Then back off
Remove hand brake parts as shown in fig. 7. screw by one turn.

Before removing brake disk 31, remove differential

unit (see section 50, group 20).

REPAIR
Check all hand brake parts for serviceability and
repair or replace, if necessary.

BRAKE FACINGS

If facings are loose or so much worn that grooves

on sides of facings are no longer visible, replace
facings. When fitting a new facing, insert rivets
from inside and peen on the outside.

BRAKE DISK

Check brake faces and carefully smoothen rough L 50244

spots. Replace brake disk, if badly worn or scored.
Fig. 8 — Adjusting Hand Brake
TENSION SPRING
Tighten brake band support screw 32 (fig. 7) at
Tension spring 23 (fig. 7) should have a specified bottom of transmission case finger-tight. Then
resilience at a given spring length (see Specifi¬ back off 2 turns and secure by means of hex. nut
cations). 34.

INSTALLATION

Install the components, reversing the sequence

observed for removal (as shown in fig. 7).

NOTE: Hook in tension spring 23 with the brake

band still removed.

Printed in Germany
60 Front Axle, Steering System and Brakes Model 2120 Tractor
15-8 Brakes TM-4252 (Dec-70)

! 51519

Fig. 9 — Operation of the Brake Valve

1 Quick disconnect coupler 5 Pressure line from hydraulic pump 9 Spool return and leak-off orifice
2 Pressure line to coupler 6 Return and leak-off line 10 Pressure spring
3 Brake valve 7 Valve cap 11 Spring cap
4 Control line from final drive 8 Spool 12 Valve body

OPERATION When the braking operation is completed, pressure

oil flows no longer through control line 4 to
With the engine running, oil under system pressure overcome spring pressure. Spring 10 moves the
from the tractor hydraulic pump, is forced through spool downwards into the neutral position.
pressure line 5 (fig. 9), into body 12 of brake valve Thereby, the return and leak-off orifice 9 is again
3, where it is blocked by spool 8 which is in connected to the passage in the valve body leading
neutral position (fig. 9). to pressure oil line 2. Oil can now return into the
rockshaft housing, and thus into the transmission
If the hydraulic brakes of the tractor are operated, case via pressure line 2, spool 8 and return and
oil from the pressure oil circuit of the foot brakes leak-off line 6.
passes s through control line 4 to the bottom of
spool 8, pushing the spool upwards after over¬
coming pressure of spring 10. The return and
leak-off orifice 9 is now closed while the oil
passage leading to pressure oil line 2 of the quick
disconnect coupler is opened. Oil under pressure in
the valve body can now pass through pressure line
2 and quick disconnect coupler 1 to the hydraulic
trailer brakes.

Printed in Germany
Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Brakes 15-9

Fig. 10 — Parts for Hydraulic Trailer Brakes

1 Brake valve, complete 9 Control line (from final drive) 17 Clamp 25 Spool
2 Securing bracket 10 Elbow connectors (90 deg.) 18 Cap screws 26 Valve body
3 Cap screws 11 Orings 19 Quick disconnect coupler 27 O-ring
4 O-rings 12 Pressure line (hydr. pump) 20 Quick disconnect coupler 28 O-ring
5 Special plug 13 Pressure line to brake valve 21 Seal 29 Pressure spring
6 Adapter 14 Elbow connectors (90 deg.) 22 Cap screws (2 used) 30 Washers
7 Return line 15 O-rings 23 Spring washer (2 used) 31 Retainer
8 Pressure line to 16 Special connector 24 Valve cover 32 Spring cap
quick-disconnect coupler

Printed in Germany
60 Front Axle, Steering System and Brakes Model 2120 Tractor
15-10 Brakes TM-4252 (Dec-70)

REPAIR ASSEMBLY AND INSTALLATION

REMOVAL OF BRAKE VALVE When assembling and installing brake valve, reverse
disassembly procedure and refer to figures 9 and
Disconnect all lines at elbow connectors of brake 10.
valve.

Unscrew both cap screws 3 (Fig. 10) attaching BLEEDING

brake valve 1to bracket 2. Remove brake valve and
discard O-rings 4. Loosen hex. nut of elbow connector 10 screwed
into spring cap 32 (fig. 10).
DISASSEMBLY OF BRAKE VALVE Operate right-hand brake pedal to bleed control
line 9 and brake valve 1.
Turn spring cap 32 (fig. 10) out of valve body 26.
Pull spool 25 with spring 29, washers 30 and Tighten spring cap 32 and hex. nut of elbow
retaining ring 31 out of valve body. connector.
Remove retaining ring 31, spring 29 and both
washers 30 from spool. TESTING
Unscrew both cap screws 22 from valve body 26 1. Use an adapter to connect a pressure gauge
and remove valve cover 24. (measuring range 0-2550 psi = 0-250 kg/cm-2) to
coupler plug 20 (fig. 10).
INSPECTION
2. Start engine. Pressure gauge should not register
any pressure.
Check spool and valve body for scoring or other
damage.
3. Press down right-hand brake pedal with
approximately 55 lbs. (25 kg) force. The gauge
The spool and valve body are not separately
should immediately show a pressure of approxi¬
replaceable. Because they are selectively fitted at mately 2130 psi (150 kg/cm2). Within a period of
the factory. If either needs replacement, the
10 seconds the brake pedal should neither sag nor
complete control valve assembly must be replaced.
should a back pressure be observed.
Check all other parts and replace where necessary.

Discard O-rings and replace with new ones.

Check tension of pressure spring 29 (fig. 10). See

specifications.

Printed in Germany
Model 2120 Tractor Front Axle, Steering System and Brakes 60
TM-4252 (Dec-70) Brakes 15-11

SPECIFICATIONS
HYDRAULIC FOOT BRAKES Dimensions of New Parts Wear Tolerance

brake pedals

Dia. of brake pedal shafts .................

Inner dia. of bushings pressed into

.................
0.688 to 0.692 in.
17.48 to 17.58 mm
0.685 to 0.688 in.
17.40 to 17.48 mm
0.705 in.
17.91 mm
0.681 in.
17.30 mm
Dia. of a brake piston

..............
Dia. of piston bearing bores in
brake valve and cylinder housing

Brake piston springs

Free length of spring
0.8715 to 0.8733 in.
22.136 to 22.182 mm

0.874 to 0.875 in.

22.199 to 22.225 mm

7.5 in.
190 mm
Spring tension at a length
of 5.75 in. (145 mm) 20 lbs.
9 kg
Springs of valve balls for regulating return oil
Free length of spring 0.42 in.
10.7 mm
Spring tension at a length of
0.24 in. (6 mm) 0.17 to 0.20 lbs.
76 to 93 g
Springs of check valves
Free length 0.89 in.
22.6 mm
Spring tension at a length of
0.33 in. (8.4 mm) 0.09 to 0.13 lbs.
40 to 60 g
Springs of equalizing valves
Free length 0.79 in.
20 mm
Spring tension at a length of
0.28 in. (7 mm) 0.13 to 0.17 lbs.
60 to 76 g
Load on a brake pedal during adjustment 10 lbs.
4.5 kg
To check brake adjustment, apply a force of 60 lbs.
for one minute 27 kg

Maximum pedal settling within 1minute

at a load of 60 lbs. (27 kg) approx. 1in.
25 mm
HAND BRAKE
Tension spring of brake band
Free length 4.8 in.
122 mm
Spring tension at a length of
5.16 in. (131 mm) 62 to 71 lbs.
p . . , • Germany
Printed in n -
ÿ
28 to 32 kg
60 Front Axle, Steering System and Brakes Model 2120 Tractor
15-12 Brakes TM-4252 (Dec-70)

SPECIFICATIONS (Cont.)
Dimensions of New Parts Wear Tolerance

PARTS FOR HYDRAULIC TRAILER BRAKE

Brake valve

.....
Diameter of control valve spool at helical edges .... 0.4728 to 0.4737 in.
12.020 to 12.043 mm

..........
Diameter of bore for bearing in valve housing 0.4729 to 0.4738 in.
12.023 to 12.046 mm
Valve housing and control valve spool are matched
pairs with a specified clearance of 0.00012 to 0.00024 in.
0.003 to 0.006 mm

Pressure spring of control valve spool

Free length approx. 1.04 in.
26.5 mm
Spring tension at a length of
0.57 in. (14.5 mm) 48 to 58 lbs.
21.5 to 26.5 kg

Operating test

Load right-hand foot pedal with

Operating pressure with this load*

...............
............. approx. 55 lbs.
25 kg

approx. 2130 psL

150 kg/cm2

* During a period of approx. 10 sees, there should be no back pressure or

sinking of clutch pedal.

Printed in Germany
Model 2120 Tractor
TM-4252 (Dec-70)

NOSING MALFUNCTIONS, PRES¬

SURE TESTS

General information
Operation
Diagnosing malfunctions
Pressure tests
Specifications
Special tools
GROUP 10 - OIL RESERVOIR, FILTER,
VALVES AND OIL COOLER
Main oil reservoir, transmission oil
filter and suction screen
General information
Repair
By-pass valve of
transmission oil filter
General information
Repair
Relief (safety) valve in clutch
housing
General information
Repair
Check valve in inlet line
to hydraulic pump (tractors without
HIGH-LOW unit)
General information
Repair
Flow control valve of
power steering
General information
Repair
Assembly
Hydraulic oil reservoir
General information
Repair
Oil cooler
General information
Specifications
GROUP 15 - HYDRAULIC PUMP AND
TRANSMISSION OIL PUMP
Hydraulic pump
General information
Repair
Adjustment
Transmission oil pump
General information
Removal
Repair
Installation
Printed in Germany
Page

5-2
5-3
5-4
5-8
5-10
5-10

10-1
10-1
10-1

10-2
10-2
10-2

10-2
10-2
10-2

10-3
10-3
10-3

10-4
10-4
10-5
10-5
10-6
10-6
10-6
10-6
10-6
10-7

15-1
15-2
15-2
15-7
15-8
15-8
15-8
15-8
15-8
Specifications
Torques for hardware
Capacities
Special tools
GROUP 20 - ROCKSHAFT
General information
Repair
Assembly
Adjustment
Load control mechanism
Repair
Installation
Adjustment
Three-point hitch
Specifications
Adjustments
Torques for hardware
Special tools

Operation
Removal
Repair
Installation
Adjustment
Specifications
Torques for hardware
...
.
Hydraulic System
General Information, Diagnosing Malfunctions, Pressure Tests

HYDRAULIC SYSTEM
CONTENTS OF THIS SECTION
GROUP 5 - GENERAL INFORMATION, DIAG¬

........
Section 70

GROUP 25 - SELECTIVE CONTROL VALVES

(Spool type)
General information

GROUP 30 - SELECTIVE CONTROL VALVE

Repair
(poppet type)
General information
Diagnosing malfunctions
Operation

Adjustment
Specifications
Torques for hardware
Special tools
GROUP 35 - REMOTE CYLINDER
General information
Repair
Bleeding
Specifications
Torques for hardware
70
5-1

Page

15-9
15-11
15-11
15-12

20-1
20-4
20-8
20-10
20-12
20-13
20-13
20-14
20-15
20-18
20-18
20-19
20-19

25-1
25-2
25-3
25-4
25-6
25-6
25-6
25-6

30-1
30-1
30-2
30-4
30-8
30-10
30-11
30-11

35-1
35-2
35-3
35-3
35-3
70 Hydraulic System Model 2120 Tractor
5-2 General Information, Diagnosing Malfunctions, Pressure Tests TM-4252 (Dec-70)

Group 5
GENERAL INFORMATION,
DIAGNOSING MALFUNCTIONS,
AND PRESSURE TESTS

=Tr=TR

JllllSli!!;

I51 521

Fig. 1 Complete Hydraulic System (Tractor Without HIGH-LOW Shift Unit,

Independent PTO and Power Steering)
Selective control valves 7 Countershaft 12 Transmission oil filter 18 Main brake cylinder
To quick couplers 8 Differential drive shaft 13 Bleed line 19 Check valve (inlet line to
Rockshaft 9 Transmission oil pump 14 Hydraulic oil reservoir hydraulic pump)
Lube oil to final drives 10 Suction screen 15 Check valve 20 Relief valve
Transmission oil cup 11 By-pass valve of 16 Hydraulic pump 21 Pressure oil (2050 to
Transmission drive shaft transmission oil filter 17 Leak-off and bleed line —
2280 psi 144 to
160 kg/cm2)
22 Intermediate pressure oil
(50 psi = 3.5 kg/cm2)
23 Pressure- free oil

GENERAL INFORMATION
The hydraulic system of the tractor includes main "Constant pressure" means that high pressure is
oil reservoir (transmission case), hydraulic pump, constantly maintained in the hydraulic system
transmission oil pump, various valves, oil lines, while engine and hydraulic pump are operating, as
filter, power steering* with flow control valve, long as none of the hydraulic units requires oil (see
hydraulic oil reservoir, oil cooler*, HIGH-LOW "stand-by pressure", Specifications).
shift unit*, independent PTO*, rockshaft and one
or several selective control valves*. For a detailed explanation of operation and repair
of power steering and hydraulic brakes see section
The hydraulic system (see figs. 1and 2) is a closed- 60.
center, constant pressure type system.
NOTE: Detailed explanation of design and
"Closed system" means that no oil flows through operation of the individual hydraulic units
hydraulic unit control valves when the latter are in see "Fundamentals of Service -Hydraulics"
neutral position. manual.

* If equipped
Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) General Information, Diagnosing Malfunctions, Pressure Tests 5-3

v-JUlrTTU

r
—
2 To quick couplers
3 Rockshaft
33

Fig. 2

1 Selective control valves

4 Lube oil to final drives

— Complete Hydraulic System (Tractor With HIGH-LOW Shift Unit,
Oil Cooler, Independent PTO and Power Steering)
13
14
15
16
Bleed line
Hydraulic oil reservoir
Check valve
Hydraulic pump
24 To disk brake of HIGH-LOW unit
25
26
27
Control valve of independent PTO
To PTO brake
Pressure regulating valve
5 Transmission oil cup 17 Leak-off and bleed line 28 To PTO clutch
6 Transmission drive shaft 18 Main brake cylinder 29 To disk clutch of HIGH-LOW unit
7 Countershaft 19 Power steering 30 Transmission shift cover
8 Differential drive shaft 20 Relief valve 31 To HIGH-LOW unit (lubrication)
9 Transmission oil pump 21 Oil cooler 32 Pressure oil (2050 to 2280 psi
10 Suction screen 22 Flow control valve of = 144 to 160 kg/cm2)
11 By-pass valve of power steering 33 Pressure oil (100 psi = 7 kg/cm2)*
transmisaon oil filter 23 HIGH-LOW control valve assy. 34 Pressure oil (50 psi - 3.5 kg/cm2)
12 Transmission oil filter 35 Pressure-free oil

OPERATION
Transmission oil pump 9 (see figs. 1and 2) sucks oil On tractors not equipped with HIGH-LOW unit or
from the main oil reservoir (transmission case) independent PTO, oil passes from transmission oil
through suction screen 10 and pushes it through filter directly to the hydraulic pump. These
transmission oil filter 12. machines have a check valve 19 (fig. 1) installed in
the inlet line to the hydraulic pump, ensuring that
The transmission oil filter 12 is provided with a when the engine is stopped or engine clutch is
by-pass valve 11 located between inlet and outlet disengaged (transmission oil pump is then not
of the filter. This by-pass valve causes the oil operating), oil does not flow back. On tractors
sucked in by the oil pump to be returned to the equipped with HIGH-LOW shift unit or in¬
main oil reservoir if a specified pressure differential dependent PTO the operation of the check valve
is reached between inlet and outlet of transmission is carried out by the pressure regulating valve 27
oil filter due to filter restriction (see Specifi¬ located in the transmission shift cover 30 (fig. 2).
cations).

* On tractors equipped with independent PTO

150 psi (10.5 kg/cm).

Printed in Germany
70 Hydraulic System Model 2120 Tractor
5-4 General Information, Diagnosing Malfunctions, Pressure Tests TM-4252 (Dec-70)

On tractors equipped with HIGH-LOW shift unit, Oil not required by hydraulic pump 16 (pump in
independent PTO or both, oil flows from trans¬ stand-by position) flows through the hydraulic
mission oil filter first to pressure regulating valve reservoir to oil cooler 21 (if equipped).
(adjusted by shims) located in gear shift cover 30
(fig. 2). The pressure regulating valve 27 regulates If the tractor is equipped with a power steering
the oil to a given pressure for engaging the HIGH- unit 19 (fig. 2), oil is supplied from the hydraulic
LOW multi-disk clutch, PTO multi-disk clutch and pump. Flow control valve 22 installed in the
for operating the PTO brake (see Specifications). hydraulic system gives priority in oil supply to
power steering.
Then oil reaches HIGH-LOW control valve 23, or
independent PTO control valve 25, or both, Pressure oil from the hydraulic pump also flows to
whatever is required. Only a small amount of oil is the rear for operating rockshaft 3, selective control
required by the HIGH-LOW unit and independent valves 1and attached implements. Return oil from
PTO, the rest flowing to the hydraulic pump. the rockshaft and attached implements flows
directly into the main oil reservoir (transmission
NOTE: For a detailed explanation of design and case).
operation of the HIGH-LOW unit and independent On tractors equipped with an oil cooler, oil flows
PTO see section 50. back into the clutch housing, fills the reservoir of
main brake cylinder 18, lubricates and cools the
Relief valve 20 (fig. 1 or 2) located in the clutch HIGH-LOW disk packs 31 (fig. 2) and lubricates
housing protects the system from excessive the transmission gears and shafts. Then it flows
pressure which may be due to excessive resistance back again into the main oil reservoir.
in the system.
On tractors not equipped with an oil cooler, the oil
flows from the oil reservoir to the clutch housing,
filling the reservoir of main brake cylinder and
lubricating transmission gears and shafts.

