~--------~~----~~~----~CHAPTER 8-----------------------------

Figure 18 Figure 19
Field Curre•nt Test Typical 0 .25 Ohm Resistor
1. Alternator 2. Ammeter 3. Field Rheostat

Field (Rotor) Circuit Test 4. Generally, this is approximately 2.0 to 2.5 amperes at
battery voltage. If the ammeter tends to vary when t he
1. This test will determine if the electrical circuit (field rotor is slightly turned, the slip rings and brushes require
winding) of the alternator rotor is in good condition. The cleaning. Use a fine grade of abrasive cloth for this purpose.
field citcuit, including the brush assembly, is shown in
Figure 13. High field current may produce uncontrolled
alternator output and probable damage to the voltage 5. If normal rotor current cannot be obtained, the alter-
regulator. Low field current will result in Iow alternator nator will require disassembly and replacement of defective
output. parts. If a satisfactory ammeter reading is noted, proceed
with the next test.
2. With the engine stopped and the key starter switch
OFF, disconnect the field lead from the alternator brush
connecting terminal. Switch test ammeter to the low current
scale (O to 1O amperes). Ser cont rai knob of fiel d rheostat in Voltage Regulator Operating Voltage Test
maximum resistance position. The field rheostat will pre-
vent damage to the test ammeter if the rotor winding is 1. This test will determine operating levei of the voltage
shorted or grounded. Place the field rheostat and the test regulator. Voltage tests are most accurate when the alter-
ammeter in a series circuit between the alternator positive nator is charging a fully charged battery, as current output
output (test point A) and field terminais as shown in is at minimum. Under this condition, charging voltage will
Figure 18. rise to the regulators limiting ma.ximum.

3. Slowly reduce field rheostat resistance, noting test

ammeter reading. If entire field rheostat resistance can be 2. A 0.25 ohm 25 watt resistor, Figure 19, may be placed
~liminated with the ammeter indicating less than 3.5 am- in series with the alternator output lead to reduce current
eres, the field winding is not shorted or grounded. The to 8 to 10 amperes for a battery that is less than fully
test ammeter reading, with t he field rheostat resistance charged. The connections for the 0.25 ohm resistor and
eliminated, is the current draw ofthe rotor (field) circuit. test equipment are shown in Figure 20.

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- - - - - -- - - - - PART 3- ELECTRICAL S Y S T E M - - - - - - - - - - -

+
+

Figure 20 Figure 21
Voltage Regulator Operatíng Voltage Output and System Test
1. Alternator 3. 0.25 Ohm Resistor 1. Alternator 4. Voltmeter
2. Voltmeter 2 . Battery 5. Ammeter
3 . Carbon Pile

3. Connect the voltmeter negative lead to gtound, and the AJternator Output and System Test
positive to the alternator output terminal. Start the engine
and ruo for a few minutes to stabilize component tempera-
ture. The volcage indicated is the levei established by the 1. This tcst will determine if t he alternator is capahle of
voltage regulator, usually 13.9 to 14.7 volts, depending on producing its minimum rated output, and is an evaluation
the regulator ambient temperature. Compare the indicated of the rotor, stator and diodes ability to produce current
voltage with the value given in the table in and voltage.
"Specifications".

4. Higb voltage may be due to a poor ground connection

for the voltage regulator circuit board. Since the circuit 2. Maximum alternator output depends on alternator
board is insulated from the regulator housing, one regulator ambient temperature as well as rotor speed, therefore a
lead, usually black, serves as rhe ground connection. The general minimum rated output is acceptable for common
ground lead must be a clean and tight connection at the reference.
alternator ground.

5. If the ground connection is not faulty, the regulator is

probably inoperative and will require replacement. 3. The charging system is also tested under partial load
to determine if an excessive voltage loss exists between the
alternator and the battery through the connecting cables.
6. A Jow charging rate is usually dueto a faulty regulator.
With the engine stopped and key starter switch OFF,
Replace regulator if necessary.
connect the carbon pile to the battery terminais as shown
in Figure 21. Connect the voltmeter negative lead to
7. Stop the engine and remove the 0.25 ohm resistor from ground and the positive lead to the alternator outpu1
the alternator positive output lead immediately after this terminal. The ammeter should be on the O to 60 ampere
test. scale.

Page 12
----------~~~----~-------CHAPTER 8------------------------------

4. Turn the key starter switch on. Start the engine and maximum output in amperes. Voltage should remain be-
run it at approximately 750 rev/min for 5 minutes to tween 13.0 and 15.0 volts (with voltmeter positive Iead on
normalize component temperature. If the ammeter indi- output terminal). The ammeter should indicate a minimum
cates less than 10 ampere charge, slowly load the battery of 43 amperes.
with the carbon pile until 10 ampere is shown on the
ammeter. Record the voltmeter reading.

7. Stop the engine and to avoid discharging the battery

turn the carbon pile loading knob to OFF after the test.
5. Move the positive voltmeter lead to the positive battery
post, note the voltmeter reading. The voltmeter readings
obtained should be within 0.3 volt of each other. If a
greater differential exists, impect all cables and connections 8. If the alternator does not produce the minimum rated
between the alternator and the battery for poor or loose output (45 amps), it should be disassembled and repaired.
connections. If satisfactory voltage loss is indicated, pro- The problem could be one or more defective rectifying
ceed with the test. diodes or defective stator windings (open or shorted).

