Tractor
Part number 47969433
1st edition English
November 2016
Replaces part number 47628612
Engine
INTRODUCTION
[10.001] Engine and crankcase
[10.102] Pan and covers
[10.106] V alve drive and gears
[10.101] Cylinder heads
[10.105] Connecting rods and pistons
Crankshaft and flywheel
Lift pump and lines
Fuel filters
Fuel injection system
Air cleaners and lines
[10.250] T urbocharger and lines
Engine cooling system
Fan and drive
Aftercooler
[10.304] Engine lubrication system
Oil cooler and lines
[18.1 10] Clutch and components
ransmission
14] Mechanical transmission
12] Power shuttle transmission
[21.1 10] Master clutch housing
[21.134] Power shuttle transmission external controls
[21.154] Power shuttle transmission internal components
[21.120] Gearbox
Gearbox external controls
Gearbox internal components
Creeper
Reverser unit
Dropbox
Front axle system
Powered front axle
Front bevel gear set and dif ferential
[25.108] Final drive hub, steering knuckles, and shafts
[25.400] Non-powered front axle
Rear axle system
[31.1 14] T wo-speed rear Power T
[35.000] Hydraulic systems
[35.104] Fixed displacement pump
[35.204] Remote control valves
[35.100] Main lift system
Steering control
Hydraulic control components
Cylinders
Wheels
Front wheels
Electrical systems
Electrical system
Harnesses and connectors
Engine starting system
Alternator
Battery
Electronic modules
External lighting
W arning and instruments
Platform, cab, bodywork, and decals
[90.1 18] Protections and footboards
[90.1 14] Operator protections
operator seat
Engine hood and panels
16] Fenders and guards
Safety rules
P A Y A TTENTION T O THIS SYMBOL
This warning symbol points out important messages involving personal safety Carefully read the safety rules contained herein and follow advised precautions avoid potential hazards and safeguard your safety and personal integrity this manual you will find this symbol together with the following key - words:
W ARNING – gives warning about improper repair operations and deriving potential consequences fecting the service s personal safety
DANGER – gives specific warning about potential dangers for personal safety the operator other persons directly indirectly
T O PREVENT ACCIDENTS
Most accidents and personal injuries taking place workshops are due from non - observance some simple and essential prudential rule and safety precautions. The possibility that accident might occur with any type machines should not matter how well the machine question was designed and
A wise and careful service technician the best precautions against accidents
Careful observance this only basic precaution would enough avoid many severe
NOTE: Never carry out any cleaning, lubrication maintenance operations when the engine running.
SAFETY RULES
Generalities
• Carefully follow specified repair and maintenance
• not wear wrist unbuttoned flapping clothing such torn open jackets shirts with open zips which could get caught moving Use approved safety clothing such footwear , safety
• W ear safety glasses with side guards when cleaning parts using compressed air
• Damaged frayed wires and chains are not use them for lifting
• W ear suitable protection such approved eye protection, helmets, special clothing, gloves and footwear whenever All persons standing vicinity the welding process should wear approved eye NEVER LOOK A T THE WELDING ARC YOUR EYES
ARE NOT SUIT ABL Y
• Never carry out any repair the machine someone sitting the operator ’ s except they are qualified operators assisting the operation carried
• Never operate the machine use attachments from a place other than sitting the operator ’ s seat the side the machine when operating the fender
• Never carry out any operation the machine when the engine running, except when specifically indicated. Stop the engine and ensure that all pressure relieved from hydraulic circuits before removing
• All repair and maintenance operations should carried out with greatest care and attention.
• Disconnect the batteries and label all controls warn that the tractor being Block the machine and all equipment which should
• Never check fill fuel tanks nor use starting liquid you are smoking near open flames such fluids are
• The fuel filling gun should always remain contact with filler Maintain this contact until the fuel stops flowing into the tank avoid possible sparks due static electricity build - • T o transfer a failed tractor , use a trailer a low loading platform trolley
• T o load and unload the machine from the transportation select a flat area providing a firm support the trailer truck Firmly tie the machine the truck the trailer platform and block wheels required the transporter
• Always use lifting equipment appropriate capacity lift move heavy
• Chains should always safely
• Ensure that fastening device strong enough hold the load persons should stand near the fastening
• The working area should always kept CLEAN and Y Immediately clean any spillage water
• Never use diesel oil other flammable liquids cleaning Use non flammable non - toxic etary
• not pile grease oil soaked rags, they constitute a great fire hazard. Always place them into a metal container
ART
• Never run the engine confined spaces which are not equipped with adequate ventilation for exhaust gas extrac-
• Never bring your body , fingers near fans rotating
ENGINE
• Always loosen the radiator cap very slowly before removing allow pressure the system Coolant should topped only when the engine
• not fill fuel tank when the engine
• Never adjust the fuel injection pump when the tractor Never lubricate the tractor when the engine running.