DIAGNOSING MALFUNCTIONS
HYDRAULIC SYSTEM Hydraulic pump operating improperly
Check hydraulic pump
SLOW OPERATION
NO OIL PRESSURE
Hydraulic system responds slowly
Increase engine speed No oil or improper oil in hydraulic system
Fill in oil of proper quality and viscosity
Oil does not reach hydraulic pump
Clutch pedal depressed Hydraulic pump does not deliver
Transmission oil pump faulty With the engine running, check pump shut-off
Transmission oil filter clogged screw (if equipped)

Improper transmission/hydraulic system oil Transmission oil pump does not operate
Drain oil and fill hydraulic system Check pump
with oil of proper viscosity and quality
Oil lines leaking
Pressure regulating valve of hydraulic pump Tighten lines or replace
improperly adjusted
Check valve seat for foreign particles or damage Hydraulic pump worn or damaged
Adjust pressure regulating valve Check pump
Internal leakage
Check hydraulic system

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) General Information, Diagnosing Malfunctions, Pressure Tests 5-5

OIL OVERHEATING ERRATIC PUMP OPERATION

Oil of improper viscosity in system Pressure regulating valve not seating properly
Use proper oil Check valve seat for damage or foreign particles

Oil cooler malfunction Leaking inlet or outlet valves, defective O-rings

Clean and repair oil cooler Repair valves, replace O-rings of valve plugs
Pressure regulating valve of hydraulic pump Piston springs not balanced
sticking Check springs for broken coils or unequal
Repair valve resilience
Crankcase outlet valve of hydraulic pump sticking Pump pistons stuck
in open position Check pistons for burrs or dirt
Check valve for foreign particles If required, replace parts

OIL IN SYSTEM FOAMING PUMP NOISE OR SQUEAL

Too little oil in system Spring guide of pressure regulating valve binding
Add oil, check system for leakage Smoothen sharp edge on lower end of spring
guide. Adjust system pressure
Water in oil
Drain oil and refill Loose pump drive coupler parts
Tighten screws and nuts to the specified torque
Improper oil viscosity
Use oil of proper viscosity Air bubble in pressure regulating valve chamber
Bleed valve chamber by backing off adjusting
Oil lines bent or dented screw of pressure regulating valve until spring
Replace lines pressure is relieved. Air will escape through
threads. Then adjust pressure regulating screw
Air leak in hydraulic pump inlet line
Tighten line connections or replace lines PUMP OPERATES SLOWLY

HYDRAULIC PUMP Pump shaft seal groove in pump housing worn

Replace pump housing and seal ring
NO PUMP OUTLET

Check pump shut-off screw

Adjust pressure regulating valve of pump

Pressure regulating valve of pump stuck open

Pump shaft broken

Printed in Germany
70 Hydraulic System Model 2120 Tractor
5-6 General Information, Diagnosing Malfunctions, Pressure Tests TM-4252 (Dec-70)

POWER STEERING ERRATIC OPERATION OF ROCKSHAFT

CONTROL VALVES
Diagnosing malfunctions see section 60
Insufficient valve play (both control valves
HYDRAULIC BRAKES remaining open)
Adjust valve play (neutral range of control
Diagnosing malfunctions see section 60 lever)

ROCKSHAFT O-ring of rockshaft piston damaged or worn

Replace O-ring and back-up ring
FAILS TO RISE OR RISES SLOWLY
Thermal relief valve defective
No pressure in system Replace valve
Check operation of hydraulic pump
Rate-of-drop valve leaking
Rate-of-drop valve stuck open Check valve for foreign particles or damaged
Turn in rate-of-drop screw completely. If lift plug, back-up ring and O-rings
arms rise, check valve for foreign particles.
Check O-rings and back-up rings of valve plugs ROCKSHAFT FAILS TO LOWER OR LOWERS
for proper condition SLOWLY

Return spring of valve operating lever unhooked or Rate-of-drop screw completely turned in
weak
Remove plug on right side of rockshaft housing Valve linkage damaged or disconnected
and watch valve linkage. If linkage moves with
the engine shut off, spring will be unhooked or ROCKSHAFT RISES QUICKLY
damaged. Hook in spring or replace.
Dump valve improperly adjusted
O-ring of rockshaft piston damaged or worn Remove shims to reduce oil flow
Replace O-ring and back-up ring
ROCKSHAFT LOWERS QUICKLY
Clutch pedal depressed
Release clutch pedal so that transmission oil Rate-of-drop screw backed off excessively
pump can operate again
ROCKSHAFT FAILS TO RISE UNDER LOAD
Low pump output
Check and adjust hydraulic pump Excessive load on hitch

Adjusting screw of load control arm improperly Insufficient delivery of hydraulic pump
adjusted Check and adjust hydraulic pump

Adjusting screw of cam follower improperly Adjusting screw of load control arm improperly
adjusted (improper reaction in load control) adjusted

Dump valve defective O-ring of rockshaft piston damaged or worn

Replace O-ring and back-up ring
Transmission oil filter contaminated or plugged

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) General Information, Diagnosing Malfunctions, Pressure Tests 5-7

Seal between rockshaft cylinder and valve housing EXCESSIVE HITCH RESPONSE
and rockshaft housing or between rockshaft
housing and transmission case leaking Selector lever in load control position (L)
Replace gasket and seals Move selector lever in load-and-depth position
(LD)
Thermal relief valve defective
Replace relief valve OIL HEATING - BY-PASSING OF OIL

INSUFFICIENT RISE IN DEPTH CONTROL Insufficient valve play (both control valves remain¬
ing open)
Control lever improperly adjusted Adjust valve play

EXCESSIVE SETTLING UNDER LOAD Control valves leaking

Check valves for foreign particles and replace
Rate-of-drop valve leaking valve plugs, O-rings and back-up rings.
To check rate-of-drop screw, turn it in
completely. Now lift arms should stop to Thermal relief valve defective or worn
settle. If this is not the case, check valve for Replace valve
foreign particles or leaking valve plug.
O-rings of one or both valves leaking
Rockshaft cylinder check valve leaking Replace O-rings and back-up rings
Replace check valve ball and rework valve seat
REMOTE CYLINDER
Plug at rockshaft cylinder end leaking
Tighten plug CYLINDER WILL NOT EXTEND

Rockshaft cylinder valve housing porous or Cylinder overloaded

damaged
Replace housing Insufficient oil pressure
Check hydraulic pump
INSUFFICIENT LOAD RESPONSE
Air in cylinder
Selector lever in depth (D) or load-and-depth (LD) Bleed cylinder
position
Move selector lever in load (L) control position O-ring of piston damaged
Replace O-rings and back-up rings
Excessive valve play
Adjust valve play CYLINDER WILL NOT RETRACT

Control valves stuck Air in cylinder

Check valves for worn springs or foreign Bleed cylinder
particles
Remote cylinder stop valve stuck
Load control shaft or bushings worn Clean and repair valve

Negative stop screw of load control arm excessively Piston rod stop improperly adjusted
turned in. Adjust stop properly

Printed in Germany
70 Hydraulic System Model 2120 Tractor
5-8 General Information, Diagnosing Malfunctions, Pressure Tests TM-4252 (Dec-70)

CYLINDER SETTLES UNDER LOAD

Piston O-ring damaged

Replace O-ring and back-up rings

CYLINDER OPERATES SLOWLY

Insufficient oil or insufficient pressure

Check hydraulic pump

Air in cylinder
Bleed cylinder

Remote cylinder stop valve stuck

Clean and repair valve

Fig. 3 — Pressure Gauge Connected to Rockshaft

PRESSURE TESTS Housing
Before making the following tests, check oil level 1 Pressure gauge No. 19,58-90,269 of special tool No. 19.58-90,260
2 Rockshaft housing
in main oil reservoir (transmission case) and 3 Pressure hose assembly of special tool No, 19.58-90.260
viscosity of oil. Check all lines and connections for 4 Special adapter No. 19.58-90.266 of special tool
leaks or damage. No. 19.58-90.260
5 Cap screw (3/8 in.)

NOTE: Operate tractor to warm hydraulic oil to Record gauge reading. If gauge does not show
approx. 120O F (50o C) before testing hydraulic specified system pressure (see Specifications),
system in the order given below. adjust pressure regulating valve of hydraulic pump
so that specified system pressure will be reached, as
TESTING PUMP STAND-BY PRESSURE explained in group 15 of this section.
Remove cap screw 5 (fig. 3) or front plug (3/8 in.)
on right side of rockshaft housing below flow TESTING ADJUSTING PRESSURE OF POWER
control valve plug. Connect gauge No. STEERING FLOW CONTROL VALVE
19.58-90,269 (measuring range of 0 to 3550 psi =
0 to 250 kg/cm2) to rockshaft housing (see fig. 3) Remove plug located in front of pump pressure
by means of special adapter No. 19.58-90.266 and regulating valve or pump shut-off screw (if
pressure hose assembly of special tool No. equipped). Install adapter No. 19.58-90.271 (see 4,
19.58-90.260. fig. 4). provided with O-ring.

Move range shift lever in park position or in neutral Screw elbow No. 19.58-90.270 (see 3, fig. 4),
position, adjusting hand brake. Start engine, engage provided with O-ring, in adapter. Connect pressure
engine clutch and increase engine speed to 2500 gauge No. 19.58-90.269 to elbow 3 (see fig. 4) and
rpm (upper idling speed). thus to hydraulic pump by means of pressure hose
of special tool No. 19.58-90.260.

Test pump stand-by pressure (see Specifications)

and check hydraulic components for proper
operation.

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) General Information, Diagnosing Malfunctions, Pressure Tests 5-9

gauge reading when actuated hydraulic component

starts to operate normally. This value indicates
flow control valve adjustment. For proper flow
control valve adjusting pressure see Specifications.
If adjusting pressure is not correct, add or remove
shims between valve spring and throttle (see group
10 of this section). One shim will change pressure
by 35 to 40 psi (2.5 to 2.8 kg/cm2).

To adjust the flow control valve, disconnect

pressure line of hydraulic pump at adapter.
Remove adapter from valve housing (see group 10).
Pull spool out of valve housing bore and install
proper number of shims between throttle plate and
spring.
Fig. 4 — Pressure Gauge Connected to Hydraulic
Adjust pressure control valve of hydraulic pump so
Pump that correct system stand-by pressure is obtained.
1 Pressure gauge No. 19.58-90.269 of special tool
No. 19.58-90.260
2 Pressure hose assembly of special tool No. 19.58-90.260 TESTING LIFT CYCLES
3 Elbow No. 19.58-90.270 of special tool No. 19,58-90.260
4 Adapter No. 19.58-90.271 of special tool No. 19.58-90.260
ROCKSHAFT
Adjust pump pressure regulating valve to 1500 psi
(105 kg/cm*). Run engine at 2100 rpm.

Actuate control lever of one of the hydraulic Lift arms should be in their lowest position. Move
components which do not have priority in oil rockshaft control lever backward until lift arms are
supply (rockshaft or selective control valve); it in top position. Rising of lift arms in top position
should not operate. If component operates, this should require a specified period (see
indicates a malfunction of the flow control valve Specifications).
(contaminated valve or broken valve spring). Deter¬
mine cause of trouble and remove (see group 10 of REMOTE CYLINDER
this section) before continuing the test.
Run engine at 2100 rpm and actuate selective
Carry out any of the following two operations: control lever to extend remote cylinder piston.
Remote cylinder should be completely extended in
1. Move rockshaft control lever fully forward so specified period (see Specifications). If extending
that lift arms are completely lowered. Then or retracting cylinder requires more or less time,
move control lever backward until lift arms turn out adjusting screws to selective control valve
have completely risen. to reduce lift cycle. Turn in screws to extend lift
cycle (see group 35).
2. Completely retract remote cylinder. Then move
selective control lever in "fast extend" position.

Turn adjusting screw of pump pressure regulating

valve so as to increase system pressure. Record

Printed in Germany
70
5-10

HYDRAULIC PUMP

4-piston pump
8-piston pump

8-piston pump

REMOTE CYLINDER

.
Hydraulic System
General Information, Diagnosing Malfunctions, Pressure Tests

Delivery per pump shaft revolution

Pump stand-by pressure

TRANSMISSION OIL PUMP

....................
....................
Delivery at 2500 rpm engine speed and a
system pressure of 2050 psi (144 kg/cm2)
4-piston pump

..................
Delivery at 2500 rpm engine speed

PLOW CONTROL VALVE OF POWER STEERING

.....
Adjusting pressure of flow control valve

One shim changes pressure by

ROCKSHAFT

Period for extending or retracting cylinder

at 2100 rpm engine speed

19.58-90.260*

2 seal rings
1fitting

1tool kit

1adapter
........... ........
Part No. when ordering from
JD Parts Depot Manufacturer

............
* This special tool includes

..............
............
........
.....
-
1adapter 3/8 in. 24 UNF
SPECIFICATIONS

.......
..........
.........
Complete lift cycle at 2100 rpm engine speed

SPECIAL TOOLS

Description

Special tool

1pressure hose with connecting parts

............ .
..

1pressure gauge, measuring range 0-355 psi (0-25 kg/cm2)

1pressure gauge, measuring range 0-3550 psi (0-250 kg/cm2)
1elbow
1adapter
2 O-rings
2 O-rings

Printed in Germany
.
.
0.69 cu.in.
1.38 cu.in.

. 5.4 Imp.gals./min.
6.5 U.S. gals./min.
10.8 Imp.gals./min.
13 US. gals./min.

2220 to 2280 psi

6.6 Imp.gals./min.
8 US gals./min.

1700 to 1800 psi

35 to 40 psi

1.8 to 2.3 sec.

.
2 sec.

Use
Model 2120 Tractor
TM-4252 (Dec-70)

Testing oil pressure

11.3 cm3
22.6 cm3

24.6 lit./min.
49 lit./min.

156 to 160 kg/cm2

30.3 lit/min

118 to 125 kg/cm2

2.5 to 2.8 kg/cm2

19.58-90.261
19.58-90.262
19.58-90.263
19.58-90.264
19.58-90.266
19.58-90.267
19.58-90.268
19.58-90.269
19.58-90.270
19.58-90.271
R 26287 R
R 26375 R
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Oil Reservoir, Filter, Valves and Oil Cooler 10-1

Group 10
OIL RESERVOIR, FILTER, VALVES
AND OIL COOLER
MAIN OIL RESERVOIR, TRANSMISSION OIL The transmission oil intake screen is located to the
FILTER AND SUCTION SCREEN rear, right, behind plug 1 (fig. 1). This intake
screen should be removed and cleaned any time the
GENERAL INFORMATION transmission oil is drained and replaced.
The transmission case is also the main oil reservoir REPAIR
for the hydraulic system. The oil level dipstick is
located to the right of the transmission case. The Transmission Oil Filter
oil filler hole is at the rear of the rockshaft
housing. Remove filter cover and take out O-ring and filter
element.
The transmission and hydraulic system drain plugs
are located underneath the transmission case. NOTE: It is not necessary to drain transmission oil
when replacing transmission oil filter element.

Install new O-ring in transmission case groove,

making sure that it is properly seated. Replace
filter cover together with new filter element and
tighten filter screw firmly, but do not overtighten.

Intake Screen

Remove plug 1 (fig. 1) and intake screen from

transmission case. Clean screen in diesel fuel.
Install screen and tighten plug.

Fill transmission case with oil, run engine at idling

speed for at least three minutes and then check oil
Fig. 1— Transmission Oil Filter and Oil Intake level. Do not screw in dipstick, just rest it on top
Screen, Installed of threads. Add oil as necessary.
1 Plug
2 Transmission oil filter

The full flow transmission oil filter is located

underneath and to the right of the transmission
case (see 2, fig. 1). It has a disposable paper filter
element.

Printed in Germany
70 Hydraulic System Model 2120 Tractor
10-2 Oil Reservoir, Filter, Valves and Oil Cooler TM-4252 (Dec-70)

BY-PASS VALVE OF RELIEF (SAFETY) VALVE IN

TRANSMISSION OIL FILTER CLUTCH HOUSING

GENERAL INFORMATION GENERAL INFORMATION

lkÿ213 A
Fig. 2 — By-pass Valve of Transmission Oil Filter
1 By-pass valve 2 Plug

A by-pass valve insures that oil drawn by the trans¬

lSIS36
mission pump and delivered to the filter is diverted
straight to the main oil reservoir, (transmission
case) whenever the filter is clogged or when the oil Fig. 3 — Relief (Safety) Valve in Clutch Housing
is still heavy during the warm-up period.
1 Ball 3 Washer
2 Spring 4 Plug with pin
REPAIR
The relief valve located at the right-hand side of
Remove plug 2 (fig. 2) of by-pass valve and with¬ the clutch housing (see fig. 3) serves as a safety
draw valve sleeve with spring and valve body from valve. It opens and diverts oil to the main oil
transmission case bore. reservoir (transmission case) whenever the pressure
in the clutch housing oil passage leading to the
Drive out spring pin retaining valve body in sleeve. hydraulic pump inlet line exceeds a specified value
Slide spring and valve body out of sleeve. (see Specifications).
Check resilience of valve spring (see Specifi¬ REPAIR
cations).
Turn plug 4 (fig. 3) out of clutch housing and
Check valve sleeve and body for burrs, scoring or remove washer 3, spring 2 and ball 1. If relief
wear and replace, if necessary. valve seat pressed into housing bore is damaged and
must be replaced, remove old valve seat and press
Install spring and valve body in valve sleeve and in new seat with chamfered end first.
insert sleeve in transmission case bore. Slide a new
O-ring on valve plug and install plug in transmission
case. Tighten plug.

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Oil Reservoir, Filter; Valves and Oil Cooler 10-3

Examine valve pin of plug for damage or wear and Check resilience of valve spring 2 (see Specifi-
replace, if required. Bottom new valve pin in plug cations).
bore.
When installing, provide plug with a new O-ring.

CHECK VALVE IN INLET LINE OF HYDRAULIC PUMP

(Tractors without HIGH-LOW unit)

GENERAL INFORMATION

A check valve 1 (fig. 4) is installed in the end of

the hydraulic pump inlet line, connected to the
flywheel housing. This check valve prevents oil
from returning to transmission case from the pump
and inlet line when transmission oil pump is not
working. By this means an immediate oil supply is
guaranteed to the hydraulic pump under almost all
conditions.

REPAIR

Remove clamp securing hydraulic pump inlet line

and return line to clutch housing and pull out inlet 145291
line from bore in clutch housing. Disconnect inlet
line at hydraulic pump and push forward. Remove Fig. 4 — Check Valve in Hydraulic Pump Inlet Line
check valve assembly from inlet line (see fig. 4).
1 Check valve assembly

Check valve spring for cracks and broken or

compressed coils and replace, if necessary. Check Check seat of check valve and spring guide for wear
resilience of valve spring (see Specifications). and damage and replace, if necessary.

Assemble, reversing disassembly sequence.

Printed in Germany
70 Hydraulic System Model 2120 Tractor
10-4 Oil Reservoir, Filter, Valves and Oil Cooler TM-4252 (Dec-70)

FLOW CONTROL VALVE

(Tractors Equipped with Power Steering)

ISM 10
L 48469 L 48470

Fig. 5 — Oil Flow in Flow Control Valve at a Pres¬ Fig. 6 — Oil Flow in Flow Control Valve at a
sure Above 1800 psi (125 kg/cm2) Pressure Below 1800 psi (125 kg/cm2)
1 Valve spring 3 To rockshaft 5 From hydraulic pump 7 To selective control 9 Pressure oil
2 Shims 4 Throttle disk 6 Valve spool valve 10 Pressure-free
8 Relief bore to trans¬ oil
mission case

GENERAL The rear of valve spool 6 has a smaller dia. than the
front part of it, consequently the oil pressure in
The flow control valve is located on the lower right front of the valve spool is larger than in the rear of
of the transmission case. it.

This valve assures priority in oil supply from the The resulting pressure differential will move the
main hydraulic pump to power steering, making valve spool rearward once the oil pressure exceeds
sure that there is always sufficient pressure for the 1800 psi (125 kg/cm2). At a lower pressure the
steering system. spring pressure will prevent such a movement.

The control valve spool 6 in the valve housing (figs. A bypass bore 8 leading to the transmission case
5 and 6) controls the oil flow to the other prevents hydraulic blocking of the valve spool due
hydraulic components dependent on power to leak-off oil in the flow control valve.
steering demand for oil.

A movable throttle 4 connects the valve spool

cavity behind and in front of the throttle, regulat¬
ing the oil pressure.
3 NOTE: For a more detailed explanation of
design and operation see "Hydraulic
Valves" in "Fundamentals of Service —
Hydraulics" manual.

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Oil Reservoir, Filter, Valves and Oil Cooler 10-5

15

@ L 51 525

Fig. 7 — Exploded View of Flow Control Valve

1 Valve housing 6 Adapter 12 Cap screw 15 O-rings
2 Spring 7 O-ring 13 Plug (tractors without 16 Pressure line for
3 Shim (use as required) 8 O-ring selective control valve) selective control valve
4 Throttle disk 9 O-ring 14 Adapter (tractor with 17 Adapter
5 Valve spool 10 Cap screw selective control valve)
11 Cap screw

REPAIR Check resilience of pressure spring (see

Specifications).
Disconnect main hydraulic pump pressure line as
well as pressure line leading to selective control Check throttle 4 for wear and replace, if necessary.
valve (if equipped) at flow control valve.
ASSEMBLY
Remove cap screws securing flow control valve to
transmission case and take valve away. Use same number of shims between spring and
throttle disk as installed before removal. Adding
Turn adapter 6 (fig. 7) out of valve housing and shims will increase pressure, removing shims will
withdraw valve spool 5, throttle disk 4, shims 3 reduce pressure.
and spring 2 from housing.
Assemble flow control valve as shown in fig. 7.
Check valve spool and housing for serviceability.
Install flow control valve and test as explained in
group 5.