6. Increase engine speed t o provide 3,000 to 4,000 rev/min This concludes the seties of initial tests. If it is necessary
alternator rotor speed (1,400 to 1,870 engine rev/min). In- to repair the alternator, carry out the following Overhaul
crease the carbon pile load, causing the alternator to deliver procedures.

3. ALTERNATOR AND VOLTAGE REGULATOR

REMOVAL AND OVERHAUL

REMOVAL

Alternator Remova!
1. Disconnect the battery ground cable (negative) from
the battery.

2. Disconnect all wires from the alternator, Figure 22.

3. Remove the alternator from the tractor by removing

the attaching bolts.

Voltage Regulator Remova!

1. Disconnect the battery ground cable (negative) from

the battery.

2. Disconnect the wiring harness from the voltage regu-

lator inside the battery compartment.
Figure 22
Alternator lnstalled on Tractor
3. Remove the attaching screws from the regulator. 1. Alternator 3. Alternator Fan Belt
2. Alternator Bracket and 4. Adjusting Bolt
Remove the regulator from the battery compartment. Retaining Bolt

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 - - - - -- - - - - - PART 3- ELECTR ICAL SYS T E M - - - - - - - - - - -

Figu re 2;s Figure 25

Alte rnator Brush Removal Rem ovin g T hrough Bolts
1. Brush Assembly 1. t in Socket

DISASSE MBLY

Brush Remova]
1. Remove the two brush mounting screws, then lift the
cover and dust shield from the brush assembly.

2. Grasp the field terminal and gently pull the brush

assembly down and away from the alternator as shown in
Figure 23.

Isolation Diode Remova]

1. Remove t he two l0-24 1ocknuts and thc 0.5 in (12.70
mm) O.D. fibre washer, Figure 24, from the auxiliary and
negative output studs.

2. Lift the isolation diode assembly from the alternator.

NOTE - Do noc lose che nylon sleeve thar insulares the diode
assembly f rom the negarive output terminal.

3. Remove the nylon sleeve and 0.75 in (19.00 mm) O.D.

Figure 24 washer frorn the negative output tetminal.
l solati o n D iode Remova l
1. Negative Output Stud 5. Locknuts
2.
NOTE - Remova/ of the brush a~sembly and isolation diode
0.75 in O.D. Washer 6. Output Terminal
3. Nylon Sleeve 7. lsolation D iode Assembly assembly can be achieved with the alternator in situ on the
4. 0.5 in O. D. Fibre Washer 8 Auxiliary Output Stud traccor.

Page 14
 Figu re 26 Figure 27
Separating Stator from Front Housing Clearance Required to Prevent Damage
1. Stator 2. Front Housing During Housing Separation
1. Screwdriver 2. Stator Winding

Rear Housing Removal

1. Remove the four through bolts and square nuts holding
the housings together, Figure 25.

2. Insert two small screwdrivers in the stator slots between

the stator and front housing, Figure 26.
NOTE - Do not insert the screwdriver biades deepe1· than
0.062 in (J .59 mm), Figure 27, to avoid damaging the stator
winding.

3. Apply pressure at several points around the stator to

extract the rotor and front housing as an assembly. Do not
burr the stator core, as it may make re-assembly difficult.

Separating Stator from Rear Housing

1. Place the stator and rear housing assembly on a clean
smooth working surface, free of metal chips that could
damage the windings.

2. Remove the remaining locknuts and insulating washers

from the rectifying diode terminal studs. Carefully slip the
Figure 28
diode plate studs from the rear housing. Do not exert Pulley Removal
unnecessary pressure on the stator leads. 1. Oversize Belt

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 - - - - - - - - - - - P A R T 3- ELECTRICAL SYSTE M----- - - - - - -

Figure 29 Figure 30
Wood ruff Key Removal Releasing Front Bearing Retainer
1. Woodruff Key 2. Spacer 1. Front Bearing Retainer

Pulley Fan and Spacer 2. ln rnost cases the housing and rotor can be separated
from the bearing by tapping the assembly on a block of
l. The pulley is a slip-fit on the rotor shaft, positioned wood, as shown in Figure 31. Special pullers are needed
with u key. Tu remove the nut and lockwasher from the if the abovt: method fails t:0 separare rhc assembly. After
shaft, clamp the pulley in a vice using an old oversize belt the use of such equipment, examine the housing for
to protect the pulley from damage, see Figure 28. possible damage.

2. After the pulley nut and lockwasher have been removed,

the pulley may be Eeparated from the alternator. A puller
may be required for this operation. The fan will then slide INSPECTION AND REP AIR
over the key.
Brush
3. Remove the key with diagonal pliers. If the sides of the
key are slightly rounded from running loose, place the nut 1. I nspect the brush assembly for excessive wear. Install
back on the shaft. Use a screwdriver to pry the key from a new assembly if the brushes are worn so they protrude
the slot as shown in Figure 29. Remove the spacer from from the brush holder less than 0.187 in (4.76 mm) (half
the shaft. the original length).

2. Check for deposits of foreign material, oil or dirt, that

may bind brush movement or result in poor slip ring
Separating the Rotor from Front Housing contact. Oean the entire assembly in cleaning solvem.
Blow dry with compressed air.
1. Using long nose pliers, compress the ears of the tront
bearing retainer, as shown in Figure 30. Lift the retainer 3. Check the brush spring tension. It should be 4 to 6 oz
free of the recess. After the rotor and front housing are (153.4 to 170.1 grams). Install a new brush a'>Sernbly if the
separated, the retainer can be removed from the shaft. tension is too high or too Jow.