ELECTRICAL SYSTEMS
• necessary use auxiliary cables must connected both sides follows: (+) (+) and ( ( A void short - circuiting the GAS RELEASED FROM TTERIES HIGHL Y During leave the battery compartment uncovered improve A void sparks flames near the battery not
• not charge batteries confined
• Always disconnect the batteries before performing any type service the electrical
HYDRAULIC SYSTEMS
• Some fluid coming out from a very small port can almost invisible and strong enough penetrate For this NEVER USE YOUR HANDS T O CHECK FOR but use a piece cardboard a piece wood for this purpose. any fluid injected into the skin, seek medical aid immediately . Lack immediate medical attention may result serious infections
• Always take system pressure readings using the appropriate
WHEELS AND TIRES
• Check that the tyres are correctly inflated the pressure specified the manufacturer . Periodically check for possible damage the rims and
• Check the pressure only when the tractor unloaded and tyres are cold avoid wrong reading due over -
• Never nor weld a rim with the inflated tire
• Never cut, nor weld a rim with the inflated tire
• Deflate the tire before removing any object caught into the tire
• Never inflate tyres using flammable gases they may originate explosions and cause injuries bystanders.
Safety rules - Health and safety
Health and safety precautions
Many the procedures associated with vehicle maintenance and repair involve physical hazards other risks This section alphabetically , some these hazardous operations and the materials and equipment sociated with
The precautions necessary avoid these hazards are The list not exhaustive and all operations and procedures and the handling should carried out with health and safety
Acid and alkalis
see Battery caustic soda, sulfuric
Used batteries and cleaning materials
Irritant and corrosive the eyes, nose and Causes
A void splashes the skin, eyes and clothing. W ear suitable protective gloves and goggles. Can destroy ordinary protective not breathe
Ensure access water and soap readily available for splashing
Adhesive and sealers
see Fire Highly
Generally should stored “ areas; cleanliness and tidiness use should disposable paper covering benches; should dispensed from applicators where possible; containers, including secondary should
Solvent based Adhesive / Sealers
See Follow manufacturer ’ s
W ater base Adhesive / Sealers
Those based polymer emulsions and rubber lattices may contain small amounts volatile toxic and harmful Skin and eye contact should avoided and adequate ventilation provided during Follow manufacturer ’ s instructions
Resin based Adhesives / Sealers
epoxied and formaldehyde resin
Mixing should only carried out well ventilated areas harmful toxic volatile chemicals may Skin contact with uncured resins and hardeners can result irritation; dermatitis and absorption toxic harmful chemicals through the skin. Splashes can damage the eyes
Provide adequate ventilation and avoid skin and eye contact Follow
Anaerobic, Cyanoacrylate and other Acrylic Adhesives
Many are sensitizing harmful the Some are eye
Skin and eye contact should avoided and the instructions followed.
Cyanaocrylate adhesives (super - glues) must not contact the skin skin eye tissue bonded cover with a clean moist pad and get medical not attempt pull tissue Use well ventilated areas vapors can cause irritation the nose and For two - pack systems see Resin based adhesives /
Isocyanate (Polyurethane) Adhesives / Sealers
Resin based Individuals suf fering from asthma respiratory allergies should not work with near these materials sensitivity reactions can occur . Any spraying should preferably carried out exhaust ventilated booths removing and spray droplets form the breathing s working with spray applications should wear supplied air respirators
Antifreeze
- see Solvents Ethylene
Highly Used vehicle cooling brake air pressure screen wash solutions.
V apors given f from coolant antifreeze (glycol) arise only when Antifreeze may absorbed through skin toxic harmful
Antifreeze swallowed fatal and medical attention must found immediately
Arc welding see W elding
Battery acids
see Acids and Gases released during charging are
Never use naked flames allow sparks near charging recently charged batteries.