Printed in Germany
70 Hydraulic System Model 2120 Tractor
10-6 Oil Reservoir, Filter, Valves and Oil Cooler TM-4252 (Dec-70)

HYDRAULIC OIL RESERVOIR the assembly so that it could fall, with its ball and
spring, into the reservoir.
GENERAL INFORMATION
If the reservoir was removed, carefully clean and
The auxiliary hydraulic oil reservoir 1 (fig. 8) rinse out reservoir. Check for leaks and broken
provides an additional supply of oil whenever the seams and replace, if necessary.
transmission oil pump is unable to meet oil
demands. OIL COOLER

GENERAL INFORMATION

Fig, 9 — Oil Cooler

Radiator 7 Hose
Oil cooler 8 Foam rubber block
Foam rubber block 9 Rubber washers
Hex.nuts (4 used) 10 Springs
Fig. 8 — Exploded View of Hydraulic Oil Reservoir Washers (4 used) 11 Cap screws
Hose clamps
1 Hydraulic oil 12 Washer (3 used)
reservoir 13 Cap screw (3 used)
2 Leak-off and bleed 14 Hose The oil cooler prevents heating of oil in the
line 15 Hose clamps
3 Clamping band 16 Oil line
hydraulic system.
4 Hollow screw 17 Hose (tractors equipped with oil
5 O-rings cooler) NOTE: For cleaning the oil cooler,
6 Hose adapter 18 Hose
follow
7 Ball 19 Oil line procedure for cleaning the radiator. See
8
9
Spring
Spring guide
20 Hose clamps
21 Washer
-
Tractors not
equipped with "Fundamentals of Service —
Engines "
10 Hose clip 22 Cap screw
oil cooler manual.
11 Leak-off and 23 Hose
bleed line

REPAIR

Remove check valve (ball 7 and spring 8) together

with hollow screw 4 and hose adapter 6. Take care
not to knock check valve spring guide 9 against the
wall of its bore since this would dislodge it from

Printed in Germany
Model 2120 Tractor
TM-4252 (Dec-70)

Spring of by-pass valve

Free length

.
........
...................
BY-PASS VALVE OF TRANSMISSION OIL FILTER

Dia. of valve sleeve bore for valve body

Dia. of valve body

.....
Valve opens at a pressure differential of

Resilience at a spring length of 1.3 in (33.5 mm)

RELIEF (SAFETY) VALVE IN CLUTCH HOUSING

Valve opens at a pressure of

Spring of pressure relief valve

Free length
Resilience at a spring length of 1.12 in. (28.5 mm)

CHECK VALVE IN INLET LINE TO HYDRAULIC PUMP

(Tractors without HIGH-LOW shift unit)

Spring of check valve

Free length

Adjusting pressure of valve

Dia. of valve spool

front
rear

Spring of flow control valve

Free length
................
Resilience at a spring length of 0.21 in. (5.3 mm)

FLOW CONTROL VALVE OF POWER STEERING

Resilience at a spring length of 3.5 in. (89 mm)

Printed in Germany
.......
50 psi

2.56 in.
9.5 to 11.5 lbs.

100 to 140 psi.

1.88 in.
. . . . 30.5 to 37.5 lbs.

0.51 in.
....0.48 to 0.60 lbs.

1700 to 1800 psi

0.7497 to 0.7503 in.

0.7257 to 0.7263 in.

4.62 in.
45 to 55 lbs.
Hydraulic System
Oil Reservoir, Filter, Valves and Oil Cooler

SPECIFICATIONS
Dimensions of New Parts

0.4995 to 0.5005 in.

0.4977 to 0.4983 in.

12.687 to 12.713 mm

12.440 to 12.557 mm
70
10-7

3.5 kg/cm2

65 mm
4.3 to 5.2 kg

7 to 10 kg/cm2

approx. 48 mm
13.8 to 17 kg

approx. 13 mm
0.21 to 0.27 kg

118 to 125 kg/cm2

19.042 to 19.057 mm
18.433 to 18.477 mm

approx. 117.5 mm
20.5 to 25 kg
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Hydraulic Pump and Transmission Oil Pump 15-1

Group 15
HYDRAULIC PUMP AND
TRANSMISSION OIL PUMP

HYDRAULIC PUMP
(0.69 cu.in. = 11.3 cm3 and 1.38 cu.in. = 22.6 cm3)

20 » i

21 CZ3

L 48 427

Fig. 1— Oil Flow in Hydraulic Pump

1 Pump crankcase 8 Piston spring (8 used)* 15 Crankcase outlet valve
2 Race 9 Piston (8 used)* 16 Stroke control valve guide
3 Cam 10 Intake valve spring (8 used)* 17 Stroke control valve adjusting screw
4 Pump shaft 11 Intake valve (8 used)* 18 Stroke control valve
5 Exhaust valve spring (8 used)* 12 Intake gallery 19 High pressure oil
6 Exhaust valve (8 used)* 13 Bleed hole 20 Medium pressure oil
7 Pressure outlet gallery 14 Crankcase outlet valve spring 21 Low pressure oil

* Only 4 used on the = 0.69 cu.in. (11.3 cm3) pump

Printed in Germany
70 Hydraulic System , Model 2120 Tractor
15-2 Hydraulic Pump and Transmission Oil Pump TM-4252 (Dec-70)

GENERAL INFORMATION When disassembling pump, proceed as follows:

The hydraulic pump is a piston type, constant 1. Remove cover from pump housing. Remove
pressure pump with variable displacement, seat and spring from crankcase outlet valve, (see
mounted ahead of the radiator and driven by the fig. 4). Using a magnetic pick-up tool, remove valve
engine crankshaft through a coupling and drive stop and pin from outlet valve bore in housing.
shaft.
2. While holding pumpshaft race in place, pull
The tractor can be equipped with a 0.69 cu.in. (= shaft from pump housing.
11.3 cm3) pump (4-piston type), or with a 1.38
cu.in. (= 22.6 cm3) pump (8-piston type). IMPOR TANT! The race is supported by 33 bearing
needles. They will fall free when shaft is removed
The pump shaft has a cam machined as an integral — do not lose them.
part. A race mounted on bearing needles is
positioned around the cam for actuating pistons, Keep pistons, springs, spring seats, valves and plugs
located radially around the race. in good order so that they can be reinstalled in the
bores from which they were removed.
The pump has a stroke control valve with adjusting
screw for setting proper system pressure. 3. Remove the piston bore plugs. Slip piston
springs, spring seats and pistons from bores.
For a detailed description of the pump and
its operation see "Fundamentals of Service Remove race and inner thrust washer.
— Hydraulics" manual under "RADIAL
PISTONPUMPS".

PUMP TESTS AND DIAGNOSING

MALFUNCTIONS
See group 5 for diagnosing malfunctions, as well as
for testing of the hydraulic pump before removal.

REPAIR
REMOVAL AND DISASSEMBLY

NOTE: Servicing is identical for both the 0.69

cu.in. (11.3 cm3) pump (4-piston type) and the
1.38 cu.in. (22.6 cm3) pump (8-piston type).
Fig. 2 — Removing Intake Valve Assemblies
Individual parts of both pump types, except for (0.69 cu.in. = 11.3 cm3 pump shown)
the pump housing, are the same, the difference
being in the quantity of various parts. 8 Valve seat 11 Spring
10 Ball 12 Valve guide
Disconnect oil lines from pump and remove pump.

Before disassembling the pump, check pumpshaft 4. Remove intake valve assemblies (see fig. 2).
end play by means of a dial indicator. Excessive
shaft end play may be an indication of worn thrust
washers.

Printed in Germany
Model 2120 Tractor Hydraulic System
"
70
TM-4252 (Dec-70) Hydraulic Pump and Transmission Oil Pump 15-3

2. Check needle sleeve in pump housing for wear

or damage. When replacing it, take care that
finished face of pump housing will not be
damaged. Drive in needle sleeve by means of driver
No. 19.58-90.272 so that its face is 0.02 in. (0.5
mm) inside face of pump housing.

3. Measure pump housing bore at groove for pump

shaft packing 25. Wear at this point may cause
crankcase oil leaks, slowing down the reaction of
the pump. Replace packing 25 whenever pump
shaft is removed. Check piston bores in housing for
scores.

Pistons and Springs (Fig. 4).

Fig. 3 — Removing Exhaust Valves 1. Check pistons 46 for scoring or pitted faces.

15 Valve disk 20 Plug 2. Replace O-rings 9 of plugs 20 on piston bores

17 Valve guide 53 Valve spring
18 Valve stop
each time the plugs are removed from housing.

3. All piston springs should be matched within

5. Turn pump housing over (see fig. 3). Remove certain tolerances (see specifications at the end of
exhaust valve plugs 20 and exhaust valve this group).
assemblies.

6. Remove plug of stroke control valve and slide Valves (Fig. 4)

filter screen from pump housing. Remove stroke
control valve adjusting screw, spring, spring seat, Inspect intake valves for damaged springs 11, valve
and valve stop from housing bore (see fig. 4). guides 12, balls 10 and valve seats 8. Replace
O-rings 9 of valve seats.

INSPECTION Check exhaust valve disks 15 for wear or damage

and check their diameter. Examine valve guides 17,
Pump Housing (Fig. 4) springs 53 and valve stops 18 for damage and
replace, if necessary. Replace O-rings 9 of plugs.
1. Check clearance between finished face of pump
housing and shoulder of cam and race bore. Wear
at this point will give pump shaft excessive end
play.

Printed in Germany
70 Hydraulic System Model 2120 Tractor
15-4 Hydraulic Pump and Transmission Oil Pump TM-4252 (Dec-70)

20-i

4,7 33

-52

—31

©— 54

Fig. 4 — Parts of Hydraulic Pump (1.38 cu.in. = 22.6 cm3 pump shown)
1 Cap screw (8 used) 20 Plugs (17 or 13 used) 37 Threaded bushing
2 Pump cover 21 Thrust washer 38 Shut-off screw
3 Needle sleeves 22 Race 39 Spring pin
4 Gasket 23 Pump shaft 40 Crankcase outlet valve spring
5 O-Rings 24 Bearing needle (33 used) 41 Elbow
6 Elbow 25 Packing 42 Plug
7 Cap screw 26 Seal 43 Crankcase outlet valve pin
8 Intake valve seat (8 used)* 27 O-Ring 44 Seal ring (2 used)
9 O-Rings (26 or 18 used) 28 Plug 45 Filter element
10 Ball (8 used)* 29 Stroke control valve 46 Piston (8 used)*
11 Intake valve spring (8 used)* adjusting screw 47 Piston spring seats (16 or 8 used)
12 Valve guide (8 used)* 30 O-Ring 48 Piston spring (8 used)*
13 Pump housing 31 Stroke control valve spring 49 Crankcase outlet valve stop
14 Exhaust valve seat (8 used)* 32 Stroke control valve stop 50 Woodruff key
15 Valve disk (8 used)* 33 Stroke control valve seat 51 Connector
16 Elbow 34 Crankcase outlet valve spring seat 52 Stoke control valve guide
17 Valve guide (8 used)* 35 Hydraulic pump shut-off parts 53 Exhaust valve spring (8 used) *
18 Valve body (8 used)* 36 O-Ring 54 Washer
19 O-Ring

* Only 4 used on the 0.69 cu.in. (= 11.3 cm3) pump

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Hydraulic Pump and Transmission Oil Pump 15-5

Check condition of valve seats 14 pressed into ex¬ Check crankcase outlet valve stop 49, valve pin 43,
haust valve bores. If necessary, drive in new seats spring seat 34 and spring 40 for damage. Check
with shoulder facing driver (see fig. 5) so that the spring tension (see specifications).
face of valve seat is 1.171 in. (29.75 mm) below
housing bore recess (see fig. 5, item 1). When driv¬ Pump Shaft (Fig. 4)
ing in valve seats, use a driver which exerts pressure
only on valve seat shoulder. Inspect pump shaft for pitting or scoring.

Inspect bearing needles 24 for wear or scores. Worn

thrust washers will give pump drive shaft excessive
end play. Check the thickness of a thrust washer
(see specifications).

Pump Cover (Fig. 4)

Inspect needle sleeve 3 in pump cover 2 for wear or

damage. Drive in new needle sleeve by means of
driver No.19.58 - 90.272 so that its face is 0.02 in
(0.5 mm) inside face of pump cover.

Inspect pump cover for cracks or other damage.

Pump Drive Assembly (Fig.6).

tWM

Fig. 5 — Installing Outlet Valve Seat

1 Recess of outlet valve bore

Check tension of intake and exhaust valve springs

(see specifications).

Inspect stroke control valve stop 32 for damage or

rough spots which might prevent valve from sealing
properly. Clean valve stops with a polishing cloth.
L 48429
Do not use lapping agent.
Fig. 6 — Pump Drive Parts
Check spring 31 for damage or insufficient tension.
(see specifications). 1 Pump drive shaft 5 Hex. nut (2 used)
2 Special screws 6 Coupler halves
3 Rubber grommets 7 Cap screw (2 used)
Check stroke control valve seat 33 for damage or 4 Cap screw
wear and replace, if necessary. Drive in new seat
with chamfered end first until it bottoms in valve
bore. Remove the coupler halves 6 and check the rubber
grommets 3 for wear or damage.
Clean stroke control valve filter element 45 thor¬
oughly. Replace seal rings 44 on each end of filter
element whenever the pump is disassembled.

Printed in Germany
70 Hydraulic System Model 2120 Tractor
15-6 Hydraulic Pump and Transmission Oil Pump TM-4252 (Dec-70)

ASSEMBLY AND INSTALLATION (Fig.4) Place new gasket 4 on pump housing and install
pump cover 2. Simultaneously insert protruding
NOTE: Install new O-rings and seal rings. Dip all end of crankcase outlet valve assembly into mating
O-rings, oil seals, valves, guides and bearing needles hole of pump cover.
into clean transmission oil (as used for tractor),
before assembly. Dip attaching screws 1 of pump cover in oil and
tighten first crosswise to a given torque, then to
Install pump shaft seal 25 into housing. Drive in oil the final torque (see specifications).
seal 26 with suitable driver (printed side outward).
Use driver which contacts outer metal rim of seal Make sure exhaust valve seats 14 are pressed into
only and drive to bottom of chamfer in oil seal mating holes of pump housing. Assemble valve disk
groove. 15, spring 53, exhaust valve stop 18 and guide 17
of each outlet valve. Install exhaust valve assem¬
Place a thrust washer 21 in pump housing with oil blies in bores. Tighten exhaust valve plugs 20 secu¬
grooves facing housing. Install bearing race on top rely. Install stroke control valve filter element 45.
of washer. Make sure seal rings 44 are in place on ends of
filter element.
Install bearing needles 24 around inner surface of
race 22 - grease needles to hold them in place. Insert stroke control valve stop 32 (small diameter
Install pump shaft 23 with grooved end (for seating first) in valve bore. Install valve guide 52 (small end
Woodruff key) first in pump housing. first) in valve 32. Place spring 31 over valve guide
52. Install stroke control adjusting screw 29 with
NOTE: Make sure all 33 needles are installed in O-ring 30.
race.

Install pistons 46, piston spring seats 47, piston Pump Drive Installation (Fig.6)
springs 48 and plugs 20. Tighten plugs to
recommended torque. Use some drops of Loctite Sealant on threads of
both special screws 2, install special screws in
Install O-rings 9 on top of intake valve seats 8. crankshaft pulley and tighten to recommended tor¬
Assemble valve seat 8, ball 10, spring 11 and valve que. Slip rubber bushes 3 on special screws. Slip
guide 12 of each intake valve. Screw valve assem¬ the 2 remaining rubber bushes 3 on the two other
blies into pump housing bores and tighten securely. special screws 2. Use some drops of Loctite Sealant
on threads and turn both screws into hydraulic
Slip crankcase outlet valve pin 43 into outlet valve pump drive shaft 1. Tighten to the recommended
bore in housing. Install crankcase outlet valve stop torque.
49 (closed side first), spring 40 and spring seat 34
in outlet valve bore. Install second thrust washer
21 with oil grooves facing outside.

Printed in Germany
 Hydraulic System 70
Model 2120 Tractor
TM-4252 (Dec-70) Hydraulic Pump and Transmission Oil Pump 15-7

Secure pump drive shaft 1 to crankshaft pulley,

using coupler halves 6, two cap screws 7 and self
locking hex. nuts 5. Tighten two coupler screws 7
only after hydraulic pump has been installed (the
two coupler halves should rest loosely on the
special screws 2).

Installing Hydraulic Pump

Place Woodruff key in pump shaft groove and

insert pump shaft in drive shaft assembly.

Fasten pump to front support and tighten four cap

screws to recommended torque.

With pump secured to front support, arrange pump

drive coupler halves so that they only contact the
rubber bushes, but not the special screws.
u
Tighten two cap screws 7 (fig. 6) of coupler halves
6 alternately to specified torque — then re-tighten
alternately to specified torque. Tighten two lock Fig. 7 — Stroke Control Valve Adjusting Screw
nuts 5 to the specified torque. Then tighten cap
screw 4 of pump drive shaft 1to specified torque. 1 Adjusting screw 2 Hydraulic pump

Connect oil lines to hydraulic pump.

Back off stroke control valve adjusting screw 1(fig.

ADJUSTMENT 7) until spring pressure on screw is completely
relieved. Then turn adjusting screw in until
Install a high pressure gauge as explained in group pressure gauge shows specified stand-by pressure
5. (see specifications). Hold adjusting screw and
tighten lock nut.
Set all hydraulic controls in neutral and place the
transmission range shift lever in park or neutral Run engine for approx. 5 - 10 minutes, then
position. Apply the handbrake. Start the engine recheck adjustment.
and run at the rated speed.

Printed in Germany
70 Hydraulic System
15-8 Hydraulic Pump and Transmission Oil Pump TM-4252 (Dec-70)

TRANSMISSION OIL PUMP On machines equipped with independent PTO:

Remove oil manifold and lines of independent PTO
(see section 50, group 10).

Remove transmission oil pump suction and

pressure lines and remove pump with pump cover.

REPAIR

Separate cover from pump housing and take out

pump gears. Check all parts for wear or scoring.
Check the grooves of the hollow power drive shaft
which engage the keys of the pump drive gear.
Check roller bearing.

Install gears in pump housing. Insert drive gear,

with recess on driving lugs of gear in front, into
pump housing. Attach cover to pump housing. Do
not tighten bolts yet.
ÿ3790

INSTALLATION
Fig. 8 — Transmission Oil Pump, Pump Housing
and Gears Install transmission oil pump with cover and
tighten four cap screws securing pump cover to
1 Drive gear 2 Driven gear
clutch housing, to the specified torque.

On machines equipped with HIGH-LOW unit:

GENERAL INFORMATION Install oil distributor and all oil lines of
HIGH-LOW unit (see section 50, group 10).
The transmission oil pump is a gear-type pump. It
is mounted on the rear wall of the clutch housing On machines equipped with independent PTO:
and is driven at engine speed by the hollow power Install oil manifold and all oil lines of PTO (see
drive shaft. section 50, group 10).

The pump supplies oil to the HIGH-LOW unit (if Tighten cap screws securing transmission oil pump
equipped), independent PTO (if equipped), and the housing, HIGH-LOW unit oil distributor (if
hydraulic pump. It also delivers oil for lubricating installed) and oil manifold of independent PTO (if
the HIGH-LOW unit and shift transmission. installed) to pump cover, to the specified torque.

BBS
For a detailed description of the pump and
its operation see Fundamentals of Service
— Hydraulics" manual under "GEAR
PUMPS"

DIAGNOSING MALFUNCTIONS
See group 5 for diagnosing malfunctions.

REMOVAL

Separate transmission from clutch housing (see

section 10, group 25).

On machines equipped with HIGH-LOW unit:

Remove oil distributor and oil lines of HIGH-LOW
unit (see section 50, group 10).

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Hydraulic Pump and Transmission Oil Pump 15-9

SPECIFICATIONS

Dimensions of new parts

HYDRAULIC PUMP

.......
...................
Finished housing face to bottom of
crankcase bore (where cam and race move) 2.660 - 2.666 in 67.564 - 67.736 mm

...................
Dia. of pump housing bore at groove for
pump shaft packing 1.011 - 1.013 in 25.675 - 25.725 mm

Dia. of pump housing bore for

......................
pump shaft seal ring 1.498 - 1.500 in 38.05 - 38.10 mm

............
Dia. of pump shaft bearing bore in
pump housing and cover (where needle sleeves

....................
are located) 1.3120 - 1.3130 in 33.325 - 33.350 mm

...............
Dia. of piston bores in housing 0.6802 - 0.6808 in 17.277 - 17.292 mm

...............
O.D. of pistons 0.6795 - 0.6799 in 17.259 - 17.269 mm

................
Bore dia. for exhaust valves 0.624 - 0.626 in 15.85 - 15.90 mm

O.D. of exhaust valve seat 0.6275 - 0.6285 in 15.938 - 15.964 mm

Dia. of exhaust valve disk

Intake valve springs

......
......
Tension at a length of 0.31 in (7.8 mm)
0.609 - 0.611 in

0.31 - 0.39 lbs.