Page 16
 Figure 3 1 Figure 32
Separ ating Fro nt Ho using from Rotor lnsulation and Continuity Test Poi nts
1. Field Terminal A 3. Grounded Brush E
2. lnsulat ed Brush C 4. Bracket D

4. Check the insulation and continuity with a 12 volt tese

lamp or ohmmeter (single terminal assembly). See Figure
32 and refer to t he following :

• lnsulation test. Point A to D, no circuit indicares no short

circuit, assembly çorreçt,

• Continuity test. Point A to C and D to E, continuous +

circuit indicares no open connection, assembly correct.

NOTE - ln each of the above teses, resistance should not vary

when the brush and connecting lead wire is moved around.

Isolation Diode

1. Test the isolation diode with a commercial diode t ester

according to the manufacturer's instructions.

NOTE - Jf a commercial tester is not available, a 9 to 12 volt

battery-operated test lamp may be used in thef ollowing manner:
Figure 33
l solation D iode Test , Red o r Yellow Diod e PI ate
2. Connect one test lead to the output terminal stud of ( Lamp s ho uld light)
1. Battery 12V 3. Positive Output Terminal
thc diodc and the other to the exposed metal area on the
2. Bare Metal Input Area of 4. Lamp should light
auxiliary terminal of the heat sink, Figure 33. Heat Sink

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- - - - - - - - - - - P A R T 3 - ELECTRICAL SYSTEM - - - -- -- - - - -

Fig ure 34 Fi gure 36

lsolation D i o de Test , Re d or Yellow Diode Plate So ld ering and Unsoldering D i ode Leads using Pliers
( Lamp sho uld not light) as a Heat Shield
1. Battery 1 2V 3. Positive Output Terminal 1. Soldering l ron 2. Pliers used as heat shield
2. Bare MP.t!ll lnptit Ama of 4. L;imp should not light
Heat Sink

3. Rept:al the Lt:St with t he lt:aul> revcrseJ, as shown in

Figure 34.
NOTE - T he lamp should light when tlie leads are connected
as shown in Figure 33. lf the lamp fails to light, the diode is
open and must be replaced. The lamp should not light when the
leads are reversed, as in Figure 34. lf the lamp does light, the
d iode i s shorted and ú must be replaced. R eplace a defeetive
isolation diode as a complete assembly. Do not immerse the
isolation diode in a severe cleaning chemical, as ir may remove
the special corrosion-resistant paim.

Rear Housing
l. Check the rear housing for cracks aroun d the drilled
openings.

2. lf the rear bearing borc has been scuffed fro m the

bearing turning in the casting, the housing must bc re-
placed.

3. Clean the housing in solvem if it is to be re-used.

Figure 35
Rear Bearing Retai ne r lnstalled 4. Install a new bearing retainer (0 - Ring) in the bore
1. Retainer (0 - Ring) recess, Figure 35.

Page 18
 ®

+ +

Figur'e37 Figu1e 38
Diode Testing Positive DiodeTesting (Red Paint on Diode)
1 Do not use Stucls 3. Diodes Current does not flow 2. Current flows
2. Connect Test Lead to Hea[ Sink

Rcctifie.r Diode

J. Separarc t.he dlode assemblies trom the ~tator leads, as

shown in Figure 36. U &e plicrs as a heat $hidd betwecri. U1e
®
d.iode.<> and solder poinr to protect. the diodes from bear
damage. Avoid be:nding or twlsting thc cliode ternúnal.
+
2. With the equipme.nt and proccdure osed for r.es ting thc
isolation diode, test each recrificr diode. Ali diodes io the
sarne heat -sink must t est alike. Replnce tbe complete
assembly 1f oue or more of tbe cliodes are defeccive.
+
NOTE - Do 1101 co1111ect t.lle tesr. lead co the heat s111k swds,
Figure 37, when resting the di<Jdes. Use the /Jea• sir1k iz~lf, a.~
the uuds may be loose. Wl1en assembled in tlte altemator, thP
swds are tigltteued wirh Jodl wm.

Diode.1 wich RED part nwnbers are Positivle Diode.s and will
conducr Positive poteniial througlt riu;, diode, as shown in
Figure 38.
Diode.~ with BLACK part numbers are Negative Diodes and
will i:onduu Negative potemiaf tlrrougll tlle dwde, as sltow11 in Figure 39
Negative Diode Testing (Black Paint on Diode)
flgurt 39. 1. Current Uows 2. Current does not flow

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 - - - - -- - - - - - P A R T 3 - ELECTRICAL S Y S T E M - - - - - - - - - - -

Figure 40 Figure 42
Stator Assembly Stator Connecting Lead Junctions
1. Slots 3. Steel Plates 1. Stator Junction 3. Stator Junction
2. Winding Ends 4. Windings 2. Stator Junction 4, Stator Junction

Stator
l. The alternator stator assembly, Figure 40, consists of
three individual windings, wound on a common core or
lamination. The lamination is epoxy coated ro provide
durable insulation.

NOTE - Discolouration of the enamel on tlze windings zs

evidence of overheating and a shorted condition.

2. The "Delta" wound stator, used in 55 ampere alter-

nators, terminates the cnds of the threc windings to form
three junctions of two conductors cach, see Figure 41.

