Bolens Simplicity / Allis Chalmers Pow'r Max Tractor Repair Manual

4040-4041 & 9020 Pow'r Max Tractors
Also covers Allis Chalmers Model 616, 620, & 720 Tractors

Table of Contents

General Information
BATTERY CARE .................................................................................................................................................1-1
BATTERY REMOVAL AND INSTALLATION ....................................................................................1-1
WATER LEVEL...................................................................................................................................1-1
CHARGING.........................................................................................................................................1-2
WINTER CARE...................................................................................................................................1-2
BEARING CLEANING AND INSPECTION ...................................................................................................1-2
CLEANING .........................................................................................................................................1-2
INSPECTION.......................................................................................................................................1-2
PRESERVATION ...............................................................................................................................1-3
TORQUE SPECS. FOR HARDWARE.................................................................................................1-3
VISCOUS COATING VC-3..................................................................................................................1-4
DRYING ...............................................................................................................................................1-4
TRANSMISSION FLUID AND FILTER ..........................................................................................................1-4
TRANSMISSION PRIMING PROCEDURE .......................................................................................1-4
BRAKE ADJUSTMENT '..............................................................................................................................1-5
CLUTCH PEDAL FREE TRAVEL ADJUSTMENT.........................................................................................1-6
CLUTCH BELT TENSION.................................................................................................................................1-6
REPLACEMENT PARTS.....................................................................................................................1-7
Tractor Repair
ENGINE ...............................................................................................................................................................1-9
...................................................................................................................................1-9
ENGINE REMOVAL............................................................................................................................1-9
ENGINE DISASSEMBLY, REPAIR, AND ASSEMBLY................................................................. 1-11
ENGINE INSTALLATION ................................................................................................................ 1-11
WHEELS AND DROP HOUSINGS .............................................................................................................. 1-12
REMOVAL AND INSTALLATION OF WHEEL.............................................................................. 1-12
REMOVAL AND DISASSEMBLY OF DROP HOUSING ............................................................. 1-12
INSPECTION AND REPAIRS OF DROP HOUSING ..................................................................... 1-13
ASSEMBLY AND INSTALLATION OF DROP HOUSING ........................................................... 1-13
BRAKES............................................................................................................................................................ 1-14
................................................................................................................................ 1-14
OPERATION .................................................................................................................................... 1-14
REMOVAL AND DISASSEMBLY OF BRAKE ASSEMBLY.......................................................... 1-15
DISASSEMBLY OF BRAKE LEVERS AND LINKAGE .................................................................. 1-16
INSPECTION AND REPAIR ............................................................................................................ 1-16
ASSEMBLY OF BRAKE LEVERS AND LINKAGE ....................................................................... 1-16
INSTALLATION AND ASSEMBLY OF BRAKE ASSEMBLY........................................................ 1-16
POWER TRAIN SYSTEM.............................................................................................................................. 1-18
................................................................................................................................ 1-18
OPERATION .................................................................................................................................... 1-18
1.CLUTCH ............................................................................................................................... 1-18
2.HYDROSTATIC TRANSMISSION ...................................................................................... 1-18
3.TRANSMISSION ................................................................................................................ 1-19
4.DIFFERENTIAL .................................................................................................................... 1-21
5. REAR PTO............................................................................................................................ 1-21
CLUTCH............................................................................................................................................................ 1-23
CLUTCH DISASSEMBLY................................................................................................................ 1-23
CLUTCH INSPECTION, CLEANING, AND REPAIR....................................................................... 1-24
CLUTCH ASSEMBLY ...................................................................................................................... 1-24
DRIVE SHAFT ................................................................................................................................................. 1-24
DRIVE SHAFT REMOVAL.............................................................................................................. 1-24