15.47 - 15.52 mm

150 - 178 g

.................
Exhaust valve springs
Tension at a length of 0.30 in (7.6 mm) 2.54 - 3.14 lbs. 1.2 - 1.4 kg

Bore dia. for crankcase

outlet valve stop

..........
........
O.D. of crankcase outlet valve stop
0.4990 - 0.5010 in

0.4978 - 0.4988 in
12.675 - 12.725 mm

12.644 - 12.670 mm

.............
Crankcase outlet valve spring

...................
Tension at a length of 2.06 in (52.4 mm) 44 -54 lbs. 20 - 24,5 kg

...................
Diameter of pump shaft cam 1.4870 - 1.4875 in 37.770 - 37.783 mm

..............
I.D. of cam race 1.8004 - 1.8010 in 45.730 - 45.745 mm

...........
O.D. of cam race 2.235 - 2.245 in 56.769 - 57.023 mm

Thickness of thrust washer 0.087 - 0.091 in 2.21 - 2.31 mm

O.D. of stroke control valve seat 0.7045 - 0.7055 in. 17.894 - 17.920 mm

Printed in Germany
70 Hydraulic System Model 2120 Tractor
15-10 Hydraulic Pump and Transmission Oil Pump TM-4252 (Dec-70)

HYDRAULIC PUMP-Continued

........
.........
Bore dia. for stroke control valve seat
Dimensions of new parts

0.7015 - 0.7025 in 17.818 - 17.844 mm

......................
O.D. of stroke control valve stop
Bore dia. for stroke control
valve stop

.......
0.743 - 0.745 in

0.750 - 0.752 in
18.87 - 18.92 mm

19.05 - 19.10 mm

..............
Stroke control valve spring
Tension at a length of 2.5 in (63.5 mm) 158 - 192 lbs. 72 - 87 kg

..................
Piston springs
Spring tension tolerance allowed
at a length of 1.25 in (31.8 mm) 0.15 lbs. 68 g

Pump shaft end play 0.004 - 0.038 in 0.1 - 0.9 mm

................
..................
TRANSMISSION OIL PUMP

..............
Dia. of driven gear shaft 0.6240 - 0.6250 in 15.850 - 15.875 mm

................
O.D. of driven gear 1.6940 - 1.6950 in 43.027 -43.053 mm

...................
I.D. of driven gear bushing 0.6265 - 0.6275 in 15.913 - 15.939 mm

.................
Thickness of driven gear 0.5075 - 0.5095 in 12.891 - 12.941 mm

................
O.D. of drive gear 3.0288 - 3.0308 in 76.932 - 76.982 mm

................
Bore dia. of drive gear 1.9965 - 1.9800 in 49.940 - 50.060 mm

.........
Thickness of drive gear 0.5075 - 0.5095 in 12.891 - 12.941 mm

...........
Width of drive gear keys 0.2834 - 0.2934 in 7.19 - 7.45 mm

Play between pump housing and gears 0.004 - 0.008 in 0.1 - 0.2 mm

O.D. of hollow power drive shaft 1.9651 - 1.9657 in. 49.914 - 49.929 mm

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Hydraulic Pump and Transmission Oil Pump 15-11

TORQUES FOR HARDWARE

HYDRAULIC PUMP Dimensions of new parts

Piston plugs 100 ft.lbs. 14 mkg

.................
Pump cover to pump housing, cap screws
1st stage 14.5 ft.lbs. 2 mkg

..................
2nd stage 36 ft.lbs. 5 mkg

Pump to front support, cap screws 85 ft.lbs. 11.7 mkg

Pump drive shaft attaching screw 32 ft.lbs. 4.4 mkg

V-belt pulley

..................
Special screws for pump drive in crankshaft

................
35 ft.lbs. 4.8 mkg

...............
Special screws in pump drive shaft 35 ft.lbs. 4.8 mkg

Pump drive coupler halves, cap screws 25 ft.lbs. 3.4 mkg

Hex. nuts for coupler halves, cap screws 25 ft.lbs. 3.4 mkg

TRANSMISSION OIL PUMP

Pump cover to clutch housing,

..............
cap screws . 35 ft.lbs. 4.8 mkg

Oil distributor (on machines with HIGH-LOW unit),

oil manifold (on machines with independent PTO) and
pump housing to pump cover, cap screws 35 ft.lbs. 4.8 mkg

CAPACITIES

Hydraulic pump capacity per revolution of

pump shaft
4-piston pump 0.69 cu.in. 11.3 cm3

.....................
8-piston pump 1.38 cu.in. 22.6 cm3

....................
Hydr, pump capacity at 2500 rpm engine
speed and 2050 psi (144 kg/cm2) operating
pressure

...............
4-piston pump 5.4 Imp.gals/min. 24.6 lit./min.

......
6.5 US. gals/min.
8-piston pump 10.8 Imp.gals/min. 49 lit./min.

..................
13 US.gals/min

Stand-by pressure . 2220 - 2280 psi 156 - 160 kg/cmÿ

Transmission oil pump capacity at

2500 rpm engine speed 6.6 Imp.gals/min 30.3 lit./min
8 US gals/min

Printed in Germany
70 Hydraulic System Model 2120 Tractor
15-12 Hydraulic Pump and Transmission Oil Pump TM-4252 (Dec-70)

............
SPECIAL TOOLS

.........
JD-Parts Depot

..............
Part number when ordering from
Manufacturer Description Use

......................
..........
L 48521 813* Mandrel Driving in needle sleeves of hydr.
pump

19.58-90.272 Driver as above

19.58-90.260** Special tool Checking oil pressure

* SERVICE TOOLS INC., 1901 INDIANA AVENUE, CHICAGO, ILLINOIS 60616, USA
** For details, see group 5

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Rockshaft 20-1

Group 20
ROCKSHAFT
GENERAL INFORMATION

The rockshaft with three-point hitch serves to raise NEUTRAL POSITION

and lower implements.
Inset "a" of fig. 1 shows the rockshaft in neutral
The load selector lever (see 12, fig. 1) is located to position.
the right of the tractor seat. It will obtain three
types of control: Depth (d), load-and-depth (LD), Pressure oil from the main hydraulic pump,
and load (L) as well as two intermediate positions: entering through oil passage 1 and flow control
one between "D" and "LD", the other between valve 16 reaches pressure valve 2. Rockshaft
"LD" and "L". This allows optimum adjustment cylinder and discharge valve 3 are filled with oil.
to varying soil conditions. When the system is set Note that check ball 15 retains trapped oil in the
for float position, the 3-point hitch will move cylinder, preventing rockshaft from settling.
freely.
RAISING THE ROCKSHAFT (DEPTH
When the system is set for depth control (selector CONTROL)
lever in position D), the position of the rockshaft is
in direct relation to the position of the control Move load selector lever 12 (fig. 1) to position "D"
lever on the quadrant. (depth control). This moves load selector link and
roller 5 to the top of cam follower 6. The cam
In either load control (L) or load-and-depth follower in turn rides against the rockshaft cam 7
control (LD), the rockshaft control valves receive which is attached to the rockshaft. The rockshaft
signals from the draft links of the 3-point hitch. cam closes pressure valve 2 through valve linkage
The draft links are connected directly to the load when the lift arms are raised to top position.
control shaft positioned through the bottom rear
of the transmission case on tapered bushings. When the rockshaft control lever 13 is moved to
Variation of pull on the draft links deflects the the rear, the valve linkage moves pressure valve 2
load control shaft. This deflection is picked up by from valve seat 18, against spring and oil pressure
the load control arm and transmitted to the rock¬ behind damping sleeve 17.
shaft valve linkage.
If the lift arms are to be raised only a small
The lowering speed of the rockshaft and amount, move the control lever just enough to
implement is regulated by the rate-of-drop screw "crack" the valve from its seat. Pressure oil flows
located on top of the rockshaft housing. from pressure valve 2 into a passage connected
with the rockshaft cylinder where it unseats check
A relief valve in the „ rockshaft housing relieves ball 15 and flows into the cylinder. The oil now
thermal expansion of oil in the rockshaft assembly, forces the piston rearward, causing piston rod and
thus preventing build-up of extreme pressures. crank arm to rotate the rockshaft and lift arms
upward.
The three-point hitch of the tractor is designed for
category II implements. It is available in a standard As the rockshaft rotates, the rockshaft cam 7
version or reinforced version, the latter having moves the cam follower 6 and load selector link
telescopic draft links. The standard version can be and roller 5 forward. This motion is transmitted
converted to category Iimplements by installing through the valve linkage, closing the pressure valve
bushings (see Operator's Manual). 2 and completing the depth cycle.

Printed in Germany
70 Hydraulic System Model 2120 Tractor
20-2 Rockshaft TM-4252 (Dec-70)

Fig. 1 — Oil Flow in Rockshaft Unit

a Neutral position 5 Load selector link with 12 Selector lever 19 Rockshaft crank arm
b Lowering (depth control) roller 13 Control lever 20 Pressure oil
c Load-and>depth control 6 Cam follower 14 Rockshaft piston 21 Pressure oil (system pressure)
1 Oil inlet 7 Rockshaft cam 15 Ball 22 Discharge oil
2 Pressure valve 8 Rockshaft 16 Flow control valve* 23 Pressure-free oil
3 Discharge valve 9 Adjusting screw of cam follower 17 Damping sleeve 24 Trapped oil
4 Rate-of-drop ball 10 Load control arm 18 Pressure valve seat
11 Load control shaft
* Only if equipped with 1.38 cu,in. <22.6 cmÿ) pump

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Rockshaft 20-3

Full upward rockshaft movement is limited by the LOAD CONTROL

shut-off rod which closes the pressure valve as soon
as the rockshaft crank arm 19 is still a specified Move selector lever 12 (fig. 1) in position "L"
distance away from the rockshaft housing (see (load control). This moves load selector link and
Specifications). roller 5 to bottom of the cam follower 6. The rock¬
shaft valve linkage now becomes independent of
The pressure valve 2 does not close abruptly the rockshaft cam rotation. Linkage signals now
because of the pressure differential between the come from the implement acting on the draft links,
front and rear of damping sleeve 17. As pressure oil load control shaft 11 and load control arm 10.
flows through an orifice in the sleeve, a gradual Moving the control lever 13 forward repositions
buildup occurs at the rear of the sleeve, moving the the valve linkage to open discharge valve 3 and
control valve toward valve seat 18 to the closed lowers the rockshaft and implement to the desired
position. This controlled pressure buildup behind working position.
the sleeve results in smooth, precise rockshaft
control. If the control lever is moved to a lower position,
the working depth will increase and if the control
The discharge valve 3 and check ball 15 trap oil in lever is moved to a higher position the working
the rockshaft cylinder to keep the lift arms from depth will decrease, resulting in higher or lower
lowering when rockshaft control lever is moved to load, respectively.
neutral.
NOTE: The horizontal soil resistance which the
LOWERING THE ROCKSHAFT (Depth Control) implement (e.g. ploughJ has to overcome auto¬
matically maintains a constant load via the
Inset "b" of fig. 1 shows lowering the rockshaft. mechanical and hydraulic controls.

If the control lever 13 is moved forward, the valve A change in soil resistance simultaneously leads to
linkage opens discharge valve 3 and the lift arms a change in the force applied to the draft links.
are lowered, the distance being determined by the Depending on whether this force is increased or
control lever. decreased, the load control shaft 11 will react
differently. Via the load control arm 10 and the
As the discharge valve is opened, the weight of the load selector link and roller 5, the lift arms will
implement on the draft links and lift links rotates either be raised or lowered until the soil resistance
the rockshaft and crank arm, moving the piston corresponding to the position of the control lever
forward. Return oil under slight pressure moves has again been reached.
out of the rockshaft cylinder past the discharge
valve. The rate of drop is determined by adjusting The pressure valve 2 and discharge valve 3 will now
special cap screw and ball 4. remain closed until the valves receive a signal that
is more or less than the established load.
As the rockshaft rotates and the lift arms are
lowered, the spring-loaded cam follower 6 moves If the soil resistance increases, the signal is picked
rearward, following the rockshaft cam 7. The valve up by the load selector link and roller 5 which is
linkage moves away from discharge valve, closing moved rearward to open pressure valve 2 and raise
the valve and completing the lowering cycle when the lift arms. As the lift arms are rising and draft is
the lift arms have reached the point determined by decreasing, the deflection of the load control shaft
the position of the control lever. 11 is lessened and the valve linkage moves forward
to a neutral position, allowing the pressure valve to
close.

Printed in Germany
70 Hydraulic System Model 2120 Tractor
20-4 Rockshaft TM-4252 (Dec-70)

If the soil resistance decreases, the draft signals In float position the mounted implement can
will by less than required to keep working depth move freely upward. The working depth of the
constant. Therefore, the load selector link and implement is controlled by the appropriate cut and
roller will be moved forward and will open the angle and/or by supporting wheels or skids.
discharge valve to lower the lift arms. The lowering
cycle will continue until the predetermined load is DIAGNOSING MALFUNCTIONS
reached, whereupon the valve linkage will be
moved rearward to close discharge valve 3. For diagnosing malfunctions see group 5.

LOAD-AND-DEPTH CONTROL REPAIR

Inset "c" of fig. 1shows the rockshaft in load-and- Remove rockshaft assembly as explained in section
depth control position. 10, group 25.
Move load selector lever 12 (fig. 1) in position NOTE: Before lifting rockshaft off transmission
"LD" (load-and-depth control). This moves the case, move selector lever in position "L".
load selector link and roller 5 to the center of the
cam follower 6. In this position both depth control Disconnect control lever from its shaft. Disconnect
(via rockshaft cam 7) and load control, caused by selector lever from its shaft. Remove cap screws
the draft load and the deflection of load control attaching quadrant to rockshaft housing.
shaft 11 transmitted to load selector link 5, will be
only partly effective (approx. one half each). Turn rockshaft assembly upside down.

This is due to the fact that the movement trans¬ Drive out spring pin securing pivot pin on lever
mitted by rockshaft cam 7 to cam follower 6 can shaft.
cause only approx. one half of the longitudinal
movement of the load selector link in depth Remove remote cylinder adapter from left side of
control since the cam follower is supported in the rockshaft housing.
center by the load selector link. On the other hand,
the longitudinal movement of the load selector link Unhook valve actuating lever return spring from
caused by load control shaft 11 is only approx. one the special pin fitted in the rockshaft housing.
half the movement in load control.
Loosen adjusting screw of shut-off rod.
The mechanical and hydraulic control cycles
during raising and lowering of the lift arms and Remove cap screw at outside front holding rock¬
implements and the neutral positions between the shaft cylinder and valve housing and also internal
raising and lowering cycles are principally the same locking screws.
in "load-and-depth control" as in the other two
control systems. They differ only in that both Lift rockshaft cylinder and valve housing off
systems are simultaneously effective in every rockshaft housing (the piston rod remains attached
raising or lowering cycle. to the crank arm and pulls away from the piston);
at the same time work load selector arm free of
The load-and-depth position is the best position for slotted load selector link.
most operations requiring load-compensated depth
control. CAUTION: Take care not to lose throttle valve ball
as it will fall free.
FLOAT POSITION

For float position of the rockshaft, move load

selector lever in position "D" and rockshaft
control lever to its most forward position.

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Rockshaft 20-5

ROCKSHAFT CYLINDER AND VALVE HOUSING

l 51 541

Fig. 2 — Exploded View of Rockshaft Cylinder and Valve Housing

Rockshaft cylinder 8 O-rings IS Thermal relief valve 23 Back-up ring (2 used)
and valve housing 9 Seal 16 Seal ring 24 Plug (2 used)
Balls 10 Connector for remote 17 Cap screw 25 O-ring (2 used)
O-ring hydraulic cylinder 18 Valve seat (2 used) 26 Snap ring (2 used)
Seal ring 11 Plug 19 Valve body (2 used) 27 Plug
Hex. nuts 12 Plug 20 Damping sleeve (2 used) 28 Plug
Link 13 O-ring 21 Valve spring (2 used) 29 Seal ring
Special screw 14 Spring 22 O-ring (2 used) 30 Seal ring
(rate of drop) 31 Locking screws (4 used)

Pull piston out of rockshaft cylinder. and valve seat 18 out of housing bore. Remove
second valve in the same way.
NOTE: If it is difficult to pull the piston out of
cylinder, remove plug 27 (fig. 2) of rockshaft Store pressure and discharge vatve parts separately.
cylinder and drive out piston.
Check rockshaft cylinder and valve housing 1for
Remove plug 12 (fig. 2) of check valve and take cracks and damage as well as piston bore for sco¬
spring 14 as well as ball 2 out of the housing. ring and wear. Clean all oil channels with compres¬
sed air.
Remove relief valve 15.
Check valve bodies 19 for wear and damage, espe¬
Remove valve linkage. cially seat face. If discharge valve seat is leaking,
lift arms may drop. If pressure valve seat is leaking,
Remove snap ring 26 of pressure or discharge valve lift arms may creep upward.
from groove of valve housing bore. Then take plug
24, spring 21, damping sleeve 20, valve body 19

Printed in Germany
70 Hydraulic System Model 2120 Tractor
20-6 Rockshaft TM-4252 (Dec-70)

Check valve seats 18 and damping sleeves 20 for Check adjusting cam 7 for wear or damage. Wear at
wear and scoring. Replace, if necessary. cam may make it more difficult to adjust the con¬
trol lever neutral range. Check all joints for flatten¬
Check resilience of valve springs 14 and 21 (see ed spots or damage.
Specifications).

Examine check valve ball 2 for damage and wear.

Excessive check ball wear will result in leakage ROCKSHAFT ASSEMBLY AND LIFT ARMS
around the ball and thus cause rockshaft settling
when engine is shut off.

Check operation of thermal relief valve 15:

Connect valve to a nozzle tester with a measuring
range up to 5000 psi (350 kg/cm2) or to a 14 13
hydraulic hand pump with an appropriate gauge.
Raise the pressure slowly. The valve should not
open before a pressure of 3500 psi (246 kg/cm2)
has been reached and not after a pressure of 4500
psi (315 kg/cm2). The valve should close again as
soon as pressure has been reduced to 2500 psi (175
kg/cm2).
Replace all O-rings of plugs. Be sure to replace seal L 50 072
ring of pressure oil inlet bore, too.

ROCKSHAFT CYLINDER AND VALVE Fig. 4 — Exploded View of Rockshaft Assembly

HOUSING LINKAGE 1 Rockshaft 8 Washer
2 Control arm 9 Spacer plate
3 Lift arms 10 Rockshaft piston
4 Cap screws 11 Oring
5 Special washers 12 Back-up ring
6 Cam 13 Piston rod
7 Cap screw 14 Spring pin

CAUTION: Before removing the rockshaft, mark

position of lift arms 3 (fig. 4) and control arm 2 in
relation to rockshaft 1 to facilitate proper
reassembly.

Remove lift arms from rockshaft.

Remove cam 6 and spacer 9 from rockshaft. Pull
rockshaft out of hydraulic housing. Thereby con¬
trol arm 2 slides off the rockshaft splines. Remove
control arm, rockshaft, back-up rings, O-rings and
L 49567
bushings (see 4, 5 and 6, fig. 5).
Fig. 3 — Exploded View of Rockshaft Cylinder and Remove spring pin 14 (fig. 4) attaching piston rod
Valve Housing Linkage
13 to control arm 2 and remove piston rod.
1 Pivot pin 10 Special washer (convex
2 Arm 11 Washers Check rockshaft 1 as well as lift arms 3, especially
3 Snap rings 12 Spring
4 Load selector link 13 Return spring splines, for wear or other damage and replace, if
with roller 14 Rod necessary.
5 Link 15 Rod tube
6 Operating link 16 Clamping piece
7 Adjusting cam 17 Pin
Examine cam 6 and piston rod 13 for damage.
8 Special nut 18 Adjusting screw
9 Special adjusting 19 Jam nut Remove O-ring 11 and back-up ring 12 of pistor
screw
and discard.
Check parts of rockshaft cylinder and valve
housing linkage for wear, distortion or defor¬ Check piston for scores or excessive wear.
mation.
Insert new back-up ring and O-ring in pistoi
groove.