3. Unsolder the diode connecting Jcads from the stator

junctions, Figure 42. Separate the leads as shown in
Figure 43.

4. With an ohmmeter or 12 volt test lamp, test cach circuit

(A, B and C) for faults. Re-use rhe stator ifthe test~ indicate
rhat it is in good condition.

Figure 41
NOTE - Th.e resistance of each winding is very low, approxi-
Delta Type Winding mately 0.1 ohm. Therefore, che olmzmecer test will indicace
continuicy, open circuit or ground without much refereuce to
1. Stator Junction 3. Stator Junction actual value or resistance. The 12 volt test lamp will also
2. Stator Junction indicate cominuity, open circuit or ground.

Page 20
 Figu r e 43 Figure 44
Stator Connect ing Leads Se parated for T est Purposes Fan lnspectio n Points
1. Circuit A 3. Circuit B 1. lnspect Bore for Wear 2. Check for Cracked Fins
2. Circuit C

5. Re-assemble the stator and diodes using only resin core

solder to secure good mechanical connections. Route
the leads in their original position for ease of assembly.

IMPORTANT - Be sure to use a heat shield to protect the

diodes when resoldering them to the stator.

Fan, Pulley and Spacer

1. Inspect the fan for cracked or broken fins, also note
the condition of the mounting hole. If the hole is worn
from running loose, install a new fan, Figure 44.

2. Inspect the pulley for possible wear at thc points

shown in Figure 45.

3. Check the spacer for cracks. Install a new spacer if

cracks exist.

Rotor and Fron t Housing

Figure 45
1. Inspect the front bearing cavity for evidence of wear. Cross -sect ion o f Typical Pulley showing
Note the condition of the retainer recess and replace the lns pectio n Points
housing if necessary. If the original housing is re-used, 1. Check for Worn Drive Surface 4. Check Condition of
2. Check for Polished Surface Key Groove
clean with solvem, then dry with compressed air. 3. Check Bore for Wear

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 - - - - - - -- - -- PART 3- ELECTRICAL S Y S T E M - - - - - - - - - - -

Figure 46 Figure 48
Front Bearing Removal Front Bearing Retainer lnstalled
1. StepPlate-ToolNo.630-1 4. Puller -ToolN o. 1001 1. Bearíng 3. Front Housing
2. Rotor 2. Retainer
3 . Pulling Attachment- Tool No. 950

2. Using the tools shown in Figure 46, pull the front

bearing from the rotor shaft. lf the bearíng ís to be re-
used, the pulling attachrnent must contact the inner race
only.

3. Remove the front bearing retainer from the shaft,

inspect for distortion, and replace if unsatísfactory.

4. Clean the front beanng cavity and remove any burrs.

5. Tap the bearing into the housing, using a 1 A in (29 mm)

socket or a driver tool that exerts pressure on the outer race
only, Figure 47. Apply only sufficient pressure to seat the
bearing against the bottom of the cavity.

6. Replace the front bearing retainer in the recess, Figure

48. Make certain the retainer ears line up with the opening
Figure 47 in the housing. Use a wood dowel ora It in (29 mm) socket
Front Bearing lnstallation
1. Mallet to exert pressure on the retainer while locking the edge into
3. Front Housing
2. 1i in Socket the recess.

Pagt: 22
----------------CHAPTER 8----------------

Figun 49 Figure 50
Rear Bearin!J Removal Rear Bearing lnstallation
1. Puller - Tool No. 1001 4. Pulling Attachment- 1. 7
16 in Socket or Sleeve to Fit 1nner Bearing Race 2. Rotor
2. -fzin Socket Tool No. 950
3. Rotor

7. Using the tools shown in Figure 49, pull the rear

bearing from the rotor. If the bearing is to bc re-used, the
pulling attachment must cont:1ct the inner race only.

8. Inspect the bearings for adequate lubrication. If re-

placement bearings are requin d, they must equa1 or exceed
original equipment.

9. Support the front ofthe rotor shaft in a press. Using a

11; in (12 mm) socket or suit: ble sleeve that contacts the
inner race only, press the i~ar bearing over the rotor,
Figure 50.

10. Support the bottom (rea bearing area) ofthe rotor in

a press, then place the front t ousing and bearing assembly
over the shaft.

11. Using a n-in ( 18 mm) c'eep socket or suitable sleeve Figure 51

contacting the inner bearin~ race only, press the front Pressing Front Housing (with Bearing lnstalled)
over Rotor Shaft
housing and bearing ovei the rotor shaft until the bearing 1. Hin deep Socket or Sleeve 2. Front Housing and Bearing
contacts the shoulder on the ,haft, Figure 51. to fit lnner Bearing Race 3. Rotor

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- - - -- - - - - - - PART 3 - ELECTRICAL S Y S T E M - - - - - - - - - - -

Figure 52 Figure 53
Rotor Test Points Rotor Coil Current Draw Test
1. Test A & B 3. Check 1. Ammeter 3. Slip Rings 5. Field Rheostat
2. Test C 2. Voltmeter 4. 12V Batterv

12. Check the rotor assembly, Figure 52, for electrical (ii) Connect the ohmmeter leads to the two slip rings. The
performance as follows: resistance should be 4.0 to 5.2 ohms.