Brake and clutch fluids (Polyalkylene Glycols)
- see Fire
Splashes the skin and eyes are slightly A void skin and eye contact far
Inhalation vapors hazards not arise ambient temperatures because the very low vapor pressure
Brazing
See welding
Chemical materials - General
- see Legal Aspects
Chemical materials such resin battery brake oils and grease should always used with caution and stored and handled with They may corrosive irritant highly inflammable and give rise hazardous fumes and The fects excessive exposure chemicals may immediate delayed; briefly experienced permanent; cumulative; superficial; life threatening may reduce life expectancy .
s
remove chemical materials from the skin and clothing soon practicable after Change heavily soiled clothing and have carefully read and observe hazard and precaution warning given material containers (labels) and any accompanying poster other Material health and safety data sheets can obtained from manufacturers’.
organise work practices and protective clothing avoid soling the skin and eyes; breathing V apors / aerosols / dusts / fumes inadequate container labelling; fire and explosion wash before job breaks; before eating, smoking, drinking using toilet facilities when handling chemical
keep work areas uncluttered and free store according national and local keep chemical materials out reach
s not mix chemical materials except under the instructions; some chemicals can form other toxic harmful chemicals; give f toxic harmful fumes; explosive when mixed together not spray chemical materials, particular those based solvents, confined spaces e.g. when people are inside a not apply heat flame chemical materials except under the Some are highly inflammable and some may release toxic harmful not leave containers Fumes given f can build harmful explosive Some fumes are heavier than air and will accumulate confined areas, pits etc. not transfer chemical materials unlabeled not clean hands clothing with chemical particularly solvents and fuels will dry the skin and may cause irritation with Some can absorbed through the skin toxic harmful not use emptied containers for other except when they have been cleaned under supervised conditions. not snif f smell chemical Brief exposure high concentrations fumes can toxic
Clutch fluids
see Brake and Clutch
Clutch linings and pads
see Brake and Clutch Linings and
Corrosion protection materials see Highly
These materials are varied and the instructions should followed. They may contain solvents, petroleum products skin and eye contact should They should only sprayed conditions adequate ventilation and not confined
Cutting see W elding - waxing
see Solvents and Fuels
Dusts
Powder , dusts clouds may
void breathing dusts from powdery chemical materials those arising from dry abrasion operations. W ear respiratory protection ventilation inadequate.
Electric shock
Electric shocks can result from the use the faulty electrical equipment from the misuse equipment even good
Ensure that electrical equipment maintained good condition and frequently Ensure that plugs and sockets are not cracked otherwise
Ensure that electric equipment protected the correct rated
Never misuse electrical equipment and never use equipment which anyway faulty . The results could fatal. Use reduced voltage equipment where possible preference electrical
cases
electrocution: -
• switch f electricity before approaching victim
• this not possible, push drag victim from source electricity using dry conductive material
• Commence resuscitation trained
• SUMMON MEDICAL ASSIST ANCE
Exhaust fumes
These contain asphyxiating, harmful and toxic chemicals and particles such carbon oxides, nitrogen oxides, lead and aromatic Engines should only run under conditions adequate extraction general ventilator and not confined
Gasoline (petrol) engine
There may not adequate warning properties odor irritation before immediate and delayed toxic harmful fects
Diesel engine
discomfort and irritation usually give adequate warning hazardous fume
Fibre insulation
see Ducts
Used noise and sound
The fibrous nature surfaces and cut edges can cause skin irritation. This usually a physical and not a chemical
Precautions should taken avoid excessive skin contact through careful organization work practices and the use
Fire
see W and Legal
Many the materials found associated with the repair vehicles are highly Some give f toxic harmful fumes burnt.
Observe strict fire safety when storing and handling flammable materials particularly near electrical ment welding
Ensure before using electrical welding equipment but that there fire hazard
Have suitable fire extinguisher available when using welding heating
First aid
Apart from meeting any legal requirements its desirable for someone the workshop trained first aid procedures.
Splashes the eye should flushed with clean water for least ten
Soiled skin should washed with soap and water
Inhalation fected individuals should removed fresh air immediately . swallowed fects persist consult a doctor with information (label) material not induce vomiting (unless indicated manufacturer)
Foams
see
Used sound and noise
Follow
Cured foams used seat and trim
Unreacted components are irritating and may harmful the skin and eyes. W ear gloves and goggles. Individuals with chronic respiratory bronchial medical problems histories allergic diseases should not work with near uncured
The spray mists can cause direct sensitivity reactions and may toxic V apors and spray mists must not These materials must applied with adequate ventilation and ratory protection. not remove respirator immediately after spraying, wait until vapor / mists have cleared. Burning the uncured components and the cured foams can generate toxic and harmful open flames the use electrical equipment during foaming operations and until vapors / mists have cleared should not Any heat cutting cured foams partially cured - foams should conducted with extraction ventilation (see Body Section Legal and Safety
Fuels
see Fire, Legal Aspects, ChemicalsGeneral, Solvents.