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Rockshaft 20-7

ROCKSHAFT HOUSING ASSEMBLY

L 51 543

Fig. 5 — Exploded View of Rockshaft Housing

l Cap screws 13 Special screw 24 Spool of flow control valve*
2 Oil filler cap (regulating rate of drop) 25 O-ring
3 Seal ring 14 Lock nuts 26 Plug
4 Back-up rings 15 Clamp 27 Plug
5 O-rings 16 Seal ring 28 Plug
6 Bushings 17 O-ring 29 O-ring
7 Cap screws 18 Start safety switch 30 Hex. nut
8 Special screw 19 Aluminium washer 31 Washer
9 Rockshaft housing (use as required) 32 Selector lever
10 Cap screw 20 O-rings 33 O-ring
11 Cap screws 21 Plugs 34 Bushing (selector lever shaft)
12 Cap screws 22 Shim (use as required) * 35 Selector lever shaft
23 Spring* 36 Gasket

* Available only if machine is equipped with 1.38 cu.in. (= 22.6 cm®) hydraulic pump

Printed in Germany
70 Hydraulic System Model 2120 Tractor
20-8 Rockshaft TM-4252 (Dec-70)

Check rockshaft housing 9 (fig. 5) for cracks or ASSEMBLY

other damage.
ROCKSHAFT CYLINDER AND VALVE
Inspect bushings 6 of rockshaft. If necessary, HOUSING (Fig. 2).
replace bushings. The new bushings should easily
turn in rockshaft housing bores. Insert seat 18 of pressure or discharge valve, small
end first, in the appropriate valve housing bore.
Check O-rings 5 of rockshaft. Check if back-up Insert valve body 19, small end first, in its valve
rings 4 are twisted or worn. seat. Slide damping sleeve 20, tapered end first,
and valve spring 21 in bore. Insert O-ring in exter¬
Check spool 24 of flow control valve (if equipped) nal groove of plug 24 and install one O-ring and
for damage. Renew all O-rings, back-up rings and one back-up ring in plug bore. Carefully insert plug
seal rings. 24 in bore of housing, and, at the same time, valve
19 in the plug. Then install snap ring 26.
Check resilience of valve spring 23.
Install the other valve in the same sequence.
Check bushing 34 of selector lever shaft and re¬
place, if necessary. Press in new bushing so that the Install back-up ring 12 (fig. 4) and O-ring 11 on
end which is not tapered is flush with outer face of rockshaft piston 10.
rockshaft housing.
Coat piston and cylinder with clean transmission
ROCKSHAFT CONTROL LEVER oil of the grade used in the tractor and slide piston
QUADRANT into cylinder.

Install ball 2 (fig. 2), spring 14 and plug 12 of

check valve.

ROCKSHAFT CYLINDER AND VALVE

HOUSING LINKAGE (Fig. 3)

Install linkage on bearing pin of rockshaft housing.

Make sure linkage moves easily.

ROCKSHAFT ASSEMBLY AND LIFT ARMS

(Fig. 4)

IMPORTANT! It is extremely important to ob¬

serve the marks for identifying the proper position
of lift arms and control arm in relation to the rock¬
L 50 230 shaft when assembling.

Fig. 6 — Exploded View of Control Lever and Guide rockshaft into bushings in the hydraulic
housing, pushing the control arm onto the
Quadrant rockshaft splines. Secure cam 6 and spacer plate 9
1 Control lever 11 Spring washers on rockshaft 1and piston rod 13 on control arm 2.
2 Handle 12 Washers
3 Control lever shaft 13 Special screw
4 Spring pin 14 Locking knob CAUTION: Do not tighten cam securing screw 7
5 Cap screw 15 O-ring until the lift arms have been installed.
6 Washer 16 Snap ring
7 Hex. nut 17 Lock washer (3 used)
8 Bushing 18 Cap screw (3 used)
9 Friction pin 19 Cotter pin
10 Quadrant

Inspect quadrant 10 for damage. If necessary,

replace bushing 8. Check control lever shaft 3 for
wear. Check serviceability of spring washers 11. If
necessary, replace parts.

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Rockshaft 20-9

Guide new O-rings, covered with grease, over rock- ring 4 and O-ring 3 on special screw 7 as shown in
shaft and press into grooves in rockshaft housing. fig. 2. Turn lock nuts sufficiently on special screw
Push both back-up rings onto the rockshaft and 7 so that the O-ring is seated in screw groove.
drive into rockshaft housing, taking care not to
damage the O-rings. Turn pre-assembled special screw into rockshaft
housing until it is seated on the ball. Turn down
Slide lift arms onto rockshaft splines and tighten lower nut until it starts to compress seal ring 4.
cap screws to the specified torque. Then tighten nut another 1/2 to maximum 1turn.
Place link 6 in extreme right front position and
After installing lift arms and tightening cap screws, tighten upper nut against link.
slide rockshaft to the left until the right-hand lift
arm lies against the rockshaft housing. Then swing Insert control lever shaft 3 (fig. 6) in housing bore
control arm 2 to the rear of the rockshaft housing. and in bore of pivot pin. Secure shaft by means of
Position spacer plate 9 so it contacts control arm. spring pin 4.
Tighten cap screw 7 attaching rockshaft cam and
spacer to the specified torque. Connect control lever to its shaft.

INSTALLING ROCKSHAFT CYLINDER AND Connect selector lever to its shaft.

VALVE HOUSING
Screw remote cylinder adapter in bore on left side
Install flow control valve*, using the same number of rockshaft housing.
of shims 22 (fig. 5) as removed previously. Insert
shims 22 in bore of rockshaft housing. Then install ADJUSTING UPPER LIFT LIMIT OF LIFT
spring 23, valve spool 24 (open end first) and plug ARMS
26.
Turn rockshaft by moving lift arms until there is a
Place seal rings 29 and 30 (fig. 2) on flange of valve clearance of 0.08 to 0.12 in. (2 to 3 mm) between
housing. Insert seal ring 16 in valve housing bore crank arm and rockshaft housing. Jam a sheet
for front attaching screw 17. metal strip, 0.08 to 0.12 in. (2-3 mm) thick,
between housing and crank arm.
Install rockshaft cylinder and valve housing in
rockshaft housing, simultaneously inserting load Set valve adjusting cam 7 (fig. 3) with special
selector arm in slot of load selector link and piston adjusting screw 9 so that there will be a small gap
rod in piston bore. between one cam and the throttle valve when the
pressure valve contacts the other cam, and vice-
Install front attaching screw 17 (fig. 2) of valve versa. Lock valve adjusting cam in this position (e.
housing and tighten carefully. g. by means of a screwdriver inserted between valve
housing and cam). Position clamping piece 16 of
IMPORTANT! Tighten this front attaching screw shut-off rod against tube 15. Tighten adjusting
first, before tightening the four locking screws 31 screw 18 and secure with jam nut 19. Remove
(fig. 2), to draw rockshaft cylinder and valve sheet metal strip inserted between crank arm and
housing into proper position in the rockshaft housing.
housing.
Check adjustment by turning rockshaft so that
Tighten rockshaft cylinder and valve housing crank arm moves away from housing, then turn in
attaching screw and locking screws to the specified opposite direction and observe pressure and
torque. throttle valves. As soon as clearance between crank
arm and housing has narrowed to 0.08-0.12 in. (2-3
Hook return spring into special bolt located in mm), the valve adjusting cam must close the
rockshaft housing. pressure valve with the throttle valve just remaining
closed.
Insert rate-of-drop valve ball in rockshaft cylinder
bore through tapped hole of rockshaft housing. INSTALLATION
Install lock nut 5, link 6, second lock nut 5, seal
Move selector lever in position "L" (load control).
Install rockshaft assembly as explained in section
10, group 25. Tighten screws to the specified
* Only on machines equipped with a 1.38 cu.in. (= torque.
22.6 cm3) hydraulic pump

Printed in Germany
70 Hydraulic System Model 2120 Tractor
20-10 Rockshaft TM-4252 (Dec-70)

ADJUSTMENT

Check oil level before making adjustments on the

rockshaft.

Run engine to bring oil to operating temperature.

Check for leaks.

The following is a list of adjustments to be made

on the rockshaft after installation on the tractor.
They should be made in the order shown below.

1. Load control arm negative stop adjustment

2. Adjustment of rockshaft control lever neutral
range
3. Control lever adjustment
4. Load control adjustment
5. Rate-of-drop adjustment

NOTE: Before adjusting rockshaft, make a pre¬

liminary adjustment of rate-of-drop valve as Fig, 7 — Adjusting Valve Linkage and/or Control
follows: Turn down on special adjusting screw so Lever Neutral Range
that the ball is pressed on its seat, then back off 1 Upper quadrant rim
one turn. 2 Adjusting screw

(1) LOAD CONTROL ARM NEGATIVE STOP

ADJUSTMENT Run engine at 2000 rpm and move load selector
lever to position "D". Pull control lever back until
If the load control arm negative stop screw has lift arms just start to move upward. Mark this
been backed off, adjust load control arm as des¬ position on the upper quadrant rim 1 (fig. 7).
cribed below under "Load Control Adjustment". Advance control lever until the lift arms just begin
to settle. Mark this position, too, on the quadrant
IMPORTANT: If the load control arm negative rim. The distance between these two marks is the
stop screw is not adjusted correctly, this will rockshaft control lever neutral range. For proper
adversely affect the remaining adjustments. neutral range see Specifications.

(2) ROCKSHAFT CONTROL LEVER NEUTRAL If necessary, reduce control lever neutral range,
RANGE ADJUSTMENT and consequently valve clearance, by turning
adjusting screw counterclockwise. Increase valve
The rockshaft control valve linkage must be clearance, and consequently neutral range, by
adjusted to obtain a clearly defined neutral range turning adjusting screw clockwise.
for the rockshaft control lever (see Specifications).
This is obtained by setting a specified clearance NOTE: To facilitate adjustment, insert guide tube
between the valve adjusting cam and the valves. No. 19.58-90.615 in rockshaft housing bore and
slide over adjusting screw.
Adjust as follows:

Remove plug 4 (fig. 8) from rockshaft housing.

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Rockshaft 20-11

(3) ADJUSTING ROCKSHAFT CONTROL (4) LOAD CONTROL ADJUSTMENT

LEVER
This adjustment is required to assure proper rock¬
Run engine at 2000 rpm. Place selector lever in shaft response to varying load conditions.
position "D" and move rockshaft control lever for¬
ward until lift arms have fully dropped. Loosen
hex. nut 3 (fig. 8) which secures the control lever
to the lever arm. Pull the control lever to the rear
until a specified distance is obtained between front
end of quadrant slot and control lever friction pin
(see "a", fig. 8 and Specifications).

Fig. 9 — Cam Follower Adjusting Screw

1 Adjusting screw

Remove oil filler cap from rockshaft housing. Run

engine at 2000 rpm and put load selector lever in
bottom position "L". Move rockshaft lever for¬
Fig. 8 — Adjusting Control Lever ward to lower the lift arms and then slowly back
a Distance between control lever friction pin and until clearance between control lever friction pin
front end of quadrant slot and rear end of quadrant slot is as specified (see
1 Quadrant slot "a", fig. 10 and Specifications).
2 Selector lever in "D" position
3 Hex. nut
4 Plug

Leave control lever fixed in position.

Tum control lever arm slowly to the rear until lift

arms just begin to rise. Then re-tighten hex. nut 3.

Pull control lever back fully into lift position. The

lift arms should now move to their highest position
and at that point there should be a small gap
between the rear end of the quadrant slot and the
control lever friction pin. Now move rockshaft
control lever fully down (lowering position). If
dimension "a" (fig. 8) between front end of
quadrant slot and control lever friction pin is not
as specified (see Specifications), adjust control Fig. 10 — Positioning Rockshaft Control Lever for
lever as explained above. Cam Follower Adjustment
a Distance between control lever friction pin and
rear end of quadrant slot
1 Load selector lever in "L" position

Printed in Germany
70 Hydraulic System Model 2120 Tractor
20-12 Rockshaft TM-4252 (Dec-70)

Should the lift arms start to rise before this lever (5) RATE-OF-DROP ADJUSTMENT
position is reached, turn cam adjusting screw 1(fig.
9) counterclockwise so that the lever can be moved The rate of lift arm and implement drop can be
back without the lift arms rising. adjusted by the special cap screw located just for¬
ward of the operator's seat on the rockshaft
With the control lever held in the position shown housing.
in fig. 10, turn adjusting screw 1(fig. 9) clockwise
until the lift arms begin to rise. Then tighten To increase lift arm and implement rate-of-drop,
adjusting screw lock nut. turn the special cap screw counterclockwise. To
reduce the rate-of drop, turn clockwise.
NOTE: Use special wrench No. 19.58-90.614 to
hold and tighten adjusting screw lock nut.

LOAD CONTROL MECHANISM

l 51 544

Fig. 11— Exploded View of Load Control Mechanism

1 Load control shaft 9 O-ring 16 Cam follower

2 Spacers 10 Control arm pivot 17 Return spring
3 Seal rings 11 Load control arm 18 Pin
4 O-rings 12 Snap rings 19 Front pin
5 Bushings 13 Cam follower 20 Rear pin Only on machines equipped
6 Special pin adjusting screw 21 O-ring with dual, independent
7 Load control arm 14 Extension 22 Lock nut PTO for 540 and 1000 rpm
negative stop screw 15 Spring pin 23 Cap screw
8 Lock nuts

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Rockshaft 20-13

REPAIR Check control arm 11 for wear or damage.

Remove 3-point hitch. Check special pin 6 for rough spots where in
contact with load control shaft. Check extension
Remove rockshaft assembly, see section 10, group 14 for wear and smooth off any roughness.
25.
Check to see that load control shaft 1 is un¬
Remove left-hand final drive, see section 10, group damaged and still perfectly straight, replace if
25, so that pivot pin 10 (fig. 11) supporting damaged or bent.
control arm can be withdrawn.
Check spacers 2, on which the draft links are
Remove return spring 17 of cam follower. carried, for wear and replace as necessary.

Withdraw control arm pivot 10 far enough to lift Check load control arm negative stop screw 7 or
control arm out of transmission case. both pins 19 and 20 for wear, especially on end
contacting load control arm. Replace O-ring 9 on
Push both spacers 2 from load control shaft. Using screw 7 or O-ring 21 on pin 20.
a suitable drift, drive load control shaft out of
transmission case and bushings. INSTALLATION

Remove load control arm negative stop screw from Coat control shaft with clean transmission oil,
transmission case (see figs. 12 and 13). On insert in bushings and slide through transmission
machines equipped with dual, independent PTO, case.
also remove pins 19 and 20 (fig. 11) from trans¬
mission case. CAUTION: Do not damage sealing rings.

Check bushings 5 in transmission case for wear or Push the two spacers on the ends of the load
damage. If required, drive old bushings from trans¬ control shaft protruding from the transmission
mission case (inserting drift through bore of other case.
bushing).
Lift control arm with extension and cam follower
Replace O-rings 4 and sealing rings 3. First insert into transmission case and insert control arm pivot.
new O-ring 4 in bushing 5, then compress sealing Install cam follower return spring.
ring 3 and install so that O-ring 4 seats on the outer
circumference of the sealing ring. Drive new Before installing the load control arm negative stop
bushing 5 complete with new sealing ring 3 and screw 7 (fig. 11) or both pins 19 and 20 and cap
new O-ring 4 into transmission case (chamfer to screw 23, coat O-ring 9 or 21 with clean transmis¬
inside), using a suitable driver. Take care when sion oil. Take care not to damage the O-ring when
driving in new bushing not to peen edges of installing stop screw 7 or pin 20. Do not tum in
bushing. screw 7 or 23 fully until final load control arm
adjustment has been made.

Printed in Germany
70 Hydraulic System Model 2120 Tractor
20-14 Rockshaft TM-4252 (Dec-70)

Install left-hand final drive, see section 10, group On tractors without dual, independent PTO:
25. Loosen lock nut 2 (fig. 12) and screw in negative
stop screw until it just touches the load control
Install rockshaft assembly, see section 10, group arm. Screw back 1/4 turn and tighten lock nut.
25.

Install 3-point hitch.

Install draft links, placing a bushing over both load

control shaft ends. Secure each link with a pin and
spring pin.

ADJUSTMENT

IMPORTANT: If control arm negative stop screw

is not properly set, this will adversely affect the
remaining rockshaft adjustments (see above).

Fig. 13 — Load Control Arm Negative Stop Screw

(On Tractors with Dual, Independent
PTO)
1 Negative stop screw 2 Lock nut

On Tractors with dual, independent PTO: Loosen

lock nut 2 (fig. 13) and screw in negative stop
screw until front pin 19 (fig. 11) touches the load
control arm. Screw back 1/3 turn and tighten lock
nut.
Fig. 12 — Load Control Arm Negative Stop Screw NOTE: Contact between screw and control arm
(On Tractors without Dual, Independent can be felt more easily by inserting a screwdriver
PTO) into the oil filler hole and holding it against upper
1 Negative stop screw 2 Lock nut end of control arm.

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Rockshaft 20-15

THREE-POINT HITCH

Disassemble and assemble 3-point hitch as shown For adjustment and operation of 3-point hitch, see
in figs. 14 and 15. Operator's Manual.
10

1 51546

Fig. 14 — Exploded View of 3-Point Hitch (Cat. II)

1 Center link bracket 10 Quick-lock pin 19 R. H. lift link 28 Spring clips
2 Cap screw 11 Headed pin 20 Bali 29 Bushings
3 Pin 12 Leveling handle 21 Washer 30 Draft links
4 Spring pin 13 Shaft 22 Washer 31 Quick-lock pins
5 Center link front end 14 Groove pin 23 Bushing 32 Quick-lock pins
6 Center link body 15 Pin with handle 24 L. H. lift link 33 Pins
7 Center link rear end 16 Ball housing 25 Lift link bodies 34 Spring
8 Handle 17 Ball joint 26 Plates 35 Bracket for towing assy.
9 Bushing 18 O-ring 27 Pins 36 Bushings (for converting to cat. I)

Printed in Germany
70 Hydraulic System Model 2120 Tractor
20-16 Rockshaft TM-4252 (Dec-70)

Fig. 15 — Exploded View of 3-Point Hitch with Telescoping Draft Links, Cat. II
(See fig. 14 for text regarding keys 1to 35)

36 Telescoping draft link 40 Spring <2 used)

37 Snap ring (2 used) 41 Special washer <2 used)
38 Special washer <2 used) 42 Locking pin <2 used)
39 Special washer (2 used) 43 Locking device

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Rockshaft 20-17

................
SPECIFICATIONS

...............
ROCKSHAFT Dimensions of New Parts

O.D. of rockshaft piston 3.6120 to 3.6320 in. 91.975 to 92.025 mm

......................
I.D. of rockshaft cylinder 3.6255 to 3.6285 in. 92.086 to 92.166 mm
Springs of pressure and discharge valves
Resilience at a spring length of

.....................
0.875 in. (22 mm) 11to 13 lbs. 4.5 to 5.5 kg

Check valve spring

Resilience at a spring length of

.....................
2.65 in. (65 mm) 12.5 to 15.5 lbs. 5.6 to 7 kg

Spring of flow control valve*

Resilience at a spring length of
0.79 in. (20 mm) 11.7 to 14.3 lbs. 5.3 to 6.5 kg

Max. permissible drop of lift arms

..........
within 15 minutes, measured between
lift arm bores (engine shut-off and
rockshaft under full load) 2.5 in. 64 mm

Opening pressure of thermal relief valve 3500 to 4500 psi. 246 to 315 kg/cm2

........................
ADJUSTMENTS
ADJUSTING CONTROL LEVER NEUTRAL RANGE

Neutral range 0.157 to 0.236 in. 4 to 6 mm

(Rotating adjusting screw 1/4 turn varies
control lever neutral range by
0.156 in. = 4 mm)

ADJUSTING ROCKSHAFT CONTROL LEVER

Distance between control lever friction pin

and front end of quadrant slot (see fig. 8) ... 0.3 in. 8 mm

ADJUSTING LOAD CONTROL RESPONSE

Distance between control lever friction pin

and rear end of quadrant slot (see fig. 10) .............. 3.62 in. 92 mm

* Available only if machine is equipped with 1.38 cu. in. (22.6 cm3) hydraulic pump

Printed in Germany
70 Hydraulic System Modell 2120 Tractor
20-18 Rockshaft TM-4252 (Dec-70)

ADJUSTING LOAD CONTROL ARM

Turn in control arm negative stop screw

until it contacts arm, then back off
on tractors not equipped with dual,
independent PTO by 1/4 turn
on tractors equipped with dual,
independent PTO by 1/3 turn
ADJUSTING UPPER LIFT LIMIT

Pressure valve should close when distance

between cam follower and rockshaft housing is ....... 0.08 to 0.12 in, 2 to 3 mm

Rockshaft cylinder and valve housing

to rockshaft housing, cap screws

Lift arms to rockshaft, cap screws

...................
TORQUES FOR HARDWARE

..................
...............
35 ft.lbs.