Test A - Rotor coil current d.raw. (iii ) If the resistance is less than 4.0 ohm5, it ind.icates a
shorted rotor coil.
(i) Connect a field rheostat in series wfrh an ammeter and
the battery positive terminal. Connect the black lead
(iv) If the resistance is greatcr than 5.5 ohms, it indicares
(negative) from the ammeter to one of the two rotor
a broken winding or defecrive slip ring connection and
slip rings, Figure 53.
the rotor assembly should bc rcplaced.

(ii) Connect a voltmeter between the slip rings. The T est C - Roror slip ring ground rest.
positive lead should be attached to the sarne slip ring (i ) Using a 12 volt te.sr light, touch one test probe to the
as the ammeter negative lead. rotor shaft.

(iii ) With the field rheostat adjusted to maximum resist- (ii ) Touch the other test probe to one slip ring and then
ance, attach a jumper from tbe battery negative tbe other.
terminal to the other slip ring.
(iii) ff the light burns when either of the slip rings are
(iv) Adjust the field rheostat until the voltmeter reads 10 contacted, it indicares a grounded slip ring and the
volts. rotor assembly should be replaced.

(iv~ Clean the brush conrncting surface of the slip rings

(v) The ammeter should read 1.65 to 2.25 amps at 70 to
with fine abrasive cloth, wipe away ali dust and
80ºF (21.1 to 26.7ºC).
residue.

Test B - Rotor coil resistancc. (v) Check for a worn key ~lot, worn bearing surfaces,
(i) Using an ohmmeter, check the resistance ofthe rotor stripped threads, and scuff marks on thc pole fingers.
coil winding. Replace the rotor if any of thc abovc faults are noted.

Pagc 24
 1

Figu1e 54 Figure 55
Rotor Coil ( Fiel J) Gr o und Test Pulley lnstallation
1. Rotor Shaft · 3. Male Wall Plug 1 . Oversize Belt
2. Slip Rings 4. 12 Watt Bulb

Test D - Rotor coil (field) gn Wld test. NOTE - Jf the rotor winding has higher current draw, it will
provide uncontrolled output while endangering the components
Defective coil or lead wire ir sulation allowing the wirc to in the vollage regulator. /f tlw rotor winding has less current
contact any metal parts of th ; rotor will ground the rotor draw, the alternator may f ail to develop its rated output at
(field) coil. Damage to the ·egulator can result and the special speeds. A grounded rotor winding will probab/y damage
alternator will fail to reach ts rated output. By using a the regulator and provide uncontrolled output.
relatively high voltage for thi > chcck, slight leakage can be
detected before actual failurc occurs. The test instrument
is a 115 volt to 120 volt AC tcst light, This can bc madc
locally using a 15 watt bulb, bulb holder, male wall plug, RE-ASSEMBLY
and necessary wiring, Figure 54.
Rotor and Front Housing
Assemble the front housing and the rotor as covered in the
(i) Insert the plug into a 1 5 volt to 120 volt AC outlet. preceding "Rotor and Front Housing Inspection" pro-
cedure.
NOTE-Avoid touching the bare test probes, as a severe
eleetrical shock will result.
Pulley, Fan and Spacer
1. Place the spacer ovcr the shaft and install the kcy.

(ii) Touch one test probe te the rotor shaft and the other
2. Place the fan and pulley over the shaft and install the
to tbe slip rings. The 15 watt bulb should not light.
lockwasher and nut.

3. Clamp the pulley in a vice, using an old oversize belt

(iii) Replace the rotor asserr bly if evcn the slightcst glow to protect the pulley as shown in Figure 55. Tighten the
is seen in t he test lamp. pulley nut to a torque of 35-50 lbf ft (5.0-6.5 Mkg).

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 - - - - - - - - - - - PART 3- ELECTRICAL SYSTEM - - - - - - - - - - -

Figure 56 Figure 58
Oiode lnsulators - Internai Rear Bearing Retainer lnstalled
1. Negative Diode Assembly 4. Positive D iode Assembly 1. Retainer (0-Ring)
2. Not lnsulated
3. lnsulating Sleeves and Washers

Stator and Rear Housing

l. Place che insulating sleeves and washcr> over thc

rectifying diode studs, Figure 56.

2. Insert the heat sink 'ituch through the openings in the

rear housing. Place thc insulating washers over the sruds,
Figure 57. Instnll thc locknurs as shown and tightcn
securcly.

Rear Housing

1. Bc sure thc rcar bea.ring rctainer (0-Ring), Figure 58,

is insralled in the recess.

2. Position thc rcar housing and stator assembly ovcr the

rotor. Hand-press the housings rogether.
Figure 57
D iode ln sulators - Externai
1. Negative D1ode Assembly 4. Positive Diode Assembly
2. Do not use lnsulators 3. Install the through bolts, Figure 59, and cightcn cvenly.
3. 0.75 in lnsulating Washers beneath Nuts Spin the rotor to test for frccdom of the bearings and rotcr.

Page 26
----------------·~-----------CHAPTER 8-----------------------------

Figure 59 Figure 60
lnstalling Thr< ugh Bolts l solation Diode lnstaltation
1. l in Socket 1. Negative Output Stud 5. Locknuts
2. 0.75 in O.D. Washer 6. Output Terminal
3. Nylon Sleeve 7. lsolation Diode Assembly
4. 0.5 in O.D. Fibre Washer 8. Auxiliary Output Stud

Isolation Diode

1. Refer to Figure 60 for ;orrect installation of the

insulators and the isolation diode assembly.