Used fuels and cleaning
Gasoline (petrol)
Highly
Swallowing can result mouth and throat irritation and absorption from the stomach can result drowsiness and Small amounts can fatal Aspiration liquid into the through a very serious
Gasoline dries the skin and can cause irritation and dermatitis prolonged repeated contact. Liquid the eye causes severe
Motor gasoline may contain appreciable quantities which toxic upon inhalation and the concentrations gasoline vapors must very low High concentrations will cause eye, nose and throat depression and symptoms V ery high concentrations will result rapid loss conscious-
Ensure there adequate ventilation when handling and using Great care must taken avoid the serious consequences inhalation the event vapor build arising from spillages confined
Special precautions apply cleaning and maintenance operations gasoline storage tanks. Gasoline should not used a cleaning must not siphoned
Kerosene (Paraf fin)
Used also heating solvent and cleaning
Irritation the mouth and throat may result from swallowing. The main hazard from swallowing arises liquid ration into the lungs Liquid contact dries the skin and can cause irritation Splashes the eye may slightly
normal circumstances the low volatility does not give rise harmful Exposure mists and vapors from kerosene elevated temperatures should avoided (mists may arise - A void skin and eye contact and ensure there adequate ventilation.
Gas - oil (diesel fuel)
see Fuels (Kerosene). Combustible.
Gross prolonged skin contact with high boiling gas oils may also cause serious skin disorders including skin cancer
Gas cylinders
see
Gases such carbon argon and propane are normally stored cylinders pressures 2000 / / m2) and great care should taken handling these cylinders avoid mechanical damage them the valve gear The contents each cylinder should clearly identified appropriate markings.
Cylinders should stored well ventilated and protected from ice and snow , direct Fuel gases acetylene and propane) should not stored close proximity oxygen Care should exercised prevent leaks from gas cylinders and and avoid sources Only trained personnel should undertake work involving gas cylinders
Gases
see Gas Cylinders
Gas shielded welding - see W
Gas welding - see W
General workshop tools and equipment
essential that all tools and equipment are maintained good condition and the correct safety equipment used where
Never use tools equipment for any purpose other than that for which they were Never overload equipment such axle and chassis stands lifting Damage caused loading not always immediately apparent and may result a fatal failure next time that the equipment not use damaged defective tools equipment, particularly high speed equipment such grinding wheels. A damaged grinding wheel can disintegrate without warning and cause serious injury
W ear suitable eye protection when using chiseling sand blasting equipment
W ear a suitable breathing mask when using sand blasting equipment, working with asbestos based materials using spraying equipment
Glues
see Adhesives and
High pressure air , lubrication and oil test
Equipment
see Lubricants and Greases.
Always keep high pressure equipment good Condition and regularly particularly joints and Never direct a high pressure nozzle the skin the fluid may penetrate the underlying tissue and cause serious injury
Legal aspects
Many laws and regulations make requirements relating health and safety the use materials and equipment
W orkshops should familiar , with associated laws and Consult local factory inspectors any
Lubricants and greases
A void all prolonged and repeated contact with mineral especially used Used oils contaminated during service routine service change sump oils) are more irritating and more likely cause serious fects including skin cancer the event gross and prolonged skin W ash skin thoroughly after work involving Proprietary hand cleaners may value provided they can removed from the skin with water . not use petrol, paraf fin other solvents remove oil from the Lubricants and greases may slightly irritating the Repeated prolonged skin contact should avoided wearing protective clothing necessary . Particular care should taken with used oils and greases containing not allow work clothing contaminated with
Dry clean launder such clothing regular Discard oil soaked not employ used engine oils lubricants for any application where appreciable skin contact likely occur Used oils may only disposed accordance with local There are publications describing the problems and advising precautionary measures.
Noise insulation materials
See Foams, Fibre Insulation.
Paints
see Solvents and Chemical MaterialsGeneral. Highly
ONE P
Can contain harmful toxic driers and other components well Spraying should only carried out with adequate ventilation.