85 ft.lbs.
4.8 mkg

11.7 mkg

...........
...............
Spacer and cam to rockshaft, cap screw

Rockshaft housing to transmission

case, cap screws .
10 ft.lbs.

85 ft.lbs.
1.4 mkg

11.7 mkg

J D Parts Depot

19.58-90.615
19.58-90.614
................
Part No. when ordering from
Manufacturer
SPECIAL TOOLS

Description

Guide tube
Special wrench ....
Use

Adjusting rockshaft unit

ditto

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Selective Control Valves (Spool Type) 25-1

Group 25
SELECTIVE CONTROL VALVES
(Spool Type)
GENERAL INFORMATION
The tractor may be equipped with the following 33, junction block 29, a pinion shaft 37 and a rack
selective control valves: 13 each. The rack splines are facing in the same
direction (fig. 3). The oil passages of the lower
1. One single selective control valve (see fig. 2) control valve are open whereas the upper valve is
closed on one side.
2. Two single selective control valves (see fig. 3)
If the tractor is equipped with a dual selective
3. One dual selective control valve (see fig. 4) control valve, the latter is made up of two single
valves. However, apart from end plate 15 there is
4. Two dual selective control valves (see fig. 4) only one pinion shaft 37 located between the two
racks whose splines face each other (see figs. 1and
5. One single selective control valve and one dual 4). The junction block 29 is not required as the
selective control valve. end plate 15 is level with the two valves.

If the tractor is equipped with two dual control

The above combinations are based on two standard valves, there are three valves with open oil passages
control valves made up of identical parts, except for and one valve closed on one (the top) side. More¬
the valve housing. The difference is that in one over, there are two end plates 15. No junction
housing the oil passages are open on both sides (see block is required (see fig. 4).
item 32, figs. 3 and 4) whereas in the other model
one side is closed (see item 1, figs. 2 and 4). If the tractor is equipped with a single and a dual
selective control valve, the parts shown in figs. 2
In addition, there are two different end plates (see and 4 are provided, with the exception that two
items 15 and 33, figs. 2 and 4). valves with open oil passages are used for the dual
control valve.
If the tractor is equipped with a single selective
control valve, the latter is provided with the end Operation of selective control valves see tractor
plate 15 and spacer 29 (see fig. 2). The oil passages Operator's Manual.
of the valve housing are open only on one side.

If the tractor is equipped with two single control

valves, the latter are provided with the end plate

Printed in Germany
70 Hydraulic System Model 2120 Tractor
25-2 Selective Control Valves (Spool Type) TM-4252 (Dec-70)

—
Fig. 1 Dual Selective Valve, Sectional View
1 Valve housing (closed on one side) 7 Shifting for "Raising" (pressure oil to annular
2 Valve housing (open on both sides) passage 4 and to quick coupler)
3 Valve spool 8 Shifting for "Lowering" (return oil from quick
4 Annular passage for oil flowing to or coupler and annular passage 5)
from Quick coupler 9 Screws for adjusting rate of drop
5 Pressure oil passage (metering return oil flow)
6 Return oil passage 10 Stop screw

OPERATION
In neutral position, oil from the pump is blocked in The bores in spool 3 allow leakage oil to drain off.
pressure oil passage 5 by valve spool(s) 3 (fig. 1). In this way leakage oil behind the spool cannot
cause a blockage and proper operation of the spool
If valve spool 3 is moved in the direction shown by is assured.
arrow 7, pressure oil flows from passage 5 into
annular passage 4 and thus to the quick coupler The position of the valve spool(s) in relation to the
and the implement connected to it, return oil passage and thus the rate of drop can be
adjusted by means of the adjusting screw(s) 9.
If the spool is moved in the direction shown by
arrow 8, annular passage 4 will be connected with
return oil passage 6. This allows the oil returning
from the implement and the quick coupler to flow
back into the transmission case.

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Selective Control Valves (Spool Type) 25-3

The pressure oil will not be affected by this adjust¬ REMOVAL

ment.
Remove lines leading to quick couplers at elbow
The valve spools are connected with a rack by adapters of control valves.
means of a cylindrical pin.
Remove both cap screws securing control valve to
The individual control valves are of the single type. junction block and lift off control valve assembly.
The dual valve consists of two single valves pro¬
vided with only one pinion shaft which is located Take care of seal rings installed between control
between the racks. Due to this arrangement, the valves or between bottom valve and junction block.
racks of the two single valves are moved into
opposite directions when operating the control Remove, only if required, inlet and return line at
lever. In this way the inlet port on one valve and junction block.
the outlet port on the other valve are opened and
vice versa. Thus the two single valves operate as a
dual valve (see fig. 1).

f/ 23
I 22
v
„
20
M
31ÿ@'

L 51 555
Fig. 2 — Exploded View of a Single Selective Control Valve
1 Valve housing and spool assembly 12 Washer 25 O-ring
(closed on one side) 13 Rack 26 Seal ring (4 used)
2 Washers 14 Pin 27 Cap screw (2 used)
3 Pressure spring 15 End plate 28 Lock washer (2 used)
4 Snap ring 17 Knob 29 Spacer housing
5 Spring cap 18 Seal ring (Teflon) 30 Elbow adapter
6 Plug 19 Pin 31 O-ring
7 O-ring 20 Hex. socket screw 34 Control lever
8 Lock nut (2 used) 37 Pinion shaft
9 Set screw 22 Lock ball 38 Cap screw
10 O-ring 23 Locking spring 39 Washer
11 V-packing 24 Stop screw

printed in Germany
70 Hydraulic System Model 2120 Tractor
25-4 Selective Control Valves (Spool Type) TM-4252 (Dec-70)

DISASSEMBLY Remove both hex. socket screws 20 of end plate

and lift end plate 15 as well as spacer housing 29
Drive pin 19 (fig. 2) out of end plate 15. away.

Remove stop screw 24, locking spring 23 and Drive pin 14 out of rack 13 and valve spool.
locking ball 22.
Screw spring cap 5 out of valve housing and re¬
Pull control lever 34 with pinion shaft 37 out of move all parts of the valve housing (see fig. 2).
end plate 15.

Remove control lever from shaft.

Fig. 3 — Exploded View of Two Single Selective Control Valves

1 Valve housing and spool 19 Pins 32 Valve housing and spool
assembly (closed on one 20 Hex. socket screw assembly (open on both
side) (2 used) sides)
11 V-pac kings 22 Locking ball (2 used) 33 End plate
12 Washers 23 Locking spring (2 used) 34 Control lever
13 Racks 24 Stop screw (2 used) 35 Cap screw (2 used)
14 Pins 25 O-ring (2 used) 37 Pinion shafts
16 Control lever 26 Seal rings (8 used) 38 Cap screw
17 Knob (2 used) 28 Lock washer (2 used) 39 Washers
18 Seal rings (Teflon) 29 Spacer housing 40 Cap screw

CAUTION: When disassembling two or more con¬ very close tolerances. Spools and housings are,
trol valves, be absolutely sure not to mix up valve therefore, available as matched sets only.
housings and spools as these parts are fitted with

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Selective Control Valves (Spool Type) 25-5

L 51557

Fig. 4 — Exploded View of a Dual Selective Control Valve

1 Valve housing and spool 19 Pin 28 Lock washer (2 used on
assembly (closed on one 20 Hex. socket screw each valve)
side) (2 used) 32 Valve housing and spool
11 V-packings 22 Locking ball assembly (open on both
12 Washers 23 Locking spring sides)
13 Racks 24 Stop screw 34 Control lever
14 Pins 25 O-ring 36 Cap screw (2 used)
15 End plate 26 Seal rings (8 used) 37 Pinion shaft
17 Knob 27 Cap screw (2 used) 39 Washer
18 Seal ring (Teflon) 40 Cap screw
41 Two dual selective control valves

INSPECTION
Check end plate 15 or 33, racks 13 and pinion
Check valve spool and housing for scores or other shafts 37 for serviceability. Replace parts, if
damage. If necessary, always replace spool and valve necessary.
housing as one set. Since they are lapped in, they
are available only as a matched set. ASSEMBLY

Discard V-packings 11 (figs. 2 to 4), seal rings 18 Assemble by reversing sequence of steps explained
and 26 as well as all O-rings. under "Disassembly", as shown in figs. 2, 3 or 4.

Check resilience of spring 3 and locking spring 23 Take care not to mix up valve spools or housings if
(see Specifications). more than one valve has been disassembled.

Printed in Germany
70 Hydraulic System Model 2120 Tractor
25-6 Selective Control Valves (Spool Type) TM-4252 (Dec-70)

Install new V-packings 11, new seal rings 18 and ADJUSTMENT

new O-rings.
Every selective control valve is provided with a
After assembly make sure valve spool moves freely screw (see item 9, figs. 1 and 2) for adjusting
in valve housing. return oil flow or rate of drop.

Install two washers 12 (see fig. 3) in control valve Extending or retracting a remote hydraulic
whose rack is located in bore of end plate 15 or 33 cylinder of 2.5 in. (63,5 mm) piston dia. and a
which does not have a protrusion. stroke of 8 in. (203 mm) should require at least 2
sec. Faster speeds may cause damage.
Install each pinion shaft 37 so that locking ball is
engaged in neutral position of valve spool or If this period is not attained, adjust both screws 9
control lever. of dual control valve for proper return oil flow and
correct remote cylinder lift cycle.

INSTALLATION On single control valves adjust return oil flow and

thus rate of drop according to the implement
When installing control valves, use new seal rings attached. The lift cycle period is indicated in the
26 (figs. 2 to 4). If several control valves are Operator's Manual of the implement concerned.
installed, mount valves with open sides facing each
other. Install valve with closed side on top. To decrease return oil flow and thus rate of drop,
turn in adjusting screw. Turn out screw to increase
Install oil lines. rate of drop.

..............
.......
SPECIFICATIONS
Dimensions of New Parts

...............
O.D. of valve spool at lands 0.4728 to 0.4737 in. 12.020 to 12.043 mm

O.D. of valve spool at V-packing location 0.3886 to 0.3900 in. 9.964 to 10.000 mm

.......................
I.D. of valve housing bore

Clearance between valve housing

and spool
0.4729 to 0.4738 in.

0.00012 to 0.00024 in.

12.023 to 12.046 mm

0.003 to 0.006 mm

Free length

..........................
Spring of valve spool

Resilience at a spring length of 0.57 in.

(14.5 mm)
1.04 in.

48 to 58 lbs.
26.5 mm

21.5 to 26.5 kg

Locking spring
Free length

.........................
Resilience at a spring length of 0.71 in.
(18 mm)

TORQUES FOR HARDWARE

1.3 in.
12.7 to 15.3 lbs.
33 mm

5.7 to 6.9 kg

of rockshaft, cap screws

............
Selective control valves to junction block

End plate to valve housing, hex. socket screws

20 ft.lbs.

11 ft.lbs.
2.5 mkg

1.5 mkg

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Selective Control Valve (Poppet Type) 30-1

Group 30
SELECTIVE CONTROL VALVE
(Poppet Type)
GENERAL INFORMATION Metering valve clogged
Clean valve
The tractor may be equipped with a single or dual
selective control valve for operating one or two Oil flow from selective control valve to cylinder
remote cylinders. The selective control valves are restricted or clogged
secured to the right-hand rear axle housing. Check oil line from selective control valve to
cylinder for foreign particles
Each selective control valve will operate either a
single or double-acting remote cylinder, and O-ring of remote cylinder piston faulty
provides two speeds of operation. Replace O-ring
The dual control valve will operate two cylinders CYLINDER WILL NOT RETRACT
independently or simultaneously. A control lever
operates each single selective control valve, having Remote cylinder stop valve seized
four detent positions. They are: (1) Neutral posi¬ Find cause and eliminate
tion, (2) fast extend position, (3) fast retract
position, (4) float position. Spring pin securing operating arm and shaft to
rocker sheared
The control lever will remain locked in "fast Install new spring pin
extend" or "fast retract" position until piston of
remote cylinder has completed its stroke. Then it Lower pressure valve or return valve of selective
automatically returns to the neutral position. The control valve leaking
control lever must be moved back manually from Clean valves, recondition valve seats and adjust
"float" to "neutral" position. operating cams
DIAGNOSING MALFUNCTIONS Top pressure valve or return valve of selective
control valve does not open
CYLINDER WILL NOT EXTEND Adjust operating cams
Insufficient oil flow or oil pressure CYLINDER SETTLES UNDER LOAD
Check oil flow to selective control valve
Valves of selective control valve leaking
Spring pin securing operating arm and shaft to
Clean valves, recondition valve seats and adjust
rocker sheared. operating cams
Install new spring pin
O-ring of remote cylinder piston faulty
Leaking top pressure valve or return valve
Replace O-ring
Clean valves, recondition valve seats, adjust
operating cams
Selective control valve housing porous
Renew housing
Lower pressure valve or return valve of selective
control valve does not open CONTROL LEVER DOES NOT RETURN TO
Adjust operating cams NEUTRAL POSITION
Selective control valve housing porous Control lever bent or seized
Renew housing Renew unserviceable parts

Control lever in float position

Move lever to "neutral" position

Remote cylinder detent piston seized

Clean piston

Printed in Germany
70 Hydraulic System Model 2120 Tractor
30-2 Selective Control Valve (Poppet Type) TM-4252 (Dec-70)

Pressure valve springs too weak CYLINDER OPERATING TOO FAST OR TOO
Check resilience of springs (see Specifications) SLOW

Return valves not seating correctly Metering valve incorrectly adjusted or sticking
Clean valves, recondition valve seats and adjust Clean and adjust metering valve
operating cams
Flow control valve sticking
Excessive leakage in remote cylinder Remove foreign material

CONTROL LEVER WILL NOT REMAIN IN Flow control valve spring worn or broken
DETENT POSITION Replace spring

Rocker detents worn or broken Pressure or return valves sticking or leaking

Replace defective parts Clean valves, recondition valve seats and adjust
operating cams
Oil flow rate set too high
Adjust metering valve Remote cylinder stop valve sticking
Check for fault and repair
Detent piston sticking
Remove foreign material

OPERATION

NOTE: The operation of one control valve, used NEUTRAL POSITION

with a double-acting remote cylinder, is explained
below. In neutral position, oil pressure is equal on both
sides of the metering valve. Both pressure valves 6
The selective control valve consists of: (fig. 1) and both return valves 7 are closed,
trapping oil on both sides of the remote cylinder
1. A metering valve 10 (fig. 1) which regulates oil piston, and retaining the piston in its present
flow to the remote cylinder and makes possible, position.
within a certain range, gradual regulation of the oil
flow. FAST EXTEND
2. A flow control valve compensating oil pressure Move control lever fully to the rear. This will turn
variations and ensuring constant flow of oil. the rocker assembly and open lower return valve as
well as lower pressure valve (see fig. 1).
3. Two return valves 7 provided with sealing cones
which control return oil flow from the remote The return valve opens a little earlier than the
cylinder. pressure valve, allowing return oil to flow into the
transmission case from one side of the piston
4. Two pressure valves 6 provided with sealing before pressure oil flows into remote cylinder from
cones which control pressure oil flow to the the other side.
remote cylinder.
Opening the pressure valve causes a pressure drop
5. A detent piston 4 for locking the selective in the circuit behind the metering valve. At the
control valve lever hydraulically in "fast extend" same time this pressure drop occurs behind detent
or "fast retract" position. piston 4, moving it into a detent of the rocker due
to the pressure differential.
6. A rocker assembly consisting of two cam plates,
four adjusting screws and the rocker itself. The
cam plates open the pressure and return valves. The
rocker is provided with detents for neutral and the
above positions.

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Selective Control Valve (Poppet Type) 30-3

1—15

Fig. 1— Selective Control Valve in "Fast Extend" Position

1 Notch for neutral position 4 Detent piston 8 Flow control valve 12 Pressure line to quick coupler
2 Control lever in "fast 5 Pressure oil from hydraulic 9 Return line from quick coupler 13 Transmission case (oil sump)
extend" position pump 10 Metering valve 14 Pressure oil
3 Detent for "fast retract" 6 Pressure valves 11 Max.quantity of oil 15 Return oil
position 7 Return valves

As soon as the remote cylinder reaches the end of lever is moved forward, opening the other return
its stroke, a temporary pressure build-up occurs at valve and other pressure valve.
the rear of flow control valve 8 and at the rear of
the opened pressure valve. This pressure build-up SLOW RETRACT
plus spring pressure closes the flow control valve.
At the same time pressure is now equal on both Move control lever only slightly forward. As the
sides of the detent piston so that cam plates rocker assembly rotates, the top return pressure
and rocker are moved, causing the control lever valves (see fig. 1) are opened. Pressure and return
and valves to return to their neutral position. oil from the remote cylinder is metered appropria¬
tely and the remote cylinder rod gradually retracts.
FAST RETRACT
In the "slow retract" position the detent follower
The operation is similar to that described under is held hydraulically between "neutral" and "fast
"fast extend", with the difference that the control retract" position.

Printed in Germany
70 Hydraulic System Model 2120 Tractor
30-4 Selective Control Valve (Poppet Type) TM-4252 (Dec-70)

When the control lever is released, the valves close FLOAT POSITION
and rocker assembly moves into neutral position.
Oil is trapped and the remote cylinder piston held When the control lever is in float position, both
in its position. return valves are opened by the cam plates and cam
followers while the pressure valves remain closed.
SLOW EXTEND Oil can now flow freely through the selective
control valve and from one side of the remote
The operation in position "slow extend" is similar cylinder to the other while the piston (together
to that of "slow retract", the difference being that with piston rod) can extend and retract freely (it
the control lever is pulled slightly to the rear. Thus "floats").
both lower valves (see fig. 1) are opened and oil
flows in the opposite direction. Pressure exerted by the valve springs against
pressure valves and operating cams mountains the
valves in "float" position until control lever is
moved back into neutral position by the operator.

REPAIR

DISASSEMBLY Remove valve guides, valve springs and pressure

and return valves from housing (see fig. 2).
Disconnect control lever from selective control
valve and remove control valve assembly.
NOTE: Identify all parts for assembly.

t 50327

Fig. 2 — Removing Bottom Cover Fig. 3 — Removal of Flow Control Valve and
Detent Piston
1 Metering valve
2 Flow control valve stop pin 1 Flow control valve
3 Bottom cover 2 Detent piston
4 Outer guide of detent piston
5 Flow control valve
6 Pressure valve Remove flow control valve and its spring.
7 Pressure valve spring
8 Return valve
Remove snap ring, outer guide of detent piston,
Remove bottom cover 3, complete with metering back-up ring, O-ring and detent piston (see fig. 3).
valve 1 and flow control valve stop pin 2 from
control valve housing.

NOTE: Remove bottom cover carefully as valve

springs are compressed. Removing the cover may
release valve guides.

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Selective Control Valve (Poppet Type) 30-5

Remove cam follower 1 (fig. 5) of detent piston

and drive inner guide of detent piston out of
housing with the aid of a brass pin.

INSPECTION

Housing 12 (fig. 6)

Check housing for cracks, scores or burrs.

Remove scores or burrs with a fine file. Replace

housing, if cracked or damaged in any other way.

Check valve seats for pitting or wear and re-lap, if

worn. Replace O-rings for sealing metering valve
and control lever shaft.

Fig. 4 — Removal of Rocker Assembly Top cover 3, bottom cover 34 and bracket
assembly 37 (fig. 6).
1 Rocker assembly 3 Spring pin
2 Cam plate 4 Control lever arm and shaft
Check bottom cover 34 (fig. 6) for cracks or any
Turn housing so that rocker assembly is at the top other damage and replace, if necessary. Replace
(see fig. 4). cover seals 33.