2. Install the assembly and se:ure with the locknuts.

Brush

1. Place the brush assembly, r;;igure 61, in the cavity.

2. Install the dust shield and 'Over plate. Sccure with the
screws.

Figure 61
A lternator Brush l nstallation
3. Bench chcck thc altcrnator a 5 covered under "Alternator
Bench Chcck". 1. Brush Assembly

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- - - - -- - - - -- PART 3- ELECTRICAL SYSTEM - - - -- - - - - --

Figure 62 Figure 63
Alternator Bench Check (less Regulato r ) Alternator l nstall ed on Tracto r
1. Field Rheostat 3. Test Voltmeter · 5. Ammeter 1. Alternator 3 . Alternator Fan Belt
2. Negative Output 4. 12V Battery 6. Auxiliary 2. Alternator Bracket and 4. Adjusting Bolt
Retaining Bolt

ALTERN;\TOR BENCH CHECK INSTALLATION

1. Mount the altemator in a test fixture capable of Alternator
providing 3000 to 4000 alternator rev/min. 1. Make sure the battery ground cable (negative) is dis-
connected from the battery.
2. Set the drive motor rotation to obtain the dir ection
dictated by the alternator fan for proper cooling.
2. Place t he alternator in position on the t ractor and install
3. Connect the circuit leads as shown in Figure 62. the attaching bolts and spacer, Figure 63. Loosely tighten
the bolts so the alternator is free to pivot when moderate
NOTE - The ammeter shown is the panel ammeter of the test
pressure is applied.
fixture, although a separate ammerer will serve the sarne
purpose.
3. Position the alternator belt ovcr the pulley.
4. Switch the arnmeter to show possible d.ischarge during
the hook-up. Reverse the meter for the output test. 4. Connect the wires to thc alternator as shown m
Figure 63.
5. Set the field rheostat to the maximum resistance before
connecting it to the system.
5. Connect the batte1y ground cable (negative) to t he
6. Start the drive motor and adjust it to obtain 3,000 to battery.
4,000 altemator rcv/min.
6. Adjust the alternator belt as outlined previously in this
7. Reduce the resistance of thc field rheostat. T he alter-
nator should now begin to charge. Chapter.

8. Continue to reduce the rheostat resistance until the Voltage Regulator

alternator reaches its rated output. DO NOT operate the L Attach the voltage regulator with the attaching screws.
alternator for more than a few minutes in this manner, due
to Jack of voltage control. If the alternator delivers rated 2. Connect the wiring harnes:. to the regulator.
current output, terminate the test. Refer to "Specifications"
for output specification. If rated output cannot be obtained, 3. Connect the battery ground cable (negative) to the
the rotor, stator or diodes are at fault. battery.

Page 28
 4. TROUBLE SHOOTING
Problem Possible Causes

Battery Discharged 1. Loose or Worn Alternator Drive Belt

2. Defective Battery (will not accept charge)
3. Alternator not Producing Rated Output
4. Defective Voltage Regulator
5. Excessive Resistance in Alternator to Battery or Battery
to Ground Terminais

Alternator Charging at High Rate 1. Defective Voltage Regulator

No Output from Alternator 1. Alternator Drive Belt Broken

2. Loose Output Connection
3. Ali Rectifying Diodes Defective
4. Defective Rotor or Stator
5. Defective Isolation Diodes (Open)
6. Defective Voltage Regulator

Intermittent or Low Alternator Output 1. Alternator Drive Belt Slipping

2. Loose Connections or Broken Cables in Charging System
3. One or Two Rectifying Diodes Defective
4. Defective Voltage Regulator
5. Wire Broken in Stator

5. SPECIFICATIONS
Alternator:
Maximum Output (Hot) (160ºF) at approximately 2,400 engine rev/min
(5,136 Alternator rev/min) and 14.4 Volts 47 amps
(5,136 Alternator rev/rnin) and 14.4 Volts 47 amps
Field Current 1.8-2.4 amps
Field Resistance 6 ohms
Brush Length (Minimum) 0.187 in (4. 76 mm)
Brush Spring Tension with New Brush (Minimum) 4 oz (113.4 gms)

Voltage Regulator (with Alternator) :

Output Terminal Voltage at 10 amp load against Ambient Air Temperature
Temperature in Degrees
ºF Oº 20º 40° 60° 80° 100° 120º 140° 160°
(ºC) ( - 18º) ( - 1°) (4º) (16º) (27º) (38º) (49°) (60°) (71º)
Minimum Output
Terminal Voltage (10 amp Load) 14.60 14.45 14.26 14.13 13.95 13.80 13.65 13.60 13.30
Maximum Output
Terminal Voltage (10 amp Load) 15.40 15.25 15.08 14.92 14.75 14.60 14.45 14.28 14.13

6. SPECIAL TOOLS
Too! No. Description
630-S Step Plate Adaptors
950 Pulling Attachments
1001 Puller

Printed in U.K. 8/75 © FORD MOT OR COMPANY, 1975 Page 29

 Chapter 6
HYDRAULIC SYSTEMS WITH LOAD MONITOR -
FORD 5000 & 7000 TRACTORS

Section Page
l. Description and Operation 1
2. Adjustments 9
3. Overhaul Load Monitor .. 16
4. Overhaul Lift Cylindcr Assembly 22