DRIVE SHAFT INSTALLATION....................................................................................................... 1-24
TRANSMISSION............................................................................................................................................. 1-25
TRANSMISSION REMOVAL AND DISASSEMBLY..................................................................... 1-25
INSPECTION, CLEANING, AND REPAIR OF
BEVEL GEAR TRANSMISSION ............................................................................................. 1-29
TRANSMISSION ASSEMBLY......................................................................................................... 1-29
TRANSMISSION INSTALLATION ................................................................................................. 1-31
DIFFERENTIAL ............................................................................................................................................... 1-32
DIFFERENTIAL REMOVAL AND DISASSEMBLY ....................................................................... 1-32
INSPECTION, CLEANING, AND REPAIR OF THE DIFFERENTIAL............................................. 1-32
DIFFERENTIAL ASSEMBLY
REAR PTO....................................................................................................................................................... 1-34
............................................................................................................................... 1-34
PTO DRIVE UNIT REMOVAL ........................................................................................................ 1-34
PTO DRIVE UNIT DISASSEMBLY................................................................................................ 1-35
PTO DRIVE UNIT INSPECTION .................................................................................................... 1-36
PTO DRIVE UNIT ASSEMBLY ...................................................................................................... 1-37
PTO DRIVE UNIT INSTALLATION ................................................................................................ 1-37
REAR PTO DRIVE UNIT KIT .......................................................................................................... 1-38
FINAL DRIVE.................................................................................................................................................. 1-38
DRIVE SHAFT ASSEMBLY REMOVAL AND INSPECTION ........................................................ 1-39
INTERMEDIATE GEAR ASSEMBLY REMOVAL AND INSPECTION ......................................... 1-39
FINAL GEAR ASSEMBLY REMOVAL AND INSPECTION .......................................................... 1-40
FINAL GEAR ASSEMBLY INSTALLATION .................................................................................. 1-40
INTERMEDIATE GEAR INSTALLATION....................................................................................... 1-42
DRIVE SHAFT ASSEMBLY INSTALLATION ................................................................................ 1-43
TRANSMISSION PRIMING PROCEDURE .................................................................................... 1-43
STEERING AND FRONT AXLE ASSEMBLIES......................................................................................... 1-44
............................................................................................................................... 1-44
STEERING GEAR REMOVAL........................................................................................................ 1-44
STEERING GEAR DISASSEMBLY................................................................................................. 1-47
STEERING GEAR INSPECTION .................................................................................................... 1-48
STEERING GEAR REPAIRS .......................................................................................................... 1-49
STEERING GEAR ASSEMBLY...................................................................................................... 1-51
STEERING GEAR BENCH ADJUSTMENT.................................................................................... 1-53
STEERING GEAR INSTALLATION................................................................................................. 1-53
STEERING SHAFT REMOVAL, INSPECTION, AND INSTALLATION......................................... 1-54
DRAG LINK REMOVAL, INSPECTION, INSTALLATION
AND ADJUSTMENT................................................................................................................ 1-56
TIE ROD REMOVAL, INSPECTION, AND INSTALLATION.......................................................... 1-57
HUB REMOVAL, INSPECTION, AND INSTALLATION ............................................................... 1-57
SPINDLE REMOVAL, INSPECTION, AND INSTALLATION ........................................................ 1-58
FRONT AXLE REMOVAL, INSPECTION, AND INSTALLATION ................................................ 1-59
POWER LIFT SYSTEM .....................................................................................................................................2-1
...................................................................................................................................2-1
FUNCTION...........................................................................................................................................2-2
HYDRAULIC CONTROL VALVE REMOVAL AND INSTALLATION.................................................2-2
HYDRAULIC CYLINDER REMOVAL .................................................................................................2-6
HYDRAULIC CYLINDER INSTALLATION..........................................................................................2-6
OIL COOLER REMOVAL, INSPECTION, AND INSTALLATION.......................................................2-6
ELECTRICAL SYSTEM.....................................................................................................................................2-7
...................................................................................................................................2-9
GENERAL CHECKOUT PROCEDURES..............................................................................................2-9
WIRING HARNESS............................................................................................................................2-9
BATTERY CIRCUIT ......................................................................................................................... 2-11
BATTERY CONDITION .................................................................................................................... 2-11
BATTERY WIRING................................................................