Drive out spring pin 3 (fig. 4) which secures If necessary, replace spring pin 42, which serves as
control lever arm and shaft 4 to rocker. Pull out a stop for the flow control valve. When driving in
arm and shaft. new spring pin, ensure that it protrudes far enough
from cover (see Specifications). If the spring pin
Remove special screws of cam plates and lift rocker does not protrude far enough from cover, jerky
out of housing. Remove cam plates. operation of the flow control valve will be the
result. Check side cover 48 for cracks or burrs.
Remove any burrs with a fine file and replace
cover, if necessary. Renew cover seal rings.

Check top cover 3 for damage and replace, if

necessary. Replace seal ring 4.

150 330'
Fig. 5 — Removal of Detent Piston Cam Follower
1 Cam follower

Printed in Germany
70 Hydraulic System Model 2120 Tractor
30-6 Selective Control Valve (Poppet Type) TM-4252 (Dec-70)

Sÿ-26-I g 43 ...45

32—®
22 33—ÿ
' -*ÿ
a
o.
—__ o

34 36—V E3--39

L 50331

Fig. 6 — Exploded View of Selective Control Valve Assembly

1 Special screw (2 used) 20 Outer guide 39 56 Control lever
2 Cap screw (2 used) 21 O-ring valve 57 Control lever arm and shaft
3 Top cover 22 Back-up ring 40 Thrust washer (for 2nd sel, control valve)
4 Seal ring 23 Snap ring 41 O-ring 58 Control lever (for 2nd sel.
5 Cam plate 24 Return valve (2 used) 42 Spring pin (flow control control valve)
6 Lock nut (4 used) 25 O-rings (6 used) valve stop) 59 Plug
7 Adjusting screws 26 Back-up rings (6 used) 43 Flow control valve 60 Seal ring
8 Spring pin 27 Spring (return valve- 2 used) 44 Flow control valve spring 61 Plug
9 Rocker 28 Pressure valve (2 used) 45 O-ring 62 O-ring
10 Cam plate -
29 Spring (pressure valve 2 used) 46 Back-up ring 63 Connector
U Special screw (2 used) 30 Spring cap (4 used) 47 Metering valve 64 Cap screw (3 used)
12 Housing 31 O-ring (4 used) 48 Side cover 65 Stop plate
13 Spring pin (5 used) 32 Back-up ring <4 used) 49 Cap screws 66 Hex.nuts (2 used)
14 Cam follower roller (5 used) 33 Seal ring (6 used) 50 Washers 67 Stop screw
15 Cam follower (detent piston) 34 Bottom cover 51 Control lever arm and shaft 68 Washer
16 Inner guide 35 Cap screw (2 used) 52 O-rings 69 Lock washer
17 Pins 36 Spring pin 53 O-rings 70 Lock plate
18 Detent piston 37 Bracket assembly 54 O-rings (4 used) 71 Spring washer
19 Detent piston assembly 38 Cap screw (4 used) 55 Plug (2 used) 72 Hex. nut
73 Stop plate

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Selective Control Valve (Poppet Type) 30-7

Valves (fig. 6)

Check all valves for wear or scoring and replace, if

necessary.

Check valve rollers for free movement, flat spots,

pitting or wear and replace, if necessary.

Check valve springs for serviceability and proper

resilience (see Specifications).

Detent Piston 19 and Cam Follower 15 (fig. 6)

Check detent piston assembly for wear or damage.

If piston pin has to be replaced, press new pin to
bottom of bore.

If spring pin of cam follower is replaced, drive in

new spring pin so that its slot is facing body of cam
follower.

Rocker 9, Cam Plates 5 and 10 (fig. 6)

Fig. 7 — Installation of Cam Plates
Check rocker detents for wear or damage. 1 Tapered end of cam plates
2 Cam with pointed lobe
Damaged detents can lead to "fast extend" or "fast 3 Side of housing not numbered
retract" becoming engaged although control lever
is in "slow extend" or "slow retract" position. If Install cam plates as shown in fig. 7. The tapered
necessary, replace rocker. end of cam plates must point toward front of valve
housing. Install cam plate with pointed lobe in
Check cam plates for wear or damage and replace, housing on side which is not numbered (see 3, fig.
if necessary. 7).

ASSEMBLY Install detent piston cam follower in housing.

Ensure that cam follower roller lies against rocker.
Assemble selective control valve by reversing
sequence of steps explained under "Disassembly". Install rocker and secure to cam plates by means of
special screws. Do not tighten special screws until
Use new O-rings and back-up rings. Dip all parts in cam plates have been adjusted. Install control lever
clean transmission oil, ensuring that all parts arm and shaft in housing and rocker so that the
remain thoroughly clean. arm faces top side of housing. Drive in spring pin
securing shaft to rocker.

Install pressure valves and return valves. Make sure

that valve rollers are properly seated on cam plates
(see fig. 1). Use the correct spring for each valve
(see Specifications).

Install flow control valve spring and flow control

valve.

Printed in Germany
70 Hydraulic System Model 2120 Tractor
30-8 Selective Control Valve (Poppet Type) TM:4252 (Dec-70)

A special adjusting tool JDH-15C is necessary to

make the valve adjustment. The tool's adjusting
screws hold the rocker in neutral position and the
valves on their seats during the adjustment.

NOTE: Special tool JDH-15C replaces special tool

JDH-15 and can be used on earlier model selective
control valves, too.

The adjustment is made as follows:

1. Remove bottom cover together with valve guides

and springs. Replace cover with special tool
JDH-15C and secure, making sure that adjusting
screws are not making contact.

2. Place selective control valve housing in a vice

Fig, 8 — Installation of Detent Piston Inner Guide with the open end facing upward. Turn the four
1 Special tool JDH-28 valve cam adjusting screws 7 (fig. 6) out and leave
loose.
Using special tool JDH-28, drive inner guide of
detent piston into relevant bore in housing (see fig. 3. Loosen cam plate special screws 11 (fig. 6) and
8). let cams rest on valve rollers, leaving the special
screws slightly loose,
Install detent piston, O-ring, back-up ring, outer
guide and snap ring. 4. Turn in the two special tool set screws on the
lever side of housing so as to hold the pressure and
Seat spring caps onto springs with off-set side of return valves on that side on their seats. Ensure
caps facing bottom valve cover. that the valve rollers are riding properly on the
cam. The rollers should turn, at the most, 90°
Secure bottom valve cover with flow control valve before contacting the cam plate.
stop pin (see Specifications) and metering valve to
housing (see fig. 2). IMPORTANT! The special tool set screws must be
tightened with the hand only. Under no circum¬
NOTE: If metering valve has been separated from stances should a wrench be used.
bottom valve cover, secure adjusting arm to
metering valve with long part of arm facing to the 5. Level the rocker in relation to the top housing
rear and metering valve slot (valve assembled) edge (see fig. 10). Gradually screw in detent piston
facing numbered side of control valve housing, set screw until detent piston follower just touches
the rocker. Move the rocker slightly until the
ADJUSTMENT follower is felt going in the neutral notch. Finger
tighten the screw to hold the rocker in neutral.
ADJUSTING PRESSURE AND RETURN
VALVES

The return and pressure valves are adjusted by

setting specified distances between curved surfaces
of cams and valve rollers while selective control
valve is in neutral position. This is to insure that
the return valves open before the pressure valves
during selective control valve operation.

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Selective Control Valve (Poppet Type) 30-9

7. Turn in two cam adjusting screws on lever side

of housing evenly until they just touch the cam.
Do not apply pressure. If screws appear uneven
against cam, reposition cam plate and retighten set
screws.

8. As soon as both set screws are contacting the

cam plate evenly, back off return valve set screw
1/8 turn and secure with lock nut. Then back off
set pressure valve screw 1/4 turn, securing also with
lock nut.

NOTE: The valve nearest to the "TOP" mark cast

on the valve housing is a pressure valve, the other
pressure valve being diagonally across from it (see
fig. 10).

1503
9. Tighten special screw securing cam plate to
rocker (see 1, fig. 10) and press cam against both
Fig. 9 — Setting Neutral Position set screws.

1 Set screw 3 Special adjusting tool JDH-15C NOTE: Each time the cam adjusting screws are
2 Dial indicator set at "0' 4 Set screws
backed off from the cams (creating a clearance
6. With the rocker held in neutral position, install a between cam plates and adjusting screws), cams
dial indicator with a minimum travel of 0.14 in. (= must be pried up against screws without loosening
3.6 mm). Seat dial indicator on control lever (see the cam-to-rocker attaching screws.
"a", fig. 11) at a distance of 2 in. (= approx.
50 mm) measured from the center of control lever
shaft. Align dial indicator so that there is a
sufficient distance to measure on both sides. Set
dial indicator at zero.

NOTE: It may be necessary to install control lever

in reverse position (turned 180°) to mount dial
indicator. Therefore, file a small groove in control
lever where contacted by indicator feeler point.

Fig. 11 — Adjusting Valves

a 2 in. (50 mm)

10. Loosen set screw of special adjusting tool for

detent piston and rotate rocker in both directions.

Fig. 10 — Adjusting Cam Plate Set Screws

1 Special screw for securing cam 3 Set screws for return valves
plate 4 Lock nut (4 used)
2 Set screws for pressure valves

Printed in Germany
70 Hydraulic System Model 2120 Tractor
30-10 Selective Control Valve (Poppet Type) TM-4252 (Dec-70)

As the cam touches the return valve roller, the dial 15. Reinstall valve springs, valve guides and cover.
indicator should read 0.01 to 0.016 in. (= 0.25 to Do not remove valves unless necessary. Valves must
0.40 mm). When the control lever or rocker is be readjusted, if they are removed and reinstalled.
moved in the opposite direction, the cam moves
against the pressure valve roller. Here the dial METERING VALVE ADJUSTMENT
indicator should read 0.037 to 0.043 in. (0.94 to
1.1 mm). To decrease play, turn adjusting screw Install selective control valve assembly.
inwards, to increase turn outwards. Tighten lock
nuts when valves are adjusted. Connect hydraulic tester (as described in section
70, group 5) to selective control valve and check
11. Check the "0" position on the dial indicator as oil flow (see Specifications).
explained in paragraphs 5 and 6.

12. Back off special adjusting tool set screws from VALVE LEAKAGE CHECK
control lever side. Tighten set screws on opposite
side to press return valve and pressure valve that Check valve leakage by connecting a hose, approx.
have not yet been adjusted against the valve seats. 2 ft. (70 cm) long, with pressure gauge to quick
Set dial indicator at zero. coupler outlet. With engine running, adjust
pressure (operating selective control valve) to 1500
13. Adjust second return valve and pressure valve psi. (105 kg/cm2).
in the same manner as before. The adjusting
dimensions are the same as above. If pressure valves are leaking, pressure will increase.
If return valves are leaking, pressure will decrease.
CAUTION: The pressure valves and return valves See Specifications for maximum permissible
are arranged "crosswise" (see fig. 10). leakage.

14. After having adjusted these valves, recheck "0"

position of dial indicator and adjustment of all
four valves. Readjust, if necessary.

.....
......
............
...
SPECIFICATIONS

.
Dimensions of new parts

................
O.D. of pressure or return valves 0.4960 to 0.4970 in. 12.600 to 12.624 mm

.......
.........
O.D. of flow control valve 0.7480 to 0.7490 in. 19.000 to 19.025 mm

O.D. of metering valve . 0.6235 to 0.6245 in. 15.837 to 15.862 mm

........
O.D. of detent piston . 0.7450 to 0.7470 in. 18.923 to 18.974 mm

Spring of pressure valve

Free length 1.812 in. 46 mm

........
Resilience at a length of 1.25 in. (31.8 mm) 36 to 44 lbs. 17 to 20 kg

Spring of return valve

Free length 1.562 in. 39.7 mm
Resilience at a length of 1.25 in. (31.8 mm) 19 to 23 lbs. 8.6 to 10.5 kg

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Selective Control Valve (Poppet Type) 30-11

SPECIFICATIONS (Cont'd)

.........
Dimensions of new parts

...........
Spring of flow control valve
Free length 2.94 in. 74.6 mm
Resilience at a length of 2.12 in. (= 54 mm) 41 to 49 lbs. 18.5 to 22 kg

Stop pin of flow control valve, exposed length 0.937 in. 24 mm

ADJUSTMENTS

Metering valve

and 2500 rpm engine speed .............

Flow rate at 1500 psi. (105 kg/cm2)

......
Metering valve arm in center position
1.66 Imp.gals./min.
2 US gals./min.

5 to 5.8 Imp.gals./min.
7.5 lit./min.

22.5 to 26.5 lit./min.

..................
6 to 7 US gals./min.

..................
Pressure and return valves
Play between pressure valve and cam
(in neutral position) 0.037 to 0.043 in. 0.94 to 1.10 mm
Play between return valve and cam

.....
(in neutral position) 0.010 to 0.016 in. 0.25 to 0.40 mm

Valve leakage
Pressure valve (set at 1500 psi. (105 kg/cm2) .... 500 psi (35 kg/cm2)/min. maximum increase
Return valve (set at 1500 psi. (105 kg/cm2) 500 psi (35 kg/cm2)/min. maximum decrease

TORQUES FOR HARDWARE

Bottom cover to control valve housing 20 ft.lbs. 2.8 mkg

Top cover to control valve housing 35 ft.lbs. 4.8 mkg

SPECIAL TOOLS
Part No. when ordering from
John Deere Parts Depot

19.58-90.279

19.58-90.280
. .
. .
Manufacturer

JDH-28*

JDH-15C*
......
..... ......
Description

Driver

Special setting tool .

Use

Installing inner detent guide

To set selective control valve

* SERVICE TOOLS, INC., 1901 INDIANA AVENUE, CHICAGO, ILLINOIS 60616, USA

Printed in Germany
Model 2120 Tractor Hydraulic System 70
TM-4252 (Dec-70) Remote Cylinder 35-1

Group 35
REMOTE CYLINDER
GENERAL INFORMATION

The double-acting remote cylinder has a piston of NOTE: For a detailed explanation of
2.5 in. (63.5 mm) dia. which is 8 in. (203 mm) remote cylinder design and operation see
long. The cylinder serves for operating a wide range under "Hydraulic Cylinders'' in "Funda¬
of implements. It is provided with an adjustable mentals of Service —Hydraulics" manual.
stop which allows a variable lift range from 0 to 8
in. (0 to 203 mm). For connecting the cylinder to the tractor see
Operator's Manual.
DIAGNOSING MALFUNCTIONS
For diagnosing malfunctions see group 5.

14

—29 26
25
30 27
33

34 32

oL 36
33 \ 37 38 39
L 51552

Fig. 1— Exploded View of Remote Cylinder

1 Packing adapter 14 Stop valve assembly 27 Groove pin
2 V-packing (3 used) 15 Stop valve spring 28 Stop rod arm
3 Packing adapter 16 Oil passage gasket 29 Stop lever
4 Spring (2 used) 30 Special washer
5 Remote cylinder 17 Gasket 31 Stop screw
6 Washer 18 Remote cylinder cap 32 Piston rod stop
7 Stop rod spring 19 Lock washer (4 used) 33 Roll pin
8 Special washer 20 Cap screw (4 used) 34 Piston rod with yoke
9 Stop rod 21 Special nut 35 Oil seal
10 Snap rings 22 Back-up rings 36 Back-up ring
11 Spring 23 O-ring 37 O-ring
12 Ball 24 Piston 38 Cap screw (3 used)
13 Valve 25 Piston rod guide gasket 39 Lock washer (3 used)
26 Piston rod guide

Printed in Germany
70 Hydraulic System Model 2120 Tractor
35-2 Remote Cylinder TM-4252 (Dec-70)

REPAIR ASSEMBLY

View and description of individual parts see fig. 1. NOTE: When assembling the remote cylinder,
always replace O-rings, back-up rings, seals and
packings.
DISASSEMBLY
Install new O-ring 37 first, then back-up ring 36, to
Remove end cap 18. piston rod guide 26.

Press rod assembly completely into cylinder and

remove stop valve assembly 14. Pull stop valve 14
from valve 13, watching ball 12, which retains
valve 13 on rod 9. After removing ball, take valve
13 out of rod 9.

Insert a rod through yoke attaching pin holes of

piston rod 34 and unscrew special lock nut 21
from piston rod. Pull piston 24 and rod 34 out of
cylinder.

Push stop 32 from piston rod 34 and, if necessary,

remove stop lever 29, washer 30 and stop screw 31.

Press rod 9 completely into cylinder so that it does

not get bent when groove pin 27 is driven out.
Drive groove pin 27 out of stop arm 28 and rod 9. Fig. 2 — Assembly of Piston Rod Oil Seal

Remove piston rod guide 26. Rod 9 can be used to Drive or press new oil seal 35, with seal lip facing
drive packing adapters 1and 3, together with the driver or press, into piston rod guide bore (see fig.
three packings 2, out of the cylinder. 2).

Install packing adapters 1 and 3, and the three

INSPECTION packings 2 to stop rod, in the order shown in fig. 1
(the seal edge of each packing facing the cylinder).
Check cylinder and piston for wear, scoring, cracks
and other damage. Fit piston rod guide 26 and seal 25, but do not yet
tighten cap screws 38.
Replace piston O-ring 23 and back-up rings 22.
Install stop rod assembly. With the help of stop
Replace piston rod guide seal 25 as well as O-ring valve assembly, press stop rod 9 through packing
37 and back-up ring 36. bores. Tighten cap screws 38 of piston rod guide to
the specified torque (see Torques for Hardware).
Check rod 9, stop valve 14 and valve 13 for exces¬
sive wear or damage and replace, if necessary. Push stop arm 28 onto stop rod and drive in groove
pin 27.

NOTE: Before driving in pin 27, push stop rod 9

completely into cylinder, so that rod does not get
bent while the pin is driven in.

Printed in Germany
Model 2120 Tractor
TM-4252 (Dec-70)

bore.

.
Install stop valve assembly 14, ensuring that ball 12
fits into recess. Press valve assembly into cylinder

Push stop 32, with smooth side away from piston

rod yoke end, into piston rod. Insert piston rod 34
into cylinder.

Install O-ring 23 and both back-up rings 22 on

piston, O-ring between back-up rings.

Push piston 24 onto piston rod 34 until it contacts

rod recess, then fit lock nut 21 and tighten. Fit
stop screw 31, special washer 30 and stop lever 29
to stop 32 (if removed) and turn stop 32 on piston
rod so that lever 29 is opposite stop arm 28.

Fit seal 17 to end cap 18. Fit both seals 16 to oil

passages.

Period required for extending or retracting

the cylinder at 2100 rpm engine speed

Cap screws of piston rod guide

Cap screws of remote cylinder cap

Printed in Germany
BLEEDING
Hydraulic System
Remote Cylinder

After remote cylinder assembly, connect hoses to

quick coupler of tractor. The hose near the stop

valve lever is moved backward.

In order to bleed, hold remote cylinder vertical

with hose end upward.
70
35-3

Slide spring 15 over stop valve end 14 and install

end cap. Tighten cap screws 2Q to the specified
torque (see Torques for Hardware).

rod side is to be connected to the inner plug of the

quick coupler. This ensures that the remote
cylinder piston extends when the selective control

Start engine and move selective control valve lever

several times into positions "retract" and "extend"
so that any trapped air can escape from the
cylinder.

SPECIFICATIONS

..................
TORQUFS FOR HARDWARE
2 sec.

35 ft.lbs.

85 ft.lbs.
4.8 mkg

11.7 mkg
Model 2120 Tractor Miscellaneous 80
TM-4252 (Dec-70) Belt Pulley 5-1

Section 80
MISCELLANEOUS
CONTENTS OF THIS SECTION

GROUP 5 - BELT PULLEY Page

Page
Rear wheels (on tractors with
General information 5-1 rack-and-pinion axle)
Removal and disassembly 5-1 General information 15-3
Repair 5-4 Removal 15-4
Assembly and adjustment 5-4 Repair 15-4
Specifications 5-6 Installation 15-4

Torques for hardware 15-4

GROUP 10 - DE LUXE SEAT

.....
General information 10-2 GROUP 20 — HYDRAULIC TRAILER HITCH
Repair 10-2
Hydraulic hitch
General information 20-2
GROUP 15 - FRONT AND REAR WHEELS Repair 20-2

Front wheels
Standard type 15-1 GROUP 25 - ROLL-OVER GUARD
Repair 15-1
Heavy-duty type 15-2 Installation 25-1
Repair 15-2 Torques for hardware 25-1

Adjusting front wheel bearings

(both front wheel types) 15-3

Group 5
BELT PULLEY
GENERAL INFORMATION REMOVAL AND DISASSEMBLY

The belt pulley assembly is driven by the PTO stub Drain oil from pulley case by removing filler plug.
shaft at 540 rpm or 1000 rpm respectively. It is a Remove pulley guard. Remove pulley from shaft,
straight bevel gear type unit and is attached to the using a puller if necessary.
transmission case.