TWO P
Can also contain harmful and toxic unreacted resins and resin hardening The manufacturer ’ s instructions should followed and the section page 5 resin based isocyanate containing Adhesives and Foams should consulted.
Spraying should preferably carried out exhausted ventilated booths removing vapor and spray mists from the breathing Individuals working booths should wear respiratory Those doing small scale repair work the open shop should wear supplied air
P AINT THINNERS - see Solvents.
PETROL - see Fuels
Pressurised Equipment - see High Pressure Air , Lubrication and Oil T est Equipment.
Resistance W elding
see W elding
Sealers
see Adhesives and
Solder
see W
Solders are mixtures metals such that the melting point the mixture below that the constituent metals (normally lead and tin). Solder application does not normally give rise toxic lead fumes, provided a gas / air flame
Oxy - acetylene flames should not they are much hotter and will cause lead fumes
Some fumes may produced the application any flame surfaces coated with grease and inhalation these should
Removal excess solder should undertaken with ensure that fine lead dust not Which can give toxic fects
Respiratory protection may necessary
Solder spillage and filing should collected and removed promptly prevent general air contamination
High standards personal hygiene are necessary order avoid indigestion lead inhalation solder dust from clothing.
Solvent
see Chemical Materials - General Fuels white
Used cleaning - thinners
Highly
Skin contact will decrease the skin and may result in. - irritation and dematitis following repeated prolonged contact. Some can absorbed through the skin toxic harmful
Splashes the eye may cause severe irritation and could lead loss
Brief exposure high concentrations vapors mists will cause eye and throat headaches and the worst
Repeated prolonged exposures excessive but lower concentrations vapors mists, for which there might not adequate warning can cause more serious toxic harmful Aspiration into the lungs through vomiting) the most serious consequence
A void splashes the eyes and W ear protective goggles and clothing necessary
Ensure good ventilation when avoid breathing vapors and spray mists and keep containers tightly sealed. not use confined spaces.
When the spraying material contains use extraction ventilation personal respiratory protection the absence adequate general not apply heat flame except under specific and detailed manufacturers instructions.
Sound Insulation
see Fibre
Spot W elding
- see W elding.
Suspended loads
There always a danger when loads are lifted suspended. Never work under unsupported suspended raised jacked suspended
Always ensure that lifting equipment such axle are adequate and suitable for the job, good condition and regularly
Never improvise lifting
Underseal
see Corrosion Protection W elding
see Electric Gas W elding processes include Resistance W elding (Spot W Arc W elding and Gas W elding.
Resistance welding
This process may cause particles molten metal emitted high velocity and the eyes and skin must
Arc welding
This process emits a high level ultraviolet radiation which may cause eye and skin burns the welder and other persons nearby Gasshielded welding processes are particularly hazardous this Personal protection must and screens used shield other
Metal spatter will also occur and appropriate eye and skin protection necessary
The heat the welding arc will produce fumes and gases from the metals being welded and from any applied coatings contamination the surfaces being worked These gases and fumes may toxic and inhalation should always The use extraction ventilation remove the fumes from the working area may necessary , particularly cases where the general ventilation poor , where considerable welding work extreme cases where adequate ventilation cannot supplied air respirators may necessary
Gas welding
Oxy - acetylene torches may used for welding and cutting and special care must taken prevent leakage these gases, with consequent risk fire and explosion.
The process will produce metal spatter and eye and skin protection necessary
The flame bright and eye protection should but the ultra - violet emission much less than that from arc welding and lighter filters may
The process itself produces few toxic but such fumes and gases may produced from coatings the particularly during cutting away damaged body parts and inhalation the fumes should toxic fumes may evolved from the metals the brazing and a severe hazard may arise brazing rods containing cadmium are this event particular care must taken avoid inhalation fumes and expert advice may required.
Special precaution must taken before any welding cutting takes place vessel which have contained bustible boiling steaming out fuel
White spirit
See solvents
[10.001] Engine and crankcase .
Pan and covers
V alve drive and gears
[10.101] Cylinder heads
[10.105] Connecting rods and pistons
Crankshaft and flywheel
Lift pump and lines
Fuel filters
[10.218] Fuel injection system
Air cleaners and lines
[10.250] T urbocharger and lines .
and drive
[10.310] Aftercooler
Engine lubrication system
Oil cooler and lines
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