5. Overhaul L ift Covcr Asscmbly .. 23

Chapter 7
HYDRAULIC SYSTEM -
FORD 260 0 , 3600, 4100 & 4600 TRACTORS

Seccio11 Page
1. Description and Operation
2. Adjustments 18
3. Overhaul Lift Cylinder Assembly 19
4. Overhaul Lift Cover Assembly .. 26
5. Overhaul FJow Control Valvc Plate and Linkage 33
6. Overhaul Oi! Filter Support Assembly -
Ford 4100 & 4600 T ractors 36

Chapter 8
HYDRAULIC SYSTEM -
FORD 5600, 6600, & 7600 TRACTORS

Seciion Page
1. Description and Operation
2. Adjustments 9
3. Overhaul Lift Cylinder Assembly 10
4. Overhau] Lift Cover Assembly .. 12
5. Overhaul Cooler Valve Assembly 13
6. Overhaul Oi! Filter Support and
Adaptor Assembly 14

Printed in U.K. 8/75 © F ORD MOTOR COMPANY, 1975 Page iü

 Chapter 9
HYDRAULIC PUMP -
ENGINE MOUNTED GEAR TYPE

Section Page
1. Description and Operation
2. Overhaul Hytlraulic LifL Purnp . . 2

Chapter 1 O
HYDRAULIC PUMP-INCREASED CAPACITY
TRANSMISSION MOUNTED GEAR TYPE

Section Page
1. Description and Operation
2. Overhaul Hydraulic Lift Pump .. 2

Chapter 11
TROUBLE SHOOTING, SPECIFICATIONS
ANO SPECIAL TOOLS -
FORD 2600, 3600, 4100, 4600, 5600,
6600 & 7600 TRACTORS

S ection Page
1. Trouble Shooting ..
2. Specifications 6
3. Special T ools 12

Pageiv
 Part 11

HYDRAULIC SYSTEMS
Chapter 7

HYDRAULIC SYSTEM -
FORD 2600, 3600, 4100 & 4600 TRACTORS

Section Page

1. Description and Operation

2. Adjustments 18

3. Overhaul Lift Cylinder Assembly 19

4. Overhaul Lift Cover Assembly .. 26

5. Overhaul Flow Control Valve Plate and Linkage 33
6. Overhaul Oil Filter Support Assembly -
Ford 4100 & 4600 T ractors 36

1. DESCRIPTION AND OPERATION

Figure l illustrates the hydraulic system for the Ford 2600 The micronic inlet filters are located externally to facilitate
and 3600 models with an engine mounted gear type renewal. The filter is situated adjacent to the engine
hydraulic pump. Various differences which exist between mounted gear pump for the Ford 2600 and 3600 models,
this syst em and that of the Ford 2600 and 3600 models Figure 2, and at the end of a manifold, undêr the left-hand
with an engine mounted piston pump, and the Ford 4100 platform, for the Ford 4100 and 4600 models, Figure 3.
and 4600 models, with a transmission mounted gear pump,
are explained throughout this Chapter.
HYDRAULIC OIL COOLER
An air-to-oil type hydraulic oil cooler is featured for the
Ford 2600 and 3600 models with the optional, high output
HYDRAULIC FILTERS engine mounted gear type hydraulic pump.
A full flow micronic suction filtcr system is featured with
the optional engine mounted gear type hydraulic pump
for the Ford 2600 and 3600 models and as standard for ali
Hydraulic system exhaust oil is passed through the cooler,
Ford 4100 and 4600 models.
situated in front of the radiator, before returning to the
rear axle centre housing.

ord 2600 and 3600 models with the standard engine NOTE - The hydraulic oi! cooler is not installed in production
,nounted piston pump retain the previous intake strainer for the Ford 4100 and 4600 models but provisions are incor-
and discharge filter system. porated to f acilitate S ervice installation if required.

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- - - - - - - - - - - PART 11- HYDRAULI C S Y S T E M S - - - - - - - - - - -

Figure 1
Hydraulic System - Schematic

1. Lift Arm 9. Unload Valve 17. M1cronic lnlet Filter

2. Draft Control Spring 1O. Oil Cooler Return to Sump 18. Flow Control Valve Restrictor Knob
3. Draft Lever 11. Dump Pipe 19. Cooler Valve
4. Position Lever 12. Hydraulic Pump lnlet Tube 20. Flow Control Valve
5. Actuating Lever 13. Pressure Relief Valve 21 . Check Valve
6. Control Valve Lever 14. Oil Cooler 22. Draft Control Lever
7. Feathermg Valve 15. Pump Pressure Tube 23. Position Control Levtn
8, Control Valve 16. Engine Mounted Gear Pump 24. Lift Cylinder Safety Valve

EXTERNAL CONTROLS NOTE - The previous single-lever control system is retained

for the Narrow, Narrow Orchard and Vineyard models.
Lift Control Levers

The two-lever control system incorporares separate lever

The previous single lift control lever and draft/position for draft and position control situated at the right-hai:
control selector lever have been superseded by a two-lever side of the operator's seat in the sarne locations as the
control system for Ford 2600, 3600, 4100 and 4600 models. single-lever system, Figure 4.