Printed in Germany
80 Miscellaneous Model 2120 Tractor
5-2 Belt Pulley TM-4252 (Dec-70)

Remove bearing cone 8 (fig. 2) and shims 9 from

inner bearing pin 10.

L 45364
Fig. 1— Removing Pulley Case from Quill
Fig. 3 — Removing Oil Seal from Belt Pulley Case
11 Belt pulley case
16 Quill 20 Oil Seal
19 Shims
Remove oil seal 20 (fig. 3) and pull outer bearing
Remove pulley case 11 (fig. 1) from quill 16. cone off shaft.
CAUTION: Be careful not to damage shims 19
between pulley case and quill.

Remove quill from transmission case.

Lift pulley drive gear hub assembly out of belt

pulley case.

Fig. 4 — Removing Drive Shaft

24 Drive shaft
27 Inner bearing cone

9— a> Remove drive shaft 24 (fig. 4) with inner bearing

cone 27 from belt pulley case.

i#53M

Fig. 2 — Removing Bearing Cone and Shims from

Inner Bearing Pin
8 Inner bearing cone
9 Shims
10 Inner bearing pin

Printed in Germany
Model 2120 Tractor Miscellaneous 80
TM-4252 (Dec-70) Belt Pulley 5-3

L47136

Fig. 5 — Parts of the Belt Pulley Drive Assembly

1 Bearing cup 11 Belt pulley case 21 Belt pulley 31 Pulley guard

2 Bearing cone 12 Aluminium washer 22 Plain washer 32 Pin
3 Woodruff key 13 Filler and drain plug 23 Nut 33 Washer
4 Drive gear hub 14 Lock washer (10 used) 24 Drive shaft 34 Cotter pin
5 Drive gear 15 Cap screw (6 used) 25 Woodruff key 35 Retainer
6 Cup plug ie Quill 26 Cotter pin 36 Cap 9crew (2 used)
7 Bearing cup 17 Oil seal 27 Bearing cone 37 Lock washer (2 used)
8 Bearing cone 18 Cap screw (4 used) 28 Bearing cups 38 Wing nut (2 used)
9 Shims 19 Quill shims 29 Snap rings 39 Washer (2 used)
L0 Inner bearing pin 20 Oil seal 30 Bearing cone

Printed in Germany
80 Miscellaneous Model 2120 Tractor
5-4 Belt Pulley TM-4252 (Dec-70)

REPAIR Install bearing cone 30 onto drive shaft. Install new

oil seal 20 in case, metal side out.
Wash all parts in a clean solvent and dry, using
compressed air, before inspecting for serviceability. As a temporary measure, install a pack of shims 9
of specified thickness (see Specifications) and
If it is necessary to replace the inner bearing pin bearing cone 8 on bearing pin 10. Place drive gear
10, be sure to install the new pin with small bore hub assembly on inner bearing cone 8 in belt
facing inward (see fig. 2). pulley case.

Fig. 6 — Removing Bearing Cup from Drive Gear Fig. 7 — Measuring for Shim Requirement
Hub a Feeler gauge 15 Cap Screws
7 Bearing cup
Position quill 16 on belt pulley case, and install
two cap screws 15 as shown in fig. 7 finger tight on
If the cup must be replaced, use a puller as shown opposite sides of the quill. Use a feeler gauge to
in fig. 6 to remove the old cup, and press a new measure clearance between case and quill to
cup into place. determine shim pack required. Install shim pack to
the measurement determined above, and secure
If the gear 5 (fig. 5) of hub 4 must be replaced, use quill to belt pulley case with cap screws 15.
a press to remove the old gear. Press a new gear
into place, making sure that the Woodruff key is in NOTE: Shim pack is temporary until correct gear
place and that the new gear is pressed fully onto backlash and hub assembly end play is adjusted.
the hub shoulder.

ASSEMBLY AND ADJUSTMENT

NOTE: For location of parts in assembly refer to

fig. 5.

Insert drive shaft 24 with bearing cone 27 into the

belt pulley case (see fig. 4).

Printed in Germany
Model 2120 Tractor Miscellaneous 80
TM-4252 (Dec-70) Belt Pulley 5-5

MEASURING AND ADJUSTING GEAR CHECKING AND ADJUSTING END PLAY OF

BACKLASH DRIVE GEAR HUB ASSEMBLY

Use a dial indicator to check end play of hub

assembly roller bearings. If required, add or remove
shims between the quill and belt pulley case to
obtain correct end play (see Specifications).

ADJUSTING DRAG TORQUE

Install belt pulley, washer and slotted hex. nut.

Tighten slotted nut to specified roll drag torque

(see Specifications).

If slot in nut does not match cotter pin hole in

shaft, tighten until next slot matches cotter pin
hole. Install cotter pin.

Mount belt pulley drive assembly to transmission

case and fill belt pulley case to level of filler hole
with recommended oil (see Operator's Manual).

Install pulley guard.

L V5377
Fig. 8 — Measuring Gear Backlash
b Cap screw and nut
c PTO stub shaft

Use a dial indicator as shown on fig. 8. Prior to

measuring, insert a cap screw in PTO stub shaft and
secure it with a nut (see "b"). Install 1000 rpm
PTO stub shaft (or 540 rpm stub shaft respec¬
tively), and tap lightly to insure proper seating.
Fasten dial indicator on quill so that its pin
touches the cap screw in the stub shaft, then rotate
drive shaft slightly to the left and right and take
backlash reading.

To establish correct backlash (see Specifications),

remove hub assembly and quill. Add or deduct
shims beneath inner bearing cone 8 (see fig. 2).

Printed in Germany
80
5-6
Miscellaneous
Belt Pulley

I.D. of drive gear bore

.
..........
.........
............
O.D. of inner drive shaft bearing seat

............
O.D. of outer drive shaft bearing seat

O.D. of shaft at pulley location

I.D. of hub bore for bearing cup

.......
...........
Height of shim pack between bearing pin and
bearing cone (temporary height)

Gear backlash

Roll drag torque

End play of hub assembly roller bearings

Oil capacity (belt pulley case)

O.D. of belt pulley

Face .
Belt pulley speed {at 2100 engine rpm)

Belt speed (at 2100 engine rpm)

Printed in Germany
SPECIFICATIONS

...................
O.D. of hub bearing seat for bearing cone

O.D. of hub at drive gear location

.........
1.7505 to 1.7511 in.

1.9365 to 1.9375 in.

1.7822 to 1.7828 in.

2.7530 to 2.7540 in.

2.750 to 2.752 in.

0.058 in.

0.005 to 0.009 in.

15 to 25 in.lbs.

0.0004 to 0.003 in.

0.3 U.S. gals.

0.25 Imp.gals.

12 in.

8.5 in.

985 rpm

3100 ft./min
Model 2120 Tractor
TM-4252 (Dec-70)

Dimensions of New Parts

1.7970 to 1.7976 in.

1.7720 to 1.7726 in.
45.643 to 45.659 mm
45.008 to 45.024 mm

44.462 to 44.478 mm

49.187 to 49.213

45.268 to 45.284 mm

69.926 to 69.952 mm

69.85 to 69.90 mm
mm

1.47 mm

0.12 to 0.22 mm

17.2 to 28.7 cmkg

0.01 to 0.08 mm

1.2 lit.

305 mm

215 mm

15.5 m/sec.
Model 2120 Tractor Miscellaneous 80
TM-4252 (Dec-70) DE LUXE Seat 10-1

Group 10
DE LUXE SEAT

L 5 1297

Fig. 1— Exploded View of DE LUXE Seat

Back rest 9 Seat frame 17 Knob 25 Snap ring
Washer (4 used) 10 Guide rollers 18 Locking lever 26 Cap (2 used)
Cap screw (4 used) 11 Seat suspension 19 Thrust bushing 27 Spring suspension bi
Seat cushion 12 Suspension pin 20 Adjusting pin 28 Damping screw
Bumper 13 Spring pins 21 Locating pin 29 Cotter pin
Washers 14 Guide bushings 22 Adjusting rail 30 Tension springs
Cap screws 15 Snap rings 23 Spring housing
Hex. nuts 16 Shock absorber shaft 24 Shock absorber

Printed in Germany
80 Miscellaneous Model 2120 Tractor
10-2 DE LUXE Seat TM-4252 (Dec-70)

GENERAL INFORMATION Disassemble seat as shown in fig. 1 and check all

parts for serviceability.
The DE LUXE seat absorbs field shocks through
two adjustable springs and a shock absorber Check spring 30 for fatigue and broken coils.
suspension system located on the rear of the seat.
The seat is adjustable for operator's height and Hold shock absorber 24 vertically, with body down
weight; range of adjustment is from 154 to 265 lbs (see fig. 1). Press in piston and pull out again.
(70 to 120 kg). Replace shock absorber if no resistance is offered
to both compression and extension.

REPAIR When assembling seat, reverse disassembly

sequence as shown in fig. 1.
Swing up seat cushion and remove the two cap
screws securing the seat to junction block of For adjusting seat to operator's height and weight,
rockshaft housing. Then lift off complete seat. see Operator's Manual.

Printed in Germany
Model 2120 Tractor Miscellaneous 80
TM-4252 (Dec-70) Front and Rear Wheels 15-1

Group 15
FRONT AND REAR WHEELS
Front Wheels

L 50 249

Fig. 1 — Exploded View of Front Wheel (Standard Type)

1 Oil seal 4 Front wheel hub 7 Washer 9 Dust cap
2 Holler bearing cone 5 Roller bearing cup 8 Slotted nut 10 Wheel bolt (6 used)
3 Holler bearing cup 6 Roller bearing cone

STANDARD TYPE between Hps of oil seal with lithium-saponified

multi-purpose grease (or SAE No. 2 multi-purpose
REPAIR grease). Pack roller bearings liberally with bearing
grease.
Remove dust cap 9 (fig. 1). Raise front of tractor
and support safely.
CAUTION: When assembling, keep bearings free
from dirt.
Remove front wheel and hub.
Slide front wheel together with hub assembly on
Clean all parts and check bearing cups and cones axle spindle. Install bearing cone 6 as well as
for damage or excessive wear. washer 7 and slotted nut 8.
Check oil seal 1 for serviceability and replace, if NOTE: Do not use a hammer when assembling
necessary. Drive new oil seal (with sealing lip facing
away from hub) into hub bore by means of a
front wheel hub bearing assembly, Tighten slotted
nut to pull assembly together.
suitable driving tool so that it is 0.3 in. (8 mm)
from hub face. When assembling, pack space

Printed in Germany
80 Miscellaneous Model 2120 Tractor
15-2 Front and Rear Wheels TM-4252 (Dec-70)

1 Oil seal 5 Hub 9 Castellated nut 12 Hub cap

2 Collar 6 Taper roller bearing cup 10 Gasket 13 Cap screw (3 used)
3 Taper roller bearing cone 7 Taper roller bearing cone 11 Square headed screw 14 Wheel bolt (6 used)
4 Taper roller bearing cup 8 Washer

HEAVY-DUTY TYPE Drive new oil seal on axle spindle with numbered
side of seal facing driving tool.
REPAIR
Pack space between lips of oil seal with lithium-
Remove hub cap 12 (fig. 2). Raise front of tractor saponified multi-purpose grease (or SAE No. 2
and support safely. multi-purpose grease). Pack roller bearings liberally
with bearing grease.
Remove front wheel with hub.
CAUTION: When assembling, keep bearings free
Clean all parts and check bearing cups and cones from dirt.
for damage or excessive wear.
Slide front wheel together with hub assembly on
NOTE: The front hubs have slots to facilitate axle spindle. Install bearing cone 7 as well as
removal of bearing cups. washer 8 and castellated nut 9.

If oil seal 1 has scored collar 2 or if bearing grease NOTE: Do not use a hammer when assembling
is dirty, drive collar out of hub. Replace collar as front wheel hub bearing assembly. Tighten slotted
well as oil seal. nut to pull assembly together.

CAUTION: The seal ring will seal effectively only

if sealing face is completely smooth and free of
scores.

Printed in Germany
Model 2120 Tractor Miscellaneous 80
TM-4252 (Dec-70) Front and Rear Wheels 15-3

ADJUSTING FRONT WHEEL BEARINGS

(Both Front Wheel Types)
Tighten slotted nut to the specified torque. NOTE: If a slot in the nut just lines up with cotter
pin hole in spindle after applying the specified
Rotate wheel several times to align bearings and torque, back off nut one slot.
retighten slotted nut to the specified torque. Then
back off nut to nearest slot and insert cotter pin. Install dust cap or gasket and hub cap.

Rear Wheels
(on Tractors with Rack-and-Pinion Axle)

L 49451

Fig. 3 — Exploded View of Rear Wheel with Rack-and-Pinion Axle

l Rear wheel rim 6 Wheel sleeve half 10 Wheel ;ve half
2 Wheel disk 7 Pinion 11 Jack sc v (2 used)
3 Clamp (12 used) 8 Cap screw (3 used) 12 Snap ri (2 used)
4 Square head bolt (12 used) 9 Pinion shaft 13 Cap scr (3 used)
5 Hex. nut (12 used) 14 Plug

GENERAL INFORMATION variable tread adjustment, turn pinion shaft 9 (fig.

3). Since a pinion engaging the rack end of the
If the tractor is equipped with rack-and-pinion axle is sp lined onto shaft 9, the relative rear wheel
axle, the rear wheels or disks are positively engaged is moved inward or outward on the axle when
by two wheel sleeve halves each to the relative turning the shaft. (Proper instructions for adjusting
axle. The wheel disks are pressed onto the tapered tread width see Operator's Manual).
seats of the wheel sleeve halves. For infinitely

Printed in Germany
80 Miscellaneous Model 2120 Tractor
15-4 Front and Rear Wheels TM-4252 (Dec-70)

REMOVAL Remove snap rings 12 of the two jack screws 11

and turn jack screws out of wheel disk. Remove
Loosen wheel bolts 13 (fig. 3) sufficiently. Lift up wheel disk from rim.
on right or left rear of tractor, using a floor jack,
until relative rear wheel comes off ground. Support Check rear wheel parts for wear, scores, cracks or
tractor safely. other damage.
Tighten both jack screws 11 until tapered seat of Attach wheel disk to rear wheel rim and tighten
wheel sleeve half comes free. Then turn pinion hex. nuts 5 (fig. 3) to the specified torque.
shaft 9 and thus pinion until it is disengaged from
rack end of rear axle. Remove rear wheel. Attach sleeve half 6 to wheel disk. Screw both jack
screws 11 into wheel disk and install snap rings 12.
REPAIR Back off jack screws until snap rings are flush
against wheel disk.
Remove plug 14 (fig. 3) from wheel disk 2 and
drive shaft 9 out of pinion 7 (see fig. 4). Turn in attaching screws 13 of sleeve half 10 only a
few threads. Position pinion 7 for installation and
drive shaft 9 into pinion bore.

INSTALLATION

Slide rear wheel on rack-and-pinion axle until

pinion engages with rack end of axle.

NOTE: Take care not to damage pinion teeth.

Adjust desired tread width by means of pinion

shaft.

Tighten attaching screws 13 to the specified

torque.
,48400

Fig. 4 — Pinion and Shaft Removed

Turn previously loosened attaching screws 13 (fig.
3) out of sleeve half 10. Also remove cap screws 8
of sleeve half 6 provided on rear of wheel disk. Lift
off both sleeve halves.

....
TORQUES FOR HARDWARE

FRONT WHEELS
Slotted nut on axle spindle 35 ft.lbs. 4.8 mkg

...........
Front wheel rim to hub, bolts 87 ft.lbs. 12 mkg

(Tractors with steel wheel disks)

Rear wheels to rear axle, ball nuts 195 ft.lbs. 27 mkg

.........
Steel disk to rear wheel rim, special bolts 145 ft.lbs. 20 mkg

(Tractors with cast wheel disks)

.............
....
Wheel disk to rear axle, wheel bolts 130 ft.lbs. 18 mkg

........
Cast disk to rear wheel rim, square head bolts 170 ft.lbs. 23.5 mkg

(Tractors with rack-and-pinion axle)

Wheel disk to hub, wheel bolts 300 ft.lbs. 41.5 mkg
Wheel disk to rear wheel rim, square head bolts 170 ft.lbs. 23.5 mkg

Printed in Germany
Model 2120 Tractor Miscellaneous 80
TM-4252 (Dec-70) Hydraulic Trailer Hitch 20-1

Group 20
HYDRAULIC TRAILER HITCH
26

Fig. 1— Exploded View of Hydraulic Trailer Hitch

1 Bearing support with tow hook 13 Cap screw (2 used) 24 Link (2 used)
2 Anti-twist brace 14 Washer (2 used) 25 Chain (2 used)
3 Stay, right-hand 15 Hex.nut (2 used) 26 Pin (2 used)
4 Stay, left-hand 16 Stop bracket 27 Shaft
5 Hex.nuts 17 Hex.socket screw (4 used) 28 Bushing
6 Threaded pin (2 used) 18 Lifting plate, left-hand 29 Release rod
7 Hex.socket screw (4 used) 19 Pin (2 used) 30 Latch
8 Lifting rod (2 used) 20 Pin (4 used) 31 Lifting plate, right-hand
9 Rod 21 Lifting bracket 32 Spring pin
10 Hex.socket screw (4 used) 22 Connecting link (4 used) 33 Tension spring
11 Yoke (2 used) 23 Hex.nut (2 used) 34 Cap screw (4 used)
12 Support 35 Cap screw (2 used)

Printed in Germany
ou Miscellaneous Model 2120 Tractor
20-2 Hydraulic Trailer Hitch TM-4252 (Dec-70)

GENERAL INFORMATION Remove towing hitch.

The raising and lowering of the towing hitch, with The assembly is made up of simple parts which
its anti-twist device, is made by operating the require very little maintenance, apart from regular
rockshaft control lever. To lower the towing hitch, greasing.
also pull up on release rod (see Operator's Manual).
If necessary, all parts can easily be taken apart or
The towing hitch is secured sideways by lifting replaced after having removed securing bolts, nuts
plates bolted to the transmission case and or cotter pins.
underneath the transmission case by means of a
support bracket. Check all parts for cracks, wear, damage or
distortion and replace, if necessary.
REPAIR
The assembly and installation of the hydraulic
Remove cotter pins securing hitch chains to hitch is made by reversing the sequence observed
rockshaft lift arms. for disassembly and removal.

Remove four hex.socket screws 10 (fig. 1) securing

the support bracket 12.

Also remove the four hex.socket screws 17 which

secure the lifting plates 18 and 31 underneath the
transmission case. Screw out four cap screws 34
and both cap screws 35 securing the lifting plates
at the right and left-hand side of the transmission
case.

........
......
TORQUES FOR HARDWARE

Lifting plates to transmission case, hex.socket screws 87 ft.lbs. 12 mkg

..................
Support bracket to transmission case, hex.socket screws

Bearing support with tow hook to right and

left-hand stays, hex.socket screws
87 ft.lbs.

55 ft.lbs.
12 mkg

7.7 mkg

Printed in Germany
Model 2120 Tractor Miscellaneous 80
TM-4252 (Dec-70) Roll-Over Guard 25-1

Group 25
ROLL-OVER GUARD
INSTALLATION

JOHN DEERE Tighten all roll-over guard cap screws and hex. nuts
to the specified torque (see fig. 1).

NOTE: Do not tighten securing bracket hex. nuts

until crossbeam has been installed. Install cross¬
beam so that the name "JOHN DEERE'"'' faces to
the rear of the machine.

...........
TORQUES FOR HARDWARE

t'
Roll-over guard to rear axle
housings, hex. nuts of securing
brackets 94 ft.lbs. 13 mkg

Both upright supports to

crossbeam, cap screws ....94 ft.lbs. 13 mkg

Fig. 1— Roll-over Guard, Installed

Printed in Germany