Page 2
 Figu re2 Figure 3
Locati on of Hydnulic lnlet Fi lter- Locat io n of H ydraulic l nlet Fi lter -
Ford 2600 and 3600 Ford 4100 and 4600
1. Micronic lnlet Filter 2. Engine Mounted Gear Pump 1. Left- hand Platform 2 . Filter Manifold
3. Micronic lnlet Filter

The system enables the opcr2tor to select full draft control

(inner lever), full position control (outer lever) or a com-
bination of both whereby maximum implement dcpth
control, in addition to draft response, may be effected in
the draft contrai modc.

The two-lever contrai syst!m provides more accurate

positioning and finer increments of contrai compared to
the single-lever system.

Draft Control
Draft contrai is selected by pushing the position control
lever co che bottom of the q1..adrant (chis action makes che
position control linkage inop !rative) and moving the draft
control lever.

Flow control override, to per11it rapid implement lift, only Figure 4

H y d raulic Syst e m Controls
comes into operation when t~ e draft control lever is moved 1. Draft Co ntrol Lever 3. Position Control Lever
to thc top of the quadrant. 2. Flow Control Knob

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- - - - - - - - - - PART 11 - HYDRAULIC S Y S T E M S - - - - - - - - - -

The flow contrai valve housing 1s snuated on the nght-

hand side of the rear axle centre housing and features a
rocking control knob, see Figure 4. This control knob

-·ll ili ia· ::-.--.._-

~---
moves t hrough an angle of approximately 45 to give a
slow flow (S) in the forward position and a fast flow (F)

- - in the rearward position.

• -. !\. -

The controJ knob is attached to the end of the restrictor

shaft and a wider relief in the restrictor caters for the
increased hydraulic flow.

The high capacity flow control valve has larger ports than
the previous valve and features anti-friction grooves,
B Figure 5.

Figure 5
Flow Control Valve The flow control valve may be used to service previous
A. Previous Valve B. Current Valve models.
1. Anti-Friction Grooves

HYDRAULIC LIFT CAPACITY

Position Control
Increased lift capaciry for the Ford 4100 and 4600 models
Position control is selected by pushing the draft control is achieved by increasing the lifr cylinder bore diameter
lever to the bottom of the quadrant (thereby making the from 3.31 in (84.14 mm) to 3.50 in (88.90 mm).
draft control linkage inoperative) and moving the position
control Iever.

Draft Control with Position Control A unique lift cylinder pisron, seal and ring are installed
and the connecting rod, ram arm, lift arms and cross shaft
When the system is in draft control, the position control are ali strengthened to cater for rhe incrcased lift capacity.
lever can be utilised to set a desired rnaximum irnplement
working depth. Draft contrai is rnaintained but the imple-
ment depth is regulated by the position control setting
which overrides the draft control linkage. VALVES IN THE LIFT CYLINDER ASSEMBLY

Flow Control Valve Featbering Valve

A high capacity manually operated flow control valve A fea1.hering valvc which modulares thc flow of hydraulic
caters for tbe increased output of the optional engine oil to the lift cylinder, depending on the size of the lift
mounted gear type hydraulic pump for the Ford 2600 and signal, is featured for ali Ford 2600, 3600, 4100 and 4600
3600 models and the standard transmission mounted gear models with or without the cwo-lever lift contrai sysrem,
pump for ali Ford 4100 and 4600 models. Figure 6.

The feathering valve is locaced within a colour coded

The Ford 3600 model with the standard engine rnounted bushing.
piston pump also features the flow control valve but the
Ford 2600 model with the lower capacity engine mounted The feathering valve fiow contrai system is described in
piston pump does not have a manual flow control system. detail in this Chapter.

Page 4
- - - - - - - - - - - -- - - - CHAPTER 7 - - - - - - - - - - -- - - - -

Control Valve

To cater for the increased flow of hydraulic oil associated

with the high output gear type pumps, the control valve
has narrow section lands. The land positions are designed r-M; ;
for compatibility with the feathering valve flow control L _ ________ ,
system, Figure 7.
ma:w
The control valve spool is matched with a unique colour A
coded bushing.
1101
'
e 1 LJ1
Previous and current control valves and bushings are not L_____ ·1
interchangeable.
a:;}J
B
Unload Valve

A unique spring assisted unload valve forms an integral Figure 7

part of the feathering valve flow control system. The Hydrau lic Li ft Control Valva and Bushing Assembly
A. Previous Valve and Bushing B. Current Valve and Bushing
spring ensures effective return of the unload valve and no
longer necessitates the inclusion of a back pressure valve The current valve is located within a one-piece colour coded
in the hydraulic system. bushing as opposed to the separate front and rear bushings
of the previous valve.
Previous and current unload valves and bushings are not
The land form of the unload valve is shown in Figure 8. interchangeable.

Figure 6 Figure 8
Feathering Valva and Bushing Assemb ly Unload V alve and Bushing Assembl y
A. Previous Valve and ~ront B. Current Valve and
and Rear Bushings Bushing Assembly

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 --
- - - - - - - - - - P A R T 11- HYDRAULIC SYSTEMS - - -- - - - -

Figure 9
Draft Control Linkage - Lowering i nto Work

Figure10
Draft Control Linkage - Raising in W ork
1. Yoke 6. Torsion Spring 11. Draft Lever
2. Draft Contrai Main Spring 7. Adjustable Stop 12. Draft Contrai Lever
3. Draft Contrai Link B. Contrai Valve Spring 13. Draft Contrai Roller
4. Contrai Valve Lever 9. Contrai Valve 14. Lift Cross Shaft
5. Actuating Lever 1O. Pivot Pin

Page 6